The copper clad laminate, or CCL, is said to be the latest addition to PCBs as it dissipates heat from the circuit to let the electronic devices function nicely. It is made of copper and resin composite to work efficiently in electronic circuits. This article will explain what copper clad laminate is and how it can help improve your PCB design by providing you with an understanding of its properties and functions.
Table of Contents
1. What is copper clad laminate?
2. Benefits of copper clad laminate
3. Types of copper clad laminates
4. copper clad laminate (CCL) Materials
5. What is the function of copper clad board?
6. Where can copper clad laminate be used?
7. Difference between the laminate and prepreg
8. Manufacturing process of copper clad laminate
9. Factors should be considered in copper clad laminate manufacturing
10. Considerations when choosing copper clad laminate manufacturers
11. Conclusion
As a base material for PCB, copper clad laminate, or CCL, is typically sold as a semi-finished product. The outer layer is laminated with copper foil over a resin-impregnated glass fiber sheet (intermediate layer). The intermediate layer provides the basic structure for the finished product, and the copper foil gives it a distinctive look that can be customized to suit your needs.
· It’s affordable.
· It can be customized to fit any space.
· It doesn’t need any maintenance and will last for years.
· In addition, to signal integrity issues, CCL boards are also useful when heat dissipation is needed because they can absorb more heat than standard materials without deteriorating over time like other types of PCBs do.
1. Based on material used
|
Paper-based lamination |
√ Consists of a thin layer of paper sandwiched between two layers of copper foil. |
|
Gass fiber cloth-based lamination |
√ Uses glass fibers for its core material instead of paper. |
|
Compound-based lamination |
√ Combines different materials together into one single unit. |
2. Based on resin/insulator used
|
Phenolic laminates |
√ Widely used for power, communications, and other equipment. |
|
Epoxy laminates |
√ Widely used in high-speed data transmission systems, such as routers and network switches. |
|
Polyester laminates |
√ Widely used in electronic equipment such as computer motherboards, printers, projectors, and others. |
|
Polyimide |
√ Very similar to polyester but has lower resistance. |
3. Based on mechanical support
|
Rigid CCL |
√ The resin used in RCDL is epoxy-based. |
|
Flexible CCL |
√ Made of lexible substrate material. |
|
Hybrid (HCL) |
√ This copper clad laminate type combines the properties of both rigid and flexible copper clad laminated (FCCL) |
copper clad laminate (CCL) materials are essential components in the manufacturing of printed circuit boards (PCBs), playing a critical role in their performance and reliability. Here’s a straightforward explanation of what CCL materials are and their significance in PCB fabrication:
CCL materials are composed of a substrate (or base material) with thin copper foil laminated to one or both sides. The substrate is typically made of materials like fiberglass (FR4), composite epoxy, or polyimide, which provide mechanical support and insulation. The copper foil layers serve as the conductive pathways that connect electronic components on the PCB.
FR4 (Flame Retardant 4): This is the most common type of CCL material, known for its high mechanical strength, good electrical insulation properties, and flame retardancy. It’s widely used in consumer electronics, telecommunications, and industrial applications.
Flexible CCL (Polyimide): Flexible CCLs use polyimide films as the substrate, allowing PCBs to be bendable or flexible. These are used in applications where space constraints or flexibility is crucial, such as in wearable devices and aerospace applications.
Metal Core CCL: In metal core CCLs, a thermally conductive metal substrate (such as aluminum or copper) replaces the traditional fiberglass substrate. This allows for efficient heat dissipation, making them suitable for high-power LED lighting, automotive lighting, and power electronics.
Electrical Performance: CCL materials ensure proper electrical insulation and signal integrity, facilitating efficient signal transmission and reducing electromagnetic interference (EMI).
Mechanical Durability: They provide a stable platform for mounting electronic components and withstand mechanical stresses during assembly, testing, and operational use.
