Electroplated spreadlight lens and design method thereof

Abstract

The electroplated spreadlight lens comprises a lens main body, a light inlet hole is formed in the bottom of the lens main body, a light outlet hole is formed in the top of the lens main body, and a first TIR inner total reflection surface, a second TIR inner total reflection surface and a third TIR inner total reflection surface are arranged on the outer side of the lens main body. The light inlet hole is provided with a light inlet hole side wall surface and a light inlet hole top surface, the light outlet hole is provided with a light outlet hole inclined surface and a light outlet hole side wall surface, the light outlet hole inclined surface is an inclined straight surface or an inclined curved surface, the light outlet hole inclined surface is a transparent total reflection surface or an electroplated reflection surface, and a connecting surface is arranged between the first TIR internal total reflection surface and the third TIR internal total reflection surface. The top of the lens main body is provided with a light-emitting surface, and the light-emitting surface is provided with a dodging microstructure. The lamp is easy to install, perfect wall washing is achieved through a single optical accessory, and the lamp is simple in structure, good in heat dissipation performance, low in light waste, high in lighting effect, universal for a conventional lamp structure in the market, low in cost and good in using effect.

Description

Technical Field

[0001] This invention relates to the field of polarized lighting technology, specifically to an electroplated polarized lens and its design method. Background Technology

[0002] In polarized lighting applications, if a light fixture is embedded in the ceiling at a distance of ≤0.3 meters from the wall, the light will almost completely illuminate the wall, creating a rectangular light spot with uniform transition and illumination. The wall will be illuminated at different heights while the floor will be almost completely dark. This is the ideal wall wash.

[0003] To achieve the ideal wall washing effect, some designers adjust the assembly of light sources and optical components, while others design numerous complex optical components to block out imperfect light. However, these methods all share the same drawbacks: complex lamp structures, poor heat dissipation, significant light waste, low luminous efficiency, and incompatibility with conventional lamp structures on the market.

[0004] Therefore, in order to avoid the shortcomings of the existing technology, it is necessary to improve the existing technology. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings and deficiencies of the prior art and provide an electroplated polarizing lens with high light efficiency and low cost.

[0006] Another object of the present invention is to provide a design method for electroplated polarizing lenses.

[0007] This invention is achieved through the following technical solution:

[0008] An electroplated polarizing lens includes a lens body, with an entrance aperture at the bottom and an exit aperture at the top. The outer side of the lens body is provided with a first TIR (Total Internal Reflection) surface, a second TIR surface, and a third TIR surface. The entrance aperture has an entrance aperture sidewall and an entrance aperture top surface. The exit aperture has an exit aperture inclined surface and an exit aperture sidewall. The exit aperture inclined surface is either a straight inclined surface or a curved inclined surface, and is either a transparent total reflection surface or an electroplated reflective surface.

[0009] Furthermore, a connecting surface is provided between the first TIR internal total reflection surface and the third TIR internal total reflection surface.

[0010] Furthermore, the first TIR internal total reflection surface is a transparent or electroplated bright silver freeform surface, and is composed of a combination of the lower left horizontal curve, the middle left horizontal first curve, the lower front vertical curve, the lower left vertical curve, and the lower rear vertical curve.

[0011] Furthermore, the second TIR internal total reflection surface is a transparent or electroplated bright silver freeform surface, and is composed of a combination of the lower right horizontal curve, the middle right horizontal curve, the lower front vertical curve, the lower right vertical curve, and the lower rear vertical curve.

[0012] Furthermore, the third TIR internal total reflection surface is a freeform surface plated with bright silver, and is composed of a combination of the left-middle horizontal second curve, the left-upper horizontal curve, the right-middle horizontal curve, the right-upper horizontal curve, the front-upper vertical curve, the rear-upper vertical curve, the left-upper vertical curve, and the right-upper vertical curve.

[0013] Furthermore, the top of the lens body is provided with a light-emitting surface, and the light-emitting surface is provided with a light-uniforming microstructure.

