Design method of spreadlight lens, spreadlight lens and wall washer

Abstract

The invention relates to the technical field of illumination, in particular to a spreadlight lens design method, a spreadlight lens and a wall washer lamp. The spreadlight lens design method comprises the steps of obtaining design target information according to index requirements of expected application on output light; carrying out light source modeling according to parameters of the selected LED light source to obtain light source input data; according to the target design information and the light source input data, performing light-emitting surface function decomposition to obtain a light-emitting surface function target; according to the light-emitting surface function target, carrying out light-emitting surface preliminary construction to obtain a light-emitting surface structure composed of a plurality of free-form surface units; and determining a preceding-stage beam-shaped structure according to the light-emitting surface structure and the light source input data. The overall lighting effect of the wall washing lamp can be improved.

Description

Technical Field

[0001] This invention relates to the field of lighting technology, and more particularly to a polarizing lens design method, a polarizing lens, and a wall washer light. Background Technology

[0002] In the current lighting technology field, traditional linear wall washer lights widely use lenses with 180-degree light distribution and no polarization design. The light distribution characteristics of this type of lens result in a limited light projection range when applied to ceiling lighting scenarios, illuminating only a localized area of ​​the ceiling and causing a large dark area in the center, severely affecting the integrity and uniformity of the lighting effect. Simultaneously, due to the inefficient distribution of light, a large amount of light energy is not effectively applied to the target lighting area, resulting in low luminous efficiency. This not only fails to meet the demands of high-quality lighting but also leads to energy waste. Summary of the Invention

[0003] In view of this, embodiments of the present invention provide a polarizing lens design method, a polarizing lens, and a wall washer light, to solve the technical problem that existing wall washer lights cannot meet the requirements for high-quality lighting.

[0004] In a first aspect, the present invention provides a method for designing a polarizing lens, comprising: S1: Obtain design target information based on the expected application's requirements for output light specifications; S2: Based on the parameters of the selected LED light source, perform light source modeling to obtain light source input data; S3: Based on the target design information and light source input data, perform functional decomposition of the light-emitting surface to obtain the target function of the light-emitting surface; S4: Based on the functional objectives of the light-emitting surface, the light-emitting surface is initially constructed to obtain a light-emitting surface structure composed of multiple freeform surface units; S5: Determine the preamp beam structure based on the light-emitting surface structure and the light source input data.

[0005] Secondly, the present invention provides a polarizing lens designed using the method described in the first aspect. The polarizing lens includes a total reflection surface, an incident surface, and an exit surface. The incident surface base plate is provided with a central convex curved optical surface and multiple reflective units. The light emitted by the light source is divided into three parts at the incident surface. The first part of the light is reflected by the total reflection surface, the second part is reflected twice by the bottom reflective unit, and the third part is refracted by the convex curved surface. The three light paths are superimposed to form a collimated beam. The exit surface is provided with a polarizing array, which consists of three discrete freeform surface optical units, and the radius of curvature of each optical unit varies in a gradient.

[0006] Thirdly, the present invention provides a wall washer light, comprising: a light source and the polarizing lens described in the second aspect.

[0007] In summary, the beneficial effects of the present invention are as follows: The polarizing lens design method, polarizing lens, and wall washer provided by this invention can meet the high lighting requirements of wall washer lights. Based on the light output indicators of wall washer lights such as rectangular shape, high uniformity, and small-angle directional deflection, and under the constraint of the parameters of the light source used, the design can meet the light output requirements. The multi-free-form surface unit at the light output end can achieve a composite shaping of lateral widening, longitudinal narrowing, and small-angle orientation. Combined with the pre-amplifier beam-shaping structure, a collimated beam is first formed, and then the beam is expanded in angle and deflected to a set angle through asymmetric refraction. This significantly improves the uniformity of wall illumination and edge smoothness, reduces glare and stray light, reduces dark bands near the wall, and improves light energy utilization and visual comfort. Attached Figure Description

[0008] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the embodiments of the present invention will be briefly introduced below. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, and these are all within the protection scope of the present invention.

[0009] Figure 1 This is a flowchart illustrating a polarizing lens design method according to the present invention; Figure 2 This is a schematic diagram of the structure of the polarizing lens of the present invention; Figure 3 This is a schematic diagram of the optical path distribution of the present invention; Figure 4 This is a light intensity distribution curve of an LED lamp that uses the polarizing lens of the present invention; Figure 5 This is a diagram showing the lighting effect of an LED lamp using the polarizing lens of this invention at a distance of 5 meters.

[0010] The components and their numbers shown in the picture: 1. Light-incident surface; 2. Light-outcrystal surface; 3. Total internal reflection surface; 4. Reflection unit; 5. Central convex curved optical surface; 6. Freeform surface optical unit; 7. Elastic claw. Detailed Implementation

[0011] The features and exemplary embodiments of various aspects of the present invention will now be described in detail. To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only configured to explain the present invention and are not configured to limit the present invention. For those skilled in the art, the present invention can be practiced without some of these specific details. The following description of the embodiments is merely intended to provide a better understanding of the present invention by illustrating examples of the invention.

[0012] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising..." does not exclude the presence of additional identical elements in the process, method, article, or apparatus that includes said element.

[0013] It should be noted that all actions involving the acquisition of signals, information, or data in this invention are carried out in compliance with the relevant data protection laws and regulations of the locality and with authorization from the owner of the relevant device.

[0014] Example 1 Please see Figure 1 This embodiment provides a polarizing lens design method, the method comprising: S1: Obtain design target information based on the expected application's requirements for output light specifications; The design target information refers to the quantification of output light and scene boundary requirements, such as far-field spot shape (e.g., near-rectangular), horizontal and vertical half-intensity angle range, overall small-angle directional deflection, illuminance uniformity threshold, target test distance, glare limitation, and back-off distance and splicing width related to wall washer installation.

[0015] This step transforms the performance requirements into acceptable objective indicators, forming a consistent criterion that runs through design, simulation, and verification, thus avoiding blind trial and error at the structural and surface levels in the future.

[0016] In practical implementation, the observation plane and test geometry can be determined, scene priorities can be collected and upper and lower limits of indicators can be fixed, and the core indicators that must be met and the secondary indicators that can be weighed can be recorded in layers. The acceptance methods and data formats (such as light intensity distribution and illuminance matrix) can be clearly defined. This facilitates cross-departmental communication, and any parameter changes can be mapped to a specific dimension, significantly shortening the convergence cycle and reducing rework.

[0017] S2: Based on the parameters of the selected LED light source, perform light source modeling to obtain light source input data; Light source modeling refers to organizing information such as the package shape, luminous surface size, angular intensity distribution, luminous flux and color temperature, operating current and junction temperature, light emission center and mounting reference position, and tolerance range of the selected LED into a complete set of data that can directly drive simulation and design. The light source input data usually includes representative ray sets, equivalent luminous surface models, angular distribution and spectral changes under different temperatures and currents, and the assembly reference surface relationship between the light source and the lens.

[0018] In practical implementation, a ray library and equivalent emitting surface can be generated based on the device datasheet and proprietary tests (angle measurement, integrating sphere, and thermo-electric coupling experiments); a temperature and current condition table can be established to obtain the angle and spectral distribution under different conditions; the assembly datum and tolerance of the light source and lens can be defined to form a unified coordinate and reference surface; thus, the design can be aligned with the real source from the beginning, the adaptability across part numbers and batches can be enhanced, the consistency of chromaticity and brightness can be more stable, and the accuracy of subsequent energy budget and efficiency evaluation can be improved.

