CN103363443B - A kind of total reflection lens and forming method thereof - Google Patents
A kind of total reflection lens and forming method thereof Download PDFInfo
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- CN103363443B CN103363443B CN201310318246.9A CN201310318246A CN103363443B CN 103363443 B CN103363443 B CN 103363443B CN 201310318246 A CN201310318246 A CN 201310318246A CN 103363443 B CN103363443 B CN 103363443B
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Abstract
The invention discloses a kind of total reflection lens, it includes planar lens portion, the bottom in described planar lens portion is formed with planoconvex spotlight portion and mirror part to downward-extension, described planoconvex spotlight portion to be positioned within mirror part and to be provided with an air barrier therebetween, the bottom in described planoconvex spotlight portion offers depressed part, described depressed area is in the focus place of mirror part, and the reflector shape of this mirror part is identical with the fully reflecting surface shape in planoconvex spotlight portion.This total reflection lens, by the reasonable setting to planoconvex spotlight portion and mirror part structure, improves the total reflection efficiency of LED light source, diffuse reflection efficiency and Luminescence Uniformity, and decreases light loss.
Description
Technical field
The present invention relates to a kind of lens and forming method thereof, particularly relate to a kind of total reflection lens and forming method thereof.
Background technology
Along with the fast development of LED illumination technology, LED lamp because of its there are energy-saving and environmental protection, the life-span is long, operating voltage is low and the advantage of the aspects such as various shapes, cause the extensive concern of scientific and technological circle and industrial quarters, become the novel illumination light source that conventional lamp is incomparable.At present, the luminous efficiency of LED lamp is own higher than incandescent lamp, even exceed fluorescent lamp, its energy-saving effect is very remarkable, based on these advantages, LED illumination technology is extended to each application just at faster speed, such as, is mainly used in large-size liquid crystal television backlight, automobile, commercial and industrial illumination.
In existing lighting, most employing LED light source, and after LED light source and secondary light-distribution combine with technique, form various product, this LED light source comprises LED, substrate etc., having the performance requirement that important in LED light source product, be exactly require very high to the light extraction efficiency of light source and Luminescence Uniformity, and problems is one of bottleneck of current LED light source product.Such as, scioptics carry out in the process of secondary light-distribution to LED light source, be mostly lens are made hemispherical, LED light source is fixedly installed in the bottom of lens, when the light that LED light source sends is injected within lens, directional light is wherein directly by the end face outgoing of lens, the scattered light in other directions is totally reflected at the critical Surface forming of lens, obtain directional light afterwards or trend towards parallel light, wherein, by the manufacturing process of lens, the impact of material and curve form, some light is in the direct outgoing in curved surface place of lens or leakage, thus cause light loss, light extraction efficiency is reduced, cause the luminous efficiency of LED lamp poor, in order to improve luminous efficiency, market there is the LED light source that COB encapsulates, namely in LED light source, multiple LED chip is encapsulated, because LED chip arrangement is intensive, the light of adjacent LED chip easily forms ghost image, so still can light loss be caused and Luminescence Uniformity is not high.
Summary of the invention
The technical problem to be solved in the present invention is, a kind of total reflection lens and forming method thereof are provided, adopt the total reflection lens that this forming method is produced, by the reasonable setting to planoconvex spotlight portion and mirror part structure, improve the total reflection efficiency of LED light source, diffuse reflection efficiency and Luminescence Uniformity, and decrease light loss.
For solving the problems of the technologies described above, the present invention adopts following technical scheme.
A kind of total reflection lens, it includes planar lens portion, the bottom in described planar lens portion is formed with planoconvex spotlight portion and mirror part to downward-extension, described planoconvex spotlight portion to be positioned within mirror part and to be provided with an air barrier therebetween, the bottom in described planoconvex spotlight portion offers depressed part, described depressed area is in the focus place of mirror part, and the reflector shape of this mirror part is identical with the fully reflecting surface shape in planoconvex spotlight portion.
Preferably, described planar lens portion is that bar shaped is arranged, and described planoconvex spotlight portion and mirror part extend along the length direction in planar lens portion.
Preferably, described depressed part is that slit-like is arranged.
Preferably, the quantity of described depressed part is multiple, and multiple depressed part sets gradually along the length direction in planoconvex spotlight portion with preset pitch.
Preferably, the setting in the form of annular discs of described planar lens portion, described planoconvex spotlight portion is hemispherical setting, and described mirror part is surrounded on this planoconvex spotlight portion.
