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A customer came to Paragon with a switch plate assembly consisting of several custom, lighted switches wired together and terminating into a 12 position plug. The LEDs which illuminated the switches would frequently stop working and would present random false illumination issues. Activating one switch could cause the LED on a different switch to light. The switches themselves would also seem to activate intermittently without having been pressed.

Several years ago a potential customer contacted Paragon regarding a large wire harness that was responsible for $15K to $20K per month due to the component’s failure rate and volume of service calls. Paragon reviewed the assembly and determined the issue was not the supplier of the harness it was the design of the unit.

LEDs have come a long ways. From the early 70s when a bulky LED watch cost thousands of dollars to LG’s announcement last month that it had created an OLED TV as thin as a magazine, these glowing little bits of magic have become wonderfully cheap and impossibly small. But guess what: they’re about to get much smaller.

Introduction Electrical coils and components have for some time been encapsulated or potted with thermosets for protection from operating environments and to provide electrical insulation and thermal dissipation.