LED Panel PCB Layout With Shared Vias for Higher Yield
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Solution Overview
Problem
The high number of via holes in LED display screens on PCB boards increases defect rates and manufacturing costs, as each LED requires multiple via holes for data and scanning lines, leading to material waste and inefficiencies.
Innovation Solution
The LED panel structure rearranges LEDs on the PCB board such that common-electrode terminals of LEDs in columns are connected to scanning lines through shared via holes, and non-common-electrode terminals in rows are connected to data lines, reducing the number of via holes needed by allowing LEDs to share connections and minimizing the size of the PCB board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of via holes on the PCB board is increased to connect each LED, then the connectivity and functionality of the LED display is improved, but the defect rate of the PCB board increases and the yield decreases
Solution Approach 1:
Multiple common-electrode terminals of LEDs in the same column are merged into a single via hole connection. The via hole serves as a shared connection point for multiple LEDs, eliminating the need for separate via holes for each LED's common electrode, thus reducing the total via hole count while maintaining electrical connectivity.
Solution Approach 2:
Each via hole is designed to serve multiple functions: it connects the common electrode terminals of multiple LEDs simultaneously, and also serves as a structural support element. This multi-functionality reduces the overall number of via holes needed in the PCB board.
2Reliability
If the number of via holes on the PCB board is increased to ensure proper electrical connections, then the electrical connectivity is improved, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple electrical connection requirements into a single via hole structure. By having multiple common-electrode terminals share one via hole, the manufacturing process requires fewer via hole creations, drilling operations, and plating steps, directly reducing manufacturing costs while maintaining proper electrical connectivity.
3Reliability
If the number of via holes is increased to connect each LED individually, then the connection reliability is improved, but the material waste increases
Solution Approach 1:
The patent combines multiple connection functions into fewer via holes, reducing the consumption of PCB material, copper plating material, and other resources required for via hole fabrication. This merging approach minimizes material waste while ensuring that each LED still has reliable electrical connection through the shared via hole infrastructure.
Data Source
AI summary
An LED panel structure includes a PCB board and a plurality of LEDs. The PCB board is provided with a plurality of data lines, a plurality of scanning lines and a plurality of via holes. The data lines and the scanning lines are respectively located at different layers of the PCB board. The LEDs are disposed on the PCB board to form LED rows and LED columns, each LED column includes a plurality of LED groups, and each LED group includes two adjacent LEDs. A plurality of adjacent LEDs are sequentially arranged in a second direction to form light-emitting pixels. The LED includes a common-electrode terminal and a non-common-electrode terminal. All common-electrode terminals in each LED column are connected to one scanning line through via holes. All non-common-electrode terminals in each LED row are connected to one data line. Two data lines are provided between adjacent LED groups.