Aluminum pcb double side for motorbikes

Why choose PCB Aluminum Double Side For motorcycles? Let’s find the benefits, applications, design guides, thermal solutions, cost and quality balance methods.

Are you worried about this problem?

• Does high temperature sustainable cause a shorter motor age?
• Traditional PCB has poor heat dissipation, making efficiency difficult to achieve?
• The layout of the two -side devices, causing heat dissipation conflict?

The best technology can provide solutions:

• The two -sided aluminum substrate with a three -dimensional heat dissipation (the aluminum substrate performs heat from both sides, increasing the efficiency of heat dissipation by 60%)
• The design of a very thermal conductive insulation layer (middle layer material holds temperatures up to 180 ° C, preventing heat accumulation)
• The copper layer that is optimized through the array (increase the speed of vertical heat conduction three times, resolve the layout conflict)

Welcome to contact us if you have a request for aluminum pcb: [email protected].

Why Choose a Double Side Aluminum PCB for Motorcycle?

Reasons why choosing PCB Aluminum Double Side For motorcycles:

â € œThe DISSTIPATE HOT SUPEROR ”

• The aluminum core (for example, 6061/5052 alloys) provides “thermal conductivity of 200W/MK”, prevent excessive heat in high -power motor drivers.
• “50% lower thermal resistance” vs. FR4, ensuring stable performance below heavy loads.

“Improved Mechanical Resistance”

• CTE that matches the motor component reduces the “stress fracture”.
• “30% higher flexural power” than ceramic substrates, ideal for a vibration -prone environment.

High density circuit design ‘

• Two -sided wiring through “VIA Metallization” increases the density of components with “60%” compared to a single layer board.
• Supports “fine-line-line (0.05mm) “for complex motor control circuits.

â € œThe cost is economical for high power applications’

• Eliminating the need for large heatsinks, cutting “assembly costs of 20%”.
• “His longer” in a strong condition (for example, EV, Industrial Motor).

Boost signal integrity ‘

• ± 5% Control Impedance “minimize EMI in PWM motor control signals.
• Low dielectric constant (îμ_R.~ 4.5) Ensure high frequency performance is stable.

Aluminum PCB Application Two -Side In Motorcycle

• Drive Motor High Efficiency: Activating 98%+ power conversion efficiency in BLDC/PMSM controllers through low copper traces and thermal management.
• Electric Vehicle Traction System (EV): Hold 200 ° C+ peak temperature in the inverter module under 100kw+ continuous load. Like the Tesla Model 3 motor controller adopts a similar PCB for a smaller 30% form factor.
• Robotics & Automation: Vibration resistant design ensures stable surgery on robot joints (for example, 6-Sumbu UR10E motor).
• Renewable Energy Motor: Wind turbine pitch control system utilizes UV PCB resistance for outdoor reliability. Like a solar sniffer motorcycle shows MTBF 20% longer with Al PCB.
• Aerospace & Defense: MIL-PRF-55182 Certified for extreme environments (for example, motor drone controller at -55 ° C ~ 125 ° C).

Aluminum pcb design guide to double motor

1. Analysis of the requirements & key specifications

• Current/voltage mapping: Identification of high current zones (for example, IGBT/Mosfet array) and voltage isolation needs.
• Thermal profile: Determine the max operating temperature (for example, 125 ° C for the automotive ECU) and ambient cooling.
• Space constraints: Measure the dimensions of the beach for PCB buildup (for example, the height of the BLDC motor <50mm).

2. Choice of Material & Design Stack-Up

Aluminum core:

• Thickness: 0.5mm (compact motor) up to 3.2mm (inverter EV).
• Layer: Anodized (corrosion resistance) or layered (solder capability).

Dielectric layer:

• High epoxy TG(Tg = 170 ° C, cost effective for <100A).
• PTFE loses low(DK = 2.2, ideal for> 200KHz PWM).

3. Layout Design: Thermal Optimization + Electricity

Thermoelectric separation:

• Place the power trail in the top layer, thermal pads in the bottom layer.
• Avoid crossing a high current path with a control signal.

Through design:

• VIAS thermal: Laser-bor (0.3mm diameter, 1.0mm pitch) under the heat component.
• Sewing Vias: Connect the land plane to the aluminum base (‰ ¥ 5 VIAS/cm ²).

4. Manufacturing & Assembly Considerations

• Solder Mask Permit: ‰ ¥ 0.2mm from the edge of the aluminum to prevent cracks of the mask.
• Stick the stencil design: Thicker stencils (0.15mm) for large soil pads.
• Wave soldering: Avoid aluminum exposure to flux solder (use nitrogen atmosphere).

5. Testing & Certification

• Thermal cycling: -40 ° C to 150 ° C, 100 cycles (ISO 16750-4).
• EMC compliance: CISPR 11 emits emissions (for medical/automotive).
• Vibration resistance: 5â € “500Hz, 2 hours (IEC 60068-2-6).

