Flexible high-power LED lighting system

A string light engine comprising:

• a flexible power cord comprising a first wire, a second wire and insulating material for the wires;
• and
• a plurality of LED modules attached to the power cord, each module comprising:
• a thermally conductive PCB having circuitry printed on a first surface of the PCB;
• an LED mounted to the first surface of the PCB and in electrical communication with the circuitry;
• a heat conductive first housing portion receiving the PCB;
• an electrically insulative second housing portion connected to the first housing portion, the second housing portion retaining the PCB against a surface of the first housing portion;
• and
• an IDC terminal operatively connected to the PCB and inserted into the insulating material of the power cord such that the LED is in electrical communication with the first wire via the IDC terminal.

A string light engine comprising:

• a flexible power cord comprising an electrical wire and an insulating material for the wire;
• a heat sink attached to the power cord;
• an IDC terminal inserted through the insulating material and in electrical communication with the wire;
• a PCB at least partially received in the heat sink, the PCB including a first surface having circuitry and a second surface opposite the first surface, the circuitry being in electrical communication with the IDC terminal, the second surface being disposed adjacent a surface of the heat sink so that heat is transferred from the LED into the heat sink;
• an LED mounted to the first surface of the PCB and in electrical communication with the circuitry;
• and
• a thermally conductive potting material contacting at least a portion of the first surface of the PCB and at least a portion of the heat sink for potting the PCB inside the heat sink and providing a thermal path from the first surface of the PCB into the heat sink.