Flexible circuit boards for LED Applications
One of the fastest growing markets in the industry is LED FLEX PCBs.
For the most part, circuit boards for LED applications are single layers of circuitry bond to an aluminum substrate by a thermally conductive heatsink.As said that, replacing the metal substrate and dielectric with a flexible PCB is now a good option.
What role does the LED strip substrate play?
The LED strip based is the circuit-board on top of which the LED chips are arranged.
In addition to offering the physical, structural base of the LED strip, the substrate also provides electricity supply through its circuitry, as well as a vital path for heat dissipation.
Flexible LED strips have poor heat dissipation
The significant downside to flexible LED strip substrates is that their thermal performance is relatively poor.
If we look at thermal conductivity numbers, Kapton (polyimide) is 0.12 W/m-K, and the 3M adhesive material is 0.18 W/m-K.
Venture LED flex PCB is transmitting heat away from operating areas or critical components to ancillary spaces.
They are using one or more of the following:
- metal heatsinks
- metallic cores (aluminum, Cu),
- thermally conductive dielectrics (Stabl-Cor, graphene)
- heavy copper plane layers
Venture is a leading Led flex PCB manufacturer and supplier in China for more than 10 years.
Your Leading Led Flex PCB Supplier in China
Are you looking for the cheapest yet durable and quality Led Flex PCB for your applications? Venture is the right place for you!
Depending on your applications, we can offer you a wide range of venture Led Flex PCB at affordable prices.
Venture Led flex PCB is widely used in different industrial use. It can be found at the following applications:
- Consumer Electronics
- Flood Lights
- Light Bulbs
- Mobile Phones
- Security Lights
- Spot Lights
- Street Lights
- Vehicle Lights
Led flex PCB is a special two layers FPC or single-sided FPC with adhesive tape at the bottom side.
All of our Led flex PCBs are easy to peel off and install.
As a professional manufacturer, we produce Led flex PCB with outstanding characteristics which are the length.
Theoretically, the length of this Venture Led flex PCB can be made according to clients’ request.
Venture Led flex PCB is not only LED lighting energy-efficient.
Our Led flex PCB also produces a fraction of the heat standard lighting solutions create.
It also allows for very unique lighting solutions due to their extremely small size.
Venture Electronics is ISO 9001-2008 certified.
That’s why we can offer co-engineering and co-design services, prototyping, just-in-time consignment, and limited series Led Flex PCB production.
We strive to provide quality Led Flex PCB as well as quality services.
As the fastest growing industry, Venture has worked with different major lighting companies.
Aside from Led flex PCB, we can also provide metal-core printed circuit boards or MCPCB that is that the forefront of heat dissipation technology.
Venture will be your best partner for Led flex PCB you need!
Contact us now!
LED FLEX PCB: The Ultimate FAQ Guide
If you have any question about LED flex PCB, you will find the answer right here.
Whether you want to learn about the best PCB material, features, specifications or classification criteria – you should read this guide.
Keep reading to learn more.
- What Is LED Flex PCB?
- What Are The Benefits Of Using An LED Flex PCB?
- What Are Some Types Of LED Flex PCB?
- What Are The Electrical Characteristics Of LED Flex PCB?
- What Are Some Design Tips That Minimize The Cost Of LED Flex PCB?
- How Can You Improve The Bend Radius And Flexibility Of LED Flex PCB?
- What Colors Can LED Flex PCBs Come In?
- What Should You Consider Before Manufacturing LED Flex PCB?
- What Materials Are Suitable For Manufacturing LED Flex PCB?
- What Quality Standards Should LED Flex PCBs Comply With?
- What Are The Applications Of LED Flex PCB?
- What Are The Thermal Properties Of LED Flex PCB Laminate You Should Consider?
- How Do LED Rigid PCB And LED Flex PCB Compare?
- What Are The Specifications Of Flexible PCBs?
- What Is The Function Of The LED Strip Substrate In LED Flex PCB?
- What Is LED Flex Aluminum PCB?
- What Are The Advantages Of Using LED Flex Aluminum PCB?
- What Can You Use To Manage Heat In LED Flex PCB?
- What Is The Design Process Of An LED Flex PCB?
- What Factors Affect The Price Of An LED Flex PCB?
- How Should You Place Copper On An LED Flex PCB?
- What Are The Benefits Of Multilayer LED Flex PCB?
- What Are The Limitations Of Multilayer LED Flex PCB?
- How Can You Test An LED Flex PCB Assembly?
- How Can You Conduct Bare-board Test On An LED Flex PCB?
- What Should You Consider When Drilling An LED Flex PCB?
