Uniform LED Strip Assembly via Segmented PCB Bonding
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Solution Overview
Problem
Conventional methods for connecting linear LED light strips fail to maintain uniform illumination due to large connection areas or insufficient LED arrangement, resulting in dark spots or regions, especially when trying to lengthen LED light sources for various applications.
Innovation Solution
A method involving a PCB-to-PCB connection technology where LEDs are closely arranged on multiple PCBs, using a connecting board with copper foil traces and bonding zones to ensure uniform illumination and strong bonding, allowing for the lengthening of LED light strips without dark spots and maintaining uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional connector or board-to-board connection technology is used to lengthen LED light strips, then the length of the LED light source can be extended, but uniform illumination is compromised due to large connection areas or insufficient LED arrangement causing dark spots
Solution Approach 1:
The connecting board is divided into multiple bonding zones (first bonding zone, second bonding zone, third bonding zone, fourth bonding zone) corresponding to different LED rows and poles. This segmentation allows each zone to independently bond with corresponding LED arrays, ensuring uniform illumination across the entire extended light source by maintaining consistent LED spacing and density throughout the connection area.
2Length of moving object
If multiple LED light strips are connected using conventional methods, then longer light sources can be achieved, but the connection area becomes large and creates dark regions
Solution Approach 1:
The connecting board extends in multiple directions with bonding zones arranged in a grid pattern (first and second bonding zones in one direction, third and fourth bonding zones in another direction). This multi-dimensional arrangement allows the connection area to be distributed across different spatial zones rather than concentrated in a single large area, maintaining uniform illumination while achieving the desired length extension.
3Illumination intensity
If LED intervals are reduced to achieve uniform illumination, then illumination uniformity improves, but the maximum length achievable with conventional PCBs is limited
Solution Approach 1:
Multiple PCBs (first PCB, second PCB, third PCB, fourth PCB) are merged through the connecting board to form a single extended LED light source. The connecting board integrates multiple bonding zones that simultaneously bond with corresponding LED arrays on different PCBs, allowing the system to achieve both uniform illumination (through closely spaced LEDs on each PCB) and extended length (through the combined structure of multiple PCBs).
Data Source
AI summary
Disclosed are a uniformly emitting linear LED light source assembly and a method thereof. The linear LED light source assembly comprises a first light strip, at least one second light strip and at least one connecting board which are all provided with a plurality of LEDs closely arranged at equal intervals, wherein the equal interval is less than 3.5 mm to realize uniform illumination. The connecting board connects the first light strip and the second light strip. The LED closest to the first light strip on the connecting board and the LED closest to the connecting board on the first light strip are formed at the same pitch as the equal interval. In addition, the LED closest to the second light bar on the connecting board and the LED closest to the connecting board on the second light bar are formed at the same pitch as the equal interval.