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EP3263981B1 - Verfahren zur herstellung von optischen elementen für beleuchtungsvorrichtungen und entsprechendes optisches element - Google Patents

Verfahren zur herstellung von optischen elementen für beleuchtungsvorrichtungen und entsprechendes optisches element Download PDF

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Publication number
EP3263981B1
EP3263981B1 EP17178407.7A EP17178407A EP3263981B1 EP 3263981 B1 EP3263981 B1 EP 3263981B1 EP 17178407 A EP17178407 A EP 17178407A EP 3263981 B1 EP3263981 B1 EP 3263981B1
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Prior art keywords
insert
light
optical element
inserts
subset
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EP17178407.7A
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English (en)
French (fr)
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EP3263981A1 (de
Inventor
Alessio SAGLIOCCO
Peter Prodell
Katrin Schroll
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Osram GmbH
Osram SBT GmbH
Osram SpA
Original Assignee
Osram GmbH
Siteco Beleuchtungstechnik GmbH
Osram SpA
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/008—Combination of two or more successive refractors along an optical axis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V17/00—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages
    • F21V17/002—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages with provision for interchangeability, i.e. component parts being especially adapted to be replaced by another part with the same or a different function
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/04—Refractors for light sources of lens shape
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]

Definitions

  • the description relates to lighting devices.
  • One or more embodiments may refer to lighting devices employing electrically-powered light radiation sources, such as solid-state sources, e.g. LED sources.
  • an optical element such as a lens or a reflector may be coupled with the light radiation source.
  • the optical characteristics e.g. the arrangement in space and/or the distribution of the lighting flux, the radiation colour, etc.
  • the optical characteristics are a function of the characteristics of the optical element.
  • optical elements may have accessories, i.e. separate parts, associated therewith, which determine the final operating characteristics of the optical element, and therefore of the corresponding lighting device.
  • This solution may lack efficiency, e.g. because in the final implementation it requires the separate management of the optical element and of the related accessories, which may have different characteristics.
  • One or more embodiments aim at overcoming the above drawbacks.
  • said drawbacks may be overcome thanks to a method having the features set forth in the claims that follow.
  • One or more embodiments may also concern a corresponding device.
  • One or more embodiments lead i.a. to the advantageous achievement of "integrated" optical elements, e.g. giving the possibility of obtaining lighting beams having different optical characteristics (e.g. as regards the radiation pattern, the beam opening angle, to mention a few examples) by using one basic structure of the optical element.
  • reference 10 generally denotes an optical element, adapted to be coupled with an electrically-powered light radiation source L.
  • light radiation source L (which may be an element distinct and separate from the embodiments) may comprise a solid-state light radiation source, e.g. a LED source.
  • optical element 10 may comprise a lens and/or a reflector.
  • optical element 10 may be adapted to perform both functions (of a lens and of a reflector), e.g. as it comprises a lens body made of a light permeable material (e.g. a transparent material) having an at least approximately parabolic external surface, so as to perform in addition (e.g. by having been treated to be reflective towards the inside) the function of a reflector.
  • a light permeable material e.g. a transparent material
  • optical element 10 may comprise two parts:
  • optical characteristics of the light radiation emitted from optical element 10 may be a function of characteristics such as shape, position, material and/or texture of insert 16.
  • insert 16 may be made of a material different from the material of body 12.
  • insert 16 may comprise an at least partially light diffusive material, or a material having in addition a certain opacity (because e.g. it is made of a white or light-coloured material and/or it contains, dispersed therein, light diffusive particles, e.g. alumina), being therefore optionally adapted to (back)scatter the light radiation impinging on insert 16 towards body 12, so that it can subsequently be emitted through output surface 14.
  • insert 16 may have the function of masking source L if device 10 is observed frontally, performing therefore an anti-glare function.