[0014] Furthermore, the bottom of the lens body is provided with a lens bottom plane, and the top of the lens body is provided with a mounting platform, the mounting platform having a platform bottom surface and a platform side surface.

[0015] Furthermore, it also includes a lens bracket and a light source bracket. The top of the lens body is provided with a limiting block, the top of the lens bracket is provided with a limiting groove corresponding to the limiting block, the top of the lens bracket is provided with a buckle, the top of the lens body is provided with a slot corresponding to the buckle, the bottom of the lens bracket is provided with a rotating hook, and the light source bracket is provided with a rotating slot corresponding to the rotating hook.

[0016] A method for designing an electroplated polarizing lens includes the following steps:

[0017] Step (1): Determine the distance between the light fixture and the wall and the width of the wall wash;

[0018] Step (2): Determine the light source information;

[0019] Step (3): Determine the lens design direction and contour characteristics, including the optical path design in the wall washing height direction and the optical path design in the wall washing width direction;

[0020] Step (4): Design of the light-mixing pattern structure on the planar light-emitting surface;

[0021] Step (5): Complete the lens optical design;

[0022] Step (6): Lens mold structure design;

[0023] Step (7): Making lens molds and electroplating molds;

[0024] Step (8): Lens injection molding;

[0025] Step (9): Lens electroplating fabrication;

[0026] Step (10): Lens optical verification.

[0027] Furthermore, in step (3), the optical path design in the height direction of the wall washing includes the longitudinal optical curve design of the first TIR reflective surface, the longitudinal optical curve design of the second TIR reflective surface, the optical design of the top surface of the light entrance aperture, the optical design of the inclined surface of the light exit aperture, and the longitudinal optical curve design of the third TIR reflective surface. The optical path design in the width direction of the wall washing includes the transverse optical curve design of the first TIR reflective surface, the transverse optical curve design of the second TIR reflective surface, and the transverse optical curve design of the third TIR reflective surface.

[0028] Compared to existing technologies, this invention features a first TIR internal total reflection surface, a second TIR internal total reflection surface, and a third TIR internal total reflection surface on the outer side of the lens body. The light exit aperture has an exit aperture inclined surface and an exit aperture sidewall surface. All three TIR surfaces are freeform surfaces, thus ensuring that the width of the light spots corresponding to the three TIR surfaces illuminating the wall remains consistent, achieving a rectangular light spot. Viewed perpendicular to the wall, the light source enters the lens entrance aperture and splits into two parts. The first part of the light is refracted by the entrance aperture sidewall surface into the lens interior, where it is further split into a third and a fourth ray. The third ray is reflected at the first TIR internal total reflection surface and then refracted at the exit surface; while the fourth ray… The first part of the light is reflected at the total internal reflection surface of the second TIR and then refracted at the exiting surface. The second part of the light is refracted at the top surface of the entrance aperture and enters the lens, is reflected at the oblique surface of the exit aperture, and is then reflected by the total internal reflection surface of the third TIR before being refracted at the exiting surface. For wall washing, the light spot formed by the second part of the light ultimately illuminates the top of the wall, while the light spots formed by the third and fourth parts of the light ultimately illuminate the entire area from the middle to the bottom of the wall. The superposition of these three parts of light can perfectly illuminate the entire wall, thus achieving perfect wall washing using a single optical component. The lamp has a simple structure, good heat dissipation performance, low light waste, high luminous efficiency, and is compatible with the structure of conventional lamps on the market, resulting in low cost. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is an exploded view of the structure of the electroplated polarizing lens of the present invention;

[0031] Figure 2 This is a schematic diagram of the first direction structure of the lens body of the present invention;

[0032] Figure 3 This is a schematic diagram of the second direction structure of the lens body of the present invention;

[0033] Figure 4 This is a bottom view of the lens body of the present invention;

[0034] Figure 5 This is the optical path diagram of collimated light formed when the inclined surface of the light-emitting aperture of the electroplated polarizing lens of the present invention is set horizontally.

