Composite LED Circuit Board Integrating Lamp Panel and Drive Plate
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Solution Overview
Problem
The existing LED illuminating lamps have a complicated production process, leading to increased manufacturing costs and inconsistent, unreliable connections between the lamp panel and the LED drive plate, due to separate manufacturing of these components.
Innovation Solution
A composite LED circuit board is introduced, where an aluminum base plate with an embedding hole is used to embed an insulating base plate, forming a composite base plate with an electrical insulation layer and conductive copper foil, allowing the lamp panel and drive plate to be connected directly through the copper foil, simplifying the connection process and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lamp panel and LED drive plate are made separately and connected through conducting wires or connection terminals, then the production process becomes complicated and manufacturing cost increases, but the connection consistency and reliability deteriorate
Solution Approach 1:
The patent merges the lamp panel and LED drive plate into a single integrated circuit board structure. The aluminum base plate serves dual functions as both the lamp panel substrate and the drive plate mounting base, eliminating the need for separate components and external connection terminals. This integration directly resolves the contradiction by simplifying the production process while simultaneously improving connection reliability through direct structural coupling.
Solution Approach 2:
The aluminum base plate is designed to perform multiple functions: it serves as the structural base for the lamp panel, provides heat dissipation, and acts as the mounting platform for the LED drive plate. This multi-functionality eliminates the need for separate connection components, thereby simplifying manufacturing while ensuring reliable connections through the unified structural design.
2Productivity
If the lamp panel and LED drive plate are made separately, then manufacturing flexibility is maintained, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
By combining the lamp panel and LED drive plate into a single integrated circuit board, the patent reduces the number of assembly steps and components. The aluminum base plate integrates both functional areas, allowing for streamlined manufacturing processes and improved production efficiency without requiring complex multi-component assembly procedures.
3Manufacturing precision
If conducting wires or connection terminals are used to connect the lamp panel and LED drive plate, then connection flexibility is achieved, but manufacturing cost increases and connection consistency deteriorates
Solution Approach 1:
The integration of the lamp panel and LED drive plate into a single circuit board structure eliminates the need for external conducting wires and connection terminals. The electrical connections are made through integrated copper traces on the circuit board, which provides consistent and reliable connections without the complexity of wire harnesses or terminal connectors.
Solution Approach 2:
The circuit board itself acts as an intermediary that provides integrated electrical pathways between the lamp panel components and the LED drive plate. The copper traces on the circuit board serve as the connection medium, replacing external wires and terminals while ensuring consistent electrical connectivity through precise manufacturing processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly simplifies the connection between the lamp panel and the LED drive plate, ensuring consistency and reliability, thereby reducing manufacturing costs and saving manpower.
Implementation Method 1
the base plate thereof often uses the aluminum base plate to facilitate connection with the radiator and bring into being good heat radiation effects
Implementation Method 2
an electrical insulation layer on the circuit board and the peripheral metal board
Data Source
AI summary
Various embodiments provide a light emitting diode (LED) module. In one embodiment, the LED module comprises a circuit board; a peripheral metal board abutting and about said circuit board; an electrical insulation layer on both a first surface and a second surface of said circuit board and said peripheral metal board; electrical traces on said electrical insulation layer; and one or more LEDs mounted on said electrical traces and said electrical insulation layer over said peripheral metal board.