- How Can You Repair LED Flex PCB?
- Do LED Lights In LED Flex PCB Interfere With Electronics?
- What Do You Require When Customizing LED Flex PCB?
- What LEDs Can You Use In Flex PCB?
- What Should You Consider When Choosing LED Flex PCB Manufacturer?
What Is LED Flex PCB?
This is a flexible PCB substrate that allows you to pack it in any geometry.
Besides, it will retain the repeatability and accurate density of PCBs.
LED flex PCB
What Are The Benefits Of Using An LED Flex PCB?
LED flex PCBs have several benefits such as:
In an electronic package, LED flex PCBs to offer a myriad of connectivity between electronic parts, user interface, and other circuit boards.
Also, you can connect them in dynamic flexible usages.
This feature allows it to continuously flex throughout the lifespan of the device or application.
For instance, you will use this feature in foldable electronics, laptops, and other displays.
When the printed circuit board has a low weight, the final product will be lighter.
This feature is vital in modern electronics since electronic designers and consumers prefer small and lightweight electronics.
LED flex PCBs apply this feature in drones and unmanned vehicles since they are lightweight.
LED rigid PCBs are thick and strong but LED flex PCBs will absorb vibrations and shocks effectively than them.
This effect will enhance the longevity, reliability, and functionality of the products.
For instance, this feature is useful in medical devices, missile guidance systems, satellites, etc.
LED rigid PCB
Flexible LED PCB
LED flex PCBs are resistant to warping from heat, radiation, or chemicals, which LED rigid PCBs can get damaged.
This feature makes it suitable for use in modern automotive electronics.
The substrate of LED flex PCBs enables them to better dissipate heat than a majority of other PCB materials.
LED flex PCBs are compatible with a wide array of parts or connectors, many of which as small or affordable connectors.
LED flex PCBs can bend or fold so that it fits the final application or device.
This feature allows designers to fit the circuitry in the device and not design the device around the printed circuit board.
For instance, flexible PCBs are suitable for wearable electronics.
What Are Some Types Of LED Flex PCB?
There are various types of LED flex PCBs and they include the following:
Single-sided LED Flex PCB
These circuits have one layer of conductor made from a metal or a conductive polymer on flexible dielectric films.
The features of the components are available only on one side.
Besides, to allow the component leads to pass for interconnection through soldering, you can drill holes on the base film.
You can fabricate single-sided LED flex PCBs with or without protective coatings as a cover coat or layer.
Double-sided LED Flex PCB
This flexible PCB contains two layers of conductors and you can fabricate it without or with plated through holes.
Depending on the application, you can fabricate this PCB with protective cover layers on one, both, or no sides of the final circuit.
Double-sided LED flex PCBs allow you to prepare to intersect connections easily.
Sculptured LED Flex PCB
These are novel separations of normal LED flex PCB structures.
The manufacturing process entails specific flex circuit multi-step etching techniques.
This technique makes flexible circuits with copper conductors whose thickness varies in many places along with the PCB.
For instance, the conductors are thick at points of intersection and thin in flexible locations.
Multilayer LED Flex PCB
This kind of PCB has three or more layers of conductors and you can connect the layers via plated through holes.
Also, you can choose not to laminate the layers in LED flex PCBs except for areas that contain plating through-holes.
Irregular lamination is famous in instances where you require the most flexibility.
This is possible by not bounding the location at which bending or flexing will occur.
Rigid-flex LED PCB
For this structure, you have a hybrid of rigid and flexible substrate materials which you laminate into one structure.
Besides, do not confuse a rigid-flex with a rigidized flex construction.
Rigidized flex PCBs contain additional stiffeners on the primary electronic weight.
Also, rigidized flex PCBs can have one or more layers of conductors.
Plated through-holes are a means to electrically connect layers of rigid-flex LED PCBs.
What Are The Electrical Characteristics Of LED Flex PCB?
Flexible PCB for LED lighting
These include the following:
Dielectric Constant [dk]
This property will affect impedance and the integrity of signals in LED flex PCB materials.
Besides, dk needs to remain constant in a wide application of frequencies for high-speed usages.
Relative Permittivity [Er]
This is also known as relative dk.
Surface Resistivity ?S [Ω-m]
This is how you measure the surface resistance of dielectric materials to electricity flow.
Besides, they can change when there is a change in moisture or temperature.
Also, surface resistivity should be high to enhance good signal integrity.
Volume Resistivity ? [Ω/m2]
This is how you will measure the volume resistance in dielectrics.
Besides, it should be high to maintain isolation between the layers.
Dissipation Factor [Df]
This is how you measure the loss of power or signal on the LED flex PCB material.
