Fiber Optic Light Panel Assembly for 3D Surface Conformity
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Solution Overview
Problem
Integration of fiber optic panels in complex vehicle lighting devices results in low manufacturing yield due to challenges in conforming to three-dimensional shapes without degrading light output.
Innovation Solution
A fiber optic light panel assembly with an optical fiber layer and adhesive layer that allows for continuous abrasions along the fibers, extending beyond the adhesive layer, enabling flexible mounting to complex surfaces while maintaining light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fiber optic cable is routed through a drop ceiling grid and secured with clips, then the cable is held in place, but the cable insulation is abraded and cut over time causing signal loss
Solution Approach 1:
The patent introduces a ceiling grid adapter as an intermediary component between the cable clip and the fiber optic cable. This adapter features a recessed cable receiving portion that cradles the cable, and a protective collar that extends over the cable to prevent direct contact between the clip's sharp edges and the cable insulation, thereby eliminating abrasion while maintaining secure cable support
Solution Approach 2:
The protective collar on the ceiling grid adapter provides beforehand cushioning by creating a protective barrier around the cable before any harmful contact can occur. The recessed cable receiving portion is designed to accommodate the cable's outer jacket dimensions, ensuring the cable is held securely without exposure to damaging forces from the cable clips
2Ease of manufacture
If cable clips are used to secure fiber optic cables, then cable installation is simplified, but cable insulation damage occurs leading to maintenance issues
Solution Approach 1:
The ceiling grid adapter serves as a mediator that preserves cable integrity while maintaining installation simplicity. The adapter attaches to the existing ceiling grid and provides a protected cable receiving area, allowing installers to secure cables without risking insulation damage, thus eliminating future repair issues while keeping the installation process straightforward
3Device complexity
If standard ceiling grid clips are used for cable support, then the support structure is simple, but signal loss occurs due to cable insulation deterioration
Solution Approach 1:
The ceiling grid adapter segments the cable support function into distinct components: the ceiling grid provides structural support, the adapter provides protected cable receptacle, and the protective collar provides insulation protection. This segmentation allows each component to perform its specific function optimally while maintaining overall system simplicity and reliability
Data Source
Figure 1~2A
Figure 2B~3
Figure 4~5
AI summary
A fiber optic light panel assembly including an optical fiber layer including a plurality of optical fibers 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. An adhesive layer is provided having a first side 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. Also included is a fiber bundle including portions of the plurality of optical fibers that are not in direct contact with the adhesive layer, and abrasions provided along a length of each of the plurality of optical fibers such that light can be emitted from the respective fiber, the abrasion being provided in the optical fiber layer and in at least part of the fiber bundle.