The Engineering Projects

Introduction to LED PCB

Hello everyone. Today is a great day that we are going to put our focus on another type of PCB. So far in the previous articles, we have looked at high speed, metalcore, high density interconnect and the ceramic types of PCBs. In this article, we are going to introduce another type of PCB that might find great use in your day-to-day interaction with the printed circuit boards. it is very important for a designer to take note of how PCBs have evolved and how they have become an important aspect in the design of successful electronic devices. It has become hardly difficult to come across any time of an electronic device that does not involve the use of printed circuit boards.

In PCB boards you come across LEDs fixed in them, and due to the evolving world of technology, things are changing so first leading to the crafting of new technologies that have led to changes in the LED areas. The LED case is an area that has involved the combination of two methods of technologies in order to come up with something else that is more efficient when it comes to solving the intended purpose. This LED PCB comes with advantages of longevity and durability.

Introduction to the LED PCBs

This is a type of PCB that is used for the purpose of lighting in the lighting appliances like modern LED bulbs. The material used in the process of making this board currently is the metal copper clad that has a very good heat-dissipating function. In general, we should note that the single layer LED PCB is made up of three layers namely the circuit layer, the ceramic layer and the insulation layer.

• The LEDs are laid directly in the circuit layer where they are mounted.
• The heat that comes out of the LED is quickly linked to the substrate layer for dissipation. This is done through the insulation layer then dissipated through the substrate layer.
• Copper, aluminum and iron are the most used thermal conductive layer material since they are readily available.
• The iron core is mostly used in motor high-end PCBs that have a lot of heat dissipation.

How to order LED PCB online?

There are numerous online PCB companies, where we can place the LED PCB order. We are going to take the example of PCBWay Fabrication House, a well renowned PCB Manufacturing House. They have an excellent support team, and it's recommended to first discuss your PCB design with the team, they will guide you at every step. So, follow these steps to place an order of LED PCB on PCBWay:

• First of all, create an account on the PCBWay official site.
• After that click on the PCBWay Calculator, which is an excellent tool to get the quote for your PCB order.

• As you can see in the above figure, I have selected Aluminium PCBs, as LED PCBs are normally aluminum PCBs to avoid heat dissipation.
• Now click on Calculate and get the quote for your order.

The LED PCB working principle

• The LED is mounted on the surface of the circuit layer and the heat that is generated when the PCB is under operation is quickly passed to the metal base layer via the insulating layer.
• This heat is then passed out by the metal base layer to achieve the purpose of heat dissipation of the device.
• See the attached diagram for a better understanding of the process;

LED PCD structure

Circuit layer

This is made up of the electrolytic copper foil and is etched to form the printed circuit board where the components are attached. When you do the comparison with the traditional boards, the LED board can carry a larger amount of current.

Insulating layer

This layer is the core technology behind this type of boards and plays greater roles in the conduction insulation and bonding of the layers.

Metal substrate layer

Here aluminum is the best choice compared to its availability and the cheap prices it offers. Stainless steel, silicon and the iron can be used if the thermal conductivity required is very high.

Types of the LED PCBs

The single layer LED PCB

This consist of the substrate layer together with a conductive layer. A solder mask together with a silkscreen offer protection functions to these layers.

• This type of the LED PCB does not have any circuit layer on the back side.
• Their structure is very thin and they are very weightless.

Double layer PCB

When you don a comparison with the single layer PCBs, you will realize that this has two copper layers which apparently makes them heavier as the number of conductive layers also increase to two.

• Double layered PCBs are durable since this type of circuit layer can withstand the high currents applied and it has the best heat dissipation mechanism.

Assembly methods of the LED PCB

There are two assembly methods that can be employed in the assembly if the LED PCBs. These methods are used to attach components on the board and we shall discuss it below;

Surface-mount assembly

This method involves mounting the electronic components directly into the board copper layer.

• the process is highly automated and offers flexible connections and offers spaces for high density connections.
• They play great roles in circuitry that require high connections and accuracy.

Through-hole assembly

This method involves the drilling of holes into the PCB boards where components are then mounted to the holes using the long leads that are then soldered and the whole filled with flux.

• The process involves a lot of inspections to make sure that the great accuracy and the effectiveness are achieved.
• This method off course provides a strong board with long durability.

Considerations while designing the LED PCBs

• Ideal board design; you must figure out which is the ideal board design that you should incorporate. In engineering everything starts with the design. It is the first step that comes in.
• Picking the proper orientation; when we talk about orientation, we are after how the flow of the circuit is achieved from one end to the other. The way in which the data and the electricity flow in the circuit is what we are referring to us the orientation.
• Component placement; in addition to the circuit and the obvious LED, there are many other components that form the printed circuit boards. these components include the resistors, the capacitors, etc. the components should be placed such that they avoid the solder side of the board were solders lie behind the through hole side of the board.
• Avoid placement of the components on the PCB outline; this will help you manage the board better and also ensure that the design is sturdy and very reliable.
• Vias should not be placed at the end of the STM Pads; vias allows the placement of circuits in tow or more layers if the PCB boards. these vias can go through the surface of the top layer through to the bottom layer. Avoid passing the via through the pads of the surface mounted devices since this will weaken the components.
• Definition of the net width design; due to consumption of different current in the circuits, the design paths will vary with the size of the tracks and this will also affect the net width of this design outcome.
• Cost optimization and the budget issues; this is how the overall budget of the designed PCB will go up to. Therefore, this must also be considered when coming up with the LED PCB.

