WO2009153326A1 - Procédé de fabrication d'une lentille et lentille fabriquée au moyen de ce procédé - Google Patents

Procédé de fabrication d'une lentille et lentille fabriquée au moyen de ce procédé Download PDF

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Publication number
WO2009153326A1
WO2009153326A1 PCT/EP2009/057634 EP2009057634W WO2009153326A1 WO 2009153326 A1 WO2009153326 A1 WO 2009153326A1 EP 2009057634 W EP2009057634 W EP 2009057634W WO 2009153326 A1 WO2009153326 A1 WO 2009153326A1
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WO
WIPO (PCT)
Prior art keywords
lens
lentiform
elements
light
shape
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/EP2009/057634
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English (en)
Inventor
Renato Barbui
Stefania Barbui
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.)
LABORATORIO BS Srl
Original Assignee
LABORATORIO BS Srl
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by LABORATORIO BS Srl filed Critical LABORATORIO BS Srl
Publication of WO2009153326A1 publication Critical patent/WO2009153326A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00365—Production of microlenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00278—Lenticular sheets
    • 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
    • F21V17/10—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening
    • F21V17/104—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening using feather joints, e.g. tongues and grooves, with or without friction
    • 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
    • F21V17/10—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening
    • F21V17/12—Fastening of component parts of lighting devices, e.g. shades, globes, refractors, reflectors, filters, screens, grids or protective cages characterised by specific fastening means or way of fastening by screwing
    • 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
    • F21V5/002—Refractors for light sources using microoptical elements for redirecting or diffusing light
    • 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
    • F21V5/007—Array of lenses or refractors for a cluster of light sources, e.g. for arrangement of multiple light sources in one plane
    • 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
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00—Reflectors for light sources
    • F21V7/0091—Reflectors for light sources using total internal reflection
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B19/00—Condensers, e.g. light collectors or similar non-imaging optics
    • G02B19/0004—Condensers, e.g. light collectors or similar non-imaging optics characterised by the optical means employed
    • G02B19/0028—Condensers, e.g. light collectors or similar non-imaging optics characterised by the optical means employed refractive and reflective surfaces, e.g. non-imaging catadioptric systems
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B19/00—Condensers, e.g. light collectors or similar non-imaging optics
    • G02B19/0033—Condensers, e.g. light collectors or similar non-imaging optics characterised by the use
    • G02B19/0047—Condensers, e.g. light collectors or similar non-imaging optics characterised by the use for use with a light source
    • G02B19/0061—Condensers, e.g. light collectors or similar non-imaging optics characterised by the use for use with a light source the light source comprising a LED
    • G02B19/0066—Condensers, e.g. light collectors or similar non-imaging optics characterised by the use for use with a light source the light source comprising a LED in the form of an LED array
    • 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
    • F21V29/00—Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems
    • F21V29/50—Cooling arrangements
    • F21V29/70—Cooling arrangements characterised by passive heat-dissipating elements, e.g. heat-sinks
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2131/00—Use or application of lighting devices or systems not provided for in codes F21W2102/00-F21W2121/00
    • F21W2131/10—Outdoor lighting
    • F21W2131/103—Outdoor lighting of streets or roads
    • 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
    • F21Y2105/00—Planar light sources
    • F21Y2105/10—Planar light sources comprising a two-dimensional [2D] array of point-like light-generating elements
    • 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 present invention refers to a method for manufacturing a lens for lighting arrangements, adapted for use in connection with lighting apparatus intended for application in residential, office, commercial and similar buildings, road lighting applications, urban design and street furniture applications, and the like.
  • the present invention also refers to a collimating lens made in accordance with such method.
  • the present invention is preferably, although not solely, suitable for use in view of optimizing the luminous flux emitted by lighting apparatus comprising LED- based light emitting elements.
  • lighting devices which comprise a plurality of LED-based light emitting elements. For a same luminous power or intensity being output, these lighting devices allow for a drastic reduction in the amount of power needed to supply them, as compared with traditional lighting apparatus based on incandescent lamps, neon glow lamps, or the like.