[0035] Figure 6 This is the optical path diagram of the electroplated polarizing lens of the present invention;

[0036] Figure 7 This is a flowchart illustrating the design method of the electroplated polarizing lens of the present invention.

[0037] In the diagram: 1-Lens body; 2-First TIR internal total reflection surface; 3-Second TIR internal total reflection surface; 4-Third TIR internal total reflection surface; 5-Outlet aperture inclined surface; 6-Outlet aperture sidewall; 7-Connecting surface; 8-Lower left transverse curve; 9-Left center transverse first curve; 10-Lower front longitudinal curve; 11-Lower left longitudinal curve; 12-Lower rear longitudinal curve; 13-Lower right transverse curve; 14-Right center transverse curve; 15-Lower right longitudinal curve; 16-Left center transverse second curve; 17 - Upper left horizontal curve; 18 - Upper right horizontal curve; 19 - Upper front vertical curve; 20 - Upper rear vertical curve; 21 - Upper left vertical curve; 22 - Upper right vertical curve; 23 - Light-emitting surface; 24 - Side wall of light-entry aperture; 25 - Top surface of light-entry aperture; 26 - Bottom plane of lens; 27 - Bottom surface of platform; 28 - Side surface of platform; 29 - Lens bracket; 30 - Light source bracket; 31 - Limiting block; 32 - Limiting groove; 33 - Buckle; 34 - Slot; 35 - Rotary hook; 36 - Rotary slot. Detailed Implementation

[0038] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] like Figures 1 to 7The electroplated polarizing lens of the present invention includes a lens body 1. The bottom of the lens body 1 is provided with an entrance hole, and the top of the lens body 1 is provided with an exit hole. The outer side of the lens body 1 is provided with a first TIR internal total reflection surface 2, a second TIR internal total reflection surface 3, and a third TIR internal total reflection surface 4. The entrance hole is provided with an entrance hole sidewall surface 24 and an entrance hole top surface 25. The exit hole is provided with an exit hole inclined surface 5 and an exit hole sidewall surface 6. The exit hole inclined surface 5 is a straight surface or a curved surface, and is a transparent total reflection surface or an electroplated reflective surface. All three TIR surfaces are freeform surfaces, ensuring that the width of the light spots corresponding to the three TIR surfaces when projected onto the wall remains consistent, achieving a rectangular light spot. Viewed perpendicular to the wall, the light from the source enters the lens entrance aperture and splits into two parts. The first part of the light is refracted through the side wall 24 of the entrance aperture into the lens, where it is further split into a third and a fourth ray. The third ray is reflected at the total internal reflection surface 2 of the first TIR surface and then refracted at the exit surface; the fourth ray is reflected at the total internal reflection surface 3 of the second TIR surface and then refracted at the exit surface. The second part of the light... The light enters the lens through the top surface of the aperture, is reflected by the inclined surface 5 of the exit aperture, and then reflected by the third TIR internal total reflection surface 4. Finally, it is refracted at the exit surface. For wall washing, the light spot formed by the second part of the light ultimately illuminates the top of the wall, while the light spots formed by the third and fourth light rays ultimately illuminate the entire area from the middle to the bottom of the wall. The superposition of these three parts of light can perfectly illuminate the entire wall, thus achieving perfect wall washing using a single optical component. The lamp has a simple structure, good heat dissipation performance, little light waste, high luminous efficiency, and is compatible with the structure of conventional lamps on the market, resulting in low cost.

[0040] A connecting surface 7 is provided between the first TIR internal total reflection surface 2 and the third TIR internal total reflection surface 4. The connecting surface 7 can be a plane or a free-form surface. If it is a free-form surface, its two ends are tangentially connected to the first TIR internal total reflection surface 2 and the third TIR internal total reflection surface 3, respectively, so that the three surfaces become a complete curved surface.

[0041] In specific implementation, the first TIR inner total reflection surface 2 is a transparent or electroplated bright silver freeform surface, which is composed of the lower left horizontal curve 8, the left middle horizontal first curve 9, the lower front vertical curve 10, the lower left vertical curve 11 and the lower rear vertical curve 12, and has high light reflection efficiency.

