Classifications

• • G—PHYSICS
  • G02—OPTICS
  • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
  • G02B3/00—Simple or compound lenses
  • G02B3/0006—Arrays
  • G02B3/0037—Arrays characterized by the distribution or form of lenses
• • G—PHYSICS
  • G02—OPTICS
  • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
  • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
  • G02B6/0001—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
  • G02B6/0011—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being planar or of plate-like form
  • G02B6/0033—Means for improving the coupling-out of light from the light guide
  • G02B6/0035—Means for improving the coupling-out of light from the light guide provided on the surface of the light guide or in the bulk of it
  • G02B6/0038—Linear indentations or grooves, e.g. arc-shaped grooves or meandering grooves, extending over the full length or width of the light guide
• • G—PHYSICS
  • G02—OPTICS
  • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
  • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
  • G02B6/0001—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
  • G02B6/0011—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being planar or of plate-like form
  • G02B6/0065—Manufacturing aspects; Material aspects

Definitions

• the present invention relates generally to edge-lit panel lighting fixtures. More particularly, the present invention relates to protecting the surface of micro-lens patterned lightguides used in edge-lit panels.
• Edge-lit light emitting diode (LED) panels are becoming an increasingly common technology used, for example, in indoor lighting fixtures. As understood by those of skill in the art, light is transmitted from an LED array to a central area of an edge-lit panel throughlightguides.
• edge-lit panels are the optical technology is embedded directly into the lightguide, optimizing light distribution, and optical efficiency. Also, their very thin physical profile enables the creation of correspondingly thin light fixtures. Additionally, as an LED-based fixture (i.e., flat-panel), edge-lit panels are generally more efficient, requiring fewer luminaires to produce more light for less energy.
• LED-based fixture i.e., flat-panel
• an optical protective sheet is used to cover a surface of an optical lightguide used in an LED flat-panel.
• the lightguide generally includes a micro-lens pattern guide distribution of the light.
• This protective sheet shields the lightguide against scratches, the effects of dust, and other contaminants.
• protective sheets provide this shielding at the expense of optical performance. More specifically, these layers generally decrease the transparency of the surface of thelightguide, ultimately reducing the optical characteristics of the LED fixture.
• an embodiment includes a micro-lens lightguide structure including a lightguide layer formed of a hybrid polymer material.
• the hybrid material is formed of at least one of a fluoropolymer and an acrylate polymer.
• Illustrious embodiments of the present invention provide a resilient nano-filler polymer coating without the need of protection sheets.
• This coating can be applied and used to increase the surface scratch resistance of the base polymer resin for a lightguide micro-lens pattern.
• the base polymer is usually formed of acrylic, epoxy, silicon, or the like.
• a micro-lens lightguide structure includes a lightguide base resin constructed of an acrylic-like material, along with a nano-filler polymer layer, such as a polymethyl methacrylate (PMMA) material.
• a micro-lens pattern is formed within the nano- filler polymer layer.
• This nano-filler polymer layer can be coated onto the lightguide base resin, via screen printing and doctor blading transfer molding to create the micro-lens pattern.
• Use of a nano-filler polymer coating eliminates the need for protective sheets. Thus, the overall weight of the micro-lens lightguide structure can be reduced while maintaining optical efficiency.
• Exemplary embodiments may take form in various components and arrangements of components. Exemplary embodiments are illustrated in the accompanying drawings, throughout which like reference numerals may indicate corresponding or similar parts in the various figures.
• the drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention. Given the following enabling description of the drawings, the novel aspects of the present invention should become evident to a person of ordinary skill in the art.
• FIG. 1 is an illustration of an LED panel lighting fixture in which embodiments of the present invention can be practiced.
• FIG. 2 is a more detailed illustration of the LED panel lighting fixture illustrated in FIG. 1.
• FIG. 3 is a detailed illustration of a conventional lightguide protection arrangement.
• FIG. 4 is a detailed illustration of a micro-lens lightguide structure constructed and arranged in accordance with an embodiment of the present invention.
• FIG. 5 is an illustration of an exemplary graph 600 of optical transmission characteristics of various nano-filler blended polymer hardcoating coated lightguide base resinconstructed in accordance with the embodiment.
• FIG. 6 is an illustration of transparency performance results of a nano-filler blended polymer hardcoatingcoated PMMA in comparison to a regular PMMA and PC (polycarbonate)based material in accordance with the embodiment after sand scratching test.
• FIG. 7 is an illustration of a hybrid polymer to construct a single layer lightguide structure in accordance with a second embodiment of the present invention.
• FIG. 1 is an illustration of an exemplary LED panel lighting fixture 100 in which embodiments of the present invention can be practiced.
• the LED panel lighting fixture 100 is commonly used office settings such as conference and meeting rooms, computer aided design (CAD) workstations, reception areas, archives, etc.
• CAD computer aided design
