Reflector Microstructures for Light Uniformity and Demoulding
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Solution Overview
Problem
Conventional reflectors with microstructures on their inner surfaces face manufacturing challenges due to limited draft angles, making it difficult to achieve angles greater than 80 degrees between the inner surface and the horizontal plane, which hinders effective light distribution and uniformity in lighting devices.
Innovation Solution
A reflector design featuring microstructures with a first surface perpendicular to the horizontal plane and a second curved surface, where the microstructures are located on the same side of a vertical plane intersecting the starting edge, allowing for larger angles and facilitating demoulding during manufacturing, while ensuring light uniformity and beam angle adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional microstructures with arc surfaces are used on the inner surface of the reflector, then light distribution control is achieved, but demoulding cannot be achieved when the angle between the inner surface and horizontal plane exceeds 80 degrees
Solution Approach 1:
The microstructure is divided into two distinct surfaces: a first surface (arc surface) for light distribution control and a second surface (curved surface) for demoulding. This segmentation allows each surface to independently fulfill its specific function without compromising the other.
Solution Approach 2:
Different surfaces of the microstructure are given different geometric properties: the first surface has an arc shape optimized for light reflection and distribution, while the second surface has a curved shape specifically designed to enable demoulding. Each local region of the microstructure has quality tailored to its functional requirement.
2Manufacturing precision
If the angle between the inner surface of the reflector and the horizontal plane is increased to improve light distribution, then light uniformity is improved, but the draft angle limitation prevents manufacturing
Solution Approach 1:
The solution moves from considering only the inner surface geometry to incorporating a second surface on the microstructure. This dimensional addition allows the reflector to achieve large angles for light uniformity while the second surface provides the necessary draft angle for manufacturing.
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
Enables the processing and manufacturing of reflectors with larger angles, achieving improved light distribution and uniformity, and enhancing the beam angle control, thus overcoming the demoulding issues in conventional designs.
Implementation Method 1
an inner surface of the reflector is mainly processed by the following treatments: a mirror treatment, a frost treatment, and a surface microstructure treatment
Data Source
AI summary
The present disclosure provides a reflector and a light source module. The reflector is provided with a first end surface and a second end surface opposite to each other; an inner surface of the reflector has a plurality of microstructures, an outer surface of at least one of the plurality of microstructures includes a first surface and a second surface, the second surface is a curved surface, the first surface has a starting edge and an ending edge opposite to the starting edge, the ending edge is connected with the second surface, at least one of the plurality of microstructures is located on a same side of a vertical plane that intersects the starting edge and is perpendicular to the first end surface. The reflector and the light source module can change the uniformity and the beam angle of the light, meanwhile, can ensure the achievability of the processing and manufacturing.