Moisture-Tight LED Array with Casting Compound Encapsulation
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Solution Overview
Problem
Existing moisture-proof lighting assemblies face challenges such as difficult LED alignment, restricted lighting effect, and shortened service life due to condensation caused by temperature fluctuations within a hose casing, which limits their effectiveness and durability.
Innovation Solution
A moisture-tight lighting arrangement where the housing is filled with a casting compound that completely encapsulates the light-emitting diode and printed circuit board, including electrical conductors, to prevent moisture ingress, and incorporates a light-scattering additive to enhance illumination, while allowing heat dissipation and using a lens for focused illumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If light-emitting diodes are placed inside a hose casing to protect against moisture, then moisture protection is achieved, but LED alignment becomes difficult and lighting effect is restricted
Solution Approach 1:
The housing is divided into a first housing part and a second housing part that can be separated from each other. The casting compound is applied only in the recess of the first housing part, allowing the second housing part to be removed for accessing and aligning LEDs without compromising the moisture protection provided by the sealed housing structure.
Solution Approach 2:
The casting compound is applied to the recess before the light-emitting diodes are mounted in the housing. This preliminary application of the casting compound creates a protective base that is then filled with additional casting compound after LED installation, ensuring both moisture protection and proper LED alignment.
2Reliability
If light-emitting diodes are placed inside a hose casing, then moisture protection is achieved, but temperature fluctuations cause condensation and service life is reduced
Solution Approach 1:
The housing is formed from a flexible plastic material that can accommodate thermal expansion and contraction of internal components. This flexibility prevents stress concentration and condensation formation that would otherwise occur with rigid housings, while maintaining the moisture barrier integrity.
Solution Approach 2:
The housing is formed from a flexible plastic material, and the casting compound provides additional protective encapsulation. This composite structure combines the moisture barrier properties of the plastic housing with the protective and dampening properties of the casting compound, preventing condensation and extending LED service life.
3Reliability
If the housing is completely filled with casting compound to protect from moisture, then absolute moisture protection is achieved, but heat dissipation from LEDs is restricted
Solution Approach 1:
The casting compound is applied selectively only to the recess area where the light-emitting diodes are mounted, rather than filling the entire housing. This local application provides moisture protection for the LEDs while leaving the rest of the housing open or equipped with heat dissipation structures, allowing thermal energy to escape effectively.
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
The solution provides absolute protection against moisture, enhances the lighting effect by scattering light, extends the service life of LEDs, and allows for cost-effective production with consistent lighting behavior, making it suitable for outdoor applications.
Implementation Method 1
the housing is filled with a casting compound in such a way that the at least one light-emitting diode and the upper side of the printed circuit board facing the housing and receiving the light-emitting diode are completely surrounded by the casting compound
Implementation Method 2
the sealing compound is advantageously designed to generate a light scattering effect at least in the emission area of the at least one light-emitting diode (3), specifically the sealing compound has an additive, in particular a granulate, to generate the light scattering effect
Implementation Method 3
the housing has a lens at least in the emission area. The light emitted by the light-emitting diode can be widened or focused by this lens
Implementation Method 4
The underside of the printed circuit board is particularly advantageously freely accessible from the outside via the opening in the housing, as a result of which the heat generated inside the housing can be dissipated via the printed circuit board to the environment
Data Source
AI summary
The invention relates to a moisture-tight illumination array comprising a plurality of printed circuit boards, each of which accommodates at least one light emitting diode (3) and which are interconnected by means of electric conductors (4), the at least one printed circuit board (2) being accommodated inside a housing (5). The housing (5) is advantageously filled with a potting compound (6) in such a way that the at least one light emitting diode (3) and the upper surface of the printed circuit board (2) that faces the housing (5) and accommodates the light emitting diode (3) are entirely surrounded by the potting compound (6).