Useful Guide - What Do You Need to Know About LED PCBs

LED PCBs are typically thin for efficiency and heat dissipation, which allows for higher performance of the assemblies.

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If you are working on an electronics-related project that requires the use of many light-emitting diodes (LEDs), then it is recommended to go for an LED PCB. They have many advantages and applications in the world of electronics.

This article will cover everything that you should know about LED PCBs to make sure all your doubts are cleared.

Foreword: What Is an LED PCB?

An LED PCB is a printed circuit board specially made for LED circuits since they produce a great amount of heat energy. LED PCBs are generally metal-based MCPCBS, and their substrate is aluminum, which has good thermal conductivity.

LED PCBs are made of a special thin layer of thermally conductive material that dissipates heat quickly as compared to the usual PCB boards. Aluminum is the main material used in LED circuit boards.

Besides aluminum, the substrate material for LED PCBs includes FR4, polyimide (PI), aluminum nitride, aluminum oxide, and copper.

The design of LED PCBs is fairly simple. One or more LEDs are soldered to the aluminum-based board along with heat sinks and a chip.

All you need to do is connect the chip to a power supply through the positive and negative terminals present on the PCB, and the LED circuit board will light up instantly.

What Are the Benefits of Using LED PCBs in Electronics?

Using LED PCBs in electronics has quite a lot of benefits. Since it is a circuit board specially made for LEDs, there is a lot that this board offers and allows LEDs to work perfectly.

Here is a list of benefits that you can enjoy while using LED circuit boards in your electronic circuit design.

Light Weight and Small Size

LED PCBs are lightweight and come in a small size, which means you can use them in projects where a small-sized, lightweight LED PCB is required. They won't add to the weight of the overall electronic circuitry.

Low Power Consumption

Compared to other sources of light, such as bulbs, LEDs have low power consumption. They don't dissipate as much heat as traditional bulbs do. According to a study, LEDs use 75% less energy than traditional bulbs, which means that using LED PCBs will help you save electricity.

Long-Lasting

Using LED PCBs instead of traditional bulbs will save you from replacing them time, and because LEDs have a much longer lifespan, they will last you for a long time.

High Efficiency

LEDs do not dissipate a large amount of heat, which means they are highly efficient as compared to other sources of light energy. Using an LED PCB for incorporating lighting in your project will save you from wasting electrical energy by converting it into heat energy. Using an LED PCB will improve the efficiency of your project.

Easy to Integrate

LED PCBs are easy to integrate, which means that you can incorporate them into complex projects and electronic circuits without any hassle. They do not need a large amount of circuitry or expertise to be connected to a circuit system. All you need to do is connect the positive and negative terminals present on the LED circuit board to a power supply.

Dust and Moisture Free

Dust and moisture are the two major enemies of electronic circuits. High-quality LED PCBs are dust and moisture-resistant, which means you don't have to worry about dust particles and moisture droplets ruining your LED circuit board.

Mercury-Free

Using LEDs instead of other types of lighting will save you from the guilt of introducing toxic substances, such as mercury, into the environment. LED circuit boards are mercury-free, which is a great benefit that they offer.

No Radiofrequency Emission

Another great advantage of using LED PCBs is that they do not emit RF waves during operation. If RF waves are sent out to a device, they will interfere with other electronic devices and components present in the surroundings. Using an LED PCB will save you from worrying about RF interference.

Environmental Friendly

Overall, LED PCBs are considered to be environmentally friendly since they do not emit harmful substances, and they last for a long time, which means you dispose of them once in a while, hence creating less waste.

Wide Range Availability

LED PCBs are available in a wide range of colors and sizes. You can choose from a variety of LED colors and can also customize the circuit board dimensions according to your application.

Reduces Operational Costs

Using LED PCBs instead of other sources of lighting has proved to reduce operational costs because they are more efficient and last for a long time, which means that they help you save money in the long run. What's better than saving money and getting a high-quality, long-lasting LED circuit board at the same time?

