High-luminous-efficiency anti-dazzle LED creative down lamp and lens manufacturing process

Abstract

The high-luminous-efficiency anti-dazzle LED creative down lamp comprises a lamp body shell, an LED light source assembly is fixedly arranged in the lamp body shell, the LED light source assembly comprises a circuit board and a plurality of LED lamp beads evenly distributed on the circuit board, an anti-dazzle lens is arranged in the lamp body shell and located above the LED light source assembly, and the anti-dazzle lens is arranged in the lamp body shell and located above the LED light source assembly. The anti-dazzle lens is hemispherical, the light-emitting surface of the anti-dazzle lens is provided with microstructure optical textures, the microstructure optical textures comprise a plurality of annular protrusions and recesses which are distributed at intervals, the geometric center area of the anti-dazzle lens is a light diffusion area, and light diffusion particles are contained in the light diffusion area. Compared with the prior art, the anti-dazzle lens has the advantages that the anti-dazzle lens is hemispherical, the light emitting face is provided with the microstructure optical texture, light can be refracted and scattered, the dazzle phenomenon is reduced, meanwhile, the light diffusion area of the geometric center area contains the light diffusion particles, and the light scattering effect is further enhanced.

Description

Technical Field

[0001] The present invention relates to the technical field of downlight devices, and in particular to a high-light-efficiency anti-glare LED cultural and creative downlight and a lens manufacturing process. Background Art

[0002] LED downlights are increasingly used in the cultural and creative fields and various lighting scenarios. However, there are some problems with traditional LED downlights. On the one hand, traditional downlights are prone to glare, which not only causes discomfort to the human eye, but also may affect the lighting effect and visual experience, especially in cultural and creative places, which may destroy the overall artistic atmosphere and viewing experience. Summary of the invention

[0003] 1. Technical issues

[0004] The purpose of the present invention is to provide a high-light-efficiency anti-glare LED cultural and creative downlight and a lens manufacturing process to solve the glare problem existing in traditional LED downlights.

[0005] (II) Technical content

[0006] In order to solve the above technical problems, the technical solution of the present invention is: a high-light-efficiency anti-glare LED cultural and creative downlight, comprising a lamp body shell, an LED light source assembly is fixedly arranged inside the lamp body shell, the LED light source assembly comprises a circuit board and a plurality of LED lamp beads evenly distributed on the circuit board, an anti-glare lens is arranged inside the lamp body shell and above the LED light source assembly, the anti-glare lens is hemispherical, the light emitting surface of the anti-glare lens has a microstructure optical texture, the microstructure optical texture comprises a plurality of annular protrusions and depressions distributed at intervals, the geometric center area of ​​the anti-glare lens is a light diffusion area, and the light diffusion area contains light diffusion particles.

[0007] Furthermore, the lamp body shell is a cylindrical structure, a plurality of heat dissipation areas are fixedly provided on its side, and a plurality of heat dissipation fins are fixedly provided on the surface of the heat dissipation area.

[0008] Furthermore, the anti-glare lens is installed inside the lamp body shell through a fixing frame, and the fixing frame is tightly connected to the inner wall of the lamp body shell.

[0009] Furthermore, the anti-glare lens is made of optical grade transparent plastic or glass with a refractive index between 1.4 and 1.6.

[0010] Furthermore, the thickness of the light diffusion area is greater than that of the edge area, the thickness of the light diffusion area is 1.2-1.5 times the thickness of the edge area, and the particle size of the light diffusion particles is between 1-5 microns.

[0011] Furthermore, the light diffusion particles are made of inorganic materials such as titanium dioxide or barium sulfate.

