Flexible Lighting Panel Delamination Prevention

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Solution Overview

Problem

Existing flexible lighting panels face delamination and separation issues due to repeated flexing and unflexing, which compromises their durability and reliability as a primary light source, especially in applications requiring frequent deployment and stowage like military and camping uses.

Innovation Solution

A flexible lighting panel design featuring a high-flexibility substrate with reflective coatings, micro-LEDs, and conductive traces, encapsulated by protective layers that maintain light transmissivity and durability, allowing for folding and rolling configurations while ensuring efficient heat dissipation and strain tolerance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the lighting panel is made flexible to allow folding and rolling, then portability and adaptability are improved, but delamination and separation of layers occur during repeated flexing

Engineering Contradiction:

ImproveflexibilityVSAvoiddurability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent employs a composite structure consisting of multiple functional layers including a flexible substrate, reflective layer, light-emitting layer, and protective encapsulant. These layers are bonded together using flexible adhesives that maintain structural integrity during repeated flexing and rolling operations, preventing delamination while preserving the flexibility needed for portability.

Inventive Principle:

Principle #40Composite materials

2Volume of moving object

If the lighting panel is made thin and flexible for compact storage, then volume and weight are reduced, but heat dissipation becomes insufficient

Engineering Contradiction:

ImprovecompactnessVSAvoidheat dissipation

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The patent utilizes a thin-film flexible substrate that serves as both the structural base and a thermal management interface. This flexible substrate is positioned in thermal contact with heat-dissipating elements, allowing efficient heat transfer from the light-emitting components while maintaining the panel's thin profile and flexibility for compact storage.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If protective layers are added to prevent delamination, then durability is improved, but light transmissivity may be compromised

Engineering Contradiction:

ImprovedurabilityVSAvoidlight transmissivity

Core Design Contradiction:

ReliabilityVSIllumination intensity

Solution Approach 1:

The patent employs thin-film protective encapsulants that provide mechanical protection and prevent layer separation while maintaining high optical transparency. These thin protective layers are sufficient to prevent delamination during flexing but thin enough to allow maximum light transmission from the light-emitting elements.

Inventive Principle:

Principle #30Flexible shells and thin films

4Stability of the object's composition

If rigid support structures are used to maintain panel shape, then structural stability is improved, but flexibility and portability are reduced

Engineering Contradiction:

Improvestructural stabilityVSAvoidflexibility

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent employs a flexible substrate with controlled mechanical properties that provides sufficient structural stability to maintain panel shape during operation while remaining flexible enough to allow folding and rolling for portable storage. The substrate's mechanical parameters are optimized to balance rigidity and flexibility.

Inventive Principle:

Principle #35Parameter changes

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 provides a durable, flexible, and efficient lighting solution that maintains light output and thermal management, enabling reliable operation across extreme temperatures and frequent deployment cycles, suitable for military and camping applications.

Implementation Method 1

A flexible lighting panel design featuring a high-flexibility substrate with reflective coatings

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

allowing for folding and rolling configurations while ensuring efficient heat dissipation

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3818298B1Flexible lighting panel and lighting fixture

Publication Date: 2024.10.23 GLOWGADGET LLC

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AI summary

Flexible lighting panel includes a substrate with a conductor pattern and apertures, solid-state light emitters electrically connected to the conductor pattern, a light-transmissive first protective layer covering at least a portion of a first surface of the substrate, and a second protective layer covering at least a portion of a second surface of the substrate. The first and second protective layers are joined to one another through the apertures and the periphery of the substrate to assist in maintaining the light-transmissive first protective layer and the second protective layer against the first and second surfaces of the substrate, respectively. One or both of the first and second protective layers encapsulate the solid-state light emitters. The lighting panel is flexible to allow opposite edges of the lighting panel to be folded over on one another and/or the lighting panel to be rolled into a tubular configuration.