• the lighting fixture 100 is a 1 x 4 recessed troffer.
• the LED panel lighting fixture 100 includes standard components, such as a power supply unit (PSU) box 102, which houses adriver 103 for the fixture 100.
• PSU power supply unit
• the driver 103 provides power LEDs within a lighting module 104, illustrated in greater detail below.
• FIG. 2 is a more detailed illustration of the lighting module 104 of FIG. 1.
• the lighting module 104 includes an LED bar 200 including LEDs 202 mounted within reflector cups 204.
• the LEDs 202 of the LED bar 200 are positioned to surround a lightguide (e.g., waveguide) 206.
• the lightguide 206 directs light, produced by the LED bar 202, to areas of the lighting module 104.
• the light is distributed via a micro-lens pattern (shown below) embedded on a surface of the lightguide 206, and through protective sheets (i.e., diffuser) 208 and 209.
• the optical protective sheets208 and 209 overlay, or are affixed to a surface of the lightguide 206.
• the optical protective sheets 222 shield the lightguide 206 from debris and other contaminants.
• FIG. 3 is a detailed illustration of a conventional lightguide protection arrangement 300.
• the lightguide arrangement 300 is similar to the lightguide arrangement 104 (e.g., the optical protective sheets208 and 209 and the lightguide 206) of FIG. 2. That is, the lightguide arrangement 300 includes a protective sheet (e.g., clear acrylic sheet) 308 shielding a top side of the lightguide 306 from debris and other contaminants.
• a micro-lens pattern 310 embedded on a surface of the lightguide 306, distributes light produced by a light source, such as LEDs.
• an additional protective sheet 309 shields a bottom side of the lightguide 306. It is noted, however, that some conventional lightguide arrangements only use a single protective sheet.
• the surface of the lightguide 306 is extremely susceptible to damagevia scratches, cleaning solvents, human touch, debris, and other contaminants etc.
• the slightest scratch of the lightguide 306 can create light leakages resulting in suboptimal performance.
• a contributing factor to this susceptibility is that conventional surface micro-lens patterns, such as the micro-lens pattern 310, are typically formed of relatively weak base resin materials. This weakness creates the need for protective sheets.
• the bottom protective sheet308and the top protective sheet309 arecollectively referred to as diffusers.
• the bottom protective sheet308 and the top protective sheet309 form a sandwich type arrangement to shield the lightguide 306 from the degrading effects of contaminants.
• top protective sheet308 A significant disadvantage in using protective sheets, such as the top protective sheet308, is that these sheets create their own optical transmission losses.
• the top protective sheet308 typically creates about a 4% loss in reflectivity in the surface of the lightguide 306. The majority of this loss is attributed toTIR (total internal reflection) effect between the micro-lens pattern and the protective sheet.
• protective sheets are generally extraordinarily expensive due to improved surface abrasion resistance.
• Embodiments of the present invention offer an alternative approach to protecting and preserving the integrity of the micro-lens patterns on lightguide surfaces.
• illustrious embodiments of the present invention provide a resilient nano-filler polymer coating without the need of protection sheets.
• This coating can be applied and used to increase the surface scratch resistance of the base polymer resin for a lightguide micro-lens pattern.
• the base polymer is usually formed of acrylic, epoxy, silicon, or the like.
• This nano-filler polymer is a clear polymer coating containing nano-fillers and actually forms the micro-lens pattern.
• a nano-filler polymer micro-lens pattern in accordance with the embodiments, can be constructed and directly deposited onto the lightguide substrate, or base polymer, using any one of a number of techniques, such as molding, doctor blading, screen printing (i.e., ink impression), and the like. These techniques are well understood by those of skill in the art.
• the nano-filler (i.e., inorganic nano-composite) polymer micro- lens material is used to form an optical diffusive pattern and can be applied as a coating atop the lightguide substrate. Since it can have substantially the same RI as the lightguide substrate, it is not necessary to reshape the micro-lens to satisfy a light distribution requirement. Additionally, the nano-filler polymer enhances the surface abrasion resistance of the lightguide at thicknesses of above 1 micrometers (um). This material also can have tunable surface properties like hydrophobic or hydrophilic characteristics that can inherently protect against dust and facilitate self-cleaningetc.
• FIG. 4 is a detailed illustration of a micro-lens lightguide structure 400 constructed in accordance with an embodiment of the present invention.
• the structure 400 includes a lightguide base resin 402 constructed of an acrylic-like material, along with a nano-filler polymerlayer 404, such as a PMMA material.
• a micro-lens pattern (e.g., the micro-lens pattern 310) is formed within the nano-filler polymer layer 404.
• the nano-filler polymer layer 404 can be coated onto the lightguide base resin 402, via screen printing and doctor blading transfer molding to create the micro-lens pattern 310.
• Use of the nano-filler polymer coating 404 eliminates the need for protective sheets, such as the protective sheets 308 and 309 illustrated in FIG. 3.
• the overall weight of the micro-lens lightguide structure 400 can be reduced while simultaneously optimizing optical efficiency.
• Nano-filler can be additional additives in polymer or self-grown nano particles during crosslinking process of base polymer.
• the polymer coating 404 can be formed of nano-fillermaterials such as silicon dioxide (Si02-x), titanium oxide (Ti02), and aluminum oxide (A1203), and the like.