[0012] A manufacturing process of an anti-glare lens in a high-light-efficiency anti-glare LED cultural and creative downlight comprises the following steps:

[0013] S1. Fabrication of prefabricated components of light diffusion zone: Select suitable optical plastic as the basic material, prepare light diffusion particles, the light diffusion particles are made of inorganic materials such as titanium dioxide or barium sulfate, and the particle size is controlled between 1-5 microns, mix the light diffusion particles with the optical plastic in a specific ratio, use a high-speed stirrer to stir during the mixing process, and add a proper amount of dispersant to improve the dispersibility and stability of the light diffusion particles in the optical plastic, and mold the mixed materials into prefabricated components of the light diffusion zone by injection molding or die casting;

[0014] S2. Mold making: The main body of the mold is made of high-quality steel, which is precision machined and heat-treated. The internal cavity of the mold is designed to be hemispherical, matching the final shape of the anti-glare lens. A reserved mounting structure is designed at the position of the prefabricated components in the light diffusion area inside the mold. The shape and size of the structure are closely matched with the prefabricated components to ensure that the prefabricated components can be accurately installed and fixed in position during the injection molding process. On the light-emitting surface of the mold, an annular convex and concave structure is designed, and the structure is made by precision electrospark machining or micro-etching technology;

[0015] S3, injection molding fusion: install the light diffusion zone prefabricated component into the reserved installation structure of the mold, ensure that the installation is firm and the position is accurate, melt the prepared plastic substrate and inject it into the mold for injection molding. During the injection molding process, the plastic substrate will fill the mold cavity and wrap the light diffusion zone prefabricated component, so that it is integrated with the plastic substrate into a whole, forming an anti-glare lens blank with a hemispherical shape, microstructure optical texture and light diffusion zone;

[0016] S4. Post-processing: Grind and polish the formed anti-glare lens blank to remove burrs and defects on the surface and improve the surface finish. Use a combination of mechanical grinding and chemical polishing. First, use sandpaper or grinding wheel to roughly grind the surface, and then use chemical polishing liquid for fine polishing to make the surface roughness meet the design requirements.

[0017] S5. Optical inspection: Conduct optical performance inspection on anti-glare lenses, including light transmittance and light diffusion effect inspection, to ensure that they meet the design requirements. Use optical inspection equipment, such as integrating sphere photometer and haze meter, to conduct a comprehensive inspection of the optical performance of the lens.

[0018] (III) Technical Effect

[0019] Compared with the prior art, the present invention has the following advantages:

[0020] 1. The anti-glare lens is hemispherical, and the light-emitting surface has a microstructure optical texture, including annular protrusions and depressions, which can refract and scatter light and reduce glare. At the same time, the light diffusion area in the geometric center area contains light diffusion particles, which further enhances the scattering effect of light and effectively improves the comfort of lighting. It is especially suitable for environments with high requirements for visual experience, such as cultural and creative venues.

[0021] 2. Multiple heat dissipation zones are arranged on the side of the lamp body shell, and a number of heat dissipation fins are arranged on the surface of the heat dissipation zone, which can quickly and effectively dissipate the heat generated by the LED light source assembly, thereby improving the service life and performance stability of the lamp.

[0022] 3. The anti-glare lens is made of optical grade transparent plastic or glass with a refractive index between 1.4-1.6, which ensures good optical performance. The special thickness design of the light diffusion area and the light diffusion particles of a specific particle size further optimize the anti-glare effect.

[0023] 4. The method of prefabricating the light diffusion zone components and then injecting them into the plastic substrate can more accurately control the performance and quality of the light diffusion zone. The prefabricated components can be optimized and quality controlled in a separate process link to ensure the uniform distribution of light diffusion particles and the stability of the light diffusion effect. Compared with traditional one-time injection molding, this step-by-step production method improves the controllability and consistency of product performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a three-dimensional structure diagram of a high-light-efficiency anti-glare LED cultural and creative downlight of the present invention. Figure 1 .

[0025] Figure 2 This is a three-dimensional structure diagram of a high-light-efficiency anti-glare LED cultural and creative downlight of the present invention. Figure 2 .

[0026] Figure 3 It is a schematic diagram of the main structure of a high-light-efficiency anti-glare LED cultural and creative downlight of the present invention.

[0027] Figure 4 It is a schematic diagram of the top view structure of a high-light-efficiency anti-glare LED cultural and creative downlight of the present invention.

[0028] Figure 5 It is a schematic diagram of the cross-sectional structure of a high-light-efficiency anti-glare LED cultural and creative downlight of the present invention.

[0029] Figure 6 It is a process flow chart of an anti-glare lens in a high-light-efficiency anti-glare LED cultural and creative downlight of the present invention.

