CN103047607A - Manufacture method of free-curved-surface lens for LED collimation - Google Patents

Manufacture method of free-curved-surface lens for LED collimation Download PDF

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CN103047607A
CN103047607A CN2012105642212A CN201210564221A CN103047607A CN 103047607 A CN103047607 A CN 103047607A CN 2012105642212 A CN2012105642212 A CN 2012105642212A CN 201210564221 A CN201210564221 A CN 201210564221A CN 103047607 A CN103047607 A CN 103047607A
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refraction
lens
light
plane
reflecting surface
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CN103047607B (en
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郑臻荣
刘鹏
吴仍茂
王会会
杨洋
李海峰
刘旭
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Zhejiang University ZJU
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Abstract

The invention discloses a manufacture method of a free-curved-surface lens for LED collimation. The free-curved-surface lens comprises a refracting surface S1, a reflecting surface S2, a cylindrical surface S3 and an emergent surface S4, wherein the refracting surface S1 is connected with the reflecting surface S2 through the cylindrical surface S3, the emergent surface S4 is a larger round outlet of the reflecting surface S2, data of the refracting surface S1, the reflecting surface S2, the cylindrical surface S3 and the emergent surface S4, obtained by computing, are inputted into 3D (three-dimensional) modeling software for establishing a model, and the model is imported into a five-axis machine tool and can be processed and formed. Light emitted by a light source is refracted by the refracting surface S1 and subjected to total internal reflection by the reflecting surface S2 prior to being emergent from the emergent surface S4 in a parallel light form. The lens is of a total internal reflection structure and is in rotational symmetry relative to a z coordinate axis, and light collection half angle is 90 degrees. The lens is simple in manufacture process, compact in structure, easy to process, good in collimation effect and high in energy use ratio.

Description

A kind of preparation method of the free-form surface lens for LED collimation
Technical field
The present invention relates to the optics field, especially relate to a kind of preparation method of the free-form surface lens for LED collimation.
Background technology
With respect to conventional light source, LED has the advantages such as long, low in energy consumption, compact conformation of life-span, flexible design, and along with climbing up and up of LED light efficiency in recent years, its application is also more and more extensive.Usually, the output intensity of LED is nearly lambertian distribution, in a lot of the application, need LED light is collimated (such as endoscope illumination etc.), therefore need redistribute the LED bright dipping by secondary optical design.The sphere of comparing, free form surface has become the first-selection of LED secondary optical design with its higher design freedom.The Random Curved Surface Designing of realization LED collimated illumination mainly adopts the method for partial differential journey.For collimated illumination, partial differential journey method normally adopts the ideal point light source, construct one group of ODE that curved surface satisfies according to incident ray, emergent ray and the corresponding Surface Method relation between the three of vowing, and make up curved surface by numerical solution and three-dimensional modeling.In order to obtain higher capacity usage ratio and less lens rising angle, the lens that are used for the LED collimation need to adopt total internal reflection (TIR) structure usually, and find the solution respectively refraction curved surface and total reflection curved surface by partial differential journey method.The problems such as because the LED tool has the dimensions, and the compact curved-surface structure LED that compares can not be considered as spot light usually, and it is bad to occur easily the collimation effect when practical application, and angle of flare is relatively large.In order to address this problem, the designer uses the method that increases aperture of lens usually obtaining better collimation effect, but the increase of this volume has limited its application in a lot of occasions (such as endoscope illumination etc.) undoubtedly.
In addition, LED collimation lens of the prior art also exists complex structure, realizes the high shortcoming of cost.Chinese patent 200510092271.5 has proposed a kind of internally-reflecting collimation lens of the funnel shaped type for LED collimation, and the inventor has designed a plurality of faces and gone to realize the function that collimates, complex steps, and complex structure is difficult to processing.
Summary of the invention
The objective of the invention is in order to overcome the deficiencies in the prior art, a kind of preparation method of the free-form surface lens that is used for the LED collimation of more closing to reality application is provided.
