Dimming module with three-layer composite structure

Abstract

The dimming module with the three-layer composite structure comprises a scattering layer, a gap layer and an angle control layer which are arranged in a composite mode, and the gap layer is arranged between the scattering layer and the angle control layer in a clamped mode. The surface of the scattering layer is provided with a plurality of first optical microstructures; a plurality of second optical microstructures are arranged on the surface of the angle control layer; and the gap layer comprises a plurality of dimming channels for guiding light from the scattering layer to the angle control layer. According to the dimming device with the three-layer composite structure, the scattering layer, the gap layer and the outer angle control layer form a whole, high light efficiency is achieved through functional coupling of the dimming channel and the angle control layer, synchronous optimization of light angle control, anti-dazzle and light spot uniformity is completed, and the dimming device has the advantages of being simple in structure, convenient to use and high in practicability. And the contradiction between scattering effect reduction and anti-dazzle non-uniformity in the traditional technology is broken through.

Description

Technical Field

[0001] The present invention relates to the technical field of dimming modules, and in particular to a dimming module with a three-layer composite structure. Background Art

[0002] In the field of lighting technology, the performance of light adjustment directly determines the optical quality and user experience of lamps. Traditional dimming systems mostly use mechanical shading structures or grid-type dimming structures to achieve light control, but in actual applications, there are the following technical bottlenecks: Although the existing grid-type dimming structure can achieve light angle control, it is easy to cause light spot edge dispersion and reduced light spot uniformity while suppressing glare; and the conventional scattering structure can improve the uniformity of the light spot, but it will weaken the light effect and reduce the anti-glare ability. There is a contradiction between the two that is difficult to reconcile. Most mainstream products on the market use independent modules to achieve the functions of diffusion and anti-glare respectively, which leads to an increase in system thickness and a decrease in light path conversion efficiency, making it difficult to meet the development needs of modern lighting equipment for thinness and integration. It is worth noting that although the dimming structure similar to the grid structure in the existing technology has basic light guiding functions, it has technical defects such as large light efficiency loss (about 35-45%) and obvious edge halo when in use.

[0003] Current dimming modules urgently need to address the following technical contradictions: 1) synergistically improving light control accuracy and light efficiency; 2) balancing angle control and light uniformity; and 3) reliability and cost control issues associated with multi-layer structural integration. This invention addresses these technical bottlenecks by proposing a dimming module with an innovative three-layer composite structure. By leveraging the synergistic effects of a scattering layer, a dimming channel, and an angle control layer, this module breaks through the performance limitations of existing technologies. Summary of the Invention

[0004] In order to solve the above-mentioned deficiencies in the prior art, the present invention proposes a dimming module with a three-layer composite structure.

[0005] In order to achieve the above technical effects, the present invention adopts the following scheme:

[0006] A dimming module with a three-layer composite structure, comprising a composite scattering layer, a gap layer, and an angle control layer, wherein the gap layer is sandwiched between the scattering layer and the angle control layer;

[0007] The surface of the scattering layer has a plurality of first optical microstructures;

[0008] The surface of the angle control layer has a plurality of second optical microstructures;

[0009] The gap layer includes a plurality of dimming channels that guide light from the scattering layer to the angle control layer, and the refractive index n of the inner wall of the dimming channel is 1.2 to 1.8;

[0010] The angle of the light in the dimming channel needs to meet the following requirements:

[0011]

[0012] or,

[0013]

[0014] Among them, the angle α is the average beam angle of the light source emitted from the scattering layer, the angle θ1 is the beam angle of the light incident on the dimming channel after passing through the dimming channel, the angle θ2 is the beam angle of the light incident on the inner wall of the dimming channel after passing through the dimming channel, D1 is the distance between the upper ends of two adjacent dimming channels, D2 is the distance between the lower ends of two adjacent dimming channels, and H is the height of the dimming channel.

[0015] And needs to be satisfied,

[0016]

[0017] According to a preferred technical solution, the inner wall material of the dimming channel is one of silicone, PVC, aluminum foil, PVB glue, PUR glue, UV glue, OCA glue, hot melt glue or epoxy glue.