[0030] As shown in the figure: 1. Lamp body shell; 2. LED light source assembly; 3. Anti-glare lens; 4. Heat dissipation area; 5. Heat dissipation fins; 6. Fixed frame; 21. Circuit board; 22. LED lamp beads; 31. Protrusions; 32. Depressions; 33. Light diffusion area. DETAILED DESCRIPTION

[0031] In the description of the present invention, it is necessary to understand that the directions or positional relationships indicated by the terms "upper", "lower", "front", "back", "left", "right", "inside", "outside", "center", etc. are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation structure and operation, and therefore cannot be understood as a limitation on the present invention.

[0032] In the description of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "provided with", "installed", "connected", "connected" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection, it can be a mechanical connection, it can be an electrical connection, it can be a direct connection, it can be indirectly connected through an intermediate medium, and it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0033] The present invention is further described in detail below in conjunction with the accompanying drawings.

[0034] Combined with Figure 1 To Attachment Figure 5 A high-light-efficiency anti-glare LED cultural and creative downlight comprises a lamp body shell 1, an LED light source assembly 2 is fixedly arranged inside the lamp body shell 1, the LED light source assembly 2 comprises a circuit board 21 and a plurality of LED lamp beads 22 evenly distributed on the circuit board 21, an anti-glare lens 3 is arranged inside the lamp body shell 1 and above the LED light source assembly 2, the anti-glare lens 3 is hemispherical, the light emitting surface of the anti-glare lens 3 has a microstructure optical texture, the microstructure optical texture comprises a plurality of annular protrusions 31 and depressions 32 distributed at intervals, the geometric center area of ​​the anti-glare lens 3 is a light diffusion area 33, and the light diffusion area 33 contains light diffusion particles.

[0035] In this embodiment, as a preferred technical solution, the lamp housing 1 is a cylindrical structure, a plurality of heat dissipation areas 4 are fixedly provided on its side, and a plurality of heat dissipation fins 5 are fixedly provided on the surface of the heat dissipation area 4 .

[0036] In this embodiment, as a preferred technical solution, the anti-glare lens 3 is installed inside the lamp body shell 1 through a fixed frame 6, and the fixed frame 6 is tightly connected to the inner wall of the lamp body shell 1. The material of the anti-glare lens 3 is optical grade transparent plastic or glass with a refractive index between 1.4-1.6.

[0037] In this embodiment, as a preferred technical solution, the thickness of the light diffusion zone 33 is greater than that of the edge zone, and the thickness of the light diffusion zone 33 is 1.2-1.5 times the thickness of the edge zone. The particle size of the light diffusion particles is between 1-5 microns, and the light diffusion particles are made of titanium dioxide or barium sulfate inorganic materials.

[0038] The working principle of the high-light-efficiency anti-glare LED cultural and creative downlight of the present invention is as follows: when the high-light-efficiency anti-glare LED cultural and creative downlight starts to work, the LED light source assembly 2 located inside the lamp body shell 1 is powered on, and the multiple LED lamp beads 22 on the circuit board 21 emit light. The light emitted by the LED lamp beads 22 first shoots toward the anti-glare lens 3 located above. The anti-glare lens 3 is hemispherical, and the microstructure optical texture of its light-emitting surface begins to play a role. The annular protrusions 31 and depressions 32 refract and scatter the light, changing the propagation direction of the light. At the same time, the light diffusion zone 33 contains light diffusion particles made of titanium dioxide or barium sulfate inorganic materials. The particle size of these particles is between 1-5 microns. Since the refractive index of the light diffusion particles is different from that of the lens main body material, the light is scattered when passing through the light diffusion particles, making the originally more concentrated light more evenly dispersed. The thickness of the light diffusion zone 33 is greater than that of the edge area, and the thickness is 1.2-1.5 times the thickness of the edge area. This special thickness design provides more opportunities for the interaction between light and light diffusion particles, further enhancing the anti-glare effect.

[0039] When the LED lamp bead 22 is working, a lot of heat is generated. The multiple heat dissipation areas 4 on the side of the lamp housing 1 start to work. A number of heat dissipation fins 5 are fixed on the surface of the heat dissipation area 4. These heat dissipation fins 5 increase the contact area with the air and can quickly transfer the heat inside the lamp body to the air, thereby effectively reducing the temperature of the lamp body.