The present invention is as follows for the scheme that solves its technical problem employing:
The preparation method that is used for the free-form surface lens of LED collimation comprises the steps:
Step 1: design the free-form surface lens initial configuration for the spot light collimation, the face type of this free-form surface lens plane of refraction is determined by following formula:
Figure 2012105642212100002DEST_PATH_IMAGE001
The face type of reflecting surface is determined by following formula:
Figure 2012105642212100002DEST_PATH_IMAGE003
Wherein, z is the coordinate of light transmition positive direction z axle, the angle of the ω corresponding light that is incident ray after plane of refraction refraction or reflecting surface reflection and z axle, and directional light is ω=0, h is that light source is disintegrated the distance of penetrating vertex of surface, d is the distance between plane of refraction summit and the origin of coordinates, and R1 is half bore of lens lower surface, and n is the index of refraction in lens, θ is the angle of incident ray and z axle, for the plane of refraction formula, the span of θ is [0 ); For the reflecting surface formula, the span of θ be [ , pi/2], wherein It is the maximum angle that plane of refraction can be collected light;
Step 2: model parameterization, at first, the data point to be optimized on the plane of refraction curve A B is determined by following equation:
Figure 96496DEST_PATH_IMAGE006
Wherein,
Figure DEST_PATH_IMAGE007
Be respectively data point to be optimized and quantity thereof on the plane of refraction curve A B with N1, the data point to be optimized on the reflecting surface curve C D can be determined by following equation:
Figure DEST_PATH_IMAGE009
Wherein,
Figure 957136DEST_PATH_IMAGE010
Be divided into the upper data point to be optimized of reflecting surface curve C D and quantity thereof with N2, take turns in the Optimized Iterative every, the coordinate of each data point to be optimized can be recomputated by following two formulas and obtain
Figure 266894DEST_PATH_IMAGE012
Figure 9723DEST_PATH_IMAGE014
Wherein,
Figure DEST_PATH_IMAGE015
For the point
Figure 992023DEST_PATH_IMAGE007
Coordinate,
Figure 769486DEST_PATH_IMAGE016
For the point
Figure 250146DEST_PATH_IMAGE010
Coordinate,
Figure DEST_PATH_IMAGE017
Be light source distance Distance,
Figure 275051DEST_PATH_IMAGE018
For incident ray and face of cylinder curve B C intersection point from
Figure 234917DEST_PATH_IMAGE010
Distance,
Figure DEST_PATH_IMAGE019
With
Figure 824161DEST_PATH_IMAGE020
Be respectively corresponding to
Figure 541581DEST_PATH_IMAGE007
With
Figure 936791DEST_PATH_IMAGE010
The incident ray of point and the angle of z axle, solve corresponding control point and knot vector according to this group data point, then construct the contour curve of plane of refraction and reflecting surface according to control point and knot vector, this contour curve is namely obtained the model of reconstruct at rotating 360 degrees;
Step 3: set up evaluation function, evaluation function MF is determined by following formula:
Figure DEST_PATH_IMAGE021
Wherein,
Figure 688846DEST_PATH_IMAGE022
For from each light of lens outgoing and the angle of z axle positive direction,
Figure DEST_PATH_IMAGE023
Be the mean square deviation from the angle of all light of lens outgoing and z axle positive direction, M is the quantity of sampling light, then chooses area source that light intensity is 1mm * 1mm that lambert's body distributes and imports optics software Tracepro and be optimized, and makes evaluation function MF convergence;
Step 4: plane of refraction links to each other by the face of cylinder with reflecting surface, exit facet is the larger round exit of reflecting surface, plane of refraction, reflecting surface, the face of cylinder and exit facet data input 3D modeling software are set up model, this model is imported five-axis machine tool get final product machine-shaping; Light that light source sends is through the refraction of plane of refraction and the total internal reflection of reflecting surface, with the form of directional light from the exit facet outgoing; These lens are the full-internal reflection type structure, and about z reference axis Rotational Symmetry, the ray-collecting half-angle is 90 °.
The present invention compared with prior art has that collimation is good, a compact conformation, size less, the simple and practical characteristics of method for designing, is specially adapted to the collimation of LED expansion light source.
