Packaged LED Module with Casting Blocking Means
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Solution Overview
Problem
Conventional LED chain modules have low protection against mechanical stress and moisture, limiting their versatility and requiring additional components for sealing and strain relief.
Innovation Solution
A housed LED module with a one-piece housing and a casting blocking mechanism that prevents capillary action between the LED and the housing, allowing for full encapsulation without additional sealing materials, and features a potting compound with high thermal conductivity for enhanced mechanical and environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-part housings with separate sealing components are used, then protection against moisture and dust is improved, but device complexity and production costs increase
Solution Approach 1:
The patent combines the housing, sealing function, and strain relief into a single integrated one-piece housing structure. The elastomeric material provides both structural support and sealing capabilities without requiring separate sealing rings or gaskets, thereby reducing component count while maintaining IP67 protection level.
Solution Approach 2:
The one-piece housing performs multiple functions simultaneously: it provides mechanical protection, acts as a seal against moisture and dust, offers strain relief for electrical connections, and enables thermal management. This multi-functionality eliminates the need for separate specialized components for each function.
2Reliability
If additional sealing materials and components are used to protect against environmental influences, then protection level is improved, but manufacturing time and production costs increase
Solution Approach 1:
The sealing function is merged into the housing structure itself through the use of elastomeric material, eliminating the need for separate sealing materials and their associated application, positioning, and curing steps. This integration significantly reduces manufacturing time while maintaining environmental protection.
Solution Approach 2:
The elastomeric housing material inherently provides sealing capabilities without requiring additional sealing components. The material's elastic properties enable it to self-seal around the LED module and electrical connections, eliminating the need for separate sealing operations during assembly.
3Strength
If casting compound is allowed to penetrate between LED and housing, then mechanical protection is improved, but light emission is blocked
Solution Approach 1:
The housing structure is segmented into distinct functional zones: an optically transparent window area that remains free of casting compound to allow light emission, and a sealing area that contains the casting compound for mechanical protection. The integrated housing design ensures the casting compound stays in the sealing zone without blocking the LED's light path.
Solution Approach 2:
The elastomeric housing material acts as an intermediary that separates the casting compound from the optical path. It allows the casting compound to provide mechanical protection in the sealing areas while preventing its penetration into the optically transparent areas where light emission occurs.
4Strength
If rigid housing materials are used, then structural strength is improved, but protection against mechanical stress and flexibility are reduced
Solution Approach 1:
The housing material's physical parameters are optimized by selecting elastomeric materials with specific properties: sufficient tensile strength for structural integrity, appropriate elasticity for flexibility and strain relief, and suitable hardness for protection. This parameter optimization enables the housing to simultaneously provide structural strength and mechanical flexibility.
Solution Approach 2:
The use of elastomeric materials combines the benefits of both rigid and flexible materials. These composite-like materials provide the structural strength needed for protection while maintaining the flexibility required for strain relief and adaptation to mechanical stress, eliminating the need to choose between rigid and flexible options.
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 effective protection against environmental influences, reduces production costs, and achieves optimal light yield with a compact and stable design, meeting IP67 standards for dust and moisture resistance.
Implementation Method 1
the casting blocking means is designed in such a way that it prevents the penetration of a casting compound introduced via the opening into the housing equipped with the module (e.g. by means of a two- or Multi-component injection system) in an area between the LED and the essentially optically transparent area, prevented by eliminating the capillary action between the module and the housing
Implementation Method 2
features a potting compound with high thermal conductivity for enhanced mechanical and environmental protection
Data Source
Figure 1
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Figure 9
AI summary
The invention relates to a packaged LED module (1) comprising a module (2) having at least one LED (3) arranged thereon, and a one-piece package (10, 100) having a receptacle for the module (2), a substantially optically transmissive region (11, 11a, 11b, 11c), which makes it possible to emit light from the LED (3) towards the outside, an opening (16) and potting blocking means (17). The package (10, 100) is embodied in such a way that a potting component is introduced via the opening (16) into the package (10, 100) equipped with the module (2). The introduced potting component forms a potting body (30), which completely fills the package (10, 100), excluding a region between the LED (3) and the substantially optically transmissive region (11, 11a, 11b, 11c) on account of the potting blocking means (17), and which connects the package (10, 100), the module (2) and connecting cables (20) that can be connected to the module (2) in an externally sealing manner.