Also, it is vital for analog and not digital signals, mostly for frequencies over 1GHz.
This is because the dissipation factor increases with an increase in frequency.
Electrical Strength [V/mil]
This is the ability of the LED flex PCB to resist electrical breakdown in the z-direction.
What Are Some Design Tips That Minimize The Cost Of LED Flex PCB?
These include the following:
- Consider how you will nest the circuit on a panel
- Keep the circuits small and consider using sets of smaller circuits and not one large circuit
- Ensure you follow the recommended tolerances
- Where necessary, you can design unbonded areas on the circuit
- Applying stiffeners are cost-effective than rigid-flex circuits when circuits contain a few layers
How Can You Improve The Bend Radius And Flexibility Of LED Flex PCB?
Two or more circuit layers are suitable for static applications which will flex during the installation process.
Several issues can arise when you sharply bend the circuit.
Also, compression can form wrinkles on the cover coats that are within the bend.
Stretching can result in rips in the cover material and/or damaged conductors along the outside of the bend.
Establish the radius of the bend when you begin the mechanical design process.
The circuit will operate reliably when the radius is 10 or more times thicker than the material thickness.
Several factors will determine the minimum commended bend radius, according to IPC-2223.
The total thickness of the circuit is less than the total sum of adhesives, single insulators, and the thickness of foil layers.
What Colors Can LED Flex PCBs Come In?
They can come in a variety of colors such as:
What Should You Consider Before Manufacturing LED Flex PCB?
There are several manufacturing offers and materials that you can use to make LED flex PCBs.
Here are some factors to consider:
When you use LED flex PCBs, you will lower the weight of various electronic devices.
LED flex PCBs are expensive but when you consider how durable they are, the price will not matter.
The flexible PCB manufacturers will offer you durable, strong, long-lasting, and cost-effective flexible PCBs.
Also, the extra cost is not a big issue when you get high-quality LED flex PCBs.
Low Assembly Time
LED flex PCBs have a minimal chance of breaking during the manufacturing process as they are not sensitive and delicate.
Since there is less risk of breaking or damaging LED flex PCBs, the assembly time is less.
Active And Dynamic Flexing
It is vital to buy polyimide with thin copper foils.
This material is suitable for manufacturing several devices requiring dynamic flexing.
Also, you can use thicker flexible PCBs for stay and bending usages.
What Materials Are Suitable For Manufacturing LED Flex PCB?
The element of LED flex PCBs should meet specific requirements and the life expectancy of the materials.
Also, these materials should work with flexible components to ensure reliable and easy manufacturing.
The various materials include the following:
The conductor carriers and insulation material influence the operation of the substrate and film.
Besides, the substrate should be able to curl and bend.
Examples of flexible PCB materials include PET (polyester) films, PI (polyimide) film, PTFE, polyethylene naphthalate, aramid, etc.
Pick the substrate material depending on performance and cost.
PI (polyimide) film is common since it can withstand high-temperature levels hence, will not melt.
Also, following thermal polymerization, they can remain flexible and elastic.
These materials assist in effectively supplying current, and copper is the main material for flex PCBs.
Copper is an effective conductor, readily accessible, and cost-effective.
Also, ensure the material can dissipate heat.
Besides, the thickness of copper will determine the amount of current it can conduct.
Other types of conductors include stainless steel, BeCu, and Cupronickel.
All flexible PCBs contain adhesives between polyimide film and copper.
The two main adhesives you can use include epoxy and acrylic.
Besides, the adhesive should withstand the high temperatures of copper.
When electric current passes via the copper or conductors, insulators will protect the users from shock.
Polyimide film is the best material for making insulators.
When making rigid-flex printed circuit boards, combine prepreg and FR4 within the rigid component.
What Quality Standards Should LED Flex PCBs Comply With?
LED Flexible PCB
- ISO 9001:2000
What Are The Applications Of LED Flex PCB?
- Automotive industry
- Communication industry
- Aerospace industry
- Medical industry
- Military industry
- Consumer electronics
- Transportation industry
- Industrial application
- ICT and tech industry
What Are The Thermal Properties Of LED Flex PCB Laminate You Should Consider?
These include the following:
Glass Transition Temperature Tg [°C]
This is the temperature at which the LED flex PCB substrate reversibly changes from hard to soft.
Also, this temperature should be less than the solder temperature.
Thermal Conductivity k [W/m]
This is the rate at which heat will move through a material, and it will be high for conductors than insulators.
Decomposition Temperature Td [°C]
This is the temperature at which the LED flex PCB substrate permanently decomposes.
