{"id":4593,"date":"2025-12-26T08:39:32","date_gmt":"2025-12-26T08:39:32","guid":{"rendered":"https:\/\/flj-pcb.com\/?p=4593"},"modified":"2025-12-26T08:39:35","modified_gmt":"2025-12-26T08:39:35","slug":"thermal-design-of-led-aluminum-pcbs","status":"publish","type":"post","link":"https:\/\/flj-pcb.com\/bs\/thermal-design-of-led-aluminum-pcbs\/","title":{"rendered":"Termalni dizajn LED aluminijskih \u0161tampanih plo\u010dica"},"content":{"rendered":"
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Uvod<\/h3>\n\n\n\n

Dioda koja emituje svjetlost (LED<\/a>) je poluvodi\u010dki ure\u0111aj u \u010dvrstom stanju koji pretvara elektri\u010dnu energiju u svjetlost. U pore\u0111enju s tradicionalnim sijalicama sa \u017earnom niti, LED diode imaju mnoge o\u010digledne prednosti. Te prednosti uklju\u010duju dug vijek trajanja, \u0161irok raspon boja, veliku izdr\u017eljivost, fleksibilan dizajn, jednostavnu kontrolu i za\u0161titu okoli\u0161a. Zbog ovih prednosti, LED diode se \u0161iroko smatraju jednim od najperspektivnijih izvora svjetlosti za budu\u0107nost.<\/p>\n\n\n\n

Crvene, zelene i plave (RGB) LED diode mogu se mije\u0161ati kako bi se generiralo bijelo svjetlo s vrlo \u0161irokom gamom boja. Zbog ove osobine, RGB LED diode su vrlo privla\u010dne za upotrebu u sistemima pozadinskog osvjetljenja zaslona s teku\u0107im kristalima (LCD). Ova vrsta pozadinskog osvjetljenja omogu\u0107ava da zasloni budu tanji, imaju du\u017ei radni vijek, pru\u017eaju ve\u0107i omjer prigu\u0161ivanja i prikazuju svjetlije i \u017eivlje boje. Istovremeno, ovi zasloni su ekolo\u0161ki prihvatljiviji.<\/p>\n\n\n\n

Zbog ovih prednosti objavljeno je mnogo istra\u017eiva\u010dkih radova o LED pozadinskim plo\u010dama s direktnim osvjetljenjem i LED pozadinskim plo\u010dama s bo\u010dnim osvjetljenjem. Prvi na svijetu LCD televizor koji je koristio mije\u0161ano RGB-LED osvjetljenje proizveo je Sony. Ovaj je proizvod postigao vrlo \u0161irok raspon reprodukcije boja, dosti\u017eu\u0107i 105% standardne palete boja Nacionalnog odbora za televizijski sistem (NTSC).<\/p>\n\n\n\n

Me\u0111utim, iza ovih istra\u017eiva\u010dkih dostignu\u0107a i dalje postoje termalni problemi. Tokom rada LED diode stvaraju toplotu. Ta toplota uzrokuje smanjenje intenziteta svjetlosnog izlaza i tako\u0111er dovodi do pomaka dominantne talasne du\u017eine. Ova dva efekta mijenjaju temperaturu boje ekrana i rezultiraju varijacijama u NTSC performansama. Osim toga, prekomjerna toplota skra\u0107uje vijek trajanja ekrana. Stoga je, kako bi se osigurala kvaliteta slike i dugoro\u010dna pouzdanost, izuzetno va\u017eno termalno upravljanje sistemom pozadinskog osvjetljenja.<\/p>\n\n\n\n

Da bismo pobolj\u0161ali toplotne performanse RGB-LED pozadinskog osvjetljenja, mogu se razmotriti dva glavna pristupa. Prvi pristup je pobolj\u0161anje sposobnosti rasipanja toplote jednog LED dioda. Drugi pristup je pobolj\u0161anje sposobnosti rasipanja toplote LED matrice. Kao dizajneri RGB-LED pozadinskog osvjetljenja, odabrali smo drugi pristup za rje\u0161avanje toplotnog problema.<\/p>\n\n\n\n

Da bi se pobolj\u0161ale toplinske performanse sistema LED matrice, postoje dvije uobi\u010dajene metode. Jedna metoda je kori\u0161tenje ventilatora za pove\u0107anje brzine protoka zraka oko sistema pozadinskog osvjetljenja. Druga metoda je smanjenje toplinske otpornosti od LED spoja do okoline. Dizajniranje modula pozadinskog osvjetljenja na ekonomskoj tiskanoj plo\u010di visoke toplinske provodljivosti je bolje rje\u0161enje.<\/p>\n\n\n\n

