Design method of novel optical system and manufacturing method of optical system
By designing a new optical system that includes a reflective cavity and a light cone blur lens, the problem of light fixtures being prone to glare and light pollution is solved, and more efficient lighting and lower energy consumption are achieved.
Patent Information
- Application Number
- CN202510118160.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-24
- Publication Date
- 2025-04-08
AI Technical Summary
Existing lamps are prone to glare and light pollution, resulting in energy waste and negative impact on the environment.
Design a new optical system, including a reflective cavity and a light cone blur lens. The reflection cavity optimizes the illumination consistency of the light cone by setting the angle of the light cone of the reflection cavity and adjusting the curvature of the reflection surface, and sets a light cone blurring lens at the outlet to blur the cutoff line on the edge of the light cone to form a uniform vignetting spot.
It effectively reduces glare and light pollution, improves lighting quality, reduces energy losses, and is in line with the development trend of energy conservation and emission reduction.
Smart Images
Figure CN119778679A_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the technical field of lamp lighting, and in particular to a design method of a novel optical system and a manufacturing method of the optical system. Background Art
[0002] With the development of the global economy and the growth of population, the demand for energy continues to grow, and lighting is an important part of energy consumption. At present, the energy efficiency of lamps is insufficient, and a large amount of electrical energy is converted into heat energy, resulting in energy waste. If it is not properly designed and controlled, it will be inefficient and may also cause light pollution. Excessive light pollution will affect the biological clocks of animals and plants, affect astronomical observations, and may even cause irreversible effects on human health.
[0003] In order to deal with the above problems, existing lamp designs usually take a variety of measures to improve energy efficiency and reduce light pollution. For example, LED light sources are used to replace traditional incandescent lamps or fluorescent lamps. However, although LED light sources can improve the energy efficiency of lamps to a certain extent, since LED light sources conform to the Lambertian distribution, if appropriate optical accessories are not used, glare and light pollution are easily generated in actual lighting applications, resulting in unnecessary energy loss. Therefore, the problem of lamp glare and unnecessary light waste is still a problem that needs to be solved urgently. Summary of the invention
[0004] In order to solve the problem that lamps easily generate glare and light pollution, the present application provides a design method of a novel optical system and a manufacturing method of the optical system.
[0005] The present application provides a novel optical system design method, which adopts the following technical solution: A design method for a novel optical system comprises the following steps: A1: A light source is provided, and a reflective cavity is provided on the light source so that the light emitted by the light source is reflected in the reflective cavity; A2: Determine the illuminated area and set the light cone angle of the reflective cavity according to the illuminated area; A3: Adjust the curvature of the reflective surface in the reflective cavity until the optimal reflection angle is achieved to optimize the illumination consistency of the light cone; A4: A light cone blurring lens is provided at the exit of the reflective cavity; A5: Adjust the light cone blurring lens so that it blurs the light cone formed by the light emitted by the light source reflected in the reflective cavity, thereby producing a uniform vignetting spot.
[0006] By adopting the above technical solution, the reflective cavity can make the light emitted by the light source be efficiently reflected in the reflective cavity, so that the propagation direction of the light is changed, the light is distributed more evenly, and the glare is reduced. After the light is reflected, it passes through the light cone blurring lens, and the originally strong light becomes soft and dispersed, and finally forms a uniform vignetting spot, which further reduces the glare. In addition, the reflective cavity limits the light to a specific irradiation area, and limits the disorderly diffusion of the light to the surroundings. The light cone blurring lens can make the light propagate at a specific angle and range, reduce the scattering of light to non-target areas, thereby reducing light pollution to the surrounding environment, and by repeatedly adjusting the light cone angle of the reflective cavity and the curvature of the arc of the reflecting surface, the illumination consistency of the light cone can be further optimized to ensure that the light distribution in the illuminated area is more uniform, which helps to improve the lighting quality, reduce energy loss, and meet the development trend of energy conservation and emission reduction.
[0007] Optionally, the reflective cavity includes a reflective layer and a substrate shell, the reflective layer includes a plurality of layers of lossless reflective dielectric films alternately covering the substrate shell, and the thickness of each layer of the lossless reflective dielectric film is a quarter of a wavelength.
[0008] By adopting the above technical solution, the reflective layer is composed of a lossless reflective dielectric film, which can enhance the reflective effect of the reflective cavity. The lossless reflective dielectric film with a thickness of one quarter of the wavelength can significantly improve the reflection efficiency, so that the light is almost not lost in the reflection process, thereby greatly improving the overall energy efficiency of the lamp, so that the light can still maintain an energy level similar to that before reflection after multiple reflections in the reflective cavity, reducing energy loss, having a wide range of applicability, being able to exhibit excellent optical properties under different types of light sources, and realizing efficient reflection of light inside the reflective cavity.
