High-Quality LED PCBs with Competitive Pricing
LED PCB Basic KnowLedge
LED PCB boards are found inside the Led strips, luminaires, displays, and signs we commonly see. They are also widely used in automotive lighting systems and medical equipment. Led circuit boards are also cost-effective, durable, and reliable. In addition, because LED PCBs require fewer components than traditional lighting systems, they can often be installed quickly and easily.
LED PCB technology continues evolving and becoming increasingly popular in commercial and residential applications. Without LED PCB boards, providing lighting with excellent quality and performance is impossible.
By the way, why not know more about the features of Led aluminum PCB?
- Adopt SMT.
- Thermal conduction is excellent.
- Low down Led bulb working temperature, enhance power density, prolong bulb work life.
- Reduce the bulb volume and cut down production costs.
- Replace the easy-break ceramic PCB.
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Viasion’s Advantages as a Professional LED PCB Manufacturer
LED PCB Thermal Dissipation Technology and Development Trend
Led industry developing until today, Led lights have become energy save, electricity save, highly efficient, quick reaction, long work life, without Hg, Environment friendly. However, led light can only convert 20% of energy into light and 80% into heat. If the heat can be transferred away from the led bulb, it would let the led surface temperature overheat, then affect the Led bulb’s stability, luminous efficiency and work life. Thus, how dissipating the heat from the Led bulb is a significant problem.
- Different Packaging technologies and heat transfer ways are different. For example, the heat can evacuate for the led bulb by the below methods:
- If it is a flip chip and eutectic technology, the heat would be transferred through the PCB through the hole out.
- The thermal energy would directly evacuate from the aluminum PCB . Transfer heat from the air. The heat is transferred out by gold wire.
- The heat transfer from the air directly, maybe from Led die aluminum circuit board to the air. The heat transfer from the bulb to the airspeed depends on the bulb system design.
- Besides, the Led die generates heat and can pass to the PCB board by electrode metal wire. Generally, wire length and shape affect thermal energy transfer by metal wire efficiency.
- So nowadays, with the eutectic and flip-chip complication, designers make the wire short and Cross-sectional area-wide, then the heat evacuation from the wire to the PCB board would become more efficient.
- After understanding the above information, some of you may conclude, " The type of LED PCB board and the Led die packaging type is essential in impacting the heat energy transfer, right?" Yes, you are right.
LED PCB Thermal Energy Transfer Substrate Layer Introduction
LED PCB Thermal Energy Transfer Substrate Layer Introduction
Some will say, “Led heat transfer board can transfer heat from an Led chip. Can this show that it has excellent heat transfer ability?” The answer is “Yes.” We make two conclusions about heat transfer from the above introduction: one is a Led die substrate, and the other is an energy transfer system. Two ways to transfer the same energy generated by the Led die, pass by the Led die substrate to the system PCB, then pass to the air, and let the heat energy evacuate to the environment.
The system PCB is the last part of led thermal transfer to the cooling fin, housing or air. In recent years PCB production technology is already matured. Initially, Led bulbs used standard PCB, but now more high-power Led bulb applications to request high heat energy transfer efficiency, but the standard PCB can’t meet the request. To solve the high-power Led bulb thermal energy problem, metal core PCB (especially aluminum) has been widely used in Led bulb production. Metal usually can put heat efficiently, solving the Led bulb’s high-power heat energy transfer problem.
Though metal core PCB can transfer thermal energy to the air efficiently, the heat evacuation from Led die to the metal core PCB is still not well, so if we want to let the Led bulb evacuate heat more efficiently, we still need to solve the problem, how the heat energy can transfer faster from Led die substrate to the MCPCB.
The Led die, substrate board, is an intermedium between the Led die and LED PCB that consist of eutectic or flip-chip, Led die and wiring bonding. Considering thermal energy evacuating, most Led die substrate boards adopt ceramic substrate. Classified by the bonding wire-making method, the Led substrate board can be classified into three types: thick film ceramic board, low-temperature burn ceramic board, and thin film ceramic board.
Because the gold wire limited the heat energy evacuated from the Electrode efficiency, many Led manufacturers have tried their best to solve this problem in recent years. There are two ways to solve this problem. One way is to find a better thermal energy transfer substrate board instead of Alumina, such as an aluminum nitride substrate, silicon carbide substrate, anodized aluminum substrate, or Silicon substrate. The silicon carbide substrate and Silicon substrate, Material with semiconductor properties, make applying difficult. In addition, the anodized aluminum substrate is too easy to break, making it hard to use. At present, the Aluminum Nitride application is the most mature.
