LED Light Engine for Signage with Molded Enclosure
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Solution Overview
Problem
Conventional flexible LED lighting systems struggle to provide uniform illumination for irregularly shaped signage due to the irregular shape of the signs, making it difficult to achieve consistent lighting.
Innovation Solution
A durable LED light engine is designed with a printed circuit board, U-shaped top enclosure, and bottom enclosure, where LEDs are positioned under lenses, and wires are sealed with molten plastic to form a strain relief, allowing for uniform illumination when connected to other light engines, and features alignment projections and receptacles for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional flexible LED lighting systems are used to illuminate irregularly shaped signage, then the system can be applied to various sign shapes, but uniform illumination cannot be achieved due to the irregular shape of the signs
Solution Approach 1:
The lighting system is divided into multiple modular LED light engines that can be individually positioned and connected along the irregular shape of the sign. Each light engine acts as an independent unit with its own LED array, allowing the system to adapt to any sign geometry while maintaining uniform illumination through controlled placement of individual segments
Solution Approach 2:
Each LED light engine is designed with localized optical components including lenses and reflectors positioned directly beneath the LED array. This local optical optimization ensures that light is distributed uniformly from each segment, and the overall uniform illumination is achieved by combining the locally optimized light distribution from multiple segments along the irregular sign shape
2Adaptability or versatility
If LED light engines are connected to form strings for irregularly shaped signage, then the system can cover complex geometries, but the connection points become vulnerable to moisture and environmental damage
Solution Approach 1:
Multiple LED light engines are connected in series to form a string that can be configured to match the irregular shape of the sign. The light engines are joined through integrated connection structures that combine electrical connectivity with mechanical attachment, creating a continuous illuminated structure that follows the sign's geometry
Solution Approach 2:
A waterproof connector or seal is introduced as an intermediary component at the connection points between adjacent LED light engines. This intermediary element provides both electrical connection and environmental sealing, preventing moisture and contaminants from entering the connection areas while allowing the light engines to be joined in a string configuration for complex geometries
3Extent of automation
If the LED light engine uses a printed circuit board with wires and electronic componentry, then the system achieves functional integration, but the assembly becomes complex and prone to manufacturing errors
Solution Approach 1:
The LED array, printed circuit board, electronic components, and optical elements are merged into a single integrated light engine module. The PCB is positioned with its LED-facing surface against the bottom of the housing, and all components are assembled in a fixed configuration that is sealed together, reducing assembly complexity while maintaining full functional integration
Solution Approach 2:
The LED light engine is pre-assembled as a complete functional unit with the PCB, LEDs, electronic components, and optical elements already integrated and tested. This preliminary assembly of the complete light engine module allows for quality control and functional verification before installation, reducing on-site assembly complexity and minimizing manufacturing errors
4Reliability
If the LED light engine is designed to be durable and moisture-resistant, then the system achieves long-term reliability, but the manufacturing process becomes more complex
Solution Approach 1:
A waterproof seal, such as a gasket or coating, is applied to the housing to create a protective barrier against moisture and environmental contaminants. This sealing layer is integrated into the housing structure and covers critical areas including the PCB connections and LED mounting surfaces, providing durability and moisture resistance without requiring overly complex multi-layer enclosures
Solution Approach 2:
Traditional mechanical sealing methods such as separate gaskets and O-rings are replaced with a conformal coating process that applies a continuous waterproof layer directly to the housing surfaces. This coating-based sealing approach simplifies the manufacturing process by eliminating multiple mechanical sealing components while achieving the same moisture protection and long-term reliability
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 enables uniform illumination of irregularly shaped signage by ensuring consistent light distribution and protection from moisture, while allowing for easy connection and secure attachment of light engines, enhancing durability and moisture resistance.
Implementation Method 1
a device for using light emitting diodes ('LED') to illuminate signage
Implementation Method 2
A molten plastic sealant material is then injected onto the combination of the substantially U-shaped top enclosure, the printed circuit board and the bottom enclosure. Once cooled, the molten plastic sealant material forms strain reliefs around, and covers the insulated wires positioned on the bottom of the printed circuit board as well as affixing the substantially U-shaped top enclosure, the printed circuit board and the bottom enclosure one to another.
Data Source
AI summary
A durable LED light engine includes a printed circuit board including LEDs mounted thereon positioned between a substantially U-shaped top enclosure and a bottom enclosure. Once assembled together using alignment holes and projections, the combination of the substantially U-shaped top enclosure, the printed circuit board and the bottom enclosure are held together with a molding material.