There are numerous factors that go into selecting materials for LED enclosures. Not only does the material have to withstand internal temperatures and pressures, but outdoor LED luminaires are also subject to inclement weather and other external liabilities.
Keep reading to learn more about a manufacturer of LED luminaires that needed a gasket solution to withstand a variety of conditions in order to meet an ideal lifespan and see how Marian helped manufacture an effective solution for their application.
The Application Challenge: Reliable Sealing at High Temperatures
Our customer is a U.S. based global leader in commercial LED lighting manufacturing sells LED luminaires intended for use in warehouses, hazardous locations, and outdoor environments.
Because LEDs offer significant energy savings and longer life cycles, ideally, the LED is replaced less often to save both the manufacturer and customer money. The manufacturer also offers a 5-year product warranty, so it was essential for the luminaire to meet a 5 to 10-year operational lifespan.
The lighting assembly is recommended for use in environments with temperatures ranging from -40°F to +150°F, and the internal temperature of an LED assembly is even warmer than outside temperatures during operation.
On top of climate challenges, there are many environmental factors for an enclosure to withstand, including:
- UV exposure
- Precipitation
- Moisture
- Dust
An example of a LED luminaire housing. This image is just a representation and not the actual LED in this story.
The Solution: Marian's Silicone Foam Sealing Gasket
To seal the exterior aluminum housing, Marian proposed a gasket made from BISCO® HT-800 Medium Density Silicone Foam.
BISCO HT-800 is a silicone foam that:
- Withstands temperatures from -67°F to +392°F
- Maintains a water-tight seal
- Has outstanding UV resistance
- Is flame retardant
- Doesn't relax or suffer serious compression set when compressed for even 5 or 10 years
Not only can Marian die-cut BISCO silicone to the exact dimensions and tolerances required for the application, but this is also one of Marian's core materials, meaning Marian locations keep rolls of the material in stock for quick prototyping and mass production.
The customer tested Marian's BISCO HT-800 prototype gaskets and confirmed its utility. The light assembly was able to pass the required IP-64 and UL 94 V-0 standards.
These silicone examples (BISCO® HT-800 in light grey) are die-cut to the customer's desired dimensions and include pinholes for mechanical fastening.
Key Takeaways: Benefits of Working with Marian for LED Housing Applications
- Marian is a Rogers Corporation Preferred Converter which means we have preferred access to their industry-leading foams and silicones.
- Marian stocks many of the industry's best thin, flexible materials in-house for rapid prototyping and production. We have years of experience in converting these materials for the LED lighting industry.
- Although it wasn't needed in this application, Marian has the capability to laminate BISCO with adhesive and other materials for sealing applications. We can also include precisely located pinholes for mechanical fastening.
- Customers can expect confidence and peace of mind that our material solutions, when implemented properly, can meet or even outperform the indicated warranty timeframe.
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Become an Expert on Enclosures and Sealing
Are you working on an enclosure application that you want to make sure is properly sealed? We partnered up with our preferred supplier Rogers Corporation to educate engineers and other technical-minded experts on sealing enclosure applications in our free training course, the Enclosure Institute™.
Marian, Inc. is an ISO 9001 certified converter of custom die-cut components made from flexible materials. We partner with leading material suppliers, and our global capacity is unmatched. This Marian application story, along with many others, uniquely demonstrates our state-of-the-art custom converting capabilities including die cutting, lamination, design for manufacturing, and more. Please contact us today to learn more or to request a quote, prototype, or material sample.
