Decorative Panel Light Extraction Deformities
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Solution Overview
Problem
Existing decorative panels with light-emitting features struggle to efficiently redirect light into visually appealing patterns due to limitations in surface deformities or disruptions, which often result in uneven light distribution and lack of design fidelity.
Innovation Solution
A decorative panel comprising a transparent first layer, a partially or fully reflective second layer with a cavity, and a partially reflective or transparent third layer, optionally with a sacrificial layer, allowing light to enter and be output in a shape similar to the design, enhancing light distribution and visual appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light extracting deformities are formed by etching or molding with uniform size, then manufacturing is simplified, but light distribution becomes uneven and design fidelity is reduced
Solution Approach 1:
The patent applies local quality by varying the size, shape, and density of light extracting deformities across different regions of the panel. Deformities closer to the light source are made larger and more sparse, while those farther away are smaller and more dense, creating optimal light extraction at each location for uniform overall distribution.
Solution Approach 2:
The patent changes physical parameters of the deformities including size, shape, depth, and spacing as a function of position relative to the light source. This systematic parameter variation enables precise control over light extraction patterns to achieve uniform illumination and high design fidelity.
2Loss of energy
If light extracting deformities are made larger or more numerous, then light extraction efficiency improves, but manufacturing complexity and design flexibility decrease
Solution Approach 1:
The patent segments the light extracting deformities into multiple zones or regions based on their distance from the light source. Each zone has optimized deformity characteristics, allowing efficient light extraction without requiring excessive deformity density across the entire panel, thus balancing efficiency with manufacturability.
Solution Approach 2:
The patent introduces dimensional variation in the deformities by changing not just their size but also their depth, shape, and three-dimensional configuration. This multi-dimensional approach enables efficient light extraction with fewer deformities, reducing manufacturing complexity while maintaining extraction efficiency.
3Manufacturing precision
If more light sources are used, then light distribution uniformity improves, but device complexity and cost increase
Solution Approach 1:
The patent extracts light more efficiently from a single light source by optimizing the deformity pattern, eliminating the need for multiple light sources. The optimized deformity distribution maximizes light extraction at each position, achieving uniform illumination with minimal light sources.
4Ease of manufacture
If the panel uses flat parallel surfaces, then manufacturing is easier, but light extraction and design visibility are limited
Solution Approach 1:
The patent introduces curved and non-planar features in the form of light extracting deformities on the panel surface. These deformities create varying surface normals that redirect light outward, enabling efficient light extraction while maintaining overall panel structural simplicity and ease of manufacture.
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 solution enables efficient light redirection and output in a visually pleasing manner, allowing for the creation of desired patterns or designs with improved light distribution, requiring minimal light sources and offering flexibility in design representation.
Implementation Method 1
The light from the light sources in a transparent panel with flat, parallel surfaces will have a shallow enough angle to continuously reflect from the surfaces of the panel and be confined within the panel.
Implementation Method 2
given a pattern of light extracting deformities or disruptions in the surface of the panel, some of the light within and passing along the panel will be interrupted and redirected outward from the surface of the panel
Data Source
AI summary
A decorative panel has a first layer, a second layer, and a third layer. The first layer may be transparent, the second layer is fully or partially reflective, and the third layer is partially reflective or transparent. A cavity having an opening in the shape of a design is formed within a portion of the second layer. The opening is configured to allow light to enter the decorative panel through the second layer. The light entering the decorative panel will be outputted by the third layer in a shape substantially similar to the design.