GB2470350A - Waterproof Electrical Item - Google Patents

Waterproof Electrical Item Download PDF

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Publication number
GB2470350A
GB2470350A GB0908133A GB0908133A GB2470350A GB 2470350 A GB2470350 A GB 2470350A GB 0908133 A GB0908133 A GB 0908133A GB 0908133 A GB0908133 A GB 0908133A GB 2470350 A GB2470350 A GB 2470350A
Authority
GB
United Kingdom
Prior art keywords
electrical
housing
item
connection means
waterproof
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB0908133A
Other versions
GB0908133D0 (en
Inventor
Geoffrey Lunn
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
VML TECHNOLOGIES BV
Original Assignee
VML TECHNOLOGIES BV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by VML TECHNOLOGIES BV filed Critical VML TECHNOLOGIES BV
Priority to GB0908133A priority Critical patent/GB2470350A/en
Publication of GB0908133D0 publication Critical patent/GB0908133D0/en
Publication of GB2470350A publication Critical patent/GB2470350A/en
Withdrawn legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L25/00—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof
    • H01L25/03—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes
    • H01L25/10—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices having separate containers
    • H01L25/13—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices having separate containers the devices being of a type provided for in group H01L33/00
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00—Apparatus or processes for manufacturing printed circuits
    • H05K3/22—Secondary treatment of printed circuits
    • H05K3/28—Applying non-metallic protective coatings
    • H05K3/284—Applying non-metallic protective coatings for encapsulating mounted components
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V31/00—Gas-tight or water-tight arrangements
    • F21V31/005—Sealing arrangements therefor
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2103/00—Elongate light sources, e.g. fluorescent tubes
    • F21Y2103/10—Elongate light sources, e.g. fluorescent tubes comprising a linear array of point-like light-generating elements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L25/00—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof
    • H01L25/03—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes
    • H01L25/04—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers
    • H01L25/075—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00
    • H01L25/0753—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00 the devices being arranged next to each other
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/0001—Technical content checked by a classifier
    • H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L33/48—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the semiconductor body packages
    • H01L33/52—Encapsulations
    • H01L33/56—Materials, e.g. epoxy or silicone resin
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/01—Dielectrics
    • H05K2201/0104—Properties and characteristics in general
    • H05K2201/0125—Shrinkable, e.g. heat-shrinkable polymer
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/01—Dielectrics
    • H05K2201/0137—Materials
    • H05K2201/0158—Polyalkene or polyolefin, e.g. polyethylene [PE], polypropylene [PP]
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
    • H05K2201/10007—Types of components
    • H05K2201/10106—Light emitting diode [LED]

Landscapes

  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • Computer Hardware Design (AREA)
  • General Engineering & Computer Science (AREA)
  • Optics & Photonics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • General Physics & Mathematics (AREA)
  • Casings For Electric Apparatus (AREA)

Abstract

A waterproof electrical item 9 comprising at least one electrical component 10, electrical connection means 15 connected to the electrical component and a housing 16 made from a heat shrunk material; whereby the housing 16 is adapted to encase the at least one electrical component 10 and at least part of the electrical connection means 15 upon the addition of heat, in order to produce a water tight seal. Preferably the electrical item 9 may comprise a rigid base, such as a circuit board. Also the electrical item 9 may be used for displaying images or decorative patterns and the electrical component may include one or more lighting components, such as LEDs 13. Additionally a former 20 may be disposed inside the housing 16, over the electrical item 9, to provide the electrical component with a particular shape, the former being made from a material that does not deform when heated.