[0018] According to a preferred technical solution, the cross-section of the dimming channel is square, hexagonal or circular.

[0019] According to a preferred technical solution, the thickness of the gap layer is 0.001-1 mm, and the duty ratio of the gap layer is 50%-99%.

[0020] A preferred technical solution is to arrange a plurality of dimming channels in a distributed array.

[0021] According to a preferred technical solution, diffused ions are provided in the scattering layer.

[0022] According to a preferred technical solution, the first optical microstructure protrusions and / or depressions are arranged on the surface of the scattering layer, and the shape of the first optical microstructure includes one of a pyramid, a prism, an ellipsoid or an irregular shape.

[0023] According to a preferred technical solution, the second optical microstructure protrusions and / or depressions are arranged on the surface of the angle control layer, and the shape of the second optical microstructure includes one of a pyramid, a prism, a lens, a V-groove or a hemisphere.

[0024] According to a preferred technical solution, a coating layer is provided on the surface of the scattering layer, and the coating layer comprises one or more layers of film systems having anti-oxidation, heat insulation, UV resistance, anti-reflection, and anti-reflection functions.

[0025] According to a preferred technical solution, the first optical microstructure is provided on the inner surface and / or outer surface of the scattering layer; and the second optical microstructure is provided on the inner surface and / or outer surface of the angle control layer.

[0026] Compared with the prior art, the beneficial effects are:

[0027] (1) Synergistic improvement of light efficiency and function

[0028] Through the functional coupling of the dimming channel and the angle control layer, high lighting efficiency is achieved while simultaneously optimizing light angle control, anti-glare, and light spot uniformity, breaking through the contradiction between "scattering and reduced efficiency" and "anti-glare unevenness" in traditional technologies.

[0029] (2)Optimization of optical path matching of composite structure

[0030] The scattering layer adopts a microstructure scattering design, forming a complementary light path guide with the honeycomb array of the dimming channel, reducing the reflection loss at the interface between layers, and performing secondary calibration of the light output angle through the microstructure of the angle control layer to achieve beam angle precision control and meet the needs of precision lighting scenes.

[0031] (3) Multifunctional integration and lightweight design

[0032] The scattering, dimming and anti-glare functions are integrated into a three-layer composite device with a total thickness of ≤2mm, achieving a combination of functions. It is suitable for ultra-thin lamps and embedded lighting equipment, and expands application scenarios such as commercial space lighting and indoor lighting.

[0033] (4) Enhanced edge spot control capability

[0034] The honeycomb microhole array of the dimming channel and the asymmetric pyramid of the angle control layer work together to suppress the edge astigmatism of the traditional structure, effectively reduce the intensity of edge glare, effectively eliminate the halo phenomenon, and improve visual comfort. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 It is a schematic diagram of the layer structure decomposition of Example 1 of the present invention.

[0036] Figure 2 yes Figure 1 Schematic cross-section of .

[0037] Figure 3 This is a schematic diagram of light control in Example 1.

[0038] Figure 4 It is a schematic diagram of the layer structure decomposition of Example 2 of the present invention.

[0039] Figure 5 yes Figure 4 Schematic cross-section of .

[0040] Figure 6 This is a schematic diagram of light control in Example 2.

[0041] Figure 7 This is a graph showing the anti-glare performance test results of the present invention.

[0042] Figure 8 This is a diagram showing the light intensity test results of the present invention.

[0043] Figure 9 This is a brightness test result diagram of the present invention.

[0044] Figure 10 This is a diagram showing the results of a plane illumination test on the present invention.

[0045] Figure numerals: 1. scattering layer; 2. gap layer; 3. angle control layer; 4. dimming channel; 5. first optical microstructure. DETAILED DESCRIPTION

[0046] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0047] Example 1

[0048] A dimming module with a three-layer composite structure comprises a composite scattering layer, a gap layer and an angle control layer, wherein the gap layer is sandwiched between the scattering layer and the angle control layer.

