A light control module with a three-layer composite structure

Abstract

The application discloses a light adjusting module with a three-layer composite structure, which comprises a scattering layer, a gap layer and an angle control layer which are arranged in a composite manner, the gap layer is arranged between the scattering layer and the angle control layer, the surface of the scattering layer is provided with a plurality of first optical microstructures, the surface of the angle control layer is provided with a plurality of second optical microstructures, and the gap layer comprises a plurality of light adjusting channels for guiding light from the scattering layer to the angle control layer. The light adjusting device with the three-layer composite structure is a whole of the scattering layer, the gap layer and the outer angle control layer, the functions of the light adjusting channels and the angle control layer are coupled, high light efficiency is realized, the synchronization optimization of light angle control, anti-dazzle and light spot uniformity is completed, and the contradiction between'scattering reduction' and 'anti-dazzle loss of uniformity' in the traditional technology is broken through.

Description

Technical Field

[0001] This invention relates to the field of dimming module technology, and specifically to a dimming module with a three-layer composite structure. Background Technology

[0002] In the field of lighting technology, the performance of light adjustment directly determines the optical quality and user experience of luminaires. Traditional dimming systems mostly use mechanical shielding structures or grid-type dimming structures to achieve light control, but in practical applications, they face the following technical bottlenecks: While existing grid-type dimming structures can control the light angle, they easily lead to edge dispersion and reduced uniformity of the light spot while suppressing glare; while conventional scattering structures can improve light spot uniformity, they weaken luminous efficacy and reduce anti-glare capabilities, creating a contradiction that is difficult to reconcile. Most mainstream products on the market use independent modules to achieve diffusion and anti-glare functions separately, resulting in increased system thickness and reduced optical path conversion efficiency, making it difficult to meet the development needs of modern lighting equipment for thinner and more integrated designs. It is worth noting that while existing dimming structures similar to grid structures have basic light guiding functions, they suffer from significant luminous efficacy loss (approximately 35-45%) and noticeable edge halo effects during use.

[0003] Current dimming modules urgently need to address the following technical challenges: 1) synergistic improvement of light control precision and luminous efficacy; 2) balancing angle control and light uniformity; and 3) reliability and cost control issues arising from multi-layer structure integration. This invention addresses these technical bottlenecks by proposing a dimming module with an innovative three-layer composite structure. Through the synergistic effect of the scattering layer, dimming channel, and angle control layer, it breaks through the performance boundaries of existing technologies. Summary of the Invention

[0004] To address the shortcomings of the prior art, this invention proposes a dimming module with a three-layer composite structure.

[0005] To achieve the above-mentioned technical effects, the present invention adopts the following solution:

[0006] A dimming module with a three-layer composite structure includes a scattering layer, a gap layer, and an angle control layer, which are compositely arranged, with the gap layer sandwiched between the scattering layer and the angle control layer;

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

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

[0009] The gap layer includes several 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 1.2~1.8;

[0010] The angle of light within the dimming channel must meet the following requirements:

[0011]

[0012] or,

[0013]

[0014] Wherein, angle α is the average beam angle of the light source emitted from the scattering layer. The angle is the beam angle of light rays incident on the dimming channel after passing through the dimming channel. The angle is the beam angle of light rays incident on the inner wall of the dimming channel after passing through the dimming channel. It is the distance between the top edges of two adjacent dimming channels. H is the distance between the lower ends of two adjacent dimming channels, and H is the height of the dimming channel.

[0015] And it needs to meet the following requirements:

[0016] .

[0017] In a preferred embodiment, the inner wall material of the dimming channel is one of silicone, PVC, aluminum foil, PVB adhesive, PUR adhesive, UV adhesive, OCA adhesive, hot melt adhesive, or epoxy adhesive.

[0018] In a preferred embodiment, the cross-section of the dimming channel is square, hexagonal, or circular.

[0019] In a preferred embodiment, the thickness of the gap layer is 0.001-1mm, and the duty cycle of the gap layer is 50%-99%.

[0020] The preferred technical solution involves the distribution and setting of several dimming channel arrays.

[0021] In a preferred embodiment, the scattering layer contains diffused ions.