Description

ELECTRICAL ITEM
The present invention relates to an electrical item and in particular to a weatherproof electrical item.
Electrical items that are suitable for submersion in water, exposure to damp and humid conditions and or direct sunlight usually include or are provided within cumbersome housings that are not aesthetically pleasing. This is not a problem for many items such as underwater torches, floodlights, outdoor speakers and so forth, where their appearance is subordinate to their functionality. However, there are many items that are to be used in wet or humid conditions for which aesthetic appeal is very important. If those items are cumbersome and not visually elegant, the aesthetic appeal will be diminished. Many electrical items, particularly lighting equipment, are housed in transparent cases to allow light to shine through and thus making it difficult to conceal any unattractive circuitry and wiring.
The popularity of modern architecture continues to increase in the developed world and consequently many commercial buildings constructed from steel frames and glass sheets are built every year. Lighting technology has developed significantly in recent years and nowadays small, low power, high intensity LEDs are available at a reasonable cost. Consequently, LED5 are being mounted in or on the glass sheets, steel frames and façade panels of commercial buildings for decorative or display purposes. Thus, the facades of these building may include interesting decorative patterns or displays on which images or videos can be viewed and used as valuable advertising space.
There are various ways of arranging such displays on the facades. Glass panels are available having LEDs mounted therein and connected by thin wires made from transparent materials such as indium tin oxide. Though these panels look attractive it is very difficult to replace defective LEDs and often the panel needs to be removed for repair or replacement. This can be very costly and inconvenient, particularly in tall buildings. It is also difficult to incorporate sophisticated drive and control electronics in such panels in an elegant and semi-transparent way.
Alternatively LEDs can be mounted on strips and encased in a transparent housing mountable to the interior or exterior of the glass panels. The strips mounted on the interior of the panels can be a distraction to office workers and can also interfere with window blinds and cleaning. Problems are also prevalent in strips mounted to the exterior of the glass panels, or other façade panels, as they are subject to extreme temperature changes, rain, sunlight and humidity. Usually a wire extends from each end of the housing and difficulties arise in preventing the ingress of water through those ends and consequent damage to the LEDs or circuitry inside. It is these external light units with which the present invention is particularly concerned and to which specific reference in the remainder of the specification will be given, though it should be understood that the invention is not limited to light units of this nature.
Some known light units for external use comprise a tubular transparent housing in which the LEDs are encased and end caps mounted on each end of the housing and through which wires extend. Seals are located between the end caps and the housing and between the end caps and the wires but these add significantly to the cost of each unit and are prone to failure. For instance, temperature changes cause the air inside the housing to contract and expand which differential pressure is known to cause the seals to fail. Furthermore, access in to the housing to replace faulty circuitry inevitably disturbs and consequently diminishes the efficiency of the seals. The spacing between each pixel of a display system is selected according to many factors, including the brightness and size of the display and the viewing distance. In view of this, the size of the units may vary considerably depending on their intended use and therefore customisation is often required. However, customisation is very time consuming and expensive due to non-recurring engineering (NRE) costs particularly relating to circuit board and housing design, design proving, tooling and the like.
Light units for external use are also available in the form of a resin base in which at least the tower portion of tamp type LEDs is potted. These are available as clusters, panels or strips, but again have many shortcomings. Specifically, LED units of this type are often too heavy, the removal and replacement of defective LEDs from the resin is difficult, they are expensive to manufacture and they are particularly expensive to customise. Furthermore, the cable entry points are known to fail. Surface mount LEDs may also be used in this type of light unit but, unlike lamp type LEDs, they are not weatherproof and must therefore be located within a protective transparent housing or embedded in a transparent resin to allow light to pass there through and to ensure they are not exposed to water.
However, not only are such resins expensive they are also susceptible to degradation when subject to UV radiation from the sun.
In addition to the above examples, visual display systems are often constructed at large outdoor events for viewing sports competitions, concerts and so forth. Such viewing systems are often constructed from hundreds of light units mounted on a frame and spaced equally apart, each light unit comprising one or more clusters of LEDs where each cluster defines a pixel of the image displayed.
Spectators viewing the display system for extended periods would inevitably notice any cumbersome, unsightly electrical items, so it is also necessary to package those items in an elegant housing. Increasingly such displays are constructed so that the gaps between adjacent light units give the display a semi-transparent appearance, and to maximise the transparency it is desirable to make the light units as thin as possible.
It is a principal object of the present invention to overcome the main problems discussed above by providing an electrical item which prevents the ingress of water. It is a further object of the present invention to provide an electrical item which will not degrade when exposed to sunlight. Another object of the present invention is to provide an electrical item which can be made relatively inexpensively. It is yet a further object of the present invention to provide such an electrical item which can be manufactured in various sizes in an aesthetically pleasing way, with relative ease and minimal NRE costs.