Preferably, described planar lens portion, planoconvex spotlight portion and mirror part are one-body molded.
Preferably, described planar lens portion and planoconvex spotlight portion one-body molded, described planar lens portion is fixedly connected with mirror part.
A kind of total reflection lens forming method, the method comprises the steps:
Step one, build the fully reflecting surface structure in planoconvex spotlight portion, with the Central Symmetry direction of principal axis in planoconvex spotlight portion for Y direction, with the direction perpendicular to this Y-axis for X-direction, set up rectangular coordinate system, the fully reflecting surface in this planoconvex spotlight portion is determined by following formula:
In above formula, m is the refractive index in planoconvex spotlight portion, LED light source depressed part sidewall be projected as A point, r is the distance of LED light source to A point, and a is the angle of incident light and Y-axis;
Step 2, by above-mentioned formula simultaneous, obtains the curvilinear equation discrete solution of this fully reflecting surface:
Step 3, according to the fixed position of LED light source and the size of LED light source, determines the initial point of curve, carries out differential afterwards solve according to Runge-Kutta method, obtains the shape of the fully reflecting surface in planoconvex spotlight portion and each point coordinates;
Step 4, builds the reflecting surface structure of mirror part, and obtains the reflector shape of mirror part and each point coordinates according to step one to step 3;
Step 5, builds the bottom curved-surface structure of depressed part, and light curved surface bottom this being injected to planoconvex spotlight portion collimates, and bottom this, the curvilinear equation of curved surface is determined by following formula:
y
1=cota·x
y
2=k
2·(x-Xn)+Yn
In above formula,
k1 is the slope of light source to the straight line of Pn+1 point, and k2 is the slope of the tangential equation of Pn point, and this Pn+1 and Pn is 2 points of infinite approach on curved surface bottom this, after above formula simultaneous, obtains:
According to the angle threshold of LED light source emitted light, determine critical ray and the intersection point of curved surface bottom this, obtain the initial point of curved surface bottom this, carry out differential according to Runge-Kutta method afterwards and solve, obtain the bottom curve form of depressed part and each point coordinates;
Step 6, is emulated by the bottom curve form of computer to the shape of fully reflecting surface in above-mentioned planoconvex spotlight portion, the reflector shape of mirror part and depressed part and is revised, obtain total reflection lens model;
Step 7, imports extruder for shaping by total reflection lens model.
Preferably, the making material of described total reflection lens is polymethyl methacrylate or Merlon.
Total reflection lens disclosed by the invention, the scattered light that LED light source injects planoconvex spotlight portion is reflected into directional light by fully reflecting surface, then to be returned by the light reflection do not utilized in 0 ° to 180 ° angle within planoconvex spotlight portion by mirror part and form directional light.Because the reflector shape of mirror part is identical with the fully reflecting surface shape in planoconvex spotlight portion, the light that the fully reflecting surface in planoconvex spotlight portion is leaked can be reflected back through mirror part within planoconvex spotlight portion, and be provided with air barrier therebetween, can avoid causing harmful effect to the total reflection ability in planoconvex spotlight portion by this air barrier.The present invention compared to existing technologies, its beneficial effect is: utilize planoconvex spotlight portion to achieve the optical alignment of major part, after by mirror part the some light that planoconvex spotlight portion reveals being reflected into directional light again, be back within planoconvex spotlight portion, thus improve the total reflection efficiency of LED light source, diffuse reflection efficiency and Luminescence Uniformity, and decrease light loss.
Accompanying drawing explanation
Fig. 1 is the overall structure schematic diagram of the total reflection lens that the present invention proposes.
Fig. 2 is the side view of the total reflection lens that the present invention proposes.
Fig. 3 for shown in Fig. 2 along the sectional view of A-A line.
Fig. 4 is the local curve figure of the fully reflecting surface in planoconvex spotlight portion.
Fig. 5 is the local curve figure of the bottom curved surface of depressed part.
Detailed description of the invention
Below in conjunction with drawings and Examples, the present invention is described in more detail.