Where Can You Get the Best LED Circuit Boards?

Are you looking for a trusted manufacturer who can provide you with the best LED PCBs at a reasonable price? If yes, we have got the perfect recommendation for you. PCBONLINE is your one-stop shop for all your PCB needs. They are best at manufacturing and assembling LED PCBs, and their services won't feel heavy on your pocket.

Here are a few reasons why you should opt for PCBONLINE to buy the best LED circuit boards.

• Free DFX/DFM/DFT: PCBONLINE offers you free services of Design For Excellence, Manufacturing, and Testing. This assures the quality and cost-saving of your LED PCB products.
• Wide Variety of LED PCBs to Customize: PCBONLINE offers a wide range of LED circuit boards, which include LED aluminum PCB, LED strips, and LED display PCB boards of different specifications. Moreover, they also manufacture custom LED PCBs which are designed according to your application.
• 21 Years of Experience: PCBONLINE has been manufacturing LED circuit boards for the past 15 years and has maintained a good reputation in the market. It's best to choose someone who very well knows how to do their job.
• Fast Delivery: with PCBONLINE, you won't have to wait for months to get your LED circuit delivered to your doorstep. They believe in providing a quick service, which means that your LED PCB will be processed and shipped to your address in no time
• Amazing Discount: What's better than getting a discount coupon code for your next purchase with PCBONLINE? They offer 100 USD coupons to every person who registers on their website.

The Applications of the LED PCB

The light-emitting diode (LED) is an electronic component that is made up of highly doped semiconductor materials, usually silicon and germanium. LEDs emit light energy when a certain level of current passes through them. They are made up of a p-n junction, just like a normal diode, but the difference is that normal diodes do not emit light energy whereas LEDs do.

LED PCBs are widely used in electronic circuits. Whether you are a student, an electronic enthusiast, or a working professional, you must have worked with LEDs many times. They have many applications, and you will find them in almost every other circuit. Let's see what the applications of LEDs are.

LED Lamps

The main use of LED PCBs is all kinds of LED lights. LED PCBs have great thermal conductivity, and LED lights can have large power.

They can be LED grow lights for agricultural planting, floodlights for business premises, stage lights in theaters, ship lights on the sea, swimming pool lights underwater, etc.

Indicators:

LEDs are most commonly used in electronic circuits as indicators. For instance, LEDs are used to show whether your computer monitor is turned on or off. A red light indicates that the monitor is OFF, while a green light indicates that it is on.

Moreover, LEDs are used in handheld torches, emergency lights, and cap lamps used by mining professionals. These lamps last a very long time and are robust, so you cannot easily break them. LEDs are also used as backlights in TV displays and monitors these days.

The warm and calming lights present inside the airplane cabins are also LED lights. They help provide a warm, cozy, and relaxing environment for the passengers. The applications of LED as an illuminator have grown significantly and will hopefully keep on growing.

Data Communication:

LEDs are also used for data communication, such as the transfer of information. Optic fiber technology uses LEDs to send information from one place to another. Moreover, visible light communication (VLC) uses LED as the main information transfer medium because LEDs provide a high data bandwidth that helps communicate effectively.

Machine Vision Systems:

A great example of a machine vision system using LED is a barcode scanner. Typically, a red LED is used in barcode scanners which you must have seen in supermarkets and grocery stores. The fact that LEDs are a source of bright light and are compact, makes them a great fit for machine vision systems.

Miscellaneous Applications:

A great example of a machine vision system using LED is a barcode scanner. Typically, a red LED is used in barcode scanners in supermarkets and grocery stores. LEDs are a source of bright light and are compact, making them a great fit for machine vision systems.

Some Considerations for Designing an LED PCB

Above is an RGBW (red, green, blue, and white) LED PCB light that PCBONLINE designed and manufactured for a client. It has 8,000 lumens and is used on ships. If you have LED PCB needs and want design assistance, you can contact PCBONLINE by at to get help.

