LED Driver Assembly and Manufacture; Why use adhesives?
LED drivers are vital to LED lighting, ensuring consistent light output and optimal performance, so it is critical to consider the materials selected to protect components, especially in demanding environments.
What are LED drivers?
Drivers regulate power supplied to the LED. They do this by converting alternating current (AC) to direct current (DC) and ensure that power is consistent and uninterrupted. This prevents overheating, flickering, changes in colour and poor performance. Many LED drivers for lighting also incorporate thermal shutdown protection which switches off the system if the temperature is too high.
What threats do LED drivers and power supplies face?
LED drivers are often exposed to harsh environments, whether they’re outside or in industrial and automotive settings. Some of the threats they face include:
- Corrosion, UV exposure, and weathering in outdoor applications
- Moisture, dust and contaminant ingress
- Vibration and mechanical stress in automotive applications
- Thermal stress and overheating
Why use adhesives for LED drivers?
Materials used within drivers need to be able to operate at high temperatures requiring UL certifications and flame-retardant grades but also provide efficient sealing, environmental protection and more. While mechanical fastenings may keep components together, they still allow for contaminant ingress and corrosion. Additionally, driver housings are getting increasingly compact making assembly more challenging.
Making adhesives the perfect solution. Liquid adhesives and tapes maximise thermal transfer, with thin bond lines increasing transfer efficiency. They also provide structural bonding, stress distribution and allow for different enclosure materials. Meaning adhesives can be used in all areas of LED driver assembly from PCB bonding to mounting the finished driver.
Where can adhesives be used?
Some LED driver applications where you can use adhesives, sealants, and tapes include:
- Fill and seal gaps in housings, connectors, and units
- Sealing enclosures to prevent moisture, dust, or chemical ingress
- Potting and encapsulating PCBs to protect sensitive components
- Securing wires
- Mounting drivers
- Bonding PCB components
- Thermally conductive adhesives for transferring heat away from sensitive components
- Bonding dissimilar materials (i.e. plastic to metal)
- Distribute stress for vibration resistance
For more information about how adhesives can be used in your LED driver manufacturing process contact an expert.
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