The thin-film process of Aluminum Nitride can enhance the heat energy transfer from Led die to substrate to system PCB efficiency.
The other way of handling thermal energy evacuation is complicated Led die and substrate in eutectic or flip-chip. It would improve the efficiency of the thermal energy transfer electrode lead to the PCB. But it strictly requests substrate wire accuracy and surface smoothness. Because the sintering shrinkage and screen opening process affects the accuracy of thick film and low-temperature burn ceramic, it is unsuitable for use.
At present usually use thin-film ceramic substrate to solve this problem. The thin-film ceramic substrate uses light yellow lithography to make the circuit PCB. It uses chemical plating or electroplating to increase the thickness of the wire, which makes out PCB with high accuracy wiring and smooth surface. Eutectic and flip-hip use of the thin-film ceramic substrate should enhance the Led bulb’s work life and lighting power.
Because the aluminum PCB developed so well, the Led bulb’s thermal energy transfer problem has been significantly improved, even developing trends to the flexible PCB. Besides, the Led die substrate board, also develops a low thermal resistance trend.
The most crucial subject is reducing the thermal resistance of Led ceramic thermal evacuating substrates to enhance the Led luminous efficiency. Classified by wiring bonding, they can be separated into thin-film ceramic substrate boards, low-temperature co-burned multilayer ceramic boards, and thick-film ceramic substrate boards.
In recent years thin-film ceramic substrate boards have been widely used as Led die-evacuating energy heat substrates. They can solve the thick-film process screen opening problem and the problem of shrinkage ratio after multi-layer sintering and lamination. Thin-film heat-dissipation substrates board are manufactured by yellow light lithography, electro/electrochemical deposition and sputtering. Its feature below:
- Under low temperature(below 300℃) process, it can avoid.
- Dimensional change and material damage by high temperature.
- Higher accurate substrate can be made out.
- It can prevent the metal wire from falling off.
With those advantages, a thin film ceramic substrate board is the best material to make a highly bright, small-size, high-power Led bulb suitable for highly accurate flip chip and eutectic processes.
Low-temperature process technical is an excellent way to form multilayer ceramic substrate. Ceramics is the core of the PCB substrate material on the surface of PCB printing screen printing. But the wiring on the low-temperature multilayer is also printing out, so it still affects by mesh opening, rerror hard to avoid. Moreover, in this technical, the shrinkage problem still exists. So it would need a higher standard if using the low-temperature co-fired multilayer ceramics to make out specific circuit alignment eutectic/flip chip Led products.
Screen printing technology is the primary technique used to produce Thick-film ceramic substrates. Materials are printed on the substrate with a squeegee and are made through drying, sintering, laser and other steps.
The screen printing technology makes out the line usually needs to be more accurate. Therefore, for high-power LED products with smaller and smaller size requirements and finer and finer circuits in the future, or LED products produced by eutectic or flip-chip processes requiring accurate alignment, the accuracy of thick-film ceramic substrates It is gradually running out of use.
LED PCB Design
A schematic diagram can start the Led circuit board design process. After you have the schematic, you should proceed with other steps, such as the component layout and Parameter setting. The LED PCB board wiring is a vital aspect to consider. It can be tricky if you don’tdon’t have experience in Led circuit board wiring.
Schematic Diagram of the LED PCB Design Process
Before starting the LED PCB design process, create a Schematic diagram. This design is the basis for the PCB design, so mistakes in the schematic diagram can cause errors in the final PCB. You should follow specific rules and guidelines when drawing a schematic diagram to get a great result. Here are a few tips to make the entire process run smoothly.
First, use the Schematic Diagram Tool.
Next, you must ensure your schematic diagram follows the same logic as your circuit. It will make it easier for you to read the circuits and make the design more readable. Make sure the connections are logically separated using global symbols instead of considerable power and ground lines. Try to avoid creating complex circuits that have multiple connections in one diagram. This way, you can quickly troubleshoot your circuit.
If you’re considering designing an Led-powered product, you might find it helpful to understand the components that make up an average PCB. These include LEDs, circuits, and a variety of other components. These components are generally shaped like tiny ”chips” or cylinders. As with any other circuit board, they should be placed on the board so they won’t block the solder side. It would be behind a through-hole plated component.
