LED Module Hermetic Sealing with Argon Atmosphere
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Solution Overview
Problem
Existing LED light modules for outdoor use, such as street lighting, face challenges in maintaining long-term sealing and preventing damage from UV components and volatile organic compounds (VOCs), which can lead to reduced light output and module failure over time.
Innovation Solution
The LED light module features a two-part housing with a metal housing plate and a transparent cover plate, where the cover plate has integrally formed light-guiding elements and a hermetically sealed connection using a 2-component acrylate adhesive, maintaining an argon atmosphere to prevent VOCs and UV penetration, ensuring long-term tightness and maintaining light quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional plastic housing with mechanical sealing is used, then the manufacturing process is simple and cost-effective, but the long-term sealing reliability deteriorates under accelerated aging conditions
Solution Approach 1:
The patent employs a composite housing structure combining a metal housing plate (aluminum or Zamak alloy) with a transparent cover plate (PMMA or PC material). This composite construction enhances sealing reliability and structural integrity compared to conventional single-material plastic housings, while the integrally formed side walls simplify the overall structure by eliminating separate sealing components.
2Illumination intensity
If the cover plate is made of UV-transparent material, then light transmission is maximized, but UV components penetrate and cause damage to LEDs and optical elements over time
Solution Approach 1:
The patent applies UV protection selectively to the cover plate by using UV-impermeable or UV-resistant materials (PMMA or UV-stabilized PC) specifically for the transparent cover, while maintaining optimal light transmission for the LED emission spectrum. This localized material selection allows the cover plate to block harmful UV radiation while remaining transparent to the useful visible light, thus protecting internal components without significantly compromising illumination intensity.
3Strength
If the housing is made of heavy metal materials for structural stability, then mechanical strength is improved, but the overall weight of the luminaire module increases
Solution Approach 1:
The patent uses lightweight metal materials such as aluminum or Zamak alloys for the housing plate, which provide sufficient structural stability and mechanical strength while maintaining low weight. These lightweight metals replace conventional heavy-duty metals, achieving the required strength-to-weight ratio for outdoor luminaire applications without excessive mass.
4Adaptability or versatility
If traditional sealing methods with multiple components are used, then adaptability to different sealing requirements is improved, but the manufacturing complexity and assembly time increase
Solution Approach 1:
The patent integrates the side walls directly into the housing plate and cover plate through integral forming, creating a unified structure that inherently provides sealing. This merging of components eliminates the need for separate sealing elements such as gaskets, O-rings, or mechanical seals, thereby simplifying manufacturing while maintaining adaptability to various sealing requirements through design variations of the integrally formed structures.
Data Source
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AI summary
An LED lighting module (5) comprising a two-part module housing (8) consisting of a light-alloy housing panel (10) and a transparent cover (60) made of a predominantly UV-impermeable, or a UV-impermeable PMMA material, or of a UV-stabilised PC material. The metal housing panel (10) and the cover (60) together delimit a hermetically sealed housing interior (9) in which a PCB (40) having multiple interspaced LEDs (44) is provided. Associated with each LED (44) is a light guide element (80) consisting of the cover material and being integrally formed on the inner face (63) lying adjacent to the PCB (40), of the cover (60). A hermetically sealed adhesive bond is formed between the light alloy housing part (10) and the cover (60), said bond being produced with the aid of a 2-component room temperature-curing acrylate adhesive. An atmosphere containing argon is produced in the housing interior (9).