The invention discloses a kind of total reflection lens, shown in composition graphs 1 to Fig. 3, described total reflection lens includes planar lens portion 1, the bottom in described planar lens portion 1 is formed with planoconvex spotlight portion 2 and mirror part 3 to downward-extension, described planoconvex spotlight portion 2 to be positioned within mirror part 3 and to be provided with an air barrier 4 therebetween, the bottom in described planoconvex spotlight portion 2 offers depressed part 5, described depressed part 5 is positioned at the focus place of mirror part 3, and the reflector shape of this mirror part 3 is identical with the fully reflecting surface shape in planoconvex spotlight portion 2.In this total reflection lens, LED light source is arranged within depressed part 5, the scattered light being injected planoconvex spotlight portion 2 by this LED light source is reflected into directional light by fully reflecting surface, and the light do not utilized in 0 ° to 180 ° angle to be come back to through the reflection of mirror part 3 within planoconvex spotlight portion 2 and to form directional light, the above-mentioned light do not utilized comprises the fully reflecting surface of failing in planoconvex spotlight portion 2 and reflection occurs and leaks to the light of mirror part 3, because the reflector shape of mirror part 3 is identical with the fully reflecting surface shape in planoconvex spotlight portion 2, air barrier 4 is made to have uniform thickness, and the total reflection layer in planoconvex spotlight portion 2 is not destroyed, thus obtain better full launching effect.
About the concrete structure of this total reflection lens, the present invention proposes following embodiment:
Embodiment 1:
In the present embodiment, described planar lens portion 1 is arranged in bar shaped, described planoconvex spotlight portion 2 and mirror part 3 extend along the length direction in planar lens portion 1, based on the planoconvex spotlight portion 2 that bar shaped is arranged, described depressed part 5 is arranged in slit-like, the depressed part 5 that this slit-like is arranged can be used for placing LED lamp bar, or the LED point light source of arranging successively.But in other embodiments of the invention, the quantity of described depressed part 5 is multiple, and multiple depressed part 5 distributes along the length direction in planoconvex spotlight portion 2 successively with preset pitch, can place LED point light source respectively within each depressed part 5.The advantage of the present embodiment is, the multiple LED light source of accessible site in the planar lens portion arranged in bar shaped, and is applicable to the illuminating product that fluorescent tube etc. has certain length.
Embodiment 2:
The difference that the present embodiment compares embodiment 1 is, the setting in the form of annular discs of described planar lens portion 1, and described planoconvex spotlight portion 2 is in hemispherical setting, and described mirror part 3 is surrounded on this planoconvex spotlight portion 2.The total reflection lens of this structure is applicable to the application scenario of single LEDs light source, and its small volume, application flexibility are good.
Embodiment 3:
In the present embodiment, planar lens portion 1, planoconvex spotlight portion 2 and mirror part 3 are one-body molded, and the total reflection lens of this structure, by extrusion equipment together machine-shaping, contributes to reducing production stage.
Embodiment 4:
The compare difference of embodiment 3 of the present embodiment is, planar lens portion 1 and planoconvex spotlight portion 2 are one-body molded, described planar lens portion 1 is fixedly connected with mirror part 3, this planar lens portion 1 is made up of optical resin material with planoconvex spotlight portion 2, this mirror part 3 is made up of PC material, this PC material and Merlon.Wherein, planoconvex spotlight portion 2 and mirror part 3 can be processed respectively, carry out concatenation more afterwards, and the total reflection lens of this structure has the advantage being easy to produce, process.
In order to realize technical scheme of the present invention better, for the design feature of above-mentioned total reflection lens, the forming method implementing total reflection lens of the present invention comprises the steps:
Step one, build the fully reflecting surface structure in planoconvex spotlight portion 2, due to the rotational symmetry in planoconvex spotlight portion 2, only need determine that its rotating curve gets final product complete design, shown in composition graphs 3 and Fig. 4, with the centre of luminescence of LED light source point for initial point, with the Central Symmetry direction of principal axis in planoconvex spotlight portion 2 for Y direction, with the direction perpendicular to this Y-axis for X-direction, set up rectangular coordinate system, the direction of arrow in this coordinate system is radiation direction, effect due to planoconvex spotlight portion 2 is to collimate light, so, light through planoconvex spotlight portion 2 outgoing should be parallel to Y-axis, wherein, y=fx curve is the rotary generatrix of fully reflecting surface, Pn is a bit on rotary generatrix, A(r, 0) be the opening part A point of depressed part 5, a is the angle of incident ray and Y-axis, B point is the intersection point of this light and depressed part 5, b and c is respectively the incidence angle of light at depressed part 5 place and the angle of emergence, the fully reflecting surface in light and planoconvex spotlight portion 2 intersects at Pn+1 point, the angle of reflection of this point is d, Pn and Pn+1 is 2 points of infinite approach on above-mentioned curve, then the connecting line of point-to-point transmission is the tangential direction of the fully reflecting surface in planoconvex spotlight portion 2, according to the law of refraction:
