Channel Letters - When the going gets small...

When the going gets small, the small ones get going. Indeed, illuminating! It often happens to sign manufacturers to come across projects that require the lighting of extremely small channel letters or boxes with extremely limited thicknesses. One of the most difficult cases is that of backlit channel letters of small dimensions and with a font that includes serifs or restrictions that make the positioning of normal LED modules complex or impossible. So how can we backlight a channel letter sign with these characteristics?

A fundamental factor to take into consideration is that of luminous uniformity: all channel letters must emit the same amount of light and it is essential that no shadow areas or points where the light is brighter than others are visible. It follows that the light sources must also be distributed uniformly. But what to do if it is not possible to use the classic LED modules for illuminated signs due to their excessive dimensions? There are two different solutions to this construction challenge: choosing a specific LED module, with extremely small dimensions and technical characteristics specifically developed for the type of application, or the use of LED strips.

Let's analyze the two possible solutions.

Solution 1: LED module

LED modules are certainly the best solution for backlighting channel signs and channel letters. They guarantee excellent energy efficiency and optimal light distribution and it is possible to arrange them according to logic, adapting them to the shapes of the project. As anticipated, however, LED modules for signs are often too bulky for application in narrow spaces, so it is necessary to resort to LED modules specifically designed to be inserted in such contexts. Here are some examples:

Moduli LED Tetra Atom

The Tetra Atom module is General Electric, Current's answer to the backlighting needs for thicknesses from 2.6 cm upwards. These LED modules are powered by 24 V and stand out for their exceptional energy efficiency, which allows up to 300 of them to be connected in a single series.

They are equipped with a patented optic that creates a 160°x145° light beam ensuring absolute uniformity, especially in projects with thicknesses greater than 5 cm, all in a dimension of just 17x8x 9.7 mm. They are IP66 certified and guaranteed for 5 years by the manufacturer. The Tetra Atom is included in the module library of the free Tetra Tool sign design software.

Moduli LED VBX Micro

The smallest IP67 module on the market! With a power of just 0.13 W per module and record dimensions (9x6.8x4.5 mm) they are the ideal choice for extremely small projects, channel letters with narrow characters or letters with serifs. They are available in three different white temperatures and are pre-wired 28mm apart. They are not equipped with optics, but thanks to their characteristics, they are the perfect product for channel signs and channel letters with thicknesses of 2.5 cm or more, where compactness is a crucial factor.

Moduli LED Z1U

Z1U modules are particularly suitable for projects with thicknesses ranging from 30 to 80 mm. These LED modules are equipped with 160° optics to maximize uniformity, are waterproof with IP68 certification and operate in low voltage at 12V, with a power of 0.24W per module. Their compact design, with a size of 12x8x8.5mm, makes them particularly suitable for channel letters and solid letters.

Moduli LED VBX 111

Another LED module equipped with optics and certified for outdoor use. It measures 17x9x9mm, allowing it to fit a variety of channel letter applications. It is powered at 12V and has a power of 0.13W per module. Also available in red and in two different white temperatures. This module is also provided with a hole on the casing for screw fixing.

Solution 2: LED strip

For the backlighting of signs and channel letters, we always recommend using LED modules: compared to LED strips, the modules are more efficient, less prone to breakdowns and breakages, more resistant to potential water infiltration in the welds, easier to apply and allow greater versatility in positioning, which translates into better luminous uniformity. However, there are projects in which the available spaces are so narrow that it is not possible to use even a module as small as the VBX Mini. In these cases, the use of LED strips is the only viable solution.

The LED strips are applied to the internal walls of the channel letters and thanks to their flexibility they can easily follow the shapes, there are also numerous LED strip connectors that allow you to limit the number of soldering required. There are also outdoor LED strips protected with resin or silicone, such as the TETRA Tape Flex Strip and VBX Flex Strip LED strips, both waterproof and with a thickness of just 8 mm. In the case of indoor projects it is possible to further reduce the size of the LED strip, with products measuring just 5 mm thick and with a virtually negligible height. It must always be kept in mind that precisely because of the installation method of the product it becomes difficult to adjust the luminous uniformity of the letters and guaranteeing a watertight seal of the welds or of the joints with the LED strip connectors can prove to be challenging.