Description of drawings
Fig. 1 (a) is the top view that is used for the free-form surface lens of LED collimation;
Fig. 1 (b) is the perspective view that is used for the free-form surface lens of LED collimation;
Fig. 1 (c) is the front view that is used for the free-form surface lens of LED collimation;
Fig. 1 (d) is the side view that is used for the free-form surface lens of LED collimation;
The schematic diagram that Fig. 2 (a) concerns for the free-form surface lens profile refraction curved surface glazed thread that is used for the LED collimation;
The schematic diagram that Fig. 2 (b) concerns for the free-form surface lens profile reflecting curved surface glazed thread that is used for the LED collimation;
Fig. 3 is the schematic diagram of data point choosing method to be optimized on the free-form surface lens contour curve that is used for the LED collimation;
Fig. 4 is the schematic diagram that is used for the free-form surface lens embodiment emergent light angular distribution of LED collimation.
The specific embodiment
As Figure 1-3, the preparation method that is used for the free-form surface lens of LED collimation comprises the steps:
Step 1: design the free-form surface lens initial configuration for the spot light collimation, the face type of the plane of refraction S1 of this free-form surface lens is determined by following formula:
The face type of reflecting surface S2 is determined by following formula:
Figure 448992DEST_PATH_IMAGE026
Wherein, z is the coordinate of light transmition positive direction z axle, the angle of the ω corresponding light that is incident ray after plane of refraction S1 refraction or reflecting surface S2 reflection and z axle, and directional light is ω=0, h is that light source is from the distance on plane of refraction S1 summit, d is the distance between plane of refraction summit and the origin of coordinates, and R1 is half bore of lens lower surface, and n is the index of refraction in lens, θ is the angle of incident ray and z axle, for the plane of refraction formula, the span of θ is [0
Figure 650778DEST_PATH_IMAGE004
); For the reflecting surface formula, the span of θ be [
Figure 849679DEST_PATH_IMAGE004
, pi/2], wherein
Figure 518557DEST_PATH_IMAGE004
It is the maximum angle that plane of refraction can be collected light;
Step 2: model parameterization, at first, the data point to be optimized on the plane of refraction curve A B is determined by following equation:
Figure DEST_PATH_IMAGE027
Wherein,
Figure 449604DEST_PATH_IMAGE007
Be respectively data point to be optimized and quantity thereof on the plane of refraction curve A B with N1, the data point to be optimized on the reflecting surface curve C D can be determined by following equation:
Figure 141617DEST_PATH_IMAGE009
Wherein,
Figure 144208DEST_PATH_IMAGE010
Be divided into the upper data point to be optimized of reflecting surface curve C D and quantity thereof with N2, take turns in the Optimized Iterative every, the coordinate of each data point to be optimized can be recomputated by following two formulas and obtain
Figure 605276DEST_PATH_IMAGE012
Figure 769541DEST_PATH_IMAGE014
Wherein,
Figure 948850DEST_PATH_IMAGE015
For the point
Figure 489552DEST_PATH_IMAGE007
Coordinate,
Figure 867444DEST_PATH_IMAGE016
For the point
Figure 405873DEST_PATH_IMAGE010
Coordinate,
Figure 869215DEST_PATH_IMAGE017
Be light source distance
Figure 151292DEST_PATH_IMAGE007
Distance,
Figure 383690DEST_PATH_IMAGE018
For incident ray and face of cylinder curve B C intersection point from
Figure 93020DEST_PATH_IMAGE010
Distance, With
Figure 926164DEST_PATH_IMAGE020
Be respectively corresponding to
Figure 219261DEST_PATH_IMAGE007
With
Figure 161809DEST_PATH_IMAGE010
The incident ray of point and the angle of z axle, solve corresponding control point and knot vector according to this group data point, then construct the contour curve of plane of refraction S1 and reflecting surface S2 according to control point and knot vector, this contour curve is namely obtained the model of reconstruct at rotating 360 degrees;
Step 3: set up evaluation function, evaluation function MF is determined by following formula:
Figure 599744DEST_PATH_IMAGE021
Wherein, For from each light of lens outgoing and the angle of z axle positive direction,
Figure 492930DEST_PATH_IMAGE023
Be the mean square deviation from the angle of all light of lens outgoing and z axle positive direction, M is the quantity of sampling light, then chooses area source that light intensity is 1mm * 1mm that lambert's body distributes and imports optics software Tracepro and be optimized, and makes evaluation function MF convergence;
Step 4: plane of refraction S1 links to each other by face of cylinder S3 with reflecting surface S2, exit facet S4 is the larger round exit of reflecting surface S2, plane of refraction S1, reflecting surface S2, face of cylinder S3 and exit facet S4 data input 3D modeling software are set up model, this model is imported five-axis machine tool get final product machine-shaping; Light that light source sends is through the refraction of plane of refraction S1 and the total internal reflection of reflecting surface S2, with the form of directional light from exit facet S4 outgoing; These lens are the full-internal reflection type structure, and about z reference axis Rotational Symmetry, the ray-collecting half-angle is 90 °.
