Designing and manufacturing shaped LED light strips - The latest design in automobiles and other vehicle lumination is the exciting decorative shaped LED lighting. The curved and stepped design of the LED lighting, utilizes a conformable aluminum backing strip with a heat conductive thin insulative printed circuit material and copper traces for the current. These elaborate looking light strips are made to fit sloped and decorative shaped car lenses, creating an eye-catching stunning lighting display to enhance the cars visual look.
To manufacture these new light strips, a few special materials is required. First the insulative heat conductive Printed circuit material is laminated on to a conformable aluminum mailable base to provide low thermal impedance to effectively move the heat away from the LED die or power supply into the aluminum backing material.
The laminate features RA copper traces and a special conformable electrical insulative laminate that can bend at severe angles without cracking or lowering voltage ratings. The Laminates low CTE and low modulus ensures the solder joints will not crack with repeated thermal cycles.
The highly thermally conductive laminate allows for higher currents in the traces at lower temperatures by distributing the current evenly to the number of high power led lights along the strip. With any new product, there is always new rules to follow, this product is no exception.
First the aluminum heat conductive base is typically. 5mm to 1.5 mm thick and made of 5754 aluminum which is easily formed in any direction and will stay as bent in the forming die.
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