Designing an LED PCB is a process that requires some standards and rules to be followed. It might sound like you only need to pop some LEDs on the printed circuit board, and you are good to go, but that's not the case. Here is what it takes to design an LED PCB:

• Component Placement: the right component placement is what it takes to design an efficient LED circuit board. Placing the right component at the right spot is crucial in PCB design. Along with LEDs, an LED PCB contains other components such as connectors, resistors, and thermistors, which need to be placed at a suitable distance from each other. The creepage (the shortest distance between two components) and the clearance (distance measured through the air) should be considered when designing an LED PCB to avoid damaging consequences such as overvoltage.
• PCB Material: choosing the right material for your LED PCB is challenging because there are multiple materials available in the market, and each has its pros and cons. You'll need to study their merits and demerits to find out which material is suitable for your application. You might need professional help with it, and the best place to go is PCBONLINE. We provide free and professional suggestions.
• Thermal Management: LEDs and other components placed on the PCB will certainly dissipate heat energy, and if that energy is not channeled the right way, then it might end up damaging your circuit board. The addition of vias and heat sinks will allow you to manage the heat energy present within the board. Professionals at PCBONLINE know exactly what it takes to manage the heat produced by electronic components.
• Tracking: tracking is the process of ensuring that no part of the net is left open or is forming a short circuit. After the components are placed, the process of tracking begins. The flow of current is also monitored such that it does not contribute to the production of heat energy in the circuit.

Conclusion

LED PCBs are used in many different applications and are almost used in every other circuit. If you are looking for a professional LED PCB manufacturing and assembly service, then you should opt for PCBONLINE. Their skilled engineers know what it takes to design the best LED circuit board at a very reasonable price. They have been present in the market for more than 20 years, which shows that they know how to do their job best. You can also get an instant quote for your LED PCB design by visiting the website. Moreover, you will get a 100 USD discount coupon after you register yourself. So hurry up and order your LED circuit board now!!

Description

How to Choose the Light PCB Assembly or PCB LED Lighting Assembly Manufacture in China?

With the development of the Lighting/LED industry, there are more and more assembly manufacturers for you to choose from&#; As a Professional PCB and PCBA Manufacture, FX PCB gives you the suggestions below on finding the proper Light PCB Assembly manufacturer to get the LED PCB assembly cost and good quality.

1, Check the LED PCB Assembly Machine

You need to consider the performance of the PCB assembly equipment, for example, the placement speed and the placement accuracy. As if the speed is not fast enough, it won&#;t be a problem for you to produce the low volume /Small batch PCB assembly for your LED board, but you will have a problem with the high volume/ mass production light PCB assembly. The accuracy of the placement equipment is the key factor you need to take into consideration, as you don&#;t want to have the poor position of your LEDs on your board, which will bring you quality problems. So check the PCB Assembly machine of your manufacturer first before placing the order.

2, Check the Manufacturers of Your LEDs

Find reliable LEDs manufacturers for your products, there are many brands for you to choose from, for example, Lumiled, Osram, Cree, Samsung, Luxeon, Everlight (Taiwan Brand), and some other China brands. Different products can choose different LEDs, you just need to find the right one based on the function, usage, and requirements.

3, Check the PCB Assembly Process

The light PCB assembly manufacturer should have a detailed assembly process, as it can improve manufacturing efficiency and make the work process more standardized.

As a contract light PCB assembly manufacturer, FX PCB strictly follows ISO and tries to be the best PCB assembly company for LED in Shenzhen China. Contact us and get the PCB assembly cost now.

What is a light PCB Assembly?

Light PCB assembly is the process of assembling and soldering PCB components onto a printed circuit board (PCB). The major purpose of this process is to build a functional electronic device. It includes inserting and soldering components such as:

• Resistors
• Transistors
• Capacitors
• and integrated circuits

Light PCB assembly includes testing the assembled PCB to ensure the functioning of the device comprehensively. Light PCB assembly is often used in the production of:

• consumer electronics
• automotive electronics
• medical devices
• and other electronic products.

