Planar waveguide condensation system, key assembly thereof, processing method and processing equipment

Abstract

The planar waveguide condensation system is plate-type condensation equipment with a matrix lighting and waveguide convergence structure, is provided with a large number of dense miniature lighting units, receives light from different directions, uniformly and directionally transmits the light to a planar waveguide and converges the light into stronger light; the optical fiber has the advantages of large incident light angle range, no tracking, low loss, multi-stage convergence, compact structure, light weight, low cost, recyclability and the like, and is suitable for being widely applied to scenes such as a lighting system, a photovoltaic system, a photo-thermal system, a signal system, multifunctional building materials or multifunctional fabrics and the like; a multi-die cooperative extrusion and additive composite forming machine, a perforated plate through-flow forming machine, a screen die forming method, a flat sheet transverse splicing forming method, a corrugated sheet lateral splicing forming method and other methods and equipment special for machining miniature dense matrix workpieces are arranged, and the method and equipment are used for producing key assemblies, so that the efficiency can be improved, and the cost can be reduced.

Description

Technical Field

[0001] The invention relates to a light-collecting device, and relates to industries such as photovoltaics, photothermal energy and lighting. Background Art

[0002] The concentrating system is a device used to gather light energy, mainly used in the field of solar energy. Solar energy is an inexhaustible clean energy. In today's global energy shortage and extremely serious environmental pollution, the development of solar energy is of great significance to the survival and development of all mankind. Due to the sparse distribution of sunlight and low energy density, high power must be obtained through large-scale collection, which requires the use of a large number of artificial light-receiving materials. Therefore, the act of using solar energy itself is often difficult to be efficient and environmentally friendly. Silicon crystal solar power stations are the mainstream way of artificial use of solar energy. They use large-area distributed silicon crystal solar panels to convert solar energy into electrical energy and then concentrate it through wires for consumption or transmission. The main problems brought by this type of structure are mainly that more than 80% of the components of silicon crystal solar panels are silicon, with a melting point of thousands of degrees Celsius. The processing process itself is highly energy-consuming, and it is born with a heavy "carbon debt". It takes a long service life to achieve the goal of contributing to environmental protection; with a large number of criss-crossing metal conductive strips connecting the battery unit, reliable waterproof and insulation protection must be provided throughout the process. The material composition and processing technology are relatively complicated, and it is not convenient to recycle after scrapping. Improper handling or Direct abandonment will cause environmental pollution; the solar panels are relatively thick and heavy, and require high-strength frames and brackets. The overall structure uses a lot of materials and is heavy, which requires a high load-bearing capacity of the roof. Doing so reluctantly will bring safety hazards; the solar panels need to be exposed to the sun to obtain as much light energy as possible, and the contradiction associated with this is that exposure to the sun can easily cause the battery temperature to be too high and reduce the power generation efficiency; the solar panels are generally installed in unobstructed places, and roofs and wilderness are ideal. A large amount of conductive materials can easily cause electrical safety accidents during thunderstorms, and the protection level needs to be increased; the solar panels are the most vulnerable parts of solar power stations, and the manufacturing and maintenance costs account for the largest proportion of the total cost, which is not conducive to improving economic benefits and carbon contribution performance. Concentrated solar power stations (CPV) are another structural method for converting solar energy. First, a large area of ​​sunlight is concentrated using concentrating equipment and then used. Because they do not have the above-mentioned problems of silicon crystal solar power stations, they are highly expected in the industry's future prospects and are known as the second-generation solar power stations. The main types of concentrated solar power stations at present are Fresnel lens concentrated power stations and plane reflector matrix concentrated power stations. Their concentration methods have a common fatal weakness - they need light source tracking devices to assist, and they also need to accurately focus the scattered collected light on one point. There are problems such as high manufacturing and installation precision, large space occupation, high energy consumption and high overall cost. Concentrating equipment is an important part of improving the performance of concentrated solar power stations, and there is still a lot of room for improvement. Summary of the invention

[0003] The purpose of the present invention is to provide a focusing device, which integrates a large number of densely distributed micro-lighting units and a common focusing component into a plate-type unit according to a bus-type optical path structure. The unit can be converged at multiple levels, and the units can be directly connected to each other or connected by optical fiber to achieve a larger range of convergence or transmission. The overall structure is compact, the material is small, and the texture is light. The advantages of a large range of incident light angles, no tracking, low loss, and recyclability are achieved through detailed arrangements, which makes up for the shortcomings of existing solar energy system lighting equipment. At the same time, low-cost and high-efficiency processing methods and equipment for key components are provided to accelerate the industrialization process of the technology.

[0004] The optical component of the present invention includes a focusing plate with a matrix layer and a convergence layer; the matrix layer is composed of a large number of densely distributed light-collecting units, which receive light from different directions at the front end surface and then propagate it in the same direction at the rear end surface; the convergence layer is a planar optical waveguide, and the light-collecting units are distributed side by side along the waveguide surface, and their front and rear ends are oriented in the same direction respectively; the light output by the matrix layer enters the convergence layer from different incident points, and is waveguided and converged in the same direction inside it.

[0005] The lighting unit of the present invention is an internal reflection type optical waveguide, or a light refractor, or a nanorod with directional light guiding performance, or a photonic crystal that relies on a microstructure to constrain the direction of photon movement; the matrix layer is a single-layer or multi-layer structure; the convergence layer has single-sided or multi-sided input or output, and is in the shape of a flat plate, a straight strip, or a shape deformed from them; the focusing plate is a single-stage convergence, multi-stage convergence, unidirectional convergence, or multi-directional convergence structure; the overall system is a single-board, multi-board, series, parallel, or mixed structure.