Also, this temperature should be lower than the solder temperature.
Coefficient Of Thermal Expansion CTE [ppm]
This is the rate at which the LED flex PCB will expand in the presence of heat.
Also, this should be low as possible.
How Do LED Rigid PCB And LED Flex PCB Compare?
Here is how these two compare:
LED flex PCBs can bend and fold while LED rigid PCBs cannot bend or fold.
LED flex PCBs offer more connectivity between other boards, electronics, and user interfaces.
Also, they are suitable for use in applications requiring regular flexing which is not suitable for LED rigid PCBs.
LED flex PCBs can withstand heat, chemicals, and radiation more than LED rigid PCBs.
This feature makes it suitable for use in the automotive industry.
LED flex PCBs can absorb vibrations and shocks more effectively than LED rigid PCBs.
This feature makes them suitable for usages that require excellent environmental survivability.
LED fled PCBs are lightweight than LED rigid PCBs.
This feature makes it suitable for use by electronic designers and consumers to make small devices.
What Are The Specifications Of Flexible PCBs?
Number Of Layers
Flexible PCBs can come with one or more layers depending on your application.
They are available in various forms and you need to specify the type you need and where you require it.
Besides, you can apply it on one or both sides of the PCB.
There are different forms of surface finish and they are not application-specific.
Examples of surface finish include immersion tin, electrolytic tin plating, organic coating OSP, gold and soldering, immersion silver, etc.
Flexible PCBs need to pass this test to show how the design will operate.
To prevent issues due to drilling, the holes need to be tighter.
This feature ensures that the components you mount on the substrate are secure even during flexing.
This ensures the design of flexible PCBs complies with the set quality standards from various bodies.
The weight of copper depends on the application and it can compromise the flexibility of the PCB.
This specification is vital when designing these PCBs.
Small spacing may compromise functionality and cause short-circuiting.
Ensure the spacing is high as possible to enhance the functionality of the device.
What Is The Function Of The LED Strip Substrate In LED Flex PCB?
The LED strip substrate is the upper part of the printed circuit board.
It is operated by:
- Providing the surface on the PCB where you will mount LED chips
- It provides a physical and structural base to the LED strips
- Also, it assists in relaying electricity via its circuitry
- It also offers a path for heat dissipation
What Is LED Flex Aluminum PCB?
The development of flexible PCBs enables you to lower the size of some products.
Besides, like the rigid printed circuit boards, flexible PCBs come with some limitations.
Several manufacturers use flexible aluminum PCBs to enhance the performance of circuit boards in high-power applications.
What Are The Advantages Of Using LED Flex Aluminum PCB?
LED flex PCB
LED flex aluminum PCBs have three major layers:
- Conductive circuitry
- Aluminum base
- Flexible dielectric insulator
Dielectric layers have high thermal conductivity enabling heat to flow from the aluminum base to the circuitry.
At this point, it will disperse thermal energy.
This design gives LED flex aluminum PCBs several benefits such as:
Layers of aluminum and dielectrics enable these PCBs to disperse heat.
Thermally conductive dielectric layers transmit more heat than standard fiberglass designs with an efficiency of up to 10 times.
This feature prevents damages from overheating thus enabling the LED flex aluminum PCB to handle strong electric currents.
Aluminum is lightweight hence LED flexible aluminum PCBs offer better performance connections in small devices.
LED flex aluminum PCBs offer better durability and strength when you build them with flexible aluminum alloys.
Mining and refining aluminum is easy hence LED flexible aluminum PCBs are cost-effective.
Also, in high-power circuitry, they can manage heat.
Being light will also lower the production costs.
What Can You Use To Manage Heat In LED Flex PCB?
This effect is possible when you include one or more of the materials below:
- Metallic cores such as aluminum and copper
- Metal heatsinks
- Thermally conductive dielectrics such as graphene
- Heavy layers of copper planes
What Is The Design Process Of An LED Flex PCB?
When you use experienced vendors, the design process will be as follows:
This process entails presenting the design to your vendor.
The time it takes relies on the complexity of the parts and revisions that optimize the design.
Here, you will review the schematics from the supplier.
Schematics control the project hence make sure it is accurate for your application.
The designer will create the PCB by opening the schematic with a PCB layout program.
Designers develop Gerber files to produce bare circuit boards once you approve the board.
The circuit board passes through an assembly process where you will place tiny components on the PCB.
The intensity of the inspection will depend on the product and the application.
What Factors Affect The Price Of An LED Flex PCB?
These include the following:
Type Of Assembly
The price of PCBs rise or lowers depending on the assembly type.