  • Such lighting devices are also largely known to further comprise a plurality of lenses, generally in the number of one lens for each LED-based light emitting element.
  • Each lens as made of a plastic or polymeric material, has such optical geometry as to be able to concentrate and collimate the luminous flux emitted by the LED in one or more desired directions in a manner that is consistent with the geometrical arrangement of the LED-based light emitting elements on a related support.
  • a drawback that is encountered with such prior-art lighting devices lies in the fact that, for such flaws as for instance material shrinkage, which may occur as the lenses are moulded, and/or air pockets, which may form in the lenses during moulding, and which may alter or modify the desired optical geometry, to be limited as far as possible, each lens is produced individually. Each lens is then associated to the corresponding LED element and mounted on a support, such as for instance an electronic power-supply board supplying the same LED elements, thereby unavoidably implying an increase in the ultimate production costs of the lighting devices.
  • a further drawback of such prior-art lighting devices lies in the fact that the marked, high degree of directionality of light rays emitted by them gives rise to undesired dazzling occurrences that, in certain fields of application, such as for instance in public environment lighting and /or road lighting applications, may turn out as being particularly dangerous.
  • a further purpose of the present invention is to provide a collimating lens for lighting apparatus, which allows the luminous flux to be optimized, and which is effective in enabling possible dazzling problems to be reduced or even totally done away with.
  • a method for manufacturing a lens according to the present invention can be applied to make and provide a collimating lens for lighting apparatus comprising a plurality of light emitting elements arranged in accordance with a pre-defined geometrical pattern on a support and/or power-supply member.
  • the manufacturing process according to the present invention comprises a modelling step, in which there is defined a shape of the collimating lens having a pre-determined optical geometry.
  • Such optical geometry is adapted to define a plurality of optical paths extending from the lens and associated to the light rays generated by the corresponding light emitting element, so as to obtain a luminous flux travelling out of the lens in one or more directions as desired and predetermined in the design process.
  • the manufacturing method also comprises a step, in which there is provided a forming mould, which has such shape and form as to be able to form the collimating lens.
  • the mould has a shape that is consistent with the previously defined optical geometry, and is provided in such manner as to ensure that at least part of the moulding surfaces thereof are made to a desired degree of accuracy. This is aimed at ensuring that conjugate surfaces are provided on the lenses, which perform a specular, i.e. mirror-like action on the light rays generated by the light emitting elements, and the desired luminous flux is obtained.
  • the manufacturing method further includes a moulding step, in which the lens is moulded by means of said forming mould.
  • the forming mould is provided so as to be capable of moulding a plurality of lentiform elements made in a one- piece unitary construction, these lentiform elements being in the number of at least two, but advantageously three, four or even more, adapted to be coupled to the support and/or power-supply member so as to allow, in a subsequent assembly step, each such lentiform element to be coupled to a related light emitting element in a manner that is consistent with the geometrical arrangement of the light emitting elements on the support and/or power-supply member, without inducing any mispositioning of adjacent lentiform elements relative to each other, not even on a micrometrical scale.
  • the light emitting elements are of the LED type.
  • the afore mentioned moulding step of the method is carried out in the form of an injection- compression process including injecting and compressing a plastic or polymeric material in the forming mould, i.e. a process that includes overcompressing the injected material prior to its setting in the mould.
  • the possibility is given in this way for the material to be closely packed together, i.e. densely compacted to thereby ensure that such flaws as air pockets and the like are eliminated from the lentiform elements being moulded, while keeping material shrinking occurrences within fully acceptable limits.
  • the forming mould is configured so as to obtain - on each lentiform element - at least an optical refraction surface comprising a plurality of micro-optic elements.
  • These micro-optic elements are arranged and adapted to refract at least part of the light rays travelling out of the lentiform elements according to a plurality of optical paths extending in a variety of directions as pre-defined at the design stage.
