LED Strip Termination Element for Casting Compound Sealing
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Solution Overview
Problem
The challenge lies in providing a reliable mechanical separation and sealing between the casting compound and the electrical contacting area of light-emitting diode strips, especially when different cable lengths and plug connectors are required, which complicates the manufacturing process and storage of lighting strips for various applications.
Innovation Solution
A closing element with a partition is designed to separate the light-emitting diode strip into areas for light-emitting diodes and electrical connections, preventing the casting compound from reaching the electrical contacting area, allowing for flexible cable lengths and post-manufacturing connector adaptations, and enabling easy installation and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the LED strip is potted with casting compound to protect from environmental influences, then reliability against moisture and corrosion is improved, but the electrical contacting area becomes contaminated with casting compound
Solution Approach 1:
The LED strip is divided into two distinct areas: a first area for light-emitting diodes that is potted with casting compound for protection, and a second area for electrical contacting that remains free of casting compound. This segmentation allows the beneficial protection to be applied while preventing contamination of the electrical contacts.
Solution Approach 2:
A termination element acts as an intermediary component between the potted and unpotted areas. This termination element provides a mechanical separation and seal that prevents the casting compound from reaching the electrical contacting area, while still allowing the LED strip to be protected in the first area.
2Adaptability or versatility
If different cable lengths and connectors are provided for different applications, then adaptability is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The termination element provides a dynamic solution by allowing the electrical contacting area to remain accessible after potting. This enables flexible assembly of different cable lengths and connectors post-manufacturing, eliminating the need to pre-configured multiple variants with fixed cable lengths and connectors.
Solution Approach 2:
The termination element is prepared in advance as a separate component that can be attached to the LED strip before potting. This preliminary preparation allows the electrical contacts to be protected from casting compound while still enabling flexible post-assembly of different cable configurations.
3Extent of automation
If cables are transported through the potting machine, then automated potting is enabled, but handling of long cables becomes problematic
Solution Approach 1:
The electrical contacting area is extracted or separated from the area to be potted. By providing a dedicated second area for electrical contacting that is mechanically separated from the first area, the cables can be attached after potting without needing to be transported through the potting machine, simplifying the automated potting process.
4Reliability
If the LED strip is divided into separate areas for LEDs and electrical connections, then reliable electrical connections are ensured, but the structure becomes more complex
Solution Approach 1:
The termination element combines multiple functions into a single component: it provides mechanical separation between areas, creates a seal to prevent casting compound contamination, and facilitates electrical contacting. This merging reduces the overall structural complexity compared to using separate components for each function.
Data Source
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AI summary
A termination element (1) is provided for arrangement on a light-emitting diode strip (20) in an inner recess (14) of a base profile (11) with a bottom wall (12) and side walls (13) extending from the bottom wall (12), wherein the termination element (1) arranged on the light-emitting diode strip (20) divides the light-emitting diode strip (20) into a first area (16) with light-emitting diodes (21) arranged on the light-emitting diode strip (20) and a second area (17) for attaching electrical connecting means (22), wherein the termination element (1) has a partition (3) between the first area (16) and the second area (17), wherein the partition (3) has a first recess (7) which is designed to receive the light-emitting diode strip (20) along a section of a longitudinal extension (15) of the light-emitting diode strip (20).wherein the edges of the first recess (7) seal around the LED strip (20) when the first area (16) of the LED strip (20) defined in the base profile (10) is potted with potting compound (30).