EP4705684A1

EP4705684A1 - Optical lens assembly

Info

Publication number: EP4705684A1
Application number: EP24720183.3A
Authority: EP
Inventors: Peter Johannes Martinus BUKKEMS
Original assignee: Signify Holding BV
Current assignee: Signify Holding BV
Priority date: 2023-05-04
Filing date: 2024-04-18
Publication date: 2026-03-11
Also published as: WO2024227622A1; CN121285712A

Abstract

An optical lens assembly (100) comprising a first (110a) and a second lens (110b) of plurality of lenses (110) arranged in a plane, P, and a connection piece (120) connecting at least the first and second lens. The connection extends in a first length direction, L1, with L1 coinciding with the plane, P. Each of the first and second lens comprises at least one lens element (130), and at least one support element (140) extending beyond the plane, P, by at least a first distance, D1, in a direction, A, perpendicular to the plane, P.

Description

Optical lens assembly

FIELD OF THE INVENTION

The present invention generally relates to the field of optical lens assemblies and luminaires incorporating such optical lens assemblies. More specifically, the present invention relates to a self-aligning optical lens assembly, to injection molded optical lenses and optical lens assemblies, to a method for manufacturing such lenses and optical lens assemblies, and to a luminaire arrangement comprising such optical lens assembly.

When used herein in connection with a method for injection molding or a mold for injection molding, the term “injection location” is intended to refer to a location at which molding material is injected into a mold for manufacturing an injection molded product.

When used herein in connection with the resulting product, that is an injection molded lens or optical lens assembly, the term “injection location” is intended to refer to a location or position on the product, which during injection molding would be located at the injection location of the mold.

BACKGROUND OF THE INVENTION

The use of light emitting diodes (LEDs) for illumination purposes continues to attract attention. Compared to incandescent lamps, fluorescent lamps, neon tube lamps, etc., LEDs provide numerous advantages such as a longer operational life, a reduced power consumption, and an increased efficiency related to the ratio between light energy and heat energy. In particular, LED lamps are highly appreciated as they may be very decorative and versatile in appearance.

When using a LED for illumination purposes, one lens is or several lenses are commonly combined with the LED unit. Desired light properties of the emitted light, and therefore the structure and/or shape of the lens(es), exist in many variations. The lens may determine for instance the distribution and intensity of the emitted LED light. A shared ambition when applying a lens to a LED unit may be to ensure an optimal positioning of the lens in regard to corresponding LED to avoid for example light leakage. Achieving these objectives may entail the desired and anticipated properties of the emitted light. The positioning of the lens(es) onto the LED unit can occur in various ways, as well as the structure of the lens. For example, an optical lens frame may comprise flanges and/or cavities to be correctly positioned to a LED frame. Regardless the approach, it is vital to have the lens(es) correctly coupled to the LED unit to result in optimal lighting output.

Hence, it is of interest or desire to provide an optical lens assembly which can accurately and easily be mounted onto a luminaire arrangement or system.

Furthermore, WO 2021/224370 Al discloses a lighting unit which comprises a lens arrangement over a LED module. The lens arrangement comprises a plate having at least one lens integrally formed by the plate for positioning over a substrate of the LED module, and at least one magnifying component integrally formed by the plate. The LED module substrate has an inspection region which is inspected through the magnifying component, so as to enable determination of a spacing between the lens arrangement and the substrate by viewing an image of the marker arrangement created by the at least one magnifying component at a given viewing location. The lens arrangement may be injection molded.

In injection molding, during mold filling, as molten plastic or other molding material comes in contact with the perimeter of any cooled mold part, such as a sprue, runner, gate and cavity, a frozen layer of molding material will develop. An initial frozen skin will develop nearly instantly, and its thickness will dynamically change throughout the mold filling and packing portions of the molding cycle. During mold filling, the thickness is significantly influenced by shear rate and will influence the filling pressure.

Injection molding of lenses is critical to setup and process. Injection molding one lens results in an asymmetrical product. Typically, in the art of injection molding of lenses, the molding material is injected from one side of the mold. The result shows an asymmetry in the thickness of the frozen layer. This asymmetry is related to the injection spot. The asymmetry more particularly is a result of early freeze of the injection material and with that the material packing differently inside the mold and thus in the resulting lens. The result is an asymmetrical lens. As an example of the above-mentioned asymmetric result, Fig. 9 shows a plot of the relative thickness of the frozen layer of molding material as a function of position in a prior art lens 1000 injection molded by injecting the molding material from one side 5000 of the mold. The scale shows the deviation in mm compared with an average thickness of the frozen layer of molding material over the lens.

Generally, areas which are not yet frozen will have a good surface copy quality. Areas which are too far frozen will have a lower copy quality or could even result in less or even no texture on the surface. It is therefore a desire to provide a method for injection molding lenses which results in a symmetrical product as well as a resulting symmetrical injection molded optical lens assembly and a resulting symmetrical light distribution.

It is further a desire to provide a symmetric injection molded optical lens assembly comprising, in use, a resulting symmetrical light distribution.

DE202012003680U1 discloses a LED light with a housing accommodating a circuit board with LEDs, wherein lenses are arranged on the circuit board in the beam direction in front of an LED.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an optical lens assembly that accommodates at least one of the above desires and/or obviates at least one of the problems described above. For example, it is an object of the present invention to provide an optical lens assembly which can easily and accurately be mounted, aligned, installed, or the like on a luminaire arrangement, system, or the like and, when in use, provide symmetrical light in an energy and optical efficient manner. Furthermore, the provided optical lens assembly can easily be dismounted, uninstalled, or the like from the luminaire arrangement, system, or the like, thus further providing an optical lens assembly which can easily and conveniently be handled during e.g. transportation and/or installation. Further objects of the invention could, for example, be to provide a symmetric injection molded optical lens assembly comprising, in use, a resulting symmetrical light distribution, to provide a method for injection molding lenses which results in a symmetrical lens assembly and/or to provide a symmetrical injection molded optical lens assembly resulting from a method according to the invention and comprising, in use, a symmetrical light distribution.

This and other objects are achieved by an optical lens assembly having the features in the independent claims. Preferred embodiments are defined in the dependent claims.

Hence, a first aspect of the invention relates to an optical lens assembly comprising a first lens connected to a second lens wherein i) the first lens is arranged with a first lens edge in a plane P and the second lens is arranged with a second lens edge in the plane P, and ii) the first and second lens are spaced apart along a first direction Li by a single, elongated connection piece, with Li coinciding with plane P, at least one support element extending beyond the plane P by at least a first distance Di in a direction A perpendicular to the plane P, wherein i) the connection piece is connected at a first connection location to the first lens edge of the first lens and at a second connection location to the second lens edge of the second lens, ii) the connection piece is fully arranged in between the first and second lens, and iii) the connection piece has a length L_cp along the first direction Li with a ratio Ric of the length to a largest cross-sectional dimension CS of the connection piece, wherein Ric >=3, wherein at least one of the at least one support element is at least partially arranged on the first and/or second lens edge.

Further, according to the present invention, there is provided an optical lens assembly comprising a plurality of lenses arranged in a plane P, and a (single elongated, i.e. having only one extending portion, so not two (parallel) or more extending portions) connection piece spacing apart and connecting at least a first and a second lens of the plurality of lenses. The connection piece extends in a first length direction, Li, with Li coinciding with the plane P. Each of the plurality of lenses comprises at least one support element extending beyond the plane P, by at least a first distance, Di, in a direction, A, perpendicular to said plane P. Furthermore, each of the plurality of lenses may comprise at least one lens element. Typically, the connection piece is connected with the first lens edge at a first connection location to the first lens and with the second lens edge at a second connection location to the second lens. Still furthermore, typically the connection piece is fully arranged in between the first and second lens, i.e. in projection on plane P along the length direction Li, the connection piece completely falls within the projection/projected area of the lenses. Still further, typically the connection piece has a length L_cp along the first direction Li with a ratio Ric of the length to a largest cross-sectional dimension CS of the connection piece, wherein Ric >=3, preferably 3 <= Ric <= 8, wherein the cross sectional dimension CS is measured in a direction perpendicular to the length direction Li. At least one of the at least one support element is at least partially arranged on the first and/or second lens edge, i.e. is at least partially arranged on the lens edge on a local position, hence not provided over the whole lens edge.