  • said forming mould is made and provided so that the lentiform elements are integrally incorporated, i.e. as a one-piece unitary construction, in a backing piece having a shape that is consistent with the geometrical arrangement of the light emitting elements on the support and/or power-supply member.
  • Such backing piece comprises at least one surface having corrugations adapted to intercept part of the light rays passing in each lens to radiate them, i.e. send them forth in a direction that is substantially coincident with the direction of the luminous flux generated by the collimating lenses.
  • the present invention also refers to the collimating lens for lighting apparatus obtained with the above-described method.
  • this lens comprises a plurality, i.e. at least two, but advantageously three, four or even more, of lentiform elements made in a one-piece unitary construction to be then coupled to the support and/or power-supply member so as to allow each such lentiform element to be subsequent assembled to a related light emitting element.
  • FIG. 1 is a top view of a collimating lens made in accordance with the present invention.
  • FIG. 2 is a first side view of the lens shown in Figure 1 ;
  • Figure 3 is a second side view of the lens shown in Figure 1 ;
  • FIG. 3A is a schematical view of a detail of Figure 2;
  • - Figure 4 is a first axonometric view of the lens shown in Figure 1 ;
  • FIG. 5 is a second axonometric view of the lens shown in Figure 1 ;
  • FIG. 6 is a cross-sectional view according to the line Vl-Vl in Figure 1 ;
  • FIG. 7 is a top view of a modified embodiment of the lens shown in Figure 1 ;
  • Figure 8 is a schematical side view of the lens shown in Figure 7;
  • Figure 8A is a schematical side view of a detail of Figure 8.
  • FIG. 9 is a first diagrammatical view of the radiating pattern of the lens made according to the present invention.
  • FIG. 10 is a second diagrammatical view of the radiating pattern of the lens made according to the present invention.
  • FIG. 11 is a third diagrammatical view of the radiating pattern of the lens made according to the present invention.
  • FIG. 12 is an axonometric view of a lighting apparatus comprising a collimating lens according to the present invention.
  • a manufacturing method according to the present invention can advantageously be used to provide a collimating lens 10 adapted to be applied on to LED-based light sources, while it shall be right away appreciated that such collimating lens 10 is anyway to be understood as being adapted to be also applied to light sources of any other kind.
  • the manufacturing method according to the present invention includes a modelling step, in which there is defined a geometrical shape of the lens 10 that is adapted to define a pre-determined optical geometry.
  • the collimating lens 10 is adapted to intercept the light rays being emitted by one or more LEDs 11 and passing through lentiform elements 16 associated therewith, and to concentrate them into a luminous flux that comprises the fluxes travelling out of each lentiform element 16 and the lens 10 in at least one pre-determined direction, thereby defining a plurality of optical paths within the lens 10.
  • each lentiform element 16 is furthermore a pre-determined geometrical pattern for arranging each lentiform element 16 within a backing piece 12, in such manner as to enable the lens 10, i.e. the lentiform elements 16 to be associated in a way that is consistent with the arrangement of the LEDs 11 on a board 40 fitted to ensure power supply to the same LEDs.
  • the lens 10 comprises four lentiform elements 16 arranged in a square-shaped pattern in the backing piece 12, but it shall be appreciated that the lens 10 is to be understood as being capable of comprising any different number of lentiform elements 16 arranged according to any different geometrical pattern in the backing piece 12.
  • the same backing piece 12 might be provided in any different geometrical shape so as to be capable of fitting, i.e. adapting to one or more particular boards 40.
  • each lentiform element 16 is further defined according to a substantially circular geometry adapted to intercept the light rays being emitted in an omnidirectional manner from each LED 11.
  • each lentiform element 16 is defined so as to comprise a first lower surface 24 having an at least partially spherical contour, as schematically illustrated in Figure 3A, wherein said surface is arranged so as to have a convexity thereof facing the LED 11.
  • This first surface 24 is adapted to reflect at least part of the light rays being emitted by the LED 11 associated therewith in directions extending obliquely relative to the plane described by the board 40 inside the lentiform element 16.
