Fabrication of Micro-structured LED Diffusion Plate Via Precision Grinding and Injection Molding

In this chapter, a new micro-structured diffusion sheet for LED (light-emitting diode) was developed by combining efficient and precise hybrid processing methods with micro-injection molding and micro-grinding, enabling cost-effective large-scale production of LED lamps with excellent light output. First, the mold core of the microstructure is machined to a controlled shape and surface quality using a precision V-shaped grinding wheel. Secondly, the micro-structured LED diffu-sion plates were rapidly processed by micro-injection molding technology. Finally, the effect of microinjection molding process parameters on the illumination of the micro-structured diffuser plate was investigated. According to the simulated optical results the illumination of the micro-structured diffuser plate can reach the highest value when the V-groove depth and V-groove angle are calculated as 300 µm and 60°, respectively. The experimental results show that the developed micro-structured diffuser plate can enhance the illuminance by about 40.82% compared to the conven-tional diffuser plate. The prediction accuracy of the developed illumination efficiency simulation method is 90.33%.