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US 10,854,796 B2Granted
LED light system having elastomeric encapsulation
AssigneeEaton Intelligent Power Limited
InventorsAdikaramge Asiri Jayawardena, Andrew Francis Scarlata
Life of this patent
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Abstract
A light system includes a first substrate and a second substrate having the first substrate thereon. A light emitting diode (LED) is connected to the first substrate. An encapsulation layer covers the LED and at least a majority of the first substrate.
Claims18
A light system, comprising:
- a first substrate;
- a second substrate having the first substrate thereon, the first and second substrates defining a hub therethrough;
- a plurality of light emitting diodes (LED) connected to a surface of the first substrate;
- the first and second substrates defining respective first and second locking openings therein;
- an elastomeric encapsulation layer covering and directly contacting the plurality of LEDs and at least a majority of the surface of the first substrate, the elastomeric encapsulation layer including a locking tab integrally formed therewith and extending through the first locking opening into the second locking opening to fill the second locking opening and fasten the elastomeric encapsulation layer to the surface of the first substrate;
- a gasket extending around a periphery of the first substrate to surround the plurality of LEDs, the gasket being positioned between the first substrate and the elastomeric encapsulation layer such that the elastomeric encapsulation covers the entire gasket;
- and
- a driver assembly electrically connected to the first substrate by a conductor extending from the first substrate through the hub to the driver assembly;
- wherein the elastomeric encapsulation layer covers and extends into the hub and the conductor is embedded in the encapsulation layer;
- and
- wherein the elastomeric encapsulation layer defines an air gap between the plurality of LEDs and an interior surface of the elastomeric encapsulation layer.
8 more elements
A method of making a light fixture, comprising:
- providing a plurality of LEDs on a first substrate, the first substrate defining a first locking opening therein;
- situating the first substrate on a second substrate, the second substrate defining a second locking opening therein, the first and second substrates defining a hub therethrough;
- electrically connecting a driver assembly to the first substrate by a conductor extending from the first substrate through the hub to the driver assembly;
- forming a gasket extending around a periphery of the first substrate to surround the plurality of LEDs;
- positioning a mold over the first substrate and the plurality of LEDs;
- and
- injecting silicone into a cavity formed by the mold and the first substrate to form an elastomeric encapsulation layer covering the plurality of LEDs and an entire top surface of the first substrate,
- wherein the silicone fills the first and second locking openings to form a locking tab extending from the elastomeric encapsulation layer though the first locking opening and into the second locking opening to fasten the elastomeric encapsulation layer to the first substrate,
- wherein the gasket is positioned between the first substrate and the elastomeric encapsulation layer such that the elastomeric encapsulation covers the entire gasket;
- wherein the elastomeric encapsulation layer covers and extends into the hub and the conductor is embedded in the encapsulation layer;
- and
- wherein the elastomeric encapsulation layer defines an air gap between the plurality of LEDs and an interior surface of the elastomeric encapsulation layer.
9 more elements
Dependencies are inferred from the claim text.