[0022] In a preferred embodiment, the first optical microstructure protrusions and / or recesses are disposed 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] In a preferred embodiment, the second optical microstructure protrusions and / or recesses are disposed 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] In a preferred embodiment, the surface of the scattering layer is provided with a coating layer, which includes one or more layers of film system with functions such as anti-oxidation, heat insulation, anti-ultraviolet radiation, anti-reflection, and anti-reflection.

[0025] In a preferred embodiment, the first optical microstructure is disposed on the inner surface and / or the outer surface of the scattering layer; the second optical microstructure is disposed on the inner surface and / or the outer surface of the angle control layer.

[0026] Compared with existing technologies, the beneficial effects are:

[0027] (1) Synergistic enhancement of light effect and function

[0028] By coupling the dimming channel and the angle control layer, high luminous efficiency is achieved while simultaneously optimizing light angle control, anti-glare, and light spot uniformity, breaking through the contradiction between "scattering efficiency reduction" 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, which forms a complementary optical path guide with the honeycomb array of the dimming channel, reducing the reflection loss at the interlayer interface. The microstructure of the angle control layer performs secondary calibration of the light output angle, achieving precise control of the beam angle and meeting the needs of precision lighting scenarios.

[0031] (3) Multifunctional integration and lightweight design

[0032] By integrating scattering, dimming, and anti-glare functions into a three-layer composite device with a total thickness of ≤2mm, the device combines these functions, is compatible with ultra-thin lamps and embedded lighting equipment, and expands its application scenarios such as commercial space lighting and indoor lighting.

[0033] (4) Enhanced edge spot control capability

[0034] The honeycomb micro-aperture array of the dimming channel, combined with the asymmetric pyramid of the angle control layer, suppresses edge scattering in traditional structures, effectively reduces edge glare intensity, effectively eliminates halo effects, and improves visual comfort. Attached Figure Description

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

[0036] Figure 2 yes Figure 1 A cross-sectional schematic diagram.

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

[0038] Figure 4 This is a layer structure exploded diagram of Embodiment 2 of the present invention.

[0039] Figure 5 yes Figure 4 A cross-sectional schematic diagram.

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

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

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

[0043] Figure 9 This is a graph showing the brightness test results of the present invention.

[0044] Figure 10 This is a diagram showing the results of a planar illuminance test of the present invention.

[0045] Reference numerals: 1. Scattering layer; 2. Gap layer; 3. Angle control layer; 4. Dimming channel; 5. First optical microstructure. Detailed Implementation

[0046] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0047] Example 1

[0048] A dimming module with a three-layer composite structure includes a scattering layer, a gap layer and an angle control layer, which are compositely arranged, with the gap layer 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, which are protrusions or depressions disposed on the surface of the scattering layer. The shape of the protrusions or depressions can be one of pyramidal, prismatic, ellipsoidal, or irregular. The arrangement of the first optical microstructures can be uniform, gradually varied, or randomly arranged. The scattering layer is attached to the surface of the gap layer with a transparent adhesive. Furthermore, the scattering layer contains diffusing particles.

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

[0051] In addition, the surface of the scattering layer is provided with a coating layer, which includes one or more layers of film system with functions such as anti-oxidation, heat insulation, anti-ultraviolet radiation, anti-reflection and anti-reflection.

[0052] The inner and / or outer surfaces of the angle control layer have several second optical microstructures. These second optical microstructures are protrusions or depressions disposed on the surface of the angle control layer. The shape of the protrusions or depressions can be one of a pyramid, prism, lens, V-groove, or hemisphere. The arrangement of the second optical microstructures can be uniform, gradually varied, or randomly arranged. The angle control layer is used to shape the light passing through the gap layer, achieving anti-glare, polarization, dual polarization, beam convergence, and diffusion.

[0053] Specifically, the angle control layer is made of any one 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, which can control light and improve the anti-glare effect. This anti-glare effect effectively reduces the impact of large-angle stray light on the indoor lighting environment while maintaining appropriate brightness output and providing a comfortable visual experience.