[0019] S3: Based on the target design information and light source input data, perform functional decomposition of the light-emitting surface to obtain the target function of the light-emitting surface; The functional decomposition of the light surface refers to mapping the requirements of the design objectives, such as the far-field shape, horizontal and vertical divergence range, overall small-angle directional deflection and uniformity, into specific functional modules that the light end needs to perform. For example, modules for horizontal widening, modules for vertical narrowing, modules for achieving small-angle orientation, and modules for suppressing ripples and improving uniformity, and clarifying the priority and synergistic relationship between each module.

[0020] This step breaks down the composite objective into manageable sub-projects, allowing subsequent geometric modeling and optimization to each have their own focus, thus reducing the coupling between different roles.

[0021] In practical implementation, the deflection direction and the shaping amplitude of the two principal axes can be determined first based on the design target information. Then, the sensitivity of each effect to the incident light field can be evaluated in conjunction with the light source input data. The light-emitting surface is divided into several functional regions, and the target refractive intensity and directional trend of each region are given. Transition and seam rules between regions are set (such as first-order or second-order continuity requirements at the boundary), and a correspondence table of function-region-indicator is formed. This allows for a one-to-one correspondence between function and geometry, clear evaluation criteria, and subsequent independent fine-tuning of a certain functional region to improve rectangularity and uniformity without sacrificing overall orientation and efficiency.

[0022] S4: Based on the functional objectives of the light-emitting surface, the light-emitting surface is initially constructed to obtain a light-emitting surface structure composed of multiple freeform surface units; A freeform surface unit refers to a curved surface region on the light-emitting surface that is divided according to function. Each region can independently control the light through curvature and local slope to achieve directional shaping and homogenization. An array composed of multiple units can be used to asymmetrically expand or narrow to achieve overall small-angle orientation.

[0023] This step transforms the required function into a manufacturable and simulable geometric shape, outputting a traceable initial surface shape, providing a stable interface for subsequent beam fitting and overall machine optimization.

[0024] In practical implementation, splines or NURBS and other surface representation methods can be used to set the initial values ​​of curvature and sagitta for each functional unit, and apply an overall micro-tilt or equivalent local slope along the target deflection direction; set continuity constraints on the unit joints to eliminate seam shadows and stripes, so that the light-emitting end has the geometric ability of asymmetric shaping and small-angle orientation, while satisfying manufacturability in the early stage, reducing the number of later mold repairs and iterations.

[0025] S5: Determine the preamp beam structure based on the light-emitting surface structure and the light source input data.

[0026] A preamplifier beamforming structure refers to an internal optical assembly placed before the light-emitting surface to organize the wide-angle beam generated by the light source and distribute it according to the target energy ratio. The preamplifier beamforming structure can be composed of a peripheral wall total internal reflection light guide surface (forming a collimation skeleton and narrow-direction control), a bottom reflection unit (providing directional supplementary light to the off-axis area and suppressing ripples), and a central convex curved light-transmitting surface (enhancing paraxial brightness and smoothing the transition from the center to the edge).

[0027] This step sets the source output to an incident state where the light-emitting surface is easily shaped, and at the same time, the energy is reasonably distributed according to the three channels, laying the foundation for the final beamforming of a far field that meets the target divergence range, has small-angle orientation, and is highly uniform.

[0028] In practical implementation, the required incident angle and intensity distribution at the light-emitting surface can be deduced based on the structure of the light-emitting surface and the input data of the light source, and the responsibilities and energy proportions of the three channels can be determined accordingly. Then, the start and end positions, wrap angles, and contour types of the peripheral wall total reflection surface are determined to form a collimation channel. The number, planar position, and tilt angle of the bottom reflection unit are arranged to supplement off-axis energy and control the skirt. The curvature and height of the central convex light-transmitting surface are set to improve paraxiality and transition. If necessary, inner light-shielding ribs are added to limit the overflow of the channel junction area and reduce glare. After completing coarse tracing and stray light verification, the pre-amplifier beam shape parameter set is output and integrated with the light-emitting surface for overall optimization. This makes the incident beam angle received by the light-emitting surface more standardized and the energy more controllable. Subsequent asymmetric refraction is more likely to form target rectangularity and uniformity, and while meeting illuminance requirements, glare and stray light are reduced, improving light energy utilization and luminaire splicing consistency.

[0029] In this embodiment, only S5: determining the pre-stage beamform structure based on the light-emitting surface structure and the light source input data includes; S51: Based on the light-emitting surface structure and the light source input data, extract the key features of the target far field to obtain the target far field feature set used for constraining the splitting; The target far-field feature set refers to a set of quantifiable far-field indicators used to constrain beam splitting and beamforming, such as spot shape and rectangularity, lateral and longitudinal half-intensity angles, overall small-angle directional deflection, illuminance uniformity threshold, edge roll-off curve, glare limitation, splicing transition width, and intensity distribution matrix at the target test distance. This feature set can transform the visual perception of a wall-washing scenario into hard constraints usable in engineering.

[0030] This step establishes the constraint coordinate system for subsequent backtracking and splitting, ensuring that the task of each optical path directly targets far-field performance, avoiding repeated trial and error caused by starting only from the structural end. In practice, the target IES curve and target illuminance matrix can be partitioned and statistically analyzed to extract hotspot locations, iso-illuminance linear density, major and minor axis energy ratios, and edge roll-off slopes. Combined with UGR or shading angle requirements, forbidden angle regions are marked, forming a weighted list of indicators and criterion thresholds. This clearly defines the desired light as the amount that must be achieved, providing a unified benchmark for the responsibilities and energy budgets of each channel, significantly improving design convergence.

[0031] S52: Based on the target far-field feature set, perform a backward mapping of the incident light field at the light-emitting surface to obtain the pre-stage collimated beam and energy ratio; Back-mapping refers to deriving the incident angle and intensity distribution that need to be received at the light surface from the far-field feature set of the target; the pre-collimating beam refers to the beam with the target angle ratio and cross-sectional shape after being organized by the internal structure before the light exits the light surface.

[0032] In practical implementation, the incident angle domain and intensity distribution of the light-emitting surface can be determined based on the divergence and deflection directions of the target's major and minor axes. Using this as a constraint, the target's far field is mapped to the incident field of the light-emitting surface through edge ray pairing or iterative optimization. This incident field is then normalized into pre-stage collimation beam parameters (angle range, cross-sectional shape) that are easy to implement in engineering, and energy channel budgeting is performed to obtain the energy ratio of the three paths. This naturally aligns the light-emitting end with the pre-stage beam shape, reducing significant rework and increasing the probability of achieving consistent luminous efficiency and uniformity.

[0033] S53: Based on the pre-amplifier collimating beam and energy ratio, functional partitioning is performed to obtain the functional, spatial, and angular allocation of the three-way splitting; Functional zoning refers to dividing the internal optical structure into several channels according to their functions. Three-way splitting refers to distributing incident light according to spatial and angular domains to the peripheral wall total internal reflection channel, the bottom reflection channel, and the central convex transmission channel. This step decouples the three tasks—collimation framework, off-axis fill light, and paraxial brightening—to different channels, clearly defining their respective spatial occupancy and incident angle domain, reducing mutual coupling, and leaving independent degrees of freedom for subsequent geometric settings. In specific implementation, the three-channel task framework is first determined based on the pre-stage collimating beam and the energy ratio of the three channels; the occupancy areas of the peripheral wall, bottom, and center are delineated based on the structural boundaries; then, the incident angle domain and allowable overlap area of ​​each channel are set according to the angular distribution of the pre-stage collimating beam, and symmetry rules and priorities are given. This ensures that each channel is responsible for only a limited number of targets, the impact of parameter tuning is predictable, uniformity improvement and glare suppression are more controllable, and overall convergence is faster.