  • Diagrammatically represented in Figure 3A are the patterns of the optical paths of three light rays emitted by the associated LED 11 according to, i.e. along three segments R1 , R2, R3, which have a different direction of emission and are reflected by the first surface 24 towards the interior of the lentiform element 16 according to, i.e. along three corresponding segments R1 ⁇ R2' and R3', respectively.
  • the first surface 24 is adapted to also intercept at least part of the light rays being emitted in a direction that extends substantially orthogonally to the board 40, and to propagate them through the same lentiform element 16. Illustrated in Figure 3A there is a light ray coming from the LED 11 according to, i.e. along a segment R4, emitted in the above-noted orthogonal direction and passing through the lentiform element 16 without any reflection.
  • Each lentiform element 16 furthermore comprises a second surface 25 which lies on the side flank of the lentiform element 16 and is obtained in the form of a rotation about an axis of symmetry x of a parabolic contour.
  • This second surface 25 becomes narrower, i.e. tapers towards a base portion 17 of the lentiform element 16 and is adapted to reflect towards the interior of the same lentiform element 16 and concentrate most of the light rays being reflected by the first surface 24 towards an upper portion thereof comprising a refractive portion 22.
  • Illustrated in Figure 3A there are three segments R1 ", R2" and R3" that are obtained as a reflection from the second surface 25 of the corresponding segments R1 ', R2' and R3', respectively.
  • each lentiform element 16 is defined so as to comprise, in the upper portion thereof that is arranged for outputting the light rays, a diffractive portion 18 along with the afore-mentioned refractive portion 22.
  • a diffractive portion 18 is arranged to allow for diffusion, in different directions, of the light rays that fail to be reflected by the second surface 25 towards the refractive portion 22.
  • This diffractive portion 18 ( Figures 1 and 6) comprises a radial optics 19 in the shape of a circular crown, or annulus, having a pre-defined extension, and featuring circular corrugations 18A around the refractive portion 22.
  • These circular or ring-shaped corrugations 18A have a pitch P, i.e.
  • FIG. 3A Shown in Figure 3A there is an optical path of a light ray R3 as reflected by the second surface 25 and being output from the diffractive portion 18.
  • the refractive portion 22 ( Figures 1 , 3A, 4) is arranged to allow for emission of most light rays being emitted by the LED 11 associated therewith, and comprises an output surface 26 for letting out the light rays from the lentiform element 16, which is in an ovoid or spherical shape comprising a plurality of micro-optical elements 23.
  • micro-optical elements 23 are adapted to refract the light rays coming from the first surface 24, or the second surface 25, and being output from the lentiform element 16, in such manner as to diffuse the light rays in non-parallel directions. This in view of preventing a luminous flux comprising a plurality of light rays from being emitted in a single direction, and avoiding possible dazzling problems in this way.
  • micro-optical elements 23 are such as to protrude from the output surface 26 and may be in an either spherical or aspheric, e.g. ovoid shape being sized and having a height relative to the output surface depending on the required luminous flux, so as defined at the modelling stage.
  • the micro- optical elements are shown in intentionally enlarged proportions for reasons of greater clarity.
  • the modelling step is carried out by making use of electronic data processing means, such as for instance an electronic data- processing computer, which are appropriately programmed and arranged for modelling the geometrical shape and simulating the luminous flux emitted in accordance with or depending on the desired geometrical shape.
  • electronic data processing means such as for instance an electronic data- processing computer
  • the possibility is in this way given for a variety of emission patterns of the luminous flux to be simulated according to and depending on both the geometrical shape of the lens 10 and the lentiform elements 16 and the optical properties of the material to be used in making the same lens 10, thereby enabling a geometrical shape to be defined, which will provide an optimum in terms of luminous flux, actually.
  • FIGS 9, 10 and 11 there are diagrams plotting the light radiation patterns of a collimating lens 10 according to the present invention, wherein it can be noticed that a large part of the luminous flux emitted by the lens 10 concentrates in a pre-defined direction, which coincides with the one set in the modelling step, since it shows components that slopes down in directions lying close to, i.e. approaching the pre-determined one.
