Novel linear ultrathin wall washer optical structure and manufacturing mold and design method thereof

Abstract

The invention discloses a novel linear ultrathin wall washer optical structure which comprises a linear array LED light source, a linear beam splitting lens and a reflector, the linear array LED light source is longitudinally arranged, a plurality of LED lamp beads are arranged on the rear side of the linear array LED light source, an incidence cavity covering the LED lamp beads is formed in the front side of the linear beam splitting lens, and the linear beam splitting lens is arranged in the incidence cavity. An upper arc-shaped refraction part is arranged on the upper portion of the rear side of the linear beam splitting lens, a lower arc-shaped refraction part is arranged on the lower portion of the rear side of the linear beam splitting lens, and the light reflecting plate is arranged above the linear beam splitting lens and is obliquely arranged downwards from front to back. The ultra-thin wall washing lamp is simple in structure, the lamp efficiency, the effective light ratio of wall washing and the installation convenience of the ultra-thin wall washing lamp are improved, no light exists outside an illuminated area, the problem of glare of the wall washing lamp is thoroughly solved, higher power can be achieved through the same size, the wall washing width is large, the number of used lamps is remarkably reduced under the same illumination requirement, and the use cost of the lamps is reduced.

Description

Technical Field

[0001] This invention relates to the field of lighting technology, specifically to a novel linear ultrathin wall washer light optical structure and its manufacturing mold and design method. Background Technology

[0002] Currently, due to increasing demands for comfortable indoor lighting and the development of light-free interior lighting designs, many museums, high-end office buildings, and homes use lighting fixtures to illuminate walls and ceilings for more comfortable lighting effects. Wall washer lights are lighting fixtures that illuminate walls, specifically walls, ceilings, and floors. Most conventional wall washer lights on the market currently use TIR lens optics, while LED strips are primarily used in home settings. The disadvantages of using ordinary TIR lens wall washer lights include poor beam cutoff, poor uniformity, glare, a large number of lights required, thick fixture volume, and limited installation options. In home settings, LED strips suffer from insufficient wall uniformity, illuminating only a small corner area, resulting in low light utilization. Furthermore, ordinary panel lights, used as ambient light, have limited effect on wall illumination, lack ambiance, and excessive brightness can cause glare, leading to a poor user experience. Therefore, to avoid the shortcomings of existing technologies, it is necessary to improve them. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings and deficiencies of the prior art and to provide a novel linear ultrathin wall washer light optical structure and its manufacturing mold and design method.

[0004] Another objective of this invention is to provide a manufacturing mold for a novel linear ultrathin wall washer light optical structure.

[0005] Another objective of this invention is to provide a design method for a novel linear ultrathin wall washer light optical structure.

[0006] This invention is achieved through the following technical solution:

[0007] A novel linear ultrathin wall washer light optical structure includes a linear array LED light source, a linear beam splitter lens, and a reflector. The linear array LED light source is arranged vertically, and a plurality of LED beads are arranged on the rear side of the linear array LED light source. An incident cavity covering the LED beads is provided on the front side of the linear beam splitter lens. An upper arc-shaped refraction part is provided on the upper part of the rear side of the linear beam splitter lens, and a lower arc-shaped refraction part is provided on the lower part of the rear side of the linear beam splitter lens. The reflector is located above the linear beam splitter lens and is inclined downward from front to back.

[0008] Furthermore, the cross-section of the incident cavity is triangular.

[0009] Furthermore, the lower arc-shaped refractive part is gradually enlarged from top to bottom, while the upper arc-shaped refractive part is gradually reduced from the middle to the upper and lower sides respectively.

[0010] Furthermore, it also includes a lamp body for mounting the linear array LED light source, the linear beam splitter lens and the reflector, with an opening at the bottom of the lamp body.

[0011] Furthermore, the reflector is a metal reflector or a plastic reflector, and the surface of the reflector is provided with a reflective coating.

[0012] Furthermore, the reflector is arranged in an arc shape.

[0013] Furthermore, the linear beam splitter is a PC linear beam splitter, a PMMA linear beam splitter, or a PS linear beam splitter.

[0014] A manufacturing mold having a shape suitable for manufacturing the linear beam splitter lens according to any one of claims 1 to 7 by forming a mold.

