What are the materials for LED PCB light boards? How to choose the suitable material based on the usage scenario?

ONESEINE PCB/What are the materials for LED PCB light boards? How to choose the suitable material based on the usage scenario?

(1) FR-4 fiberglass board

FR-4 is currently the most widely used general-purpose PCB substrate due to its low cost and mature manufacturing process. With a thermal conductivity of only 0.2-0.5W/(m·K), it is suitable for low-power LEDs (<0.5W), such as indicator lights. However, FR-4 tends to warp at high temperatures, making it unsuitable for high-power applications.

(II) Aluminum substrate (MCPCB)

It is a metal-based copper-clad laminate specifically designed for medium and high-power LEDs, making it the preferred choice for these applications. With a thermal conductivity ranging from 1.0 to 4.0 W/(m·K), its heat dissipation is 3 to 8 times better than that of FR-4. It features fast heat dissipation, high strength, and good thermal expansion matching, making it suitable for 1-10W lighting products. However, the insulating layer is not resistant to high voltage, making it unsuitable for high-frequency scenarios.

(III) Copper substrate

Copper-based boards can be regarded as an upgraded version of aluminum-based boards, utilizing copper as the substrate for circuit boards, with thermal conductivity reaching 300-400W/(m·K) and top-notch performance, suitable for ≥50W ultra-high power LED or laser equipment. Due to high cost and difficult processing, they are only used in high-end scenarios.

Budget by cost

1. Cost-sensitive: If strict cost control is required and the LED power is low, FR-4 fiberglass board is the most economical choice.

2. Cost-effective and balanced type: Domestic aluminum substrates are the mainstream choice for medium and high-power LED applications, with a cost of about 1000-2000 yuan per square meter and a lifespan of up to 50,000 hours, achieving a good balance between heat dissipation performance and cost.

3. High-end demand type: For scenarios where product lifespan and reliability are highly critical, such as aerospace and medical equipment, aluminum nitride ceramic substrates or imported aluminum substrates can be chosen. Although the initial investment is high, in the long-term usage, its lower maintenance costs and longer replacement cycle make it more economical