  • a diffractive surface 28 of the backing piece 12 ( Figures 2, 4 and 5), wherein said diffractive surface is provided to extend below the same backing piece 12.
  • This diffractive surface 28 is arranged and adapted to intercept part of the light rays being emitted by the LEDs 11 associated therewith, and diffuse them onto the same backing piece 12. This enables the luminous flux of the collimating lens 10 to be partially emitted also from the backing piece 12 itself, thereby allowing light to be perceived as being emitted all over the surface of the lens 10, i.e. by the entire lens 10 and not solely by parts thereof.
  • Such diffractive surface 28 comprises longitudinal corrugations 29 extending rectilinearly and parallel to each other.
  • the diffractive surface 28 is modelled in such manner as to comprise a plurality of recesses 30, or cuneiform micro-optical elements, having a conical, frusto-conical or partially conical shape and receding into the backing piece 12, arranged according to a regular pattern on the diffractive surface 28.
  • These cuneiform, i.e. wedge-shaped micro-optical elements 30 are adapted to act as light guides to intercept the portion of the light rays emitted by the LED 11 that circulates in the backing piece 12, so as to substantially deflect them into the direction x.
  • Figure 8A can be noticed to schematically illustrate a light ray R5 being intercepted by a cuneiform micro-optical element 30 and being output from the lens 10 according to a segment R5'.
  • the diffractive surface 28 further comprises wrinkled, i.e. rough portions 3OA showing a surface roughness typical of a sandblasting finish. These rough portions 3OA are provided in an interpolated arrangement between adjacent ones of the above-mentioned cuneiform micro-optical elements 30 and are adapted to further assist in intercepting the light rays circulating in the backing piece 12.
  • the diffractive surface 28 comprises a plurality of protrusions jutting from the same surface 28 and having a conical, pyramidal or prismatic shape.
  • support pillars 13 which are provided to allow the lens 10 to rest on the board 40.
  • These support pillars 13 further comprise dowel-like portions 15 adapted to plug into corresponding bores in the board 40 so as to facilitate mechanical coupling of the collimating lens 10 to the board providing power supply to the LEDs 11.
  • the support pillars 13 located at the corners are advantageously provided with a bore 14 for a screw used to fasten the lens to the same board 40 to be received thereinto.
  • the inventive manufacturing method further comprises a step, in which there is provided a forming mould having such shape and contour as to be adapted to mould the collimating lens 10 according to the definition of the geometrical shape of the same lens 10, and has in fact a form that is consistent with the geometrical form as defined in the modelling step.
  • the forming mould is provided in such manner as to ensure that the forming surfaces thereof that are conjugate to the first surfaces 24 and second surfaces 25 of the lentiform elements of the collimating lens 10 have a surface accuracy lying at least in the nanometre order.
  • Such forming surfaces of the mould are made of metal and are machined and finished with the help of diamond tools, such as those used in ultra-high-precision CNC machining centres or units for surface processing and machining in the field of nanotechnologies, in order to obtain the above-cited surface accuracy.
  • diamond tools such as those used in ultra-high-precision CNC machining centres or units for surface processing and machining in the field of nanotechnologies, in order to obtain the above-cited surface accuracy.
  • the manufacturing method further comprises a moulding step for forming the collimating lens 10 by a process that includes injecting a clear, i.e. transparent plastic or polymeric material at a melting temperature thereof, i.e. in the molten state thereof, into the afore-considered forming mould.
  • This plastic material may for instance be polycarbonate.
  • the plastic material is the one carrying the trade-name Makrolon.
  • the lens is moulded by means of an injection-compression process, i.e. a process wherein the plastic or polymeric material is injected and over-compressed in the forming mould.
  • the injection of the material takes place at a point corresponding to a central, substantially symmetric region of the lens 10 in the ultimate form thereof, in such manner as to allow for the material being injected into the forming mould to distribute evenly therein. Material injection takes place by means of a so-called hot-runner nozzle system so as to prevent the injection point from being visible on the lens 10.