Thus, the present invention is based on the concept or idea of providing an optical lens assembly which can provide light in an energy efficient way, e.g. by avoiding optical efficiency loss and/or light leakage. This is achieved by having the at least one support element of each plurality of lenses extending by at least a first distance, Di, beyond, and perpendicular to, the plane P. Thus, the present invention provides an optical lens assembly which ensures an (optimal) distance between the lens and (any) other element. For example, the present invention may provide a desired or optimal distance between the lens and a corresponding light source, e.g. when mounted on e.g. a luminaire arrangement or the like, resulting in an energy efficient light. The connection piece being so slim renders the optical lens assembly to have several advantages, i.e. i) it is relatively compact and lightweight, ii) it is relatively cheap because of requiring relatively little material, iii) it enables the connection piece to be flexible, even when it is made from relatively rigid material, and thus to adapt in shape to a shape of a carrier on which it would rest, and iv) when combined with a light emitting device receiving structures, such as a reflector cup, it only requires a relatively small opening/cut out in a reflective surface of the reflector cup (for the connection piece to be extending through), thus reducing/minimizing optical efficiency loss and/or light leakage .

The optical lens assembly may have the feature that the first and second connection location are each provided with one of the at least one support element. This is typically the case for lenses with a relatively thick wall, i.e. wall has thickness which is l/8th or larger than l/8th of the lens diameter (as measured in a direction parallel to plane P). It will thus be appreciated that each of the plurality of lenses comprises at least one support element extending by at least a first distance, Di. The at least one support element may provide a hindrance, barrier, blockage etc. to opposing elements, structures, or the like. For example, this feature of the optical lens assembly is advantageous to provide between a lens and a corresponding light source of a luminaire arrangement or the like. In other words, the support element(s) may define a separation between the lenses and corresponding light sources. The provision of support element(s) provides for an optimization of the optical center of respective lens element of the optical lens assembly. Hence, the optical lens assembly, in use, entails for an improved energy efficiency of emission of light. The present invention is further advantageous in that the support element(s) further enables removing tolerance(s) for the optical lens assembly. Thus, the provision of support element(s) provides for a more perfectly symmetrical light distribution for an optical lens assembly, when in use.

The support elements may be configured to abut, engage with, be in contact with, or the like, for example, a portion of a printed circuit board, PCB. The PCB typically is built up by a stack of a substrate, a conductive track pattern provided on a main surface of the substrate and onto which LEDs are mounted and to which the LEDs are electrically connected. To limit losses of generated light and thus to increase the energy efficiency of light emission from a luminaire or the like, said main surface of the PCB is preferably provided with a white layer, a so-called solder mask, that essentially fully covers the mains surface and the conductive track pattern, except for the locations where the LEDs are mounted and the LEDs need to electrically contact the conductive track. Finally, said stack comprises the plurality of lenses extending at least over the LEDs. Thus, the support elements may be configured to define a separation, in a direction perpendicular to the PCB main surface, between the plurality of lenses and LED(s) by at least a second distance, D2. According to an example, DI>D2 is fulfilled. However, other ratios of the first and second distances Di, D2, may be feasible, such as DI=D2. Preferably, the support elements do not abut on the solder mask, but at the locations of the support elements the solder mask on the PCB is removed/not provided and at these locations the support elements protrude through the solder mask layer and abut directly on the main surface of the PCB or on the conductive track. Thus the mutual positional accuracy (in a direction perpendicular to the PCB main surface) between the LEDs and the lenses is further improved.

It should be noted that the optical lens assembly comprises a connection piece connecting at least the first and second lens of the plurality of lenses. Connecting at least the first and second lens of the plurality of lenses via the connection piece allows for an increased positional accuracy for the optical lens assembly, in use, in regard to a luminaire or the like whereon the optical lens assembly is mounted. This may entail an increase in energy efficiency of an emission of light from the luminaire or the like. Additionally, the connection piece further enables removal of tolerance(s) for the optical lens assembly.

According to the present invention, there is provided a connection piece connecting at least two of a plurality of lenses. By the term “connection piece”, it is here meant an (elongated) element, body, structure, or the like suitable or configured to connect lenses together. Furthermore, each of the plurality of lenses comprises one or more lens element(s). By the term “lens element”, it is here meant an (optical) lens element which may affect and/or influence light. More specifically, it may be an element which may act upon incoming light in such a manner that at least some of the incoming light can pass through the element, such as a lens or a prism. Each of the plurality of lenses further comprises one or more support element(s). By “support element”, it is here meant a structure, component, segment, or the like suitable or configured to engage with, be in contact with, abut, or the like, a structure, component, segment, body, or the like.

The optical lens assembly may have the feature that it further comprises at least one first alignment element. For example, according to an embodiment of the present invention, each of the plurality of lenses, such as the first and second lens, may comprise at least one first alignment element. Thus, all of the lenses may comprise (a) first alignment element(s). By the term “alignment element”, it is here meant a structure, component, segment, or the like suitable or configured for mating, pairing, coupling, etc. with an opposing structure, component, segment, or the like, for a (positional) alignment of the optical lens assembly. The present embodiment is advantageous in that the first alignment element(s) may enable an easier and more accurately mounting, alignment, installment, etc. of the optical lens assembly on a luminaire arrangement or other device on which the optical lens assembly is to be mounted. Thus, the provision of (first) alignment elements may provide for an even more symmetrical light distribution for an optical lens assembly.

According to an embodiment of the present invention, at least one of the at least one first alignment element may be arranged on at least one of i) the first and second lens of the at least one of a plurality of lenses at a first geometrical center point, Ci, of the first and second lens of the at least one of the plurality of lenses, wherein the plane P, may comprise the first geometrical center point, Ci. The plurality of lenses may comprise only the first and second lens, or may comprises further lenses in addition to the first and second lens. In other words, one or several first alignment elements may be arranged on the corresponding lens(es) at a first geometrical center point, Ci, and ii) on at least two mutually distributedly arranged locations on the edge of each lens. The term distributedly may comprise evenly or oppositely arranged (for example in the case of two first alignment elements). By the term “geometrical center point”, it is here meant a point of a lens that define the (arithmetic) mean position of all the points of the surface of lens. The embodiment is advantageous in that the mounting, alignment, installment etc. of the optical lens assembly may be easier and more accurately performed. Additionally, the light distribution for the optical lens assembly may be symmetrical to an even higher extent.

According to an embodiment of the present invention, the connection piece may be at least partially flexible. For example, the connection piece may be arranged in the plane P, wherein the at least one support element is configured to allow a deformation of at least a portion of the connection piece beyond the plane P, parallel to the direction, A. Flexible may comprise deformation, which may comprise permanent deformation and resilient deformation. Thus, the connection piece may be fully flexible, or (only) a portion of the connection piece may be flexible, i.e. partially flexible. The present embodiment is advantageous in that the connection piece may flex, deform, bend, adjust, etc. in such a way that tolerance(s) is (are) removed from the optical lens assembly. The present embodiment is further advantageous in that the aligning of the optical lens assembly to e.g. a luminaire or other device on which the optical lens assembly is to be mounted may be performed easier and more accurately.

