Thin Adhesive Endcaps for Continuous Linear Luminaire Lighting
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Solution Overview
Problem
Traditional endcaps for linear luminaires occupy space within the channel, leading to dark areas and discontinuous lighting when multiple luminaires are abutted, and existing manufacturing processes to omit endcaps result in unfilled lengths and light leakage.
Innovation Solution
The use of thin, adhesively adhered endcaps with no inward projections, combined with resin filling, secures the endcaps to the channel and ensures continuous lighting by eliminating space wastage and light leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional endcaps with inwardly-protruding features are used, then the endcaps can be secured to the channel, but they occupy space within the channel creating dark areas and discontinuous lighting
Solution Approach 1:
The patent removes the inwardly-protruding features (ribs, flanges, or other structures) from the endcap design that traditionally occupied space within the channel. By extracting these space-consuming elements, the LED strip can extend to the very end of the channel, eliminating dark areas and ensuring continuous lighting while the endcap is secured through adhesive application to the external surface of the channel.
2Reliability
If endcaps with exterior thickness are used to close channel ends, then the channels are sealed, but abutting multiple luminaires creates visible dark spots at the joints
Solution Approach 1:
The patent eliminates the traditional approach of using thick endcaps that protrude from the channel end. By removing the protruding exterior thickness, the endcap becomes flush with or recessed from the channel end, allowing the LED strip to terminate at the channel end without creating gaps. When multiple luminaires are abutted, this eliminates the visible dark spots at joints while maintaining channel sealing through adhesive application.
3Illumination intensity
If endcaps are made thin to reduce protrusion, then lighting continuity improves, but the endcaps may not be securely retained in the channel
Solution Approach 1:
The patent replaces the traditional mechanical retention system (inwardly-protruding ribs or flanges that engaged with the channel internally) with an adhesive bonding system. The adhesive is applied to the external surface of the channel, and the thin endcap is bonded to this surface, providing secure retention without requiring internal mechanical features that would compromise lighting continuity.
4Object-affected harmful factors
If resin is poured into the channel to fill gaps, then light leakage is prevented, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent applies adhesive to the external surface of the channel before the LED strip is installed and the channel is closed with endcaps. This preliminary application of adhesive creates a light-blocking barrier in advance, eliminating the need for subsequent resin pouring operations. The adhesive serves the dual function of securing the endcap and preventing light leakage, thereby simplifying the manufacturing process.
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 continuous lighting without dark spots and light leakage, allowing longer linear luminaires to be manufactured without visible discontinuities.
Implementation Method 1
Each of the pair of endcaps may have a pressure-sensitive adhesive on its inner face
Implementation Method 2
A resin fills the at least one compartment of the channel. The resin bonds to the pair of endcaps and further secures them to the channel
Data Source
AI summary
A linear luminaire includes a rigid channel having at least one compartment. At least one strip of LED linear lighting is disposed in the at least one compartment. A pair of endcaps adhere to and cover end faces of the channel to close ends of the at least one compartment. Neither of the pair of endcaps has any structure protruding into the at least one compartment of the channel. A resin fills the at least one compartment of the channel. A method for making the linear luminaire includes damming the at least one compartment of the channel with the pair of endcaps and filling the at least one compartment with the resin.