[0006] In the present invention, an optimization layer is arranged upstream of the matrix layer to pre-process the incident light. The optimization layer has point-distributed cones or side-by-side strip prisms as light-collecting units, so that the incident light converges toward the normal direction as a whole after refraction. The optimization unit is also called an optimization unit. The single layer or multiple layers are staggered and can perform two-dimensional or three-dimensional optimization on the incident light. Alternatively, a photoluminescent layer is arranged upstream of the matrix layer, which absorbs the incident light and emits fluorescence, which is transmitted to the matrix layer arranged above, below or on the side thereof.

[0007] The lighting unit of the present invention is an optical waveguide, whose core layer is in a filamentous, film-like or shape composed of surrounding entities of a hole, and the optical path is an arc-shaped or straight-line type; the cross-sectional area of ​​the core layer changes gradually or remains unchanged along the optical path; the incident light enters the core layer from the front face or the side; the matrix layer, the optimization layer or the convergence layer adopts a solid structure, or adopts a hollow structure to achieve weight reduction, heat insulation, heat dissipation or impact safety, or uses a circulating fluid as the optical waveguide cladding to reduce temperature, or adopts a flexible material to adapt to the scene that requires deformation and convenient storage, or adopts a recyclable material to improve the resource utilization rate; the focusing system is managed manually or has an intelligent management system.

[0008] The optical material of the present invention includes one or more matrix layers composed of a large number of densely packed optical units; the matrix layer is a matrix layer for optimizing light convergence, also known as an optimization layer, or a matrix layer for uniformly propagating light, also known as an assimilation layer, or a combination of the two, the former can increase the proportion of incident light effectively utilized by the latter; the optical units of the optimization layer are point-distributed cones or side-by-side strip prisms, and the optical units of the assimilation layer are optical waveguides, refractors, nanorods or photonic crystals; the matrix layer is a solid structure or a hollow structure, and is made of rigid materials, flexible materials or recyclable materials.

[0009] The molding device of the present invention includes an extrusion die head or multiple synchronously cooperating extrusion dies; an extrusion die head has one or more die lips, the structure of multiple die lips includes one or more die lips, and in the structure including multiple die lips, different die lips extrude different materials and are merged into one before or after extrusion; it is a composite process equipment of extrusion molding and additive molding, which extrude long strips of profiles and splice them horizontally into dense matrix workpieces at the same time.

[0010] The molding device of the present invention includes a porous inlet plate with dense inlet holes; a fluid is used as a processing medium, and enters from the inlet holes to process a thermoplastic workpiece into a porous shape; the holes in the workpiece are formed once or multiple times; the back of the workpiece is a free surface, or there is a baffle in this direction, a fully enclosed structure or an outlet hole with a number and distribution position corresponding to the inlet holes of the inlet plate, and the thickness of the workpiece or the shape of the through hole can be controlled by longitudinal movement, lateral movement or longitudinal and lateral movement relative to the inlet plate; the processing fluid is a single-function pressure molding medium, or it is also a heating or cooling medium.

[0011] The present invention uses a porous screen mold to process the processing material into dense modeling units at one time; the screen mold has fine wires that are stretched in parallel in one direction to form grid holes or stretched vertically and horizontally to form mesh holes, or has an integral template with dense holes, and drives the screen mold and the solid processing material to vibrate or reciprocate relative to each other to perform room temperature cutting and molding, or allows the molten processing material to pass through the pores of the screen mold to be shaped into the appearance of the modeling unit; the modeling unit is retained on the parent material to form an integral matrix workpiece, or the modeling unit is connected to another piece of material when it comes out of the pores of the porous screen mold to form an integral matrix workpiece; in the aforementioned thermal processing scheme, The work material passes through the screen mold under its own gravity and extends downward, or pressure is applied to the work material from the back, or traction is applied to the front of the work material, or pressure and traction are used simultaneously; the following methods are used to control the slope or curvature of the center line of the molding unit - in the hot forming scheme, it is achieved by controlling the inclination of the screen mold or the relative position of the traction force point and the cutting force point of the molding unit, or, in the normal temperature cutting scheme, it is achieved by the movement of the screen mold relative to the workpiece, or, first process a vertical molding unit matrix and then collectively trim it into an inclined or curved shape.

[0012] The core layer and cladding of the planar waveguide of the present invention are alternately stacked and connected transversely; the core layer and cladding are flat thin sheets or sprayed layers, and the cladding is all solid or partly solid and partly air; they are first transversely spliced ​​into block blanks with larger thickness, and then divided into plates according to the thickness requirements of the processed products.