The optical lens assembly may have the feature that it further comprises a first and second end piece, the first end piece extending from the first lens edge opposite to first connection location along the first length direction, Li and the second end piece extending from the second lens edge opposite to second connection location along the first length direction, Li. In general the term "along" may comprise substantially parallel (i.e. within 10 degrees) or coinciding with the length direction Li. Hence, according to an embodiment of the present invention, the connection piece may comprise at least two end pieces, opposingly extending from a respective lens of the plurality of lenses and aligned with the first length direction, Li. Thus, the end pieces may extend from a respective lens at a position diametrically opposite to the connection piece. The present embodiment is advantageous in that the provision of a connection piece comprising end pieces may facilitate the mounting of the optical lens assembly on a luminaire arrangement or the like. The present embodiment is further advantageous in that the end pieces may contribute to a further improved alignment of the optical lens assembly, for example in that the optical lens assembly may be clamped between a reflector cup of the luminaire and the L2-type LED module.

The optical lens assembly may have the feature that each of the first and second lens comprises at least two neighboring lens elements wherein respective lens element edges do not coincide with a respective one of the first and second lens edge, and at least one of the at least one support element is arranged between the two neighboring lens elements on a respective lens element edge. This may be considered as a separate invention. For example, according to an embodiment of the present invention, each of the plurality of lenses comprises at least two lens elements. Furthermore, at least one of the at least one support element may be arranged between two neighboring lens elements. Hence, (a) support element(s) may be arranged between two neighboring lens elements of one or several (of the first and second lens) of the plurality of lenses. The present embodiment is advantageous in that the optical center of respective lens element of the optical lens assembly may be further optimized. Furthermore, said arrangement of the support element(s) may improve the removal of tolerance(s) of the optical lens assembly.

According to an embodiment of the present invention, the connection piece may be arranged in the plane P, and wherein the at least one support element may be configured to allow a deformation of at least a portion of the connection piece beyond the plane P, parallel to the direction, A. In other words, (a portion of) the connection piece may be deformed, adjusted, bent, flexed, etc. beyond the plane P. The present embodiment is advantageous in that it may enable a possibility to adjust, tune, adapt, modify, etc. the optimization of the optical center of the optical lens assembly according to particular use scenarios. Furthermore, the allowance of deformation of (a portion of) the connection piece may enable a possibility to adjust, tune, adapt, modify, etc. the removal of tolerance(s) from the optical lens assembly according to particular use scenarios. This is favorable as it provides a more versatile optical lens assembly, in use, regarding different lighting needs and/or desires, e.g. providing light in an energy efficient manner.

The optical lens assembly may have the feature that at least two support elements are arranged equidistant on at least one of the first and second lens edge from a respective first geometrical center point, Ci, of respectively the first and second lens, wherein the plane P, comprises the first geometrical center point, Ci. For example, according to an embodiment of the present invention, at least two support elements may be arranged equidistant on at least one of the plurality of lenses with respect to a first geometrical center point, Ci, of the at least one of the plurality of lenses, wherein the plane P, may comprise the first geometrical center point, Ci. In other words, support elements may be arranged equidistant, with respect to a first geometrical center point, Ci, on the lens(es), respectively. By the term “equidistant”, it is here meant geometrically equidistant, whether in one, two, or three dimensions, that is equidistant in one or more directions of the plane P, and the direction, A. The embodiment is advantageous in that the mounting, alignment, installment etc. of the optical lens assembly may be simplified and/or more accurately performed. Additionally, the light distribution for the optical lens assembly, in use, may be even more perfectly symmetrical.

According to an embodiment of the present invention, at least one of the first and second lens of the plurality of lenses may be configured to be mirror symmetric around a first axis of symmetry Si (or first symmetry line, Si), aligned with the first length direction, Li, wherein the first symmetry line, Si, may be centrally arranged with respect to the at least one of the plurality of lenses. In other words, (a) lens(es) may be mirror symmetric around a first symmetry line, Si, which is centrally arranged on the lens(es) and aligned with the first length direction, Li. The present embodiment is advantageous in that the provision of (a) (mirror) symmetric lens(es) may result in even more perfectly symmetric light distribution of the optical lens assembly, in use. Furthermore, symmetry of the lens(es) may be desirable during alignment and/or mounting of the optical lens assembly to a luminaire or the like, as it may simplify these procedures. According to an embodiment of the present invention, the optical lens assembly may be configured to be mirror symmetric around a second axis of symmetry S2 (or second symmetry line, S2), perpendicular to the first length direction, Li, wherein the second symmetry line, S2, may intersect a second geometrical center point, C2, of the optical lens assembly, wherein the plane P, may comprise the second geometrical center point, C2. Hence, the optical lens assembly may be mirror symmetric around a second symmetry line, S2, which intersect a second geometrical center point, C2, of the optical lens assembly. The present embodiment is advantageous in that the provision of a (mirror) symmetric optical lens assembly may provide for an optical lens assembly comprising, in use, an even more perfectly symmetrical light distribution. Additionally, alignment and/or mounting of the (mirror) symmetric optical lens assembly may be performed more easily and in a simplified manner.

According to an embodiment of the present invention, the optical lens assembly may be at least partially injection molded and comprises (a scarf remainder at) an injection (molding) location. Hence, only a part of, or all of, the optical lens assembly may be injection molded. Preferably, the injection location is arranged in at least one of i) a geometrical center point of the optical lens assembly, ii) a point of symmetry (C) of the optical lens assembly, iii) on at least one of a first axis of symmetry (Si) of the optical lens assembly and a second axis of symmetry (S2) of the optical lens assembly, and iv) on a plane of symmetry (Q; R) of the optical lens assembly (1) perpendicular to plane P. The present embodiment is advantageous in providing an (at least partially) injection molded optical lens assembly may entail for a more precise and accurate structure of the affected elements, features, etc. of the optical lens assembly, according to a desired structure. This may further entail for a more precise and accurate light distribution of the optical lens assembly, in use. The present embodiment is further advantageous in that the provision of an (at least partially) injection molded optical lens assembly provides for a high repeatability during manufacturing of the optical lens assembly. This is favorable as this may provide for an optical lens assembly comprising an even more perfectly symmetrical light distribution, in use in e.g. a luminaire or the like comprising a plurality of optical lens assemblies. To further improve the more perfectly symmetrical light distribution, in use the optical lens assembly may have the feature that the at least one first alignment element is arranged centrally on the connection piece, preferably opposite or at 90° with the injection location (over the circumferential crosssection of the connection piece). It is a still further object of the invention to provide a symmetrical, injection molded optical lens assembly resulting from a method according to the invention and comprising, in use, a symmetrical light distribution. According to a further aspect of the invention, this and other objects are achieved by means of an optical lens assembly, the optical lens assembly being injection molded, the optical lens assembly comprising i) a first and second lens of a plurality of lenses each comprising at least one lens element, ii) at least one connection piece connecting at least two of the plurality of lenses, and iii) an injection location, where the injection location is located at a position on the optical lens assembly corresponding to an injection location at which molding material was injected during injection molding of the optical lens assembly, and wherein the injection location is located centrally on the optical lens assembly.

Thereby, and in particular by providing an injection location being located at a position on the optical lens assembly corresponding to an injection location at which molding material was injected during injection molding of the optical lens assembly, and further by providing that the injection location is located centrally on the optical lens assembly, the optical lens assembly is provided with a mirrored (surface) defect. Thereby a symmetrical optical lens assembly is provided for. Thus, an injection molded optical lens assembly comprising, in use, a resulting symmetrical light distribution is provided for.