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

[0055] The angle of light within the dimming channel must meet the following requirements:

[0056]

[0057] or,

[0058]

[0059] Wherein, angle α is the average beam angle of the light source emitted from the scattering layer (the radius-vector angle at 50% of the maximum light intensity). The angle is the beam angle of light rays incident on the dimming channel after passing through the dimming channel. The angle is the beam angle of light rays incident on the inner wall of the dimming channel after passing through the dimming channel. It is the distance between the top edges of two adjacent dimming channels. H is the distance between the lower ends of two adjacent dimming channels, and H is the height of the dimming channel.

[0060] And it needs to meet the following requirements:

[0061]

[0062] Conversely, since the light exit interface inside the incident dimming channel is the boundary between the material and the air, it is necessary to comprehensively consider the influence of total internal reflection and high-reflectivity coating on the light efficiency. The tilt angle has an important influence on dimming performance. When the average beam angle of the incident angle control layer is less than 115°, it has a better uniform light and angle control effect.

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

[0064] Specifically, the inner wall material of the dimming channel is one of silicone, PVC, aluminum foil, PVB adhesive, PUR adhesive, UV adhesive, OCA hot melt adhesive, or epoxy adhesive. For example, the gap layer uses a transparent silicone film as the substrate, and a mesh structure composed of several dimming channels is constructed inside it. Another example is that the gap layer uses a PVC board bonded with double-sided tape, and several through dimming channels are formed on the PVC board.

[0065] In this invention, light passing through the scattering layer is uniformly diffused due to the scattering effect of the first optical microstructure on the surface. Since the scattering layer is adjacent to the dimming channel, some of the light incident on 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 light comes into contact with 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-prismatic structure with anti-glare effect, which further controls the light whose angle has been adjusted by the dimming channel, thus giving it a better anti-glare effect.

[0066] This design allows for better control of the emitted beam angle, and the overall thickness can be controlled to below 2mm. Compared with traditional structures, it has higher light efficiency, a more delicate structure, and can suppress the scattering phenomenon at the edge of the light spot, effectively reducing the intensity of edge glare and halo phenomenon.

[0067] Since the prism array structure of the angle control layer has the function of controlling anti-glare, the less large-angle scattered light of the incident light, the better the anti-glare effect. In addition, 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, in Example 2, the inner wall of the dimming channel is vertically arranged, the surface of the dimming channel is perpendicular to the scattering layer, and the dimming channel material is a light-absorbing material. Most of the large-angle light rays are absorbed after hitting the inner wall of the dimming channel, with a small portion being reflected and refracted before hitting the angle control layer. After the light rays enter the angle control layer, they are precisely focused at the beam angle by the surface microlens array. By adjusting the depth and aperture size of the dimming channel and the microlens array parameters of the angle control layer, beam angle focusing at various angles can be achieved.

[0070] This design allows the beam angle of the desired emitted light to be pre-selected before it reaches the angle control layer, achieving precise control of the beam angle.

[0071] After passing through the scattering layer, light rays striking the inner wall of the dimming channel are absorbed. Light rays at small angles that do not contact the aperture wall continue to exit into the angle control layer. The exit angle of the light in the dimming channel depends on the ratio of the aperture size to the depth of the dimming channel. 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] Because 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 at the required angle is filtered out, thereby achieving precise control of the beam angle.

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

[0076] Table 1

[0077]

[0078] Table 2

[0079]

[0080] Table 3

[0081]

[0082] The tests show that, as shown in Table 1, with the dimming channel height remaining constant, the lower the UGR value and the better the anti-glare performance as the duty cycle increases, while the luminous flux remains unaffected. Similarly, in Table 3, with the duty cycle remaining constant, the anti-glare performance improves as the dimming channel height increases; however, once the height exceeds 1.0 mm, the UGR value gradually increases again, and the anti-glare performance decreases. Therefore, considering Tables 1, 2, and 3, this invention employs a gap layer duty cycle of 50-99% and a gap layer height of 0.001-1 mm to maintain the anti-glare performance within a certain excellent range.

