TV is one of our favorite items. And if it’s a high-resolution and high-definition TV, then there’s nothing like it—it’s simply amazing. The most critical component that enables this outstanding technology is the TV PCB.
A TV PCB typically combines various other TV components, like the display, speaker, and so on. Some TVs even come with cameras. We call it a smart TV. Some TVs are computers. The type of TV typically depends on the complexity of the TV PCB you are using.
This article typically talks about what TV PCBs are. It also explores the various components used in a typical LED TV.
Perhaps you are seeking opportunities to launch your first LED TV brand. This article offers some helpful information. Additionally, it provides guidance on selecting the ideal TV PCB manufacturer for your project.
Standard TV Components and Types of TV PCB
LED TVs are made up of several essential parts. Each part has its unique purpose and uses a specific kind of PCB. If you want to learn how an LED TV works, you must understand these parts. Besides, when you have enough knowledge about each TV part, you will know how to repair them.
Display Panel
The display panel is one of the most critical components of an LED TV. It shows the picture or allows you to touch the screen to interact with it. In LED TVs, this panel does not create light but instead uses light from the backlight.
You might misunderstand the difference between an IPS display and an LED display. Well, IPS display offers you various view angles and colors. They are typically ideal for picture-related works. LED, on the other hand, is much lighter and cheaper. However, it cannot offer you color reproduction as an IPS display.
Backlight Unit
This LED TV component typically gives light to the display. Without it, we wouldn’t see anything on the screen. A small LED TV PCB board usually powers the backlight. It controls everything from brightness to color levels.
Power Supply Unit
The power supply unit is critical for your LED TV. Its primary purpose is to supply the correct voltage to the whole TV. It has a special type of PCB designed just to handle high power and keep your TV safe. A faulty power board is a common reason for TV PCB board repair.
Main Board
The mainboard is like the brain of the TV. It connects everything an LED TV has. It comes with a CPU, memory, video processor, and other smart functions. The smart LED TVs are typically large versions of Android. It comes with RAM, CPU, and all the features of a smartphone. Nowadays, some smart TVs are literally a giant computer. You can use it based on your needs. Therefore, the main board mainly depends on how smart your LED TV is.
Getting Started with Your First LED TV Brand
It is exciting to start your own LED TV brand. However, it’s also a complex process, from designing the circuit to manufacturing the board, each step matters. When you are starting an LED TV business, you must know the competition in the market. To find the strength of your business strategy, you must include the quality, cost, and features.
Why should customers choose your brand? What feature are you including in your product? Is it a smart TV that can be controlled, or how about the price compared to other brands? Did you think about the competitors? Finally, did you choose the right LED TV PCB manufacturer?
Schematic Design
Schematic design is the first step. It’s like drawing a map for your TV’s electronic system. The company you choose to make your TV can help you with this task. You may also submit your design or preferences. Based on this information, the engineers can finalize the design.
In this step, the engineers typically decide how different components will connect and work together. Power supply, video processor, the audio chip, HDMI ports, and USB ports are some of the crucial elements.
The schematic design typically doesn’t show the real shape of the parts. It shows only the symbols and lines. Each symbol may represent each component used on the PCB. The lines show how the electricity will flow throughout the device.
PCB Layout Design
Once your schematic design is complete, you must do the PCB layout design. However, if you only have the schematic, you can let engineers in the PCB factory do this for you. This is where the map turns into a real board design.
The PCB (Printed Circuit Board) is what holds all the parts. It’s the green board you see inside your LED TV. Here, you take the schematic and decide where each part will sit on the board. You create the copper tracks to connect all the parts.
In an LED TV, there can be several PCBs. You will separate the PCB for the power supply, tuner board, display signal board, and, of course, the main PCB.
You must pay attention to follow EMI and EMC rules. If not, the TV creates signals that affect other devices, or they may experience signal loss.
PCB Manufacturing for LED TVs
This step is the most crucial one. You will get good service if you choose a reliable TV PCB manufacturer. When selecting a reliable PCB manufacturer, you should consider their capabilities, sourcing abilities, and partnerships. Is it a factory or a trading company? It’s better if you can visit the business location to see whether they are suitable for your project.
Each company has a dedicated customer service or sales team for its customers. You can visit the company location and check whether the salesperson is capable of handling your project. Whether he/she can communicate efficiently with the engineering department and with you. It’s not like he/she has to be a technical person, but can be smart enough to complete your task.
By the way, the PCB manufacturing for LED TVs is usually similar to that of making other products. Starting from creating the PCB layers, drilling holes, plating, and etching, to solder mask, every step is carefully done.
Testing and Validation
Testing and validation are equally crucial as designing and manufacturing. There are various types of testing and validation necessary for the LED TV PCB. Starting from basic electrical tests, functional testing, and safety checks, you must ensure every test is done correctly. You must also provide the durability of the PCB, heat-sinking abilities, and various other factors.
How Much Does an LED TV PCB Cost?
There is a wide range of LED TVs out there. Therefore, the exact price typically depends on what type of LED TV you are making. Simple LED TVs used in commercial areas cost from $20 to $40 per piece. On the other hand, a digital PCB LED may cost from $1300 to $1500. Note that this price range is wholesale. The retail price may be double or triple this price.
Besides, if you are doing custom LED TV PCB manufacturing, you may have to count on other costs. It may include custom designing, component sourcing, special tooling, and testing. Therefore, you must assess carefully before you are ready.
Difference Between an Internal and External LED Driver in LED TV PCB?
In an LED TV, the LED driver is typically a small device, but very important. It controls the power that goes to the backlight. Yeah, you are right. Without it, the screen would not light up properly. In general, there are two types of LED drivers used in LED TVs: internal and external.
Before knowing the differences between each type, let’s understand what an LED driver is. It is like a power manager. It makes sure the backlight gets the right amount of power. If the power is too high or too low, the LEDs can flicker, dim, or even stop working. In general, the following are the typical functions of an LED driver.
(1) It typically converts AC to DC and supplies it to the LEDs. A high-quality LED driver also offers consistent brightness, even with voltage variations.
(2) LEDs are susceptible to variations in voltage and fluctuations. An LED driver typically regulates voltage and current to prevent this damage.
(3) The LED driver also plays a crucial role in the thermal management of the LEDs.
(4) High-quality LED drivers also offer dimming controls. It provides you with flexibility in lightning control.
(5) The LED driver also improves the power factor. A power factor determines how effectively your LEDs are using electrical power.
Internal LED Driver
As the name implies, this LED driver is built inside the TV’s main PCB. It is part of the same board. Of course, it saves space, needs fewer wires and connectors, is cheaper, and easier to assemble. However, if the driver fails, the whole main board might need to be replaced. Besides, it may generate heat inside the board.
External LED Driver
An external LED driver is placed on a separate PCB. It is typically away from the main board. It only handles the LED backlight and connects to the main board using a cable. It can offer you better heat control. Besides, it is easy to repair and can handle more powerful or high-voltage LEDs. However, it takes up a lot of space and adds extra wires and connectors. This type of LED driver is typically expensive.
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