Dhizaini yeAluminium LED PCB uye Gwaro reDFM

Kupisa kwe LED junction ndiyo imwe chete inochinja-chinja inosarudza mwero wekuderera kwe lumen, kuchinja kwemavara, uye nguva yekukundikana. Zvese zviri mu aruminiyamu LED PCB dhizaini zvinobatsira kana kuderedza tembiricha ye junction. Mugadziri anonzwisisa thermal chain kubva junction kuenda ku ambient anogona kuita sarudzo dzemarongero dzinodzoreredza 10–20°C ye margin kubva ku heatsink yakapihwa. Mugadziri anobata PCB se substrate yekuisa michina uye anosiya thermal optimization kumutengesi we heatsink anodzorera margin iyoyo zvisina basa. Gwaro iri rinofukidza sarudzo dzekugadzira dzinokosha.

Chain yeThermal: Kunoenda Kunopisa uye Kwazvinomira

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1. Chain yeThermal: Kunoenda Kunopisa uye Kwazvinomira
2. Kumhanya Kutevedzera Kupisa Usati Wazvipira Kurongeka
3. Geometry yePad ye LED: Kururama kweNyaya uye Kuvimbika kweJoint yeSolder
4. Upamhi hweCopper Trace yeStrings dzeLED dzeHigh-Current
5. Nzvimbo dzekuchengetedza uye Kureba kweCreepage kune Vatyairi ve LED Vakabatanidzwa
6. Mitemo yeDFM Yakanangana neAluminium LED PCB Layout
7. Rondedzero yeKugadzirisa Kugadzirwa kweAluminium LED PCB
8. FAQ

Kupisa kunoyerera kubva pa LED junction → LED package → solder joint → copper pad → dielectric layer → aluminum base → heatsink → ambient. Interface yega yega ine thermal resistance value, uye PCB inobatsira zvitatu: solder joint resistance, copper-to-dielectric interface, uye dielectric layer pachayo.

Kudzivirira kwe dielectric ndiyo izwi guru rePCB rekupisa:

• Pa 1.0 W/m·K, 100 µm dielectric: θ_dielectric ≈ 1.0°C/W pa cm² yenzvimbo yepad
• Pa 2.0 W/m·K, 100 µm: θ_dielectric ≈ 0.5°C/W pa cm²
• Pa 3.0 W/m·K, 100 µm: θ_dielectric ≈ 0.33°C/W pa cm²

Kune 3W LED iri papad ye3 × 3 mm, musiyano uripo pakati pe1.0 ne3.0 W/m·K dielectric inenge 5°C yekupisa kwejunction padhi. Edza kuti isvike pa150W fixture ine 50 LEDs uye kukanganiswa kwesystem-level kwakakosha.

Hwaro hwearuminiyamu hunowedzera kudzivirira kupisa zvishoma kana hwakakora zvakakwana (≥1.0 mm) uye chinongedzo cheheatsink chinoshandisa TIM yakakodzera (thermal interface material). Chinongedzo chebase-to-heatsink chinowanzova chinodzivisa kupisa zvakanyanya muchikamu — asi chiri kunze kwekutonga kwakananga kwemugadziri wePCB.

Kumhanya Kutevedzera Kupisa Usati Wazvipira Kurongeka

Kutevedzera kupisa kwemhepo usati waisa PCB kunodzivirira zvikanganiso zviviri zvinodhura: kuvaka bhodhi risingatonhodze zvakanaka pamagetsi akayerwa, uye kuwedzera zvakanyanya dielectric pamutengo usingakoshi.

FEA inputs yealuminium LED PCB simulation:

• Kudzivirira kupisa kwepakeji ye LED (θ_j-s, kubva padatasheet)
• Simba re LED rinoenderera mberi pakushanda kwazvino
• Zviyero zvePad uye thermal slug
• Chiyero cheDielectric uye ukobvu (iyi ndiyo parameter yauri kugadzirisa)
• Zviyero zvechigadziko chearuminiyamu uye chiwanikwa
• Kudzivirira Heatsink uye interface yekuisa TIM kukosha
• Kupisa kwenzvimbo (kwakanyanya kuipa: kazhinji 50–60°C kune zviedza zvakavharirwa)

