What can we do more to improve the shockproofness of led work lights

In some cases such as construction sites or off road adventures, there are occasionally strong vibrations when the installed led work lights are operating. To extend the lifetime of led work lights and ensure durability, we need to adopt some solutions with some more advanced ideas to achieve our purpose.

Make the diecast or CNC aluminum housings thicker based on higher strength-to-weight ratio for harsh applications. Thicker mounting brackets are also recommended for securing the led work lamps well.Explore engineered plastics like impact-resistant polycarbonate, or other composite materials combining strength with vibration dimpling. Internal ribbing or bracing can be provided inside the led work lamps to enhance rigidity and prevent deformation upon impact. For off-road cars, a dedicated shock absorber is suggested to be installed at the bottom of vehicles.

For the polycarbonate lenses, protective coatings can be applied to the optics or lens to guard scratch and impact. Also, when making housing designs, it is better to make the optics recessed so as to provide a physical barrier against direct impact.

Secured LED mounting is also very important. A conformal coating can be applied onto the aluminum PCBA to protect the electronic components from moisture, dust and vibration. Encapsulate the LEDs and other sensitive components in a potting compound  epoxy to provide cushioning and secure them in place.

Use a big longer power wires to achieve proper strain relief for all wiring connections to prevent them from being pulled or stressed during impacts.If connectors are connected to the led lamps, locking or vibration-resistant DT connectors are recommended to ensure a reliable electrical connection even under shock. Our special-purpose hard rubber+stainless steel mounting bracket can absorb significant impact forces in some way.

For separated bottom mounting brackets, rubber washers are need to be inserted the space of the mounting kits.

If possible, try to mount the led work lamp higher up or behind protective structures and minimize direct exposure to impacts.

It is necessary to weight the balance between shockproofness,weight,size and cost. The level of shockproofness will depend on the specific application.A LED work light for heavy duty equipment will need to be more stronger than that for general workshop use.