World Class LED PCB Manufacturer in China
PCBMay is a Professional LED PCB Boards Manufacturer in China,Who Provides Many Different Kinds of LED Circuit Board.
The progress achieved in recent years in the LED PCB sector is a direct consequence of a constant research and study of solutions that the market requires to be increasingly performing, reliable, efficient and at low cost.
The design process is often an iterative flow and requires careful consideration. The quality of the final component is the result of a correct design, from manufacturing to precision in the assembly phase.
In high power or high current regimes,LED PCB design is far from trivial, since it involves a number of factors and parameters. For example, as explained above, a good thermal conductivity of the material will help heat dissipation and effective thermal distribution, moreover, material.
There're Main Advantages of LED Circuit Boards which are Produced in PCBMay
LED Strip PCB Board
LED strip PCB is a simple board,now led strip light PCB have many kinds, double layer PCB, single layer PCB, rolled copper foil, plating copper. Best double layer PCB can bear large current, very good heat dissipation and has high stable quality.
Medical LED PCB Board
There are 4 branches in medical LED lighting application: room illumination, surgical lighting, light therapy and UV disinfection&sterilization. High CRI and glare-free light environment is paramount for the staff to faciliate medical care for the patient.
Automotive LED PCB Board
Automotive LED PCB design needs very accurate tolerance,because it's related to safty,what's more,PCBs for the Automotive industry require high reliability, long life service, at a highly competitive rate. The sector consists of passenger vehicles, trucks, trailers, sub assemblies, and dealer support systems.
Indoor LED PCB Board
LED light circuit boards are very popular,PCBMay has been producing PCBs for indoor LED since 2008, well ahead of most competition. With this head start we can assist with design and have helped many companies gain a significant lead over their competition.
Outdoor LED PCB Board
Outdoor lights are sold very well nowadays,the LED circuit board plays a very important and almost indispensable role,because PCB LED lights can be incorporated into numerous lighting applications due to their combination of excellent energy efficiency, low cost and maximum design flexibility.
Landscrape LED PCB Board
Most of landscrape LED are made of solar panels,the LED industry utilizes breakthrough technology opening a vast array of new products that didn’t exist just a few years ago; technology that is managed by LED printed circuit boards. The majority of LED PCBs we produce include some form of aluminum PCBs and FR4 boards.
Frequently Asked Questions (FAQ) About Our LED Circuit Board Process and Capabilities
Here you will find many quick questions and answers about led circuit board,don’t hesitate to contact us,our email is email@example.com.
Yes,most LED PCBs are aluminum boards,but some of them are FR4 boards.
We can produce the prototype of LED boards with quick turn 48h and one week for standard leading time,2-3 weeks for mass production of LED PCBs.
Our standard color for soldermask of LED board is white. We can also provide soldermask in green,blue or black,red also matte green,matter black,matter red or matter blue for an additional amount.
The largest size PCB we can produce is 47″ x 19″ or 1200mm x 500mm.
Yes,we can provide different kinds of LED strip lighting to you.
No,LED circuit boards are including FR4 board,Aluminum board and metal core board.
No,we can produce 1 to 10,000 pieces,what’s more,there is also no minimum order surcharge or additional fees
A separate LED lighting element consists of an LED, a lens and a board. The boards for LEDs act as a base on which, in fact, the light source is fixed. The LED housing is attached to the board,power is supplied.LED Circuit Boards are calculated according to special formulas and are manufactured on high-precision modern equipment.
At the same time,printed circuit boards for LEDs are produced in several types:
- Multi-layer printed circuit boards for LED
- Aluminum Board
High Power LED Aluminum Boards help to dissipate heat during high power LED operation,thereby extending its life.Aluminum boards for LEDs are produced in several standard sizes:
- Line (ruler)
- Round (circle)
The Choice of the Shape and Size of the LED PCB Board Depends on the Characteristics of the LEDs
To remove the heat that occurs during the operation of LEDs,special boards are used that have a metal base with high thermal conductivity.Externally,an aluminum-based PCB looks almost the same as a conventional PCB,on the back of which there is an aluminum plate with a thickness of 0.51mm,1.02mm,1.57mm,2.03mm and 3.18mm.