[0034] S54: Based on the energy ratio and the function, space and angle allocation of the three-way split, the channel boundary and transition constraints are set to obtain the incident beam shape and energy ratio target required for the three-way split; Channel boundary and transition constraints refer to the rules for angle overlap, energy gradient and structural transition set for the adjacent boundaries of three channels, which are used to avoid bright stripes, dark seams or glare leakage at the joints.

[0035] This step, with a clear division of labor, ensures smooth energy and angle transitions between channels, so that the composite beam shape satisfies both divergence and deflection targets while maintaining a fine beam texture. In practice, the width of the overlap zone and the gradient function (linear, S-shaped, etc.) can be determined based on the energy ratio and angular domain division, limiting the maximum slope and allowable deviation of each channel edge; if necessary, inner light-blocking ribs or micro-labyrinth grooves can be added to cut off outgoing light; stray light is simultaneously rapidly evaluated and iteratively corrected to output the incident beam shape and energy ratio target required for the three-way splitting. Its beneficial effects are a cleaner far-field edge and a significant reduction in fringes.

[0036] S55: Determine the preamplifier structure for each optical path based on the incident beam shape and energy ratio target required for the three-way split.

[0037] The preamplifier beamform structure refers to the specific initial geometric values ​​of each channel, including the start and end positions, wrap angle and profile type of the total reflection surface on the perimeter wall, the number, planar position and tilt angle of the bottom reflection unit, and the curvature and height of the central convex light-transmitting surface.

[0038] This step transforms the beam shape and energy target into structural parameters, providing a stable starting point for subsequent optimization. In practice, based on the incident shape and energy target output by S54, the wrap angle and initial contour values ​​of the peripheral wall channel are first established to form a collimated skeleton; then, several bottom reflective units are arranged according to the off-axis supplementary lighting direction and the tilt angle is set; subsequently, the curvature and sagitta of the central convex light-transmitting surface are determined to smooth the transition from the center to the edge.

[0039] In this embodiment, step S55: determining the pre-stage beamform substructure of each optical path according to the incident beam shape and energy ratio target required for the three-way splitting includes: S551: Based on the incident beam shape and energy ratio target, determine the position and geometry of the total internal reflection surface of the peripheral wall, and obtain the initial parameters of the total internal reflection light guide surface of the peripheral wall; The peripheral wall total internal reflection guiding surface refers to the curved surface of the lens cup wall used to achieve total internal reflection guiding; the start and end positions refer to the geometric start and end points of this curved surface in the axial and radial directions; the wrap angle is the angular range of the peripheral wall surrounding the incident light along the optical axis; the profile type can be conical or spherical, free-form spline, or segmented composite. Based on the incident beam shape and energy ratio target, this step establishes a narrow-direction controlled, efficiency-priority collimating skeleton, enabling the pre-stage channel to stably deliver the required energy to the output surface without glare leakage. In the implementation process, the peripheral wall light guiding elements are first extracted based on the narrow-directional target and energy ratio of the incident beam, obtaining quantitative constraints on the critical angle, safety margin, and energy passband. Then, combined with the aperture, the start and end positions of the curved surface are determined, and the candidate envelope angle range is checked based on the total internal reflection condition. Subsequently, within the feasible region, the target envelope angle that satisfies the energy ratio and narrow-directional divergence control is selected, the contour type is selected, and initial values ​​of curvature or slope are given. Finally, edge rays and off-axis rays are used for rapid checks on spillover and leakage, obtaining an initial solution including start and end positions, envelope angle, and contour parameters. Relying on this technical feature, the peripheral wall channel can achieve narrow-directional shaping and spillover suppression with high efficiency, reducing the risk of stray light and direct glare, and providing a stable and repeatable incident edge for subsequent channel supplementary lighting and center transition.

[0040] S552: Based on the incident beam shape and energy ratio target, determine the initial parameters of the bottom reflective unit according to its geometry, number, position and tilt angle; The bottom reflector unit refers to a small mirror-like surface or freeform surface located on the incident light base plate, used to directionally reflect part of the source light back to the main output direction; its geometry can be a plane, a cylindrical / conical cross section, or a small freeform surface; the number and planar position are usually distributed according to the principle of optical axis symmetry; the tilt angle is used to control the output direction and coverage area after reflection. This step provides directional supplementary lighting to address off-axis energy and uniformity gaps, suppressing skirt ripples and light spot stripes, so that the composite beam achieves a smoother illuminance distribution while meeting divergence and deflection indices. In the implementation process, the light-deficient and energy-excess regions can be identified first based on the incident beam shape and energy ratio. The effective area of ​​the bottom unit can then be defined, and its quantity determined (e.g., bi-symmetric or quadri-symmetric). Subsequently, while ensuring assembly and electrical clearances, the initial planar position of each unit is determined, ensuring that its reflected light falls into the target angular region and overlap area. Next, the geometric shape type is selected based on the supplementary lighting direction and coverage width requirements (planar surfaces are easier to control, while cylindrical / freeform surfaces are beneficial for widening or narrowing), and the initial tilt angle and opening size are set to meet the energy quota. Finally, considering surface quality and process limitations, edge chamfering and transitions are processed to avoid imaging edges and bright lines. Through these technical features, the bottom channel can improve far-field uniformity and reduce stripes without significantly sacrificing efficiency.

[0041] S553: ​​Based on the incident beam shape and energy ratio target, determine the curvature and height of the central convex surface of the central convex light-transmitting surface, and obtain the initial parameters of the central convex surface.

[0042] The central convex curved light-transmitting surface is a refractive surface located at the center of the incident light surface base plate. It is used to enhance paraxial brightness and smooth the energy transition from the center to the edge. The curvature determines the refractive intensity and paraxial convergence. The height (sagitta) determines the undulation of the surface relative to the reference surface and affects the refraction path and process feasibility. This step establishes a centrally supported refractive channel in the three-way split, eliminating central concavity or bright spot overshoot, so that the composite beam has a smoother axial energy distribution before entering the exit light front, thereby obtaining higher rectangularity and comfort for subsequent asymmetric refraction. In the implementation process, the quantitative requirements for paraxial brightness enhancement and transition smoothing can be extracted first based on the incident beam shape and energy ratio target, as well as the initial parameters of the peripheral wall and bottom unit. Then, under the condition of meeting the light source packaging height and safety clearance, the reference position of the surface is anchored, a suitable shape type (spherical, aspherical, or locally freeform surface) is selected, and an initial curvature value is given to match the target refractive intensity. Then, combined with the central energy quota, the initial height value is set, and the initial parameters of the central convex curved surface are output. Based on this structure, paraxial energy is effectively supported and the center-edge transition is smoother, which can improve visual uniformity and effective illumination without increasing glare. At the same time, it provides a more controllable incident basis for the light-emitting surface to achieve small-angle orientation and asymmetric widening.