A PCB with LEDs is usually made of a multilayer FR-4 substrate. Because LEDs produce a significant amount of heat, it’s crucial to design the board to accommodate this heat. Additionally, LED PCB boards should have plenty of space between metals, pads, and traces. Proper component tolerances also reduce board errors. Finally, when designing an LED PCB, take the base material seriously since the base material will determine how well the LEDs will transfer heat.
Led circuit board wiring is relatively straightforward, but you should pay attention to the leg lengths of each component. Typically, the cathode lead is the shortest and connects to the same socket as the anode. The same goes for the resistor, which should be connected to the same socket as its anode. The same applies to the other wire, which should be red or black.
Please keep in mind the following guidelines for Led circuit board wiring.
- Choose Led components according to your Led circuit board design requirements.
- Plan out the LED PCB wiring layout and confirm its correctness before starting to wire up your Led boards.
- Ensure all Led components are appropriately grounded on the circuit board.
- Use the appropriate wires gauge for each section of the LED PCB depending on the current load.
- Clamp any wire leads that cross over other conductive paths to prevent interference or contact with any other components.
- Heat shrink any exposed wire junctions as an additional measure against interference or short circuits.
- Check for continuity between all points throughout the LED PCB circuitry before powering it up.
- Always use approved power sources when connecting external power supply voltage to an LED PCB board.
- Before applying power, confirm no short-circuiting, open-circuit, reverse polarity or incorrect component placement.
- Test Leds regularly and ensure optimum performance under different working conditions. Proper LED PCB wiring is vital for Led operation.
What is Led Driver PCB?
To understand how this circuit works, let’slet’s first discuss some of the characteristics of Led drivers—led connect with AC Power through Led driver. They convert incoming AC power into DC output current and are available in wide varieties. The most common are buck-boost and flyback.
The Led-driven output line usually comprises a positive red and black negative pole. The other lines are coloured grey, white, and blue-brown. The Led also connects the positive and negative lines on an Led driver PCB. The Led-driven output line is connected to a positive supply voltage through a pin on the board, while the negative and ground connections connect to the other two pins.
EMI (electromagnetic compatibility) refers to the ability of Led drivers to function in an electromagnetic environment without disturbing adjacent equipment. Good EMI design means the Led driver is compatible with various electrical and electronic components. The THD value is a percentage and is crucial because it can lead to issues with power distribution equipment. If THD is too high, the Led driver will not work correctly or may even lead to electrical shock.
LEDs have several advantages over other lighting sources, including low power consumption, fast turn-on time, and low heat generation. However, a vital issue with LEDs is that their driver must be cost-effective. Discrete Led drivers are not very cost-effective, but an integrated Led driver may be better for your Led lighting system. So, which one is the best?
A constant-current Led driver is characterized by a voltage stabilizer that allows it to operate without a load-short circuit. A regulated drive circuit also depicts it, and each Led string is fitted with a resistor based on the average brightness of a resistor. The Feedback voltage is a considered factor in adjusting Led string voltage, and the voltage determines the brightness of Led. Several layers of LEDs are connected to an Led driver. Led drivers can operate several Led modules in parallel or series. A constant current driver must also withstand power dissipation when the load is short-circuited, as it would result in a short circuit.
Types of LED PCB
Hybrid LED PCBs are printed circuit boards (PCBs) that utilize a combination of light-emitting diodes (LEDs), which are used to produce various colours and effects, as well as other components like resistors and capacitors. Hybrid Led circuit boards can be used in multiple applications – from automotive lighting to consumer electronics – making them an attractive choice for many industries. The advantages of Hybrid LED PCB boards are mainly stated below.
- Low power consumption
- Long life span
- High brightness levels
- More efficient thermal management
With the proper design considerations, hybrid Leds can provide superior performance while reducing costs significantly. As a result, hybrid LED PCBs are becoming increasingly popular due to their many advantages, making them an ideal choice for many applications.
Single-sided LED PCBs are circuit boards that provide a simple and cost-effective way to utilize LEDs in various applications. Single-sided LED PCB boards consist of one layer of copper foil, which is etched with the desired circuitry and then laminated onto an insulating substrate. Single-sided Led circuit boards are ideal for lighting systems, automotive components, medical instruments, smart home devices, communication equipment and more. They can be designed to fit any application requirement with features such as high-speed signal routing or custom mounting options.
Many types of Led need to be bent or twisted when under use. So the normal Led made with rigid PCB can’t meet this request. So, in this case, the flexible LED PCB was developed.
One of the essential features of a board is its flexibility. It allows you to create different design solutions for your board. In addition, you can save money by not having to spend a lot of money on creating other circuit boards.
