{"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\/da\/thermal-design-of-led-aluminum-pcbs\/","title":{"rendered":"Termisk design af LED-printkort i aluminium"},"content":{"rendered":"
\n\n\n\n

Introduktion<\/h3>\n\n\n\n

En lysemitterende diode (LED<\/a>) er en halvlederenhed i fast tilstand, der omdanner elektrisk energi til lys. Sammenlignet med traditionelle gl\u00f8delamper har LED mange klare fordele. Disse fordele omfatter lang levetid, bredt farveomr\u00e5de, st\u00e6rk holdbarhed, fleksibelt design, enkel kontrol og milj\u00f8beskyttelse. P\u00e5 grund af disse fordele betragtes LED i vid udstr\u00e6kning som en af de mest lovende lyskilder i fremtiden.<\/p>\n\n\n\n

R\u00f8de, gr\u00f8nne og bl\u00e5 (RGB) LED'er kan blandes for at generere hvidt lys med et meget bredt farvespektrum. P\u00e5 grund af denne funktion er RGB-LED'er meget attraktive til brug i baggrundsbelysningssystemer til flydende krystalsk\u00e6rme (LCD). Denne type baggrundsbelysning g\u00f8r det muligt for sk\u00e6rme at blive tyndere, have en l\u00e6ngere levetid, give et h\u00f8jere d\u00e6mpningsforhold og vise lysere og mere levende farver. Samtidig er disse sk\u00e6rme mere milj\u00f8venlige.<\/p>\n\n\n\n

P\u00e5 grund af disse fordele er der udgivet mange forskningsartikler om direkte oplyste LED-baggrundsbelysningskort og kantbelyste LED-baggrundsbelysningskort. Verdens f\u00f8rste LCD-tv med blandet RGB-LED-baggrundsbelysning blev udgivet af Sony. Dette produkt opn\u00e5ede et meget bredt farvegengivelsesomr\u00e5de, der n\u00e5ede 105% af National Television System Committee (NTSC) standardfarveskala.<\/p>\n\n\n\n

Men bag disse forskningsresultater findes der stadig termiske problemer. Under drift genererer LED'er varme. Denne varme for\u00e5rsager en reduktion i lysintensiteten og f\u00f8rer ogs\u00e5 til et skift i den dominerende b\u00f8lgel\u00e6ngde. Disse to effekter \u00e6ndrer sk\u00e6rmens farvetemperatur og resulterer i variationer i NTSC-ydelsen. Desuden forkorter overdreven varme sk\u00e6rmens levetid. For at sikre billedkvalitet og p\u00e5lidelighed p\u00e5 lang sigt er det derfor ekstremt vigtigt med termisk styring af baggrundsbelysningssystemet.<\/p>\n\n\n\n

For at forbedre den termiske ydeevne i et RGB-LED-baggrundsbelysningssystem kan man overveje to hovedtilgange. Den f\u00f8rste tilgang er at forbedre varmeafledningsevnen for en enkelt LED. Den anden tilgang er at forbedre LED-arrayets varmeafledningsevne. Som designere af et RGB-LED-baggrundsbelysningssystem valgte vi den anden tilgang til at l\u00f8se det termiske problem.<\/p>\n\n\n\n

Der er ogs\u00e5 to almindelige metoder til at forbedre et LED-array-systems termiske ydeevne. Den ene metode er at bruge ventilatorer til at \u00f8ge luftstr\u00f8mningshastigheden omkring baggrundsbelysningssystemet. Den anden metode er at reducere den termiske modstand fra LED-krydset til det omgivende milj\u00f8. Det er en bedre l\u00f8sning at designe baggrundsbelysningsmodulet p\u00e5 et \u00f8konomisk printkort med h\u00f8j varmeledningsevne.<\/p>\n\n\n\n

P\u00e5 nuv\u00e6rende tidspunkt bruger den udbredte konventionelle IMS-teknologi (Insulated Metal Substrate) polymer- eller epoxyharpiksmaterialer som det isolerende lag. Denne teknologi kr\u00e6ver en s\u00e6rlig overfladebehandling af metalbasen. Desuden er minimumstykkelsen p\u00e5 det isolerende lag normalt omkring 75 mikrometer. Denne tykkelse \u00f8ger den samlede termiske modstand p\u00e5 IMS-kortet. Desuden kan traditionelle IMS-kort under h\u00f8je temperaturer lide af delaminering mellem det isolerende lag og metalbasen.<\/p>\n\n\n\n