How to Choose a PCB LED Lighting PCB Board Assembly Material?

Factors Determining Type of PCB Material

Fire Retardant

The material should be fireproof. If a fire breaks out, this material should be able to slow or stop its spread.

This characteristic is due to chemical reactions. Such reactions reduce the flammability of the fuels.

They also efficiently extend the fuel&#;s combustion time. This keeps the light board from catching fire.

Dielectric Constant

Another factor to consider is the substance&#;s ability to store electrical energy.

The dielectric constant should be able to tell you the magnitude of the electrical force as well. This is an important factor to think about. Generally, all light boards are intended for use in electrical appliances. Check the material&#;s ability to store electrical energy.

Loss Factor

Dielectric loss is another effect of the substrate material used. The dissipation factor is used to compare the loss performance of various materials.

If the dissipation factor is low, the laminate has a dielectric loss.

Check the dielectric loss of the laminate material utilized in the substrate.

Tensile Stability

This is the ability of a substance to break while under tension. In layman&#;s terms, it refers to the highest sustainable load that the material can withstand.

This means that no fractures will be reported even in cases of stretching.

Make sure your light PCB material has the necessary tensile strength.

Glass Transition Temperature (Tg)

This is an extremely significant feature to think about when choosing polymers for end use.

Plastics&#; physical qualities are converted into crystalline or even glassy states at glass transition temperatures.

The same materials turn rubbery when heated above the glass transition point.

Make sure you use a material with a high Tg in your light PCB design. This will help to ensure that the board functions well even under adverse conditions (temperatures).

Z-axis Expansion Coefficient

The size of the object changes as a result of exposure to various temperatures. Thermal expansion is another way to describe it.

Calculating the thermal expansion coefficient requires constant pressure. There have been several techniques developed recently for monitoring thermal expansion. Volumetric, area, and even linear are some of them.

What Are Light PCB Board MaterialS?

CEM 1 and CEM 3

CEM-1 Three components are typically used to create composite materials. These comprise paper core and woven glass fabric linked together. After that, epoxy resin is added to these two.

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The printed circuit board industry frequently uses this material. It often has great electrical characteristics and is simple to punch.

In comparison to grades made from paper, CEM has a higher flexural strength. This results in exceptional mechanical and even electrical qualities.

These factors have helped it become more well-known in the Asian market. Additionally, it is popular due to its benefit of being a flame retardant.

They are typically employed in the production of both multilayered and double-sided light PCBs.

As a new PCB substrate material, CEM-3 depends on the technology of FR4. This explains why it has recently been employed to replace FR-4.

FR4

Most manufacturers prefer FR-4 because it performs well in all the desired areas of a good substrate.

1. Its strength-to-weight ratio is quite good.
2. This material is also flame-resistant, which makes it particularly reliable in situations with changing temperatures. In such circumstances, its physical characteristics are unchanged.
3. Mechanical and electrical abilities are included in this.
4. High-performance FR-4 laminate has a higher glass transition temperature, which makes it more dependable.
5. Due to its low dielectric characteristics, it is also more accommodating for circuits that operate at high frequencies.
6. When producing light PCB designs, these characteristics are preferred.

 

Aluminum

This is talking about PCBs with an aluminum metal core. The PCB&#;s primary component in this PCB is aluminum. This contrasts with the standard FR4, CEM-1, or CEM-3.

Aluminum metal core PCB provides superior heat dissipation characteristics compared to other materials.

They can transfer heat away from the components in this way. Typically, a thermally conductive dielectric layer is used to achieve this.

Aluminum is the most popular material for Light PCBs because of its heat conductivity.

Copper Alloy

These are metallic alloys, primarily made of copper. They have a very strong resistance to corrosion as a result.

