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Fabrication of Micro-Structured LED Diffusion Plate Using Efficient Micro Injection Molding and Micro-Ground Mold
Yanjun Lu1, Wang Luo1, Xiaoyu Wu1
1Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China.
Polymers
|June 12, 2020
Summary
A novel micro-structured LED diffusion plate was developed using hybrid processing, improving illumination by 40.82%. This cost-effective method enables mass production of high-performance LED lamps.
Area of Science:
- Optics and Photonics
- Materials Science
- Manufacturing Engineering
Background:
- Traditional LED diffusion plates lack optimal light distribution and efficient manufacturing methods.
- Mass production of advanced LED components requires cost-effective and precise fabrication techniques.
Purpose of the Study:
- To develop a novel micro-structured LED diffusion plate using a hybrid processing method.
- To achieve mass production and low-cost manufacturing of LED lamps with enhanced lighting performance.
- To investigate the impact of micro injection molding parameters on illumination characteristics.
Main Methods:
- Hybrid processing combining micro injection molding and micro-grinding technology.
- Machining of micro-structured mold core using a precision V-tip grinding wheel.
- Fabrication of micro-structured LED diffusion plates via micro injection molding.
Main Results:
- Optimized V-groove depth (300 μm) and angle (60°) maximize illumination.
- Experimental results show a 40.82% illumination improvement over traditional plates.
- The light efficiency simulation method achieved a prediction accuracy of 90.33%.
Conclusions:
- The developed micro-structured LED diffusion plate significantly enhances illumination performance.
- The hybrid processing method is suitable for mass production and low-cost manufacturing of advanced LED components.
- Precise control over micro-structure design and manufacturing parameters is crucial for optimizing LED lighting performance.