  • the forming mould is caused to undergo a compression action so as to drive the injected material into a more closely, i.e. densely packed and evenly compacted form and increase the homogeneous character of the physical properties of the same plastic material, thereby both avoiding residual or internal stresses in the polymeric or plastic material and preventing such flaws as air pockets, vacuums, sinks or the like from forming in the lentiform elements 16.
  • Such compacting action is effective in further enabling material shrinkage to be controlled as the plastic material injected in the mould goes through the setting process thereof, so as to keep shrinkage within pre-defined, allowable limits. In this way, the thus moulded collimating lens 10 will be able to most accurately fit the board 40, on which it shall then be applied, while at the same time allowing each lentiform element 16 to be automatically associated to a corresponding LED 11.
  • the collimating lens 10 provided in accordance with the present invention can be applied on to the related support board 40, which may in turn be arranged so as to provide power supply to the LEDs 11 , in quite quick and convenient a manner, in a process that enables several lentiform elements 16 to be correctly associated to said board 40 at the same time, actually.
  • the present invention also refers to a lighting apparatus 50, such as for example an apparatus for road or street lighting purposes, comprising one or more collimating lenses 10 provided in accordance with the present invention.
  • the lighting apparatus 50 ( Figure 12) comprises one or more support and/or power- supply boards 40, in which the LEDs are arranged according to a pre-defined geometrical pattern.
  • the boards 40 are mechanically coupled to a so-called heat- sink 52, which is made of a metal material and is adapted to absorb and dissipate heat generated by the LEDs when they are turned on.
  • the heat-sink 52 may be provided with a surface for coupling to the boards 40 that shall not necessarily be perfectly planar, but - as illustrated in Figure 12 - may rather be a surface consisting of several portions that are not co-planar, so as to allow the boards 40 to be applied thereon in such arrangement as to provide a luminous flux being output in several directions.
  • the lighting apparatus further comprises one or more collimating lenses 10, each one of which being mechanically coupled to a corresponding board 40.
  • Each collimating lens 10 is applied so as to rest with its pillars 13 on the same board 40, while the dowel-like portions 15 (not shown in Figure 12) fit into the corresponding bores.
  • the lighting apparatus also comprises a containment shell, or casing, formed of an upper shell 56 and a lower shell 58 that are adapted to be coupled together so as to provide a casing for containing the heat-sink 52 and the boards 40 along with the collimating lenses 10.
  • Both the upper shell 56 and the lower shell 58 are preferably made of a material such as clear or colourless polycarbonate.
  • the lighting apparatus 50 is electrically energized by means of a power-supply device (not shown in the Figures), which may be provided either inside or outside the containment casing.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Ophthalmology & Optometry (AREA)
  • Mechanical Engineering (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)
  • Eyeglasses (AREA)

Abstract

L'invention concerne un procédé de fabrication d'une lentille (10) destiné à un dispositif d'éclairage qui comprend plusieirus élément électroluminescents disposés selon un motif géométrique prédéfini sur un support et(ou un élément d'alimentation (12). Ce procédé comprend une étape de modelage, au cours de laquelle la forme de la lentille (10) est définie