I denne artikel bruger vi magnetronforst\u00f8vningsteknologi til at fremstille en ny type PCB med isoleret metalsubstrat. Et kemisk dannet isolerende lag med en tykkelse p\u00e5 30 til 35 mikrometer genereres p\u00e5 overfladen af en aluminiumsbase. Derefter dannes det designede kredsl\u00f8b p\u00e5 det isolerende lag ved hj\u00e6lp af magnetronforst\u00f8vning. Dette nye isolerede metalsubstrat-PCB har en fremragende termisk ydeevne og kan ogs\u00e5 eliminere problemer med delaminering eller afskalning under h\u00f8je temperaturer.<\/p>\n\n\n\n

Testresultaterne viser, at den termiske modstand for det nye isolerede aluminiumsunderlag er 4,78 \u00b0C\/W, mens den termiske modstand for et traditionelt polymerisoleret aluminiumsunderlag er 7,61 \u00b0C\/W.<\/p>\n\n\n\n

\n\n\n\n

Magnetron-sputtering-teknologi<\/h3>\n\n\n\n

Grundl\u00e6ggende sputteringsproces<\/h4>\n\n\n\n

Sputtering er en vakuumproces, der bruges til at aflejre materialer som metaller, keramik og plast p\u00e5 en overflade, s\u00e5 der dannes en tynd film. Den grundl\u00e6ggende sputteringsproces fungerer p\u00e5 f\u00f8lgende m\u00e5de.<\/p>\n\n\n\n

Elektroner kolliderer med inerte gasatomer, normalt argon, og ioniserer dem. Disse h\u00f8jenergi-ioner accelereres af et elektrisk felt og bombarderer det m\u00e5lmateriale, der skal deponeres. P\u00e5 grund af dette st\u00e6rke bombardement bliver atomer slynget ud fra overfladen af m\u00e5lmaterialet. Under p\u00e5virkning af det elektriske felt aflejres disse atomer til sidst p\u00e5 overfladen af substratet og danner en atomar tyndfilm. Tykkelsen af denne tynde film afh\u00e6nger af sputteringstiden.<\/p>\n\n\n\n

Et konventionelt PCB med polymerisoleret metalsubstrat best\u00e5r typisk af et kobberlag, et kl\u00e6belag, et polymerisolerende lag, en LED-chip, et kl\u00e6belag og en aluminiumsbase. I mods\u00e6tning hertil introducerer magnetronforst\u00f8vning et ekstra magnetfelt i processen.<\/p>\n\n\n\n

Magnetron-forst\u00f8vningsproces<\/h4>\n\n\n\n

Processen med fuld magnetronforst\u00f8vning adskiller sig fra almindelig j\u00e6vnstr\u00f8msforst\u00f8vning, prim\u00e6rt fordi der anvendes et st\u00e6rkt magnetfelt i n\u00e6rheden af m\u00e5lomr\u00e5det. Dette magnetfelt tvinger elektronerne til at bev\u00e6ge sig langs de magnetiske feltlinjer n\u00e6r m\u00e5lets overflade i stedet for at blive tiltrukket af underlaget.<\/p>\n\n\n\n

Sammenlignet med almindelig sputtering giver magnetronsputtering tre store fordele. For det f\u00f8rste er plasmaomr\u00e5det begr\u00e6nset i n\u00e6rheden af m\u00e5lmaterialet og beskadiger ikke den tynde film, der dannes. For det andet bliver elektronens banel\u00e6ngde l\u00e6ngere, hvilket \u00f8ger sandsynligheden for at ionisere argonatomer. Som f\u00f8lge heraf bliver flere m\u00e5latomer kastet ud, og sputteringseffektiviteten forbedres. For det tredje indeholder de tynde film, der produceres ved magnetronsputtering, f\u00e6rre urenheder, hvilket sikrer en h\u00f8j filmkvalitet.<\/p>\n\n\n\n

