Led PCB Board | High-Quality LED Circuit Board Designs

LED PCB: All You Need to Know

Printed circuit boards, primarily known as PCBs, are dominantly present in our technological society. You will undoubtedly find a PCB in cars, computers, industrial machines, and many other electronic products. However, PCB manufacturers tailor numerous PCBs to suit their various purposes. This article looks at one such PCB called LED PCB. Read on to learn more.

LEDs on a PCB board

What is an LED PCB?

An LED PCB refers to a printed circuit board designed for mounting light-emitting diodes (LEDs). These LEDs are connected to the PCB, which facilitates the lighting of the diodes. Due to the significant heat generated by LEDs during operation, an effective heat dissipation method is necessary.

Manufacturers often use aluminum-based (metal core) PCBs, as the thin thermal conductive dielectric material in aluminum helps dissipate heat more efficiently than traditional PCBs. Partnering with a trusted metal core PCB manufacturer ensures that the aluminum core and thermal conductive dielectric material are optimized for efficient heat dissipation, outperforming traditional PCBs.

Most LED devices use surface-mounted design (SMD) packaging, and since SMDs support only one LED, the circuit board connects multiple LEDs to provide sufficient light.

LEDs bulbs

What are the benefits of an LED PCB?

• Longer lifespan: With a well-designed LED PCB, LEDs can last up to 25,000 hours, significantly reducing the need for replacements and maintenance. The efficient heat dissipation in the PCB helps preserve the LED's lifespan.

LED on a stripe

• High efficiency: LEDs on a PCB use less energy than traditional lighting solutions. The PCB efficiently manages the LED’s power, ensuring that minimal energy is lost as heat, thereby improving overall energy efficiency.
• Compact design: LED PCBs allow manufacturers to use smaller, more versatile designs. Their compact size makes them ideal for use in various applications, such as electronics, traffic systems, and other compact installations.
• Environmentally friendly: LED PCBs do not require harmful substances like mercury, making them safer for the environment. The choice of materials, such as aluminum, further enhances their eco-friendly profile.
• Reduced power consumption: By using an LED PCB, energy consumption is reduced by up to 90% compared to traditional incandescent lighting, leading to lower operational costs and energy savings.

What are the challenges of LED PCB design?

• Heat management: LEDs produce significant heat during operation, which can affect their lifespan and performance. The PCB must incorporate efficient heat dissipation methods, such as using aluminum substrates or heat sinks, to manage this issue.
• Material selection: The choice of materials for the PCB, such as aluminum or ceramic, plays a crucial role in managing heat. Poor material selection can lead to inefficient heat dissipation, causing overheating and potentially damaging the LEDs.
• Current control: Ensuring that the PCB can handle the correct amount of current for the LEDs is essential. Overloading the PCB with current can lead to overheating and shortened LED lifespan.
• Trace routing and component placement: Improper trace routing or poor component positioning can lead to short-circuiting, overheating, or inefficient performance of the LED PCB. Designing the PCB with precise trace paths and optimal component locations is necessary to avoid these issues.

What are the components of an LED PCB board?

The most basic LED PCB consists of four layers, the primary one being the substrate. Since LEDs emit a lot of heat, the substrate is usually a metal (aluminum) to channel the heat out fast. This metal layer must have an insulation layer to separate its conductive nature from the copper traces, which form the second layer.

LED PCBs with different bulb configurations

The third component is the solder mask, which forms a protective layer above the traces to prevent short-circuiting, oxidation, and corrosion. Above it is the silkscreen, which contains important markings and labels about the assembled components and where to mount them.

We can’t fail to mention the primary electronic components in this board as the fifth element in the stack. LEDs are semiconductor chips that emit red, blue, or green light when current passes through them from the anode to the cathode.

What are the types of LED printed circuit boards?

Different LED Circuit Boards types work well on various applications.

LEDs on a PCB

They include;

Hybrid LED PCB

A hybrid circuit board constitutes a base metal (mostly aluminum) and a non-thermal material (FR4). Hybrid LED PCBs are rigid and inexpensive.

Aluminum circuit board

Single-layer LED PCB

A single-layer LED PCB Board contains only one layer of the copper conductive substrate.

Manufacturers use copper to make the metal layer because copper is a good conductor.

Single-layer LED PCBs are easy to design, affordable and versatile.

Flexible LED Circuit Boards

As the name suggests, this type of PCB Board is highly malleable.

Since you can twist a flexible LED PCB in various directions and even fold it, they are more preferred than a rigid PCB.

Multilayer LED PCB

A multilayer LED PCB consists of several copper conductive layers between insulators. Copper-plated holes interlink these layers.

Also, the materials stay together with the aid of a powerful adhesive.

