LED Lamp Panel Structure with Reduced PCB Via Holes
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Solution Overview
Problem
The existing LED display screens have a high number of via holes on the PCB board, leading to increased defect rates and manufacturing costs.
Innovation Solution
The LED panel structure arranges LEDs in an array manner on the PCB board, connecting common-electrode terminals of adjacent LEDs through via holes on the inner or bottom layer to form scanning lines and connecting non-common-electrode terminals on the surface layer to form data lines, reducing the number of via holes required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the scanning line and data line are arranged on different layers of PCB board with via holes connecting them, then the electrical connection is improved, but the number of via holes increases leading to higher defect rates and manufacturing costs
Solution Approach 1:
The patent transitions from a traditional multi-layer PCB structure with numerous vertical via holes to a planar surface-layer routing structure. By redistributing both scanning lines and data lines on the surface layer and using LED internal connections, the design eliminates the need for deep via hole penetrations, thereby improving PCB yield while maintaining electrical connectivity.
Solution Approach 2:
The patent extracts the electrical connection function from the PCB via holes and relocates it to the LED components themselves. The LED's internal structure is utilized to provide the necessary electrical pathways, removing the burden of creating numerous via holes in the PCB and thus reducing defect rates.
2Adaptability or versatility
If more via holes are added to the PCB board to accommodate data lines on inner or bottom layers, then the routing flexibility is improved, but the manufacturing cost and material waste increase
Solution Approach 1:
The patent achieves routing flexibility primarily on the surface layer of the PCB board through careful trace routing. By utilizing the XY plane extensively and employing LED internal connections for layer transitions, the design obtains adequate routing adaptability without requiring complex multi-layer via hole structures, thereby reducing manufacturing costs.
Solution Approach 2:
The LED components themselves provide the electrical connection service that would otherwise require additional PCB via holes. The LED's internal anode and cathode structures serve as built-in connection pathways, eliminating the need for separate via hole routing and reducing overall manufacturing complexity and cost.
3Reliability
If via holes are increased to connect common-electrode terminals on different layers, then the electrical connectivity is improved, but the number of defects and material waste increase
Solution Approach 1:
The patent extracts the electrical connection function from PCB via holes and relocates it to the LED components themselves. The LED's internal structure is utilized to provide the necessary electrical pathways, removing the burden of creating numerous via holes in the PCB and thus reducing defect rates.
Solution Approach 2:
The LED component serves multiple functions: light emission, electrical connection between layers, and signal transmission. By utilizing the LED's internal structure for electrical connectivity, the design eliminates the need for separate via holes, reducing material waste while maintaining reliable electrical connections.
Data Source
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AI summary
An embodiment of the present disclosure provides an LED panel structure, which includes a PCB board provides with a plurality of via holes; a plurality of LEDs arranged on the PCB and arrayed in a first direction and a second direction. The plurality of adjacent LEDs are sequentially arranged in the second direction to form a plurality of light-emitting pixels. Common-electrode terminals of LEDs in rows in the second direction are electrically connected through the via holes to form one scanning line in the second direction, non-common-electrode terminals of the LEDs in each row in the first direction are electrically connected on a surface layer of the PCB board to form one data line in the first direction. According to the LED panel structure disclosed in the embodiment of the present disclosure, the number of via holes on the PCB board may be less than the number of LEDs, thereby improving the yield of the PCB, reducing waste of materials, and reducing the manufacturing cost of the PCB.