In both flexible LED strips and encapsulation of rigid aluminum profiles production process, understanding the resin layering concept is very important. Resin layering allows significant performance advantages in the LED luminaries build-up. The benefits of this encapsulation technique are such as forgetting its complexity.

Resin layering is a process that involves applying a layer of PU resin on the surface of LED lights. The resin acts as a protective barrier, preventing dust, moisture and weather to damage LED luminaires. Resin layering can also enhance the aesthetics of LED lights by giving them a glossy and smooth finish. 

Resin layering allows the encapsulation to be specifically customized which enhances the performance and durability of the luminaries.

A typical layering profile is as follows

  1. LED CIRCUIT BASIC ENCAPSULATION: This is usually a thin layer of soft elastic encapsulation compound. Once cured, this thin layer of soft resin will provide the LED fixture with increased mechanical strength on the PCB components. Casting a thin layer of resin will also rende + semplice la gestione e rimoz di any trapped air-related troubles.
  2. BULK ENCAPSULATION: This is usually the most significant amount of encapsulation dispensed and the resin mixture, “recipe”, is set according to the flexibility and performance target.
  3. TOP COATING: This final layer of resin is applied on the fixture; it is extremely important since it determines the aesthetic appearance, light color, finish, and durability performances.

It provides – 

a – Aesthetical appearance since it can be clear, opal or coloured such as for example cement gray finish

b – The light color through the thickness and the composition of the layer can move the color coordinates of the emitted light

c – The finish since a harder more cross-linked layer is something more pleasant to touch similar to the glass

d – Performance because a more cross-linked surface will prevent and delay troubles due to abrasion, heat, pollution or chlorine resistance.

Benefits of resin layering on LED lights

There are several benefits to resin layering on LED lights. These include:

  • Increased durability 
    Resin layering allows the use of several types of resinSoft and flexible resin can be used only where strictly necessary, it provides an additional layer of protection to the LED lights, making them more resistant to weather. This increases their lifespan, reducing maintenance and installation.
  • Improved aesthetics
    Resin layering can give LED lights a glossy and smooth finish, enhancing their overall appearance. This is especially useful in commercial settings where aesthetics play a crucial role in creating a favorable impression.
  • Resistance to environmental factors 
    Resin layering can protect LED lights from dust, moisture, and other environmental factors that can damage the lights. This makes them extremely suitable for outdoor use as well.

When casting, you must consider the needed time between one layer and the other. The resin layering in the LED encapsulation is usually considered a “WET on GEL” layering, it is not required that the previous layer has finished the curing process, but at the same time the process cannot be performed “WET on WET”. This is especially true when using a translucent finish, a “WET on WET” casting may cause a layering blend that makes it difficult to reach the technical lighting targets. 

This special layering technique may result in the need to shorten the curing time and invest in heated jigs or other alternative systems to accelerate the curing of the polyurethane.

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