\n\n\n\n

Design af PCB med anodiseret, isoleret aluminiumssubstrat<\/h3>\n\n\n\n

Det anodiserede isolerede aluminiumssubstrat PCB best\u00e5r af tre lag: aluminiumsbaselaget, det anodiserede isoleringslag og metalliseringslaget. Selve metalliseringslaget best\u00e5r af tre tynde film, som er basisfilmen, den ledende film og den loddebare film.<\/p>\n\n\n\n

Underlag af aluminium<\/h4>\n\n\n\n

Aluminiumsbaselaget danner fundamentet for printkortet. N\u00e5r man v\u00e6lger aluminiumsmateriale, skal man overveje to faktorer. For det f\u00f8rste skal aluminiummet have tilstr\u00e6kkelig mekanisk styrke og god bearbejdelighed. For det andet skal det v\u00e6re egnet til anodisering og isoleringsbehandling. Under visse betingelser kan aluminiumsbasen ogs\u00e5 forarbejdes til en finneformet struktur for yderligere at forbedre varmeafledningen.<\/p>\n\n\n\n

Anodiseret isolerende lag<\/h4>\n\n\n\n

Det anodiserede isoleringslag dannes gennem en s\u00e6rlig anodiseringsproces, der skaber en mikropor\u00f8s struktur. Denne mikropor\u00f8se struktur bestemmer lagets elektriske isoleringsevne. Afh\u00e6ngigt af den anvendte forarbejdningsteknologi kan dette lags dielektriske styrke variere fra 250 V til 3000 V.<\/p>\n\n\n\n

Ved hj\u00e6lp af fotolitografi eller maskeringsteknologi dannes kredsl\u00f8bsm\u00f8nsteret p\u00e5 dette lag. Dette design giver mulighed for problemfri integration mellem basislaget og det isolerende lag. Samtidig er LED-chippene monteret direkte p\u00e5 dette lag. Resultatet er, at LED-chip, printkort og k\u00f8leplade udg\u00f8r en enkelt integreret struktur. Dette forbedrer i h\u00f8j grad printkortets samlede termiske ydeevne.<\/p>\n\n\n\n

Metalliseringslag<\/h4>\n\n\n\n

Metalliseringslaget best\u00e5r af en basisfilm, en ledende film og en film, der kan loddes. Dette lag skal ikke kun give god elektrisk ledningsevne, men ogs\u00e5 sikre st\u00e6rk vedh\u00e6ftning mellem metalliseringslaget og det anodiserede isoleringslag. Kredsl\u00f8bet dannes p\u00e5 dette lag ved hj\u00e6lp af magnetronforst\u00f8vningsteknologi.<\/p>\n\n\n\n

Basisfilmen har en tykkelse p\u00e5 mellem 0,1 og 0,15 mikrometer. Den dannes ved sputtering af metaller som krom eller titanium. Basisfilmens vigtigste funktion er at give st\u00e6rk vedh\u00e6ftning mellem metalliseringslaget og det anodiserede isoleringslag. Med magnetronforst\u00f8vning kan vedh\u00e6ftningsstyrken n\u00e5 op p\u00e5 1000 N\/cm\u00b2, hvilket g\u00f8r bindingen meget stabil. Desuden har basisfilmen en fremragende modstandsdygtighed over for h\u00f8je temperaturer. Selv ved temperaturer over 320 \u00b0C i 10 sekunder opst\u00e5r der ingen bl\u00e6rer eller afskalning. Derfor er den fuldt ud egnet til blyfri loddeprocesser.<\/p>\n\n\n\n

Den ledende film har en tykkelse p\u00e5 mellem 1 og 2 mikrometer. Den dannes ved sputtering af kobber, nikkel eller kobber-nikkel-legeringer. Denne film tjener to hovedform\u00e5l. Det ene form\u00e5l er at b\u00e6re en vis str\u00f8mt\u00e6thed. Det andet form\u00e5l er at fungere som et bufferlag, n\u00e5r der opst\u00e5r deformation p\u00e5 grund af forskelle i varmeudvidelseskoefficienter mellem basisfilmen og den loddebare film. Denne buffereffekt hj\u00e6lper med at opretholde stabiliteten i hele metalliseringslaget.<\/p>\n\n\n\n

