Uniform Luminance LED Circuit Board via Segmented Trace Layout
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Solution Overview
Problem
Conventional LED circuit boards face issues with inconsistent luminance due to varying current flow through LEDs, requiring additional resistors and voltage boosting, which increases production costs and complexity.
Innovation Solution
A uniform luminance LED circuit board design featuring wider primary traces to limit current and eliminate the need for series-connected resistors, along with auxiliary traces that provide additional current paths to adjust current flow and ensure identical luminance across all LEDs, reducing resistance and eliminating the need for additional voltage boosting or complex LED power drivers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If series connection is used to connect LEDs, then voltage utilization efficiency is improved, but driving voltage increases with the number of LEDs requiring additional voltage-boosting circuit
Solution Approach 1:
The circuit board is divided into multiple independent zones, each zone containing LEDs connected in series. Each zone has its own trace system, allowing the circuit to be segmented into manageable units that can be driven independently, thus maintaining voltage utilization efficiency without requiring a single complex voltage-boosting circuit for all LEDs
Solution Approach 2:
The patent transitions from a single-trace linear layout to a multi-zone two-dimensional layout. By arranging LEDs in multiple zones with independent trace systems, the circuit board utilizes spatial dimensionality to distribute voltage requirements across multiple zones, eliminating the need for voltage boosting while maintaining efficient voltage utilization
2Device complexity
If parallel connection is used to connect LED strings, then driving voltage is reduced, but current flowing through different LEDs varies causing inconsistent luminance
Solution Approach 1:
The circuit board is divided into multiple independent zones, each zone containing LEDs connected in series. Each zone has its own trace system, allowing the circuit to be segmented into manageable units that can be driven independently, thus maintaining voltage utilization efficiency without requiring a single complex voltage-boosting circuit for all LEDs
Solution Approach 2:
By designing each zone with independent trace systems and ensuring symmetrical trace layouts, the patent creates equipotential conditions for corresponding LEDs across different zones. This ensures that voltage drops and current flows are consistent for LEDs in similar positions, achieving uniform luminance without requiring additional resistors or complex control circuits
3Illumination intensity
If resistors are added in series to each LED string to adjust current, then luminance consistency is improved, but manufacturing cost increases and power utilization efficiency drops
Solution Approach 1:
The circuit board is divided into multiple independent zones, each zone containing LEDs connected in series. Each zone has its own trace system, allowing the circuit to be segmented into manageable units that can be driven independently, thus maintaining voltage utilization efficiency without requiring a single complex voltage-boosting circuit for all LEDs
Solution Approach 2:
The patent applies different trace width specifications to different regions of the circuit board. By locally optimizing trace dimensions in high-current areas versus low-current areas, the design achieves current control and luminance uniformity without requiring additional resistors, thereby reducing manufacturing cost while maintaining luminance consistency
4Illumination intensity
If LED power driver with multiple channels is used to adjust current, then luminance consistency is improved, but device complexity and cost increase
Solution Approach 1:
The circuit board is divided into multiple independent zones, each zone containing LEDs connected in series. Each zone has its own trace system, allowing the circuit to be segmented into manageable units that can be driven independently, thus maintaining voltage utilization efficiency without requiring a single complex voltage-boosting circuit for all LEDs
Solution Approach 2:
The circuit board design itself provides current control functionality through its trace layout and zone segmentation. The PCB structure acts as a passive current regulator, eliminating the need for active LED power drivers with multiple channels. The circuit board serves its own current control needs through careful trace design, reducing overall system complexity
Data Source
AI summary
A uniform luminance light-emitting diode (LED) circuit board includes a first primary trace and a second primary trace mounted on a substrate along a direction and are spaced apart, multiple LED strings mounted on the substrate along the direction and parallelly connected between the first primary trace and the second primary trace, a first power trace and a second power trace respectively connected to the first primary trace and the second primary trace, and a first auxiliary trace with two ends respectively connected to the second primary trace and the second power trace. By adjusting trace widths of the first primary trace and the second primary trace to limit current passing through each LED string and using the first auxiliary trace to provide an additional current path, identical current flowing through all the LED strings results in uniform luminance of the LED strings.