[0043] In this embodiment, step S551: determining the position and geometry of the peripheral wall total internal reflection surface based on the incident beam shape and energy ratio target, and obtaining the initial parameters of the peripheral wall total internal reflection light guide surface includes: Based on the incident beam shape and energy ratio target, the light guiding control elements are extracted to obtain the peripheral wall light guiding target: Light guiding control elements refer to the set of key parameters that determine whether the peripheral wall can efficiently capture and guide incident light. These include, for example, the allowable incident angle window, the safety margin for the critical angle, the desired energy passband, restrictions on edge rays, requirements for suppressing stray light and glare, and constraints on surface quality and roughness. The peripheral wall light guiding objective integrates these elements into actionable engineering goals, such as capturing energy in a specific polar angle band, guiding the light forward with minimal loss, and forming a narrow collimating skeleton. This step transforms the design requirements of how the incident beam should be handled by the peripheral wall into clear control objectives, ensuring that subsequent geometric design and verification are based on sound principles. In implementation, an angle-intensity decomposition can be performed on the preceding incident beam to identify the polar angle region and energy proportion that needs to be handled by the peripheral wall channel, extracting edge rays and high-weight rays as the skeleton; combining glare limitations and assembly tolerances, the safety margin for the critical angle, the allowable number of reflections, and the upper limit requirements for spillover light are given; and a target table of angle window—energy target—quality constraint is formed. This allows the peripheral wall design to meet the optimal requirements of high efficiency and low glare, reducing subsequent rework and improving the overall convergence speed.

[0044] Based on the light guiding target on the peripheral wall, the channel occupancy, and the structural boundary conditions, determine the start and end positions of the peripheral wall: The starting and ending positions of the peripheral wall refer to the geometric beginning and end points of the total internal reflection light guide surface in the axial and radial directions. The channel occupancy is the spatial layout boundary of the three-way split, used to avoid mutual interference. This step delineates the most reasonable geometric corridor for the peripheral wall channel, ensuring that it does not encroach on the working space of the bottom and central channels while providing sufficient reflection stroke for stable beam formation. During implementation, a usable envelope can be given based on the assembly relationship between the lamp body and the lens; a buffer zone for the splice and transition of the light-emitting surface is reserved at the light-emitting end, and light source pads and wires are avoided on the light-incident side; through the intersection of two-dimensional sectioning and three-dimensional envelope, feasible starting radius, ending radius, and axial height range are quickly obtained, and the symmetry reference plane and positioning datum are locked. This allows the structure and optics to be aligned synchronously, avoiding passive modifications due to mechanical interference or channel conflicts in the later stages, and ensuring that the peripheral wall channel has a stable working length and field of view coverage.

[0045] Based on the starting and ending positions of the perimeter wall and the relative position of the light source, the total internal reflection condition is checked to obtain the feasible wrap angle range: Total internal reflection condition verification refers to checking whether the peripheral wall meets the total internal reflection requirements under the combined conditions of material refractive index, surface quality, and incident angle distribution, and leaving a safety margin. The feasible wrap angle range refers to the angular range in which the peripheral wall wraps around the optical axis to contain the light ray, provided that the above verification is passed. This step is used to ensure that the peripheral wall works in a stable total internal reflection zone, avoiding energy leakage, streaks, and glare caused by local transmission. In the implementation process, edge rays and high-angle rays can be used as the most unfavorable samples to perform batch tracing under the influence of refractive index fluctuations caused by different temperatures and batches, as well as the influence of surface micro-roughness. The effective total internal reflection ratio and safety margin are calculated for each candidate wrap angle, and the cumulative loss is evaluated for multiple reflection paths. The set of wrap angles that pass the threshold is defined as the feasible wrap angle range, and its influence trend on energy and narrow-direction divergence is recorded, so that the far field will not have light leakage edges, bright edges, or glare enhancement due to slight deviations, ensuring the stability of efficiency and light quality.

[0046] Based on the feasible envelope range and the target energy ratio of the channel, the envelope angle is selected to obtain the target envelope angle.

[0047] The target envelope angle is the operating point selected within the feasible range, considering overall efficiency, uniformity, and the synergy of the three energy paths; the energy proportion target is the constraint on the energy distribution ratio of the three channels. This step ensures that the peripheral wall bears its due share of energy without compromising the functional space of the bottom supplementary lighting and the central transition. During implementation, parameter scanning can be performed on the feasible envelope angle range to record the total coupling efficiency, narrow-direction half-intensity angle, the impact on incident coupling of the bottom and central channels, and stray light indicators; combining the energy proportion target and uniformity weight, a multi-objective scoring method is used to select the target envelope angle; if necessary, sensitivity analysis is introduced to favor solutions that are less sensitive to assembly and batch differences, thereby making the three-path division of labor more balanced. The peripheral wall provides a stable collimation framework while leaving room for optimization in other channels, resulting in a synergistic improvement in overall efficiency and uniformity.

[0048] Based on the target containment angle and the narrow-directional divergence control target, the contour type is selected to obtain the peripheral wall contour type and curvature.

[0049] Contour type refers to the selection of the geometric family of the peripheral wall in the generatrix direction, which can be a single cone or spherical cone, spline free curve, or piecewise composite. Curvature is a parameter describing the strength and rhythm of contour bending. This step accurately shapes narrow-direction divergence and suppresses texture by using appropriate contour families and curvature distributions, while taking into account manufacturability and demolding requirements. During implementation, a candidate contour library can be established: regular generatrixes are easy to manufacture and stable, while free splines allow for fine-tuning of local angular responses. Under the premise of a fixed target wrap angle, initial values ​​of curvature and slope are given first, and then the shape of the generatrix is ​​fine-tuned using edge rays and weighted rays to make the narrow-direction half-intensity angle and edge roll-off meet the target. The minimum radius of curvature, demolding angle, and edge finishing method are checked simultaneously to prevent thin lips and sharp transitions. If necessary, the contour is piecewise composited to reduce stripes while maintaining efficiency. This allows for a cleaner collimated skeleton output from the peripheral wall, controllable narrow-direction divergence, and smooth edges. It also makes it easier to obtain a rectangular and highly uniform far field after subsequent combination with the bottom and central channels, while maintaining consistency and yield in mass production.

[0050] In this embodiment, step S552: determining the initial parameters of the bottom reflective unit based on the incident beam shape and energy ratio target, according to the geometry, number, position, and tilt angle of the bottom reflective unit, includes: Based on the incident beam shape and energy ratio target, off-axis energy and uniformity gap identification are performed to obtain the supplementary lighting target of the bottom reflective unit; Off-axis energy refers to the light intensity component that should be present but is insufficient in the angular domain far from the optical axis; uniformity gaps refer to significant deviations (such as stripes, dark grooves, or overly bright stripes) between the target illuminance or light intensity distribution and the current distribution in a specific region. In practice, the far-field intensity matrix of the simulation or sample can be statistically analyzed by angular binning and radial ringing at the target test distance to calculate the difference heatmap with the target matrix; then, combined with the iso-illuminance linear density and edge roll-off curve, the location of dark grooves and ripples and their angular width can be located; at the same time, the energy ratio of the three paths can be obtained to infer which areas should be handled by the bottom channel, so that the supplementary lighting task is fixed in point, quantity, and angle, reducing the disturbance to the peripheral wall and central channel, steadily improving uniformity and suppressing the generation of stripes.

[0051] Based on the supplementary lighting target and the incident light requirements of the light-emitting surface of the bottom reflective unit, the supplementary lighting area is delineated to obtain the effective area of ​​the bottom reflective unit: The effective area refers to the deployable area of ​​the bottom reflective unit on the lens base plate and its corresponding exit angle window. This step ensures that supplementary lighting only occurs in spaces beneficial to the light-emitting surface and without conflicting with other channels. In practice, the supplementary lighting target can be mapped to the required incident angle region of the light-emitting surface, and then the base plate coordinates can be derived through reflection geometry. Combined with channel occupancy and structural boundaries (e.g., wires, positioning posts, and snap-fit ​​transition areas), forbidden areas are excluded. Within the deployable area, a priority zone that is easier to hit the target angle region and a buffer zone for fine-tuning and transition are provided to form an effective area mask. This avoids rework caused by space contention or occupancy later and improves the coupling efficiency of each reflective unit to the target angle region.

