lenticular sheet

Abstract

The invention relates to a lens plate (10) for an LED device (100), comprising: a plurality of lens elements (12a-e); and a flexible connection (24a-d) between two lens elements of the plurality of lens elements, such that at least one of a distance (P 11 ) and an angle between the two lens elements can be adjusted, wherein the two lens elements and the flexible connection are made of the same material.

Description

Technical Field

[0001] This invention relates to a lens plate for use in LED (light-emitting diode) devices. The invention also relates to LED devices including such a lens plate, the use of such a lens plate, and methods for manufacturing such a lens plate. Background Technology

[0002] In various LED devices, a lens plate with multiple lens elements can be used on the LED board (i.e., the board or carrier on which light-emitting diodes are mounted) to influence the light distribution of the light-emitting diodes. However, every change in the LED spacing (the distance between LEDs) on the LED board requires an investment in new manufacturing tools, even if one wants to maintain a consistent light distribution (the shape of the lenses in the lens plate). For example, if the LED spacing is changed by only 0.05 mm in a 2-foot LED device with 48 light-emitting diodes, the position of the last light-emitting diode changes by 0.05 × 47 = 2.35 mm, which is significant from an optical point of view.

[0003] US2012189800 discloses an array of elements in which spacing errors between elements in the array are reliably absorbed during the lamination process, enabling high-precision alignment of each group of elements arranged in the lamination direction. The array of elements has multiple lenses arranged in one or two dimensions and a flexible support formed of a material more elastic than the material forming the lenses. The lenses are coupled to each other via the support. The lenses and the support are integrally formed using a dual-mode process. Summary of the Invention

[0004] The purpose of this invention is to overcome or at least mitigate the above-mentioned problems and to provide an improved lens plate.

[0005] According to a first aspect of the invention, this and other objects are achieved by a lens plate for an LED device, the lens plate comprising: a plurality of lens elements; and a plurality of flexible connectors between two consecutive lens elements, such that at least one of the distance and angle between each pair of the two lens elements can be adjusted, wherein each pair of the two lens elements and the flexible connector are made of the same material.

[0006] This invention is based on the understanding that by stretching (or possibly compressing) flexible connectors between lens elements, these connectors allow a type of lens plate to be adapted to LED boards with different LED spacings and / or even different shapes. Therefore, the lens plate of this invention is versatile, which saves costs when manufacturing many different types of LED devices / boards. Furthermore, since the lens elements and flexible connectors of the lens plate are made of the same material, the construction of the adjustable lens plate is simplified and it is easy to manufacture.

[0007] The flexible connector can be molded together with two lens elements, for example, by injection molding.

[0008] The flexibility of a flexible connector can be achieved by at least one of the shape, size, and position of the flexible connector, rather than by choosing a different material for the flexible connector compared to the lens element (e.g., more elastic).

[0009] The flexible connector may include two (parallel) spring members.

[0010] Flexible connectors can, for example, comprise two V-shaped members. The advantage of V-shaped members is that they can be stretched and compressed. Furthermore, the V-shaped members do not need to overlap, which makes them easy to shape. The V-shaped members are preferably located in a plane perpendicular to the optical axis of the multiple lens elements, because this way they do not cover the lens (part) of the lens element or the beam emitted from the lens (part). They also require less material.

[0011] Other shapes of flexible connectors are also possible, such as W-shaped or U-shaped or... Other orientations / positions of the flexible connector are also possible, such as vertical placement in a plane parallel to the optical axes of multiple lens elements.

[0012] Furthermore, each of the two lens elements may have a base portion, wherein the two base portions at least partially define two triangular or isosceles trapezoidal spaces between the two base portions pointing towards each other, and wherein each space in the two triangular or isosceles trapezoidal spaces accommodates one of the two V-shaped (or W-shaped) members of the flexible connector. The advantage of doing this is that a relatively short minimum distance can be achieved between the (two) lens elements despite the flexible connector. To realize the two triangular or isosceles trapezoidal spaces, the bases may be, for example, hexagonal or octagonal.

[0013] When no force is applied to the flexible connector, a gap may exist between the two lens elements. In this way, the lens element spacing can be increased or decreased, allowing the lens plate to be adapted to various LED panels. The gap may, for example, exist between one side of the hexagonal or octagonal base of one of the two lens elements and the opposite side of the hexagonal or octagonal base of the other lens element. In another embodiment, when no force is applied to the flexible connector, there is (substantially) no gap between the two lens elements.