Double sided aluminum pcb thermal solution

1. Material selection and structural optimization

• Aluminum PCB Design Two -Side: The structure of the two-sided aluminum aluminum (thickness that can be adjusted 0.3-3mm) is used, with an intermediary layer of XPE or FR4 foam material that provides thermal insulation and buffering.
• The thickness of the copper layer: The 1oz/2oz copper layer is recommended. VIAS connects inside and outside copper foil to form three -dimensional heat dissipation networks, reduce thermal resistance by more than 30%.
• Surface maintenance: Hot air leveling process (pg) or organic solderrability (OSP) is preferred to prevent degradation of heat dissipation caused by silver migration.

2. Design of Hot Discovery Pathway

• Integration of Fluid Cooling Two -Side Fluid: Drawing on automotive power module technology, the cooling channel is reserved on the back of the PCB. This two -sided heat dissipation increases thermal density by 40%.
• Thermal via array: VIAS Diameter 0.3mm is regulated on a 5mm pitch and filled with thermal conductive silicon rubber to ensure rapid heat transfer from PAD chip to aluminum PCB.
• Copper foil extension: Star-shaped copper coating design is used around the motor driver IC, with an increase in the width of the IPC-2221 standard (7mm width is needed for current 10A).

3. Control the manufacturer’s process

• Lamination: Vacuum laminated technology is used to ensure bubble -free contact between aluminum substrates and isolation layers, with thermal conductivity ‰ ¥ 2.0W/mâ · k.
• Laser cutting: The formation of UV laser is used to eliminate grinding, ensuring the surface of the heat of the heat dissipation â ‰0.1mm.
• Testing Temperature Increase: Full load operating conditions are monitored using the thermal infrared imager, with an increase in temperature â ‰ ¤25 ° C for the main component.

Aluminum Motor Two Side PCB Optimizing Costs ‘Costs’

• TIRING MATERIALSâ € œ:: Use standard level aluminum (6061) for low-power applications and premium alloys (7075) for high-performance motors, reduce material costs by 15-20% without reducing thermal performance.
• Through optimization ‘:: Standardization through sizes up to 0.3-0.5mm and use mechanical drilling rather than laser drilling, reduce production costs by 10-15% while maintaining electricity reliability.
• Surface final selection ‘:: Prioritizing OSP (Organic Solder Preservatives) rather than Enig (Electric Nickel Soaking Gold) for saving costs 30-40%, with the proven solder capability for motor control applications.
• Design for Testability (DFT) “: Integrate the test point during the layout to minimize post-production testing time, reducing the QA cost by 20% without sacrificing the detection rate of defects.
• Thermal management efficiency ‘:: Use the thermal staggering through the pattern of switching -a solid array, reaching 25% better heat dissipation with 15% smaller VIAS, saving time and fabrication material.
• The source of the bulk component ‘:: Partnering with suppliers for standard capacitor and resistor values, reduce procurement costs by 10-20% through volume discounts.
• Automatic Optical Inspection (AOI) “: Apply AOI to the steps of a critical process to capture defects earlier, reduce the cost of re -work by 30% and increase yield.
• Simplification of the pile layer ‘:: Use the 2-lapi design as far as possible instead of 4-lairis, cutting material and laminated cost of 25% for non-critical motor control circuits.

Case Study of Our Motorcycle Motorcycle Aluminum Aluminum PCB

In the best technology, we have been very involved in the field of two -sided aluminum PCB for 19 years, successfully providing hundreds of Aluminum Motor PCB projects. From design optimization to making precision, assembly, and testing, we provide one -stop service to ensure high performance and reliability, help customers reduce the temperature of motor products by 30% and increase product life by 25%. This is a photo of our motorbike PCB Aluminum Double Side case:

Why choose the best technology as an aluminum PCB manufacturer?

• Very high current capacity: Supports 100 – 800A+ current (EV inverters, Industrial Drive) through 2 € “4oz copper layers. Eliminating 2 € “3 layers of PCB FR-4, cutting the cost of 30% and space of 40%.
• Extraordinary thermal conductivity: Aluminum Core (200+ W/MK) Removes heat 10x faster than FR-4. Reducing the temperature of the component intersection by 35 & 45%, extending the life of the motor to> 50,000 hours.
• Precision signal integrity: Low Dielectric PTFE-Loss (DK = 2.2â € “3.5) Ensuring PWM signals are clean up to 500kHz. Passing EMC Standards (CISPR 11) Without additional protectors, saving 500 €” 1,500 per unit.
• Vibration & resistance to shocks: Design that matches CTE (23 ppm/° C) Preventing solder joint fatigue. Surviving 5â € “500Hz Vibration Test (IEC 60068-2-6), reduced field failure by 60%.
• Cost -effective scalability: 30% cheaper than ceramic substrates at the same performance. Reducing prototyping costs by 2,000 € “5,000, accelerating the R&D cycle.
• ISO certified compliance: Pre-qualifications for automotive standards (IATF 19649) and medical (ISO 13485). Secondary testing, cutting compliance costs by 30% and a time of 50%.
• Optimization of DFM is free: Analysis of layouts driven by AI traces of distance flags, through placement, and material mismatch. Reducing a redesign by 80% and material waste by 25%.
• Fast prototype (24 hour turnaround): Laser in-house drilling and coating paths allow fabrication of the same day. Shorten the R&D cycle by 50%, speeding up time-to-market with 4â € “6 weeks.

Welcome to contact us if you have a request for aluminum pcb: [email protected].

Tag: PCB Aluminum Multiple Side