[0052] The number of bottom reflective units is determined by considering the functional area of ​​the bottom reflective units, the channel occupancy, and the structural boundary conditions. The quantity determination refers to identifying the appropriate number of reflective elements and their symmetry. The goal is to achieve the desired supplemental lighting target with the minimum number of elements while maintaining left-right or four-quadrant symmetry to avoid new sources of inhomogeneity. In practice, rapid ray tracing or response surface evaluation can be performed using symmetrical numbers such as 2, 4, and 6, from smallest to largest, to examine far-field ripple suppression, dark groove filling effects, and energy perturbations between channels. The minimum number of elements that performs stably within assembly tolerances and is easy to manufacture should be prioritized. This approach reduces manufacturing complexity and parameter tuning dimensionality while ensuring improved uniformity, minimizes side effects on the peripheral walls and central channel, and improves mass production consistency.

[0053] Based on the number and symmetry requirements of the bottom reflective units, the planar positions are arranged to obtain the initial values ​​of the planar positions of each bottom reflective unit; The initial planar position refers to the radial distance and azimuth angle of each reflecting unit in the base plate coordinate system. The goal is to ensure that the reflected light from each unit accurately falls into its responsible angular region, covering the dark slot and forming a smooth energy transition with adjacent units. This can be achieved by working backward from the target angular region to the reflection normal and then to the incident trajectory: after determining the target emission direction, the desired normal is obtained using the law of reflection; then, combined with the light-emitting surface of the light source and the installation height, the corresponding unit center position is determined; subsequently, short-range tracing is used to fine-tune the radial and azimuth angles to avoid mutual occlusion and light path conflicts with the peripheral walls and central channel; for the four-quadrant scheme, angular symmetry and consistent radii are maintained, or slight gradients are applied as needed. This layout allows the light to hit the target angular region with the shortest optical path, reducing spillover and cross-interference.

[0054] Based on the initial planar position of each bottom reflective unit and the target supplementary lighting direction, the geometry is selected to obtain the geometry type of the bottom reflective unit; The geometric shapes can include triangular planes, cylindrical or prismatic curved surfaces, small freeform surfaces, or conical / aspherical patches. The goal is to match the angular width and distribution pattern of the target illumination with a suitable family of surface shapes, hitting the target angular region while suppressing local spikes and caustics. The process can begin by selecting the surface shape based on the illumination direction and coverage width: a plane is chosen for narrow-band orientation, a cylinder for widening along a principal axis, and a freeform or aspherical surface for bidirectional fine-tuning and de-rippling. Initial values ​​for curvature or surface shape parameters are then provided, and the minimum radius of curvature and surface difference controllability are verified based on manufacturing and polishing capabilities. If necessary, segmented composite surfaces are used to balance efficiency and smoothness. This allows for smoother energy filling and lower risk of streaks without sacrificing overall luminous efficacy.

[0055] Based on the geometry of the bottom reflective unit and the incident light requirements of the light-emitting surface, the tilt angle is set to obtain the initial tilt angle value of each bottom reflective unit.

[0056] The initial tilt angle refers to the installation tilt angle or normal direction of the reflecting surface relative to the reference surface, used to determine the direction of the reflected light. The purpose is to ensure that the supplementary light truly hits the required incident angle range and overlap area of ​​the emitting surface, and achieves a smooth connection with the peripheral wall and central channel at the interface. The process involves calculating the surface normal from the target emission direction according to the law of reflection, based on the given position and surface shape, and then making tolerance corrections based on the light source height and installation tolerances. The sensitivity of the tilt angle to the far field is verified through rapid Monte Carlo tracing; if necessary, angle sweeping is performed within a small range to find a smooth and efficient working point. Finally, the initial tilt angle value is solidified and the allowable fine-tuning range is recorded. This results in a high supplementary light hit rate, minimal waviness at joints, greater robustness against assembly drift and light source batch differences, and more predictable improvements in overall uniformity and rectangularity.

[0057] In this embodiment, step S553: ​​determining the curvature and height of the central convex surface of the central convex light-transmitting surface based on the incident beam shape and energy ratio target, and obtaining the initial parameters of the central convex surface includes: Based on the incident beam shape and energy ratio target, as well as the initial parameters of the peripheral wall and bottom unit, the functional target of the central convex surface is obtained; The central convex curved light-transmitting surface refers to the refracting surface located at the center of the incident light surface base plate, which enhances paraxial brightness through refraction and smooths the energy transition from the center to the edge. The functional objective refers to a quantitative description of the role this surface should play, such as the paraxial brightness enhancement, the center-to-edge transition slope, the allowable hot spot peak, and its weight in synergy with the three-channel energy. This step, after the peripheral channels have formed a narrow collimating framework and the bottom channel undertakes off-axis supplementary lighting, clarifies the quantitative task of the central channel in centering and smoothing, avoiding central concavity or overshoot, and providing a smoother incident field for subsequent small-angle orientation and asymmetric shaping of the exiting light surface. In specific implementation, the initial values ​​of the three channels can be quickly traced at the target test distance to generate a heat map of the illuminance difference in the central region and a radial energy curve, identifying paraxial gaps and oversaturation areas, providing numerical thresholds for the center proportion, transition slope, and peak suppression, and determining the energy quota and priority of the central channel in conjunction with the three-channel energy ratio. This makes the central channel constraints executable, and the subsequent form and parameter selection are based on evidence, reducing repeated trial and error and local hotspots caused by ambiguity of the target.

[0058] The location of the central convex surface is determined based on its functional objectives, channel occupancy, and structural boundaries. Channel occupancy refers to the spatial division of the three-way split within the lens to avoid mutual interference between channels. Structural boundaries include the height of the light source top surface, the safety clearance between the solder wire and the solder pad, the base plate thickness, the demolding angle, and the avoidance of assembly clips. The purpose of this step is to determine a position for the central curved surface that satisfies the optical lever function without encroaching on the peripheral walls and bottom channels, while still being manufacturable and assembleable. In specific implementation, using the light source's emitting surface and the assembly datum as references in the three-dimensional coordinate system, first determine the maximum allowable aperture radius and minimum edge distance of the central curved surface to ensure that the optical paths between it and the bottom reflective unit do not obstruct each other; then, leave a safe distance in the axial height from the top of the light source and the solder wire, while satisfying the minimum wall thickness and demolding angle constraints; finally, determine the center point and normal direction of the curved surface based on optical axis symmetry, allowing for slight decentering if necessary to compensate for source end offset, thereby ensuring that the central curved surface has sufficient effective aperture and travel, does not compete for space with other channels, reduces manufacturing risks and assembly interference, and ensures the reproducibility of subsequent optical performance.

[0059] Based on the location and functional objectives of the central convex surface, the morphology type is selected to obtain the morphology type of the central convex surface; The morphology types include spherical, aspherical, and locally freeform surfaces. Spherical surfaces are suitable for gentle, rotationally symmetric paraxial brightening; aspherical surfaces offer more flexible refractive intensity distribution at the same sagittal height; locally freeform surfaces allow for precise control of the center-edge energy transition or suppression of fringes. This step uses the family of morphologies that best match the functional objectives and are controllable to handle the central channel task, avoiding overly complex or difficult-to-mass-produce surfaces. In specific implementation, selection rules can be established based on three factors: the brightness enhancement level of the functional objectives, the smoothness of the transition, and the allowable complexity: spherical surfaces are preferred for those requiring gentle brightness and emphasizing rotational symmetry; aspherical surfaces are selected for those requiring higher brightness and control of peak values; locally freeform surfaces or segmented composites are used if targeted modifications to local ripples, seams, or asymmetrical gaps are needed.