Moreover, conventional kinds are used. These include bronze, which requires a large amount of tin.

The third option is brass, which has a large amount of zinc.

Light PCB Manufacturing Process

The light PCB manufacturing process starts with design and verification and continues through circuit board manufacturing. Several phases demand computer direction and machine-driven equipment in order to maintain quality and prevent short circuits.

Step 1: Design and Output

Design is the first stage in the manufacture of PCBs. This will serve as the schematic blueprint that directs how the board is made. It is a laid-out plan that complies with all of the demands of the intended board.

Typically, the software is used to implement this design. The most widely used PCB design software is Extended Gerber, often known as IX274X. Altium Designer, KiCad, Eagle, OrCAD, and Pads are examples of commonly used PCB-design software.

Step Two: Design Review

This is a crucial stage in the production of printed circuit boards. It involves inspecting the design for potential flaws or defects, including breaches of the manufacturing standards and PCB layout rules, as well as ensuring that it adheres to the necessary specifications.

These are some crucial questions for this review:

• Is the design compatible with the requirements listed for the project?
• Can the design be manufactured?
• Are we certain that we won&#;t make common design errors?

Step Three: Printing the LED PCB Assembly Design

The PCB design is printed after all the checks have been carried out. The PCB design is printed using a unique printer known as a plotter printer. The printer creates a film that displays the board&#;s layers and finer details.

This film is exactly like the board itself in a photo negative. On the inside layer of the board, two ink colors are applied during printing: Clear ink is used to highlight non-conductive components like the fiberglass foundation.

Step Four: Light PCB Fabrication Process

Aluminum is the most often used material for light PCBs, as we already mentioned. This aluminum PCB&#;s fabrication procedure often differs slightly from that of conventional PCBs.

Cut Lamination

This is the method of cutting the big incoming sheets of material to the necessary smaller sizes for manufacture. As the title suggests, the procedure entails choosing and cutting the sheets.

The first piece&#;s size during cut lamination must be carefully monitored to ensure accuracy. Additionally, you must pay great attention to the scrapping of aluminum and copper and be cautious of blisters.

Drilling

Drill holes in the through-hole component holes once the lamination has been cut.

Make sure the holes you drill match the design in terms of size and number. Additionally, watch out for drilling that can scratch the sheet.

The burr on the metal surface should be checked as a further precaution. Additionally, make sure there are no hole deviations.

Always check the drill tool to make sure it is operating flawlessly before replacing it to get the best results.

Dry/Wet Film Imaging

In this case, you&#;ll grind the plate before exposing the film and developing it. The purpose of doing this is to draw attention to the components on the page that the circuit will require.

After development, make sure to check for open circuits. Additionally, keep an eye out for any changes in how the development is aligned. Potentially, this could stop the formation of dry film.

Additionally, keep an eye out for faulty circuits. Particularly if there is a surface scratch, they can happen.

When exposed, avoid air residue. If this happens, the exposure may be poor. Allow fifteen minutes to pass once the exposure is over before developing.

Acid/Alkaline Etching

The goal is to keep the necessary amount of electricity in while removing any excess. As a result, you will etch, strip, dry, and then check the board.

You must always pay attention to the circuit width and space when acid/alkaline etching. Do not let even light scratching or oxidation of the copper surface occur.

Solder mask and Silk Screening

In order to protect the board&#;s non-solderable areas and avoid short circuits, a solder mask is applied.

Make sure to properly inspect the board and eliminate any extraneous materials throughout this process. Additionally, check that the stencil you&#;re using is clean.

Once the silk screening is finished, procure at least 30 minutes to make sure the circuit is bubble-free. Chill the procuring plate to prevent it from sticking to the film.

Therefore, the entire silkscreening and solder masking process can be summarized as follows:

1. silk-screening,
2. acquiring,
3. exposure,
4. development,

V-Cut, Rout Out

Basically, the purpose of this process is to disassemble the constituent circuit units to make packaging and shipment simpler. Routing also aids in removing extra board components.