[0015] A design method for a novel linear ultrathin wall washer lamp optical structure, characterized by the following steps:

[0016] Step (1): Determine the application scenario;

[0017] Step (2): Select a suitable linear array LED light source;

[0018] Step (3): Set up a linear beam splitter to split the light into near-end light and far-end light;

[0019] Step (4): Set up the reflector and adjust the curvature;

[0020] Step (5): Set up a structure to fix each component.

[0021] Furthermore, step (4) includes adjusting the geometry of the linear beam splitter, which is generally thinner in the middle and thicker at the top and bottom. The linear beam splitter is adjusted so that the light from the far end is irradiated onto the reflector as much as possible.

[0022] Compared to existing technologies, this invention features an incident cavity housing LED beads on the front side of a linear beam splitter lens, an upper arc-shaped refraction section on the upper rear side of the linear beam splitter lens, and a lower arc-shaped refraction section on the lower rear side of the linear beam splitter lens. A reflector is positioned above the linear beam splitter lens, tilted downwards from front to back. This design splits the light emitted by the linear array LED light source into two parts: a near-light end and a far-light end on the wall. The near-light end portion of the light is directly refracted by the linear beam splitter lens and emitted directly, achieving better brightness uniformity on the near-light end of the wall. However, the far-light end cannot achieve the same brightness uniformity solely through the linear beam splitter lens. The addition of a reflector to the far-light end portion allows for greater light intensity reflection, illuminating the far-light end of the wall and thus filling the gap in the washout function of ultra-thin panel lights. Addressing the gaps in wall applications, ultra-thin wall washer lights improve luminous efficiency, the effective light ratio during wall washing, and ease of installation. With no light outside the illuminated area, they completely solve the glare problem. They achieve higher power within the same volume, offer a wider wall washing width, and significantly reduce the number of lights needed for the same illumination requirements, lowering operating costs. Simultaneously, the lights are more energy-efficient and aesthetically pleasing while providing excellent lighting effects. The lights achieve a comfortable level of visibility, where the light source is not visible. In indoor lighting applications, compared to panel lights, they provide a more comfortable atmosphere and anti-glare effect. Compared to light strips, they offer better anti-glare performance, energy efficiency, and uniform wall illuminance. Light loss in home lighting is significantly reduced, comfort is significantly improved, achieving energy conservation and emission reduction while meeting people's demand for high-quality lighting effects and providing a superior user experience. Attached Figure Description

[0023] 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.

[0024] Figure 1 This is an exploded view of the optical structure of the novel linear ultrathin wall washer lamp of this invention;

[0025] Figure 2 This is a schematic diagram of the cross-sectional structure of the novel linear ultrathin wall washer light optical structure of the present invention;

[0026] Figure 3 This is a schematic diagram of the light emission from the inlet end of the novel linear ultrathin wall washer lamp optical structure of the present invention;

[0027] Figure 4 This is a schematic diagram of the far-end light emission of the novel linear ultrathin wall washer lamp optical structure of the present invention;

[0028] Figure 5 This is a flowchart illustrating the design method of the novel linear ultrathin wall washer light optical structure of the present invention.

[0029] In the diagram: 1-Linear array LED light source; 2-Linear beam splitter lens; 3-Reflector; 4-LED lamp beads; 5-Incident cavity; 6-Upper arc-shaped refraction part; 7-Lower arc-shaped refraction part; 8-Lamp body. Detailed Implementation

[0030] 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.