For instance, surface-mounted devices cost less than through-hole soldering.
Quantity And Size Of The Batch
If you plan to buy plenty of LED flex PCBs at one go, you will spend less than when you buy only in small amounts.
Placement Of Components
How you decide to place the parts on printed circuit boards affects the price.
Evaluate how you need to place the parts since surface placement is affordable than through-hole soldering.
The cost of LED flex PCBs increases if you want to include special parts.
Number Of Components
The number of parts will affect the price of the PCB since you need to buy these parts besides manufacturing.
Package Size Of Components
When you purchase standard industry-sized parts, you will spend less.
The cost increases if you use special, delicate, and sizeable components.
How Should You Place Copper On An LED Flex PCB?
Try to balance copper on both sides of the foil otherwise, they warp during manufacturing processes.
More bend will be on the weaker side of the flex when it experiences stress.
What Are The Benefits Of Multilayer LED Flex PCB?
These LED flex PCBs can function as single systems instead of operating with other components of the printed circuit board.
This feature enables you to fit the PCBs in small devices and lower weight and size.
They are more functional due to their layered design.
Multilayer LED flex PCBs are strong as they have to handle heat, pressure, and weight that join them.
This feature allows you to place them in any configuration and can withstand bending.
Since they pass several manufacturing processes, they tend to be of high quality and reliable.
High-density multilayer LED flex PCB contain several single-layer PCBs and the tight system makes them more connective.
They have fewer connectors that interlink making them suitable for modern mobile electronics.
What Are The Limitations Of Multilayer LED Flex PCB?
They have the limitation of being costly to produce and difficult to troubleshoot since they have components within the layers.
How Can You Test An LED Flex PCB Assembly?
The available methods include the following:
- Visual inspection
- In-circuit testing
- Functional testing
- Analog signature testing
- Automated optical inspection
- Power-off testing
How Can You Conduct Bare-board Test On An LED Flex PCB?
Bare-board test entails testing isolation and the continuity of electrical connection on bare PCBs before you attach any components.
Isolation testing entails verifying the resistance between two individual electrical connections and ensuring that they are met.
Continuity testing entails verifying that no open points exist within the PCBs.
What Should You Consider When Drilling An LED Flex PCB?
- Choose maximum micro via in the design structures
- Maintain a minimum aspect ratio for better signal intensity and electrical performance
- Apply vias in thermal pads within QFNs to enhance solder flow to conductive planes
- Fill via-in-pads if they are not within thermal pads
- Select staggered vias as stacked vias require fillings and planarization
How Can You Repair LED Flex PCB?
To repair LED flex PCBs, you need a soldering iron and a replacement LED bulb.
Begin by identifying the faulty LED by powering up the LED flex PCB.
Remove the faulty LED with the assistance of the soldering iron, or pulling them out, depending on the design.
Also, make sure you recall the polarity of the faulty LED light.
Replace the LED with a light of similar voltage, but you do not need to match the voltage by standard resistance values.
You can use general values.
Connect and secure the replacement LED, and test to ensure it is working.
If the LED does not light, assess the polarity of the socket and alight it in one direction across the entire circuit.
Do LED Lights In LED Flex PCB Interfere With Electronics?
Some reports by consumers illustrate that some LED lights in gadgets produce noise, thus interfering with radio and DAB signals.
The switch circuitry that controls them operates at high frequencies even though the LEDs do not create much noise.
Ensure you connect them properly as they may cause electromagnetic interference.
What Do You Require When Customizing LED Flex PCB?
The basic requirements include the following:
- Reliable software where you will create the blueprint of the PCB
- PCB design solutions that will design your PCB
What LEDs Can You Use In Flex PCB?
These include the following:
Surface Mount LED
These are LEDs that you mount on the surface of the PCB using Surface Mount Technology [SMT].
This LED is also known as integral single point LED and comes in various color ranges.
This LED is also known as single-point LED.
It is also popular since you can use it in several applications.
Also, they provide light diffusion as the surface is textured or matte.
What Should You Consider When Choosing LED Flex PCB Manufacturer?
These include the following:
Range Of Expertise
Ensure they manufacture all types of PCBs such as rigid, flex, or rigid-flex, and single and multilayer PCBs.
Ensure they provide high-quality PCBs for various applications.
Ensure the manufacturer offers project management from beginning to end.
Responsiveness And Flexibility
Make sure they can make changes efficiently and quickly.
This will ensure you make changes before you begin manufacturing thus, lower the costs of remanufacturing new designs.
At Venture Electronics, we will help you choose a perfect LED PCB design for your applications.
Contact us now for all your LED flex PCBs.