[0009] Optionally, the number of layers of the lossless reflective dielectric film ranges from 7 to 9.
[0010] By adopting the above technical solution, the light can achieve good reflectivity during the reflection process, improve the overall light output efficiency of the lamp, maintain effective reflection within the visible light band, ensure the consistency and uniformity of the light, reduce light loss, and thus achieve the goal of energy saving and consumption reduction.
[0011] Optionally, the substrate shell is used to be installed at the light source position, and the substrate shell is made by a spinning process, a stamping process, a die-casting process or an injection molding process.
[0012] By adopting the above technical solution, the substrate shell is designed to be manufactured through a variety of processes, ensuring that the substrate shell can accurately match the position and size of the light source, and ensuring that the substrate shell can be made of different raw materials according to needs, thereby improving the flexibility and adaptability of design and manufacturing, and helping to achieve the optimal performance of the reflective cavity.
[0013] Optionally, the light cone virtualizing lens is made by an injection molding process, and the light cone virtualizing lens is assembled with a reflective cavity.
[0014] By adopting the above technical solution, the light cone blurring lens is manufactured through an injection molding process, thereby improving the processing uniformity of the lens and improving production efficiency.
[0015] Optionally, the edge of the light cone virtualizing lens is a free-form surface virtual light structure.
[0016] By adopting the above technical solution, the edge of the light cone blurring lens is designed as a free-form surface virtual light structure, which can effectively blur the cutoff line of the edge of the light spot, making the light transition smoother and more natural, thereby reducing the visual discomfort and glare problems caused by hard light boundaries, and can adjust the light output by the light source into a light spot of a specific shape or a specific illumination distribution. By precisely designing the shape of the free-form surface, the divergence angle, convergence angle, etc. of the light beam can be finely controlled, so as to better illuminate the target area, reduce light waste and irradiation to non-target areas, and effectively reduce light pollution.
[0017] Optionally, the optimal size design of the free-form surface virtual light structure of the light cone virtualizing lens depends on the geometric relationship between the diameter of the light source and the size of the reflective cavity.
[0018] By adopting the above technical solution, the cutoff line at the edge of the light spot can be eliminated as much as possible, so that the light can transition smoothly and naturally, improving visual comfort, and further optimizing the diffusion effect of the light cone, so that the light is uniform in the entire illuminated area.
[0019] Optionally, the reflective cavity is in a circular, square, elliptical or polygonal shape.
[0020] By adopting the above technical solution, the reflective cavity can select different shapes according to the specific application scenario, so that the lamp can better adapt to various lighting needs and installation environments, thereby achieving better light efficiency utilization and anti-glare effect.
[0021] On the other hand, the present application provides a method for manufacturing a novel optical system, which adopts the following technical solution: A method for manufacturing a novel optical system comprises the following steps: B1: Prepare light source; B2: Prepare the reflective cavity shape by spinning, stamping, die casting or injection molding; B3: Fix the reflective cavity with a fixture, and alternately deposit a quarter-wavelength thick refractive material on the inner surface of the reflective cavity to form several layers of lossless reflective dielectric film; B4: Remove the fixture and complete the production of the reflection cavity; B5: Injection molding light cone blur lens; B6: Assemble the light cone blurring lens and the reflective cavity, and then install it at the light source to form a complete lamp optical system.
[0022] By adopting the above technical solution, refractive materials are alternately deposited on the inner surface of the reflective cavity to form a lossless reflective medium film, which can significantly improve the reflectivity of the reflective cavity, reduce the loss of light in the reflection process, enable more light to be effectively reflected, and reduce unnecessary light waste. The light cone blurring lens is prepared by an injection molding process, assembled with the reflective cavity, and finally installed at the light source. The light cone blurring lens can effectively blur the cutoff line at the edge of the light cone and produce a uniform vignetting spot, thereby reducing glare and comprehensively achieving energy conservation and emission reduction.
[0023] Optionally, before implementing step B2, the geometric shape and size of the reflective cavity are set according to the light cone angle set for the illuminated area.
[0024] By adopting the above technical solution, the geometric shape and size of the reflective cavity can be accurately controlled in the design stage, so that the reflective cavity can set the optimal light cone angle according to the requirements of the illuminated area.