Industrial applications of the LED PCBs

Consumer lighting

This is one of the common applications the LED PCBs where they find great use on the consumer lighting from flash lights, lamps, spotlights, lanterns to solar powered lighting applications.

Consumer electronics

LED are also becoming a common application in the electronic devices such as the computer keyboards backlights. Other devices that have employed this technology are smartphones, tablets and the televisions.

Telecommunications

Telecommunication displays and indicators use the LED PCBS because of their durability the ability to transfer heat and their longevity since telecommunication gadgets generate a lot of heat.

Transportations

LEDs have a lot of use in the traffic and the transportation industry ranging from the stop lights and the automotive themselves. In the car this PCs are found in the headlights, fog lights, brake lights, reverse lights and the indicators. Highways tunnel lighting also use this technology. The modern streetlighting system is done using the LED PCBs.

Medical

Medical lighting and the medical equipment lighting that are used for medical examination and surgery often use this type LED PCBs.

Benefits of this LED PCBs

1. Reduced consumption of power
2. More efficiency compared to the traditional boards.
3. They are smaller in size
4. This type of board is mercury free
5. It is radiofrequency free
6. It is much environment friendly
7. Cheap and this implies reduced cost.
8. It has a longer life compared to others.

Introduction to Double Layer PCB

Hello! Friends I hope you are all fine. In today's article, we tend to unlock the details on the double sides of PCB which is a type of PCB. It comes with a conductive copper layer on both sides of the board, unlike single layer PCB which has only layer one side of the board. I will try to elaborate on each and everything about double-sided PCB with the best of my effort. So you do not need to move your attention to another source for elaborating this article. In this article, we illustrate the double-layer PCBs, their advantages and disadvantages. We will also study double-layer construction methodology, its applications. In termination, we will discuss the conclusion of today’s article. Let’s start our article by exploring PCB and its main applications. Let’s start to absorb the basic and advanced information about double layer PCB.

Before discussing the double layer PCB. we must have an idea about what’s PCB.

PCB and its classification

 PCB is an abbreviation of printed circuit boards. PCB may be a sleeky chip created by compound epoxy glass fiber or laminated completely different substances. It includes a plate of insulated substantial and a sheet of copper foils coated to the substrate.

Criteria of Classification of PCB

PCBs are classified according to their number of layers and holes on them.  There are three types of PCB depending on the number of their layers.

• Single-layer PCB
• Double-layer PCB
• Multilayer PCB

Now to move our attention back to our article which is double layer PCB

Introduction to double-layer PCB

A double-sided PCB is also known as a Two-layer PCB is a kind of PCB that has a copper layer on both sides aboard. Here copper layers means the conductive layers. Simply we can say that it Comes with two conductive patterns on two sides of the base material which is called the substrate. The pattern on the sides is connected using a connection bridge which is known as VIA.

2-Layer PCB Pricing

• Let's have a look at the pricing of 2 Layer PCB, so I am going to take the example of PCBWay Fabrication House.
• If you have a look at the below figure, you can see that, if we place an order of:
  • Size: 150x100mm
  • Quantity: 10
  • Layer: 2
• It will cost us $41 in total, and it's quite affordable.
• The price per PCB board decreases as you increase the quantity.

What is via?

 Via is a hole in the vertical direction on the PCB board which is filled with metal foils due to which we connect the writing patterns.

• The area of double-sided PCB is twice that of single-layer PCB that allowing it to be used in vast applications with high-density components

Purpose of double-sided PCB 

• The main purpose of this board over single layer PCB is that on this board we can connect components on one side with the other due to the presence of the hole on it. We can easily tackle with connections on this board although it is no easy task to develop a double layer PCB.

Types of double-layer PCB 

 There are two types of double-layer PCB.

• Without through-hole metallization (non-PTH)
• With through-hole metallization ( PTH)

PCB Manufacturing Process

 Following steps are included in making a PCB:

1. Initialization
2. Optical lithographic
3. Etching
4. Stripping
5. Plating of tin
6. Drilling
7. Testing
8. Component loading
9. Soldering

Initialization

• First of all, we must have a print of layout which may be obtained from Computer-aided machine, then cut the copper layer according to requirements and make sure that board is clean and free from any dust than mounting holes on it.

