As the world's leading manufacturer of copper substrates for automotive electronics, XDCPCBA focuses on the research and development of high-performance copper substrates for automotive lights, providing efficient heat dissipation and long life for lighting systems such as automotive headlights, taillights, and daytime running lights. With 15 years of industry experience, the company combines vacuum pressing, DBC/AMB technology, and buried copper block design to achieve thermal resistance as low as 0.3℃·in⊃2;/W, ensuring that the lights can operate stably in extreme environments from -40℃ to +125℃.
1. Core technology breakthroughs in copper substrates for automotive lights**
1. **Material and structural innovation**
- **High thermal conductivity substrate**: Using 94HB copper clad laminate with ceramic filling technology, the thermal conductivity reaches 2.5W/m·K, which is more than 5 times higher than the traditional FR4 substrate.
- **Double-sided metal layer process**:
- DBC (direct copper bonding) process: The bonding strength between the copper layer and the ceramic substrate is >40MPa, which is suitable for high-power LED modules.
- AMB (Active Metal Brazing) process: achieves metallurgical bonding of copper layer and Al₂O₃ ceramic, with a temperature resistance of 800℃, meeting the heat dissipation requirements of laser headlights.
- **Buried copper block design**: partially embedding 3mm thick copper blocks, reducing thermal resistance by 40%, suitable for centralized layout of LED chips above 50W.
2. **Precision manufacturing process**
- **Line accuracy**: minimum line width/line spacing 4mil/4mil, through-hole aperture 0.3mm, supporting high-density LED array and drive circuit integration.
- **Surface treatment**:
- Chemical immersion gold (ENIG): nickel layer ≥3μm, gold layer 0.05-0.1μm, antioxidant capacity increased by 3 times, adapting to coastal high salt fog environment.
- Lead-free tin spraying (HASL): thickness 3-5μm, suitable for wave soldering process, welding yield >99.8%.
- **Three-dimensional molding technology**: supports curved copper substrate (minimum bending radius 5mm), fitting the design of headlight lens structure.
3. **Reliability Verification System**
- **Environmental Test**: Passed AEC-Q200 component-level test (temperature and humidity cycle, mechanical shock, etc.), meeting ISO 16750 automotive electronic reliability standards.
- **Life Test**: After accelerated aging test (85℃/85%RH, 1000 hours), LED light decay <5%.
- **Compliance Certification**: Passed IATF 16949, UL 94 V-0, RoHS and other certifications, and complies with VW 80100, GM 9172 and other automotive standards.
2. Application Scenarios and Cases of Copper Substrates for Car Lamps**
1. **Headlamp Module**
- **Technical Solution**: 8OZ thick copper substrate + heat pipe integration, supporting heat dissipation of LEDs above 50W.
- **Customer Case**: Customized headlamp substrates for Volkswagen ID. series models, optimized flow channel design through thermal simulation, and shortened thermal response time by 20%.
2. **LED taillight**
- **Technical solution**: Ultra-thin copper substrate (0.6mm) + waterproof coating (IP67), suitable for compact space layout.
- **Customer case**: Developed taillight substrate for Toyota hybrid models, using buried copper block + laser slotting technology to achieve a balance between lightweight and high reliability.
3. **Daytime running lights (DRL)**
- **Technical solution**: Buried copper block design + local blackening treatment, thermal resistance 0.5℃·in⊃2;/W, 15% increase in light efficiency.
- **Customer case**: Batch supply of DRL substrates for BMW X series models, no failure after 100,000 switching cycle tests.
4. **Intelligent car lights (ADB)**
- **Technical solution**: Multi-layer copper substrate with integrated temperature sensor and drive circuit, supporting dynamic dimming and fault diagnosis.
- **Customer case**: Developed substrate for Bosch ADB system, achieving 0.1℃/s high-precision temperature monitoring, response time <50ms.
3. XDCPCBA service value and advantages**
1. **Full-process customized service**
- **DFM design support**: Provide thermal simulation (FloTHERM software), optical simulation (TracePro) and DFMEA analysis.
- **Sample delivery**: Free proofing of copper substrate for headlights, delivery within 3 days; support small batch trial production (50-500 pieces).
- **Mass production capacity**: Annual production capacity of 300,000 square feet, full-process traceability using MES system, and stable yield above 99.6%.
2. **Cost and efficiency optimization**
- **Step-by-step quotation**: 10% off for 1-5㎡, 15% off for 5-10㎡, and 20% off for 10+㎡.
- **Material utilization rate**: AI layout algorithm is increased to 90%, and the cost of a single substrate is reduced by 12%.
- **Delivery cycle**: 7-10 days for mass production orders, support JIT delivery, and urgent orders can be expedited within 48 hours.
3. **Global service network**
- **Localized support**: Technical service centers are set up in China, Europe and North America, providing 24-hour on-site response.
- **Compliance guarantee**: Provide material reports specified by car companies (such as REACH, ELV) and third-party testing certificates.