The injection location may further be arranged equidistant from each lens (for example the first and second lens) of the plurality of lenses of the optical lens assembly. By equidistant is in this connection to be understood geometrically equidistant, whether in one, two or three dimensions, that is equidistant in one or more of a length direction, a width direction, and a height direction of the optical lens assembly. This especially applies when the optical lens assembly comprises an even number of lenses. Thereby an improved symmetry of the optical lens assembly is provided for.

The injection location may further be arranged in a geometrical center point of the optical lens assembly. Thereby a further improved symmetry of the optical lens assembly is provided for. It is noted that the injection location need not be arranged precisely in the geometrical center point of the optical lens assembly but may in fact be located approximately in the geometrical center point of the optical lens assembly. The injection location may be arranged on a side or on a top of the optical lens assembly around the geometrical center point of the optical lens assembly.

The injection location may further be arranged in a point of symmetry C of the optical lens assembly, for example in a point of symmetry on the connection piece between the first and second lens. Thereby a particularly improved symmetry of the optical lens assembly is provided for. The injection location may further be arranged on at least one of a first axis of symmetry of the optical lens assembly and a second axis of symmetry of the optical lens assembly. Thereby any symmetrical defect is positioned both to the left and right side of the respective axis of symmetry. Thereby, a totally symmetrical lens is provided for.

In case the injection location is arranged on both the first axis of symmetry of the optical lens assembly and the second axis of symmetry of the optical lens assembly, double symmetry is achieved, which in turn further improves the symmetry of the optical lens assembly.

The injection location may further be arranged on a plane of symmetry of the optical lens assembly. Thereby any symmetrical defect is positioned both to the left and right side of the plane of symmetry. Thereby, a totally symmetrical lens is provided for, even in case of more complex lens assemblies having a plurality of lenses arranged in two dimensions, such as for instance having an array of lenses of size 2x2 or larger.

It is noted that it is of importance to achieve both geometrical symmetry and weight symmetry around the point, axis/axes, or plane of symmetry. This means that it is desired to achieve that the opposite sides of the point, axis/axes or plane of symmetry are at least 90 % identical, at least 97 % or in ideal cases 99 % identical. This is indeed achieved by any one of the above described embodiments of the present invention.

The optical lens assembly may further comprise a length direction Li (also referred to or indicated as P_y) and a width direction W (also referred to or indicated as P_x) both lying in plane P intersecting all lenses of the plurality of lenses in the same height, the length direction and the width direction extending perpendicular to one another, a height direction H extending perpendicular to the said plane P, and thus to both the length direction and the width direction, and a plurality of support elements (also referred to as supporting elements) extending in the height direction.

The provision of support elements provides for an optimization of the optical center of the optical lens assembly. The provision of support elements further provides for removing tolerances from the optical lens assembly. In other words, the provision of support elements provides for an optical lens assembly comprising, in use, an even more perfectly symmetrical light distribution.

The support elements may be arranged between two neighboring lens elements of the plurality of lens elements, such as between lens elements of the first and second lens. Thereby, the optimization of the optical center of the optical lens assembly and the removal of tolerances from the optical lens assembly becomes improved.

The support elements may be configured to allow an adjustment of at least a part of the optical lens assembly in the height direction by a distance of at least 0.1 mm. Thereby, it becomes possible to adjust the optimization of the optical center of the optical lens assembly and the removal of tolerances from the optical lens assembly to the particular use scenario at hand.

At least one lens of the plurality of lenses may comprise a positioning element, the positioning element being arranged centrally on the lens edge when it comprises at least two lens elements. The provision of a positioning element provides for easy and simple alignment of the optical lens assembly on a luminaire or other device on which the optical lens assembly is to be mounted, even over two or more lenses of the optical lens assembly.

At least one lens of the plurality of lenses may further comprise a surface texture comparable to the mold texture standard Verein Deutscher Ingenieure (VDI), the Society of German Engineers, or a surface texture being in the range of VDI 1 and VDI 33, or a surface texture like VDI 12, see https://www.plastopialtd.eom/vdi-3400/#card. Alternatively, at least one lens, such as the first and/or second lens, of the plurality of lenses may further comprise a surface texture obtained by technologies like etching or laser texturing.

It is noted that the surface textures will also develop symmetrical around the injection location, thus adding to the symmetry of the optical lens assembly.

The connection piece may be straight. Alternatively, the connection piece may be non-straight. For instance, the connection piece may be curved, such as S-shaped. A curved connection piece provides the advantage that it helps overcoming thermal expansion when the optical lens assembly becomes much longer when heated.

According to a further aspect of the present invention, there is provided a luminaire arrangement comprising a housing extending in a second length direction, L2, and a plurality of light emitting devices arranged inside the housing. The plurality of light emitting devices comprises at least one light emitting diode, LED, arranged to emit LED light. The luminaire arrangement further comprises at least one of the optical lens assembly arranged to optically influence the LED light. The second length direction, L2, is parallel to the first length direction, Li. Furthermore, the at least one support element of the at least one optical lens assembly is configured to define a separation between the at least one support element and the at least one LED by at least a second distance, D2. By the term “light emitting device”, it is here meant an element, arrangement, unit, or the like, suitable or configured to comprise LEDs, and to emit light. The present embodiment is advantageous in providing support element(s) configured to define a separation between the first and second lens (of the plurality of lenses) and the LED(s) by at least the second distance, D2. The provision of a support element(s) provides for a luminaire arrangement which may establish an optimal distance between a lens and a corresponding LED of the luminaire arrangement. This may result in a reduced risk of light leakage and/or loss of optical efficiency. Therefore, the present embodiment may provide an optical and/or energy efficient luminaire arrangement. The present embodiment is further advantageous in that the optimal distance between lens(es) and LED(s) provided by the support element(s) may entail the emitted light from the luminaire arrangement having a symmetric light distribution.

According to an embodiment of the present invention, in the luminaire, each of the first and second lens (of the plurality of lenses) of the optical lens assembly may comprise at least one first alignment element and wherein the luminaire arrangement may further comprise at least one second alignment element arranged on each of the plurality of lighting emitting devices. The at least one first alignment element and the at least one second alignment element may be configured for mating positional alignment engagement of the at least one optical lens assembly and the housing. In other words, the first and second alignment element(s) may be configured to couple, pair, link, connect, or the like to each other in a manner that results in a positional alignment between the first and second alignment element(s). The present embodiment is advantageous in providing (mating) first and second alignment elements. This may simplify the assembly of the luminaire arrangement. Furthermore, the (mating) first and second alignment elements may give rise to an improved alignment accuracy between the first and second alignment elements. This may provide a luminaire arrangement emitting light with a more perfectly symmetric light distribution.

According to an embodiment of the present invention, the luminaire arrangement may further comprise at least one engagement structure configured for mating attachment with the at least one optical lens assembly for positional fastening of the at least one optical lens assembly. Thus, the engagement structure(s) and the optical lens assembly (ies) may be configured to join, attach, secure, affix, or the like, to each other in a manner that results in a positional fastening between the engagement structure (s) and the optical lens assembly(ies). The present embodiment is advantageous in the provision of the (mating) engagement structure(s). The positional fastening between the engagement structure(s) and the optical lens assembly(ies) may provide a luminaire arrangement with an improved alignment accuracy between lenses and corresponding LEDs. Consequently, the luminaire arrangement may provide an even more perfectly symmetric light distribution. Additionally, the provision of the engagement structure(s) may result in a luminaire which is easy and simple to assemble.

According to an embodiment of the present invention, the at least one optical lens assembly may be adhesively fastened to the housing. In other words, the optical lens assembly(ies) may be attached, fastened, affixed, or the like to the housing in an adhesive manner. The present embodiment is advantageous in that the optical lens assembly(ies) may be adhesively fastened to the housing. This may entail an improved alignment accuracy between lenses and corresponding LEDs for the luminaire arrangement. Furthermore, the emitted light from the luminaire arrangement may provide an even more perfectly symmetric light distribution.