Embodiment
The preparation method that is used for the free-form surface lens of LED collimation comprises the steps:
Step 1: design the free-form surface lens initial configuration for the spot light collimation.Fig. 2 (a) reflects the schematic diagram that the curved surface glazed thread concerns for the free-form surface lens profile that is used for the LED collimation, the schematic diagram that Fig. 2 (b) concerns for the free-form surface lens profile reflecting curved surface glazed thread that is used for the LED collimation.With reference to Fig. 2, it is as shown in table 1 to choose the initial design parameter of lens.
The initial parameter of Lens Design in table 1 embodiment of the invention
h d θ
Figure 606380DEST_PATH_IMAGE004
 ω n
6mm 5mm [0,π/2] 30° 0 1.4935
The following formula of parameter substitution in the table 1 can be determined the plane of refraction S1 of free-form surface lens:
Figure 469294DEST_PATH_IMAGE028
The following formula of parameter substitution in the table 1 can be determined the reflecting surface S2 of free-form surface lens:
Figure DEST_PATH_IMAGE029
Wherein, z is the coordinate of light transmition direction z axle, the angle (directional light is ω=0) of the ω corresponding light that is incident ray after plane of refraction S1 refraction or reflecting surface S2 reflection and z axle, h is that light source is from the distance on plane of refraction S1 summit, d is the distance between plane of refraction summit and the origin of coordinates, R1 is half bore of lens lower surface, and lens material adopts the Pmma plastics, and refractive index n is 1.4935.θ is the angle of incident ray and z axle, for the plane of refraction formula, the span of θ be [0,
Figure 631285DEST_PATH_IMAGE004
), for the span of reflecting surface formula θ be [ , pi/2], wherein
Figure 977132DEST_PATH_IMAGE004
It is the maximum angle that plane of refraction can be collected light.
Step 2: the initial configuration model parameterization that step 1 is obtained.At first, the data point to be optimized on the plane of refraction curve A B can be determined by following equation:
Wherein,
Figure 355341DEST_PATH_IMAGE007
Be respectively data point to be optimized and quantity thereof on the plane of refraction curve A B with N1.Data point to be optimized on the reflecting surface curve C D can be determined by following equation:
Figure DEST_PATH_IMAGE031
Wherein,
Figure 474607DEST_PATH_IMAGE010
Be divided into the upper data point to be optimized of reflecting surface curve C D and quantity thereof with N2.Number of data points to be optimized on the Free-Form Surface Profile too much can reduce optimization efficiency, crosses that I haven't seen you for ages and reduce the accuracy of model reconstruction, makes N1=4 here, N2=5.According to each discrete optimization data point, utilize interpolation arithmetic can try to achieve LED rising angle corresponding to each discrete point
Figure 929859DEST_PATH_IMAGE032
With
Figure DEST_PATH_IMAGE033
, and select each point corresponding With
Figure DEST_PATH_IMAGE035
As optimized variable.Take turns in the Optimized Iterative every, the coordinate of each data point to be optimized can be recomputated by following two formulas and obtain
Figure 5579DEST_PATH_IMAGE036
Figure 307248DEST_PATH_IMAGE014
Wherein,
Figure 871084DEST_PATH_IMAGE015
For the point
Figure 992624DEST_PATH_IMAGE007
Coordinate, For the point
Figure 453354DEST_PATH_IMAGE010
Coordinate,
Figure 250409DEST_PATH_IMAGE017
Be light source distance
Figure 796928DEST_PATH_IMAGE007
Distance,
Figure 704841DEST_PATH_IMAGE018
For incident ray and face of cylinder curve B C intersection point from
Figure 653205DEST_PATH_IMAGE010
Distance,
Figure 621161DEST_PATH_IMAGE019
With Be respectively corresponding to
Figure 366580DEST_PATH_IMAGE007
With
Figure 231768DEST_PATH_IMAGE010
The incident ray of point and the angle of z axle.Solve corresponding control point and knot vector according to this group data point, then construct the contour curve of plane of refraction S1 and reflecting surface S2 according to control point and knot vector.This contour curve can be obtained the model of reconstruct at rotating 360 degrees.