[0025] In summary, the present application includes at least one of the following beneficial technical effects: 1. The reflective cavity can make the light emitted by the light source reflect efficiently in the reflective cavity, change the propagation direction of the light, make the light more evenly distributed, reduce the strong light directly directed to the human eye, and thus reduce glare. After the light is reflected, it passes through the light cone blurring lens, and the originally strong light becomes soft and scattered, and finally forms a uniform vignetting spot, which further reduces glare. In addition, the reflective cavity limits the light to a specific irradiation area, and limits the disorderly diffusion of light to the surroundings. The light cone blurring lens can make the light propagate at a specific angle and range, reduce the scattering of light to non-target areas, and thus reduce light pollution to the surrounding environment. In addition, by repeatedly adjusting the light cone angle of the reflective cavity and the curvature of the arc of the reflecting surface, the illumination consistency of the light cone can be further optimized to ensure that the light distribution in the illuminated area is more uniform, which helps to improve the lighting quality, reduce energy loss, and meet the development trend of energy conservation and emission reduction; 2. The reflective layer is composed of a lossless reflective dielectric film, which can enhance the reflective effect of the reflective cavity. Each layer of lossless reflective dielectric film with a thickness of one quarter of a wavelength can significantly improve the reflection efficiency, so that the light is almost not lost during the reflection process, thereby greatly improving the overall energy efficiency of the lamp, so that the light can still maintain a high energy level after multiple reflections in the reflective cavity, reducing energy loss. It is suitable for the visible light band of 380nm-700nm, has a wide range of applicability, can show excellent optical performance under different types of light sources, and realize efficient reflection of light inside the reflective cavity; 3. Refractive materials are alternately deposited on the inner surface of the reflective cavity to form a lossless reflective medium film, which can significantly improve the reflectivity of the reflective cavity, reduce the loss of light in the reflection process, enable more light to be effectively reflected, and reduce unnecessary light waste. The light cone blurring lens is prepared by injection molding process, assembled with the reflective cavity, and finally installed at the light source. The light cone blurring lens can effectively blur the cutoff line at the edge of the light cone and produce a uniform vignetting spot, thereby reducing glare and comprehensively achieving energy conservation and emission reduction. BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Figure 1 It is a flow chart of the optical system design method in an embodiment of the present application.
[0027] Figure 2 It is a schematic diagram of the structure of the optical system in the embodiment of the present application.
[0028] Figure 3 It is a structural cross-sectional view of the optical system in an embodiment of the present application.
[0029] Figure 4 It is a flow chart of the optical system manufacturing method in an embodiment of the present application.
[0030] Description of reference numerals: 1. Reflection cavity; 11. Base material shell; 12. Lossless reflection medium film; 2. Light cone blurring lens. DETAILED DESCRIPTION
[0031] The following is combined with Figure 1-4 This application is described in further detail.
[0032] The embodiment of the present application discloses a novel design method of an optical system.
[0033] Reference Figure 1 , a novel optical system design method, comprising the following steps: A1: An LED light source is provided, and a reflective cavity 1 is provided on the light source, so that the reflective cavity 1 covers the light source, and the light emitted by the light source is reflected in the reflective cavity 1; A2: Determine the illuminated area and set the light cone angle of the reflective cavity 1 according to the illuminated area; A3: Adjust the curvature of the reflective surface in the reflective cavity 1 until the best reflection angle is achieved to optimize the illumination consistency of the light cone; A4: a light cone blurring lens 2 is arranged at the exit of the reflective cavity 1; A5: Adjust the light cone blurring lens 2 so that the light cone blurring lens 2 blurs the light cone formed after the light emitted by the light source is reflected in the reflection cavity 1, thereby generating a uniform vignetting spot.
[0034] The reflective cavity 1 is provided so that the light emitted by the LED light source can be preliminarily reflected in the reflective cavity 1, so that the propagation direction of the light is changed, and the reflected light is more evenly distributed when it is emitted from the exit of the reflective cavity 1, and most of the light is controlled within a certain angle range, so as to reduce the situation where the strong light of the LED light source is scattered and directly emitted to the human eye, and reduce glare. After the light is emitted from the reflective cavity 1, it passes through the light cone virtual lens 2, and the light cone virtual lens 2 diffuses and scatters the light, so that the light is more evenly distributed, and a uniform light spot is obtained, and the light is softened at the same time, thereby further reducing glare and light pollution, reducing light loss, improving light energy utilization, reducing unnecessary light waste, and achieving energy conservation and emission reduction.