The invention further relates to a method for injection molding optical lenses. The method comprising the steps of:

- providing a mold, the mold comprising: i) at least a first and second lens compartment of a plurality of lens compartments, each lens compartment of the plurality of lens compartments comprising at least one lens cup, ii) at least one connection piece connecting (via respective edge portions) the first and second lens compartments of the plurality of lens compartments, the connection piece comprising a support element compartment at an edge portion and being elongated having a length L_cp with a ratio Ric of the length to a largest cross-sectional dimension CS of the connection piece, wherein Ric >=3, and iii) an injection location configured for receiving molding material to be injected into the mold, wherein the injection location is arranged on the mold on the connection piece and in a position being equidistantly with respect to the plurality of lens compartments, and

- injecting a molding material into the mold at the injection location.

The injection location may be arranged on the mold in a position being in a geometrical center point of the plurality of lens compartments.

The injection location may be arranged on the mold in a position being in a point of symmetry of the plurality of lens compartments. The injection location may be arranged on the mold in a position being on at least one of a first axis of symmetry of the plurality of lens compartments and a second axis of symmetry of the plurality of lens compartments.

The injection location may be arranged on the mold in a position being on a plane of symmetry of the plurality of lens compartments.

The mold may further comprise a length direction and a width direction both lying in a plane intersecting all lens compartments of the plurality of lens compartments in the same height, the length direction and the width direction extending perpendicular to one another, a height direction extending perpendicular to both the length direction and the width direction, and a plurality of support element recesses extending in the height direction.

The support element recesses may be arranged between two neighboring lens cups of the plurality of lens cups.

At least one lens compartment of the plurality of lens compartments may comprise a positioning element recess, the positioning element recess being arranged centrally on the lens compartment.

At least the lens cups of the mold may further comprise a surface texture comparable to the mold texture standard Verein Deutscher Ingenieure (VDI), the Society of German Engineers, or a surface texture being in the range of VDI 1 and VDI 33, or a surface texture like VDI 12. Alternatively, at least one lens of the plurality of lenses may further comprise a surface texture obtained by technologies like etching or laser texturing

The molding material may be chosen from the group comprising optical transparent materials, PC, PMMA, SAN, HIPS, PS, PU, Silicone, and LDPE.

The invention further relates to an optical lens assembly being injection molded using a method according to the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

This and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing embodiment(s) of the invention.

Fig. la and lb are a perspective view and a side view, respectively, of an optical lens assembly according to an exemplifying embodiment of the present invention.

Figs. 2a and 2b are a perspective view and a top view, respectively, of an optical lens assembly according to an exemplifying embodiment of the present invention. Fig. 3 is a side view of an optical lens assembly according to an exemplifying embodiment of the present invention.

Fig. 4a is a cross sectional top view of a section IX of a luminaire arrangement comprising optical lens assemblies according to an exemplifying embodiment of the present invention.

Fig. 4b is a cross sectional top view of a section X of a luminaire arrangement without optical lens assemblies according to an exemplifying embodiment of the present invention.

Fig. 4c is a top view of a section XI of a luminaire arrangement partly with optical lens assemblies and partly without optical lens assemblies according to an exemplifying embodiment of the present invention.

Fig. 5 is a side view of a luminaire arrangement comprising an optical lens assembly according to an exemplifying embodiment of the present invention.

Figs. 6a and 6b are a top view and a perspective view, respectively, of a luminaire arrangement comprising optical lens assemblies according to exemplifying embodiments of the present invention.

Fig.7a and 7b respectively show a bottom view and a cross-sectional view of another embodiment of the optical lens assembly 100 according to the invention.

Fig. 8 shows a bottom view of yet another embodiment of the optical lens assembly 100 according to the invention.

Fig. 9 shows a plot of the relative thickness of the frozen layer of molding material as a function of position in a prior art lens. The scale shows the deviation in mm compared with an average thickness of the frozen layer of molding material over the lens.

Fig. 10 shows a top view of an optical lens assembly according to the invention.

Fig. 11 shows a plot of the relative thickness of the frozen layer of molding material as a function of position in an optical lens assembly as shown in Figs. 2b, 3, 10. The scale shows the deviation in mm compared with an average thickness of the frozen layer of molding material over the optical lens assembly.

Fig. 12 shows a top view of another optical lens assembly according to the invention.

Fig. 13 shows atop view of another optical lens assembly according to the invention.

Fig. 14 shows a flow diagram illustrating a method according to the invention. As illustrated in the figures, the sizes of layers and regions are exaggerated for illustrative purposes and, thus, are provided to illustrate the general structures of embodiments of the present invention. Like reference numerals refer to like elements throughout.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which currently preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and fully convey the scope of the invention to the skilled person.

Figs, la and lb are a perspective view and a side view, respectively, of an optical lens assembly 100 according to an exemplifying embodiment of the present invention.

The optical lens assembly 100 in Fig. la comprises a first 110a and second lens 110b (of a plurality of lenses 110) arranged in a plane P, and a connection piece 120 connecting the first 110a and second lens 110b. The optical lens assembly 100 in Fig. la comprises only two lenses, i.e. first lens 110a and second lensllOb. However, other numbers of lenses 110 are feasible. The connection piece 120 extends in a first length direction, Li, wherein the first length direction, Li, coincides with the plane P and is fully arranged in between the first 110a and second lens 110b. Fig. la illustrates a straight connection piece 120, connecting the two lenses 110. However, the connection piece 120 may also be a nonstraight connection piece 120. For example, the connection piece 120 may be a curved, such as S-shaped, connection piece 120. A curved connection piece 120 provides the advantage that it may help overcoming thermal expansion if the optical lens assembly 100 is heated and becomes longer.

Each of the first 1 lOaland second lens 110b comprises at least one lens element 130 and at least one support element 140. In the embodiment shown, each lens 110a, 110b comprises four lens elements 130. It should be noted that other numbers of lens elements 130 are also feasible. The at least one support element 140 extends beyond the plane P, by at least a first distance, Di, in a direction, A, perpendicular to said plane P. According to Fig. la, each support element 140 is arranged between two lens elements 130, hence not on a lens edge. The support elements 140 may be arranged to be rotational symmetric around a geometrical center point, Ci, of the lens 110. In the embodiment shown, each lens 110 comprises four support elements 140. However, other numbers of support element 140 on each lens may also be feasible, such as one.

Fig. lb shows a side view of a portion of the optical lens assembly 100 of Fig. la. The portion of the embodiment of the optical lens assembly 100 illustrates the first distance, DI, with which the support element(s) 140 (at least) extend(s) beyond the plane P, in a direction, A, perpendicular to said plane P.

Fig. 2a is a perspective view of an optical lens assembly 100 according to an exemplifying embodiment of the present invention. Fig. 2b is a top view of an optical lens assembly 100 according to an exemplifying embodiment of the present invention.

It should be noted that the optical lens assembly 100 shown in Figs. 2a and 2b has several features in common with the optical lens assembly 100 shown in Figs, la-lb, and it is hereby referred to Figs, la-lb and the associated text for an increased understanding of some of the features and/or functions of the optical lens assembly 100.