[0049] The inner and / or outer surfaces of the scattering layer have a plurality of first optical microstructures. The first optical microstructures are protrusions or depressions disposed on the surface of the scattering layer. The protrusions or depressions can be in the shape of a pyramid, prism, ellipsoid, or irregular shape. The first optical microstructures can be arranged uniformly, in a gradient arrangement, or in a random, irregular pattern. The scattering layer is attached to the surface of the gap layer with a transparent adhesive. The scattering layer is also provided with diffusing particles.

[0050] Specifically, the scattering layer is made of high-haze polystyrene (PS) material, whose surface is precisely laser-etched to form a series of tiny circular depressions. These circular depressions effectively reflect and refract light from the LED light source at multiple angles, achieving uniform light diffusion and avoiding the "hotspot" phenomenon that can occur in traditional lamps.

[0051] In addition, a coating layer is provided on the surface of the scattering layer, and the coating layer includes one or more film systems with anti-oxidation, heat insulation, anti-ultraviolet, anti-reflection and anti-reflection functions.

[0052] The inner and / or outer surfaces of the angle control layer have a plurality of second optical microstructures. These second optical microstructures are protrusions or depressions arranged on the surface of the angle control layer. The shapes of these protrusions or depressions can be pyramids, prisms, lenses, V-grooves, or hemispheres. The second optical microstructures can be arranged uniformly, gradually, or randomly. The angle control layer is used to shape the light passing through the gap layer, and can achieve anti-glare, polarization, dual polarization, focusing, diffusion, and other effects.

[0053] Specifically, the angle control layer is made of any of PET, BOPET, PC, PS, PMMA, and PVC, or other transparent polymer materials, with a thickness of 0.01-2mm. The angle control layer is a thin film with a hexagonal microstructure that controls light and enhances anti-glare. This anti-glare effect effectively reduces the impact of high-angle stray light on indoor lighting environments while maintaining appropriate brightness output for a comfortable visual experience.

[0054] The gap layer includes a plurality of dimming channels that guide light from the scattering layer to the angle control layer, the plurality of dimming channels are distributed in an array, and the refractive index n of the inner wall of the dimming channel is 1.2 to 1.8;

[0055] The angle of the light in the dimming channel needs to meet the following requirements:

[0056]

[0057] or,

[0058]

[0059] Among them, the angle α is the average beam angle of the light source emitted by the scattering layer (the vector angle of 50% maximum light intensity), the angle θ1 is the beam angle of the light incident on the dimming channel after passing through the dimming channel, the angle θ2 is the beam angle of the light incident on the inner wall of the dimming channel after passing through the dimming channel, D1 is the distance between the upper ends of two adjacent dimming channels, D2 is the distance between the lower ends of two adjacent dimming channels, and H is the height of the dimming channel.

[0060] And needs to be satisfied,

[0061]

[0062] In contrast, since the light exit interface on the inner wall of the incident dimming channel is the boundary between the material and the air, it is necessary to comprehensively consider the effects of total reflection on the interface and high-reflection coating on the light efficiency. The size of the inclination angle has an important influence on the dimming performance. When the average beam angle of the incident angle control layer is less than 115°, it has better uniform light and angle control effects.

[0063] The thickness of the gap layer is 0.001-1 mm, and the duty ratio of the gap layer is 50%-99%. The duty ratio is the ratio of the air area in the gap layer to the entire area.

[0064] Specifically, the inner wall of the dimming channel is made of one of silicone, PVC, aluminum foil, PVB adhesive, PUR adhesive, UV adhesive, OCA adhesive, hot melt adhesive, or epoxy adhesive. For example, the gap layer uses a transparent silicone film as a base material, and a grid structure composed of multiple dimming channels is constructed therein. For another example, the gap layer uses a PVC board bonded with double-sided tape, and the PVC board is provided with multiple dimming channels.

[0065] In the present invention, light passing through the scattering layer is evenly diffused due to the scattering effect of the first optical microstructure on the surface. The scattering layer is adjacent to the dimming channel, so part of the light entering the dimming channel will be directed toward the inner wall of the dimming channel. The dimming channel is made of a transparent material with an inclined inner wall. When the light contacts the inner wall of the dimming channel, due to the inclination of the inner wall, most of the light is reflected at a smaller angle toward the angle control layer. The surface of the angle control layer has a micro-prism structure with an anti-glare effect, which further controls the light whose angle is adjusted by the dimming channel, so that it has a better anti-glare effect.