[0060] Based on the shape and functional objectives of the central convex surface, the curvature is set to obtain the initial curvature value; The initial curvature value refers to the first set of parameters that determine the refractive intensity and paraxial convergence capability. The purpose of this step is to provide the central surface with a refractive intensity starting point that roughly meets the paraxial brightening target without overshooting, thus shortening subsequent optimization time and reducing hotspot risk. This can be achieved by using paraxial approximations of edge rays and representative rays, combined with the material's refractive index and the target brightening magnitude, to provide an initial radius or aspherical coefficient based on the morphology type. Subsequently, small-step mesh scanning or response surface fitting is performed to evaluate the impact of different curvatures on the central peak value, half-maximum width, and transition slope, eliminating schemes that produce significant caustics or TIR risks. After manufacturing and demolding verification, the initial curvature value is solidified. This reduces the need for large-scale back-and-forth adjustments and lowers the probability of local hotspots and streaks.

[0061] Based on the initial curvature value and paraxial energy requirement, the sagittal height is set to obtain the height value of the central convex surface.

[0062] The sag, representing the maximum undulation of the curved surface relative to the reference plane, directly affects the refraction path length, thickness, and manufacturability. This step adjusts the surface lift under a given curvature to ensure that the paraxial energy reaches the quota, the center-edge transition conforms to the slope index, and process constraints such as minimum wall thickness and demolding angle are met. In practice, a single-parameter sweep of the sag can be performed under a fixed curvature to trace the center peak value, transition smoothness, and interference with the peripheral wall / bottom channel. A sag that meets the energy quota without overshoot is selected, thereby ensuring stable support capacity of the central channel, no obvious hot spots or collapse at the center, improved far-field rectangularity and uniformity after composite formation, and moderate structural thickness, ensuring manufacturing yield and assembly tolerance.

[0063] In this embodiment, step S53: performing functional partitioning based on the pre-stage collimating beam and energy ratio to obtain the functional, spatial, and angular allocation of the three-way splitter includes: The S531 obtains a three-channel mission framework based on the pre-amplifier collimating beam and energy ratio.

[0064] The three-channel task framework refers to dividing the internal optical structure according to its function into a peripheral wall total internal reflection channel (responsible for collimation skeleton and narrow-axis control), a bottom reflection channel (responsible for off-axis fill light and suppressing fringes), and a central convex refractive channel (responsible for paraxial brightening and center-to-edge transition). This step transforms the pre-stage collimating beam and energy ratio into a clear task list, forming a basis for subsequent allocation in three dimensions: space, angle, and energy. This avoids coupling amplification and mutual constraints on parameter tuning caused by overlapping functions between channels. The implementation process can begin by defining the angular domain, target energy ratio, uniformity weight, and glare boundary of each of the three channels based on the major and minor axis divergence of the pre-stage collimating beam and the overall energy ratio. Furthermore, it can mark the prohibited angular domains or spatial forbidden zones for each channel.

[0065] S532: Based on the three-channel mission framework and structural boundary conditions, the spatial domain is delineated to obtain the channel occupancy of the perimeter wall, bottom and center.

[0066] Spatial domain delineation refers to defining usable volumetric corridors for each channel within the three-dimensional structural envelope. Channel occupancy refers to assigning corridors to three types of channels: peripheral walls, bottom, and center. The purpose of this step is to provide non-interfering, manufacturable, and buffered arrangement space for the three channels within the limits of aperture, thickness, flange, and assembly boundaries, reducing subsequent optical path contention and mechanical interference from the outset. Channel occupancy masks are provided according to the S531 task framework, reserving seams and transition areas for the optical surfaces, and occlusion and shadow risks are checked through section analysis and coarse tracing. Finally, the axial start and end heights, radial ranges, and necessary safety distances for each channel are output. This enables integrated structural optics, eliminating the need for repeated relocation in subsequent curved surface design and assembly processes, ensuring stable channel optical paths, and minimizing occlusion risks.

[0067] S533: Based on the channel occupancy and the angular distribution of the pre-amplifier collimating beam, the incident angle range is set to obtain the angular domain division of the three channels.

[0068] The incident angle range setting defines the incident angle window that each channel is responsible for, while the angular domain division divides the pre-stage collimating beam into a set of complementary regions in angular space. The implementation process involves sampling and binning the angle-intensity distribution of the pre-stage collimating beam. Based on channel occupancy, the angular domain is initially divided into a narrow core region supported by the peripheral wall, an off-axis filler band supported by the bottom, and a paraxial lifting region supported by the center, with allowable overlap zones set. Simultaneously, a shading angle limit is introduced to exclude forbidden angles. By tracing edge rays and representative rays, it is verified that each angular domain division can be effectively captured by the corresponding channel. This results in clear angular division, short and deterministic energy transport paths, and reduced stripes, dark slits, and light leaks caused by angle overshoot.

[0069] S534: Based on the angular domain division and energy ratio, the energy window is set to obtain the energy ratio and overlap area of ​​each channel.

[0070] The energy window refers to the target energy percentage range within a given angular domain, and the overlap region refers to the flexible transition zone between adjacent channels in terms of angle. This step, based on a defined angular domain, allocates achievable and tolerable energy budgets to the three channels and reduces brightness fluctuations at channel boundaries through gradient changes in the overlap region. The implementation process involves integrating the defined angular domain to obtain the baseline energy distribution of the pre-stage collimating beam; allocating the target percentage of each of the three channels to their respective energy windows according to the design objectives, and setting the width of the overlap region and the gradient function (linear, S-shaped, or piecewise exponential); using fast tracing to iterate the upper and lower limits of the window to ensure total energy conservation and meet uniformity thresholds and glare limits; and outputting the target percentage, tolerance range, and overlap region parameters for each channel. The resulting benefits include orderly and smooth energy transfer within the angular space, clean far-field boundaries after composite processing, significantly reduced fringes, and decreased sensitivity to assembly and batch variations. S535: Based on the energy proportion and overlap area of ​​each channel, channel boundary and symmetry rules are set to obtain the function, space and angle of the three-way split.

[0071] Channel boundary treatment refers to the spatial and angular boundary handling and transition strategies for adjacent channels. Symmetry rules refer to the geometric and energy symmetry constraints applied around the optical axis or principal section. The purpose of this step is to establish rigid and flexible rules for the interconnection of the three channels, preventing bright-dark seams and suppressing far-field eccentricity and color / brightness deviations through symmetry. The implementation process can be based on the overlap area and energy window of S534, specifying the maximum slope at the boundary, the allowable angular overshoot, and the usage conditions of the shading components; at the same time, overall left-right or four-quadrant symmetry is set, and slight offset is allowed when necessary to compensate for source end offset; the robustness of the rules is verified through Monte Carlo tracing and tolerance stacking analysis, and the final functions, spatial and angular allocation tables of the three-way split are output. This results in a natural transition between channels, further improves far-field rectangularity and uniformity, and reduces glare and stray light.

