Continuous LED Tape Encapsulation With Elastic Base Profile
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Solution Overview
Problem
Conventional encapsulation methods for LED strips are limited by low automation and productivity, restricting the production of LED strips to fixed lengths, making it impossible to manufacture 'endless' strips, which hinders customer-specific length adjustment, large-scale applications, and cost reduction.
Innovation Solution
The method involves using profile extrusion to create an elastic base profile with adjustable SHORE hardness, combined with a casting compound, and optionally a cover profile, to produce LED strips that can be wound into specified lengths, allowing for flexible lengths, improved adhesion, and enhanced protection against mechanical and environmental influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional encapsulation methods are used, then LED strips can be protected from mechanical damage and environmental influences, but the production is limited to fixed lengths with low automation and productivity
Solution Approach 1:
The patent changes the physical state and properties of the encapsulation material by using a two-component system that transitions from liquid to elastic solid upon mixing and curing. This allows the material to flow during production for continuous manufacturing, then provide rigid protection after curing, resolving the contradiction between production flexibility and protective reliability
Solution Approach 2:
The invention uses a composite encapsulation system combining a base profile made of one material (e.g., polyurethane) with a casting compound made of another material (e.g., silicone). This multi-material approach allows optimization of each component for its specific function: the base profile provides structural support and flexibility for continuous production, while the casting compound provides protective encapsulation, thus achieving both high productivity and reliable protection
2Reliability
If conventional encapsulation methods are used, then LED strips are protected, but the degree of automation is low and productivity is limited
Solution Approach 1:
The base profile is pre-formed through extrusion into the desired shape and size before the LED strip is inserted. This preliminary preparation of the encapsulation structure enables continuous, automated production where the LED strip can be simply inserted into the pre-formed profile and sealed, significantly increasing automation level while maintaining protection quality
Solution Approach 2:
The invention replaces complex mechanical assembly and sealing operations with a chemical curing process. The two-component system is mixed and then cures automatically through chemical reaction, eliminating the need for complex mechanical sealing mechanisms and enabling highly automated continuous production while ensuring consistent protection quality
3Productivity
If conventional encapsulation methods are used, then LED strips are manufactured, but continuous manufacturing of endless strips is not possible
Solution Approach 1:
The encapsulation material's viscosity and state are optimized to allow continuous flow during the manufacturing process. The liquid state enables the material to continuously encapsulate LED strips as they move through the production line, while the subsequent curing process transforms it to a solid protective layer, enabling continuous manufacturing of endless strips without compromising manufacturing simplicity
Solution Approach 2:
The extrusion process continuously forms the base profile, the LED strip is continuously fed and inserted, and the two-component casting compound is continuously mixed and applied. This continuous operation throughout the manufacturing process enables the production of endless LED strips, significantly increasing productivity while keeping the manufacturing process simple and straightforward
4Adaptability or versatility
If fixed length LED strips are produced, then conventional encapsulation is sufficient, but customer-specific length adjustment and large-scale applications are hindered
Solution Approach 1:
The LED strip system becomes dynamic in terms of length configuration. The continuous production capability allows the strip length to be adjusted on-demand according to customer specifications and application requirements, transforming the product from fixed-length to variable-length, thereby increasing adaptability and versatility for different applications such as vehicles and architecture
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of endlessly manufactured LED strips with customer-specific lengths, increased design freedom, cost reduction, and improved durability, suitable for large-scale applications such as vehicles and architecture, while maintaining protection against mechanical and environmental stress.
Implementation Method 1
The production of the LED strip involves the wavy, alternating formation of the LED strip along its longitudinal direction relative to a mounting surface for the LED strip, between local high points and local low points. The elastic base profile is produced by profile extrusion.
Implementation Method 2
In order to improve the adhesion of the casting compound to the base profile, a surface quality of the material of the base profile, in particular its surface tension, is modified by means of a corona, a plasma, a chemical and/or a mechanical process.
Implementation Method 3
The base profile provided with the LED strip and the potting compound and/or the cover profile is treated in a curing or drying oven.
Data Source
Figure 1~2
Figure 3A~3H
Figure 4~5
AI summary
The invention relates to a method for producing an LED tape, comprising the following steps: producing an elastic base profile (1) and rolling up the elastic base profile (1) onto a first roll (11); producing an LED strip (323) comprising a flexible conductor tape (flexible PCB) (32) populated with LED chips (3) and rolling up the LED strip (323) onto a second roll (33); unrolling the base profile (1) from the first roll (11); unrolling the LED strip (323) from the second roll (33) and inserting the LED strip (323) into the base profile (1) and covering the LED strip (323) in the base profile (1) with a potting compound (2) and/or with a covering profile (7). The invention also relates to an LED tape in which a rollable LED strip (323) which has a flexible conductor tape (flexible PCB) (32) populated with LED chips (3) is fixed in a rollable elastic base profile (1) and is covered with a potting compound (2) and/or an, in particular rollable, covering profile (7). The invention also relates to an LED strip (323) in which the flexible conductor tape (32) is corrugated in its longitudinal direction (L).