[0014] In one embodiment, each of the plurality of lens elements includes two protrusions adapted to engage with corresponding notches in an LED panel of an LED device for positioning the lens panel on the LED panel. This positioning addresses the problem of the effect of thermal expansion on light distribution because the position of the lens element relative to the light-emitting diode of the LED panel is stable. In another embodiment, each lens element includes two notches adapted to engage with corresponding protrusions on the LED panel. Combinations of these two embodiments are also possible. Additional elements (e.g., frames) can also be used for positioning.

[0015] Multiple lens elements can be arranged in a linear array. The array can be a straight (linear) array. In another embodiment, the linear array is curved in a plane perpendicular to the optical axes of the multiple lens elements.

[0016] According to a second aspect of the present invention, an LED device is provided, comprising: a plate having a plurality of LED light sources; and a lens plate according to the first aspect, wherein the spacing of a plurality of lens elements of the lens plate matches the spacing of a plurality of LED light sources of the plate.

[0017] Each of the multiple lens elements may include two protrusions that engage with a corresponding notch in the plate for positioning the lens plate on the plate.

[0018] A third aspect of the invention relates to the use of a lens plate according to the first aspect with any one of at least two LED plates having different LED spacing and / or different shapes.

[0019] According to a fourth aspect of the present invention, a method for manufacturing an LED device is provided, the method comprising: providing a lens plate according to a first aspect; providing a plate having a plurality of LED light sources; if necessary, stretching and / or compressing a flexible connector by applying a force such that the spacing of a plurality of lens elements of the lens plate matches the spacing of a plurality of LED light sources of the plate; and positioning the lens plate on the plate.

[0020] It should be noted that the present invention relates to all possible combinations of the features described in the claims. Attached Figure Description

[0021] These and other aspects of the invention will now be described in more detail with reference to the accompanying drawings, which illustrate embodiments of the invention.

[0022] Figure 1 and Figure 3a This is a top view of the lens plate according to an embodiment of the present invention when no force is applied to its flexible connector.

[0023] Figure 2 yes Figure 1 Side view of the lens plate.

[0024] Figure 3b yes Figure 3a A top view of the lens plate, in which its flexible connector is stretched.

[0025] Figure 3c This includes those positioned on the LED board. Figure 3a An exploded perspective view of the LED device on the lens plate.

[0026] Figure 3d This includes those positioned on another LED panel. Figure 3b An exploded perspective view of the LED device on the lens plate.

[0027] Figures 4a-4d Alternative flexible connectors are shown.

[0028] Figure 5 yes Figure 1 A top view of the lens plate in a curved configuration.

[0029] Figure 6 This is a flowchart of a method according to an embodiment of the present invention.

[0030] The same reference numerals always denote the same elements. Detailed Implementation

[0031] The invention will now be described more fully below with reference to the accompanying drawings, in which presently preferred embodiments of the invention are illustrated. However, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness and to fully convey the scope of the invention to those skilled in the art.

[0032] Figure 1 and Figure 2 (and Figure 3a The image shows a lens plate 10 according to an embodiment of the present invention.

[0033] Lens plate 10 includes a plurality of lens elements 12a-e. The lens elements 12a-e may be (substantially) rigid. The lens elements 12a-e are arranged in a linear array. Each lens element 12a-e includes a lens portion 14 and a base portion 16. The lens portion 14 may be, for example, dome-shaped, but other shapes are also possible. Each lens portion 14 has an optical axis 18. For non-imaging lens portions, the optical axis 18 can be interpreted as a line coinciding with the axis of the associated light-emitting diode (see, for example, LED light source 104 discussed below), i.e., the axis for which the lens portion is designed. Here, the base portion 16 is octagonal in a plane 20 perpendicular to the optical axis 18. Each two adjacent base portions 16 (e.g., the base portions of lens elements 12a and 12b) may define at least partially two triangular or isosceles trapezoidal spaces 22a-b pointing towards each other between the two base portions 16.

[0034] The lens plate 10 also includes flexible connectors 24a-d between every two consecutive lens elements 12a-e, such as flexible connector 24a between lens elements 12a-b, flexible connector 24b between lens elements 12b-c, and so on. The number of lens elements in the lens plate 10 can be N, and the number of flexible connectors in the lens plate 10 can be N-1, where N is an integer (e.g., in the range of 2-200). An exemplary approximately 2-foot lens plate may, for example, have 48 lens elements and 47 flexible connectors. Another exemplary approximately 1-foot lens plate may, for example, have 24 lens elements and 23 flexible connectors. Each flexible connector 24a-d allows adjustment of at least one of the distance and angle between its two lens elements 12a-e, which will be further described below.

