Continuous Encapsulated Linear Lighting Produced in Segments

Abstract

A method for making continuous encapsulated linear lighting is disclosed. In this method, a PCB is placed within a channel, and the channel is dammed by one or more stoppers. The dammed segment is filled and then caused or allowed to cure. The stoppers are then removed from their initial positions and moved along the channel. If one runs out of channel before the desired length of linear lighting is achieved, a second piece of channel is abutted to the previous segment of channel, the PCB is laid into it, and a segment is dammed, filled, and cured. The process continues iteratively until the desired length is achieved or more channel is required. The PCB may initially be cut to the full desired length and applied to the channel piecewise as needed.

What is claimed is: 
     
         1 . An encapsulated linear lighting product, comprising:
 a plurality of channels arranged in end-to-end abutting fashion;   a continuous length of cured resin disposed within and extending along the plurality of channels; and   a length of linear-lighting printed circuit board (PCB) extending along about the full length of the encapsulated linear lighting as either a single continuous strip of PCB or a series of electrically connected, end-to-end adjacent PCB segments, the PCB having mounted thereon a plurality of electronic components including a plurality of light engines,   wherein the length of PCB is disposed along interior surfaces of the plurality of channels and is encapsulated within the continuous length of cured resin.   
     
     
         2 . The encapsulated linear lighting product according to  claim 1 , further comprising a power cable that is electrically connected to the PCB and that extends from an end of the encapsulated linear lighting, with an end of the power cable being encapsulated within the continuous length of cured resin.