Trenutno, \u0161iroko kori\u0161tena konvencionalna tehnologija izolovanog metalnog podloga (IMS) koristi polimerne ili epoksidne smole kao izolacijski sloj. Ova tehnologija zahtijeva posebnu obradu povr\u0161ine metalne osnove. Pored toga, minimalna debljina izolacijskog sloja obi\u010dno iznosi oko 75 mikrometara. Ova debljina pove\u0107ava ukupnu toplotnu otpornost IMS plo\u010de. \u0160tavi\u0161e, u uslovima visokih temperatura, tradicionalne IMS plo\u010de mogu do\u017eivjeti delaminaciju izme\u0111u izolacionog sloja i metalne osnove.<\/p>\n\n\n\n

U ovom radu koristimo tehnologiju magnetron sputtering za izradu nove vrste PCB-a sa izolovanim metalnim podlogom. Hemijski formiran izolacijski sloj debljine od 30 do 35 mikrometara stvara se na povr\u0161ini aluminijske podloge. Zatim se dizajnirani krug formira na izolacionom sloju pomo\u0107u magnetron sputtering tehnologije. Ovaj novi PCB s izolovanim metalnim podlogom ima izvrsna toplotna svojstva i tako\u0111er mo\u017ee eliminirati probleme delaminacije ili lju\u0161tenja pri visokim temperaturama.<\/p>\n\n\n\n

Rezultati testova pokazuju da je toplotni otpor nove izolirane aluminijske plo\u010de s podlogom 4,78 \u00b0C\/W, dok je toplotni otpor tradicionalne aluminijske plo\u010de s podlogom izolirane polimerom 7,61 \u00b0C\/W.<\/p>\n\n\n\n

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Tehnologija magnetronnog raspr\u0161ivanja<\/h3>\n\n\n\n

Osnovni proces isparavanja<\/h4>\n\n\n\n

Sputtering je vakuumski proces koji se koristi za talo\u017eenje materijala poput metala, keramike i plastike na povr\u0161inu kako bi se formirao tanki sloj. Osnovni proces sputtering-a radi na sljede\u0107i na\u010din.<\/p>\n\n\n\n

Elektroni se sudaraju s atomima inertnog plina, obi\u010dno argona, i ioniziraju ih. Ti visokoenergetski ioni ubrzavaju se elektri\u010dnim poljem i bombardiraju materijal mete koji treba nanijeti. Zbog ovog sna\u017enog bombardiranja atomi se izbacuju s povr\u0161ine materijala mete. Pod utjecajem elektri\u010dnog polja ti atomi se na kraju talo\u017ee na povr\u0161inu podloge i formiraju atomski tanak sloj. Debljina tog tankog sloja ovisi o vremenu rasprskavanja.<\/p>\n\n\n\n

Konvencionalna PCB plo\u010da s metalnom podlogom izoliranom polimerom obi\u010dno se sastoji od bakrenog sloja, sloja ljepila, polimernog izolacijskog sloja, LED \u010dipa, ljepila i aluminijske osnove. Suprotno tome, magnetron sputtering uvodi dodatno magnetsko polje u proces.<\/p>\n\n\n\n

Magnetronski proces raspr\u0161ivanja<\/h4>\n\n\n\n

Cjelokupan proces magnetronskog raspr\u0161ivanja razlikuje se od osnovnog raspr\u0161ivanja istosmjernom strujom prvenstveno zato \u0161to se u blizini podru\u010dja cilja primjenjuje sna\u017eno magnetsko polje. Ovo magnetsko polje prisiljava elektrone da se kre\u0107u du\u017e linija magnetskog polja u blizini povr\u0161ine cilja umjesto da budu privu\u010deni prema podlozi.<\/p>\n\n\n\n

U pore\u0111enju s osnovnim isparavanjem, magnetron sputtering nudi tri glavne prednosti. Prvo, plazma je ograni\u010dena blizu materijala cilja i ne o\u0161te\u0107uje tanki sloj koji se formira. Drugo, putanja elektrona postaje du\u017ea, \u0161to pove\u0107ava vjerovatno\u0107u ionizacije atoma argona. Kao rezultat toga, vi\u0161e atoma ciljnog materijala se izbacuje, a efikasnost raspr\u0161ivanja se pobolj\u0161ava. Tre\u0107e, tanki slojevi proizvedeni magnetronskim raspr\u0161ivanjem sadr\u017ee manje ne\u010disto\u0107a, \u0161to osigurava visok kvalitet sloja.<\/p>\n\n\n\n