[0042] In specific implementation, the second TIR inner total reflection surface 3 is a free-form surface plated with bright silver, and is composed of a combination of the lower right horizontal curve 13, the middle right horizontal curve 14, the lower front vertical curve 10, the lower right vertical curve 15, and the lower rear vertical curve 12, which has high light reflection efficiency.

[0043] In specific implementation, the third TIR internal total reflection surface 4 is a transparent or electroplated bright silver freeform surface, which is composed of the left middle horizontal second curve 16, the left upper horizontal curve 17, the right middle horizontal curve 14, the right upper horizontal curve 18, the front upper vertical curve 19, the rear upper vertical curve 20, the left upper vertical curve 21, and the right upper vertical curve 22, and has high light reflection efficiency.

[0044] The top of the lens body 1 is provided with a light-emitting surface 23. The light-emitting surface 23 is provided with a light-uniforming microstructure, which makes the light emission more uniform. The light-emitting surface 23 is a light-mixing surface, which has a light-mixing microstructure or has been treated with a sandblasting or other frosting process.

[0045] The lens body 1 has a bottom plane 26 at its bottom and a mounting platform at its top. The mounting platform has a bottom surface 27 and a side surface 28 to facilitate lens installation.

[0046] It also includes a lens bracket 29 and a light source bracket 30. The top of the lens body 1 is provided with a limiting block 31, the top of the lens bracket 29 is provided with a limiting groove 32 corresponding to the limiting block 31, the top of the lens bracket 1 is provided with a buckle 33, the top of the lens body 1 is provided with a slot 34 corresponding to the buckle 33, the bottom of the lens bracket 29 is provided with a rotating hook 35, and the light source bracket 30 is provided with a rotating slot 36 corresponding to the rotating hook 35, which facilitates the positioning and installation of the lens. The lens is fixed on the lens bracket 29 through the cooperation of the buckle 33 and the slot 33, and the lens bracket 29 is also fixed on the light source bracket 29 through the buckle structure, making the installation quick and convenient.

[0047] A method for designing an electroplated polarizing lens includes the following steps:

[0048] Step (1): Determine the distance between the light fixture and the wall and the width of the wall wash;

[0049] Step (2): Determine the light source information;

[0050] Step (3): Determine the lens design direction and contour characteristics, including the optical path design in the wall washing height direction and the optical path design in the wall washing width direction;

[0051] Step (4): Design of the light-mixing pattern structure on the planar light-emitting surface;

[0052] Step (5): Complete the lens optical design;

[0053] Step (6): Lens mold structure design;

[0054] Step (7): Making lens molds and electroplating molds;

[0055] Step (8): Lens injection molding;

[0056] Step (9): Lens electroplating fabrication;

[0057] Step (10): Lens optical verification.

[0058] In step (3), the optical path design in the height direction of the wall washing includes the longitudinal optical curve design of the first TIR reflective surface, the longitudinal optical curve design of the second TIR reflective surface, the optical design of the top surface of the entrance aperture, the optical design of the inclined surface of the exit aperture, and the longitudinal optical curve design of the third TIR reflective surface. The optical path design in the width direction of the wall washing includes the transverse optical curve design of the first TIR reflective surface, the transverse optical curve design of the second TIR reflective surface, and the transverse optical curve design of the third TIR reflective surface.

[0059] The exit aperture inclined surface 5 is a complete inclined straight surface or inclined curved surface. The exit aperture inclined surface 5 can be a transparent surface or an electroplated bright silver reflective surface. The light refracted from the top surface 25 of the entrance aperture will be totally reflected by the exit aperture inclined surface 5 to the third TIR internal total reflection surface 4. If the exit aperture inclined surface 5 is an electroplated surface, it can enhance the reflection effect.

