The Light Emitting Diode (LED) is one of the most significant innovations in the field of lighting. Its exceptional energy efficiency, long lifespan, and compact size have led to its widespread use in a variety of applications&#;from home lighting to advanced industrial and automotive systems. However, like any electronic component, LEDs are sensitive to external factors such as moisture, dust, and fluctuating weather conditions. Encapsulation of LED s is a process designed to protect these delicate components from degradation, ensuring long-lasting and reliable performance.
Encapsulation primarily protects LEDs from external factors, significantly extending their lifespan. As a result, LEDs can operate reliably for many years, even in harsh environments.
Protection against moisture and dust is crucial, especially in outdoor applications or humid environments. Encapsulation prevents these harmful elements from penetrating the LED, protecting against corrosion and short circuits.
LEDs are often used in environments exposed to extreme temperatures, vibrations, and UV radiation. Encapsulation ensures stable operation under such conditions, which is essential in industrial, automotive, and aerospace applications.
Some encapsulating materials help dissipate heat from the LED, preventing component overheating and thereby increasing efficiency. This is especially important in applications where LEDs operate at high power levels.
Encapsulated LEDs are ideal for use in streetlights, architectural lighting, and garden lighting, where they are exposed to changing weather conditions.
LEDs are used in vehicles for interior lighting, headlights, and signaling systems. Encapsulation ensures their reliability and durability in challenging road conditions.
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In factories and warehouses, LEDs must withstand intense working conditions, including vibrations, impacts, and exposure to chemicals. Encapsulation protects the LEDs while ensuring high-quality lighting.
Encapsulation of LEDs is a crucial process that provides protection from external factors, enhances durability, and improves performance. Various encapsulation techniques allow the use of LEDs in a wide range of applications, from outdoor lighting to automotive and advanced industrial systems. Investing in LED encapsulation ensures the long-term, trouble-free operation of these vital components.
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ENCAPSULATION PROCESS
LED&#;s are widely used throughout the lighting industry. Their use is becoming extremely diversified, and the design requirements and technical challenges have found successful answers using an encapsulation process. Encapsulation was originally introduced to protect the LED and the related electronics creating high-quality LED lighting and making them suitable for the most demanding outdoor applications. However, with the wide spread growth the use of encapsulation has also become an aesthetically significant and functional answer to new market demands and special design requirements. Flexible LED strips are a good example of this development.CHEMISTRY AND RAW MATERIALS
Several encapsulation chemistries are available on the market today such as epoxy and silicon resins. Polyurethane resins (PU) provide the most versatile choice. PUs have a vast and easily modifiable range of properties and are therefore one of the most frequently used two-component (2K) materials in industry. PU is the result of the additive reaction of polyisocyanates (the hardeners) with polyvalent alcohols known as polyols (the resins). Using suitable ingredients and additives, the properties of polyurethanes can be varied much more than any other class of materials, depending on the requirement and application. It is possible to create &#;custom materials&#;, which have properties ranging from hard and brittle to pliable and soft, from highly fluid to highly paste-like. Properly filled they can provide enhanced flame resistance and improved thermal conduction. PUs are available in colours and with various degrees of opacity permitting you to get outdoor durable aesthetical effects. ENCAPLED PU resins and hardeners are a custom developed group of ingredients which can be used to satisfy a large variety of encapsulation polymers. Their combined use is an industry best in the production of high quality flexible LED strips.EQUIPMENT
COLOR-DEC LED dispensing units, and automated robotic units, are designed to be modular and upgradable. PU-based casting resins always have to be protected from moisture during processing, since the curing components react with water. To produce high quality polymers, the use of a dispensing machine equipped with proper raw material degassing and storage system is highly recommended. Additionally in the LED encapsulation process there is a large variety of possibilities and the use of a programmable gear-pump automatic mixing and dosing machine is the best industrial solution. The ENCAPLED 400GP4 equipment is an example of an LED encapsulation dispensing machine. The 400GP4 can be used as a standalone metering and dispensing unit or used in combination with XYZ Cartesian robotic units. The 400GP4 can be configured to use up to six ingredients, which permits a wide variety of encapsulation possibilities. Ingredients combinations are based on adjustable and preset ratios each one of them can be easily saved and recalled on demand.FLEXIBLE LED STRIP PRODUCTION
Producing flexible LED strips is similar to encapsulating an LED strip in an aluminium housing. A substantial amount of the basics described above remain the same. The main difference is that the rigid, and easily moveable aluminium housing is replaced by a flexible housing. The handling of the flex introduces some complexity, but they can be easily managed.
Encapsulated LED strips can be produced according to two different manufacturing processes.
Each production method has its advantages, but also disadvantages, so evaluate them carefully, in relation to you own organization and production targets.
THE HOLDING JIGS
In the production of flexible strips the holding jigs are an important part of the process. Regardless of the production method the use of a jig to house the strips is necessary. The jig must house the strip and keep it in the proper shape throughout the production of the strip from the casting processes until the casted PU is cured enough to maintain the proper shape. The size of the jig must match the size of the final strips so consequently the jigs must always be considered in the setup cost.ENCAPSULATION PROCESS: EXTRUDED THERMOPLASTIC PROFILE
The thermoplastic profile is available as a flat tape or as C-profile. They are available in thermoplastic PVC or PU and supplied in rolls. According to their dimensions the profiles can be used for the production of top view and side view profiles. When producing the side view the LED strip will be mounted on the side of the flexible housing and not on the bottom.Are you interested in learning more about optical encapsulants for led? Contact us today to secure an expert consultation!