Make sure the &#;V &#;&#;s&#; depth is appropriate while performing the V-cut. Additionally, look for flaws toward the edges. Be on the lookout for detours as well.

The routing tool needs to be checked frequently, exactly as we previously advised with regard to the drill tool. If necessary, repair or replace them to make sure they are in great operating order.

Make sure not to scrape the board when you remove the burr.

Electronic Test, OSP

This method is helpful in determining whether the circuit is functioning properly. Additionally, you may verify that the circuit can survive the required voltage environment. Additionally, it is to make sure that the circuit is flawlessly soldered.

Make sure to correctly discern between products with flaws and those that are good. Make sure the circuit is completely unharmed.

Packaging and Shipping

Here, you may confirm that the board has good quality by doing the final overall quality check. It entails selecting a few samples from the finished circuit boards and evaluating their caliber.

Separate outboards whose look does not demonstrate perfection via visual assessment.

The boards that pass this inspection are then packed and sent to the appropriate purchasers. Be careful when packaging to avoid mixing good and faulty boards or providing the wrong boards to the consumer.

Make sure the boards are stored in accordance with the recommended methods for storing aluminum substrates in the industry.

Step 3: Light Circuit Board Assembly Process

An extra level of care must be taken during light PCB assembly, just as it is throughout the fabrication process, to ensure flawless results. Boards with poor solder joints and alignment will be the outcome of reckless work.

This is especially true given how delicate the silver base material is. During the assembling process, different light PCBs will require different considerations.

The steps involved in light PCB assembly are as follows:

Preparation of the Materials

Check each component, PCB stencil, solder paste, and bare board in great detail.

Check the tools as well to make sure they are all in excellent shape. Keep in mind that even the smallest error in PCB construction can result in the complete failure of the finished product. Make sure, among other things, that the soldering iron, wire remover, pliers, and tin are ideal and prepared.

Additionally, you need to place your BOM list and Gerber file on the desk. During the assembly process, you will keep referring to them.

1. Bare Board Baking When you start adding components to the bare board, make sure it is dry.
2. Solder Paste Application Solder paste is put onto the necessary areas of the board using the solder paste printing machine. Make sure the soldering is flawless by performing a comprehensive inspection.
3. Component mounting SMT components are precisely picked up by the pick-and-place machine and attached to the PCB. Before reflowing, you must still personally verify the board to make sure the location is accurate.
4. Reflow Soldering Get your light-printed circuit board and put it in the reflow machine. The SMT components are soldered by the machine, and the junctions are strengthened by cooling.

Utilize the AOI tool to inspect the soldering for any issues after soldering.

5. Insertion of Through-Hole Components

Connect the leads of the through-hole components to the boards through holes. Make sure each piece is inserted in the proper location.

6. Wave soldering,

Put the wave soldering machine where you placed your light PCB now. For stronger joints, the machine will use spray welding flux, preheating, soldering, and ultimately cooling.

7. Final Inspection and Packaging

Cleaning the board is the first step after completing the component assembly. After that, run the finished board through one more quality check to make sure there are no defects.

The final tests have been completed, and all PCBs are now prepared for packaging and shipping.

Conclusion

The manufacturing process for printed circuit boards (PCBs) is lengthy and complex and each step must be carefully carried out to guarantee the best possible performance of the finished board. Although the processes are repeated for a multilayered board, the fabrication process for single, double, and multilayered PCBs is essentially the same.

Shenzhen PCB assembly manufacturers like SFX PCB developed methods that enable the assembling of all LEDs. Shenzhen PCB assembly manufacturer is the ideal place for your Light PCB assembly needs. We can assist you in assembling everything from industrial high-power LEDs to commercial flood LEDs.

Contact us to discuss your requirements of Led Lighting PCB Assembly. Our experienced sales team can help you identify the options that best suit your needs.