"One of the issues we face all the time is the wide difference between data sheets and what the supplier actually produces." - Mark Bent, SunNight Solar

Bent discusses dual-purpose solar lights, time-to-market concerns and the things that keep him up at night.

SunNight Solar is a company dedicated to delivering products that solve problems plaguing the developing world.

In 2008, SunNight Solar produced a dual-purpose solar light to serve as both a lamp and a flashlight for communities where there is limited or no access to electricity. The solar flashlight is based on a solution that SunNight Solar found through InnoCentive's open innovation web site - which acts ostensibly as the company's research and development team.

The device is now being used in African villages, the Gaza Strip, and other areas to provide sufficient light for security at night, enabling children to study and allowing family members to safely walk outdoors after dark.

PD&D Design Daily: How does the design and development for solar flashlights differ from standard flashlights?

Mark Bent, CEO, SunNight Solar: The two main areas are the panel and the circuit board, neither of which are present on conventional flashlights.

The dual-purpose solar light serves as both a lamp and a flashlight with 800 MaH AA NiMH batteries that last 500 to 750 cycles.

The circuit boards are, in reality, a power management system. We have three circuit boards in the light - one for the LEDs, one for the switch and one main one, which controls everything. The big advantage is that it can ensure proper care of the batteries - so they are not overcharged or run all the way to zero.

We also run the LEDs very carefully and have it set so that the illumination will be at a steady rate - not bright at the beginning and a steady fade - we run at full and then drop down when the batteries have 15 percent left.

PD&D: How long will the product last?

Bent: We have 800 MaH AA NiMH batteries, which will last 500 to 750 cycles.They can be replaced easily. We have UV retardant in the ABS plastic.The lights - if used every night, will last for probably 5 to 7 years - the epoxy which covers the solar panel will darken gradually with UV hitting it daily. In the developed world, where most people leave it on an interior window ledge and use only for emergencies or for camping, the solar flashlight should last for many years.

PD&D: What was the biggest design challenge you faced during development?

Bent: Getting the light to illuminate a room. This is where the Rockefeller/InnoCentive partnership came in so helpful - actually, 100 percent essential to getting us to where we are today. We have the only hand-held solar powered light which fits into your pocket, but also lights a room. Without the room lighting, we are just another solar flashlight - with it - we replace kerosene lanterns in the developing world.Huge.

PD&D: What key features do you look for when choosing components?

Bent: Cost, reliability and performance. One of the issues we face all the time is the wide difference between data sheets and what the supplier actually produces. We have a very robust in-house testing programand are frequently surprised at the variations in components from the same supplier. Test, test and re-test.

PD&D: What are the most vital components in the flashlights?

Bent: LEDs.The batteries and the panels are fairly similar regardless of the supplier. But the variation in the LEDs between types and manufactures is huge.

PD&D: What qualities do you look for when choosing a component supplier?

Bent: Cost is important, of course. But we often do not choose the cheapest component, which surprises our suppliers. Most have been beat up so much over pricing that they are surprised when we buy an upgraded component. Since our lights have to work in really rough climates and environments, a few pennies more is actually okay with us if we can be very sure it will work and work for a long time.

PD&D: What was the size of your development team?

Bent: Well, how big is the world?With InnoCentive, we have the ability to reach out to such a wide group. So, my research and development costs are limited - I pay for what I need when I need it - so we are way ahead of some our competitors in this area.

PD&D: Looking at the current state of the industry, what keeps you up at night?

Bent: Too many possibilities - the whole concept of solar-powered consumer products is an untapped field for the most part and the future is positive.