[0040] In another aspect of the present embodiment, a process for manufacturing an anti-glare lens is provided, comprising the following steps:

[0041] S1. Fabrication of prefabricated components of light diffusion zone: Select suitable optical plastic as the basic material, prepare light diffusion particles, the light diffusion particles are made of inorganic materials such as titanium dioxide or barium sulfate, and the particle size is controlled between 1-5 microns, mix the light diffusion particles with the optical plastic in a specific ratio, use a high-speed stirrer to stir during the mixing process, and add a proper amount of dispersant to improve the dispersibility and stability of the light diffusion particles in the optical plastic, and mold the mixed materials into prefabricated components of the light diffusion zone by injection molding or die casting;

[0042] S2. Mold making: The main body of the mold is made of high-quality steel, which is precision machined and heat-treated. The internal cavity of the mold is designed to be hemispherical, matching the final shape of the anti-glare lens. A reserved installation structure is designed at the position of the prefabricated components in the light diffusion area inside the mold. Generally, it is an embedded groove structure. The prefabricated components in the light diffusion area are embedded and fixed in the embedded groove. The shape and size of the structure are closely matched with the prefabricated components to ensure that the prefabricated components can be accurately installed and fixed in position during the injection molding process. On the light-emitting surface of the mold, an annular protrusion and concave structure are designed. The structure is made by precision electrospark machining or micro-etching technology;

[0043] S3, injection molding fusion: install the light diffusion zone prefabricated component into the reserved installation structure of the mold, ensure that the installation is firm and the position is accurate, melt the prepared plastic substrate and inject it into the mold for injection molding. During the injection molding process, the plastic substrate will fill the mold cavity and wrap the light diffusion zone prefabricated component, so that it is integrated with the plastic substrate into a whole, forming an anti-glare lens blank with a hemispherical shape, microstructure optical texture and light diffusion zone;

[0044] S4. Post-processing: Grind and polish the formed anti-glare lens blank to remove burrs and defects on the surface and improve the surface finish. Use a combination of mechanical grinding and chemical polishing. First, use sandpaper or grinding wheel to roughly grind the surface, and then use chemical polishing liquid for fine polishing to make the surface roughness meet the design requirements.

[0045] S5. Optical inspection: Conduct optical performance inspection on anti-glare lenses, including light transmittance and light diffusion effect inspection, to ensure that they meet the design requirements. Use optical inspection equipment, such as integrating sphere photometer and haze meter, to conduct a comprehensive inspection of the optical performance of the lens.

[0046] By prefabricating the light diffusion zone components and then injecting them into the plastic substrate, the performance and quality of the light diffusion zone can be more accurately controlled. The prefabricated components can be optimized and quality controlled in a separate process step to ensure uniform distribution of light diffusion particles and stability of the light diffusion effect. This step-by-step production method improves the controllability and consistency of product performance compared to traditional one-time injection molding.

[0047] In the mold design, the reserved installation structure is used to accurately install the prefabricated parts of the light diffusion area, and the precision design of the microstructure texture molding part reflects the innovation and refinement of the process. These designs can ensure that the prefabricated parts of the light diffusion area are closely combined with the plastic substrate during the injection molding process, and at the same time realize the microstructure optical texture of the light-emitting surface, effectively improving the anti-glare effect.

[0048] During the entire process, from material selection and mixing, prefabricated parts production, mold design to injection molding and post-processing and inspection, each link has been carefully designed and optimized to form a complete and creative production process system. This process can produce anti-glare lenses for LED cultural and creative downlights with high light efficiency and good anti-glare performance, meeting the market demand for high-quality optical components.

[0049] The present invention and its embodiments are described above, and such description is not restrictive. The drawings show only one embodiment of the present invention, and the actual structure is not limited thereto. In short, if ordinary technicians in the field are inspired by it, without departing from the purpose of the invention, they can design a structure and embodiment similar to the technical solution without creativity, which should belong to the protection scope of the present invention.

