I am trying to create a design (about 2" round & as thin as
possible)using led's - lcd's (either the same color or
multi-colored)steady &/or flashing that could be powered by a small
battery(ies). I have gotten many run around answers as to voltage,
amps, etc.. Is there either a manufacturer for something custom like
this or how can I figure out how to make them myself?

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Request for Question Clarification by aht-ga on 20 Dec 2003 22:30 PST

mikist-ga:

Would you be able to clarify the design a bit? You mention using a
combination of LEDs and possibly a LCD, a total of 2" in diameter max.
Since you mention flashing lights, I assume that you wish to focus on
using LEDs in this design. In order to provide the necessary
backlighting to make an LCD flash, you'd be looking at some difficulty
matching the hue of the backlight to the LEDs.

Can you describe the purpose of the design? For example, is this
something similar to the small flashing lapel pin designs that are
made in China (for the most part), are powered by a couple of button
cells, and are available in all sorts of designs including Xmas trees,
snowmen, Santa Clauses, reindeer, etc? Similar designs are also
available for the rave/club scene, with the strangest ones I've seen
being in the form of mouthguards and pacifiers to light up a raver's
mouth with flashing lights.

All of these use surface-mount LEDs, extremely basic circuits
featuring a simple controller, and a couple of button cells. With the
exception of the batteries (they tend to use readily-available LR44 or
AG10 batteries; cheap and plentiful, but kind of thick), the devices
are extremely thin... basically just the substrate, the surface-mount
components, and a clear epoxy encapsulation.

If this is the sort of design you have in mind, I should be able to
point you towards some resources that may be of use to you. Please let
me know.

Regards,

aht-ga
Google Answers Researcher

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Request for Question Clarification by aht-ga on 20 Dec 2003 22:32 PST

Here is an example of the type of device I described above:

http://www.bakatronics.com/shop/imageview.asp?file=Christmas3.JPG

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Clarification of Question by mikist-ga on 21 Dec 2003 10:37 PST

If you've seen some of the "Cell Phone batteries" that flash, the
entire design is in lights. The site you pointed me to has the
Christmas tree that has a few lights blinking on the shape of the
tree. I'm trying to create the entire Christmas tree in lights. I'm
trying to make my company logo completely in lights. It may be 35-100
lights (no backgroung color). Then it would have to be housed with a
clear plastic cover, with an on/off/blinking switch. I hope I've
clarified myself. Sometimes it's hard to convey a vision one has in
his mind.
Thanks.

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Request for Question Clarification by aht-ga on 21 Dec 2003 12:12 PST

It's all a matter of cost... in the case of the example picture I
provided, the retail cost can be as low as $3 US per unit, which is
why there are only a few LEDs in the design.

For what you are considering, the best path to take is indeed to use
surface-mount technology (SMT) LEDs, which have extremely low current
requirements. Even so, if you go with 35-100 LEDs, then the total
current draw may be a problem. Each LED will require approx. 20 mA at
a color-dependent voltage between 2-4 VDC. So, 100 LEDs would be 2A
current flow if all are lit simultaneously and in parallel. That's a
lot to ask of any small battery.

Your best option therefore is to consider a design where a smaller
number of LEDs are used in a 'light tube' effect to achieve the same
look (basically, your company logo in lights, floating in a clear
plastic case).

I can provide you with the contact information for a manufacturer in
California who should be able to advise you on the effective cost of
doing what you want to do. The final effective cost will depend
greatly on the quantity involved, and the complexity of the circuitry
needed to form the logo design. If you are looking to just make a
small batch, one time only, then they should be able to direct you to
one of their customers who may be willing to take this on for you. I
will warn you, though, that the amount of custom work involved will
likely drive the unit cost quite high after design and labor is
factored in.

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Clarification of Question by mikist-ga on 21 Dec 2003 19:16 PST

Yes. Please provide me with the contact information of a manufacturer in
California who should be able to advise me on the effective cost of
doing what I want to do.
Thank you

mikist-ga:

Thank you for your Question regarding a custom-designed LED sign in
the shape of your company's logo.

For such an application, your best option is to use surface-mount
LEDs. These will have the smallest size and lowest current
requirements. Depending on your exact specifications, it should be
possible make a design that uses anywhere from 35-100 such LEDs, in
whichever color you wish, that can be powered by batteries.

You asked about a manufacturer that may be able to help you achieve
this goal. One such manufacturer located in California is American
Opto Plus LED Corporation. They provide custom design engineering
services for custom LEDs, LED signs and assemblies, and dot-matrix
displays. You can find out more about this firm at:

   http://www.aopinc.net

Their custom design contact information can be found at:

   http://www.aopinc.net/services.html

	American Opto Plus LED Corp. 
	1206 E. Lexington Ave. 
	Pomona, CA 91766 
	Call Toll Free: 877-LED-7272 
	Phone: 909-465-0080 
	Fax: 909-465-0130 
	
	Email: Info@aopinc.net


They indicate that one of their differentiators in the marketplace is
their willingness to take on any custom design proposal. Whether or
not they will be able to provide the complete service that you will
need, depends on the complexity of the end design. They are the best
equipped to tell you how manufacture-able your request is, and whether
it is economical to do so.

What I cannot tell you in this Answer is how feasible this design will
be; however, I expect that American Opto Plus LED Corp.'s sales
engineers will be able to answer that.

In your request to American Opto Plus LED Corp., I recommend that you
provide a diagram of your idea, along with general parameters that you
wish the design to conform to, such as overall dimensions (2"
diameter; shape; thickness), power source (batteries), and any
packaging requirements. Depending on the quantity that you wish to
manufacture, you may be best to consider some form of epoxy potting
using a clear epoxy.

If for some reason American Opto Plus LED Corp. is not able to help
you, you may consider contacting a custom design shop to take this to
the next step. One such company located in California is:

PCB Design Express
http://www.pcbdesignexpress.com/

I hope that this is the lead you need in order to put your (company's)
name in lights!

Regards,

aht-ga
Google Answers Researcher


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Search Strategy

"surface mount" LED custom assembly design

LED voltages vary considerably from microvolts up to large battery votages 24&12
If building a one of it, may be less expensive to go visit a lot of
dollar stores to find cheap little gadgets with LED's and batteries
already included.
any good electronics surplus store will have drawers of LED's and one
can usually find something that will suit. Have fun!