[0031] like Figures 1 to 5 The present invention discloses a novel linear ultrathin wall washer light optical structure, including a linear array LED light source 1, a linear beam splitter lens 2, and a reflector 3. The linear array LED light source 1 is arranged vertically, and a plurality of LED beads 4 are provided on the rear side of the linear array LED light source 1. An incident cavity 5 covering the LED beads 4 is provided on the front side of the linear beam splitter lens 2. An upper arc-shaped refraction part 6 is provided on the upper part of the rear side of the linear beam splitter lens 2, and a lower arc-shaped refraction part 7 is provided on the lower part of the rear side of the linear beam splitter lens 2. The reflector 3 is located above the linear beam splitter lens 2 and is inclined downward from front to back. By designing a linear beam-splitting lens 2, the light emitted by the linear array LED light source 1 is divided into two parts on the wall: the near end and the far end. The light from the near end is directly refracted by the linear beam-splitting lens 2 and then emitted directly, achieving better brightness uniformity on the wall near the light source. However, the brightness uniformity at the far end cannot be achieved solely by adjusting the light using the linear beam-splitting lens 2. A reflector 3 is added to the far end portion of the light, and the reflected light from the reflector 3 achieves a higher light intensity, thus illuminating the far end of the wall. This fills the gap in wall washer applications for ultra-thin panel lights, improves the luminaire efficiency, effective light ratio, and ease of installation of ultra-thin wall washer lights, and eliminates light outside the illuminated area, completely solving the problem of wall washer lights. Addressing the glare issue of lighting fixtures, this solution achieves higher power output within the same volume, wider wall washing width, and significantly reduces the number of fixtures required for the same illumination requirements, thus lowering operating costs. Simultaneously, the fixtures are more energy-efficient and aesthetically pleasing while providing excellent lighting effects, achieving a level of comfort where the light source is not visible. Compared to panel lights, it offers a more comfortable atmosphere and anti-glare effect in indoor lighting applications. Compared to LED strips, it provides better anti-glare performance, energy efficiency, and uniform wall illuminance. Light loss in home lighting is significantly reduced, comfort is significantly improved, achieving energy conservation and emission reduction while meeting people's demand for high-quality lighting effects and providing a superior user experience.

[0032] The cross-section of the incident cavity 5 is triangular, which controls the incident light at the near end and the far end of the lamp respectively.

[0033] The lower arc-shaped refractive part 7 is set to gradually increase in size from top to bottom, while the upper arc-shaped refractive part 6 is set to gradually decrease in size from the middle to the upper and lower sides, respectively controlling the illumination range of near-end light and far-end light.

[0034] It also includes a lamp body 8 for mounting the linear array LED light source 1, the linear beam splitter 2 and the reflector 3. The bottom of the lamp body 8 is open to facilitate the installation and reflection control of the linear array LED light source 1, the linear beam splitter 2 and the reflector 3.

[0035] The reflector 3 is a metal reflector or a plastic reflector, and the surface of the reflector 3 is provided with a reflective coating to improve the uniformity and fullness of reflection.

[0036] The reflector 3 is curved, which makes the reflected light more concentrated.

[0037] Linear beam splitter 2 is a PC linear beam splitter, a PMMA linear beam splitter, or a PS linear beam splitter.

[0038] A manufacturing mold having a shape suitable for manufacturing linear beam-splitting lenses by forming a mold.

[0039] A novel linear ultrathin wall washer light optical structure design method, characterized by the following steps:

[0040] Step (1): Determine the application scenario;

[0041] Step (2): Select a suitable linear array LED light source;

[0042] Step (3): Set up a linear beam splitter to split the light into near-end light and far-end light;

[0043] Step (4): Set up the reflector and adjust the curvature;

[0044] Step (5): Set up a structure to fix each component.

[0045] Step (4) includes adjusting the geometry of the linear beam splitter, which is generally thinner in the middle and thicker at the top and bottom. Adjusting the linear beam splitter allows the light from the far end to be irradiated onto the reflector as much as possible.

[0046] First, determine the required light color of the lamp and select a suitable LED light source, or encapsulate a strip LED light source according to the light requirements. Determine the length of the linear array LED light source based on the lamp power. Set the height of the linear beam splitter 2 according to the height of the LED emitting surface, generally 3-5 times the height of the LED emitting surface. Set the curvature of the linear beam splitter 2 according to the wall height. The near-light end should have a shape that is thinner at the top and thicker at the bottom, while the far-light end should have a shape that is thicker in the middle and thinner at the top and bottom, or of equal thickness. Set the width and height of the reflector 3 according to the wall height and the height of the linear array LED light source 1. The height of the reflector 3 is approximately equal to the height of the linear beam splitter 2, and the width of the reflector 3 is approximately 5-10 times the height of the linear array LED light source 1, generally depending on the height of the wall being illuminated. The curvature is generally a parabola with the linear array LED light source 1 as the focal point. The reflector 3 can achieve a suitable geometric shape through stretching or extrusion. Metal reflectors can achieve reflective function through processes such as oxidation, spraying, and evaporation coating, while plastic reflectors can achieve reflective function through processes such as spraying and evaporation coating. Based on the above basic structure, by finely adjusting the surface shape curvature of each component, the light intensity distribution of y=1 / cos²Θ can be approximately achieved. Since E (illuminance)=I (light intensity) / r (distance)², the wall surface can approximately achieve equal illuminance everywhere.