[0083] Furthermore, the anti-glare performance of the dimming module of the present invention was tested, and the results are as follows: Figure 7As shown, the glare level of light within 65° can reach level C. Generally, UGR < 13, UGR < 16, and UGR < 19 are three levels, and currently it falls at the level of 16 < UGR < 19. This invention achieves high luminous efficiency while simultaneously optimizing light angle control, anti-glare, and light spot uniformity through the functional coupling of the dimming channel and the angle control layer, breaking through the contradiction between "scattering efficiency reduction" and "anti-glare unevenness" in traditional technologies.

[0084] Furthermore, a light intensity test was conducted on the dimming module of the present invention, and the results are as follows: Figure 8 As shown, the 10%-90% isothermal curves indicate a uniform light intensity distribution. Brightness tests were 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 this invention adopts a microstructure scattering design, which forms a complementary optical path guide with the honeycomb array of the dimming channel, reducing the reflection loss at the interlayer interface. Furthermore, the microstructure of the angle control layer performs secondary calibration of the light output angle, achieving precise control of the beam angle and meeting the needs of precision lighting scenarios.

[0085] Furthermore, a planar illuminance test was conducted on the dimming module of the present invention, and the results are as follows: Figure 10 As shown in the figure, halo phenomena typically cause secondary peaks in illuminance at the edge of the light spot. However, as can be seen from the figure, the planar illuminance curve of this invention is smooth and gentle, effectively eliminating the halo phenomenon. The honeycomb micro-pore array of the dimming channel, combined with the asymmetric pyramid of the angle control layer, suppresses edge scattering in traditional structures, effectively reduces edge glare intensity, effectively eliminates the halo phenomenon, and improves visual comfort.

[0086] In the description of this invention, it should be understood that the terms "upper," "lower," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use, or the orientation or positional relationship commonly understood by those skilled in the art. They are only used to facilitate the description of this invention and to simplify the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0087] 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 technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0088] Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of this invention.

Claims

1. A dimming module with a three-layer composite structure, characterized in that, It includes 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 several first optical microstructures; The surface of the angle control layer has several second optical microstructures; The gap layer includes several 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 1.2~1.8; The angle of light within the dimming channel must meet the following requirements: or, Wherein, angle α is the average beam angle of the light source emitted from the scattering layer. The angle is the beam angle of light rays incident on the dimming channel after passing through the dimming channel. The angle is the beam angle of light rays incident on the inner wall of the dimming channel after passing through the dimming channel. It is the distance between the top edges of two adjacent dimming channels. H is the distance between the lower ends of two adjacent dimming channels, and H is the height of the dimming channel. And it needs to meet the following requirements: 。 2. The dimming module with a three-layer composite structure as described in claim 1, characterized in that, The inner wall material of the dimming channel is one of the following: silicone, PVC, aluminum foil, PVB adhesive, PUR adhesive, UV adhesive, OCA adhesive, hot melt adhesive, or epoxy adhesive.

3. The dimming module with a three-layer composite structure as described in claim 1, characterized in that, The cross-section of the dimming channel is square, hexagonal, or circular.

4. The dimming module with a three-layer composite structure as described in claim 1, characterized in that, The thickness of the gap layer is 0.001-1mm, and the duty cycle of the gap layer is 50%-99%.

5. The dimming module with a three-layer composite structure as described in claim 1, characterized in that, Several dimming channel arrays are distributed and set up.

6. The dimming module with a three-layer composite structure as described in claim 1, characterized in that, The scattering layer contains diffused ions.

7. The dimming module with a three-layer composite structure as described in claim 1, characterized in that, The first optical microstructure has protrusions and / or recesses disposed 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 as described in claim 1, characterized in that, The second optical microstructure protrusions and / or recesses are disposed 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 as described in claim 1, characterized in that, The surface of the scattering layer is provided with a coating layer, which includes one or more layers of film system with functions such as anti-oxidation, heat insulation, anti-ultraviolet radiation, anti-reflection and anti-reflection.

10. The dimming module with a three-layer composite structure as described in claim 1, characterized in that, The first optical microstructure is disposed on the inner surface and / or outer surface of the scattering layer; the second optical microstructure is disposed on the inner surface and / or outer surface of the angle control layer.

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