[0060] The third TIR internal total internal reflection surface 4 must be an electroplated bright silver emitting optical surface. According to the principle of light refraction, in order to obtain light that can illuminate the top of the wall, the third TIR internal total internal reflection surface 4 must be able to reflect light at a large angle. If it is a transparent surface, according to the critical condition analysis of total internal reflection, the light at the largest angle will be refracted out from the third TIR internal total internal reflection surface 4, and the light that illuminates the top of the wall cannot be obtained. Therefore, this surface must be an electroplated surface to compensate for the light leakage defect of total internal reflection through physical structural reflection.

[0061] The top surface 25 of the entrance aperture is a collimation arc obtained through calculation, which can refract light into collimated light rays.

[0062] The light spot mainly consists of three parts, which are ultimately obtained by reflection from three different total reflection surfaces, all of which are freeform surfaces.

[0063] All the horizontal curves of the TIR total reflection surface are irregular curves, and each curve is different, thus achieving different rectangular wall-washing light spots.

[0064] The first TIR internal total reflection surface 2 and the second TIR internal total reflection surface 3 can be a transparent surface or an electroplated surface. Neither property affects the wall washing effect of the light spot. Their surface properties depend on the production of the electroplating masking mold.

[0065] The light on the wall is composed of three parts, each with a different angle and a gradual change. When it shines on the wall, the overall light spot is nearly rectangular.

[0066] The light is divided into three parts by three TIR total internal reflection surfaces and the inclined surface 5 of the light outlet. The light is then sequentially irradiated from the top to the bottom of the wall, thus illuminating the entire wall.

[0067] Optical and wall-washing principles:

[0068] The principle behind the shape and height of the wall-washing spot: According to geometric principles, when the length of one side of a triangle is fixed, the higher the triangle, the smaller the angle corresponding to that side. Therefore, in conventional rectangular or circular wall washing, the spot is narrower in areas where the wall is lower and wider in areas where the wall is higher, resulting in an overall fan-shaped or hill-shaped wall washing spot.

[0069] Due to the installation position of the light fixtures, the angle formed between the light fixtures and the wall is generally in the range of 0°-90°. For conventional light fixtures, the light distribution cannot basically reach 90°, so the top of the wall is generally not illuminated.

[0070] Ideally, the wall-washing effect should result in a rectangular light spot, and the washing height should be able to reach from the top to the bottom of the wall.

[0071] To achieve a rectangular wall-washing spot, the angle of the spot must gradually change at each position, with the largest angle at the top of the wall, gradually decreasing in angle. This is achieved by adjusting the shapes of the horizontal curves: lower left (curve 8), left-middle (curve 9), left-middle (curve 16), upper left (curve 17), lower left (curve 8), lower right (curve 13), right-middle (curve 14), and upper right (curve 18). This ensures that all three TIR surfaces are freeform surfaces, resulting in a consistent width of the spot hitting the wall, thus creating a rectangular spot. Furthermore, the final width of the rectangular spot is generally determined by the optical principles of the lens parallel to the wall (e.g., ...). Figure 5 When light rays are refracted through the sidewall 24 of the entrance aperture to the directions of the lower front longitudinal curve 10 and the upper front longitudinal curve 19, the light rays are totally internally reflected and finally refracted out at the exit surface. These light rays determine the width of the wall-washing spot. If collimated light is ultimately formed, then the width of the rectangular wall-washing spot is the smallest (e.g., Figure 5 ).

[0072] To achieve a wall-washing height that extends from the top to the bottom of the wall: Looking perpendicular to the wall, light from the light source enters the lens's entrance aperture. The light splits into two parts. The first part is refracted by the side wall surface 24 of the entrance aperture into the lens, where it splits again into a third and fourth ray. The third ray is reflected at the first TIR (Total Internal Reflection) surface 2 and then refracted at the exit surface. The fourth ray is reflected at the second TIR surface 3 and then refracted at the exit surface. The second part of the light is refracted by the top surface of the entrance aperture into the lens, reflected by the inclined surface 5 of the exit aperture, then reflected again by the third TIR surface 4, and finally refracted at the exit surface (e.g., ...). Figure 6 ).

