Encapsulated led engine and a process for encapsulating an led engine
AssigneeAppleton Grp LLC
InventorsBharat Chaturvedi, Sumit Kumar
Life of this patent
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Abstract
An encapsulated LED engine including a printed circuit board, a plurality of LED arrays, each of the LED arrays mounted on the printed circuit board, and electrically connected to each other wherein, in each of the LED arrays, LEDs are electrically connected to each other; and an encapsulation layer configured to encapsulate each of the LED arrays and the electrical connections therebetween, wherein the encapsulation layer includes at least one blister configured to encapsulate at least one LED, and is further configured to transform the light emitted by said LED into a desired light beam pattern; and at least one planar portion configured to encapsulate at least one electrical connection formed on the printed circuit board.
Claims19
An encapsulated LED engine (100) comprising:
- a printed circuit board (105);
- a plurality of LED arrays (108), each of said LED arrays (108) mounted on said printed circuit board (105), and electrically connected to each other wherein, in each of said LED arrays (108), LEDs are electrically connected to each other;
- and
- an encapsulation layer (110) configured to encapsulate each of said LED arrays (108) and the electrical connections (135) therebetween, wherein said encapsulation layer (110) includes:
- at least one blister (115) configured to encapsulate at least one LED (125), and is further configured to transform the light emitted by said LED (125) into a desired light beam pattern;
- and
- at least one planar portion (120) configured to encapsulate at least one electrical connection formed on said printed circuit board (105).
A process for encapsulating an LED engine (100) having a plurality of LED arrays (108) and a printed circuit board (105), said LED arrays (108) mounted on said printed circuit board (PCB) (105), said process comprising the following steps:
- coating a primer on said LED arrays to obtain a primer coated LED engine;
- heating said primer coated LED engine to a first predetermined temperature to obtain a heated primer coated LED engine;
- disposing said heated primer coated LED engine in a mould;
- injecting a silicone mixture into the mould cavity of said mould at a predetermined pressure to encapsulate said LED arrays of said LED engine;
- heat treating said mould in a thermal chamber for a predetermined time period;
- cooling said heat treated mould to a second predetermined temperature;
- and
- opening said mould to obtain an encapsulated LED engine.
Dependencies are inferred from the claim text.