[0035] The reflective cavity 1 includes a reflective layer and a substrate shell 11. The reflective layer includes a plurality of lossless reflective dielectric films 12 which are alternately covered on the inner wall of the substrate shell 11 and are made of materials with different high and low refractive indices. The thickness of each layer of the lossless reflective dielectric film 12 is one-quarter wavelength, which can realize constructive interference of reflected light and reduce the loss of light in the reflection process, so that most of the light is effectively reflected instead of being absorbed or scattered, and after multiple reflections, it still maintains a high energy level close to the state before reflection. It is suitable for the visible light band of 380nm-700nm and for most different types of light sources, and has a wide range of applicability.
[0036] The number of layers of the lossless reflective dielectric film 12 ranges from 7 to 9 layers. In the present embodiment, the number of layers of the lossless reflective dielectric film 12 is specifically set to 9 layers, so that the light emitted by the LED light source can achieve good reflectivity in the reflective cavity 1, so that the reflectivity is close to 100%, which is suitable for the visible light band of 380nm-700nm. Compared with the laser system, it has a wider spectral width. The thickness of the lossless reflective dielectric film 12 interferes at a quarter wavelength and reaches a reflection efficiency close to the limit, so that the light is effectively reflected instead of being absorbed or scattered, reducing light loss and achieving energy saving and consumption reduction.
[0037] The substrate shell 11 is used to be installed around the light source position. The substrate shell 11 can be made by a spinning process, a stamping process, a die-casting process or an injection molding process, ensuring that the substrate shell 11 can be made of different raw materials according to usage requirements, accurately matching the position and size of the light source, thereby achieving the best performance of the reflective cavity 1.
[0038] The light cone blurring lens 2 is made by an injection molding process. The light cone blurring lens 2 is assembled with the reflective cavity 1. The injection molding process can satisfy the light cone blurring lens 2 to realize the curved surface structure with different process requirements, thereby realizing the design requirements and enabling the light cone blurring lens 2 to have good optical properties.
[0039] The edge of the light cone blurring lens 2 is a free-form surface virtual light structure, which can evenly distribute the light so that the light will not be too concentrated at the edge, thereby reducing the glare and light pollution caused by the concentration of light. Secondly, it reduces the sudden change of light at the edge and avoids the glare caused by the sudden change of light. By precisely designing the shape of the free-form surface, the angle and distribution of the light beam can be controlled, so that the light is evenly distributed in a specific direction, reducing the scattering of light in non-target directions, thereby reducing glare and light pollution.
[0040] The optimal size design of the free-form surface virtual light structure of the light cone virtualizing lens 2 depends on the geometric relationship between the diameter of the light source and the size of the reflective cavity 1, so that the light can transition smoothly and naturally, optimize the diffusion effect of the light cone, make the illuminated area evenly illuminated, reduce the local over-brightness or over-darkness caused by uneven light spots, and enhance the overall lighting quality of the lamp.
[0041] The shape of the reflective cavity 1 can be set to be circular, square, elliptical or polygonal. In this embodiment, the substrate shell 11 is in the shape of a round cup with a gradually increasing diameter, which can effectively converge the light emitted by the LED into a specific direction and area, forming a concentrated light beam in the lighting area, reducing the light loss rate, and reducing the scattering of light to non-target areas, thereby reducing glare and light pollution.
[0042] The embodiment of the present application also discloses a method for manufacturing a novel optical system.
[0043] Reference Figure 1 , a novel method for manufacturing an optical system, comprising the following steps: B1: Prepare LED light source; B2: The outer shape of the reflective cavity 1 is prepared by spinning, stamping, die-casting or injection molding. In this embodiment, the substrate shell 11 is prepared by spinning, stamping, die-casting or injection molding; B3: Fix the reflective cavity 1 with a fixture, and alternately deposit high and low refractive index materials with a thickness of a quarter wavelength on the inner surface of the substrate shell 11 to form several layers of lossless reflective dielectric films 12; B4: Remove the fixture to complete the production of the reflection cavity 1; B5: Setting the geometrical dimensions and shape of the light cone blurring lens 2, and injection molding the light cone blurring lens 2; B6: Assemble the light cone blurring lens 2 with the reflective cavity 1, install the light cone blurring lens 2 at the exit of the reflective cavity 1, and then install the reflective cavity 1 at the LED light source to form a complete lamp optical system.
[0044] The substrate shell 11 can be made of different raw materials according to needs, which improves the flexibility and adaptability of manufacturing. Refractive materials are alternately deposited on the inner surface of the substrate shell 11 to form a lossless reflective medium film 12, thereby forming a reflective cavity 1. The reflection efficiency of the reflective cavity 1 can be improved and light loss can be reduced. The light cone virtualizing lens 2 is prepared by an injection molding process, and the light cone virtualizing lens 2 is assembled with the reflective cavity 1 and installed at the light source to form a complete optical system. The light cone virtualizing lens 2 can reduce the scattering of light to non-target areas. The originally strong light becomes soft and dispersed, producing a uniform vignetting spot, thereby reducing glare and comprehensively achieving energy conservation and emission reduction.