[0073] For wall washing, the light spot formed by the second part of the light ultimately illuminates the top of the wall, while the light spots formed by the third and fourth light rays ultimately illuminate the entire area from the upper middle to the bottom of the wall. The superposition of these three parts of light can perfectly illuminate the entire wall, thus achieving perfect wall washing using a single optical accessory.

[0074] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An electroplated polarizing lens, characterized in that: The lens body includes a light entrance hole at its bottom and a light exit hole at its top. The outer side of the lens body is provided with a first TIR internal total reflection surface, a second TIR internal total reflection surface, and a third TIR internal total reflection surface. The light entrance hole has a sidewall and a top surface. The light exit hole has an inclined surface and a sidewall. The inclined surface is either a straight or curved surface, and is either a transparent total reflection surface or an electroplated reflective surface.

2. The electroplated polarizing lens according to claim 1, characterized in that: A connecting surface is provided between the first TIR internal total reflection surface and the third TIR internal total reflection surface.

3. The electroplated polarizing lens according to claim 1, characterized in that: The first TIR internal total reflection surface is a transparent or electroplated bright silver freeform surface, and is composed of a combination of the lower left horizontal curve, the left middle horizontal first curve, the lower front vertical curve, the lower left vertical curve, and the lower rear vertical curve.

4. The electroplated polarizing lens according to claim 1, characterized in that: The second TIR internal total reflection surface is a transparent or electroplated bright silver freeform surface, and is composed of a combination of the lower right horizontal curve, the middle right horizontal curve, the lower front vertical curve, the lower right vertical curve, and the lower rear vertical curve.

5. The electroplated polarizing lens according to claim 1, characterized in that: The third TIR internal total reflection surface is a free-form surface plated with bright silver, and is composed of a combination of the left-middle horizontal second curve, the left-upper horizontal curve, the right-middle horizontal curve, the right-upper horizontal curve, the front-upper vertical curve, the rear-upper vertical curve, the left-upper vertical curve, and the right-upper vertical curve.

6. The electroplated polarizing lens according to claim 1, characterized in that: The top of the lens body is provided with a light-emitting surface, and the light-emitting surface is provided with a light-uniforming microstructure.

7. The electroplated polarizing lens according to claim 1, characterized in that: The lens body has a bottom plane at its bottom and a mounting platform at its top, with a bottom surface and a side surface.

8. The electroplated polarizing lens according to claim 1, characterized in that: It also includes a lens bracket and a light source bracket. The top of the lens body is provided with a limiting block, the top of the lens bracket is provided with a limiting groove corresponding to the limiting block, the top of the lens bracket is provided with a buckle, the top of the lens body is provided with a slot corresponding to the buckle, the bottom of the lens bracket is provided with a rotating hook, and the light source bracket is provided with a rotating slot corresponding to the rotating hook.

9. A design method for an electroplated polarizing lens, characterized in that: Includes the following steps: Step (1): Determine the distance between the light fixture and the wall and the width of the wall wash; Step (2): Determine the light source information; Step (3): Determine the lens design direction and contour characteristics, including the optical path design in the wall washing height direction and the optical path design in the wall washing width direction; Step (4): Design of the light-mixing pattern structure on the planar light-emitting surface; Step (5): Complete the lens optical design; Step (6): Lens mold structure design; Step (7): Making lens molds and electroplating molds; Step (8): Lens injection molding; Step (9): Lens electroplating fabrication; Step (10): Lens optical verification.

10. The design method of the electroplated polarizing lens according to claim 9, characterized in that: In step (3), the optical path design in the height direction of the wall washing includes the longitudinal optical curve design of the first TIR reflective surface, the longitudinal optical curve design of the second TIR reflective surface, the optical design of the top surface of the light inlet aperture, the optical design of the inclined surface of the light outlet aperture, and the longitudinal optical curve design of the third TIR reflective surface. The optical path design in the width direction of the wall washing includes the transverse optical curve design of the first TIR reflective surface, the transverse optical curve design of the second TIR reflective surface, and the transverse optical curve design of the third TIR reflective surface.

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