• a thickness (T) of the polymer coating 404 is desirably above 1 um.
• the nano-fillerparticle size is desirably below 100 nm. Restricting the particle size of nano-filler to less than about 100 nm increasesthe surface abrasion resistance, prevents particle scattering, and maintains good transparency of the surface of the base resin 402, with minimalimpact to light output or total lumens.
• FIG. 5 is an illustration of an exemplary graph 500 of optical transmission characteristics of micro-lens lightguide structures constructed in accordance with the embodiment.
• a snapshot of transmission capabilities of various materials, when used as a coating is displayed for various light wavelengths.
• teijin clear PC 2 mm 502, HT-121 PMMA 3 mm 504, which can be as base material of lightguide, HT-121 PMMA 3 mm/hydrophilic anti-fog coating 506, and HT-121 PMMA 3 mm/hydrophobic coating 508, which both coating have improved surface abrasion resistance are shown.
• Any of the materials 504-508 can be used in the embodiments, with each achieving greater than 90% optical transmission and very minimum effect on lightguide transparency.
• the nano-filler blended polymer coating 404 can be chemically bonded with the base resin 402 after polymerization under ultraviolet(UV) light or heat, thus forming superior adhesion via covalent bonding, and good thickness uniformity.
• the polymer coating 404 exists as rigid micropatterndots (e.g., ink based material) among polymer chains to increase the surface scratch resistance of the base resin 402. Overlaying the base resin 402 with the nano-filler polymer coating 404.
• FIG. 6 is an illustration of transparency performance results 600 of a nano-filler blended polymer coating coated PMMA602 (as used in the illustrious embodiments) in comparison to a regular PMMA based material 604. In FIG.
• the nano-filler blended polymer coatingcoated PMMA 602 displayed much better transparency than the regular PMMA604.
• the nano-filler blended polymer coatingcoated PMMA 602 displayed less haze than the regular PMMA 604.
• haze is a measure of scratch resistance after sanding scratching test.
• the application technique of the nano-filler polymer coating 404 can be modified to adjust the surface properties of the base resin 402 in accordance with customer and/or user requirements. More particularly, additives to the nano-filler polymer coating 404 can create hydrophobic and hydrophilic surface properties of the base resin 402.
• the underlying nano-filler polymer material is non-solvent based. Its viscosity can be increased by further adding nano-fillers. Also, since it is non-solvent based type coating, after molding process fabricated micropattern dots (nano/micro structurejcan keep very good fidelity with mold structure.
• Hydrophobic surface features are generally water repellent, inherently protect against dust, thus enhancing the self-cleaning characteristics of the micro-lens lightguide structure 400. Hydrophilic surface features are more water-soluble, and as such, can reduce the possibility of being damage during cleaning. Surface tension characteristics canbe added or modified based upon customer requirements.
• FIG. 7 is an illustration of a hybrid polymer including a fluoropolymer, such as polyvinylidene fluoride (PVDF), to construct a single layer lightguide structure 700 having a micro-lens pattern 310 formed therein.
• PVDF polyvinylidene fluoride
• FIG. 7 is an illustration of a hybrid polymer including a fluoropolymer, such as polyvinylidene fluoride (PVDF), to construct a single layer lightguide structure 700 having a micro-lens pattern 310 formed therein.
• PVDF has exceptional chemical resistance, UV resistance, thermal stability, and low surface energy or inherent hydrophobicity. By way of example, these characteristics are suitable for extensive use as a coating material for outdoor lighting applications.
• a hybrid polymer including a fluoropolymer like PVDF and acrylate polymer like PMMA can be used as a based material for various optical components with surface micro/nano structures.
• Such structures can include lightguides, optical lens, refractors, diffusers, and the like.
• the ratio between acrylate and fluoropolymers polymers can enhance the performance of the hybrid polymer on surface abrasion resistance.
• PMMAs and PVDFs are completely miscible in their molten state.
• a low surface PVDF can flow above to the PMMA, blendinga hydrophobic layer onto the PMMA after cool down.
• blending the PVDF with the PMMA improves the PMMA's surface hydrophobicity, blue and UV resistance. It also improvesthe PMMA's thermal stability.
• controlling the percentage of crystallinity of PVDF in PMMA can also improve the hardness of PMMA.
• This hybrid polymer is also moldable, thus enabling its use asa base material for both substrates and micro/nano structured elements.
• a PVDF-PMMA hybrid polymer is particularly well-suited for use as a float light panel.
• PVDF-PMMA hybrid polymers can not only bring negative influence on PMMA transmissionbut enhance surface scratching resistance of high density PMMA (e.g., Arkema HT121 for use as a single layer circular float), but also provides hydrophobic surface features to flat panels due to low surface energy from fluoropolymer component.
• high density PMMA e.g., Arkema HT121 for use as a single layer circular float

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• Physics & Mathematics (AREA)
• General Physics & Mathematics (AREA)
• Optics & Photonics (AREA)
• Planar Illumination Modules (AREA)

Applications Claiming Priority (1)

Publications (2)

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Family Applications (1)

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• 2013
  • 2013-12-16 WO PCT/CN2013/089560 patent/WO2015089708A1/en active Application Filing
  • 2013-12-16 EP EP13899350.6A patent/EP3084485A4/de not_active Withdrawn

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