[0047] Linear array LED light sources can be composed of LED chips of different color temperatures, colors, and wavelengths. The luminous power of each chip can be adjusted to match any color temperature and color of light, and the emitted light follows a Lambertian distribution near the surface. Based on improving the effect of wall washer lights, the design method of this invention cleverly utilizes the structural advantages of the linear beam splitter 2 and the reflector 3. By designing the linear beam splitter 2, the light emitted by the linear array LED light source 1 is divided into two parts on the wall surface: the near end and the far end. The light on the wall surface near the light source is directly refracted by the linear beam splitter 2 and emitted directly, achieving better brightness uniformity on the wall surface near the light source. However, the brightness uniformity on the far end cannot be achieved by simply adjusting the light with the linear beam splitter 2. The far end of the light source is illuminated by the reflector 3, which reflects the light to achieve a higher light intensity, thereby illuminating the far end of the wall surface.

[0048] The components of this invention include, but are not limited to, a linear array LED light source 1, a linear beam splitter 2, and a reflector 3. By adjusting the light distribution and spot shape in this configuration, various practical application effects can be achieved. The linear array LED light source 1 can be any strip-shaped light source manufactured using any process. The linear beam splitter 2 can also be any free-form surface shape or a particle array to achieve a linear effect. The reflector 3 can be of any shape. Combined together, they can adjust the light distribution accordingly, thereby meeting different usage requirements. The relative positions of the component structures are not fixed; different diameters and shapes can create new light distribution effects.

[0049] 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. A novel linear ultrathin wall washer lamp optical structure, characterized in that: The device includes a linear array LED light source, a linear beam splitter lens, and a reflector. The linear array LED light source is arranged vertically, and a plurality of LED beads are arranged on the rear side of the linear array LED light source. The front side of the linear beam splitter lens has an entrance cavity covering the LED beads. The upper part of the rear side of the linear beam splitter lens has an upper arc-shaped refraction part, and the lower part of the rear side of the linear beam splitter lens has a lower arc-shaped refraction part. The reflector is arranged above the linear beam splitter lens and is inclined downward from front to back.

2. The novel linear ultrathin wall washer light optical structure according to claim 1, characterized in that: The cross-section of the incident cavity is triangular.

3. The novel linear ultrathin wall washer light optical structure according to claim 1, characterized in that: The lower arc-shaped refractive part gradually increases in size from top to bottom, while the upper arc-shaped refractive part gradually decreases in size from the middle to the upper and lower sides.

4. The novel linear ultrathin wall washer lamp optical structure according to claim 1, characterized in that: It also includes a lamp body for mounting the linear array LED light source, the linear beam splitter and the reflector, with an opening at the bottom of the lamp body.

5. The novel linear ultrathin wall washer light optical structure according to claim 1, characterized in that: The reflector is a metal reflector or a plastic reflector, and the surface of the reflector is provided with a reflective coating.

6. The novel linear ultrathin wall washer lamp optical structure according to claim 1, characterized in that: The reflector is arranged in an arc shape.

7. The novel linear ultrathin wall washer light optical structure according to claim 1, characterized in that: The linear beam splitter is a PC linear beam splitter, a PMMA linear beam splitter, or a PS linear beam splitter.

8. A manufacturing mold, characterized in that: It has a shape suitable for manufacturing the linear beam splitter according to any one of claims 1 to 7 by forming a mold.

9. A design method for a novel linear ultrathin wall washer lamp optical structure, characterized in that: Includes the following steps: Step (1): Determine the application scenario; Step (2): Select a suitable linear array LED light source; Step (3): Set up a linear beam splitter to split the light into near-end light and far-end light; Step (4): Set up the reflector and adjust the curvature; Step (5): Set up a structure to fix each component.

10. The design method of the novel linear ultrathin wall washer lamp optical structure according to claim 9, characterized in that: Step (4) includes adjusting the geometry of the linear beam splitter, which is generally thinner in the middle and thicker at the top and bottom. Adjusting the linear beam splitter allows the light from the far end to be irradiated onto the reflector as much as possible.

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