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Dizajn anodiziranog izolovanog aluminijskog podloge za \u0161tampane plo\u010dice<\/h3>\n\n\n\n

Anodizirana izolirana aluminijska podloga za tiskane plo\u010dice (PCB) sastoji se od tri sloja: aluminijskog baznog sloja, anodiziranog izolacijskog sloja i sloja metalizacije. Sam sloj metalizacije sastoji se od tri tanka filma: baznog filma, provodnog filma i lemljivog filma.<\/p>\n\n\n\n

Aluminijska bazna podloga<\/h4>\n\n\n\n

Aluminijska bazna plo\u010da \u010dini temelj tiskane plo\u010dice. Prilikom odabira aluminijskog materijala moraju se uzeti u obzir dva faktora. Prvo, aluminij mora imati dovoljnu mehani\u010dku \u010dvrsto\u0107u i dobru obradivost. Drugo, mora biti pogodan za anodizaciju i izolacijsku obradu. U odre\u0111enim uvjetima aluminijska baza se tako\u0111er mo\u017ee obraditi u strukturu s rebrima kako bi se dodatno pobolj\u0161ala disipacija topline.<\/p>\n\n\n\n

Anodizirani izolacijski sloj<\/h4>\n\n\n\n

Anodizirani izolacijski sloj formira se posebnim procesom anodizacije koji stvara mikroporoznu strukturu. Ova mikroporozna struktura odre\u0111uje elektri\u010dne izolacijske performanse sloja. Ovisno o primijenjenoj tehnologiji obrade, dielektri\u010dna \u010dvrsto\u0107a ovog sloja mo\u017ee se kretati od 250 V do 3000 V.<\/p>\n\n\n\n

Kori\u0161tenjem fotolitografije ili tehnologije maskiranja, na ovom sloju se formira uzorak kola. Ovaj dizajn omogu\u0107ava besprijekornu integraciju izme\u0111u osnovnog sloja i izolacionog sloja. Istovremeno se LED \u010dipovi direktno montiraju na ovaj sloj. Kao rezultat, LED \u010dip, PCB i hladnjak \u010dine jedinstvenu integrisanu strukturu. To znatno pobolj\u0161ava ukupne termalne performanse PCB-a.<\/p>\n\n\n\n

Sloj metalizacije<\/h4>\n\n\n\n

Metalizacijski sloj se sastoji od osnovnog filma, provodnog filma i lemivog filma. Ovaj sloj ne samo da mora osigurati dobru elektri\u010dnu provodnost, ve\u0107 i sna\u017enu adheziju izme\u0111u metalizacijskog sloja i anodiziranog izolacionog sloja. Kolos se formira na ovom sloju pomo\u0107u tehnologije magnetron sputtering.<\/p>\n\n\n\n

Osnovni sloj ima debljinu izme\u0111u 0,1 i 0,15 mikrometara. Formira se raspr\u0161ivanjem metala kao \u0161to su krom ili titanij. Glavna funkcija osnovnog sloja je da osigura sna\u017eno prianjanje izme\u0111u sloja metalizacije i anodiziranog izolacionog sloja. Kod magnetronog raspr\u0161ivanja, \u010dvrsto\u0107a prianjanja mo\u017ee dosti\u0107i 1000 N\/cm\u00b2, \u0161to vezu \u010dini veoma stabilnom. Pored toga, bazni sloj ima odli\u010dnu otpornost na visoke temperature. \u010cak i na temperaturama iznad 320\u00b0C tokom 10 sekundi ne dolazi do stvaranja mjehuri\u0107a niti lju\u0161tenja. Stoga je u potpunosti pogodan za procese lemljenja bez olova.<\/p>\n\n\n\n

Provodni film ima debljinu izme\u0111u 1 i 2 mikrometra. Formira se pulverizacijom bakra, nikla ili bakreno-nikl legura. Ovaj film slu\u017ei dvjema glavnim svrhama. Jedna je svrha da prenosi odre\u0111enu gusto\u0107u struje. Druga je svrha da djeluje kao tamponski sloj kada do\u0111e do deformacije zbog razlika u koeficijentima toplinske ekspanzije izme\u0111u osnovnog filma i lemljivog filma. Ovaj tamponski u\u010dinak poma\u017ee u odr\u017eavanju stabilnosti cijelog sloja metalizacije.<\/p>\n\n\n\n