[0035] Lens elements 12a-e and flexible connectors 24a-d are made of the same material. That is, the lens plate 10 can be made of a single material. Lens elements 12a-e and flexible connectors 24a-d can be made of a non-elastic material. Lens elements 12a-e and flexible connectors 24a-d can be made, for example, of PC (polycarbonate) (which is a non-elastic material). Alternatively, lens elements 12a-e and flexible connectors 24a-d can be made of silicone resin. Flexible connectors 24a-d can be molded together with lens elements 12a-e, for example. Therefore, lens elements 12a-e and flexible connectors 24a-d of the lens plate 10 can be integrally formed. Furthermore, lens elements 12a-e and flexible connectors 24a-d can be manufactured in a single process, such as injection molding or injection molding of liquid silicone resin (LSR).

[0036] Each flexible connector 24a-d may include two V-shaped members 26a-b. The V-shaped members 26a-b are located in plane 20. The V-shaped members 26a-b (typically) point towards each other. Specifically... Figure 1 As can be seen in the enlarged portion, one end 28a of each V-shaped member 26a-b is connected to a lens element 12a, and the other end 28b of each V-shaped member 26a-b is connected to an adjacent lens element 12b. Specifically, the V-shaped members 26a-b can be accommodated in the aforementioned triangular or isosceles trapezoidal spaces 22a-b, wherein the end 28a is connected to the side surface 30a of the base 16 of the lens element 12a, which partially defines the space 22a, and the end 28b is connected to the side surface 30b of the base 16 of the lens element 12b, which also partially defines the space 22a. Figure 1 The figure shows exemplary dimensions (in mm) of the V-shaped component.

[0037] exist Figures 4a-4d Various alternative flexible connectors are shown in the diagram. Figure 4a In this design, the flexible connector includes a V-shaped member 26', which is placed vertically in a plane perpendicular to plane 20. Figure 4b In this context, the flexible connector includes a V-shaped member 26", which is located in plane 20 but points away from the opposing flexible connector. Figure 1 In comparison, the V-shaped member 26" can be made longer and is therefore more flexible. Figure 4c In the process, the flexible connector includes a W-shaped member 26"' that can be located in plane 20. Figure 4d In the middle, flexible connectors include Shaped component 26" ("three-sided rectangle"), which may be located in plane 20 and point away from the opposite flexible connector.

[0038] Back Figure 1 When no force is applied to the flexible connectors 24a-d, gap 32 may exist between every two consecutive lens elements, such as lens elements 12a-b. Specifically, gap 32 may exist between the side 34a of the octagonal base 16 of one lens element 12a and the opposing (and here parallel) side 34b of the octagonal base 16 of the adjacent lens element 12b. In particular, side 34a is located between the side 30a of the partially defining space 22a and the corresponding side 30'a of the partially defining space 22b.

[0039] As described above, each flexible connector 24a-d allows adjustment of the distance between its two lens elements 12a-e. Specifically, the distance between the lens elements 12a-e can be increased by stretching the flexible connector 24a-d (by applying an external force F), such as... Figure 3bAs shown. That is, the spacing between lens elements 12a-e can be increased to, for example, 40%, for example from P. 11 =12mm increased to P 12 =14mm. Note that the distance (spacing) between the lens elements is adjusted in plane 20, which is along the straight line direction of the aforementioned linear array.

[0040] like Figure 3c As shown, in Figure 3a The lens plate 10 in the state shown can be positioned with a value equal to P. 11 Spacing P 21 On a plate 102 with multiple LED light sources 104, wherein the lens plate 10 and the plate 102 having the LED light sources 104 form part of the LED device 100. However, as Figure 3d As shown, in Figure 3b The state shown is such that the lens plate 10 can be similarly positioned with a position equal to P. 12 Different (larger) LED pitch P 22 On another plate 102', the lens plate 10 and the plate 102' having the LED light source 104' form part of the LED device 100'. Therefore, the lens plate 10 can be adapted to have different LED spacing P. 21 and P 22 The LED panels 102 and 102' make the lens plate 10 of the present invention universal.

[0041] Board 102 (102') may be a printed circuit board. Board 102 (102') may be rectangular. Multiple LED light sources 104 (104') may be mounted on the surface of board 102 (102'). Multiple LED light sources 104 (104') may be arranged in a linear array. The number of LED light sources 104 (104') may be N. LED device 100 (100') may be a lighting device or form part of a lighting device.

[0042] Furthermore, each lens element 12a-e of the lens plate 10 may include two protrusions 36a-b adapted to engage with corresponding notches 106a-b (106'ab) in the plate 102 (102') for positioning the lens plate 10 on the plate 102 (102'). Specifically, one protrusion 36a may be located on the lateral side 38a of the octagonal base 16, while the other protrusion 36b may be located on the opposite lateral side 38b. The corresponding notches 106a-b (106'ab) may be located at the longitudinal edges 108a-b (108'ab) of the plate 102 (102'). Since the position of the lens element 16 relative to the LED light source 104 (104') of the plate 102 (102') is stable, this positioning solves the problem of the effect of thermal expansion on light distribution.