[0013] The present invention adopts a plurality of corrugated sheets to be spliced ​​piece by piece laterally in a manner of wave crests to wave troughs to form an integrated workpiece with a porous matrix; the corrugated sheets are formed by blow molding, vacuum forming, spray molding or dipping molding; the corrugated sheet profiles are pre-processed in batches and then spliced, or the corrugated sheets are formed and spliced ​​simultaneously; they are spliced ​​into a workpiece unit at one time or into a larger blank at one time and then divided longitudinally into a plurality of workpiece units. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is the basic principle diagram of the concentrator; Figure 2 It is a matrix of linear daylighting units; Figure 3 is an embodiment in which the lighting unit is a geometrically directional refractor; Figure 4 A cross-sectional view of a matrix of daylighting units formed by the surrounding solid bodies of apertures; Figure 5 It is a concentrator panel with an optimized layer; Figure 6 It is a structure with optimized layers and multiple layers staggered; Figure 7 It is a concentrating plate with a photoluminescent layer; Figure 8 It is a secondary focusing structure; Fig. 9 It is a multi-mode collaborative extrusion and additive composite molding machine; Fig.10 It is a die head with various lip units; Fig.11 It is a porous plate through-flow forming machine; Fig.12 It is one of the schematic diagrams of the screen mold forming method; Fig.13 This is the second schematic diagram of the screen mold forming method; Fig.14 It is a schematic diagram of the horizontal splicing molding method of flat thin sheets; Fig.15 It is a schematic diagram of the lateral splicing forming method of corrugated sheets. DETAILED DESCRIPTION

[0015] The optical component of the present invention includes a light collecting plate with a matrix layer and a convergence layer; the matrix layer is composed of a large number of densely distributed light collecting units, which receive light from different directions at the front end and then propagate it in the same direction at the rear end; the convergence layer is a planar optical waveguide, and the light collecting units are arranged side by side along the waveguide surface, and their front and rear ends are oriented in the same direction; the light output by the matrix layer enters the convergence layer from different incident points, and is waveguided and converged in the same direction inside the convergence layer. Figure 1 , the concentrator is a multi-layer plate structure, the lighting unit 2 is an optical fiber or a planar waveguide made of a light-transmitting material with air as the cladding, which guides the direction of light by bending or tilting its own optical path, and is partially connected to form an integral matrix layer 1; the front end face of the matrix layer 1 is the incident surface of the light, that is, the upper side in the figure, and the rear end face is the emission surface of the light, that is, the lower side in the figure; the converging layer 3 is a planar waveguide, which is arranged in the downstream direction of the matrix layer 1; the ends of the lighting units 2 are in the same direction, all facing the right side in the vertical direction, and the angle formed with the converging layer 3 can make the light emitted in the direction indicated by the end be totally reflected inside the converging layer 3; light A, light B and light C represent all the light incident on the front end of the lighting unit 2 from different angles in the air, among which the part of the light whose incident angle meets the total reflection condition in the lighting unit 2 is waveguided to the end inside the lighting unit 2, and then incident on the converging layer 3, and waveguided in the X direction inside it to converge into stronger light. The matrix layer and the light-collecting layer adopt a separate structure, or the matrix layer is integrated with the light-collecting layer at the end of the light-collecting unit. The statement about the same or different directions of light in this article does not mean whether the trajectories are exactly the same in space, but whether the directions are consistent under the necessary accuracy and specific observation angle, for example, Figure 1In the observation dimension, the ends of all lighting units 2 are facing right, and the emitted light is also facing right. It can be determined that their directions are the same, even though they may be very different from the perspective of the normal direction of the matrix layer. In the concentrator, the horizontal direction refers to the arrangement direction of the lighting units of the matrix layer on the side where their ends are facing, the vertical direction refers to the direction in which the matrix layer and the converging layer are superimposed, and the lateral direction refers to the direction perpendicular to both the horizontal and vertical directions.

[0016] The lighting unit of the present invention is an internal reflection type optical waveguide, or a light refractor, or a nanorod with directional light guiding performance, or a photonic crystal that relies on a microstructure to constrain the direction of photon movement; the matrix layer is a single-layer or multi-layer structure; the convergence layer has single-sided or multi-sided input or output, and is in the shape of a flat plate, a straight strip, or a shape deformed from them; the focusing plate is a single-stage convergence, multi-stage convergence, unidirectional convergence, or multi-directional convergence structure; the overall system is a single-board, multi-board, series, parallel, or mixed structure. Figure 1 The lighting unit 2 is an internal reflection arc-shaped optical waveguide with air as the cladding; it can also be a refraction body with directional geometric shape, such as Figure 3 As shown, the light-collecting unit is a pyramid 18 whose cross-sectional area gradually decreases in the direction of light propagation. It is arranged in multiple layers, and the inclination decreases layer by layer. The light incident from the bottom will move closer to the tip, and the direction of the light is guided by the direction of the tip. The light-collecting unit can also use nanorods with directional light-guiding properties as light-collecting units, and arrange them into a matrix through nano-pen technology. The light-collecting unit can also be a photonic crystal, and the grains in the crystal are arranged according to a certain rule through magneto-electro-thermal or mechanical processing technology, artificial induced crystal growth or liquid phase grain growth and other technical means to form a photonic crystal light-collecting unit matrix with directional light-guiding properties. The matrix layer of the single-layer structure has only one layer of light-collecting unit matrix, such as Figure 1 The structure shown is a single-layer structure. The matrix layer of the multi-layer structure has a matrix of multi-layer lighting units, such as Figure 2 As shown, the matrix layer includes five matrix layers, each layer uses a small segment of a straight optical waveguide as a lighting unit; the lighting unit constituting the first layer on the top is an optical waveguide composed of a core layer 31 and an air cladding layer 32, and the light path inclination is 90 degrees. The remaining layers have the same structure, but the inclination of the lighting unit changes from top to bottom layer by layer, and the inclination of the last layer can make the emitted light fully reflected in the convergence layer; the core layer of the lighting unit is a book page structure cut out from a whole piece of material. In order to save materials, the first and second layers adopt a conjoined structure, or a monomer structure like the bottom layer. The convergence layer has single-sided or multi-sided input or output; Figure 1The convergence layer 3 has input from the top and output from the right side, which is single-sided input and single-sided output. A second matrix layer can be added below it in the opposite direction to the matrix layer 1, so that the convergence layer 3 can have input from the bottom and output from the left side. Multi-sided input can expand the source of light, and multi-sided output can achieve the goal of optical path load distribution or avoid excessive load concentration that causes excessive component temperature. Figure 8 The converging layer 25 is in the shape of a flat plate, and the second converging layer 28 is in the shape of a straight strip. They are essentially narrow and long plate-like structures. After deformation, they form curved plates, annular plates or curved strips, etc., which can adapt to different application scenarios and installation conditions. The converging plate is a one-stage converging, multi-stage converging, unidirectional converging or multi-directional converging structure; Figure 1 The convergence layer 3 has only one convergence direction. Figure 7 The light emitting layer 12 has multiple convergence directions such as sides and bottom; Figure 8 It is a two-stage convergence structure. There is a corresponding first matrix layer upstream of the first convergence layer 25, which guides the light incident from the Z direction into the first convergence layer 25 for convergence. This link is the first-stage convergence; the light in the first convergence layer 25 passes through the second optimization layer 26 and the second matrix layer 27 from the Y direction and converges to the second convergence layer 28. This link is the second-stage convergence; more convergence links can be added downstream as needed. The overall system is a single-board, multi-board, series, parallel or hybrid structure; the single-board structure has only one focusing board, and the multi-board structure contains more than two focusing boards connected by the optical path. Different focusing boards are directly spliced ​​at the edge at a close distance through their respective convergence layers to achieve optical path connection, or are connected over a long distance through optical fibers; the series, parallel and hybrid relationships of the components of the multi-board structure in the optical path are similar to the relationship between electrical components in the circuit. The front-to-back connection is series connection, the parallel connection is parallel connection, and both series connection and parallel connection are hybrid connection.