[0066] This design can better control the angle of the outgoing light beam, and the overall thickness can be controlled below 2mm. Compared with the traditional structure, it has higher light efficiency and more delicate structure. It can suppress the astigmatism phenomenon at the edge of the light spot and effectively reduce the edge glare intensity and halo phenomenon.

[0067] Since the prism array structure of the angle control layer has the function of controlling anti-glare, generally the less large-angle scattered light of the incident light, the better the anti-glare effect, and due to the light reflection effect of the dimming channel, the light efficiency loss of the composite structure is greatly reduced.

[0068] Example 2

[0069] Compared to Example 1, Example 2 features a vertically oriented inner wall of the dimming channel, with the channel surface perpendicular to the scattering layer. The dimming channel is constructed of a light-absorbing material. Large-angle light rays striking the inner wall of the dimming channel are largely absorbed, with a small portion reflected and refracted before striking the angle control layer. Upon entering the angle control layer, the light is acted upon by the surface microlens array, achieving precise beam convergence. Adjusting the depth and aperture of the dimming channel, as well as the microlens array parameters of the angle control layer, allows for precise beam convergence at various angles.

[0070] This design enables the required beam angle of the emitted light to be screened in advance before the light reaches the angle control layer, achieving the effect of precise control of the beam angle.

[0071] After passing through the scattering layer, the light directed toward the inner wall of the dimming channel is absorbed, and the light at a small angle that does not touch the hole wall continues to exit into the angle control layer. The exit angle of the light in the dimming channel depends on the ratio of the dimming channel aperture size to the depth. The exit angle of the light after passing through the dimming channel is approximately:

[0072]

[0073] Where H is the height of the dimming channel and L is the width of the dimming channel.

[0074] Since the microlens array structure of the angle control layer has the function of reducing the beam angle, and the light incident on the angle control layer is a shaped beam, the light of the required angle is screened out, thereby achieving precise control of the beam angle.

[0075] In the present invention, tests were conducted based on different heights and different duty cycles of the gap layer of the dimming module. The results are shown in Table 1, Table 2, and Table 3:

[0076] Table 1

[0077]

[0078] Table 2

[0079]

[0080]

[0081] Table 3

[0082]

[0083] It can be seen from the test that in Table 1, when the height of the dimming channel remains unchanged, as the duty cycle increases, the lower the UGR value, the better the anti-glare performance, and the luminous flux is not affected; and in Table 3, when the duty cycle remains unchanged, as the dimming channel increases, the anti-glare performance becomes better, but after the height exceeds 1.0 mm, the UGR value will gradually increase again, and the anti-glare performance will decrease accordingly. Therefore, based on Tables 1, 2 and 3, in the present invention, a duty cycle of the gap layer of 50 to 99% and a height of the gap layer of 0.001 to 1 mm are adopted, so as to comprehensively maintain the anti-glare performance within a certain excellent range.

[0084] In addition, the anti-glare performance test of the dimming module of the present invention was carried out, and the results are as follows: Figure 7As shown, the glare level for light within 65° can reach Class C. Generally speaking, there are three levels of UGR: <13, UGR <16, and UGR <19, with the current level falling at 16 < UGR <19. This invention achieves high luminous efficiency through the functional coupling of the dimming channel and the angle control layer, while simultaneously optimizing light angle control, anti-glare, and spot uniformity. This overcomes the contradiction between "scattering and reduced efficiency" and "uneven anti-glare" in traditional technologies.

[0085] Furthermore, the light intensity test of the dimming module of the present invention was carried out, and the results are as follows: Figure 8 As shown in the figure, the 10%-90% isoluminous intensity curve shows that the light intensity distribution is uniform. A brightness test was also conducted, and the results are as follows Figure 9 As shown, the average brightness difference at the same angle does not fluctuate by more than 5%. The scattering layer of the present invention adopts a microstructure scattering design, forming a complementary light path guidance with the honeycomb array of the dimming channel, reducing interlayer interface reflection loss. The microstructure of the angle control layer is used to perform secondary calibration of the light output angle, achieving beam angle precision control to meet the requirements of precision lighting scenarios.