Lemljivi film ima debljinu izme\u0111u 0,3 i 0,8 mikrometara. Nastaje raspr\u0161ivanjem metala poput zlata ili srebra, koji imaju dobru toplotnu i elektri\u010dnu provodnost te lemljivost. Glavna funkcija ovog sloja je olak\u0161ati lemljenje elektroni\u010dkih komponenti, uklju\u010duju\u0107i LED \u010dipove.<\/p>\n\n\n\n

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Tehnologija proizvodnih procesa<\/h3>\n\n\n\n

Cijeli proizvodni proces obuhvata pet koraka, koji se mogu grupisati u tri glavne faze. Te faze uklju\u010duju anodizaciju aluminijske osnove, formiranje uzorka kola na anodiziranom izolacionom sloju pomo\u0107u fotolitografije ili maskiranja, talo\u017eenje osnovnog sloja, provodnog sloja i sloja pogodnog za lemljenje pomo\u0107u magnetron sputtering tehnike, te na kraju sitotisak i nano\u0161enje fluksa i maske za lem.<\/p>\n\n\n\n

Anodizacija aluminijske osnove<\/h4>\n\n\n\n

Prvo se aluminijska podloga podvrgava povr\u0161inskom odma\u0161\u0107ivanju i \u010di\u0161\u0107enju. Zatim se postavlja u elektrolitsku kupku napunjenu elektrolitom. Elektrolit mo\u017ee biti sumporna kiselina ili oksalna kiselina, ovisno o potrebnim svojstvima oksidnog sloja i uvjetima procesa. Tijekom anodizacije aluminijska podloga djeluje kao anoda. Klju\u010dni parametri procesa uklju\u010duju koncentraciju elektrolita, gusto\u0107u struje i temperaturu elektrolita. Da bi se dobio kvalificirani anodizirani izolacijski sloj, vrijeme anodizacije mora biti pa\u017eljivo kontrolirano.<\/p>\n\n\n\n

Magnetronsko talo\u017eenje<\/h4>\n\n\n\n

Prije nano\u0161enja filmovog sloja, \u0161ablona kruga mora biti stvorena na anodiziranom izolacionom sloju pomo\u0107u fotolitografije ili tehnologije maskiranja. Kada se koristi fotolitografija, anodizirana aluminijska plo\u010da se premazuje fotoresistom, izla\u017ee i razvija. Zatim se montira u stezni ure\u0111aj bez maske. Kada se koristi tehnologija maskiranja, masena plo\u010da se postavlja na povr\u0161inu steznog ure\u0111aja prilikom stezanja anodizirane aluminijske plo\u010de.<\/p>\n\n\n\n

Koraci post-obrade<\/h4>\n\n\n\n

Prema zahtjevima dizajna, flukso i maska za lemljenje nanose se na odre\u0111ena podru\u010dja premazanog anodiziranog aluminijskog podloge tiskane plo\u010dice kako bi se pripremila za monta\u017eu elektroni\u010dkih komponenti.<\/p>\n\n\n\n

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Metoda za izra\u010dunavanje toplotnog otpora<\/h3>\n\n\n\n

Temperaturni otpor odnosi se na otpor toplinski provodljivog materijala protoku topline od izvora topline do ure\u0111aja koji apsorbira toplinu. Jedinica mu je \u00b0C\/W. Temperaturni otpor se defini\u0161e kao razlika u temperaturi podijeljena brzinom prijenosa toplinske snage.<\/p>\n\n\n\n

\"Thermal<\/figure>\n\n\n\n

Temperaturni otpor izme\u0111u dva ta\u010dke mo\u017ee se izraziti kao razlika temperatura podijeljena sa snagom koja se raspr\u0161uje izme\u0111u tih ta\u010daka.<\/p>\n\n\n\n

Metoda mjerenja toplotnog otpora<\/h4>\n\n\n\n

Za mjerenje termi\u010dkih karakteristika LED-ova obi\u010dno se koriste nekoliko metoda. To uklju\u010duje infracrveno termalno snimanje, spektralne metode, metode opti\u010dke snage, metode temperature grla i metode elektri\u010dnih parametara. U ovom radu predlo\u017eena je pobolj\u0161ana metoda elektri\u010dnih parametara.<\/p>\n\n\n\n