A simple multilayer LED PCB contains only four layers; however, some used in complicated tasks can have 50 layers.

Rigid LED PCB

A rigid LED PCB constitutes solid materials that also function as substrates.

Rigid LED PCBs are commonly used in applications that require the LED PCB to constantly stay in shapes, such as computers and remote controls.

Also, rigid PCBs come in various forms, for example, single, double, and multilayer LED PCBs.

How To Make an LED PCB Board

Determine the Requirements

Begin the process by determining the board’s requirements, including weight, dimensions, maximum power rating, IP rating, number of LEDs, etc.

The type of LEDs is also important to consider in this phase. Through-hole LEDs take up more space but are easy to solder. Surface-mount LEDs take up little space but can be difficult to mount manually.

Through-hole LEDs on a PCB

COB LEDs are brighter than the other LEDs but are mounted directly on the substrate, which complicates the fabrication process, implying a higher production cost.

Design the Circuit Board

With all the requirements in place, use your preferred design software to create the circuit’s schematic with the components connected by electrical lines.

Pick the Most Suitable Materials

The most typical PCB material is FR4 (fiberglass), but this might not be the best for LED boards. Consider substrates like copper and aluminum alloys or even ceramic. Each material has different thermal, electrical, dielectric, and weight properties, so consider these to pick the most suitable base layer.

Create the Board Layout

Translate the schematic diagram into a physical representation of the board, with all the components in their specific locations and the traces properly routed. When creating this layout, consider things like EMI and crosstalk prevention.

A PCB layout

Manufacture the PCB

For simple LED board designs, you can try building the board as a DIY project if you have the technical know-how. But for complex circuits, we recommend looking for a professional fab house to build the board either as a low-volume or high-volume batch.

Assemble the Components

The next process is to assemble the LEDs and other components on the board. Like with manufacturing, you can do this assembly as a DIY project if handling a small batch of PCBs with simple circuits. But professional assembly is the best option for large batches of complex board circuits.

Test the Complete Board

Assembly goes hand-in-hand with testing before use, and the most common testing steps include electrical and shock/vibration testing, as well as visual checks, usually using automated optical inspection.

Factors to Consider When Designing LED PCB

They include;

• Material
• Heat management
• Trace routing
• finish

Let us scrutinize these factors closely;

Material

The materials you use need to work together to serve three essential functions; conductor insulation, heat dissipation, and effective LED component connection.

Most LED circuit boards use aluminum as the base layer, and it is on this layer that the other PCB electronic components sit.

Circuit board with LEDs and other electronic components

After the base layer, we have a thermal insulation layer made of polymer that guards the board against mechanical and thermal destruction.

As the circuit functions, it produces heat, which the thermal insulation layer absorbs and subsequently transfers to the base layer. The base layer then dissipates the heat.

Some PCBs have a ceramic base and thermal heat sink for increased heat transfer capabilities.

Aluminum heat sinks

Next is the circuit layer constituting copper circuits arranged according to the LED PCB Board design.

Manufacturers call this structure design an insulated metal substrate (IMS).

Thermal Management

LED PCBs produce a large volume of heat; hence, thermal management is critical to increasing your device's lifespan.

A printed circuit board

Therefore, your design needs to include heat sinks and aluminum cores (Aluminum PCB) for effective heat dissipation.

Above all, consider the Light-emitting diode placement and component positioning as they affect heat release and heat circulation.

Trace routing

Accurate trace routing reduces overheating, short-circuiting, and circuit cross-talk. Also, consider the mounting hole spaces for effective functioning.

Finish

The circuit board's finish safeguards the circuit layer while ensuring adequate component soldering locations.

You can choose a finish depending on your project needs and budget.

The Application of LED PCB

• Telecommunication
• Consumer lights
• Medical Equipment
• Consumer electronics
• Street lighting

• Automotive industry
• High growth plant lighting

Problems often Encountered in LED PCB Assembly.

LED PCB Board assembly may seem simple, but it is far from it, as there are problems you will encounter, such as material selection and current control.

However, you can quickly get over these hurdles.

OurPCB: Leader in LED PCB Circuit Design, Manufacturing, and Assembly

If you’re looking to get your LED PCBs designed, manufactured, and assembled professionally, OurPCB has the equipment and expertise to help you realize your project. We will help you create a PCB stack that dissipates the heat quickly from the LEDs to manage the thermal issue.

Additionally, we are ISO 9001:2015 certified and provide Lead-free, RoHS-certified assembly, which means we can deliver electronic products that you can sell to most parts of the world.

OurPCB has handled led lighting from the infancy stages of this technology. Our experienced and caring support team is eager to hear your LED PCB requirements; contact us for high-quality PCBs at competitive prices.