PCB Voltage Suppression for LED Series Arcing
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Solution Overview
Problem
LED tubular lamps face the risk of arcing and subsequent fire due to disconnections in the series connection of LEDs across multiple PCBs, particularly when used with traditional electronic ballasts, as existing solutions do not effectively prevent voltage surges at broken points.
Innovation Solution
Incorporating voltage suppression elements across the terminals of circuit boards in a series connection configuration, which become conductive when a voltage threshold is reached, shunting voltage and preventing arcing across disconnections, thereby protecting the circuit from overvoltage and fire risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multiple PCBs are used to create a long-shaped circuit board for LED tubular lamps, then the desired shape and flexibility are achieved, but the connection reliability deteriorates due to weak connections that may break under vibration
Solution Approach 1:
The circuit board is divided into multiple separate PCBs connected in series to achieve the long tubular shape required for LED lamp replacements. Each PCB segment contains LED strings and connection terminals, allowing the overall system to flex and fit into existing lamp fixtures while maintaining electrical continuity through the segmented structure.
2Adaptability or versatility
If traditional electronic ballasts are used with multi-PCB LED lamps, then compatibility with existing fixtures is maintained, but the risk of arcing and fire increases when connections break due to high voltage generation
Solution Approach 1:
Voltage suppression elements are pre-installed across the terminals of each PCB segment before assembly. These elements remain dormant during normal operation but automatically activate when a connection breaks, clamping the voltage to safe levels before arcing can occur. This preliminary protective measure ensures that even if mechanical connections fail under vibration, the electrical system remains safe from high-voltage arcing and fire hazards.
3Reliability
If voltage suppression elements are added across the terminals of each PCB, then protection against arcing and overvoltage is achieved, but the device complexity increases
Solution Approach 1:
The voltage suppression elements used are simple, inexpensive components such as varistors or gas discharge tubes that provide robust overvoltage protection without requiring complex circuitry. These elements are designed to fail safely after activating once, clamping the voltage and protecting the expensive LED strings and driver circuits from damage. Their simplicity and low cost make them ideal for mass production in multi-PCB LED lamp assemblies.
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
The solution effectively reduces voltage stress and prevents arcing between series-connected LEDs, mitigating the risk of fire by shunting voltage away from potential disconnections, ensuring safer operation of LED lamps, especially in environments prone to vibrations.
Implementation Method 1
voltage suppression elements across the terminals of circuit boards in a series connection configuration, which become conductive when a voltage threshold is reached, shunting voltage and preventing arcing across disconnections
Data Source
Figure 1~2
Figure 3~4
AI summary
A circuit board arrangement assembled by at least a first and a second circuit boards, each circuit board comprising: a portion of a circuit; and a first and a second electrical terminals to be electrically connected to a respective first and a second electrical terminals of the other circuit board of the first and the second circuit boards, so as to couple the portions of the circuit of the first and the second circuit boards, wherein the first and second electrical terminals on the circuit board are coupled with each other via the portion of the circuit on the other circuit board of the first and the second circuit boards, at least one board further comprising: a voltage suppression element (TSS1, TSS2) in the board connected across the first and second electrical terminals of the board, said voltage suppression element (TSS1, TSS2) is adapted to become conductive when a voltage thereacross reaches a threshold; characterized in that the portion of the circuit comprising at least one LED, and said LED (LED1) of the first circuit board (B1) and said LED (LED4) of the second circuit board (B2) are forwarded in the same direction and to be series connected between a first interconnection (LED+) of the first electrical termainals of the first and the second circuit boards and a second interconnection (LED-) of the second electrical terminal of the first and the second circuit boards. The voltage suppression element is able to prevent overvoltage/arcing due to a disconnection of the series connection of the LEDs of the first and second circuit boards, as well as a disconnection of a interconnection of first terminals, and a interconnection of the second terminals.