Transparent Reflector with Sawtooth Structures for Lighting
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Solution Overview
Problem
Existing electroplated reflectors in lighting devices have low light-emitting efficiency due to high light absorption rates of their metal coatings and are costly to produce.
Innovation Solution
A reflecting device comprising two transparent optical elements, a first optical element acting as a lens to adjust light emergent angles and a second optical element with sawtooth structures on its surface to achieve total reflection without the need for plating, enhancing light distribution and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If electroplated reflector with metal film coating is used, then light reflection function is achieved, but light absorption rate increases and light-emitting efficiency decreases
Solution Approach 1:
The patent removes the metal film coating layer from the reflector surface, extracting the harmful light-absorbing component while retaining the reflector's structural function. The transparent reflector body itself performs the reflection function without needing the metal coating, thereby eliminating the 5-12% light absorption loss associated with electroplated surfaces.
Solution Approach 2:
The patent replaces expensive electroplated metal film coatings with a simple transparent material structure. The transparent reflector achieves its function through geometric design rather than costly material coating, significantly reducing manufacturing costs and material waste while maintaining or improving light-emitting efficiency.
2Reliability
If electroplated reflector with metal coating is used, then light reflection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the metal film coating process from the manufacturing workflow. By using a transparent reflector where the substrate itself provides the reflection function through its geometric shape and refractive properties, the complex electroplating工序 is removed, simplifying manufacturing and reducing costs.
Solution Approach 2:
The patent replaces the chemical/electrical electroplating process with a purely geometric and optical solution. The transparent reflector's shape and material properties provide the necessary light reflection function without requiring metal deposition processes, thereby eliminating associated manufacturing complexity and cost.
3Ease of manufacture
If transparent reflector with sawtooth structures is used, then total reflection is achieved without plating, but device complexity increases
Solution Approach 1:
The patent employs curved surfaces including sawtooth structures and arc-shaped reflection surfaces on the transparent reflector. These geometric features guide light paths to achieve total internal reflection without metal coating. The curvature and angular structures are integrated into the single transparent component, making the complexity inherent to the design rather than added through separate coating processes.
Solution Approach 2:
The patent uses a transparent material with specific refractive index properties to achieve total internal reflection. The combination of the transparent substrate material and its geometric structures creates a composite optical system that provides reflection functionality without metal films, where the material properties and geometric design work together to control light paths.
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 results in a lighting device with improved light-emitting efficiency and reduced costs, as the transparent reflector achieves total reflection without the need for a plating process, enhancing both performance and economic viability.
Implementation Method 1
the outer surface includes a plurality of successively arranged sawtooth structures... achieve total reflection without the need for plating
Implementation Method 2
the first optical element has a light incident surface and a light emergent surface... acting as a lens to adjust light emergent angles
Data Source
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AI summary
A reflecting device (10, 10a, 10b, 10c, 10d), a light source module (100, 100a, 100b, 100c, 100d) and a lighting device (100e, 100f) are provided. The reflecting device (10, 10a, 10b, 10c, 10d) includes a first optical element (12, 4e, 4f) and a second optical element (13, 5e, 5f); the first optical element (12, 4e, 4f) and the second optical element (13, 5e, 5f) are both transparent; the second optical element (13, 5e, 5f) has a side wall (130, 130a, 130b, 130c, 130d, 50e) and a light emergent port (14, 14a, 14b, 14c, 14d, 54e); the side wall (130, 130a, 130b, 130c, 130d, 50e) encloses an optical space (501e) in communication with the light emergent port (14, 14a, 14b, 14c, 14d, 54e); the first optical element (12, 4e, 4f) is surrounded by the side wall (130, 130a, 130b, 130c, 130d, 50e) of the second optical element (13, 5e, 5f) and extends into the optical space (501e); the first optical element (12, 4e, 4f) has a light incident surface (121, 41e) and a light emergent surface (122, 42e); and the light incident surface (121, 41e) encloses an accommodating chamber (120, 410e). The lighting device (100e, 100f) provided by the present disclosure involves low costs and has high light-emitting efficiency because the reflecting device (10, 10a, 10b, 10c, 10d) therein is incorporated with two types of optical elements (12, 4e, 4f, 13, 5e, 5f), the first optical element (12, 4e, 4f) is a commonly used lens for adjusting a light emergent angle, the second optical element (13, 5e, 5f) is a transparent reflector for changing a light emergent direction, and the reflector (13, 5e, 5f) does not need to be subjected to a plating process to achieve a total reflection effect.