Step 3: set up the evaluation function MF that following formula is determined:
Figure 308308DEST_PATH_IMAGE038
Wherein,
Figure 891737DEST_PATH_IMAGE022
For from each light of exit facet S4 outgoing and the angle of z axle positive direction,
Figure 407032DEST_PATH_IMAGE023
Be the mean value from the angle of all light of exit facet S4 outgoing and z axle positive direction, M is the quantity of sampled point.
Step 4: at present, modal led chip size is on the market
Figure 64409DEST_PATH_IMAGE039
, therefore, in optics software, set up
Figure 374168DEST_PATH_IMAGE039
And the area source that light intensity becomes lambert's body to distribute, unite above three steps and carry out repeatedly ray tracing and optimization, making the MF convergence continue to converge to minimum 0.013842 rear optimization stops automatically, can be met the free-form surface lens of designing requirement, with reference to accompanying drawing 1 and accompanying drawing 2, its structural parameters are as shown in table 2.
The structural parameters of table 2 embodiment of the invention
h H R1 R2
6mm 16.2mm 5mm 15.5mm
Wherein, H is the height of free-form surface lens, and R2 is the radius of free-form surface lens exit facet.This free form surface collimation lens is imported optics software Tracepro, adopts 1,000,000 light to carry out trace, with reference to Fig. 4, these lens can with
Figure 382575DEST_PATH_IMAGE039
Size led chip 99% of the energy that emits beam all concentrates on the axle with z
Figure 435982DEST_PATH_IMAGE040
Angle in.The result shows that the present invention in the situation that has guaranteed the lens arrangement compactness, has obtained fabulous collimation effect, greatly be better than prior art.Utilize the 3D modeling software to set up the model of this free-form surface lens, with these mode input five axis processing machine beds, can obtain these lens.
The above only is preferred embodiments result of the present invention, not in order to limiting the present invention, allly makes any modification, is equal to replacement, improvement etc. within the present invention's spirit and principle, all should be included within the protection domain of the present invention.