[0086] Furthermore, the dimming module of the present invention was tested for plane illumination, and the results are as follows: Figure 10 As shown, haloing typically causes secondary peaks in the illumination at the edges of the spot. However, the present invention achieves a smooth, gentle planar illumination curve, effectively eliminating haloing. The honeycomb micro-hole array in the dimming channel, combined with the asymmetric pyramids in the angle control layer, suppresses the edge astigmatism of traditional structures, effectively reducing edge glare intensity and eliminating haloing, thereby enhancing visual comfort.

[0087] In the description of the present invention, it should be understood that the terms "upper", "lower", "top", "bottom", "inside", "outside", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, or are the orientations or positional relationships in which the inventive product is conventionally placed when in use, or are the orientations or positional relationships conventionally understood by those skilled in the art. These are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0088] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature identified as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, "plurality" means two or more, unless otherwise specifically defined.

[0089] Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative work shall fall within the scope of protection of the present invention.

Claims

1. A dimming module with a three-layer composite structure, characterized in that: It comprises a composite scattering layer, a gap layer and an angle control layer, wherein the gap layer is sandwiched between the scattering layer and the angle control layer; The surface of the scattering layer has a plurality of first optical microstructures; The surface of the angle control layer has a plurality of second optical microstructures; The gap layer includes a plurality of dimming channels that guide light from the scattering layer to the angle control layer, and the refractive index n of the inner wall of the dimming channel is 1.2 to 1.8; The angle of the light in the dimming channel needs to meet the following requirements: or, Among them, the angle α is the average beam angle of the light source emitted from the scattering layer, the angle θ1 is the beam angle of the light incident on the dimming channel after passing through the dimming channel, the angle θ2 is the beam angle of the light incident on the inner wall of the dimming channel after passing through the dimming channel, D1 is the distance between the upper ends of two adjacent dimming channels, D2 is the distance between the lower ends of two adjacent dimming channels, and H is the height of the dimming channel. And needs to be satisfied, 2. The dimming module with a three-layer composite structure according to claim 1, wherein: The inner wall material of the dimming channel is one of silica gel, PVC, aluminum foil, PVB glue, PUR glue, UV glue, OCA glue, hot melt glue or epoxy glue.

3. The dimming module with a three-layer composite structure according to claim 1, wherein: The cross section of the dimming channel is one of square, hexagonal or circular.

4. The dimming module with a three-layer composite structure according to claim 1, wherein: The thickness of the gap layer is 0.001-1 mm, and the duty ratio of the gap layer is 50%-99%.

5. The dimming module with a three-layer composite structure according to claim 1, wherein: Several dimming channels are arranged in an array distribution.

6. The dimming module with a three-layer composite structure according to claim 1, wherein: The scattering layer is provided with diffused ions.

7. The dimming module with a three-layer composite structure according to claim 1, wherein: The first optical microstructure protrusions and / or depressions are arranged on the surface of the scattering layer, and the shape of the first optical microstructure includes one of a pyramid, a prism, an ellipsoid or an irregular shape.

8. The dimming module with a three-layer composite structure according to claim 1, wherein: The second optical microstructure protrusions and / or depressions are arranged on the surface of the angle control layer, and the shape of the second optical microstructure includes one of a pyramid, a prism, a lens, a V-groove or a hemisphere.

9. The dimming module with a three-layer composite structure according to claim 1, wherein: The surface of the scattering layer is provided with a coating layer, and the coating layer includes one or more film systems with anti-oxidation, heat insulation, anti-ultraviolet, anti-reflection and anti-reflection functions.

10. The dimming module with a three-layer composite structure according to claim 1, wherein: The first optical microstructure is provided on the inner surface and / or outer surface of the scattering layer; the second optical microstructure is provided on the inner surface and / or outer surface of the angle control layer.

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