[0072] In this embodiment, step S52: based on the target far-field feature set, performing a backward mapping of the incident light field at the light-emitting surface to obtain the pre-stage collimated beam and energy ratio includes: S521: Based on the target far-field feature set and the light-emitting surface structure, the far-field functional area and deflection direction are extracted to obtain the far-field functional area layout; The far-field functional area is a set of regions that divide the far field of the target according to function. Examples include a core area to ensure the subject's illumination, a skirt area to smooth boundaries, a no-entry area to suppress glare, and a transition area reserved for splicing. The deflection direction is the direction in which the overall light beam needs to be slightly pushed, used to project energy more effectively onto the wall or ceiling. In practice, the target light intensity distribution or illuminance matrix can be partitioned and analyzed using contour lines to extract the major and minor axis directions, edge roll-off slopes, and hotspot locations. Combined with the scene, the preferred direction and magnitude of the overall deflection are determined, resulting in a weighted functional area layout map.

[0073] S522: Based on the layout of the far-field functional area and the structure of the light-emitting surface, the incident direction of the light-emitting surface is reversed to obtain the target range of the incident angle of the light-emitting surface. The incident direction backward deduction refers to tracing back from the far-field functional region along the desired optical path to the light-emitting surface, obtaining the set of incident directions required for each functional region at the light-emitting surface. The incident angle range target is to summarize these directions into an acceptable angle window for each functional region. In this specific implementation, reverse tracing or the critical edge ray method can be used to trace back from the functional region boundary and core point to the light-emitting surface. By combining the material refractive index, surface continuity, and anti-glare boundary, the incident angle window for each functional region is obtained, and extreme angles that may trigger light leakage or total internal reflection failure are eliminated. The incident angle range target obtained in this way can be directly used to constrain the beam shape of the preamplifier, ensuring the physical accessibility of subsequent designs and reducing rework.

[0074] S523: Based on the target and uniformity index of the incident angle range of the light-emitting surface, the incident intensity is allocated to obtain the target of incident intensity distribution of the light-emitting surface; Incident intensity allocation refers to assigning appropriate intensity weights to each direction within a defined incident angle window to satisfy uniformity and rectangularity; the incident intensity distribution target is the quantitative result of this allocation. This step focuses on the uniformity and smooth boundary requirements in the intensity weights of the angular domain, avoiding hot spots, stripes, or dark grooves after shaping. In practice, a weight model can be established for the angular windows of each functional area based on the uniformity threshold and edge roll-off requirements: the core area has a stable weight, the boundary area uses a gradual attenuation, and a penalty is applied to directions prone to stripes; then energy normalization is performed to make the total energy consistent with the target light flux, forming an incident intensity distribution target that can directly drive the pre-stage beamforming. This allows uniformity control to be moved forward to the incident end, reducing the difficulty of subsequent effect correction through fine-tuning geometry, and making the far-field texture more delicate.

[0075] S524: Based on the incident angle and intensity distribution target of the light-emitting surface, the beam profile is deduced to obtain the angle range and cross-sectional shape of the pre-stage collimated beam; Beam profile derivation combines the required incident angle and intensity at the light-emitting surface into a beam shape description; the angle range describes the beam's angles along the two principal axes; and the cross-sectional shape describes the beam's cross-sectional shape (e.g., near-elliptical or near-rectangular). This step transforms the dispersed angle and intensity targets into beam profile specifications, facilitating the coordinated implementation of the peripheral, bottom, and central channels. In practice, the incident angle-intensity targets can be fitted with an equivalent outer envelope and principal axes to obtain the major and minor axis angles and cross-sectional shape. Simultaneously, the mechanical aperture and thickness are checked to ensure the beam profile can pass through. If necessary, the outer envelope is fine-tuned to balance manufacturability and light-shielding limits, outputting the angle range and cross-sectional shape as the pre-stage beam profile.

[0076] S525: Based on the angle range and cross-sectional shape of the pre-amplifier collimating beam, energy channel budgeting is performed to obtain the energy ratio of the three channels.

[0077] Energy channel budgeting refers to the reasonable distribution of total energy among the peripheral, bottom, and central channels, considering the coupling efficiency and losses of different channels under a given initial beam shape configuration. The energy ratio of the three channels is the quantitative result of this distribution and includes a tolerance band. In practice, the angle-intensity target within the outer envelope of the beam shape can be integrally applied across the three channel angular domains to obtain the theoretical energy distribution value. Path losses caused by material refraction, total internal reflection paths, surface quality, and assembly tolerances can also be introduced to correct the theoretical value, forming a more accurate target ratio, and upper and lower tolerances can be set to facilitate subsequent optimization convergence. This ensures a one-to-one correspondence between the three channel tasks and energy, with clear boundaries, making subsequent geometric settings and joint optimization more targeted, and making it easier to simultaneously achieve the overall system efficiency and uniformity targets.

[0078] Example 2 like Figure 2 As shown, this embodiment provides a polarizing mirror, which includes a total reflection surface 3, an incident light surface 1, and an exit light surface 2.

[0079] The polarizing lens includes a lens cup with a composite optical surface. The lens cup is geometrically composed of a total reflection surface 3, an incident light surface 1, and an exit light surface 2. The polarizing lens has opposing rear and front ends. A light source accommodating cavity is provided at the rear end. In use, the light source is located in the light source accommodating cavity, wherein the light source can be an LED light source such as an SMD3030 or SMD2835.

[0080] The light-incident surface 1 has a central convex curved optical surface 5 and multiple reflective units 4. Through precise optical path design, the light emitted by the light source is divided into three parts at the light-incident surface 1. The first part of the light is reflected by the total internal reflection surface 3, the second part is reflected twice by the bottom reflective unit 4, and the third part is refracted by the convex curved surface. The three parts of the light path are superimposed to form a collimated beam. The light-exit surface 2 is provided with a polarizing array, which consists of three discrete freeform surface optical units 6. The radius of curvature of each optical unit changes in a gradient.

[0081] The bottom has four integrated reflective surfaces, which are arranged in a V-shape with the optical axis as the axis of symmetry. The angle between the reflective surfaces and the optical axis is 30°.

[0082] The reflecting surface can be set as a total reflection interface with a Fresnel loss compensation structure, with a surface roughness Ra≤0.05μm and a reflectivity≥98%.

[0083] The lens cup has a snap-fit ​​mounting structure on its outer edge, which includes two elastic claws 7, and the ends of the claws are provided with guide bevels and positioning bosses.

[0084] The lens cup is made of polycarbonate or polymethyl methacrylate optical material by injection molding, with a light transmittance of ≥92% and a haze of ≤1%.

[0085] like Figure 3 As shown, the optical path of the polarizing lens is as follows: The first optical path a: the light is emitted from the light source, reflected by the first total internal reflection arc surface, and then refracted at the first light-emitting surface 2 before exiting into the air medium.

[0086] In the second optical path b, the light emitted by the light source undergoes a secondary reflection by the bottom reflection unit 4, and then is refracted at the second light-emitting surface 2 before exiting into the air medium.

[0087] The third optical path c, after the light is emitted by the light source, is refracted at the light-transmitting surface of the third convex curved surface, and then refracted at the light-emitting surface 2 before being emitted into the air medium.

[0088] The three optical paths are superimposed to form a collimated beam with a half-intensity angle of 40° × 8°.

[0089] like Figure 4 and Figure 5 As shown, the light-emitting surface 2 is configured with a polarizing array consisting of three freeform surfaces, which causes the collimated beam to be oriented and deflected by 5° after asymmetric refraction, and the half-intensity angle of the output light spot is expanded into a rectangular uniform distribution of 38°×15°.

[0090] The above description is merely a specific embodiment of the present invention. Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, modules, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here. It should be understood that the protection scope of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and these modifications or substitutions should all be covered within the protection scope of the present invention.