Zvinotaurwa nemuenzaniso wesimulation:

• Tembiricha yepamusoro ye LED junction — enzanisa ne T_j rating (kazhinji 125–150°C yemapakeji e LED emazuva ano)
• Nzvimbo dzinopisa dzinobva mukusanganiswa kwe LED — kana ma LED akaiswa pedyo zvakanyanya, kuramba kupisa kubva ku LED dziri pedyo kunowedzera kupisa kwe junction.
• Inodiwa dielectric Tc kuti igare mukati mebhajeti rekupisa kwejunction

Highleap Electronics inopa rutsigiro rweMCPCB thermal simulation kune vatengi vanoda kusimbisa specification yavo ye stack vasati vazvipira kugadzira. Izvi zvinonyanya kubatsira kana sarudzo iri pakati pe 2.0 ne 3.0 W/m·K dielectric ichikanganisa mutengo wezvinhu zvakanyanya.

Geometry yePad ye LED: Kururama kweNyaya uye Kuvimbika kweJoint yeSolder

Maitiro ekugadzira mapedhi paaruminiyamu LED PCBs ane mhedzisiro yakamanikana kupfuura pastandard FR-4 nekuti thermal mass yearuminiyamu yakakwira uye kudzora tembiricha yekudzoreredza mvura kwakaoma. Zvikanganiso zvinowanzo itika pakugadzira mapedhi:

Mapedhi ekupisa akakura : Pedhi rekupisa rakakura kupfuura footprint ye LED package rinogadzira nzvimbo yekunyungudutsa mvura panguva yekudzokorodza inogona kunyungudutsa solder kubva kumapedhi echiratidzo, zvichikonzera kusakwana kwemajoini pa signal/anode/cathode pads. Saizi ye thermal pad 0–0.1 mm padivi rega rega yakakura kupfuura thermal slug ye package, kwete 0.3–0.5 mm sezvakatsanangurwa dzimwe nguva kuFR-4.

Chiyero chekuvhurwa kwemasiki esimbi : Kune mapedhi makuru ekupisa (>3 × 3 mm), shandisa kuvhurwa kwemasiki esimbi akapatsanurwa - maburi madiki akawanda pane pedhi rimwe rakanyatsobuda - kudzora vhoriyamu yekuisa paste uye kudzivirira kubuda kwemvura. Tarisa 50–70% yenzvimbo yemhangura yekusvibisa mapedhi ≥ 9 mm².

Pad coplanarity : Mabhodhi ealuminium ane ukobvu hwe dielectric hwakasiyana-siyana anochinjika zvishoma panguva yekuyererazve. Pad coplanarity ye ≤0.05 mm inogoneka neukobvu hwe dielectric hwakadzorwa. Kana kudhinda kwako kwepaste kuchitsamira pa tight coplanarity, kurukura izvi nefekitori senzira inodzorwa. Ongorora kuti dhizaini yemasikisi e solder paPCBs inokanganisa sei goho re assembly pasimbi core substrates.

Upamhi hweCopper Trace yeStrings dzeLED dzeHigh-Current

Iyo IPC-2152 standard (yaimbova IPC-2221) inopa referensi yehupamhi hwetrace uchienzaniswa nehukuru hwemazuva ano. PamaPCB ealuminium LED, shandisa matafura etrace emukati mejira kwete ekunze - nekuti trace iri pamusoro asi base yealuminium inotora kupisa kubva pasi, ichidzokorora zvishoma maitiro ekupisa emukati mejira.

Mirayiridzo inoshanda yehupamhi hwetrace ye 1 oz copper pa aluminium LED PCBs, 10°C inokwira:

Pamagetsi ari pamusoro pe5 A, chinja kuenda ku2 oz kana 3 oz mhangura. Upamhi hwetrace hunodiwa pa1 oz ye10 A (5 mm) hunotora nzvimbo yekurongeka inoshandiswa zviri nani kune mamwe ma LED mumagadzirirwo ane density yakakura. Ongorora misimboti yekugadzira PCB yemhangura inorema kana huremu hwemhangura huchipfuura 2 oz.

