Cameras & Lighting

The demand for lighting projects across the globe is exponentially growing due to the continuous expansion of the industrial and commercial sectors. With this growth comes an increased need for high-tech printed circuit board assemblies (PCBAs). As a leading supplier of PCBAs, wire harnesses, cables, and box builds to clients in the lighting industry, PGF Technology is here to help meet these growing demands. Our cutting-edge facilities, hands-on experience, and up-to-date knowledge allow us to anticipate the needs of our customers and provide the ideal solutions.

What Are LED PCBs?

Light-emitting diodes, or LEDs, have become the preferred lighting choice across multiple industries. An LED is a solid-state technology that uses a semiconductor to convert electricity into light. Their lifespan can be 25 times longer than traditional light bulbs while using up to 80% less energy. LEDs are also generally smaller and more environmentally friendly than traditional lighting.

PCBAs play a key role in supporting LEDs. They are thin boards commonly made of metals, fiberglass, and other materials designed to connect electronic components. Within LED applications, PCBs transfer heat away from the bulb to prevent damage and enhance performance. PCB lighting assemblies also facilitate the precise control of the electrical current flowing through the lights to ensure maximum efficiency while reducing energy consumption.

Common types of PCB assemblies used within the lighting industry include:

• LED Driver PCBA. LED driver circuits regulate the electrical current that flows through an LED light. LED driver PCBs allow for the control of current flow to ensure the LED lights operate at the proper current levels and voltage. This increases the efficiency and lifespan of LED lights.
• Control PCBA. These are used to control the many functions of a lighting system, such as setting color temperatures, adjusting brightness levels, and turning the lights on and off. Control PCBAs can be designed to be controlled through various methods, including remote controls, smartphones, push-button switches, and more.
• Wireless communication PCBA. This type of PCB lighting assembly facilitates wireless control and communication, providing a fast and efficient way to control LED lights remotely via Wi-Fi Bluetooth, etc. By being able to control and monitor LED lights remotely, these PCBs offer added convenience and cost savings.

Utilizing PCBAs in the lighting industry has led to the development of smart lighting systems that can be controlled by a central hub, such as a tablet or smartphone. These systems can be programmed to change the light’s colors, adjust brightness, and turn lights on or off at specific times. Smart PCBA lighting systems can also be integrated with other devices, such as security cameras and thermostats, for even more convenience and control.

Lighting Industry PCBA Materials

PCBAs for LED lighting must be designed to withstand temperature changes, high vibration levels, and harsh environments. They must also adhere to safety standards like CE and UL, and they must undergo strict quality control during manufacturing to ensure longevity and reliability. Common materials used to manufacture PCBs for the lighting industry include:

• FR-4: One of the most common PCBA materials with a glass and epoxy base. Although flame-retardent, FR-4 transfers heat less efficiently than other materials.
• Epoxy: A less common PCBA substrate material offering manufacturers an affordable but less durable option.
• Metal-Core: A material that excels in heat transfer, making it ideal for various applications. The base is typically composed of aluminum with a copper laminate. The combination of metals provides enhanced thermal conductivity and electrical insulation.

Due to their lower cost, FR-4 or epoxy bases are typically preferred for applications where thermal qualities are not critical. However, metal-core PCBAs are essential when thermal qualities are crucial for the proper function of the end product.

Cable, PCBA, and Wiring Harness Applications for the Lighting Industry

Various applications require PCBAs with specific properties, such as LED lighting PCBAs for temperature-sensitive applications. The cost and energy efficiency of LED lighting solutions have led to an increase in demand, but the functionality of LED lights depends on its system temperature. The solution to this is aluminum-based PCBs, which we call LED PCBs. The following applications depend on LED PCBAs:

• Consumer Lighting: A primary driver in LED PCBA demand, requiring LED PCBAs for spotlights, lamps, lanterns, flashlights, and solar lighting.
• Consumer Electronics: A growing driver of LED PCBA demand, requiring them for TVs, smartphones, computers, and other devices with LED displays. Because consumer electronics are heat-sensitive, aluminum PCBAs are extremely valuable to this industry.
• Interior lighting systems in vehicles: Wire harnesses and cables are used to connect various lights in the interior of vehicles, such as overhead lights, dome lights, and reading lights. They can also be used for ambient lighting systems that create a comfortable and visually appealing atmosphere inside the vehicle.
• Exterior lighting systems in vehicles: Wire harnesses and cables are used to connect the headlights, taillights, turn signals, and other exterior lighting systems in vehicles. This helps to ensure that the lights work properly and can be controlled from the driver’s seat.
• Stage lighting systems: Wire harnesses and cables are used in stage lighting systems to connect various lights and controllers, ensuring that the lights are properly powered and controlled. This can include both traditional theatrical lighting systems and modern LED lighting systems.
• Architectural lighting systems: Wire harnesses and cables can be used in architectural lighting systems to connect various lights and controls, ensuring that the lights are properly powered and controlled. This can include indoor and outdoor lighting systems for commercial and residential buildings, as well as decorative lighting systems for events and displays.
• Industrial lighting systems: Wire harnesses and cables are used in industrial lighting systems to connect various lights and controllers, ensuring that the lights are properly powered and controlled. This can include lighting systems for factories, warehouses, and other industrial facilities.
• Emergency lighting systems: Wire harnesses and cables are used in emergency lighting systems to connect various lights and controls, ensuring that the lights work properly when needed. This can include emergency lighting systems in buildings, vehicles, and other locations.
• Landscape lighting systems: Wire harnesses and cables are used in landscape lighting systems to connect various lights and controllers, ensuring that the lights are properly powered and controlled. This can include outdoor lighting systems for residential and commercial properties, as well as public parks and other outdoor areas.

Assemblies for the Lighting Industry From PGF Technology

PCB assemblies are a crucial element in modern lighting systems, providing the control mechanisms and electrical connections these systems need to operate effectively and efficiently. PCB assemblies are energy-efficient and can be customized to meet the requirements of your specific lighting application. Whether you need wire harnesses, cables, PCBAs, or box builds, PFG Technology has the skills and experience to deliver quality assemblies that can hold up under harsh conditions while ensuring optimal safety and performance.

For more information about our assembly solutions for the lighting industry, contact us or request a quote today.