If you are looking for a Led board that can be used in harsh environmental conditions, such as in hazardous areas, then the flexible Led board is the one for you.
A Led made of flexible PCB would be sound-in, waterproof or shockproof, giving the Led higher survival ability when working in harsh environments.
It will be a good idea if you want to create a multi-layer Led circuit board. This type of board can provide you with the kind of efficiency that you need. This type of board design involves multiple layers of insulating materials being stuck between them.
Each layer has unique electrical properties, and several layers combine to be a Led board, improving the LED PCB performance. On the other hand, the insulating materials used on the board can prevent the melting of the Led components.
Unlike the flexible Led circuit board, which can be bent, rigid LED PCBs are not designed to be bent. Instead, they are made with solid materials that prevent them from being twisted or turned in different directions. It is the main reason they cannot be used for other applications.
Despite the disadvantages of having a rigid Led board, it is still essential to consider using it in specific applications. For instance, a rigid Led board is the best choice to create a circuit board that doesn’t change its original design.
According to the number of rigid PCB layers, rigid PCB can also be classified into single-layer Rigid PCB, double-layer Rigid PCB, and multi-layer rigid PCB.
Why Is Aluminum Popular in LED PCB?
- Aluminum is famous for LED PCBs because it is lightweight and robust. Moreover, it plays a key role in cooling down LED PCB boards so they can function well. Aluminum is also great for conducting electricity, so it helps ensure the current flows properly throughout the PCB. It's also a good choice because of its cost-effectiveness and availability.
- As a widespread material used in LED bulb circuit board, Aluminum is durable and can withstand wear and tear better than other materials. It also provides excellent thermal conductivity, allowing for efficient cooling of Led circuit boards. As a result, it helps to reduce the risk of overheating and improves performance.
- LED PCBs require layers of materials to make them functional. The aluminum layer is usually at the top or bottom of the board, and it helps to protect the components from environmental damage. The aluminum layer also helps to conduct electricity, providing a good base for the other layers of materials.
- LED PCB boards are highly efficient and reliable when properly designed. With the help of aluminum, these PCBs can be constructed with high-quality parts that will last for years. It is also cost-effective and readily available, making it an excellent choice for LED PCB manufacturing. With its outstanding thermal conductivity, strong durability and low cost, aluminum is perfect for your PCB LED light needs.
The Benefits of Using Aluminum to Make LED PCB
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Frequently Asked Questions
As the name suggests, LED PCBs are circuit boards designed to be used with Led lights. They play a crucial role in controlling the flow of electricity through Led lighting systems. Moreover, they provide a reliable and efficient way to power Led lights while ensuring they last longer and perform better than other lighting solutions.
An LED PCB assembly usually includes resistors, capacitors, inductors, transistors, diodes, relays, and connectors. But the mostly commonly used components are light-emitting diode, since LED printed circuit boards are PCBs for the LED lighting industry.
There are many advantages of using LED PCBs. Some advantages are as follows.
LED PCBs are incredibly energy efficient.
LED PCB boards are also safer than other types of lighting options.
Led circuit boards are also highly versatile.Therefore, they are used in both interior and exterior lighting applications.
Although there are advantages to using LED PCBs, we can’t ignore the disadvantages.
The cost is higher than standard PCBs since LED PCBs are usually made of high thermal conductive material, which is more expensive.
Since LED PCBs tend to run hotter than traditional circuit boards, they need additional cooling elements such as fans or heat sinks, causing increased costs.
The manufacturing cost of LED circuit boards is higher because LED components are usually more expensive than conventional components.
We can ensure the high quality of your LED PCBs since:
1. High-quality materials are used;
2. overall quality inspections are done 100%, such as open/short E-testing, functional test, and all kinds of quality inspections;
3. We have 15+ years of experience in producing LED PCBs.
If you have doubts about ensuring the quality of your LED PCB design, please contact us, and our engineers will provide you with technical support. Furthermore, whenever you have questions, please feel free to contact us. We will try our best to satisfy your needs.
Yes, besides rigid LED PCB boards such as FR4 and Aluminum material, we also produce and assemble flexible LED circuit boards. Generally speaking, we can supply all kinds of circuit boards in the LED industry.
The following aspects should be considered when you want to find a good Led PCB Board Manufacturer:
1) Strong team and high quality;
2) Cost-effective;
3) Quick response.
Viasion started production of LED circuit boars in 2007. Our strong purchasing, engineering and production team can ensure we provide you with high quality and low-cost LED boards.