Claims

1. A high-light-efficiency anti-glare LED cultural and creative downlight, comprising a lamp housing (1), wherein an LED light source assembly (2) is fixedly arranged inside the lamp housing (1), wherein the LED light source assembly (2) comprises a circuit board (21) and a plurality of LED lamp beads (22) evenly distributed on the circuit board (21), characterized in that: An anti-glare lens (3) is arranged inside the lamp housing (1) and above the LED light source assembly (2); the anti-glare lens (3) is hemispherical; a light-emitting surface of the anti-glare lens (3) has a microstructure optical texture; the microstructure optical texture comprises a plurality of annular protrusions (31) and depressions (32) distributed at intervals; the geometric center area of ​​the anti-glare lens (3) is a light diffusion area (33); and light diffusion particles are contained inside the light diffusion area (33).

2. According to claim 1, a high light efficiency anti-glare LED cultural and creative downlight, characterized in that: The lamp body shell (1) is a cylindrical structure, a plurality of heat dissipation areas (4) are fixedly provided on its side, and a plurality of heat dissipation fins (5) are fixedly provided on the surface of the heat dissipation area (4).

3. According to claim 1, a high light efficiency anti-glare LED cultural and creative downlight, characterized in that: The anti-glare lens (3) is installed inside the lamp body shell (1) via a fixing frame (6), and the fixing frame (6) is tightly connected to the inner wall of the lamp body shell (1).

4. According to claim 1, a high light efficiency anti-glare LED cultural and creative downlight, characterized in that: The anti-glare lens (3) is made of optical-grade transparent plastic or glass, with a refractive index between 1.4 and 1.

6.

5. According to claim 1, a high light efficiency anti-glare LED cultural and creative downlight, characterized in that: The thickness of the light diffusion area (33) is greater than that of the edge area; the thickness of the light diffusion area (33) is 1.2-1.5 times the thickness of the edge area; and the particle size of the light diffusion particles is between 1-5 micrometers.

6. The high light efficiency anti-glare LED cultural and creative downlight according to claim 5, characterized in that: The light diffusion particles are made of inorganic materials such as titanium dioxide or barium sulfate.

7. The manufacturing process of the anti-glare lens in the high light efficiency anti-glare LED cultural and creative downlight according to claim 1 is characterized in that: The following steps are involved: S1. Fabrication of prefabricated components of light diffusion zone: Select suitable optical plastic as the basic material, prepare light diffusion particles, the light diffusion particles are made of inorganic materials such as titanium dioxide or barium sulfate, and the particle size is controlled between 1-5 microns, mix the light diffusion particles with the optical plastic in a specific ratio, use a high-speed stirrer to stir during the mixing process, and add a proper amount of dispersant to improve the dispersibility and stability of the light diffusion particles in the optical plastic, and mold the mixed materials into prefabricated components of the light diffusion zone by injection molding or die casting; S2. Mold making: The main body of the mold is made of high-quality steel, which is precision machined and heat-treated. The internal cavity of the mold is designed to be hemispherical, matching the final shape of the anti-glare lens. A reserved mounting structure is designed at the position of the prefabricated components in the light diffusion area inside the mold. The shape and size of the structure are closely matched with the prefabricated components to ensure that the prefabricated components can be accurately installed and fixed in position during the injection molding process. On the light-emitting surface of the mold, an annular convex and concave structure is designed, and the structure is made by precision electrospark machining or micro-etching technology; S3, injection molding fusion: install the light diffusion zone prefabricated component into the reserved installation structure of the mold, ensure that the installation is firm and the position is accurate, melt the prepared plastic substrate and inject it into the mold for injection molding. During the injection molding process, the plastic substrate will fill the mold cavity and wrap the light diffusion zone prefabricated component, so that it is integrated with the plastic substrate into a whole, forming an anti-glare lens blank with a hemispherical shape, microstructure optical texture and light diffusion zone; S4. Post-processing: Grind and polish the formed anti-glare lens blank to remove burrs and defects on the surface and improve the surface finish. Use a combination of mechanical grinding and chemical polishing. First, use sandpaper or grinding wheel to roughly grind the surface, and then use chemical polishing liquid for fine polishing to make the surface roughness meet the design requirements. S5. Optical inspection: Conduct optical performance inspection on anti-glare lenses, including light transmittance and light diffusion effect inspection, to ensure that they meet the design requirements. Use optical inspection equipment, such as integrating sphere photometer and haze meter, to conduct a comprehensive inspection of the optical performance of the lens.

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