msinc=sinb=cosa
Obtain fully reflecting surface equation:
Meanwhile, according to the relation of B point and Pn+1 point, obtain:
In above formula, m is the refractive index in planoconvex spotlight portion 2, LED light source depressed part 5 sidewall be projected as A point, r is the distance of LED light source to A point, and a is the angle of incident light and Y-axis;
Step 2, by above-mentioned formula simultaneous, obtains the curvilinear equation discrete solution of this fully reflecting surface:
Step 3, according to the fixed position of LED light source and the size of LED light source, determines the initial point of curve, carries out differential afterwards solve according to Runge-Kutta method, obtains the shape of planoconvex spotlight portion 2 fully reflecting surface and each point coordinates;
Step 4, builds the reflecting surface structure of mirror part 3, and obtains the reflector shape of mirror part 3 and each point coordinates according to step one to step 3;
Step 5, builds the bottom curved-surface structure of depressed part 5, and light curved surface bottom this being injected to planoconvex spotlight portion 2 collimates, and bottom this, the curvilinear equation of curved surface is determined by following formula:
y
1=cota·x
y
2=k
2·(x-Xn)+Yn
In above formula,
k1 is the slope of light source to the straight line of Pn+1 point, and k2 is the slope of the tangential equation of Pn point, and this Pn+1 and Pn is 2 points of infinite approach on curved surface bottom this, after above formula simultaneous, obtains:
According to the angle threshold of LED light source emitted light, determine critical ray and the intersection point of curved surface bottom this, obtain the initial point of curved surface bottom this, carry out differential according to Runge-Kutta method afterwards and solve, obtain the bottom curve form of depressed part 5 and each point coordinates;
Step 6, is emulated by the bottom curve form of computer to the shape of above-mentioned planoconvex spotlight portion 2 fully reflecting surface, the reflector shape of mirror part 3 and depressed part 5 and is revised, obtain total reflection lens model;
Step 7, imports extruder for shaping by total reflection lens model, in actual applications, realizes extrusion molding by Dual-color extruder, and makes production process more perfect with reference to two-shot molding process.In the Material selec-tion of product, as a kind of preferred version, the making material of described total reflection lens is polymethyl methacrylate or Merlon.
Solve with reference to the reflecting surface of the above-mentioned fully reflecting surface to planoconvex spotlight portion 2, mirror part 3 and the bottom curved surface of depressed part 5,2 dimension cross section drawings of this total reflection lens can be obtained, thus the initial designs completed planoconvex spotlight portion, computer is utilized to emulate further and revise afterwards, if this total reflection lens makes strip, then above-mentioned total reflection lens model is stretched and can obtain.For mirror part 3, the Merlon that this mirror part 3 reaches 97% by most high reflectance is made, and according to the shape of planoconvex spotlight portion 2 fully reflecting surface, determine the diffuse surface shape of this mirror part 3, when light is gone out by high-efficiency reflective after this diffuse surface, and turn back among planoconvex spotlight portion, again by planar lens portion 1 outgoing, because planoconvex spotlight portion 2 assume responsibility for the optical alignment of about 90%, so, the proportion that the energy diffused accounts for gross energy is lower, finally in the efficiency of light energy utilization, improves illuminating effect, and less on the impact of distribution curve flux.
Total reflection lens disclosed by the invention, the scattered light that LED light source injects planoconvex spotlight portion 2 is reflected into directional light by fully reflecting surface, then to be returned by the light reflection do not utilized in 0 ° to 180 ° angle within planoconvex spotlight portion 2 by mirror part 3 and form directional light.Because the reflector shape of mirror part 3 is identical with the fully reflecting surface shape in planoconvex spotlight portion 2, the light that the fully reflecting surface in planoconvex spotlight portion 2 is leaked can be reflected back within planoconvex spotlight portion 2 through mirror part 3, and be provided with air barrier 4 therebetween, can avoid causing harmful effect to the total reflection ability in planoconvex spotlight portion 2 by this air barrier 4.The present invention compared to existing technologies, planoconvex spotlight portion 2 is utilized to achieve the optical alignment of major part, after by mirror part 3 some light that planoconvex spotlight portion 2 reveals being reflected into directional light again, be back within planoconvex spotlight portion 2, thus improve the total reflection efficiency of LED light source, diffuse reflection efficiency and Luminescence Uniformity, and decrease light loss.On this basis, the total reflection lens that the present invention proposes can also be set to the structure of the various ways such as long strip type, single type, thus meets the different requirements of market to lens.As the forming method of this total reflection lens, emulate by the model of computer to this total reflection lens, and to obtain in production process required parameters, thus coordinate the manufacturing equipment machine-shapings such as extruder, make shaping after product there is certain accuracy and reliability.What time can find out in conjunction with above, the present invention achieves larger progress in the optical lens of LED lamp, is adapted at applying in this area, and has good market prospects.