Each of the first 110a and second lens 110b of the plurality of lenses 110 of the optical lens assembly 100 of Figs. 2a and 2b comprises at least one first alignment element 150. According to the embodiment, each lens 110a, 110b comprises (exactly) one first alignment element 150. However, other numbers of first alignment elements 150 arranged on each lens 110 may be feasible, such as two. At least one of the first alignment elements 150 is arranged on at least one of the plurality of lenses 110 at a first geometrical center point, Ci, of the at least one of the plurality of lens elements 130, hence not on the lens edge. The plane P comprises the first geometrical center point, Ci. In other words, at least one first alignment element 150 is centrally arranged on a corresponding lens 110. According to the embodiment, each first alignment element 150 is arranged at a first geometrical center point, Ci, of the corresponding lens 110. It should be noted that the first alignment elements 150 need not be arranged precisely at the first geometrical center point, Ci, of the corresponding lenses 110 but may in fact be located approximately to the first geometrical center point, Ci, of the corresponding lenses 110. The first alignment elements 150 extend in a direction parallel to the direction, A, perpendicular to the plane P. However, the first alignment elements 150 may extend in a direction other than one parallel to the direction, A, and perpendicular to the plane P. For instance, at least one first alignment element 150 may extend in a direction coinciding with the plane P, or extending in an inclined direction forming an (acute) angle with the plane P. The first alignment elements 150 may enable the lens elements 130 to be positional aligned with corresponding light sources, e.g. when the optical lens assembly 100 is mounted on a luminaire, or the like. The positional alignment between the lens elements 130 and corresponding light sources may minimize the risk of emitted light of the light sources being hindered, scattered, dispersed, etc. in an undesirable direction. Furthermore, the positional alignment between a lens element 130 and corresponding light source may optimize the optical center of the lens element 130.

The connection piece 120 according to the embodiment is at least partially flexible. In other words, all of, or only a portion of, the connection piece 120 is flexible. The flexibility of at least a portion of the connection piece 120 allows for (at least a portion of) the connection piece 120 to be deformed. As the connection piece 120 is at least partially flexible, tolerance(s) may be removed from the optical lens assembly 100, in use.

The connection piece 120 further comprises at least two end pieces 160, opposingly extending from the plurality of lenses 110 and aligned with the first length direction, Li. According to the embodiment shown, the connection piece 120 comprises (exactly) two end pieces 160. The end pieces 160 extend from a respectively the first lens 110a and the second lens 110b of the plurality of lenses 110 at a position diametrically opposite to the connection piece 120 in the present embodiment. Furthermore, the optical lens assembly 100 may be at least partially injection molded. According to the embodiment, all of the optical lens assembly 100 is injection molded.

Each of the plurality of lenses 110 comprises at least two lens elements 130. In the embodiment shown, each of the two lenses 110a, 110b comprises four lens elements 130. At least one of the at least one support element 140 of each lens 110 is arranged between two neighboring lens elements 130. According to Figs. 2a and 2b, each support element 140 of each lens 110 is arranged between two neighboring lens elements 130. Furthermore, at least two support elements 140 are arranged equidistant on at least one of the plurality of lenses 110 with respect to a first geometrical center point, Ci, of the at least one of the plurality of lenses 110. The plane P comprises the first geometrical center point, Ci. As illustrated in Figs. 2a and 2b, all of the support elements 140 are arranged equidistant with respect to a first geometrical center point, Ci, of a corresponding lens 110. The support elements 140 may be further arranged to be rotational symmetric around the geometrical center point, Ci, of the corresponding lens 110.

According to Fig. 2a, at least one of the first 110b and second lens 110b of the plurality of lenses 110 is configured to be mirror symmetric around a first symmetry line, Si, aligned with the first length direction, Li. The first symmetry line, Si, is centrally arranged with respect to the at least one of the plurality of lenses 110. As an example, the first symmetry line, Si, may intersect a first geometrical center point, Cl, of the corresponding lens 110. According to the embodiment, both of the two lenses 110a, 110b are mirror symmetric around the first symmetry line, Si. According to an example, the lens elements 130 are asymmetrical lens elements 130 of the plurality of lenses 110. As a result, the light distribution from the luminaire arrangement 300 may be asymmetrical. This may provide a luminaire arrangement 300 with a reduced risk of glare and/or casting of sharp shadows.

The optical lens assembly 100 is configured to be mirror symmetric around a second symmetry line, S2, perpendicular to the first length direction, Li. The second symmetry line, S2, intersects a second geometrical center point, C2, of the optical lens assembly 100, wherein the plane P, comprises the second geometrical center point, C2.

Referring particularly to Fig. 2b, the lenses 110 may comprise a alignment element 150. A respective alignment element 150 is arranged centrally between the lens elements 130 of the first 110a respectively the second lens 110b. More particularly, the alignment element 150 is arranged in or at a point of symmetry C of the respective lens 110a, 110b.

Furthermore, one or more support elements 140 are provided. The support elements 140 extend in the height direction H. More particularly, the support elements 140 extend in the height direction H in an opposite direction than the lens elements 130. The support elements 140 are arranged between each two lens elements 130, hence neither on the lens edge not on the connection piece. The support elements 140 may be arranged in a symmetrical pattern around a center point Ci of the lens 110. In the embodiment shown, each lens 110 is provided with four support elements 140. Other numbers of support elements 140, such as two, may also be feasible. Each of the first 110a and second lens 110b comprises four neighboring lens elements (130) with respective lens element edges 131 a, 131b not coinciding with a respective one of the first 11 la and second lens edge 111b. The one support elements 140 are arranged between the neighboring lens elements 130 on a respective lens element edge 131a, 131b.

For the sake of clarity, P_x and P_y as indicated in the figures refer to the x- direction respectively the y-direction in plane P in a cartesian coordination system, wherein the Py-direction corresponds to the first length direction Li.

Fig. 3 is a side view of an optical lens assembly 100 according to an exemplifying embodiment of the present invention. It should be noted that the optical lens assembly 100 shown in Fig. 3 has several features in common with the optical lens assembly 100 shown in Figs. 1 and 2, and it is hereby referred to Figs. 1 and 2, and the associated text for an increased understanding of some of the features and/or functions of the optical lens assembly 100.

According to the embodiment, the connection piece 120 is arranged in the plane P, and wherein the at least one support element 140 is configured to allow a deformation of at least a portion of the connection piece 120 beyond the plane P, parallel to the direction, A. Thus, the support element(s) 140 allows an adjustment of at least a portion of the connection piece 120 in a direction parallel to the direction, A. The deformation of (a portion of) the connection piece 120 may be a third distance, Ds, extending in a height direction, H, parallel to the direction, A. For instance, the third distance, Ds, may be at least 0.1 mm. Such deformation may be made by applying a force to the optical lens assembly 100. In Fig. 3, such a force is illustrated being applied to the connection piece 120 and the end pieces 160, in a direction, F. The dashed line, E, represents the magnitude of deformation of the connection piece 120, in the height direction, H. As Fig. 3 illustrates, the magnitude of the deformation may vary depending on the position along the optical lens assembly 100. As may be noticed in the figure, little or no deformation may be made in locations nearby or at a first alignment element 150. This is due to the fact that the first alignment element(s) 150 may be fastened to a luminaire or the like, and in that, fastening the optical lens assembly 100 to the luminaire or the like. Therefore, the first alignment element(s) 150 may prevent or restrict a deformation of the connection piece 120 nearby or at the position of the first alignment element(s) 150. The farther away from a first alignment element 150, the more deformation of the connection piece 120 may be made. The support element(s) 140 (not shown) may also contribute to the prevention or restriction of the deformation of the connection piece 120. This may be achieved as the support element(s) 140 extend(s) by at least a first distance, Di, in a direction, A, and may be configured to abut, engage with, be in contact with, or the like, a portion of a luminaire or the like whereon the optical lens assembly 100 is mounted. Referring now also to Fig. 3, the support element, which in fact function/are height adjustment elements, 140 (not shown) are configured to allow an adjustment of at least a part of the optical lens assembly 100 in the height direction H by a distance D of at least 0.1 mm. Such an adjustment may be made by applying a force to the optical lens assembly 1, and in particular the connecting piece 120 or the end pieces 160, in a direction F as shown on Fig. 3. The dashed line E in Fig. 3 illustrates the magnitude of the adjustment in the height direction H depending on position on the optical lens assembly 100. As may be seen, little or no adjustment may be made in locations near or at a positioning element 150, since at that position the lens 110 is, when mounted in or on a structure, e.g., a luminaire, fixed to the structure. The farther away from the positioning element 150, the more adjustment may be made.

