Annular Sector Reflector Sheet with Perpendicular Optical Structures
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Solution Overview
Problem
Current methods for producing custom specular reflectors for lighting devices are costly and lack versatility, with 3D printing unable to produce specular reflecting surfaces and traditional methods resulting in suboptimal light collimation and beam shaping.
Innovation Solution
A starting sheet material shaped as a sector of an annulus, featuring optical structures applied perpendicular to the radial direction, allowing for easy bending into parabolic or truncated cone reflectors while maintaining optical properties and flexibility, and can be produced through 3D printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional deep drawing or segmenting processes are used to produce custom specular reflectors, then manufacturing precision and optical performance are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent changes the manufacturing approach from traditional metal forming (deep drawing, segmenting) to 3D printing with optical structures. By modifying the printing parameters and incorporating optical structures directly into the printed material, the patent achieves comparable optical performance while simplifying the manufacturing process and reducing costs for custom reflectors.
Solution Approach 2:
The patent uses composite material structures by combining 3D printed material with integrated optical structures. These optical structures are embedded within the printed reflector body, creating a composite that achieves specular reflection performance through the combination of the printed substrate and the optical elements, thereby eliminating complex separate manufacturing steps.
2Ease of manufacture
If 3D printing process is used to produce reflectors, then ease of manufacture and customization are improved, but manufacturing precision and optical properties deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-designing and pre-integrating optical structures into the 3D printing process. The optical structures are programmed into the printing workflow beforehand, ensuring that the necessary optical properties are built into the reflector during manufacturing rather than requiring post-processing or assembly, thus maintaining both ease of manufacture and optical precision.
Solution Approach 2:
The patent applies local quality by incorporating optical structures at specific locations within the 3D printed reflector where they are most needed for optical performance. The optical structures are strategically positioned and sized to provide the necessary light control functions while maintaining the overall simplicity and customization benefits of 3D printing.
3Illumination intensity
If optical structures are applied perpendicular to the radial direction, then light collimation and beam shaping are improved, but the complexity of the starting sheet material increases
Solution Approach 1:
The patent applies dimensionality change by transitioning from traditional radial optical structures to structures oriented perpendicular to the radial direction. This dimensional reorientation enables improved light collimation and beam shaping by exploiting a different geometric configuration, while the structures remain integrated into the simple annular sector format of the starting sheet material.
4Ease of manufacture
If the flat reflective sheet material is made flexible for easy bending, then ease of manufacture is improved, but manufacturing precision of the final reflector shape may deteriorate
Solution Approach 1:
The patent uses flexible shells and thin films by employing a flexible flat reflective sheet material that can be easily bent into the required reflector shapes (parabolic or truncated cone). The flexibility is achieved through appropriate material selection and thickness control, while the final shape accuracy is ensured by the integrated optical structures that guide the light paths regardless of minor dimensional variations.
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 high degree of design versatility, cost-effectiveness, and efficient light collimation and beam shaping, maintaining the flexibility of the sheet material and achieving similar optical effects to traditional reflectors.
Implementation Method 1
optical structures enabling collimation and/or beam shaping of incident light
Implementation Method 2
flat reflective sheet material comprising a first surface, a second surface
Data Source
AI summary
Starting sheet material (1) adapted for forming a reflector (2) for a lighting device (40), the starting sheet material (1) comprising a flat reflective sheet material (14) shaped as a sector of an annulus bendable into a parabolic reflector or a truncated cone reflector, the flat reflective sheet material (1) comprising a first surface (3), a second surface (4), a first edge (5) shaped as a segment of a circle with a first radius and a second edge (6) shaped as a segment of a circle with a second radius, the second radius being smaller than the first radius, a third edge (7) and a fourth edge (8), the third edge (7) and the fourth edge (8) extending between said first edge (5) and said second edge (6), wherein optical structures (9) are provided on at least a part of one of the first surface (3) and the second surface (4), said optical structures (9) enabling collimation and beam shaping of incident light, said optical structures (9) being applied to the flat reflective sheet material (14) along a direction (11) perpendicular to the radial direction (12) of the flat reflective sheet material (1).