[0017] In the present invention, an optimization layer is arranged upstream of the matrix layer to pre-process the incident light. The optimization layer has point-distributed cones or side-by-side strip prisms as light-collecting units, so that the incident light converges toward the normal direction as a whole after refraction. The optimization unit is also called an optimization unit. The single layer or multiple layers are staggered and can perform two-dimensional or three-dimensional optimization on the incident light. Alternatively, a photoluminescent layer is arranged upstream of the matrix layer, which absorbs the incident light and emits fluorescence, which is transmitted to the matrix layer arranged above, below or on the side thereof. Figure 5The matrix layer 6 is composed of lighting units 7, and an optimization layer 4 composed of optimization units 5 is arranged upstream thereof; the optimization units 5 are cones distributed in a point shape or strip prisms distributed side by side, and the cross-sectional area gradually decreases from the front end to the rear end in the direction of the light path, and are connected to each other at the front end to form a whole; the incident light enters from the front end, and is emitted from the side or the rear end after refraction. The light with a larger incident angle moves toward the vertical direction with a relatively large amplitude after refraction, and the light with a smaller incident angle deviates from the vertical direction with a relatively small amplitude after refraction or the direction remains unchanged. Compared with before and after refraction, it is convergent on the whole, and more light meets the conditions for total reflection inside the downstream lighting unit, thereby improving the utilization rate of light. Figure 5 The optimization layer is a single-layer structure, which occupies less vertical space. The incident light can only have a larger incident angle range in the arrangement direction of the optimization unit 5, which is a two-dimensional optimization. Figure 6 The optimization layer is a multi-layer structure. The arrangement directions of the optimization units of the upper layer 10 and the lower layer 9 are vertically staggered. The incident light can have a large incident angle range in the two arrangement directions, which is a three-dimensional optimization. If space permits and it is necessary, more layers can be set for optimization. Figure 7 In addition to the optimized layer 13 composed of optimized units, the case also reduces light loss through optical path recombination and multi-path convergence structure. The matrix of the photoluminescent layer 12 is a planar optical waveguide, which is enriched with photoluminescent material groups 11. After absorbing the incident light, it emits fluorescence, most of which is waveguided to the side of the light-emitting layer 12, and propagates to the matrix layer 17 and the convergence layer 16 through the optimized layer 18. A part of it overflows from the bottom and propagates to the matrix layer 14 and the convergence layer 15 through the optimized layer 13; the matrix layer can be set on the top, bottom, any side of the light-emitting layer or in multiple directions; the light-emitting layer can also be connected to the components or equipment on the side and outside the focusing panel unit or outside the system; the position order of the optimization layer and the light-emitting layer can be interchanged, and the optimization layer can be omitted between the matrix layer and the light-emitting layer.