Claims (1)

1. a preparation method that is used for the free-form surface lens of LED collimation is characterized in that comprising the steps:
Step 1: design the free-form surface lens initial configuration for the spot light collimation, the face type of the plane of refraction of this free-form surface lens (S1) is determined by following formula:
Figure 504377DEST_PATH_IMAGE001
The face type of reflecting surface (S2) is determined by following formula:
Figure 914630DEST_PATH_IMAGE002
Wherein, z is the coordinate of light transmition positive direction z axle, the angle of the ω corresponding light that is incident ray after plane of refraction (S1) refraction or reflecting surface (S2) reflection and z axle, and directional light is ω=0, h is that light source is from the distance on plane of refraction (S1) summit, d is the distance between plane of refraction summit and the origin of coordinates, and R1 is half bore of lens lower surface, and n is the index of refraction in lens, θ is the angle of incident ray and z axle, for the plane of refraction formula, the span of θ is [0
Figure 762500DEST_PATH_IMAGE003
); For the reflecting surface formula, the span of θ be [
Figure 625414DEST_PATH_IMAGE003
, pi/2], wherein
Figure 849722DEST_PATH_IMAGE003
It is the maximum angle that plane of refraction can be collected light;
Step 2: model parameterization, at first, the data point to be optimized on the plane of refraction curve A B is determined by following equation:
Figure 114481DEST_PATH_IMAGE004
Wherein,
Figure 398832DEST_PATH_IMAGE005
Be respectively data point to be optimized and quantity thereof on the plane of refraction curve A B with N1, the data point to be optimized on the reflecting surface curve C D can be determined by following equation:
Wherein,
Figure 511461DEST_PATH_IMAGE007
Be divided into the upper data point to be optimized of reflecting surface curve C D and quantity thereof with N2, take turns in the Optimized Iterative every, the coordinate of each data point to be optimized can be recomputated by following two formulas and obtain
Figure 83050DEST_PATH_IMAGE009
Wherein,
Figure 920556DEST_PATH_IMAGE010
For the point
Figure 486666DEST_PATH_IMAGE005
Coordinate, For the point
Figure 86592DEST_PATH_IMAGE007
Coordinate, Be light source distance
Figure 515616DEST_PATH_IMAGE005
Distance,
Figure 671791DEST_PATH_IMAGE013
For incident ray and face of cylinder curve B C intersection point from Distance,
Figure 15365DEST_PATH_IMAGE014
With
Figure 126540DEST_PATH_IMAGE015
Be respectively corresponding to
Figure 137222DEST_PATH_IMAGE005
With
Figure 105178DEST_PATH_IMAGE007
The incident ray of point and the angle of z axle, solve corresponding control point and knot vector according to this group data point, then construct the contour curve of plane of refraction (S1) and reflecting surface (S2) according to control point and knot vector, this contour curve is namely obtained the model of reconstruct at rotating 360 degrees;
Step 3: set up evaluation function, evaluation function MF is determined by following formula:
Figure 138993DEST_PATH_IMAGE016
Wherein,
Figure 585017DEST_PATH_IMAGE017
For from each light of lens outgoing and the angle of z axle positive direction,
Figure 715784DEST_PATH_IMAGE018
Be the mean square deviation from the angle of all light of lens outgoing and z axle positive direction, M is the quantity of sampling light, then chooses area source that light intensity is 1mm * 1mm that lambert's body distributes and imports optics software Tracepro and be optimized, and makes evaluation function MF convergence;
Step 4: plane of refraction (S1) links to each other by the face of cylinder (S3) with reflecting surface (S2), exit facet (S4) is the larger round exit of reflecting surface (S2), plane of refraction (S1), reflecting surface (S2), the face of cylinder (S3) and exit facet (S4) data input 3D modeling software are set up model, this model is imported five-axis machine tool get final product machine-shaping; Light that light source sends is through the refraction of plane of refraction (S1) and the total internal reflection of reflecting surface (S2), with the form of directional light from exit facet (S4) outgoing; These lens are the full-internal reflection type structure, and about z reference axis Rotational Symmetry, the ray-collecting half-angle is 90 °.
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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016004724A1 (en) * 2014-07-09 2016-01-14 华南理工大学 Free-form curved surface optical lens of ultrathin direct led backlight system
CN107062157A (en) * 2017-05-31 2017-08-18 杭州光锥科技有限公司 Underground lamp lens, light emitting module and underground lamp with the underground lamp lens
CN107062157B (en) * 2017-05-31 2023-02-10 浙江光锥科技有限公司 Underground lamp lens, light emitting module with same and underground lamp
CN112377877A (en) * 2020-11-10 2021-02-19 浙江光锥科技有限公司 Lens design method and system and line lamp lens
CN112377877B (en) * 2020-11-10 2022-12-02 浙江光锥科技有限公司 Lens design method and system and line lamp lens
CN114017743A (en) * 2021-11-17 2022-02-08 广东省科学院半导体研究所 Collimating lens and collimating lens design method

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