The above is preferred embodiment of the present invention, is not limited to the present invention, all make in technical scope of the present invention amendment, equivalent to replace or improvement etc., all should be included in scope that the present invention protects.
Claims (1)
1. a total reflection lens, it is characterized in that, described total reflection lens includes planar lens portion (1), the bottom of described planar lens portion (1) is formed with planoconvex spotlight portion (2) and two mirror part (3) to downward-extension, described planoconvex spotlight portion (2) is positioned within two mirror part (3), and be provided with an air barrier (4) between planoconvex spotlight portion (2) and mirror part (3), the bottom of described planoconvex spotlight portion (2) offers depressed part (5), described depressed part (5) is positioned at the focus place of mirror part (3), the reflector shape of this mirror part (3) is identical with the fully reflecting surface shape of planoconvex spotlight portion (2), described planar lens portion (1) is arranged in bar shaped, described planoconvex spotlight portion (2) and mirror part (3) extend along the length direction of planar lens portion (1), the quantity of described depressed part (5) is multiple, multiple depressed part (5) distributes along the length direction of planoconvex spotlight portion (2) successively with preset pitch, described planar lens portion (1), planoconvex spotlight portion (2) and mirror part (3) one-body molded.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105737099A (en) * | 2016-04-12 | 2016-07-06 | 深圳市百康光电有限公司 | High-efficiency light deflecting device |
| CN105904748A (en) * | 2016-05-12 | 2016-08-31 | 广东鼎鹤环保型材科技有限公司 | Plastic extrusion process for angled plastic extrusion lens |
| CN107452727A (en) * | 2017-07-06 | 2017-12-08 | 深圳市旭晟半导体股份有限公司 | A kind of band lens LED encapsulation structure and manufacture method |
| CN108758558A (en) * | 2018-06-07 | 2018-11-06 | 厦门普为光电科技有限公司 | The lampshade of lighting angle can be concentrated |
| CN112413440A (en) * | 2019-08-22 | 2021-02-26 | 浙江宝铭光学材料有限公司 | LED lamp for blackboard |
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| JP2007266180A (en) * | 2006-03-28 | 2007-10-11 | Okaya Electric Ind Co Ltd | Lens for light-emitting element |
| CN201254229Y (en) * | 2008-07-16 | 2009-06-10 | 成贯企业有限公司 | Bicycle lamp translucent mirror base |
| JP2009146841A (en) * | 2007-12-18 | 2009-07-02 | Mitsubishi Electric Corp | Led lighting device |
| CN203442677U (en) * | 2013-07-26 | 2014-02-19 | 深圳市百康光电有限公司 | Total reflection lens |
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2007266180A (en) * | 2006-03-28 | 2007-10-11 | Okaya Electric Ind Co Ltd | Lens for light-emitting element |
| JP2009146841A (en) * | 2007-12-18 | 2009-07-02 | Mitsubishi Electric Corp | Led lighting device |
| CN201254229Y (en) * | 2008-07-16 | 2009-06-10 | 成贯企业有限公司 | Bicycle lamp translucent mirror base |
| CN203442677U (en) * | 2013-07-26 | 2014-02-19 | 深圳市百康光电有限公司 | Total reflection lens |
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Effective date of registration: 20230403 Address after: 518000, 2nd Floor, Building B4, Xinjianxing Science and Technology Industrial Park, Fengxin Road, Guangming New District, Shenzhen, Guangdong Province Patentee after: SHENZHEN BAIKANG OPTICAL Co.,Ltd. Patentee after: ZHEJIANG BICOM OPTICS Co.,Ltd. Address before: 518000, 2nd Floor, Building B4, Xinjianxing Science and Technology Industrial Park, Fengxin Road, Guangming New District, Shenzhen, Guangdong Province Patentee before: SHENZHEN BAIKANG OPTICAL Co.,Ltd. |
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