Den loddbare film har en tykkelse p\u00e5 mellem 0,3 og 0,8 mikrometer. Det dannes ved at sputtere metaller som guld eller s\u00f8lv, der har god varmeledningsevne, elektrisk ledningsevne og loddeevne. Dette lags vigtigste funktion er at lette lodningen af elektroniske komponenter, herunder LED-chips.<\/p>\n\n\n\n

\n\n\n\n

Teknologi til fremstillingsprocesser<\/h3>\n\n\n\n

Hele fremstillingsprocessen omfatter fem trin, som kan grupperes i tre hovedfaser. Disse trin omfatter anodisering af aluminiumsbasen, dannelse af kredsl\u00f8bsm\u00f8nster p\u00e5 det anodiserede isolerende lag ved hj\u00e6lp af fotolitografi eller maskering, aflejring af basisfilmen, den ledende film og den lodbare film ved hj\u00e6lp af magnetronforst\u00f8vning og til sidst serigrafi og p\u00e5f\u00f8ring af flux og loddemaske.<\/p>\n\n\n\n

Anodisering af aluminiumsbasen<\/h4>\n\n\n\n

F\u00f8rst bliver aluminiumsbasen affedtet og rengjort p\u00e5 overfladen. Derefter placeres den i et elektrolytisk bad fyldt med en elektrolyt. Elektrolytten kan v\u00e6re svovlsyre eller oxalsyre, afh\u00e6ngigt af de \u00f8nskede egenskaber ved oxidlaget og procesbetingelserne. Under anodisering fungerer aluminiumsbasen som anode. De vigtigste procesparametre omfatter elektrolytkoncentration, str\u00f8mt\u00e6thed og elektrolyttemperatur. For at opn\u00e5 et kvalificeret anodiseret isoleringslag skal anodiseringstiden kontrolleres omhyggeligt.<\/p>\n\n\n\n

Aflejring ved magnetronforst\u00f8vning<\/h4>\n\n\n\n

F\u00f8r filmdeponeringen skal kredsl\u00f8bsm\u00f8nsteret skabes p\u00e5 det anodiserede isolerende lag ved hj\u00e6lp af fotolitografi eller maskeringsteknologi. N\u00e5r der anvendes fotolitografi, bliver den anodiserede aluminiumsplade belagt med fotoresist, eksponeret og fremkaldt. Derefter monteres den i et armatur uden maske. N\u00e5r der anvendes maskeringsteknologi, monteres en maskeplade p\u00e5 armaturets overflade, n\u00e5r den anodiserede aluminiumsplade fastsp\u00e6ndes.<\/p>\n\n\n\n

Efterbehandlingstrin<\/h4>\n\n\n\n

I henhold til designkravene p\u00e5f\u00f8res flux og loddemaske p\u00e5 specifikke omr\u00e5der af det coatede anodiserede aluminiumssubstrat PCB for at forberede det til samling af elektroniske komponenter.<\/p>\n\n\n\n

\n\n\n\n

Metode til beregning af termisk modstand<\/h3>\n\n\n\n

Termisk modstand refererer til et varmeledende materiales modstand mod varmestr\u00f8m fra en varmekilde til en varmeabsorberende enhed. Enheden er \u00b0C\/W. Termisk modstand defineres som temperaturforskellen divideret med varmeeffektoverf\u00f8rselshastigheden.<\/p>\n\n\n\n

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

Den termiske modstand mellem to punkter kan udtrykkes som temperaturforskellen divideret med den effekt, der afgives mellem disse punkter.<\/p>\n\n\n\n

Metode til m\u00e5ling af termisk modstand<\/h4>\n\n\n\n

Der bruges ofte flere metoder til at m\u00e5le LED'ers termiske egenskaber. Disse omfatter infrar\u00f8d termisk billeddannelse, spektrale metoder, optiske effektmetoder, blytemperaturmetoder og elektriske parametermetoder. I denne artikel foresl\u00e5s en forbedret elektrisk parametermetode.<\/p>\n\n\n\n