\"Method<\/figure>\n\n\n\n

Termalni otpor izme\u0111u spojnice i okoline izra\u010dunava se koriste\u0107i temperaturu spojnice, temperaturu okoline i disipiranu snagu. Porast temperature spojnice linearno je povezan s promjenom napona u pravcu napred kada je struja dovoljno mala. Budu\u0107i da je po\u010detna temperatura spojnice gotovo jednaka temperaturi okoline, razlika u temperaturi izme\u0111u spojnice i okoline mo\u017ee se dobiti izravno.<\/p>\n\n\n\n

Kombiniranjem relevantnih jedna\u010dina mo\u017ee se izra\u010dunati toplotni otpor od spojke do okoline. U praksi je opti\u010dka snaga mnogo manja u odnosu na elektri\u010dnu snagu, pa se mo\u017ee zanemariti.<\/p>\n\n\n\n

Postupak mjerenja uklju\u010duje odabir LED diode visoke snage kao izvora za grijanje, kori\u0161tenje standardne LED diode kao testnog ure\u0111aja, njihovo elektri\u010dno izoliranje, mjerenje promjena napona prije i nakon grijanja, izra\u010dunavanje porasta temperature, odre\u0111ivanje disipirane snage i na kraju izra\u010dunavanje toplotnog otpora.<\/p>\n\n\n\n

\"Schematic<\/figure>\n\n\n\n
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Rezultati toplotnog otpora anodiziranog izolovanog aluminijskog podloge za PCB<\/h3>\n\n\n\n

Koriste\u0107i opisanu metodu, mo\u017ee se izra\u010dunati toplotni otpor i konvencionalnih PCB-ova s polimerski izolovanim metalnim podlogama i PCB-ova s anodiziranim aluminijskim izolovanim podlogama. Pored ukupnog toplotnog otpora, mjeri se i toplotni otpor svakog pojedina\u010dnog sloja.<\/p>\n\n\n\n

Temperaturni otpori razli\u010ditih slojeva su spojeni serijski. Ukupni temperaturni otpor je zbir otpora od spojnice do metalnog sloja, od metalnog sloja do podloge i od podloge do okoline.<\/p>\n\n\n\n

\"Thermal<\/figure>\n\n\n\n

Rezultati pokazuju da je toplotni otpor anodiziranog izoliranog aluminijskog podloge za PCB 59,21 TP3T ni\u017ei nego kod konvencionalnog PCB-a s metalnom podlogom izoliranom polimerom. Ovo pobolj\u0161anje je uglavnom posljedica dva faktora. Prvo, konvencionalni PCB ima jedan strukturni sloj vi\u0161e nego anodizirani PCB. Drugo, anodizirani izolacijski sloj je znatno tanji i ima mnogo bolju toplotnu provodnost od polimernog izolacijskog sloja.<\/p>\n\n\n\n

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Zaklju\u010dak<\/h3>\n\n\n\n

Termalno upravljanje je klju\u010dno pitanje u razvoju RGB-LED pozadinskih osvjetljiva\u010dkih sistema. U ovoj studiji razvijen je novi tip PCB-a sa anodiziranim izolovanim aluminijskim podlogom, te je predlo\u017eena pobolj\u0161ana metoda elektri\u010dnih parametara za mjerenje toplotnog otpora.<\/p>\n\n\n\n

U pore\u0111enju sa konvencionalnim PCB-ovima sa polimerski izolovanim metalnim podlogama, PCB sa anodiziranom aluminijskom izolacijskom podlogom ima nekoliko prednosti. Ne postoji mehani\u010dki razmak izme\u0111u anodiziranog izolacionog sloja i aluminijske osnove, \u0161to pobolj\u0161ava ukupnu mehani\u010dku \u010dvrsto\u0107u. Tro-slojna struktura metalizacije formirana magnetronskim raspr\u0161ivanjem osigurava sna\u017enu adheziju od najmanje 1000 N\/cm\u00b2, \u0161to dodatno pove\u0107ava mehani\u010dku stabilnost. Osim toga, smanjeni broj slojeva i tanji izolacioni sloj zna\u010dajno smanjuju ukupni toplotni otpor za 59,21 \u00b0C.<\/p>\n\n\n\n

Zbog ovih prednosti, anodizirane PCB plo\u010de s izoliranim aluminijskim podlogom pogodnije su za upotrebu u RGB-LED pozadinskim osvjetljavaju\u0107im sistemima nego konvencionalne PCB plo\u010de s metalnom podlogom i polimernom izolacijom.<\/p>\n\n\n\n

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Introduction A light-emitting diode (LED) is a solid-state semiconductor device that converts electrical energy into light. Compared with traditional incandescent 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