LED Tailgate Light with Dual Encapsulant Sealing
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Solution Overview
Problem
Conventional light bars for vehicles, particularly in the space between the bumper and tailgate, face challenges due to harsh environmental conditions, including water infiltration, contaminants, and temperature extremes, leading to short lifespans and design complexities such as compact form factors that complicate electronic assembly, heat dissipation, and installation.
Innovation Solution
A tail light system with a housing that includes a circuit board with independently controllable LED segments, a universal controller, and encapsulation with flowable plastic, allowing for customizable illumination, heat dissipation, and a compact, durable design that can be easily installed without drilling into the vehicle, using adhesives and clips for securement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional light bars are installed in the space between bumper and tailgate, then improved illumination and visibility are achieved, but the harsh environment (water, contaminants, temperature extremes) causes short lifespan and premature failure
Solution Approach 1:
The patent applies a multi-layer encapsulation system consisting of a first encapsulant material sealing the circuit board and LEDs, and a second encapsulant material filling the housing cavity. This creates a protective barrier that isolates the electronic components from harsh environmental conditions including water, contaminants, and temperature extremes, thereby preventing premature failure while maintaining illumination functionality
Solution Approach 2:
The patent uses composite material structures including the combination of different encapsulant materials (first and second encapsulants), the circuit board substrate (FR-4 or similar), and the housing material. These composite structures provide enhanced protection against environmental factors while maintaining the light-emitting function, resolving the contradiction between illumination intensity and reliability
2Volume of moving object
If light bars are made compact to fit limited vertical space, then installation feasibility is improved, but heat dissipation becomes difficult and electronic assembly complexity increases
Solution Approach 1:
The patent addresses heat dissipation in the compact structure by utilizing the third dimension (depth) for heat management. The circuit board is positioned with its back surface facing the housing, allowing heat to dissipate toward the rear of the housing where there is more space. The encapsulants are applied in layers (first encapsulant on circuit board, second encapsulant in housing cavity) to manage thermal pathways while maintaining compact external dimensions
Solution Approach 2:
The encapsulant materials serve as intermediary substances that facilitate heat management in the compact design. The first encapsulant material is in direct contact with the circuit board, providing thermal interface and protection, while the second encapsulant material fills the remaining space and provides additional thermal management and environmental sealing, enabling compact form factor without compromising heat dissipation
3Illumination intensity
If conventional light bars are exposed to elements, then improved visibility function is achieved, but water infiltration and contaminants lead to premature failure
Solution Approach 1:
The patent employs a dual-encapsulant sealing system where the first encapsulant material forms a protective layer over the circuit board and LEDs, and the second encapsulant material fills the housing cavity to seal out water and contaminants. This creates a hermetic barrier that allows the light bar to maintain visibility function while being protected from harmful environmental factors
Solution Approach 2:
The combination of different encapsulant materials creates a composite protective system with enhanced resistance to water infiltration and contaminants. The first encapsulant provides direct protection to sensitive electronics, while the second encapsulant provides bulk sealing and environmental isolation, enabling the light bar to function in exposed conditions without premature failure
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 long-lasting, customizable, and aesthetically pleasing light bar system that is durable, efficient in heat dissipation, and easy to install, offering improved safety and visibility with independently controllable segments, while being resistant to water and contaminants.
Implementation Method 1
The space between the outward facing surface of the circuit board and an inward facing surface of the tail light housing may be filled with an encapsulant thereby sealing the LEDs within the tail light housing
Implementation Method 2
A circuit board is positioned within the hollow interior of the tail light housing and comprises independently controllable segments having light emitting diodes (LEDs) configured to transmit light from an outward facing surface of the circuit board
Data Source
AI summary
A tail light for installation on a vehicle having an electrical system includes a tail light housing configured to replace an existing housing of an existing tail light of the automobile, the tail light housing having a hollow interior, a circuit board positioned within the hollow interior of the tail light housing and comprising independently controllable segments having light emitting diodes (LEDs) configured to transmit light from an outward facing surface of the circuit board; and a controller electrically connected to the electrical system of the vehicle and the tail light. The controller has a microprocessor and memory. The controller is configured to receive signals from the electrical system of the vehicle, interpret the signals received from the electrical system of the vehicle, and in response control illumination of the independently controllable segments.