It is connected to the PCB using an insulating strip (prepreg) with good thermal conductivity.Typical thermal conductivity values for such prepregs are units (1-5) W / (m * k) WATT / (METER * Kelvin or Celsius).
The front side of the LED PCB contains conductors and mounting pads.On which (by soldering) LEDs and other radio components (if required) are placed. In view of the above features of the board for mounting superbright LEDs,mounting of output radio components is impossible due to the absence of through mounting holes on the board).
However,it is allowed to use multilayer printed circuit boards with up to 10 layers.
LEDs have long and firmly established themselves in many areas of our life.They replaced conventional incandescent lamps and are used in almost all areas of lighting technology:street and decorative lighting, advertising signs and creeping lines,LED panels,etc.
LED PCB Benefits
The main benefits of LEDs in comparison with conventional light sources are in a long service life – they last ten times longer and in greater efficiency – with the same brightness,LED lamps consume 3-5 times less energy than halogen or incandescent lamps.
For efficient operation of LEDs, the process of heat removal is very important. Because 65-85% of the electricity during their operation is converted into heat. And if the thermal regime is violated,the service life of the LED can drop tenfold. Heat is removed both from the LED housing and further along the chain through the LED PCB board and the heat sink into the environment.
For LEDs with a power of up to 0.5 W,ordinary PCBs made of FR-4 textolite are quite suitable.For more powerful ones,printed circuit boards with a metal base and a dielectric layer (prepreg) with improved thermal conductivity are used. In the international classification,such boards have the abbreviation IMPCB (Insulated Metal Printed Circuit Board ).
To ensure the recommended temperature regimes for the operation of the LED crystal,the underside of the LED PCB board is installed on additional heatsinks through special thermal pastes.It smooth out irregularities and ensure good thermal contact and maximum thermal conductivity of the system.
LED PCB Boards for super-bright LEDs are usually covered with a black or white solder mask to further increase light absorption or light reflection,respectively. It has a beneficial effect on both temperature conditions and luminaire design.
The Use of LED PCBs in the Electronic Field Brings the Following Advantages:
- Weight reduction;
- Reduced energy consumption;
- Dimensional stability;
- Availability in different sizes, colors and intensities;
- Thermal expansion and heat dissipation;
- Resistance to dust and humidity and long duration;
- High power and energy efficiency;
- Reduced costs and design flexibility.
Thermal Management in LED PCBs
Thermal management is aimed at transmitting heat from components to less critical areas such as heat sinks,metal core or copper layer;for a good yield of the component,thermal management must therefore be consistent with the type of application chosen.
Thermal management is based on thermodynamics and heat transfer,thus allowing the correct regulation of the component temperature.Let’s now analyze what PCB technologies are available on the market for use in LED applications,but first we make some purely design considerations and related to thermal design,which any LED PCB designer must always keep in mind.
SMD LEDs: What They are and What They are for?
For LED SMD means all modules LED (Light Emitting Diode) that exploit the technology SMT (Surface Mount Technology) for mounting the LED chip on the PCB (Printed Circuit Board). The acronym becomes SMD LED because all the boards made with SMT technology are called Surface Mount Device (SMD, in fact).
SMD LED modules are usually called “standalone devices”, as they are designed to work alone or with compatible units.
The convenience of an SMD LED lies in the fact that it takes much less time to make it and therefore the result is also a considerable economic saving. Because? It’s very simple: SMT technology allows you to apply components on the printed circuit through a solder paste and without the need to apply holes. In this way, the boards are reduced in size and so are the components to be applied on the circuits themselves.
The SMD LEDs are found in most devices LED lighting on the market. Sui SMD LEDs are applied to the LED chips, usually of light-emitting diodes mounted on one face of the printed circuit board. The shape of the chips present on SMD LEDs is very similar to a parallelepiped: inside these chips there is the emitting surface, while on its sides there are the “pins” that allow the chip to receive power.
If you are looking for a company that produces SMD LEDs at low cost, without sacrificing quality, rely on PCBMAY. For information and quotes, visit the official website.
