Compact Lighting System with Hermetic Sealing and Segmented Mounting
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Solution Overview
Problem
There is a need for a compact, lightweight, and cost-effective portable lighting system that can be easily applied to various substrates and is reusable, with the ability to conserve battery power by being selectively turned on and off, suitable for use in dim or dark environments and for tactical, safety, and emergency applications.
Innovation Solution
A compact lighting system comprising a removable battery, light, and switch assembly that can be hermetically sealed and mounted on clothing, accessories, or other substrates, featuring a textured on-off switch for easy operation in the dark, with options for different light modes and colors, including ultraviolet and infrared for tactical use, and a waterproof design for durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the lighting system is made compact and lightweight, then portability and ease of application are improved, but manufacturing complexity and sealing requirements increase
Solution Approach 1:
The lighting system is divided into separate functional modules: a hermetically sealed light assembly containing the LED and battery, and a separate mounting component with adhesive backing. This segmentation allows each module to be optimized independently - the light assembly focuses on waterproof sealing while the mounting component provides easy attachment, resolving the contradiction between compactness and manufacturing complexity
Solution Approach 2:
An adhesive mounting strip or removable mounting mechanism serves as an intermediary between the compact light assembly and the substrate (clothing, helmet, etc.). This intermediary simplifies the overall mounting process by providing a dedicated attachment interface, reducing the complexity of integrating sealing and mounting functions into a single compact unit
2Use of energy by moving object
If the lighting system is made reusable with on-off capability, then battery power conservation is improved, but device complexity increases
Solution Approach 1:
The lighting system incorporates a simple manual on-off switch that allows the user to control power consumption directly. This self-service approach enables the user to turn the light off when not needed, conserving battery power without requiring complex automated sensing or control systems, thus resolving the contradiction between energy efficiency and device complexity
Solution Approach 2:
The lighting system is designed to be periodically activated and deactivated based on user need rather than operating continuously. This periodic action pattern, enabled by the on-off switch, significantly reduces overall battery power consumption while maintaining simple device architecture, addressing the contradiction between energy efficiency and complexity
3Reliability
If the lighting system is hermetically sealed for protection, then durability against moisture and shock is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The hermetic sealing is applied only to the light assembly portion that contains sensitive electronic components (LED, battery, circuitry), while the mounting components and external surfaces remain open and simple. This segmented approach provides necessary protection against moisture and vibration where needed without requiring complex hermetic sealing across the entire device, thus resolving the contradiction between reliability and ease of manufacture
Solution Approach 2:
The mounting components and external housing are designed as simple, non-hermetic, cost-effective parts that can be easily manufactured and replaced if needed. Only the critical light assembly requires hermetic sealing, allowing the system to achieve adequate reliability while keeping overall manufacturing complexity and cost manageable through this differentiated approach
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides effective visibility and safety in various environments, extends battery life through selective power usage, and is adaptable for multiple applications, including military, law enforcement, and emergency services, while being durable and easy to use.
Implementation Method 1
A compact lighting system has been developed which can be carried on or removably applied to a substrate such as clothing, shoes, hats, helmets, gloves, shirts, pants, belts and the like to assist in alerting others of the presence of a person located in dim or dark lighting (in the dark)
Implementation Method 2
The outer surface of the pouch overlying an on-off light switch may be textured to allow an operator to easily locate and operate the light switch solely by feel in either the light or in the dark
Implementation Method 3
The lightweight system can be hermetically sealed in a clear or translucent pouch or covered with a waterproof coating for protection against vibration, shock, harsh environments and moisture
Data Source
AI summary
A layered lighting assembly includes a circuit board having a battery, a light, a switching circuit and a push button switch selectively powering the light with the battery via the switching circuit. The circuit board is protected from vibration and impact with a relatively soft compressible foam layer provided adjacent the circuit board. A semi-rigid protective sheet of flexible plastic is layered over or layered adjacent to the circuit board to resist bending and flexing of the circuit board and thereby further protect the circuitry.