Highlighter 4

Next generation low power linear lighting. The Highlight 4 (HL4) is an industry leading design with its high control ability, modular and accessible design that enables it to be used in nearly any environment. This product is IP68 rated and IK4 rated. All while maintaining leading customization options, whether that be LED selection, power output, size requirements, or Diffusion needs.

The Challenge

Highlighter 4 (HL4) is a highly controllable lighting module. The goal was to create an industry leading device, while not altering its footprint from the previous generation, and adding in a half length version of the module called HL4-150. This jump in technology left a need for innovative ways of sealing the module to maintain the IP66 rating, while keeping the electronic components safe.

For the sealing, a few ideas were explored, one with a moat style barrier that would allow for a potting fluid to seal the perimeter of the top and bottom body components. This was replaced with an idea that allowed for a wall to be made to separate the cable entry and the electronic board from each other. While the perimeter of the bodies sealed with a gasket.

Initial concepts used a self crimping idea that allowed for wires to be pre-placed into the lower body, and during PCB insertion would crimp the power and data wires. This was removed as testing showed that potting fluid needed to be kept away from the PCB due to heat expansion and contraction.

Testing the seal of the injection moulded parts, these parts were put into a temperature chamber that would cycle between -50 Degree C to +70 Degree C. Anti freeze additive as added to the water for the colder temperatures.