3D Fiber Optic Light Panel Adhesive Design
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Solution Overview
Problem
Conventional fiber optic light panels face challenges in providing aesthetically appealing and technically compliant vehicle lighting that can conform to complex three-dimensional shapes without degrading light output, often resulting in non-homogeneous illumination and delamination issues due to stress at adhesive interfaces.
Innovation Solution
A fiber optic light panel design featuring an optical fiber layer with an adhesive layer thicker than 58 micrometers, devoid of a carrier film, and a releasing layer for easy mounting, which allows for greater formability and reduced risk of delamination, enabling the panel to conform to complex shapes without significant light output degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional fiber optic light panels use thin adhesive layers with carrier films, then manufacturing is simpler and cost is lower, but the panels delaminate under stress and cannot conform to complex three-dimensional shapes
Solution Approach 1:
The patent changes the adhesive layer thickness parameter from conventional thin layers to a thickness greater than 58 micrometers. This parameter change provides sufficient adhesive volume to accommodate stress variations on three-dimensional surfaces while maintaining bond integrity, preventing delamination during bending and contouring operations.
Solution Approach 2:
The patent removes the carrier film from the adhesive layer construction. By taking out the carrier film, the adhesive layer becomes a self-supporting, flexible layer that can conform to complex three-dimensional shapes without the rigidity and delamination risks associated with carrier films, while still providing sufficient structural support during handling.
2Illumination intensity
If fiber optic panels are contoured to match vehicle styling, then aesthetic appeal is enhanced, but light output becomes non-homogeneous and manufacturing complexity increases
Solution Approach 1:
The patent uses a flexible adhesive layer without carrier film that allows the fiber optic panel to be contoured to match complex vehicle styling surfaces. This flexibility enables homogeneous light output across curved and three-dimensional surfaces by maintaining proper fiber spacing and orientation even when contoured, eliminating the need for complex rigid lens structures.
3Shape
If thick adhesive layers without carrier films are used, then formability and delamination resistance improve, but manufacturing precision and handling become more challenging
Solution Approach 1:
The patent incorporates a release layer on the adhesive layer before mounting. This preliminary action of adding the release layer protects the thick adhesive layer during handling and manufacturing, preventing premature bonding while enabling precise positioning. The release layer is removed only when ready for final mounting, ensuring manufacturing precision is maintained despite the increased thickness.
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 the fiber optic light panel to maintain homogeneous light output and adhere effectively to non-planar surfaces, including those with complex contours, reducing the risk of delamination and ensuring compliance with safety regulations while enhancing aesthetic appeal.
Implementation Method 1
an adhesive layer having a first surface in direct contact with the mounting side of the optical fiber layer, and a second side opposing the first side and configured to directly contact a surface of a supporting structure such that the adhesive later mechanically connects the optical fiber layer to the support structure
Data Source
AI summary
A fiber optic light panel includes an optical fiber layer having a plurality of optical fibers each configured to emit light along a length of the optical fiber. The plurality of optical fibers are arranged in a predetermined form such that the optical fiber layer has a light emitting side configured to emit light, and a mounting side opposing the light emitting side. Also included is an adhesive layer having a first surface in direct contact with the mounting side of the optical fiber layer, and a second side opposing the first side and configured to directly contact a surface of a supporting structure such that the adhesive layer connects the optical fiber layer to the support structure.