Nzvimbo dzekuchengetedza uye Kureba kweCreepage kune Vatyairi ve LED Vakabatanidzwa

Madhizaini mazhinji e LED PCB ealuminium anobatanidza circuitry ye LED driver pabhodhi rimwe chete ne LED array. Izvi zvinogadzira nzvimbo ine voltage yakawanda (divi rekupinda kwe driver: 100–350V AC kana DC) padyo ne LED string ine voltage shoma. Mitemo yekugadzira:

Kureba kwenzvimbo dzinodonhedza : IEC 60950-1 uye IEC 62368-1 zvinotsanangura zvinodiwa pakudonhedza nekubvisa zvinhu pakati pemaconductor ane voltage yepamusoro neasina voltage. Kuti pave nekusimbaradzwa kwesimba remagetsi pavoltage yekushanda ye250V AC, kureba kushoma kwekudonhedza paPCB i6.4 mm (Pollution Degree 2, Material Group IIIa). PamaPCB ealuminium LED ane aluminium apo chigadziko chealuminium chiri pachassis potential, kureba kubva kune chero conductor iri mhenyu kusvika kumucheto webhodhi uri pedyo kana gomba rekukwirisa kunodawo kuongororwa kwekudonhedza.

Kudzivirira maburi ekukwirisa ane voltage yakawanda : Maburi ekukwirisa ane aluminiyamu anobatanidza hwaro nechasi yekuisa. Chero chinhu chine voltage yakawanda chinofanira kuchengetedza daro kubva pamaburi aya, zvichireva dhayamita yekubatanidza inofambisa mhepo.

Mapedhi ekupisa emutyairi weIC : Mamwe maIC ekutyaira eLED ane mapedhi ekupisa anoonekwa pamagetsi ane simba guru (kwete pasi). Tarisa voltage yepad usati wasarudza nzvimbo dzinovhurika mask dzesolder uye copper pours pedyo nezvikamu izvi.

Mitemo yeDFM Yakanangana neAluminium LED PCB Layout

Dhizaini yekugadzirwa kwezvinhu paaruminiyamu substrates yakasiyana neFR-4 munzvimbo dzakasiyana siyana:

Hapana ma-vias muma-thermal pads : Kusiyana neFR-4 uko dzimwe nguva kunoshandiswa via-in-pad ine copper fill, ma-aluminum LED PCB haatsigire ma-vias akavigwa kana kuti akapofumara. Kufambisa kwese kunofanirwa kuitwa mu-single copper layer. Kudira kwemhangura uye ma-wide traces anotsiva via-based heat spreading.

Mhete shoma ye annular yekuboorera aruminiyamu : Nekuda kwekukweshwa kwe aruminiyamu kwezvishandiso zvekuboorera, drill wander yakakwira zvishoma pane iri pa FR-4. Mhete shoma ye annular yemaburi akaputirwa pa aruminiyamu LED PCBs inofanira kunge iri 0.25 mm, kwete 0.15 mm sezvinogamuchirwa pa FR-4.

Kuchengetedzwa kwezvikamu kubva pamitsetse yeV-score : Kuchengetedzwa kwakajairika kubva paV-score i0.5 mm yezvikamu zviri paFR-4. Paaruminiyamu, musiyano wehupamhi hweV-score blade unogona kuva ±0.1 mm, uye score yearuminiyamu inokonzera kukanganiswa kudiki kwenzvimbo. Wedzerai kuchengetedzwa kwezvikamu kubva pamitsetse yeV-score kusvika ku0.75 mm paaruminiyamu LED PCBs.

Kuisa mapendekete emucheto hakupo : MaPCB eAluminium LED haatsigire kuisirwa mapendekete emucheto. Chero chinodiwa chekubatanidza magetsi pamucheto webhodhi chinofanira kugadzirwa kuburikidza nemapedhi akadhonzwa kubva kumucheto ne ≥0.5 mm.

Kuti uwane ongororo yakazara yeDFM usati waendesa dhizaini yako yekugadzira, shandisa cheki yePCB DFM sereferensi yekutanga kutumira.

