This looks like the perfect application for Dupont Pyralux sheets:
http://www2.dupont.com/Pyralux/en_US/products/laminate/index.htmlEtch the copper layer of the flexible circuit board, use a craft cutter like CirCut to cut out the LED areas which need to touch the aluminium, then stick the flex onto the aluminium sheets.
Which leads to the next "bright idea" - Can a standard laser printer print directly onto Pyralux, at least the very thin highly flexible variety? If so, homebrew flexible circuits just got easier than rigid PCBs, no toner transfer needed, just fuse toner in a laminator and etch!
Regards
--
--- In Homebrew_PCBs@yahoogroups.com, Rogerio F Cunha <rogerio.cunha@...> wrote:
>
> This is the stuff I talked about:
>
> "MCPCB's offer one of the most effective methods of thermal management for
> lighting designs utilising LEDs.
>
> MCPCB's comprise of 3 main components;
>
> 1 - Copper conductor layer where the LEDs are mounted.
>
> 2 - Insulator; a very thin thermally conductive but electrically isolated
> laminate material (NOT FR4)
>
> 3 - Metal cladding - a sheet of aluminium or copper substrate which
> dissipates the heat produced by the LEDs.
>
> These MCPCB's also allow easy interface to a heatsink or the outer housing
> of the customers application to aid cooling further."
>
>
> After all collaboration on this thread, I believe it's hard to home brew.
>
> "Nuno T." gave me an idea that looks feasible and might give a good result.
>
> "Have no idea if what you ask is possible. Have you considered using a
> common
> FR4 copper PCB with common Al/Cu heat sinks bolted/screwed on the sides of
> the led with some thermal paste? Much cheaper..."
>
> Thanks,
>
>
>
>