Case Studies Leading automakers reduce costs and increase energy efficiency with Q-Prime

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	Leading automakers reduce costs and increase energy efficiency with Q-Prime

Leading automakers reduce costs and increase energy efficiency with Q-Prime

Technology Category	Sensors - Optical Sensors
Applicable Industries	Automotive
Applicable Functions	Discrete Manufacturing Product Research & Development
Services	Hardware Design & Engineering Services
Challenge	In the automotive industry, style and energy efficiency are paramount. Automakers are increasingly using energy-efficient LED lighting in designs, from taillights to instrument panels. As more products become “smart”, the underlying technologies need to adapt to new shapes and offer powerful functionality in ever-smaller packages. The challenge was to optimize LED solutions for customers in the automotive industry by making the flexible circuit technology lighter, simplifying the design, and reducing costs. Read More
About Customer	The customer in this case study is the automotive industry at large. The industry is characterized by a focus on style and energy efficiency, with an increasing trend towards the use of LED lighting in vehicle designs. This includes applications in taillights and instrument panels. The industry is also marked by the growing prevalence of 'smart' products, necessitating underlying technologies that can adapt to new shapes and offer powerful functionality in increasingly compact packages. The goal for the industry is to optimize LED solutions by making the flexible circuit technology lighter, simplifying the design, and reducing costs. Read More
Solution	The solution involved the development of a more cost-effective LED lighting solution with a simplified design that could dissipate heat more efficiently and better suit the desired vehicle design. The material science and interconnect product development teams at Sheldahl, a Flex company, pushed the boundaries of electrical, thermal, and mechanical requirements for LEDs. The result was Q-Prime, a circuit with a proprietary thermally conductive adhesive and a thin composite structure. This LED lighting solution is flexible for processing, yet has sufficient rigidity to hold shape when bent. Read More Log in to view content
Contents

Technology Category

Sensors - Optical Sensors

Applicable Industries

Automotive

Applicable Functions

Discrete Manufacturing

Product Research & Development

Services

Hardware Design & Engineering Services

Challenge

In the automotive industry, style and energy efficiency are paramount. Automakers are increasingly using energy-efficient LED lighting in designs, from taillights to instrument panels. As more products become “smart”, the underlying technologies need to adapt to new shapes and offer powerful functionality in ever-smaller packages. The challenge was to optimize LED solutions for customers in the automotive industry by making the flexible circuit technology lighter, simplifying the design, and reducing costs.

About Customer

The customer in this case study is the automotive industry at large. The industry is characterized by a focus on style and energy efficiency, with an increasing trend towards the use of LED lighting in vehicle designs. This includes applications in taillights and instrument panels. The industry is also marked by the growing prevalence of 'smart' products, necessitating underlying technologies that can adapt to new shapes and offer powerful functionality in increasingly compact packages. The goal for the industry is to optimize LED solutions by making the flexible circuit technology lighter, simplifying the design, and reducing costs.

Solution

The solution involved the development of a more cost-effective LED lighting solution with a simplified design that could dissipate heat more efficiently and better suit the desired vehicle design. The material science and interconnect product development teams at Sheldahl, a Flex company, pushed the boundaries of electrical, thermal, and mechanical requirements for LEDs. The result was Q-Prime, a circuit with a proprietary thermally conductive adhesive and a thin composite structure. This LED lighting solution is flexible for processing, yet has sufficient rigidity to hold shape when bent.

Impact #1	The Q-Prime circuit has a proprietary thermally conductive adhesive and a thin composite structure, which allows for lower component operating temperatures.
Impact #2	The design of copper on one side and aluminum on the other side disperses heat faster.
Impact #3	The use of aluminum that is 90% thinner than previous solutions results in significant weight reduction.

Impact #1

The Q-Prime circuit has a proprietary thermally conductive adhesive and a thin composite structure, which allows for lower component operating temperatures.

Impact #2

The design of copper on one side and aluminum on the other side disperses heat faster.

Impact #3

The use of aluminum that is 90% thinner than previous solutions results in significant weight reduction.

Benefit #1	Weight reduction with aluminum that is 90% thinner than previous solutions
Benefit #2	Cost reduction by eliminating tools in the manufacturing process

Benefit #1

Weight reduction with aluminum that is 90% thinner than previous solutions

Benefit #2

Cost reduction by eliminating tools in the manufacturing process

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Overview

Leading automakers reduce costs and increase energy efficiency with Q-Prime

Operational Impact

Quantitative Benefit