Figs. 4a-4c illustrates different sections of a luminaire arrangement 300. Fig. 4a is a cross sectional top view of a section IX of a luminaire arrangement 300 comprising optical lens assemblies 100 according to an exemplifying embodiment of the present invention. Fig. 4b is a cross sectional top view of a section X of a luminaire arrangement 300 without optical lens assemblies according to an exemplifying embodiment of the present invention. Fig. 4c is a top view of a section XI of a luminaire arrangement 300 partly with optical lens assemblies 100 and partly without optical lens assemblies 100 according to an exemplifying embodiment of the present invention. It should be noted that the optical lens assembly 100 shown in Figs. 4a and 4c has several features in common with the optical lens assembly 100 shown in Figs. 1-3, and it is hereby referred to Figs. 1-3, and the associated text for an increased understanding of some of the features and/or functions of the optical lens assembly 100.

The luminaire arrangement 300 comprises a housing 310 extending in a second length direction, L2 and a plurality of light emitting devices 320 arranged inside the housing 310. The plurality of light emitting devices 320 comprises at least one light emitting diode, LED 330, arranged to emit LED light.

The luminaire arrangement 300 further comprises at least one optical lens assembly 100 arranged to optically influence the LED light. In Fig. 4a and 4b, only sections of the luminaire arrangement 300 are shown, wherein the sections each comprises three light emitting devices 320. For the sake of clarity, the illustrated light emitting devices 320 in Fig. 4a are illustrated with a corresponding mounted optical lens assembly 100 whereas the illustrated light emitting devices 320 in Fig. 4b are illustrated without a corresponding optical lens assembly 100. Furthermore, some of the light emitting devices 320 in Fig. 4c are illustrated with corresponding mounted optical lens assemblies 100, while remaining of the light emitting devices 320 are illustrated without corresponding optical lens assemblies 100. Generally, a luminaire arrangement 300 according to the invention may comprise lens assemblies 100 according to any embodiment of the invention. The second length direction, L2, is parallel to the first length direction, Li. According to Fig. 4a-4c, optical lens assemblies 100 are mounted on top of the light emitting devices 320.

The support elements 140 of the optical lens assembly(ies) 100 are configured to define a separation between the plurality of lenses 110 and LED(s) 330 by at least the second distance, D2, see Fig. 5. To define the separation between a lens element 130 and corresponding LED 330, the support element(s) 140 may be configured to abut, engage with, be in contact with, or the like, a portion of the luminaire arrangement 300. The support element(s) 140 may be configured to define the separation between the lens element 130 and corresponding LED 330 at an optimal distance between a lens element 130 and a corresponding LED 330. The optimal distance may be such that the distance between the lens element 130 and corresponding LED 330 results in a reduced risk of loss of optical efficiency and/or light leakage. This may thus be a trade-off between (at least) minimizing the distance between the lens element 130 and corresponding LED 330 to avoid e.g. light leakage, and simultaneously having a particular distance between the lens element 130 and corresponding LED 330 to optimize the optical center of the lens element 130 and therefore the optical efficiency. The provision of support element(s) 140 configured to define a separation between the plurality of lenses 110 and LED(s) 330 may also remove tolerances from the luminaire arrangement 300. This further reduces the risk of light leakage and/or optical efficiency loss.

Each of the plurality of lenses 110 comprises at least one first alignment element 150. Furthermore, the luminaire arrangement 300 comprises at least one second alignment element 340 arranged on each of the plurality of lighting emitting devices 320. The at least one first alignment element 150 and the at least one second alignment element 340 are configured for mating positional alignment engagement of the at least one optical lens assembly 100 and the housing 310. The first 250 and second alignment elements 340 are configured to couple, pair, link, connect, or the like to each other in a manner that results in a positional alignment between the first 150 and second alignment element 340 (see also Fig. 7b). As a result, lens 110 (and/or lens elements 130) may be aligned with corresponding LEDs 330. The mating positional alignment engagement of the optical lens assembly(ies) 100 and the housing 310 by the first and second alignment elements 150, 340 may be favorable if for instance thermal expansion of the luminaire arrangement 300 occurs. The lenses 110 (lens elements 130) may therefore be retained in their positional alignment in regard to corresponding LEDS 330 within an acceptable deviation in the plane P.

According to the embodiment, each light emitting device 320 comprises one second alignment element 340. However, other numbers of second alignment elements 340 arranged on each light emitting device 320 may also be feasible, such as two. According to Fig. 4b, the second alignment elements 340 are centrally arranged on each light emitting device 320. However, other configurations of the second alignment elements 340 on each light emitting device 320 may be feasible, such as centrally in between two neighboring light emitting device receiving structures 360. For instance, the second alignment elements 340 may each comprise a mating recess to corresponding first alignment elements 150. The (mating) recess may extend in an opposingly parallel direction to the direction, A, and perpendicular to the plane P. However, the second alignment elements 340 may extend in a direction other than one opposingly parallel to the direction, A, and perpendicular to the plane P. For instance, at least one second alignment element 340 may extend in a direction coinciding with the plane P, or extending in an inclined direction forming an (acute) angle with the plane P.

The luminaire arrangement 300 further comprises at least one engagement structure 350 configured for mating attachment with the at least one optical lens assembly 100 for positional fastening of the at least one optical lens assembly 100. It should be noted that the mating attachment between the engagement structure(s) 350 and the optical lens assembly (ies) 100 may be reversed, i.e. the optical lens assembly (ies) 100 may be removed from the engagement structure(s) 350. When mounting the optical lens assembly(ies) 100 on the luminaire arrangement 300, the connection piece 120 and/or the end pieces 160 of the lens assemblies 100 may be used to ensure correct positioning of the optical lens assemblies 100 on the luminaire arrangement 300. The positional fastening of the optical lens assembly(ies) 100 to the luminaire arrangement 300 may furthermore ensure the positional fastening of the light emitting devices 320 arranged within the housing 310. The light emitting devices 320 may be retained in their positional arrangement within an acceptable deviation in the plane P. The present embodiment may result in none or only a small tolerance between the optical lens assembly(ies) 100, the light emitting device(s) 320, and/or the housing 310. Furthermore, the support element(s) 140 may enable a deformation of at least a portion of the connection piece 120. This deformation may allow a compression of the optical lens assembly (ies) 100 and the light emitting device(s) 320 to the housing 310. Said compression may entail to a further reduction of the tolerance between the optical lens assembly (ies) 100, the light emitting device(s) 320, and the housing 310.

Fig. 4a shows a cross sectional top view of the section IX illustrating a part of the luminaire 300 where lens assemblies 1 have been added. Fig. 4b shows a cross sectional top view of the section X illustrating a part of the luminaire 300 where no optical lens assemblies 100 have been added. Fig. 4c shows a top view of the section XI of the luminaire 300. Generally, a luminaire 300 according to the invention may comprise lens assemblies 100 according to any embodiment of the invention, including also optical lens assemblies manufactured by a method according to the invention and described further below. Referring first to Figs. 6b and 4b, the luminaire 100 generally comprises a housing 310 and a plurality of light emitting devices 320. Each light emitting device 320 comprises a plurality of LEDs 330 or other suitable light sources configured to, in operation, emit light. The luminaire 100 further comprises an electrical outlet 370 for connection to a source of electrical energy, such as a battery or mains, for supplying electrical energy to the light emitting devices 320.