Printed Circuit Boards for High-power Ultra-bright LEDs
Recently, in connection with the latest advances in LED lighting technology, interest in the creation of light sources based on powerful ultra-bright LEDs has sharply increased. The luminous efficiency of semiconductor LEDs has already reached 100lm / W. Such ultra-bright LEDs replace conventional incandescent lamps and find their application in almost all areas of lighting technology: street lamps, automotive lighting, emergency lighting, advertising signs, LED panels, indicators, creeping lines, traffic lights, etc.
These LEDs have become indispensable in decorative lighting, in dynamic light systems due to their monochrome color and turn-on speed. It is beneficial to use them also where it is necessary to strictly save electricit.
The Main Advantages of High-power Ultra-bright LEDs over Traditional Light Sources are:
- A long service life (tens and even hundreds of times longer than in the case of conventional incandescent lamps) makes it possible to replace burned-out lamps much less often, which is especially important for hard-to-reach places;
- Efficiency and high efficiency: at the same brightness, LED lamps consume 3-5 times less energy than halogen lamps or incandescent lamps;
- Ease of installation and compactness: surface SMD mounting and small geometric dimensions of LEDs allow developers and designers to choose interesting solutions for creating a lighting system;
- A wide range of shades of white, color and RGB LEDs: allow you to implement interesting ideas of developers of lighting or decorative lighting, using dynamic color and brightness change;
- Low thermal radiation from LED luminaires allows them to be installed in places where the use of incandescent lamps is unacceptable due to their high heating.
How LED PCBs are Ideal Choice for Companies?
Unlike conventional incandescent lamps, LEDs do not emit heat into the surrounding space, but conduct it in the direction from the pn junction to the heat sink in the LED housing (usually either the output of the LED or a special metal plate).
Therefore, the process of heat removal is more complex and specific. The heat dissipation path consists of many thermal resistances: “pn junction – housing heat sink”, “housing heat sink – printed circuit board “, ” printed circuit board – heat sink”, “heat sink – environment”. As a result, the use of high-power LEDs is associated with a high probability of an excessive increase in the junction temperature, which directly affects the life, reliability and light performance of the LED.
What Research Data Says about LED PCB Consumption?
Research data indicate that approximately 65-85% of the electricity generated by an LED is converted to heat. However, provided that the thermal conditions recommended by the LED manufacturer are observed, the life of the LED can reach 10 years.
But, if the thermal regime is violated (usually this is work with a junction temperature of more than 120 … 125 ° C), the service life of the LED can fall 10 times! And in case of gross non-observance of the recommended thermal conditions, for example, when emitter-type LEDs are turned on without a radiator for more than 5-7 seconds, the LED may fail already during the first turn-on.
An increase in the transition temperature, in addition, leads to a decrease in the brightness of the glow and a shift in the operating wavelength. Also, the polymer from which the LED housing is made cannot be heated above a certain limit, because, due to the difference in the linear expansion coefficients of the LED parts (contacts, frame, crystal, lens material), the contact connection may be torn off.
Why it is Important to Calculate Thermal Regime on LED PCB?
Therefore, it is very important to correctly calculate the thermal regime and, if possible, dissipate the heat generated by the LED as much as possible.
If LEDs with a power of less than 0.5 W are used, then installation of LEDs on ordinary PCBs made of FR-4 PCB will be quite acceptable. However, when dissipating higher powers, it may be necessary to use special printed circuit boards with a metal base and a dielectric layer with improved thermal conductivity and thermal resistance of 0.45 to 1.5 K / W.
What are LEDs Clusters?
Major manufacturers of high-power LEDs pcb, such as PCBMAY, has long been to simplify and enable expansion of applications of LEDs, made in the form of LED modules, or clusters on PCBs ah with a metal base (in the international classification IMPCB – Insulated Metal Printed Circuit Board, or AL PCB – printed circuit boards on an aluminum base).