[0045] Before implementing step B2, the geometric shape and size of the reflective cavity 1 are set according to the light cone angle set for the illuminated area, and then the shape and size of the substrate shell 11 are set accordingly to perform production and processing of the substrate shell 11.
[0046] The implementation principles of a design method for a novel optical system and a manufacturing method of the optical system in an embodiment of the present application are as follows: the reflective cavity 1 can make the light emitted by the light source to be preliminarily reflected in the reflective cavity 1, so that the propagation direction of the light is changed, and the reflected light is more evenly distributed when it is emitted from the exit of the reflective cavity 1, and most of the light is controlled within a certain angle range to reduce glare. After the light is emitted from the reflective cavity 1, it passes through the light cone virtualization lens 2, and the light cone virtualization lens 2 diffuses and scatters the light to make the light evenly distributed and soften the light at the same time, thereby further reducing glare and light pollution, reducing light loss, improving light energy utilization, and reducing unnecessary light waste.
[0047] The above are all preferred embodiments of the present application. The embodiments are only explanations of the present application and do not limit the protection scope of the present application in turn. Therefore, all equivalent changes made according to the structure, shape, and principle of the present application should be covered within the protection scope of the present application.
Claims
1. A novel optical system design method, characterized in that: The following steps are involved: A1: a light source is provided, and a reflective cavity (1) is provided on the light source so that light emitted by the light source is reflected in the reflective cavity (1); A2: Determine the illuminated area and set the light cone angle of the reflective cavity (1) according to the illuminated area; A3: Adjust the curvature of the reflective surface in the reflective cavity (1) until the optimal reflection angle is achieved to optimize the illumination consistency of the light cone; A4: a light cone blurring lens (2) is arranged at the exit of the reflective cavity (1); A5: Adjust the light cone blurring lens (2) so that the light cone blurring lens (2) blurs the light cone formed after the light emitted by the light source is reflected in the reflection cavity (1), thereby generating a uniform vignetting spot.
2. The design method of a novel optical system according to claim 1, characterized in that: The reflective cavity (1) comprises a reflective layer and a substrate shell (11); the reflective layer comprises a plurality of layers of lossless reflective dielectric films (12) alternately covering the substrate shell (11); the thickness of each layer of the lossless reflective dielectric film (12) is one quarter of a wavelength.
3. The design method of a novel optical system according to claim 2, characterized in that: The number of layers of the lossless reflective dielectric film (12) ranges from 7 to 9.
4. The design method of a novel optical system according to claim 2, characterized in that: The substrate shell (11) is used for being installed at a light source position, and the substrate shell (11) is manufactured by a spinning process, a stamping process, a die-casting process or an injection molding process.
5. The design method of a novel optical system according to claim 1, characterized in that: The light cone virtualizing lens (2) is manufactured through an injection molding process, and the light cone virtualizing lens (2) is assembled with the reflective cavity (1).
6. The design method of a novel optical system according to claim 1, characterized in that: The edge of the light cone virtualizing lens (2) is a free-form surface virtual light structure.
7. The design method of a novel optical system according to claim 6, characterized in that: The optimal size design of the free-form surface virtual light structure of the light cone virtualizing lens (2) depends on the geometric relationship between the diameter of the light source and the size of the reflective cavity (1).
8. The design method of a novel optical system according to claim 1, characterized in that: The shape of the reflective cavity (1) is circular, square, elliptical or polygonal.
9. A method for manufacturing a novel optical system, based on a design method for a novel optical system according to claims 1 to 8, characterized in that: The following steps are involved: B1: Prepare light source; B2: preparing the outer shape of the reflective cavity (1) by spinning, stamping, die casting or injection molding; B3: Fixing the reflective cavity (1) with a fixture, alternately depositing a refractive material with a thickness of a quarter wavelength on the inner surface of the reflective cavity (1) to form a plurality of layers of lossless reflective dielectric films (12); B4: Remove the fixture and complete the production of the reflection cavity (1); B5: Injection-molded light cone blur lens (2); B6: Assemble the light cone blurring lens (2) and the reflective cavity (1), and then install them at the light source to form a complete optical system of the lamp.
10. The method for manufacturing a novel optical system according to claim 9, characterized in that: Before implementing step B2, the geometric shape and size of the reflective cavity (1) are set according to the light cone angle set for the illuminated area.