According to the invention, there is provided a waterproof electrical item comprising: at least one electrical component, electrical connection means connected to the electrical component and a housing made from a heat shrunk material which encases the at least one electrical component and at least part of the electrical connection means, the housing being heated during manufacture so as to shrink around the electrical component and electrical connection means located therein to create a water tight seal and through which seal the electrical connection means extend.
In a preferred arrangement the at least one electrical component includes at least one light source. It is envisaged that the invention will be particularly useful for external visual display systems using lighting to display images and videos so the light source might include appropriate control means. Preferably the light source comprises one or more LED.
Advantageously the at least one electrical component includes a rigid base to provide some rigidity and shape to the electrical item. Many electrical items will include an electrical circuit and are likely to include a circuit board such as a PCB on to which components such as surface mount devices (SMD) may be fixed.
Such circuit boards are likely to be light and rigid so can therefore form the base.
Preferably the housing is translucent and most preferably it is transparent to allow any tight emitted from the at Least one electrical component to pass therethrough. Since the housing is to be exposed to all weather conditions, including sunlight, the housing is advantageously made from a material that is not prone to degradation when subject to UV radiation. In a preferred arrangement the housing is made from a plastics material such as polyolefin.
Preferably the housing is generally tubular before being shrunk and has a circular cross-section, though the material may be flexible before shrinking and in fact any shaped cross-section may be selected since it is likely to deform when heated. In some applications it may be preferable to heat only the ends of the housing so that they deform to create an effective seal but the remainder of the housing may retain its initial shape. For instance, if the electrical item is to be mounted along an internal edge defined by two surfaces arranged perpendicular to each other, a housing having a triangular cross-section may be used so it fits snug along the internal edge. Of course, in this instance only the ends of the tube should be heated to minimise deformation between the ends of the housing.
Preferably the material from which the housing is made shrinks only in one direction such that, in the case of a tube, the housing shrinks radially but not longitudinally. In cases where the housing is made from a material that shrinks in all directions, a sufficiently large housing must be used to account for the shrinkage.
In an alternative arrangement the housing is formed from a sheet of heat shrinkable material wrapped around the at least one electrical component and electrical connection means before being shrunk. This could be a more cost effective solution since a film is likely to be less expensive than an extruded tube and the film could be used with electrical items of all sizes and no attention need be paid to the girth or the length.
It may be preferable to arrange the housing so that it moulds closely around the contours of the at least one electrical component and any other features inside the housing. This can be achieved by shrinking the entirety of the housing. In this way, all air spaces between the housing and the at least one component will be minimised and the volume of air inside the housing will be minimised.
Temperature differences between the interior and exterior of the housing are likely to cause the air pressure inside the housing also to change, but with such a small volume of air inside the housing any change in air pressure are unlikely to affect the seals. Changes in internal air pressure of known electrical items are believed to be a common cause of seal failure.
In an alternative arrangement the at least one electrical component is mounted in a former and the housing encases the former, thus improving the appearance of the electrical item. For instance, the former may comprise a rigid tube made from an opaque material and having transparent portions or apertures behind which any tight sources may be mounted. Most preferably the former is heat resistant so as to retain its shape even when the housing is heated and shrinks around the former.
In an alternative arrangement the at least one electrical component and heat shrunk housing assembly is mounted inside a further protective outer housing, which may be required to provide increased rigidity or protection against mechanical disturbance.
In one arrangement the electrical connection means includes at least one electrical cable electrically connected to the at least one electrical component and which passes out of the housing and can be connected to another electrical item, electrical power source, control system or the like. The housing shrinks around a peripheral portion of the electrical cable when heated.
Additionally or alternatively, the electrical connection means may include at least one electrical connector to facilitate connection of the electrical component to other electrical items or power supplies external of the electrical item. The electrical connector may include a waterproof body around which the housing shrinks to form a watertight seal, a wire extending internally of the housing and connected to the at least one electrical component and an electrical contact disposed external of the housing for engagement with a corresponding electrical connector.
An adhesive may also be provided between the housing and the electrical connection means to improve the seal. The adhesive may be heat activated so that it sets or cures only when heated and forms a strong bond between the housing and the electrical connection means.
According to the invention, there is also provided a method of manufacturing an electrical item comprising the steps of: -providing at Least one electrical item and electrical connection means electrically connected to the at least one electrical component; -introducing the electrical component and the electrical connection means into a heat shrinkable housing; -arranging the electrical connection means so that they extend out of the housing; and -heating the housing so that it shrinks around the at least one electrical component and the electrical connection means so as to form a waterproof seal around the electrical connection means.