[0018] The lighting unit of the present invention is an optical waveguide, whose core layer is in a filamentous, film-like or shape composed of surrounding entities of a hole, and the optical path is an arc-shaped or straight-line type; the cross-sectional area of ​​the core layer changes gradually or remains unchanged along the optical path; the incident light enters the core layer from the front face or the side; the matrix layer, the optimization layer or the convergence layer adopts a solid structure, or adopts a hollow structure to achieve weight reduction, heat insulation, heat dissipation or impact safety, or uses a circulating fluid as the optical waveguide cladding to reduce temperature, or adopts a flexible material to adapt to the scene that requires deformation and convenient storage, or adopts a recyclable material to improve the resource utilization rate; the focusing system is managed manually or has an intelligent management system. Figure 1 , the core layer of the lighting unit 2 is filamentary or film-like; the lighting unit with a filamentary core layer is actually a small section of optical fiber, and the cross-sectional shape includes but is not limited to circular and rectangular; for the convenience of manufacturing, the core layers of the same row of filamentary lighting units are connected together to form a film-like structure; Figure 4The surrounding entities of the elliptical hole 32 constitute the core layer 35 of the special-shaped lighting unit, and the air inside the elliptical hole 32 is the cladding. The optical path center line of the arc-shaped lighting unit includes arc segments, such as Figure 1 The light path center line of the linear light unit is a straight line segment, such as Figure 2 The light-collecting unit is composed of a core layer 31 and a cladding layer 32. Different matrix layers of the multi-layer structure can be composed of light-collecting units of the same type, or can be composed of matrix layers of light-collecting units of different types. In order to make full use of the light-collecting area of ​​the matrix layer, the longitudinal cross-section of the core layer of unit 2 gradually shrinks from upstream to downstream, and the front end is densely packed with no dead angles to cover the entire front lighting surface. Under ideal conditions, light at any point with an incident angle that meets the total reflection condition can enter from the front surface and be waveguided to the end; for ease of processing, the light-collecting unit is made into a shape with an unchanged longitudinal cross-section, and gaps are retained between the front ends, such as Figure 2 As shown, the lighting surface includes the front end surface of the core layer 31 and the cladding layer 32 of the lighting unit, and the incident light enters directly from the front end surface of the core layer 31, or passes through the cladding layer 32 and then enters the core layer 31 from the side. In order to reduce light loss, the thickness of the cladding layer 32 or the incident angle of the light is as small as possible, and the cladding layer 32 is made of a material with a refractive index close to that of the core layer 31, so that after the light enters the core layer from the side, although the angle between the light and the side of the core layer becomes larger, it can still meet the total reflection condition. Figure 7 In order to avoid the problem of insufficient rigidity, the matrix layer 14 is clad with solid materials, and the sides of the optimization units of the optimization layer 13 are filled with solid light-transmitting materials with low refractive index. The lighting units of the matrix layer 14 are clad with clean air or water, and the sides of the optimization units of the optimization layer 13 can also be air or water, which can reduce weight, insulate, dissipate heat or improve collision safety. When the amount of waste heat is relatively large, a heat recovery device can be set to utilize it. The various layers of the concentrator can be a rigid structure, or can be made of flexible materials including but not limited to optical silicone, which can not only adapt to the use scenarios that require deformation and facilitate storage, but also can be recycled to improve the utilization rate of resources. In order to make the system run safely and efficiently, the concentrator is equipped with an optical path valve to control the light flux of the optical path, thereby realizing the distribution of power on different lines and avoiding excessive component temperature. The optical path valve adjusts the light flux by changing the longitudinal projection area of ​​the valve core or the transparency of the material, or guides the light to other directions, thereby realizing power and temperature management. The management process is carried out manually, or an intelligent management system is set up to complete a wider range of management tasks such as sampling, monitoring, statistics, analysis, prediction, decision-making, alarm, execution, reporting or archiving.

[0019] The optical material of the present invention includes one or more matrix layers composed of a large number of dense optical units; the matrix layer is a matrix layer for optimizing light convergence, also known as an optimization layer, or a matrix layer for uniformly propagating light, also known as an assimilation layer, or a combination of the two, the former can increase the proportion of incident light effectively utilized by the latter; the optical units of the optimization layer are point-distributed cones or side-by-side strip prisms, and the optical units of the assimilation layer are optical waveguides, refractors, nanorods or photonic crystals; the matrix layer is a solid structure or a hollow structure, and is made of rigid materials, flexible materials or recyclable materials. The optical material of the lighting board includes one or more matrix layers composed of a large number of dense lighting units, and incident light from different directions is input from the top of the matrix layer, and the propagation direction is optimized or assimilated and then output from the bottom. Figure 1 The optical material of the embodiment includes a matrix layer 1 composed of lighting units 2, Figure 2 The optical material of the embodiment includes five longitudinally stacked matrix layers composed of light-collecting units of the same type. Figure 5 The embodiment also includes multiple matrix layers, but the functions are different. The optical material includes a matrix layer composed of lighting units 7 and a matrix layer composed of optimization units 5. The former can unify the direction of light with different incident angles, so it is called an assimilation layer, and the latter can converge the incident light in the normal direction, which can increase the proportion of the incident light effectively used by the former, and is also called an optimization layer. The lighting units of the optimization layer are also called optimization units, which are point-distributed cones or strip prisms distributed side by side, and the cross-sectional area gradually decreases from the front end to the rear end, which can make the incident light converge in the normal direction as a whole; the lighting units of the assimilation layer are also called assimilation units, which have inclined or curved optical paths, and the ends of the optical paths of different units are in the same direction, thereby assimilating the propagation direction of the incident light. They are internal reflection optical waveguides, or light refractors, or nanomaterials with directional light guiding properties, or photonic crystals that rely on microstructures to constrain the direction of photon movement. In order to avoid the problem of insufficient rigidity, the lighting unit 7 is clad with solid materials, and the side of the optimization unit 5 of the optimization layer 4 is filled with solid light-transmitting materials with a low refractive index, or the lighting unit 7 is clad with air, and the side of the optimization unit 5 is air, which plays a role in weight reduction, heat insulation, heat dissipation or improving collision safety, or it is made of flexible materials including but not limited to optical silicone, which can not only adapt to the use scenarios that require deformation and convenient storage, but also can be recycled to improve resource utilization. The lighting board can output parallel light, quasi-parallel light or simulated parallel light. In addition to being used in planar waveguide focusing systems, it is also widely used in lighting, high beams, UV curing, UV printing, UV surface treatment, machine vision or optical experiments.