  • insert 16 may comprise, e.g. at an "outer" side extending at light emitting surface 14, a surface sculpturing 160 adapted to perform both an aesthetic and a specific optical function (e.g. said sculpturing being implemented essentially as a Fresnel lens).
  • texture is used herein in its current meaning in graphics, to denote characteristics of insert 16 such as e.g. the colour or the surface finishing of the insert.
  • the optical characteristics of the light radiation emitted through the emitting surface 14 may be at least partially determined by the shape and texture characteristics (e.g. thanks to a reflective treatment such as aluminization) of surface 162 of insert 16, in the position wherein the latter is coupled with body 12 of element 10.
  • said coupling may be achieved e.g. via a (co)moulding process, e.g. in an injection moulding process.
  • Figure 2 exemplifies possible embodiments wherein insert 16 is coupled with body 12 through mechanical coupling.
  • said coupling may be achieved if body 12 comprises a soft, i.e. resilient, optionally elastic material (e.g. silicone), adapted to have optical characteristics as well as mechanical characteristics of resiliency, so that insert 16 may be inserted into a corresponding cavity 120 formed in the body, while deforming body 12 locally.
  • a soft, i.e. resilient, optionally elastic material e.g. silicone
  • insert 16 is adapted to be “captured” by cavity 120 and to be retained therein, e.g., through lip formations 120a adapted to close, so to say, behind insert 16 once the latter is inserted in cavity 120, establishing therefore a sort of hooking coupling.
  • optical elements such as optical elements 10 exemplified in Figures 1 and 2 may be obtained via a method as exemplified in an ideal flow diagram in Figure 3 .
  • block 100 denotes a step wherein a set of optical bodies 12 are provided, adapted to be ideally considered all identical.
  • a corresponding set of optical inserts 16 may be provided, which are to be coupled with bodies 12.
  • said provision of optical inserts 16 may take place in two different ways, i.e. by providing (e.g. in the step exemplified in block 102a) a first subset of inserts 16, which may be defined as "a first type", while in the step exemplified in block 102b, a second subset of optical inserts 16 may be provided.
  • optical inserts of the first set provided in step 102a are different (e.g. as regards shape and/or material) from the inserts of the second subset of step 102b.
  • the result consists in two subsets of optical elements, ideally represented by blocks 106a and 106b which, although having identical optical bodies 12, may have different optical characteristics, especially as regards the features of the light radiation to be emitted from output surface 14. This is due to the fact that such different emission characteristics derive from inserts 16 provided in steps 102a and 102b, with mutually different features.
  • the example shown in Figure 3 refers to only two subsets (102a, 102b) of different inserts 16, adapted to originate two corresponding subsets (106a, 106b) of optical elements 10 having mutually different characteristics.
  • the final user can change the characteristics of optical element 10, e.g. according to application needs or according to aesthetics and tastes which change in time, by simply replacing insert 16 without replacing the optical element 10 as a whole.
  • the embodiments described in the foregoing may be used for any kind of lighting application, including lighting devices both for external applications (such as flood lights, street lights, decorative external lights, gallery lights) or internal applications (such as lighting devices for halls or offices).
  • lighting devices both for external applications (such as flood lights, street lights, decorative external lights, gallery lights) or internal applications (such as lighting devices for halls or offices).
  • external applications such as flood lights, street lights, decorative external lights, gallery lights
  • internal applications such as lighting devices for halls or offices.
  • such lighting devices comprise an optical element with uniform optical characteristics, which at most may comprise lateral reflectors.
  • various embodiments of the present description are based on an optical element 10 comprising at least two parts:
  • the optical characteristics of the body 12 and the insert 16 are different.
  • the optical element 10 may have any form, and has not necessarily a rotational symmetric form with respect to an optical axis as shown in Figure 2 .
  • the radiation source L may be arranged central, e.g. in the axis of a rotational symmetric optical element 10, or any other position still permitting that the light emitted by the radiation source L enters the optical element 10.
