Design method of LED rear fog lamp based on freeform micro-surface reflectors

Abstract

We propose a practical method for the design of a light-emitting diode (LED) rear fog lamp based on freeform micro-surface reflectors. The lamp consists of nine LEDs and each of them has a freeform micro-surface reflector correspondingly. The micro-surface reflector design includes three steps. An initial freeform reflector is first built based on the light energy maps. The micro-surface reflector is then constructed on the bias of the initial one. Finally, a two-step method is designed to optimize the micro-surface reflector. With the proposed method, a module is designed and LCW DURIS E5 LED source whose emitting surface is 5.7 mm × 3.0 mm is adopted for simulation. A prototype is also assembled and fabricated to verify the real performance. Both the simulation and experimental results demonstrate that the luminous intensity distribution can well fulfill the requirements of ECE No.38 regulation. Furthermore, more than 79% energy can be saved when compared with the rear fog lamps using conventional sources.