Rondedzero yeKugadzirisa Kugadzirwa kweAluminium LED PCB

Usati watumira mafaira kumugadziri:

• Mafaira eGerber: jira remhangura, jira remasiki rinosungirirwa pamusoro, jira resiriki, bhodhi (DXF kana jira reGerber rakatsaurirwa)
• Faira rekuboorera: maburi ese ane dhayamita, zita rekuti jira rakaputirwa/risina jira
• Tsanangudzo yeStack-up: giredhi realuminium, ukobvu, giredhi re dielectric Tc, huremu hwemhangura, ukobvu hwebhodhi rose
• Tsanangudzo yekupedzisa pamusoro: ENIG gold/nickel thickness, kana HASL/OSP
• Kudiwa kwemagetsi eHi-pot
• Kirasi yeIPC (2 kana 3)
• Zvinotarisirwa: kushivirira kwehukobvu hwe dielectric, kushivirira kwehukobvu hwemhangura
• Ruvara rwemasiki eSolder uye chiyero chekuvhura pamapedhi makuru ekupisa
• Kuisa maburi echamfer kana countersink ruzivo kana zvichidikanwa

Chikwata chemainjiniya cheHighleap Electronics chinoita ongororo yeDFM yemahara pamafaira akatumirwa vasati vatora mashoko, vachiona chero dambudziko riri pamusoro apa risati rava kukanganisa kugadzirwa kana kuti mabhodhi akarambwa. Ongororo yacho inodzoserwa mukati memazuva 1-2 ekushanda.

FAQ

Ndechipi chishandiso chekuyedza chandinofanira kushandisa pakugadzira thermal ye LED PCB yearuminiyamu? ANSYS Icepak neMentor FloTHERM zvishandiso zveFEA zvizere zvine maraibhurari ekushandisa MCPCB dielectrics. Kuti uwane mhedzisiro inokurumidza panguva yekugadzira kwekutanga, zvishandiso zvekuyedza zvemugadziri we LED (Lumileds SiteMap, OSRAM LED Expert) zvinosanganisira mamodheru ethermal akareruka. Chero chii zvacho chinoyedza chiri nani pane kusava ne modelling - kunyangwe modheru yespredishiti ye junction-to-ambient thermal resistance inobata zvikanganiso zvikuru zvekugadzira isati yaitwa prototyping.

Ndingabata sei mapurani epasi nemagetsi paPCB yealuminium LED ine layer imwe chete? Mabhodhi ane layer imwe chete haana plane yepasi nenzira yechinyakare yeFR-4 multilayer. Simba nepasi (kana kudzoka kwemagetsi) zvinofanirwa kuendeswa sezvisaririra zvakasiyana. Kudururwa kwemhangura panzvimbo isina kushandiswa kunogona kushanda senzira dzekudzoka kwemagetsi emunharaunda asi hazvina kubatanidzwa nemagetsi nechigadziko chearuminiyamu. Hwaro hwearuminiyamu hungave hwakaganhurirwa kana kuti hunoyangarara, zvichienderana nekugadzirwa kwechinhu - kwete otomatiki circuit ground.

Ndechipi chipeto chandinofanira kutaura nezve COB LED arrays pamabhodhi ealuminium? ENIG ndiyo sarudzo chaiyo yeCOB (chip-on-board) LED PCB assembly . Nzvimbo yakati sandara, inogona kudzokororwa inokosha pakugadzira ma "die attachment" uye "wire bonding process" anoshandiswa mukugadzira COB. Kusiyana kwenzvimbo yeHASL hakuenderane ne "bond height tolerances" muCOB assembly.

Chigadziko chearuminiyamu chinokanganisa sei chimiro cheSMT chekuyerera kwemvura? Chigadziko chearuminiyamu chinotora kupisa panguva yekukwira kwemvura, zvichida mwero wekudzikira kwemvura (2°C/s) uye tembiricha yepamusoro yenzvimbo yepamusoro kuti pave netembiricha yakakwana yepad. Chigadziko chinochengetedzawo kupisa mushure mekubuda munzvimbo dzakakwirira, zvichiwedzera nguva pamusoro pemvura. Kumbira chimiro chakatsaurirwa chekudzoka kwemvura kubva kune mumwe wako wekugadzira kana uchichinja kubva kuFR-4 kuenda kualuminium LED PCBs.