Edge-Lit SSL Panel Substrate with Integrated Rails
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Solution Overview
Problem
In edge-lit solid-state lighting arrangements, the thickness of light-diffusive panels is often excessive due to the arrangement of SSL elements, leading to increased weight and cost, while efficient power distribution and heat dissipation are also challenging, especially in large panel applications.
Innovation Solution
The use of an elongate substrate with a power supply rail and ground rails attached to one surface, where SSL packages are serially coupled between the rails, allowing for thinner panels and efficient power and heat management, with the ground rails also serving as spacers between the substrate and light-diffusive panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If SSL elements are arranged in conventional configurations, then light distribution function is achieved, but panel thickness becomes excessive leading to increased weight and cost
Solution Approach 1:
The patent transitions from conventional face-mounted SSL element arrangements to an edge-lit configuration where SSL elements are positioned at the perimeter edges of the panel. This dimensional repositioning allows light to be introduced from the edges rather than the face, enabling thinner panel construction while maintaining illumination effectiveness.
Solution Approach 2:
The patent segments the panel construction into distinct functional layers: a thin light-diffusive panel, a separate substrate carrying SSL elements and power distribution infrastructure, and a backing structure. This segmentation allows the panel itself to be minimized in thickness while power and control functions are handled by the substrate assembly.
2Weight of stationary object
If panel thickness is reduced, then weight and cost decrease, but power distribution and heat dissipation become challenging
Solution Approach 1:
The patent merges the power distribution infrastructure (supply rails and ground rails) directly with the substrate that carries the SSL elements. This integration creates efficient current pathways and reduces power loss. Additionally, the ground rails serve dual functions as both electrical ground connections and thermal management pathways.
Solution Approach 2:
The ground rails perform multiple functions simultaneously: providing electrical ground reference for the SSL elements, serving as thermal conduction pathways for heat dissipation, and acting as structural spacers between the substrate and the light-diffusive panel. This multi-functionality reduces the need for separate components.
3Area of stationary object
If SSL packages are densely arranged, then light coverage is improved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The substrate serves as an intermediary platform that pre-organizes SSL elements, power rails, and ground rails in a standardized configuration before final panel assembly. This intermediate fabrication stage allows for modular production and simplifies the final integration with the light-diffusive panel.
Solution Approach 2:
The patent employs serial coupling of SSL packages through the rail system, changing the electrical connection topology from individual wired connections to a daisy-chain configuration. This parameter change in connection methodology reduces the number of discrete connection points and simplifies the manufacturing process.
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
This configuration reduces the thickness of light-diffusive panels, decreases weight and cost, and enables efficient power distribution and heat dissipation, while allowing for individual control of SSL elements, thereby addressing the design challenges of cost, weight, and power distribution in large panel applications.
Implementation Method 1
A supply rail is disposed on the second surface of the substrate... The SSL packages are serially coupled from the first package to the last package. One contact pad of each pair of the contact pads of the first package is coupled to the supply rail through the substrate.
Implementation Method 2
With an edge-lit light-transmitting panel, light from the SSL elements is spread evenly through the panel by total internal reflection.
Implementation Method 3
Disruptions formed on the surface of the panel scatter incident light so that light is emitted from the surface of the panel.
Data Source
AI summary
A lighting apparatus includes an elongate substrate, a supply rail disposed on one surface of the substrate, and first and second ground rails disposed on the other surface. SSL packages are disposed parallel to the longitudinal axis of the substrate and between the first and second ground rails. Each package has SSL elements disposed on a first side and pairs of contact pads disposed on a second side. The SSL packages are serially coupled from the first package to the last package. One contact pad of each pair of the contact pads of the first package is coupled to the supply rail through the substrate, one contact pad of a first pair of the pairs of contact pads of the last package is coupled to the first ground rail at the first surface of the substrate, and one contact pad of a second pair of the pairs of contact pads of the last package is coupled to the second ground rail at the first surface of the substrate.