  • Figure 4 shows an embodiment of a lighting device again comprising a light radiation source L and an optical element 10, wherein the light radiation source L is located at a side 12a of the body 12.
  • the light radiation source L such as one or more LEDs
  • the light radiation source L is mounted on support 20, such as a printed circuit board, which may be coupled to the side 12a of the optical element 10.
  • the optical element 10 comprises again a body 12 in a material having a first refraction index and an insert 16 having a second refraction index, which is different from the first refraction index, e.g., the first refraction index may be smaller than the second refraction index.
  • the refraction indices for the body 12 and the insert 16 may be between 1.41 (e.g. for silicon) and 1.74 (e.g. for plastic materials doped with oxides).
  • the body 12 and/or the insert 16 may be realized, e.g., with silicon, acrylic (polymethyl methacrylate, PMMA), polycarbonate (PC), polypropylene (PP) or a combination thereof.
  • the optical element may be implemented by coupling the insert 16 to the body 12, e.g. by means of extrusion/co-extrusion, co-moulding, injection moulding, compression moulding, exjection or a combination thereof.
  • the light emitted by radiation source L will pass first through a first refraction surface B' represented by the internal surface of the body 12 enclosing the light source L, thereby entering the body 12. Specifically, a first portion of the light will then exit a refraction surface B represented by the external surface of the body 12 not being in contact with the insert 16, thereby exiting the optical element 10 without passing through the insert 16. Conversely, a second portion of the light will pass a refraction surface B" represented by the external surface of the body 12 being in contact with the insert 16, thereby entering the insert 16. The second portion of the light will then pass a refraction surface B"' represented by the external surface of the insert 16, thereby exiting the insert 16 and the optical element 10.
  • the second portion of the light may be influenced differently by the optical characteristics of the insert 16.
  • the body 12 and the insert 16 (and thus the whole optical element 10) have a rotational symmetric form with respect of an optical axis, wherein the light source L is arranged on the optical axis.
  • the insert 16 represents a lens insert, which may be used to focus the second portion of the light exiting though the fourth refraction surface B"'.
  • the second refraction surface B may be used to emit also light laterally.
  • Figure 5a shows an embodiment of a rotation symmetric optical element 10 comprising also a lateral reflector R. Specifically, the embodiment shows that the light may also exit only through the surface B"' of the insert 16, e.g., because the surface B described with respect to Figure 4 is covered with reflective material, thereby implementing a total internal reflection wall. Moreover, Figure 5a shows that a part of the light emitted by the light source L may directly enter the insert 16 without passing through the body 12.
  • Figure 5b show that the optical element 10 may also comprise a plurality of inserts, i.e. the optical element 10 may comprise three zones 12, 16 and 16s having different optical characteristics.
  • the optical element 10 is again rotation symmetric, but by using materials with different refraction indices for the zones 12 and 16s, the optical element 10 may generate an asymmetric light distribution.
  • Figures 6a and 6b show an embodiment of an optical element 10 having as a whole a rotation symmetric form (similar to what has been described with respect to Figure 4 ), but the insert 16 is displaced with respect to the optical axis. Accordingly, also in this case, an asymmetric light distribution may be obtained.
  • the optical element 10 may have a rotational symmetric form with respect to an optical axis, wherein the light source L may be arranged on this optical axis.
  • the insert 16 may have a rotational symmetric form with respect to an optical axis, which may or may not corresponds to the optical axis of the whole optical element 10.
  • Figure 7 shows an embodiment of a linear optical element 10 having the section of Figure 6a .
  • the optical element is a linear optical element having a symmetric and preferably constant section with respect to a plane.
  • one or more light sources L may be arranged along this plane.
  • the body 12 and the insert 16 may have any form, wherein the surface B" of the body 12 is complementary to the respective surface of the insert 16.
  • the body 12 (and possibly also part of the insert 16) may be covered with a reflective material R.
