Encapsulated LED Switch for High-Current Marine Loads
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Solution Overview
Problem
Existing LED switches are limited in their ability to handle high current applications due to their low DC amp load capacity, making them unsuitable for devices like pumps and horns, despite their compact size and durability, which is advantageous in marine environments.
Innovation Solution
An encapsulated LED switch design that incorporates a MOSFET power driver or high power transistor PCB, allowing the low-power LED switch to control high-power outputs, with the PCB being interchangeable and the assembly sealed for environmental protection, enabling operation in hostile conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a standard LED switch is used, then the switch provides compact size and durability, but it is limited to low DC amp loads (5A resistive or 3A inductive) and cannot handle high current applications
Solution Approach 1:
The patent combines a low-power LED switch with a high-power MOSFET driver circuit into a single integrated assembly. The LED switch controls the MOSFET gate, which in turn controls high-current output to pumps and horns. This merging allows the compact LED switch to control high-power applications without requiring separate control circuits.
Solution Approach 2:
The switch assembly is designed to perform multiple functions: it can control both low-power LED indicators and high-power loads (pumps, horns) simultaneously. The modular design with interchangeable PCBs allows the same basic assembly to be adapted for different power requirements and applications, making it universally applicable across marine devices.
2Adaptability or versatility
If the switch assembly is exposed to marine environment, then the switch can be used in various applications, but the circuitry is vulnerable to high humidity, salt water, and other environmental factors
Solution Approach 1:
The patent uses a polyurethane foam encapsulation that completely seals the circuit board and electronic components. This flexible yet protective encapsulation creates a waterproof barrier against salt water and humidity while allowing for thermal management and mechanical stress relief. The encapsulation protects the circuitry without requiring rigid sealing mechanisms.
3Volume of moving object
If a compact switch design is used, then space is saved on marine vehicles, but the switch cannot deliver sufficient current for high-power applications
Solution Approach 1:
The MOSFET acts as an intermediary device between the low-power LED switch and the high-current loads. The LED switch provides control signals to the MOSFET gate, which then switches the high-current power delivery to pumps and horns. This intermediary approach allows compact control while maintaining high power output capability.
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 a compact, thermally conductive, waterproof, and ignition-proof switch capable of handling high current loads up to 20 ADC, expanding the range of applications while protecting circuitry from environmental factors, and allowing for programmable functions and adaptability to various load requirements.
Implementation Method 1
sealed via epoxy or a suitable alternatives to provide a thermally conductive, waterproof and ignition proof switch
Data Source
AI summary
An encapsulated LED switch that incorporates a MOSFET power drivers, high current transistors, or other suitable power drivers in a PCB that attaches to the LED switch such that a low power LED switch controls the output of a high-power driver. The selected power driver PCB can be adapted to different load requirements by making simple changes. The PCB's can be interchanged to provide for a predetermined output power required for a particular application. In addition, the wire gauge size of the wires attached to the MOSFET power driver PCB can also be varied to match intended load requirements. For applications in which the LED switch is used in hostile environments, such as marine applications, the LED switch and its associated power driver PCB are encapsulated to protect the circuitry from environmental factors such as high humidity, salt water, etc.