[0020] The molding device of the present invention includes an extrusion die head or multiple synchronously cooperating extrusion die heads; an extrusion die head has one or more die lips, a structure of multiple die lips includes one or more die lips, and in a structure including multiple die lips, different die lips extrude different materials and are combined into one before or after extrusion; it is a composite process equipment of extrusion molding and additive molding, which extrudes long strips of profiles and splices them horizontally into dense matrix workpieces. Fig. 9 and Fig.10 In an embodiment, a mobile processing head 44 of a forming device of the equipment is equipped with three synchronously cooperating extrusion dies 43; one extrusion die 43 has a plurality of lips, namely three core layer lips 46 and three cladding layer lips 47; the core layer lip 46 extrude core layer material, and the cladding layer lip 47 extrude cladding layer material, which are combined after extrusion into a strip-shaped blank 42 with alternating core layer and cladding layer; the processing head 44 reciprocates in a cycle, with a working stroke to the right and a reset stroke to the left, or the extrusion die 43 is a retractable and rotatable structure, with both left and right being working strokes; in the working stroke, the three extrusion die heads 43 extrude the blank 42, and bond them layer by layer into an optical waveguide matrix board 41 with alternating core layer and cladding layer.

[0021] The molding device of the present invention includes a porous inlet plate with dense inlet holes; a fluid is used as a processing medium, and enters from the inlet holes to process a thermoplastic workpiece into a porous shape; the holes in the workpiece are formed once or multiple times; the back of the workpiece is a free surface, or there is a baffle in this direction, a fully enclosed structure or an outlet hole with a number and distribution position corresponding to the inlet holes of the inlet plate, and the thickness of the workpiece or the shape of the through hole can be controlled by longitudinal movement, lateral movement or longitudinal and lateral movement relative to the inlet plate; the processing fluid is a single-function pressure molding medium, or it is also a heating or cooling medium. Fig.11 The molding device includes a porous inlet plate 74 with dense inlet holes, and the hole axis is perpendicular or oblique to the plate surface. When the pressure of the pressure equalization chamber 75 is increased by a pressure device, the processing fluid passes through the inlet hole to the opposite side, blows the molten thermoplastic workpiece out of the blind hole or through hole, and then cools and forms. The holes in the workpiece are formed at one time, or after blowing through holes on a layer of material, a layer of liquid material is added on it and blown again, and deeper holes are obtained after multiple processing. The back of the workpiece is a free surface, or there is a porous outlet plate 71 in this direction, with outlet holes corresponding to the inlet holes of the inlet plate 74 in number and distribution position. The thickness of the workpiece or the shape of its through hole contour can be controlled by longitudinal movement, lateral movement, or longitudinal and lateral movement relative to the inlet plate 74. Longitudinal refers to the thickness direction of the porous plate, and lateral refers to the arrangement direction of the holes. The processing fluid is a single-function pressure shaping medium, or it is also a heating or cooling medium.

[0022] The present invention uses a porous screen mold to process the processing material into dense modeling units at one time; the screen mold has fine wires that are stretched in parallel in one direction to form grid holes or stretched vertically and horizontally to form mesh holes, or has an integral template with dense holes, and drives the screen mold and the solid processing material to vibrate or reciprocate relative to each other to perform room temperature cutting and molding, or allows the molten processing material to pass through the pores of the screen mold to be shaped into the appearance of the modeling unit; the modeling unit is retained on the parent material to form an integral matrix workpiece, or the modeling unit is connected to another piece of material when it comes out of the pores of the porous screen mold to form an integral matrix workpiece; in the aforementioned thermal processing scheme, The work material passes through the screen mold under its own gravity and extends downward, or pressure is applied to the work material from the back, or traction is applied to the front of the work material, or pressure and traction are used simultaneously; the following methods are used to control the slope or curvature of the center line of the molding unit - in the hot forming scheme, it is achieved by controlling the inclination of the screen mold or the relative position of the traction force point and the cutting force point of the molding unit, or, in the normal temperature cutting scheme, it is achieved by the movement of the screen mold relative to the workpiece, or, first process a vertical molding unit matrix and then collectively trim it into an inclined or curved shape. Fig.12 , a porous screen mold 63 is used to process the processing material into dense modeling units at one time. The screen mold 63 has dense unidirectional parallel tensioning or longitudinal and transverse tensioning cutting lines, or an integral template with dense holes. The pressing plate 61 presses down, or the bottom plate 65 pulls downward, or the pressing plate 61 and the bottom plate 65 move at the same time, driving the molten processing material 62 through the pores of the screen mold 63 to be cut into modeling units 64. The modeling units 64 are retained on the parent material to form a continuous matrix workpiece. After the workpiece is taken out, new material is added to process the next workpiece. It can also be used Fig.13 In the continuous processing method shown, the modeling unit 68 is welded to another piece of material 66 when it comes out of the hole of the porous screen mold 63 to form an integral matrix workpiece, and then cut and removed along the dotted line L, and the pressing plate 61 continues to press down the remaining material to process the next product. In the hot processing scheme, in order to simplify the equipment, the power for the processed material to pass through the screen mold can also be only its own gravity. The cutting of the material can also be carried out at room temperature by driving the screen mold and the solid processing material to vibrate or reciprocate relative to each other. The following method is used to control the slope or curvature of the center line of the modeling unit - in the aforementioned hot processing scheme, it is achieved by controlling the inclination of the screen mold 63 or the relative position of the traction force point and the cutting force point of the modeling unit 68, or, in the normal temperature cutting scheme, it is achieved by controlling the relative motion trajectory of the screen mold and the workpiece, or, first process a vertical modeling unit matrix and then collectively trim it into an inclined or curved shape, and the trimming method includes but is not limited to blowing or combing with hot air in one direction.