[0043] Go to Figure 5 The lens plate 10 can also be positioned on the curved plate 102". Here, the linear array of lens elements 16 is curved (in plane 20). This can be achieved by applying an external force, such that... Figure 1 and Figure 3a Compared to the state shown, only (or primarily) the V-shaped member 26b on one side of the lens plate 10 is stretched, while the V-shaped member 26a on the other side of the lens plate 10 can be (slightly) compressed. Figure 5 As shown, the angle between every two consecutive lens elements has been adjusted (in... Figure 1 (Above), as shown by the misaligned dashed line.

[0044] Figure 6 This is a flowchart of a method for manufacturing LED devices 100, 100' according to an embodiment of the present invention.

[0045] In S1, the method includes providing a lens plate 10, for example, as Figure 1 and Figure 3a As shown.

[0046] In S2, boards 102, 102' with multiple LED light sources 104 (104') are provided.

[0047] In S3, the method includes—if necessary—stretching and / or compressing the flexible connectors 24a-d by applying a force F, such that the spacing P of the plurality of lens elements 12a-e of the lens plate... 12 The spacing P between multiple LED light sources is 104'. 22 Matching. It's important to note here that if you want to... Figure 1 and Figure 3a If the lens plate 10 is positioned on the plate 102, then step S3 is not required. However, if the lens plate 10 is to be positioned on the plate 102', then step S3 (stretching the flexible connector 24a-d) is actually performed.

[0048] In S4, for example, the lens plate 10 is positioned on the plate 102 (102') using the aforementioned protrusions / notches.

[0049] Those skilled in the art will recognize that the present invention is by no means limited to the preferred embodiments described above. Rather, many modifications and variations are possible within the scope of the appended claims. For example, in Figure 1 , Figure 2 and Figure 3a In the embodiment shown, the gap 32 is relatively small, but if the gap is wider when no force is applied to the flexible connector, the flexible connector can also be compressed, allowing the spacing between the lens elements to decrease.

[0050] Additionally, from a study of the drawings, disclosure, and appended claims, those skilled in the art can understand and implement variations of the disclosed embodiments when practicing the claimed invention. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite articles "a" or "an" do not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not imply that combinations of these measures cannot be advantageously used.

Claims

1. A lens plate (10) for an LED device (100), the lens plate comprising: a plurality of lens elements (12a-e), each having an optical axis (18), the plurality of lens elements (12a-e) being arranged in a plane (20) perpendicular to the optical axes; and flexible connections (24a-d) between further pluralities of two consecutive lens elements of the plurality of lens elements (12a-e) enabling adjustment of at least one of a distance (P 11 ) and an angle between each two of the two lens elements in the plane (20) wherein each of the two lens elements and the flexible connection are made of the same material, and wherein the flexible connection is molded together with the two lens elements.

2. The lens plate according to claim 1, wherein the flexibility of the flexible connection is achieved by at least one of the shape, size and position of the flexible connection.

3. The lens plate according to any of the preceding claims, wherein the flexible connection comprises two V-shaped members (26a-b).

4. The lens plate according to claim 3, wherein the two lens elements each have a base (16), wherein the two bases at least partly define two triangular or isosceles trapezoidal spaces (22a-b) between the two bases pointing towards each other, and wherein each of the two triangular or isosceles trapezoidal spaces accommodates one of the two V-shaped members of the flexible connection.

5. The lens plate according to claim 1 or 2, wherein there is a gap (32) between the two lens elements when no force is applied to the flexible connection.

6. The lens plate according to claim 1 or 2, wherein each of the plurality of lens elements comprises two protrusions (36a-b) adapted to engage with corresponding recesses (106a-b) in an LED plate (102) of the LED device for positioning the lens plate on the LED plate.

7. The lens plate according to claim 1 or 2, wherein the plurality of lens elements are arranged in a linear array.

8. The lens plate according to claim 7, wherein the linear array is curved in a plane (20) perpendicular to the optical axes (18) of the plurality of lens elements.

9. An LED device (100; 100'), comprising: a plate (102; 102') with a plurality of LED light sources (104; 104')； and The lens sheet (10) according to any one of the preceding claims, wherein the pitch (P 11 ; P 12 ) of the plurality of lens elements (16) of the lens sheet matches the pitch (P 21 ; P 22 ) of the plurality of LED light sources of the sheet member.

10. The LED device according to claim 9, wherein each of the plurality of lens elements comprises two protrusions (36a-b) engaging with corresponding recesses (106a-b; 106'a-b) in the plate for positioning the lens plate on the plate.

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