PCT/EP2009/057634 2008-06-20 2009-06-18 Procédé de fabrication d'une lentille et lentille fabriquée au moyen de ce procédé Ceased WO2009153326A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITUD2008A000145 2008-06-20
IT000145A ITUD20080145A1 (it) 2008-06-20 2008-06-20 Procedimento per la fabbricazione di una lente e relativa lente

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WO2009153326A1 true WO2009153326A1 (fr) 2009-12-23

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PCT/EP2009/057634 Ceased WO2009153326A1 (fr) 2008-06-20 2009-06-18 Procédé de fabrication d'une lentille et lentille fabriquée au moyen de ce procédé

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011098515A1 (fr) * 2010-02-11 2011-08-18 Ewo Srl/Gmbh Module d'éclairage pour l'éclairage de voies de circulation et appareil d'éclairage de voies de circulation
JP2013178946A (ja) * 2012-02-28 2013-09-09 Panasonic Corp 照明器具
EP2687774A1 (fr) * 2012-07-18 2014-01-22 Bilfinger Construction GmbH Dispositif dýéclairage
US8673186B2 (en) 2010-03-02 2014-03-18 Microsoft Corporation Fabrication of an optical wedge
WO2016180814A1 (fr) * 2015-05-12 2016-11-17 Osram Opto Semiconductors Gmbh Lentille et dispositif d'éclairage optoélectronique
DE102019126892A1 (de) * 2019-10-07 2021-04-08 Siteco Gmbh Positionierung eines silikonlinsenkörpers an einer led

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DE4215584A1 (de) * 1992-05-12 1993-11-18 Bosch Gmbh Robert Beleuchtungseinrichtung
WO2004097946A2 (fr) * 2003-04-29 2004-11-11 Osram Opto Semiconductors Gmbh Source lumineuse
US20050180690A1 (en) * 2004-02-06 2005-08-18 Masahiko Sugiyama Micro lens array and a method of manufacturing a replication mold for the same
EP1577608A2 (fr) * 2004-03-16 2005-09-21 Schefenacker Vision Systems Germany GmbH Luminaire avec une structure optique pour influencer le rayonnement
EP1600908A2 (fr) * 2004-05-29 2005-11-30 FER Fahrzeugelektrik GmbH Corps optique
US20060072199A1 (en) * 2002-12-16 2006-04-06 Kenichiro Morishita Lens array sheet and molding method

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Publication number Priority date Publication date Assignee Title
JPS57187224A (en) * 1981-05-14 1982-11-17 Fuji Xerox Co Ltd Manufacture of lens unit at assembled optical system
DE4215584A1 (de) * 1992-05-12 1993-11-18 Bosch Gmbh Robert Beleuchtungseinrichtung
US20060072199A1 (en) * 2002-12-16 2006-04-06 Kenichiro Morishita Lens array sheet and molding method
WO2004097946A2 (fr) * 2003-04-29 2004-11-11 Osram Opto Semiconductors Gmbh Source lumineuse
US20050180690A1 (en) * 2004-02-06 2005-08-18 Masahiko Sugiyama Micro lens array and a method of manufacturing a replication mold for the same
EP1577608A2 (fr) * 2004-03-16 2005-09-21 Schefenacker Vision Systems Germany GmbH Luminaire avec une structure optique pour influencer le rayonnement
EP1600908A2 (fr) * 2004-05-29 2005-11-30 FER Fahrzeugelektrik GmbH Corps optique

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011098515A1 (fr) * 2010-02-11 2011-08-18 Ewo Srl/Gmbh Module d'éclairage pour l'éclairage de voies de circulation et appareil d'éclairage de voies de circulation
US8673186B2 (en) 2010-03-02 2014-03-18 Microsoft Corporation Fabrication of an optical wedge
JP2013178946A (ja) * 2012-02-28 2013-09-09 Panasonic Corp 照明器具
EP2687774A1 (fr) * 2012-07-18 2014-01-22 Bilfinger Construction GmbH Dispositif dýéclairage
WO2016180814A1 (fr) * 2015-05-12 2016-11-17 Osram Opto Semiconductors Gmbh Lentille et dispositif d'éclairage optoélectronique
CN107532791A (zh) * 2015-05-12 2018-01-02 奥斯兰姆奥普托半导体有限责任公司 透镜和光电子照明设备
CN107532791B (zh) * 2015-05-12 2019-11-08 奥斯兰姆奥普托半导体有限责任公司 透镜和光电子照明设备
US10480748B2 (en) 2015-05-12 2019-11-19 Osram Opto Semiconductors Gmbh Lens and optoelectronic lighting device
DE102019126892A1 (de) * 2019-10-07 2021-04-08 Siteco Gmbh Positionierung eines silikonlinsenkörpers an einer led

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