Optical lithographic

• In this step, we may transfer the copper tracks by exposing them to radiation sources like UV radiations

Etching

• This is used to remove the copper-clad which is unnecessary.  For this purpose the board is  dipped in the etching solution  and remains in solution for 6 to 7 minutes at 40° C . There are  many types of etching solutions like

1. Ferric chloride
2. Cupric chloride
3. Alkaline ammonia

Stripping and tin plating

•  In this step final touch is given to the copper layer on board and plating is optional which protects the copper from being oxidizing.

Drilling and testing

•  In this step, components are created on board of different widths. This may be done by using manually operating drill machines by using CNC drilling machines.

Techniques for interconnecting components onboard

Technically two methods are used for this task.

• Through-hole technology
• Surface-mounted technique

Through-hole technology

• It is a technique in which we can make an electric circuit by using a wire which passed through holes and bored into PCB. In the late 1980s, every component was pointed through this technique on PCB.

 Surface-mounted technology 

• In this technique, there is no separate use of Wire. In its place, we can join components straight to chips which reduces space requirements.

Construction of double-layer PCB 

• The construction of this board is alike to single-layer PCB, its construction is delineated here with elaborate.
• In this circuit substrate is factory-made by the fiber or epoxy resins, the sort of base material depends on rigidity and adaptability of aboard.
• In the double layer PCB, PCB over base substances copper lamination is done to supply a semi-conductive method for parts.
• To protect From setting each side of the Board contains a solder mask over copper covering.
• There exists a silkscreen on top of the sides whose purpose is to able a person to add symbols and character on board so that a standard person will perceive the Board function.
• Double-sided PCB area units are terribly like single-sided PCB except that they need two-sided traces with high and bottom layers. These boards will mount conductive copper on either side of the card that permits the trace to cross over one another. This leads to the next density of circuit while not the Requirements of point to point fastening. These kinds of circuit boards area units are a lot of advanced than single-sided PCBs that are often harder to supply. However, the advantage of victimization double-sided PCB so much outweighs the con’s

Double-sided circuit boards are one of the foremost well-liked kinds of PCBs. They allow makers to supply a lot of advanced circuits which may have profit uses in higher technology applications.

Advantages of double-layer PCB over single layer PCB 

• The most important point is that number of interconnection are approximately double that of single-sided PCBs
• They are more flexible and have easier electrical interconnections.
• Single-layer PCB has only one conducting layer over base material while double layer PCB has two conductive layers on both sides of base material known as a substrate which is made of fiberglass and is compact in its sense.
• Both double layer PCB and single layer PCB  works as an electronic catalyst to deliver power to other components
• Double-sided PCB tends to increase the circuit density and reduce the overall cost.
• Although double-sided PCBs have complex circuits as compared to single-sided PCBs they are perfect and more suitable for advanced electronics because they can be used on both sides which reduces the side of the board in return reduces the overall cost.•The most important advantage of double-sided PCB is that we can repair and rework their connections.

Disadvantages of double-layer PCB 

• We need very careful attention for manufacturing of layout of double-sided PCBs especially in the distribution of power across the different components.
• As they have the open structure of circuit loop there may be a chance of EMI radiations which may change the crosstalk between closely spaced tracks overboard

Application of double-layer PCB 

• Due to the availability of flexibility in their structure, Double-sided PCBs are used in many applications for various purposes.
• High low temperature and solder coating are one of few important applications of Double-layer PCB.
• Double-sided PCBs are used in merchandising machines, amplifiers, automotive dashboards, and plenty of lots.
• Double-layer PCBs are used in the red lightning circuit which makes the light circuit.
• Double-layer PCBs are used in printers.
• Double-sided PCBs are used in Industrial controls for various purposes.
• Double-sided PCBs are used for instrumentation.
• Double-sided PCBs are used for testing the types of equipment.
• Double-sided PCBs are used in power supplies and hard drives.
• Double-layer PCBs are used in converters.
• Double-layer PCBs are used for control relay purposes.
• Double-layer PCBs are used in the Automotive dashboard for controlling the different functions.
• Double-sided PCBs are used in traffic systems
• Double-sided PCB has wide use in vending machines.
• Double-layer PCBs are used in inline reactors.

Conclusion

In the end, we concluded that double-layer PCBs have two layers than a single layer which has one layer. Due to advanced technology requirements, we need double-layer PCBs. Double layer PCBs are less costly but they have innovative features than single layer PCBs. This worthy feature is the demand of the modern era. Double layer PCBs have worthy applications. It also has some drawbacks which demanded that we have to develop PCBs that are effective than double-layer PCBs. You always need to opt for which kind of PCBs you would need.

That’s all for today’s article. I hope you've got enjoyed the article and built a grip on the understanding points. However, if you continue to face any skepticism concerning double-sided PCB then please be at liberty to depart your queries within the comment section. I'll give a solution to those inquiries to the simplest of my data and researching skills. Also, give North American country along with your innovative feedbacks and suggestions you improve the standard of our work and supply you content in keeping with your wants and expectations. keep tuned! thanks for reading this text.