Thermal Management: Certain types of CCL materials, like metal core CCLs, help dissipate heat generated by components, preventing overheating and ensuring reliability in high-temperature environments.
Manufacturing Flexibility: Different types of CCL materials cater to diverse application needs, from rigid PCBs for standard electronics to flexible or metal core PCBs for specialized applications.
copper clad laminate materials are used in a wide range of applications across various industries:
Consumer Electronics: Smartphones, computers, TVs, and home appliances rely on CCL materials for their compact size and reliable performance.
Automotive: In vehicle electronics, engine control units (ECUs), dashboard displays, and safety systems benefit from the durability and thermal management capabilities of CCL materials.
Industrial Equipment: Control systems, robotics, and instrumentation use CCL materials for their robustness and reliability in demanding environments.
In essence, copper clad laminate (CCL) materials are foundational to PCB fabrication, providing the structural integrity, electrical conductivity, and thermal management necessary for modern electronic devices to function effectively and efficiently. Their versatility and performance characteristics make them indispensable in advancing technology across various sectors.
Copper alone is an important building point of PCBs. But it serves as the advanced printed circuit board’s base material and the circuit’s starting point when clad on impregnated glass fibre or resin.
Etching Process of copper clad board
Through a process called etching, the unwanted copper is removed to create the desired circuit pattern. After etching process, the left-over copper traces on the board shape the electrical connections between the different elements of PCB.
Structural support for the PCB
Apart from its conducting abilities, Copper clad boards also support the formation and retention of PCB structure. It helps to hold the components in place and prevents them from shifting or becoming damaged during handling or use.
It is often used in the following applications:
l Electrical enclosures: Used to make the outer shells or bodies of electrical enclosures, which are used to protect electrical components from the environment and prevent electrical shocks.
l PCB prototyping: Used to create prototype circuit boards for testing and development purposes.
l Electrical and mechanical seals: Create seals that are resistant to electrical and mechanical stress, such as those found in motors, generators, and other electrical equipment.
l Insulation for wiring and cable management: Insulate wires and cables, helping to prevent electrical short circuits and improve safety.
|
Characteristics |
Laminate |
Prepreg |
|
Definition: |
Composite material made of layers of fibers or fabric bonded together with a resin |
Fibers or fabrics layered with resin that are cured by exposing them to heat and pressure |
|
Usage: |
Base material for PCBs |
Intermediate layer in the construction of multilayer PCBs |
|
Stackup location: |
Outermost layer of a PCB |
The manufacturing process for copper-clad laminate (CCL) is a three-step process:
1. The raw materials for CCL include copper sheets, resin, and aluminum foil. The sheets are coated with PCB epoxy resin to protect them from corrosion.
2. The aluminum foil is then pressed into the sheet to form a laminate sheet.
3. The finished product is then heat sealed by placing it between two heat plates so that they bond together. This allows the product to be shipped without any damage caused by air pressure or cold temperatures.
● Quality of the materials used in the laminate
If not checked, it can affect its overall performance, including its strength, durability, and electrical conductivity.
● Design and production standards
It is important to ensure that the laminate meets necessary specifications and performs as expected.
● Performance requirements for the laminate
The performance requirements for the laminate, such as its required electrical conductivity or strength, should be considered when selecting materials and designing the laminate.
● Reliability of the key components of the product
A copper clad laminate is a fine combination of insulating layers and copper foils that provide longevity and performance of the product components.
Choosing the right copper clad laminate manufacturers is crucial for the success of your project. The first thing to look for in copper clad laminate manufacturers is their material selection and product durability. The second important factor is the expertise of your chosen manufacturer. Choose a company that has been around for a long time and has a reputation for providing quality products.
If you are looking for a company that can advance your electronic circuit, then YILONG INSULATION is the right choice for you. YILONG INSULATION is one of China’s leading copper clad laminate manufacturers with years of experience in manufacturing high-end CCLs.
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