Elemental Led, Inc.

Brian McKay

Robert L Green

Gilberto Lopez-Martinez

Bernard Barcega

Paulo Dacia

A strip of encapsulated linear lighting with a partially encapsulated electrical connector is disclosed, as are processes for manufacturing such strips of encapsulated linear lighting. In these processes, connecting structure is connected to a strip of linear lighting. A portion of the connecting structure is then sheathed in a stopper. The stopper is used to dam a vessel or channel, the dammed vessel or channel is filled with resin, and the resin is caused or allowed to cure. The stopper protects the connecting structure from resin during the encapsulation process and leaves its contacts unencapsulated and exposed. The connecting structure can be connected to external structures, like a power cable or another segment of encapsulated linear lighting, after manufacture. A joint between the connecting structure and another structure can be overmolded or otherwise protected.

Encapsulated linear lighting with partially encapsulated connectors

A method for making continuous encapsulated linear lighting is disclosed. In this method, a PCB is placed within a channel, and the channel is dammed by one or more stoppers. The dammed segment is filled and then caused or allowed to cure. The stoppers are then removed from their initial positions and moved along the channel. If one runs out of channel before the desired length of linear lighting is achieved, a second piece of channel is abutted to the previous segment of channel, the PCB is laid into it, and a segment is dammed, filled, and cured. The process continues iteratively until the desired length is achieved or more channel is required. The PCB may initially be cut to the full desired length and applied to the channel piecewise as needed.

Continuous encapsulated linear lighting produced in segments

The disclosure relates to methods for connecting encapsulated linear lighting to power, including the use of through-hole mounting into flexible encapsulated linear lighting, and the creation of overmolds to protect electrical connections. The disclosure also relates to linear luminaires having channels that accommodate overmolds and allow electrical cables to exit the encapsulated linear lighting in desired, and controllable, directions.

Growing community of inventors

Reno, NV, United States of America

Brian McKay