  • a total internal reflection surface is also implemented by means of the shape of the optical element 10. Specifically, total internal reflection of light occurs also in case a light ray is directed to a flat surface between two materials (e.g., the refraction surface B between the body 16 and air, the refraction surface B" between the body 16 and the insert 12, or the refraction surface B"' between the insert and air) with different refraction index (n1, n2), when the light arrives from a material with higher refraction index (n1).
  • two materials e.g., the refraction surface B between the body 16 and air, the refraction surface B" between the body 16 and the insert 12, or the refraction surface B"' between the insert and air
  • the body 12 and the insert (s) 16 may also have a different diffusive behaviour.
  • the body has a diffusive behaviour.
  • the diffusive material may be in a range of 1 to 30% of the material implementing the body 12 and/or the insert 16.
  • the previously mentioned materials may be used for this purpose a base material, and additional diffusive particles mixed to the base material, such as coloured particles.
  • the body 12 may have a slight diffusive behaviour. Accordingly, while the light near the optical axil will be focused, the lateral light will be broadened.
  • the floor of a corridor may be illuminated specifically with a stronger intensity, while the lateral walls are illuminated via the diffused lateral light with less intensity.
  • the use of a linear optical element 10 may be particular useful.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Claims (10)

  1. Beleuchtungsvorrichtung, die eine Vielzahl von Beleuchtungsquellen (L) und ein lineares optisches Element (10) umfasst, wobei das optische Element (10) beinhaltet:
    - einen Körper (12) des optischen Elements (10), wobei eine innere Oberfläche des Körpers (12) die Lichtquellen (L) umschließt, wobei Licht, das durch die Lichtquellen (L) emittiert wird, durch eine erste Refraktionsoberfläche (B') hindurchgeht, die durch die innere Oberfläche des Körpers (12) dargestellt wird, wobei es in den Körper (12) eintritt, wobei der Körper (12) eine gesamte innere Refraktionsoberfläche (R) umfasst und einen Lichtausbreitungspfad für Licht bereitstellt, welches durch die Lichtquellen (L) emittiert wurde, hin zu einer lichtemittierenden Oberfläche (14) des optischen Elements (10),
    - einen Einsatz (16), der mit dem Körper (12) gekoppelt ist, wobei der Einsatz (16) in dem Lichtausbreitungspfad zwischengeschaltet ist, wobei:
    a) ein erster Teil des Lichts von einer ersten Refraktionsoberfläche (B) austritt, die durch eine äußere Oberfläche des Körpers (12) dargestellt wird, die nicht mit dem Einsatz (16) in Kontakt ist, wobei es aus dem optischen Element (10) austritt, ohne durch den Einsatz (16) hindurchzugehen;
    b) ein zweiter Teil des Lichts durch eine zweite Refraktionsoberfläche (B") hindurchgeht, die durch die äußere Oberfläche des Körpers (12) dargestellt wird, der mit dem Einsatz (16) in Kontakt ist, wobei es in den Einsatz (16) eintritt, wobei die zweite Refraktionsoberfläche (B") des Körpers (12) komplementär zu der jeweiligen Oberfläche des Einsatzes (16) ist, wobei der zweite Teil des Lichts durch eine dritte Refraktionsoberfläche (B"') hindurchgeht, die durch eine äußere Oberfläche des Einsatzes (16) dargestellt wird, wobei es aus dem Einsatz (16) und dem optischen Element (10) austritt;
    wobei die optischen Eigenschaften von Licht, welches von der lichtemittierenden Oberfläche (14) emittiert wird, eine Funktion von zumindest einem von der Form, der Position, dem Material und/oder der Textur des Einsatzes (16) sind, wobei der Refraktionsindex des Körpers (12) kleiner ist als der Refraktionsindex des Einsatzes (16), wobei der Einsatz (16) einen Linseneinsatz darstellt, der konfiguriert ist, um den zweiten Teil des Lichts, welcher durch die dritte Refraktionsoberfläche (B"') austritt, zu fokussieren, und wobei der Körper (12) ein diffusives Verhalten aufweist.