[0023] The core layer and cladding of the planar waveguide of the present invention are alternately stacked and connected transversely; the core layer and cladding are flat thin sheets or sprayed layers, and the cladding is all solid or partly solid and partly air; they are first transversely spliced ​​into block blanks with larger thickness, and then divided into plates according to the thickness requirements of the processed products. Fig.14 The core layer 91 and cladding 92 of the optical waveguide are alternately stacked laterally to form a block blank with a larger thickness, and then divided into several plates along the dotted line according to the thickness requirements of the planar waveguide matrix board. The core layer 91 and the cladding 92 use a whole piece of prefabricated sheet or coating material, and one piece of material constitutes a complete layer, or the core layer 91 is a prefabricated sheet occupying the entire layer area, and the cladding 92 is a local coating material or a prefabricated strip material, which plays a role of connection, reinforcement or light guidance, and the complementary area part is air. The core layer 91 and the cladding 92 are connected into one body by welding technology, and the process types include but are not limited to ultrasonic welding, laser welding or melt-spray bonding of the workpiece material itself.

[0024] The present invention uses a plurality of corrugated sheets to be spliced ​​piece by piece laterally in a wave crest-to-wave trough manner to form an integrated workpiece with a porous matrix; the corrugated sheets are formed by blow molding, vacuum forming, spray molding or dipping molding; the corrugated sheet profiles are pre-processed in batches and then spliced, or the corrugated sheets are formed and spliced ​​simultaneously; they are spliced ​​into a workpiece unit at a time or spliced ​​into a larger blank at a time and then longitudinally divided into multiple workpiece units. The optical waveguide matrix layer, which uses solid materials around the holes as the core layer and air as the cladding, contains a large number of dense holes. When the longitudinal section profile of the holes is arc-shaped and irregular, or the size is microscopic, it is difficult and uneconomical to use a direct punching processing method, while the corrugated sheet butt molding method is very convenient and fast, and the cost is also low. Fig.15 , transverse refers to the horizontal direction, lateral refers to the vertical direction, and the direction perpendicular to the transverse and lateral directions is the thickness direction. The corrugated plate 58 is spliced ​​piece by piece along the side in a wave crest-to-wave trough manner to form an integrated workpiece with a porous matrix, and the splicing method includes but is not limited to ultrasonic welding or laser welding. The corrugated plate 58 is formed on the rotary mold 57 by blow molding, vacuum molding, spray molding or dipping molding; molding and demolding are respectively carried out at different circumferential positions of the mold 57; the mold 57 transports part of the molded material to the demolding position by rotation; the demolded part of the material is immediately spliced ​​onto the workpiece; a processing flow of pre-batch processed corrugated sheet profiles and then spliced ​​can also be adopted. Splice into one workpiece unit at a time according to the product thickness requirements, or splice into a larger blank at a time and then divide it into multiple workpiece units according to thickness.

Claims

1. A planar waveguide focusing system, comprising an optical component, a connecting component and a fixing device, characterized in that The optical component includes a focusing plate with a matrix layer and a convergence layer; the matrix layer is composed of a large number of densely distributed light-collecting units, which receive light from different directions at the front end and then propagate it in the same direction at the rear end; the convergence layer is a planar optical waveguide, and the light-collecting units are distributed side by side along the waveguide surface, and their front and rear ends are oriented in the same direction; the light output by the matrix layer enters the convergence layer from different incident points, and is waveguided and converged in the same direction inside it.

2. The planar waveguide focusing system according to claim 1, characterized in that The lighting unit is an internally reflective optical waveguide, or a light refractor, or a nanorod with directional light guiding properties, or a photonic crystal that relies on a microscopic structure to constrain the direction of photon movement; the matrix layer is a single-layer or multi-layer structure; the convergence layer has single-sided or multi-sided input or output, and is in the shape of a flat plate, a straight strip, or a shape deformed from them; the focusing plate is a single-stage convergence, multi-stage convergence, unidirectional convergence, or multi-directional convergence structure; the overall system is a single-board, multi-board, series, parallel, or mixed structure.

3. The planar waveguide focusing system of claim 2, characterized in that An optimization layer is arranged upstream of the matrix layer to pre-process the incident light. It has point-distributed cones or side-by-side strip prisms as light-collecting units, so that the incident light converges toward the normal direction as a whole after refraction. It is also called an optimization unit. Single or multiple layers are staggered and can perform two-dimensional or three-dimensional optimization on the incident light. Alternatively, a photoluminescent layer is arranged upstream of the matrix layer, which absorbs the incident light and emits fluorescence that is transmitted to the matrix layer arranged above, below or on the side thereof.

