3D Printed Reflector With Varying Corrugations
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Solution Overview
Problem
Fused Deposition Modeling (FDM) 3D printing technologies face challenges in creating specular reflecting elements with high reflectivity, as they often produce structures with low reflectivity and 'ripples' or 'corrugations' that are difficult to control, limiting their use in optical elements like LED luminaires and lighting solutions.
Innovation Solution
The development of a 3D printed reflector with a light transmissive material, featuring a reflector wall with varying corrugation heights, widths, radii, and top-to-top distances, optimized for total internal reflection to achieve high specular reflection, allowing for customized optical performance and improved light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If FDM 3D printing is used to create reflector structures, then manufacturing complexity is reduced and printability is improved, but the reflectivity and optical performance deteriorate due to uncontrollable ripples and corrugations
Solution Approach 1:
The patent applies parameter changes by systematically varying corrugation geometry parameters (height, width, spacing, curvature radius) to optimize optical performance. The method transforms the uncontrolled ripples of FDM printing into controlled corrugations with specific geometric parameters that enable total internal reflection, achieving >90% specular reflectance while maintaining printability
Solution Approach 2:
The patent implements local quality by creating non-uniform corrugation patterns where different sections of the reflector have different corrugation characteristics. This allows optimization of light distribution in specific directions and achieves customized angular distribution of reflected light while maintaining the overall reflector structure
2Shape
If photo-polymerisable materials are used in polyjet technique for mold making, then surface smoothness is improved, but thermal stability and thermal conductivity deteriorate
Solution Approach 1:
The patent uses composite materials by combining light-transmissive polymer material with specific corrugation geometries to achieve both optical and thermal performance. The corrugated structure itself acts as a thermal management feature, providing pathways for heat dissipation while maintaining the light-transmissive properties needed for optical applications
3Productivity
If FDM printing parameters are optimized for speed, then productivity is improved, but manufacturing precision of corrugation geometry deteriorates
Solution Approach 1:
The patent converts the harmful effect of FDM printing artifacts (ripples and corrugations) into a beneficial optical feature. Instead of trying to eliminate these artifacts, the method embraces them and optimizes their geometric parameters to achieve total internal reflection, thereby converting a manufacturing limitation into an optical advantage that enables high reflectivity
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
This approach enables the creation of 3D printed reflectors with high specular reflectance (>90%) and optimized angular distribution of reflected light, suitable for LED-based lamp shades and reflectors, enhancing the performance of lighting systems while maintaining printability and cost-effectiveness.
Implementation Method 1
optimized for total internal reflection to achieve high specular reflection
Implementation Method 2
achieve high specular reflection, allowing for customized optical performance and improved light distribution
Data Source
AI summary
The invention provides a reflector (2) comprising a reflector wall (20), the reflector wall (20) comprising a first wall surface (22) and a second wall surface (23) defining said reflector wall (20), the reflector wall (20) comprising a light transmissive material (21), wherein the reflector wall (20) has a first dimension (d1) and a second dimension (d2) defining a first reflector wall area, wherein each wall surface (22,23) comprises a plurality of parallel arranged elongated corrugations (210), wherein the corrugations have corrugation heights (h2) relative to recesses (220) between adjacent corrugations (210) and corrugation widths (w2) defined by the distance between adjacent recesses (220) at the respective wall surfaces (22,23), wherein the corrugations (210) have curved corrugation surfaces (230) between said adjacent recesses (220) having corrugation radii (r2) at the respective wall surfaces (22,23), and wherein over at least part of one of the first dimension (d1) and the second dimension (d2) one or more of (i) the corrugation heights (h2), (ii) the corrugation widths (w2), (iii) the corrugation radii (r2), and (iv) a shortest top-top distance (w12) of corrugations tops (211) configured at different wall surfaces (22,23) vary over said wall dimension (d1,d2) for at least one of the wall surfaces (22,23). The reflector (2) has a first end (3) and a second end (4), wherein a third distance (d3) between the first end (3) and the second end (4) is bridged by one or more reflector walls (20), wherein the one or more reflector walls (20) are configured tapering from the second end (4) to the first end (3), and wherein the reflector (2) has a reflector cavity (5).