LED clusters are ready-to-connect boards of various shapes (round, linear, rectangular, hexagonal in the form of stars and rings) with a seat for one or more LEDs and provide for the installation of lenses (collimators), simple power connection and convenient mounting. The cluster is connected to the LED power supply driver either by soldering to the contact pads of the board, or to the connector installed on the board. Such clusters sometimes contain both limiting resistances and the power driver itself, therefore they can be directly connected to the low-voltage power supply.
What Kind of LED PCB Design is Best to Choose?
Such clusters are used in the installation of non-standard lamps, in interior and landscape lighting, in the creation of dynamic light shows – that is, wherever, without additional costs, it is possible to assemble and place LED clusters of these sizes and shapes as elements of an LED matrix.
But if it is difficult or impossible to do with standard forms – you are not satisfied with the dimensions, the step between the LEDs or the layout, then your own individual design of the printed circuit board is developed and ordered – technological and adapted for the best solutions for the lighting system.
How to Install Clusters on LED PCB?
Clusters based on printed circuit boards with a metal base, together with LEDs mounted on it, can, if necessary, be installed on an additional heat sink – the final link of the thermal path. The choice of this heat sink, and it can be an aluminum radiator and a metal case of the product, depends on how much of the total budget of thermal resistance “transition – environment” was “wasted” on the previous links of the thermal path.
An LED with a power dissipation of 1 W (assuming natural unhindered convection at 25 ° C) requires a board with an aluminum base of at least 6.5 cm2. If the area of the board under the LED approximately corresponds to this value, such a cluster device does not need additional heat dissipation when the LED is operating in nominal mode.
When working in a closed case, as well as in conditions of elevated ambient temperatures without the use of additional cooling, either an additional heat sink or an increase in the board area is needed.
How to Ensure LED PCB Crystal Temperature?
To ensure the recommended temperature regimes for the operation of the LED crystal, the lower side of the board is installed on additional heatsinks corresponding to the type of cluster used through special plastic mixtures – heat-conducting pastes or, as they are also called, thermal pastes that fill in irregularities and ensure good thermal contact and maximum thermal conductivity of the system.
When using additional radiators, it is possible, for example, to increase the supply current of a cluster with a Cree XR-E LED to 1 A, a cluster with an XP-E LED to 700 mA, a cluster with an XP-C, XR-C LED to 500 mA, which will give an increase in glow intensity by about 70%.
Let’s focus on the printed circuit board used for high-power LED clusters – a printed circuit board with a metal base. In such a board, a metal plate is used as a base, on which one or more conductive layers of copper foil are glued using a fiberglass cloth impregnated with resin (prepreg). Such boards are used in products where there are increased local or widespread thermal loads. The simplest type of PCB, and therefore the most cost effective for SMD LEDs, is the single layer PCB. with an aluminum base. This board is essentially a single-layer printed circuit board glued to an aluminum plate. The generated heat easily passes through the dielectric, and then quickly dissipates through the aluminum – a solidly glued heat sink made as a part of a printed circuit board.
LED PCB Coating
Boards for super-bright LEDs are usually covered with a black or white solder mask to further increase light absorption or light reflection, respectively, which has a beneficial effect on both temperature conditions and luminaire design.
Let’s take a quick look at the materials used in boards with a metal base:
Copper foil – standard copper foil for the production of printed circuit boards is used with a thickness of 35-350 microns.
Dielectric- prepreg – glass fabric impregnated with epoxy resins 50-150 microns thick. As a prepreg, both ordinary FR-4 epoxy glass fabric and a special heat-conducting compound (T-preg) can be used, which has the best thermal and electrical insulating properties. It is a special chemically resistant structure with high thermal conductivity, 75-200 microns thick, made of a special dielectric – a mixture of polymer with special ceramics.
The polymer is selected based on its dielectric properties, while the ceramic filler is designed to improve thermal conductivity, resulting in both excellent dielectric properties and very low thermal resistance. For example, the volume resistivity of the material Bond Ply Thermal Clad IMS (Bergquist) of this layer is not less than 1014 Ohm • cm. With a dielectric thickness of 75 microns, the permissible operating voltage between the layers is 5.5 kV AC and more, the thermal conductivity is at least 1.3 W / mK, which is quite enough for most applications.
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