Claims

1. A method for designing a polarizing lens, characterized in that, include: S1: Obtain design target information based on the expected application's requirements for output light specifications; S2: Based on the parameters of the selected LED light source, perform light source modeling to obtain light source input data; S3: Based on the target design information and light source input data, perform functional decomposition of the light-emitting surface to obtain the target function of the light-emitting surface; S4: Based on the functional objectives of the light-emitting surface, the light-emitting surface is initially constructed to obtain a light-emitting surface structure composed of multiple freeform surface units; S5: Determine the preamp beam structure based on the light-emitting surface structure and the light source input data.

2. The polarizing lens design method according to claim 1, characterized in that, S5: Determining the pre-stage beamform structure based on the light-emitting surface structure and the light source input data includes; S51: Based on the light-emitting surface structure and the light source input data, extract the key features of the target far field to obtain the target far field feature set used for constraining the splitting; S52: Based on the target far-field feature set, perform a backward mapping of the incident light field at the light-emitting surface to obtain the pre-stage collimated beam and energy ratio; S53: Based on the pre-amplifier collimating beam and energy ratio, functional partitioning is performed to obtain the functional, spatial, and angular allocation of the three-way splitting; S54: Based on the energy ratio and the functional, spatial and angular allocation of the three-way split, the channel boundary and transition constraints are set to obtain the incident beam shape and energy ratio target required for the three-way split; S55: Determine the preamplifier structure for each optical path based on the incident beam shape and energy ratio target required for the three-way split.

3. The polarizing lens design method according to claim 2, characterized in that, S55: Determine the pre-stage beamform structure for each optical path based on the incident beam shape and energy ratio target required for the three-way splitting, including: S551: Based on the incident beam shape and energy ratio target, determine the position and geometry of the total internal reflection surface of the peripheral wall, and obtain the initial parameters of the total internal reflection light guide surface of the peripheral wall; S552: Based on the incident beam shape and energy ratio target, determine the initial parameters of the bottom reflective unit according to its geometry, number, position and tilt angle; S553: ​​Based on the incident beam shape and energy ratio target, determine the curvature and height of the central convex surface of the central convex light-transmitting surface, and obtain the initial parameters of the central convex surface.

4. The polarizing lens design method according to claim 3, characterized in that, S551: Based on the incident beam shape and energy ratio target, determine the position and geometry of the peripheral wall total reflection surface, and obtain the initial parameters of the peripheral wall total reflection light guide surface, including: Based on the incident beam shape and energy ratio target, the light guiding control elements are extracted to obtain the peripheral wall light guiding target: Based on the light guiding target on the peripheral wall, the channel occupancy, and the structural boundary conditions, determine the start and end positions of the peripheral wall: Based on the starting and ending positions of the perimeter wall and the relative position of the light source, the total internal reflection condition is checked to obtain the feasible wrap angle range: Based on the feasible range of the enclosure angle and the target energy ratio of the channel, the enclosure angle is selected to obtain the target enclosure angle; Based on the target containment angle and the narrow-directional divergence control target, the contour type is selected to obtain the peripheral wall contour type and curvature.

5. The polarizing lens design method according to claim 3, characterized in that, S552: Based on the incident beam shape and energy ratio target, determine the initial parameters of the bottom reflector unit according to its geometry, number, position, and tilt angle, including: Based on the incident beam shape and energy ratio target, off-axis energy and uniformity gap identification are performed to obtain the supplementary lighting target of the bottom reflective unit; Based on the supplementary lighting target and the incident light requirements of the light-emitting surface of the bottom reflective unit, the supplementary lighting area is delineated to obtain the effective area of ​​the bottom reflective unit; The number of bottom reflective units is determined by considering the functional area of ​​the bottom reflective units, the channel occupancy, and the structural boundary conditions. Based on the number and symmetry requirements of the bottom reflective units, the planar positions are arranged to obtain the initial values ​​of the planar positions of each bottom reflective unit; Based on the initial planar position of each bottom reflective unit and the target supplementary lighting direction, the geometry is selected to obtain the geometry type of the bottom reflective unit; Based on the geometry of the bottom reflective unit and the incident light requirements of the light-emitting surface, the tilt angle is set to obtain the initial tilt angle value of each bottom reflective unit.

6. The polarizing lens design method according to claim 5, characterized in that, S553: ​​Based on the incident beam shape and energy ratio target, determine the curvature and height of the central convex surface of the central convex light-transmitting surface, and obtain the initial parameters of the central convex surface, including: Based on the incident beam shape and energy ratio target, as well as the initial parameters of the peripheral wall and bottom unit, the functional target of the central convex surface is obtained; The location of the central convex surface is determined based on its functional objectives, channel occupancy, and structural boundaries. Based on the location and functional objectives of the central convex surface, the morphology type is selected to obtain the morphology type of the central convex surface; Based on the shape and functional objectives of the central convex surface, the curvature is set to obtain the initial curvature value; Based on the initial curvature value and paraxial energy requirement, the sagittal height is set to obtain the height value of the central convex surface.

7. The polarizing lens design method according to any one of claims 1 to 6, characterized in that, S53: Based on the pre-stage collimating beam and energy ratio, functional partitioning is performed to obtain the functional, spatial, and angular allocation of the three-way splitter, including: S531 obtains a three-channel mission framework based on the pre-stage collimating beam and energy ratio; S532: Based on the three-channel mission framework and structural boundary conditions, the spatial domain is delineated to obtain the channel occupancy of the perimeter wall, bottom and center; S533: Based on the channel occupancy and the angular distribution of the pre-stage collimating beam, the incident angle range is set to obtain the angular domain division of the three channels; S534: Based on the angular domain division and energy ratio, the energy window is set to obtain the energy ratio and overlap area of ​​each channel; S535: Based on the energy proportion and overlap area of ​​each channel, channel boundary and symmetry rules are set to obtain the function, space and angle of the three-way split.

8. The polarizing lens design method according to any one of claims 1 to 6, wherein the polarizing lens design method is characterized in that, S52: Based on the target far-field feature set, perform a backward mapping of the incident light field at the output surface to obtain the pre-stage collimated beam and energy ratio, including: S521: Based on the target far-field feature set and the light-emitting surface structure, the far-field functional area and deflection direction are extracted to obtain the far-field functional area layout; S522: Based on the layout of the far-field functional area and the structure of the light-emitting surface, the incident direction of the light-emitting surface is reversed to obtain the target range of the incident angle of the light-emitting surface. S523: Based on the target and uniformity index of the incident angle range of the light-emitting surface, the incident intensity is allocated to obtain the target of incident intensity distribution of the light-emitting surface; S524: Based on the incident angle and intensity distribution target of the light-emitting surface, the beam profile is deduced to obtain the angle range and cross-sectional shape of the pre-stage collimated beam; S525: Based on the angle range and cross-sectional shape of the pre-amplifier collimating beam, energy channel budgeting is performed to obtain the energy ratio of the three channels.

9. A polarizing lens, characterized in that, Designed using the method of any one of claims 1 to 8, the polarizer includes a total reflection surface, an incident surface, and an exit surface. The incident surface base plate is provided with a central convex curved optical surface and multiple reflective units. The light emitted from the light source is divided into three parts at the incident surface. The first part of the light is reflected by the total reflection surface, the second part is reflected twice by the bottom reflective unit, and the third part is refracted by the convex curved surface. The three light paths are superimposed to form a collimated beam. The exit surface is provided with a polarizing array, which consists of three discrete freeform surface optical units, and the radius of curvature of each optical unit varies in a gradient.

10. A wall washer light, characterized in that, include: The light source and the polarizing lens as described in claim 9.

Images