Preferably, the method described above also includes the step of reducing the air pressure inside the housing while heating the housing so that the heat shrinkable material is drawn around the at least one electrical component and the electrical connection means. The housing should shrink around the electrical component by the application of heat alone, but the possibility of any small void spaces remaining within the housing is likely to be reduced even further by decreasing the pressure in the housing when applying the heat.
Advantageously, the method may further comprise the step of applying adhesive between the housing and the electrical connection means before heating the housing to improve the seal therebetween.
By way of example only, two embodiments of the invention will now be described in detail, with reference to the following drawings, in which: Figure 1 is a perspective view of an electrical component; Figure 2 is a perspective view of a housing for the electrical component of Figure 1; Figure 3 is a perspective view of the electrical component and housing prior to the housing being heated; Figure 4 is a perspective view of an electrical item according to the first embodiment of the invention; Figure 5 is a perspective view of a former for use with a second embodiment of the invention; Figure 6 is a perspective view of the electrical component located inside the former; Figure 7 is a perspective view of the former located inside a housing; Figure 8 shows a complete electrical item according to a second embodiment of the invention; and Figure 9 shows a perspective view of an electrical item according to a third embodiment of the invention.
Referring initially to Figure 1, there is shown an electrical component 10 forming part of an electrical item 9. The electrical component comprises an elongate printed circuit board (PCB) 11 having an upper surface 12 on which there is mounted a plurality of LED5 13 and a lower surface 14 on which there is provided the metallic tracks and other components (not shown). The LEDs 13 are equally spaced along the length of the PCB 11 and the distance between any two adjacent LEDs is set during manufacture according to the intended use of the device. For instance, if the electrical component is to be used in connection with other similar electrical components to form a visual display screen where each LED 13 forms a pixel of the image displayed, the distance between each LED depends on the intended viewing distance of the screen and the brightness of the LEDs. Insulated electrical cables 15 are electrically connected to the PCB 11 at opposed ends thereof and which include power leads (not shown) and control leads (not shown) for selectively illuminating the LEDs 13.
Figure 2 shows a plastic tube 16 having a circular cross-section, the length of the tube being slightly greater than the length of the PCB 11 and the internal diameter of the tube 16 being slight greater than the width of the PCB 11. The tube 16 is made from a transparent polyolefin which contracts in a radial direction when heated, while remaining substantially constant in an axial direction.
Figure 3 shows the electrical component 10 located inside the plastic tube 16. Since the tube 16 is slightly longer than the PCB 11 the tube extends beyond both ends of the PCB and also partway along the electrical cables 15.
Once heat is applied along the length of the plastic tube 16 it shrinks around the electrical component 10 so as to minimise any air spaces therein. Most importantly it shrinks around a portion of each cable 15 extending from the PCB 11 so as to form a fluid tight seal therewith.
A second embodiment of the invention is shown in Figures 5 to 8. All features common to the first and second embodiments will be given like reference numerals in both embodiments. The second embodiment comprises an electrical item 30 including a housing 16 formed from a plastic tube and an electrical component 10 provided with LEDs 13 and electrical cables 15.
The electrical item 30 also includes a former 20 made from a heat resistive material which maintains its shape when subject to the heat applied to the plastic tube. The former 20 is also tubular but has a rectangular cross-section so as to define opposed upper and lower walls 21,22 and opposed side walls 23. The spacing between the two side watts 23 is equal to the width of the PCB 11 and the spacing between the upper and lower walls 12,22 is substantially equal to the height of the electrical component 10, that is the PCB 11, the LEDs 13 and any further components on the underside of the PCB. In this way, the electrical component 10 can locate inside the housing and form a snug fit therewith, as shown in Figure 7.
The former 20 is made from an opaque material so as to conceal its contents and improve the appearance of the electrical item 30. However, so that the light emitted from the LEDs 13 can pass through the electrical item 30, a plurality of squares 25 are formed in the upper walls 21 of the former 20 and spaced apart so as to align with the LEDs 1 3.
Once the electrical component 10 is located inside the former 20, the electrical component and former can then be introduced into the housing 16.
Again, the housing 16 is longer than the former 20 and the PCB 11 so as to extend partway along the electrical cables 15. The housing 16 is heated so as to shrink around the former 20 and the cables 1 5 and the electrical item 30 adopts the shape of the former 20 as shown in Figure 8.
Figure 9 shows a third embodiment of the invention which is very similar to the second embodiment discussed above and therefore like features are given like reference numerals. In fact, the third embodiment includes all the features of the second embodiment and is made in the same way, the only difference being that this embodiment includes a pair of boots 31 fitted over the ends of the electrical item 30. Each boot 31 is formed from a tubular piece of heat shrinkable material provided with adhesive on its internal surface (not shown) and which is arranged to overlie an end of the housing 16 and part of the cable extending from that end. As the boots 31 are heated they shrink around the housing 16 and the cables 15 and the adhesive forms a strong bond between the boots 31 and the housing 16 and the boots 31 and the cables 1 5 to prevent the ingress of water between those parts.