4. The planar waveguide focusing system according to claim 1, 2 or 3, characterized in that The lighting unit is an optical waveguide, the core layer of which is in the shape of a filament, a film or a shape formed by the surrounding entities of the aperture, and the optical path is an arc or a straight line; the cross-sectional area of ​​the core layer changes gradually or remains unchanged along the optical path; the incident light enters the core layer from the front face or the side; The matrix layer, optimization layer or convergence layer adopts a solid structure, or a hollow structure to achieve weight reduction, heat insulation, heat dissipation or impact safety, or uses a circulating fluid as an optical waveguide cladding to reduce temperature, or is made of flexible materials to adapt to scenes that require deformation and facilitate storage, or is made of recyclable materials to improve resource utilization; the focusing system is managed manually or has an intelligent management system.

5. Dense matrix lighting panels with optical materials, characterized by The optical material includes one or more matrix layers composed of a large number of densely packed optical units; the matrix layer is a matrix layer for optimizing the convergence of light, also known as an optimization layer, or a matrix layer for propagating light in a uniform direction, also known as an assimilation layer, or a combination of the two, the former can increase the proportion of incident light effectively utilized by the latter; the optical units of the optimization layer are point-distributed cones or side-by-side strip prisms, and the optical units of the assimilation layer are optical waveguides, refractors, nanorods or photonic crystals; the matrix layer is a solid structure or a hollow structure, and is made of rigid materials, flexible materials or recyclable materials.

6. A multi-mode cooperative extrusion and additive composite molding machine for dense matrix workpieces, used to process dense matrix workpieces of horizontal strip units, with a power device, a feeding device, a heating device, a molding device and a control device, characterized in that the molding The device includes an extrusion die head or multiple synchronously cooperating extrusion die heads; an extrusion die head has one or more die lips, the structure of multiple die lips includes one or more die lips, and in the structure including multiple die lips, different die lips extrude different materials and are merged into one before or after extrusion; it is a composite process equipment of extrusion molding and additive molding, which extrude long strips of profiles and splice them horizontally into dense matrix workpieces at the same time.

7. A multi-hole plate through-flow forming machine for dense matrix workpieces, used to process dense matrix integrated workpieces of hole and seam units, with a pneumatic device, a feeding device, a cooling and heating device, a control device and a forming device, characterized in that the forming The device includes a porous inlet plate with dense inlet holes; a fluid is used as a processing medium, and enters from the inlet holes to process the thermoplastic workpiece into a porous shape; the holes in the workpiece are formed once or multiple times; the back of the workpiece is a free surface, or there is a baffle in this direction, a fully enclosed structure or an outlet hole with a number and distribution position corresponding to the inlet holes of the inlet plate, and the thickness of the workpiece or the shape of the through hole can be controlled by longitudinal movement, lateral movement or longitudinal and lateral movement relative to the inlet plate; the processing fluid is a single-function pressure shaping medium, or it is also a heating or cooling medium.

8. The sieve die forming method for dense matrix workpieces is used to process dense matrix integrated workpieces with point-shaped or horizontal strip-shaped modeling units, characterized in that A porous screen mold is used to process the processed material into dense modeling units at one time; the screen mold has fine wires that are stretched in parallel in one direction to form grid holes or stretched vertically and horizontally to form mesh holes, or has an integral template with dense holes, and the screen mold and the solid processed material are driven to vibrate or reciprocate relative to each other to perform room temperature cutting and molding, or the molten processed material is allowed to pass through the pores of the screen mold to be shaped into the shape of the modeling unit; the modeling unit is retained on the parent material to form an integral matrix workpiece, or the modeling unit is connected to another piece of material when it comes out of the pores of the porous screen mold to form an integral matrix workpiece; in the aforementioned hot processing scheme, the processed material passes through the screen mold under the action of its own gravity and droops and extends, or pressure is applied to the processed material from the back, or traction is applied to the front of the processed material from the front, or pressure and traction are used simultaneously; The following methods are used to control the slope or curvature of the center line of the molding unit - in the hot forming solution, it is achieved by controlling the inclination of the screen mold or the relative position of the traction force point and the cutting force point of the molding unit, or, in the room temperature cutting solution, it is achieved by the movement of the screen mold relative to the workpiece, or, first process a vertical molding unit matrix and then collectively trim it into an inclined or curved shape.

9. A method for horizontally splicing and forming a dense matrix workpiece of a flat sheet, used to process a dense matrix integrated workpiece of a long film-shaped planar waveguide unit, characterized in that The core layer and cladding of the planar waveguide are alternately stacked and connected laterally; the core layer and cladding are flat thin sheets or sprayed layers, and the cladding is all solid or partly solid and partly air; they are first spliced ​​laterally into block blanks with larger thickness, and then divided into plates according to the thickness requirements of the processed products.

10. A method for forming a dense matrix workpiece by side splicing of corrugated sheets, which is used to process a dense matrix integrated workpiece of a hole unit, wherein the longitudinal section profile of the hole is a straight hole, a curved hole or an irregular hole, and is characterized in that A plurality of corrugated sheets are spliced ​​one by one laterally in a wave crest-to-wave trough manner to form an integrated workpiece with a porous matrix; the corrugated sheets are formed by blow molding, vacuum forming, spray molding or dipping molding; the corrugated sheet profiles are pre-processed in batches and then spliced, or the corrugated sheets are formed and spliced ​​simultaneously; they are spliced ​​into a workpiece unit at one time or into a larger blank at one time and then divided longitudinally into multiple workpiece units.

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