  2. Beleuchtungsvorrichtung nach Anspruch 1, wobei der Körper (12) und der Einsatz (16) zusammen geformt sind.
  3. Beleuchtungsvorrichtung nach Anspruch 1, wobei:
    - der Körper (12) ein elastisches Material beinhaltet,
    - der Einsatz (16) in das elastische Material eingefügt ist, wobei der Einsatz (16) mechanisch durch den Körper (12) zurückgehalten (120a) wird.
  4. Beleuchtungsvorrichtung nach irgendeinem der Ansprüche 1 bis 3, wobei der Einsatz (16) ein Material beinhaltet, das von dem Material des Körpers (12) unterschiedlich ist.
  5. Beleuchtungsvorrichtung nach irgendeinem der Ansprüche 1 bis 4, wobei der Einsatz (16) mit dem Körper (12) an einer Kopplungsoberfläche (162) gekoppelt ist, wobei die optischen Eigenschaften des Lichts, das von der lichtemittierenden Oberfläche (14) emittiert wird, eine Funktion von zumindest einem von der Form und der Textur der Kopplungsoberfläche (162) sind.
  6. Beleuchtungsvorrichtung nach irgendeinem der Ansprüche 1 bis 5, wobei:
    - das optische Element (10) einen symmetrischen Abschnitt mit Bezug zu einer Ebene aufweist, wobei die Lichtquellen (L) entlang der Ebene angeordnet sind.
  7. Beleuchtungsvorrichtung nach irgendeinem der Ansprüche 1 bis 6, wobei die gesamte innere Reflektionsoberfläche implementiert ist:
    - durch Abdecken des Körpers (12) mit einem reflektierenden Material (R); oder
    - durch Mittel von der Form des optischen Elements (10).
  8. Verfahren zum Herstellen von Beleuchtungsvorrichtungen gemäß irgendeinem der Ansprüche 1 bis 7, wobei das Verfahren beinhaltet:
    - Bereitstellen (100) eines Satzes von identischen Körpern (12) für die optischen Elemente (10),
    - Bereitstellen (102a, 102b) eines Satzes von Einsätzen (16), die mit den Körpern (12) koppelbar sind, wobei der Satz von Einsätzen zumindest einen ersten Untersatz (102a) von Einsätzen beinhaltet und zumindest einen zweiten Untersatz (102b) von Einsätzen beinhaltet, wobei die Einsätze in dem ersten Untersatz (102a) unterschiedlich von den Einsätzen in dem zweiten Untersatz (102b) sind, und
    - Koppeln (104a, 104b) der Einsätze (16) mit den Körpern (12) durch Herstellen von zumindest einem ersten Untersatz (106a) und zumindest einem zweiten Untersatz (106b) von optischen Elementen, wobei die optischen Elemente (10) in dem ersten Untersatz (106a) unterschiedlich von den optischen Elementen (10) in dem zweiten Untersatz (106b) sind.
  9. Verfahren nach Anspruch 8, wobei das Koppeln (104a, 104b) ein gemeinsames Formen der Körper (12) und der Einsätze (16) beinhaltet.
  10. Verfahren nach Anspruch 8 oder Anspruch 9, wobei:
    - die Körper (12) ein elastisches Material beinhalten,
    - das Koppeln ein Einfügen der Einsätze (16) in das elastische Material beinhaltet, wobei die Einsätze (16) mechanisch durch die Körper (12) zurückgehalten (120a) werden.
EP17178407.7A 2016-06-28 2017-06-28 Verfahren zur herstellung von optischen elementen für beleuchtungsvorrichtungen und entsprechendes optisches element Active EP3263981B1 (de)

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WO2023237811A1 (en) * 2022-06-07 2023-12-14 Ledil Oy An optical device for modifying a light distribution and a method for manufacturing the same

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