Claims (21)

  1. CLAIMS1. A waterproof electrical item comprising: at least one electrical component, electrical connection means connected to the electrical component and a housing made from a heat shrunk material which encases the at least one electrical component and at least part of the electrical connection means, the housing being heated during manufacture so as to shrink around the electrical component and electrical connection means located therein to create a water tight seal and through which seal the electrical connection means extend.
  2. 2. A waterproof electrical item as claimed in claim 1, wherein the at least one electrical component includes at least one light source.
  3. 3. A waterproof electrical item as claimed in claim 1 or claim 2, wherein the at least one electrical component includes a rigid base.
  4. 4. A waterproof electrical item as claimed in claim 3, wherein the rigid base comprises a circuit board.
  5. 5. A waterproof electrical item as claimed in any preceding claim, wherein the housing is transparent or translucent.
  6. 6. A waterproof electrical item as claimed in any preceding claim, wherein the housing is made from a material that is resistant to ultraviolet electromagnetic radiation.
  7. 7. A waterproof electrical item as claimed in any preceding claim, wherein the housing is made from a plastics material.
  8. 8. A waterproof electrical item as claimed in claim 7, wherein the housing is made from polyolefin.
  9. 9. A waterproof electrical item as claimed in any preceding claim, wherein the housing is generally tubular before being heated.
  10. 10. A waterproof electrical item as claimed in any of claims 1 to 8, wherein the housing is formed from a sheet of heat shrinkable material wrapped around the at least one electrical component and electrical connection means before being heated.
  11. 11. A waterproof electrical item as claimed in any preceding claim, wherein the housing closely matches the exterior profile of the or each component after heating to minimise any void spaces existing inside the housing.
  12. 12. A waterproof electrical item as claimed in any of claims 1 to 10 and further comprising a former in which the at least one electrical component is enclosed and around which former the housing is shrunk.
  13. 13. A waterproof electrical item as claimed in any preceding claim, wherein the electrical connection means includes at least one electrical cable.
  14. 14. A waterproof electrical item as claimed in any preceding claim, wherein the electrical connection means include at least one electrical connector to facilitate connection of the electrical component to other electrical items or power supplies external of the electrical item.
  15. 15. A waterproof electrical item as claimed in any preceding claim, and further comprising an adhesive between the housing and the electrical connection means.
  16. 16. A waterproof electrical item as claimed in any preceding claim, wherein a boot is arranged to overlie the housing and the electrical connection means so as to form an improved seal between those parts.
  17. 17. A waterproof electrical item as claimed in any preceding claim, wherein the heat shrunk housing locates in an outermost housing for improved rigidity and protection.
  18. 18. A waterproof electrical item as claimed in claim 1 and substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.
  19. 19. A method of manufacturing an electrical item comprising the steps of: -providing at least one electrical item and electrical connection means electrically connected to the at least one electrical component; -introducing the electrical component and the electrical connection means into a heat shrinkable housing; -arranging the electrical connection means so that they extend out of the housing; and -heating the housing so that it shrinks around the at least one electrical component and the electrical connection means so as to form a waterproof seal around the electrical connection means.
  20. 20. A method of manufacturing an electrical item as claimed in claim 18, and further including the step of reducing the air pressure inside the housing while heating the housing so that the heat shrinkable material is drawn around the at least one electrical component and the electrical connection means.
  21. 21. A method of manufacturing an electrical item as claimed in claim 19 or claim 20, and further comprising the step of applying adhesive between the housing and the electrical connection means before heating the housing to improve the seal therebetween.
GB0908133A 2009-05-12 2009-05-12 Waterproof Electrical Item Withdrawn GB2470350A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0908133A GB2470350A (en) 2009-05-12 2009-05-12 Waterproof Electrical Item

