Metallic LED Reflector with Annular Conical Sidewalls
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Solution Overview
Problem
Conventional LED reflectors are inefficient in reflecting light emitted at high angles, require costly molds for minor shape changes, and are not easily adaptable for different lighting applications, leading to high production costs and installation challenges.
Innovation Solution
A metallic reflector device with a planar base and annular conical sidewall elements, made from aluminum with a high reflective surface, which can be formed to accommodate LEDs and other light sources, allowing for efficient reflection of light at high emission angles and easy integration into various lighting systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional plastic molding techniques are used to construct reflectors, then the reflector can be manufactured with a reflective coating, but the initial capital cost for molds is high and minor changes require new molds
Solution Approach 1:
The patent transitions from plastic molding to metal sheet forming, where the reflector is created by forming metal sheets into desired shapes. This allows minor changes in size, orientation, or shape to be achieved through simple adjustments in the forming process rather than requiring new molds, significantly reducing the cost of adaptability.
Solution Approach 2:
The patent eliminates the need for expensive, reusable molds by using a process where metal sheets are formed directly into the desired reflector shapes. This approach replaces the high initial capital cost of mold fabrication with a more flexible, lower-cost forming process that can be easily adjusted.
2Illumination intensity
If refracting optics are used to direct light from LEDs, then light can be controlled and directed in a predetermined direction, but the lens must be supported separately and installation is complex
Solution Approach 1:
The patent combines the reflector function with the mounting structure into a single integrated component. The reflector is formed as one piece with mounting features that allow direct attachment to the LED device or PCB, eliminating the need for separate lens supports and simplifying installation while maintaining light direction control.
3Reliability
If conventional plastic reflectors with metallized surfaces are used, then a reflective finish can be provided, but production costs are high and removal of improperly installed reflectors is time consuming
Solution Approach 1:
The patent uses metal sheets that can be easily formed and attached, allowing for quick installation and removal. The metal sheet construction provides a durable reflective surface while enabling easy adjustment or replacement without the time-consuming removal process associated with permanently affixed plastic reflectors.
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 metallic reflector device effectively directs and reflects light from LEDs at high angles, reducing production costs and installation complexity while providing a versatile solution for various lighting applications.
Implementation Method 1
A metallic reflector device with a planar base and annular conical sidewall elements, made from aluminum with a high reflective surface, which can be formed to accommodate LEDs and other light sources, allowing for efficient reflection of light at high emission angles
Data Source
AI summary
A metallic reflector device having one or an array of individual reflector elements for positioning over a corresponding one or array of light sources, preferably comprising one or more light emitting diodes (LEDs). The metallic reflector device includes a planar base and a plurality of the reflector elements. The planar base has one or a plurality of apertures, each aperture having an edge that defines a proximal rim of the reflector element. Each reflector element includes an annular sidewall having an inner surface that extends from the proximal annular rim to a distal annular rim. The proximal annular rim defines a first opening through which direct and reflected light from a light source is emitted. The distal annular rim defines a second opening through which the light source is disposed. The inner surface of the annular sidewall is formed from the material of the planar sheet by mechanically deforming the planar sheet, such as by stamping or drawing.