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

Den termiske modstand mellem forbindelsen og det omgivende milj\u00f8 beregnes ved hj\u00e6lp af forbindelsestemperaturen, den omgivende temperatur og den afgivne effekt. Forbindelsens temperaturstigning er line\u00e6rt relateret til \u00e6ndringen i forsp\u00e6nding, n\u00e5r str\u00f8mmen er tilstr\u00e6kkelig lille. Da den oprindelige overgangstemperatur n\u00e6sten er lig med omgivelsestemperaturen, kan forskellen mellem overgangs- og omgivelsestemperatur beregnes direkte.<\/p>\n\n\n\n

Ved at kombinere de relevante ligninger kan den termiske modstand mellem forbindelsen og omgivelserne beregnes. I praksis er den optiske effekt meget lille sammenlignet med den elektriske effekt, s\u00e5 den kan ignoreres.<\/p>\n\n\n\n

M\u00e5leproceduren omfatter valg af en h\u00f8jeffekt-LED som varmekilde, brug af en standard-LED som testenhed, elektrisk isolering af dem, m\u00e5ling af sp\u00e6ndings\u00e6ndringer f\u00f8r og efter opvarmning, beregning af temperaturstigning, bestemmelse af afledt effekt og endelig beregning af termisk modstand.<\/p>\n\n\n\n

\"Schematic<\/figure>\n\n\n\n
\n\n\n\n

Resultater af termisk modstand for anodiseret isoleret aluminiumsunderlag PCB<\/h3>\n\n\n\n

Ved hj\u00e6lp af den beskrevne metode kan den termiske modstand for b\u00e5de konventionelle polymerisolerede metalsubstrat-PCB'er og anodiserede isolerede aluminiumssubstrat-PCB'er beregnes. Ud over den samlede termiske modstand m\u00e5les ogs\u00e5 den termiske modstand for hvert enkelt lag.<\/p>\n\n\n\n

De termiske modstande i forskellige lag er forbundet i serie. Den samlede termiske modstand er summen af modstanden fra krydset til metallaget, fra metallaget til substratet og fra substratet til det omgivende milj\u00f8.<\/p>\n\n\n\n

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

Resultaterne viser, at den termiske modstand for det anodiserede isolerede aluminiumsunderlag er 59,2% lavere end for det konventionelle polymerisolerede metalunderlag. Denne forbedring skyldes hovedsageligt to faktorer. For det f\u00f8rste har det konventionelle printkort et strukturelt lag mere end det anodiserede printkort. For det andet er det anodiserede isoleringslag meget tyndere og har meget bedre varmeledningsevne end det isolerende polymerlag.<\/p>\n\n\n\n

\n\n\n\n

Konklusion<\/h3>\n\n\n\n

Varmestyring er et kritisk sp\u00f8rgsm\u00e5l i udviklingen af RGB-LED-baggrundsbelysningssystemer. I denne unders\u00f8gelse udvikles en ny type anodiseret isoleret aluminiumssubstrat-PCB, og der foresl\u00e5s en forbedret elektrisk parametermetode til m\u00e5ling af termisk modstand.<\/p>\n\n\n\n

Sammenlignet med konventionelle polymerisolerede metalsubstrat-PCB'er har det anodiserede isolerede aluminiumssubstrat-PCB flere fordele. Der er ikke noget mekanisk mellemrum mellem det anodiserede isoleringslag og aluminiumsbasen, hvilket forbedrer den samlede mekaniske styrke. Den trelags metalliseringsstruktur, der er dannet ved magnetronforst\u00f8vning, giver en st\u00e6rk vedh\u00e6ftning p\u00e5 mindst 1000 N\/cm\u00b2, hvilket yderligere forbedrer den mekaniske stabilitet. Derudover s\u00e6nker det reducerede antal lag og det tyndere isoleringslag den samlede termiske modstand betydeligt med 59,2%.<\/p>\n\n\n\n

P\u00e5 grund af disse fordele er anodiserede isolerede aluminiumsprintkort mere velegnede til brug i RGB-LED-baggrundsbelysningssystemer end konventionelle polymerisolerede metalsubstratprintkort.<\/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. 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