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0908133A GB2470350A (en) 2009-05-12 2009-05-12 Waterproof Electrical Item

Publications (2)

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GB0908133D0 GB0908133D0 (en) 2009-06-24
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JP5103557B2 (en) * 2011-02-21 2012-12-19 グンゼ株式会社 Light diffusion heat shrinkable tube and straight tube type LED light
WO2013160246A1 (en) * 2012-04-23 2013-10-31 Osram Gmbh Electronic module and illuminating device comprising the electronic module
WO2014183231A1 (en) * 2013-05-16 2014-11-20 Tian Maofu Led light bar with fully waterproof potted structure and manufacturing method
WO2015127411A1 (en) * 2014-02-24 2015-08-27 Tyco Electronics Canada Ulc Light assembly with conforming seal
EP2957815A1 (en) * 2014-06-17 2015-12-23 Petrus Pfundt Light fixture with at least one led strip
EP3373710A1 (en) * 2017-03-08 2018-09-12 Sick AG Optoelectronics module
US10364002B2 (en) 2015-07-30 2019-07-30 Koninklijke Philips N.V. Water lock to prevent water ingress
WO2020011558A1 (en) * 2018-07-12 2020-01-16 Osram Gmbh Optoelectronic assembly and method for producing an optoelectronic assembly

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CN2437951Y (en) * 2000-06-23 2001-07-04 樊邦弘 Rubber line lamp string
CN2551853Y (en) * 2002-06-14 2003-05-21 陈玄德 Rope lamp structure with thermal shrinkage sleeve
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Cited By (18)

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CN102959431A (en) * 2011-02-21 2013-03-06 郡是株式会社 Light-diffusing heat shrinkable tube and linear led light
KR101258871B1 (en) 2011-02-21 2013-04-29 군제 가부시키가이샤 Light-diffusing heat shrinkable tube and linear led light
CN102959431B (en) * 2011-02-21 2014-02-26 郡是株式会社 Light-diffusing heat shrinkable tube and linear led light
US8723404B2 (en) 2011-02-21 2014-05-13 Gunze Limited Light-diffusing heat shrinkable tube and linear LED light
JP5103557B2 (en) * 2011-02-21 2012-12-19 グンゼ株式会社 Light diffusion heat shrinkable tube and straight tube type LED light
WO2013160246A1 (en) * 2012-04-23 2013-10-31 Osram Gmbh Electronic module and illuminating device comprising the electronic module
WO2014183231A1 (en) * 2013-05-16 2014-11-20 Tian Maofu Led light bar with fully waterproof potted structure and manufacturing method
CN106029443B (en) * 2014-02-24 2018-04-24 泰科电子加拿大有限公司 With the optical assembly for complying with seal
WO2015127411A1 (en) * 2014-02-24 2015-08-27 Tyco Electronics Canada Ulc Light assembly with conforming seal
CN106029443A (en) * 2014-02-24 2016-10-12 泰科电子加拿大有限公司 Light assembly with conforming seal
US9709727B2 (en) 2014-02-24 2017-07-18 Tyco Electronics Canada Ulc Light assembly with conforming seal
EP2957815A1 (en) * 2014-06-17 2015-12-23 Petrus Pfundt Light fixture with at least one led strip
US10364002B2 (en) 2015-07-30 2019-07-30 Koninklijke Philips N.V. Water lock to prevent water ingress
US10730594B2 (en) 2015-07-30 2020-08-04 Koninklijke Philips N.V. Water lock to prevent water ingress
EP3373710A1 (en) * 2017-03-08 2018-09-12 Sick AG Optoelectronics module
DE102017104893A1 (en) 2017-03-08 2018-09-13 Sick Ag Photonics module
DE102017104893B4 (en) 2017-03-08 2022-01-13 Sick Ag Optoelectronics module and method for producing an optoelectronics module
WO2020011558A1 (en) * 2018-07-12 2020-01-16 Osram Gmbh Optoelectronic assembly and method for producing an optoelectronic assembly

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