The luminaire 100 may further comprise lens element receiving structures 380 such as to ensure correct positioning of the respective lens elements 130 of the lenses 110 over the respective light sources 330. The luminaire 300 may further comprise an engagement structure 350 configured for receiving and positionally securing the lenses 110 of an optical lens assembly 100. The luminaire 300 may further comprise one or more positioning elements 340 configured for engagement with the positioning elements 6 provided on the lenses 110 of the optical lens assembly 100.

Referring specifically to Figs. 6b and 4c, the light emitting devices 320 may be arranged in respective light emitting device receiving structures 360. These light emitting device receiving structures 360 may also work as a reflector for directional control of the light emitted by the light sources 330 of the light emitting devices 320. To this end, the light emitting device receiving structures 360 may comprise a reflective coating or layer.

Referring specifically to Fig. 4a, optical lens assemblies 100 mounted on top of the light emitting devices 320 are shown. When mounting the optical lens assemblies 100, the connecting piece 120 and the end pieces 160 of the optical lens assemblies 100 may be used to ensure correct positioning of the optical lens assemblies 100 on the luminaire 300.

Reference is first made to Figs. 2b, 3 andlO of which Fig. 10 shows a top view of an optical lens assembly 100 according to the invention. Fig. 2b shows a bottom view of the optical lens assembly 100, and Fig. 3 shows a side view of the optical lens assembly 100.

The optical lens assembly 100 shown in Figs. 2b, 3 andlO is manufactured by injection molding and comprises two lenses 110 and a connection piece 120. The optical lens assembly 100 is made of a molding material. The molding material may be a transparent material, such as PMMA, PC, Silicone, Transparent Casting Plastics or PET.

The optical lens assembly 100 further comprises a length direction Li extending perpendicular to and between the two lenses 110, a width direction W extending transverse to the connection piece 120 and perpendicular to the length direction Li, and a height direction H extending perpendicular to both the length direction Li and the width direction W. Put in other words, the length direction Liand the width direction W both he in plane P intersecting all lenses 110 of the plurality of lenses essentially in the same height, the length direction Liand the width direction W extend perpendicular to one another, and the height direction H extends perpendicular to the plane P.

Each of the two lenses 110 comprise a plurality of lens elements 130. In the embodiment shown, each of the two lenses 110 comprise four lens elements 130. However, other numbers of lens elements 130 are also feasible. The lens elements 130 extend upwards in the height direction H, cf. also Fig. 3.

The connection piece 120 connects the two lenses 110 with each other. The connection piece 120 comprises mutually opposite longitudinal sides 41 and 42, cf. Fig. 10. The connection piece 120 is in the embodiments shown on the figures a straight connection piece 120. However, the connection piece 120 may also be a non-straight connection piece. For instance, the connection piece 120 may be a curved, such as S-shaped, connection piece 120. A curved connection piece 120 provides the advantage that it helps overcoming thermal expansion when the optical lens assembly 100 becomes much longer when heated.

Generally, and irrespective of the embodiment, the optical lens assembly 100 comprises an injection location 5. The injection location 5 is located in a position on the connection piece 120 corresponding to an injection location at which molding material was injected during injection molding of the optical lens assembly 100. Generally, the injection location 5 may be on any side, whether on the top surface, bottom surface, or side surface, of the connection piece 120 or the optical lens assembly 100. Generally, the injection location 5 is located centrally on the connection piece 120. More particularly, the injection location 5 is located equidistant from each of the two lenses 110. For instance, the injection location 5 may be arranged on a second axis of symmetry S2 (or second symmetry line S2) of the optical lens assembly 100 extending in the length direction Li of the optical lens assembly 100, or in a point of symmetry C of the optical lens assembly 100 - cf. Fig. 10. The injection location 5 may additionally or alternatively also be arranged equidistant from the mutually opposite longitudinal sides 41 and 42 of the connection piece 120, such as on the second axis of symmetry S2 and equidistant from the mutually opposite longitudinal sides 41 and 42. Alternatively, or additionally, the injection location 5 may also be arranged on a first axis of symmetry Si (or first symmetry line Si) of the optical lens assembly 100 extending in the width direction W of the optical lens assembly 100.

The optical lens assembly 100 further comprises mutually opposite end pieces 160. Each end piece 160 extends from a respective lens 110 at a position diametrically opposite to the connection piece 120. The end pieces 160 are optional elements. Fig. 5 is a side view of a luminaire arrangement 300 comprising an optical lens assembly 100 according to an exemplifying embodiment of the present invention. It should be noted that the optical lens assembly 100 shown in Fig. 5 has several features in common with the optical lens assembly 100 shown in Figs. 1-4, and it is hereby referred to Figs. 1-4, and the associated text for an increased understanding of some of the features and/or functions of the optical lens assembly 100. It should also be noted that the luminaire arrangement 300 shown in Fig. 5 has several features in common with the luminaire arrangement 300 shown in Figs. 4a-c, and it is hereby referred to Figs. 4a-c, and the associated text for an increased understanding of some of the features and/or functions of the luminaire arrangement 300.

In Fig. 5, it is illustrated how the at least one support element 140 extends beyond the plane P, by (at least) the first distance, Di, in a direction, A, perpendicular to the plane P. Furthermore, the support element(s) 140 is (are) configured to define a separation between the plurality of lenses 110 and LED(s) 330 by at least a second distance, D2. According to an example, the housing 310 comprises a printed circuit board, PCB, whereon the plurality of light emitting devices 320 comprising LED(s) 330 are arranged. The support elements 140 may be configured to abut, engage with, be in contact with, or the like, a portion of the PCB. Thus, the support elements 140 may be configured to define a separation between (at least the first and second lens) of the plurality of lenses 110 and LED(s) 330 by at least the second distance, D2. According to the example, Di>D2 is fulfilled. However, other ratios of the first and second distances Di, D2, may be feasible, such as Di=D2. Figs. 6a and 6b is a top view and a perspective view, respectively, of a luminaire arrangement 300 comprising optical lens assemblies 100 according to exemplifying embodiments of the present invention. It should be noted that the optical lens assembly 100 shown in Figs. 6a and 6b has several features in common with the optical lens assembly 100 shown in Figs. 1-5, and it is hereby referred to Figs. 1-5, and the associated text for an increased understanding of some of the features and/or functions of the optical lens assembly 100. It should also be noted that the luminaire arrangement 300 shown in Fig. 6 has several features in common with the luminaire arrangement 300 shown in Figs. 3 and 5, and it is hereby referred to Figs. 3 and 5, and the associated text for an increased understanding of some of the features and/or functions of the luminaire arrangement 300.

Referring to Fig. 6a, 6b for the sake of clarity and simplicity, only some of the light emitting devices 320 are illustrated with a corresponding mounted optical lens assembly 100, whereas remaining light emitting devices 320 are illustrated without a corresponding optical lens assembly 100. Generally, a luminaire arrangement 300 according to the invention may comprise lens assemblies 100 according to any embodiment of the invention. According to the embodiment, the optical lens assemblies 100 are adhesively fastened to the housing 310. According to an example, the luminaire arrangement 300 comprises a fastening system 390 configured to mechanically fasten the optical lens assemblies 100 to the housing 310. The fastening system 390 may allow for example clicking, forging, and/or sliding the optical assemblies 100 in place in relation to the housing 310. The fastening system 390 may thus remove tolerances from the luminaire arrangement 300. It should be noted that the optical assemblies 100 may be unfastened and removed from the housing 310. This may facilitate the handling of the luminaire arrangement 300 during e.g. transportation and/or installation. Additionally, reparations and/or recycling of the luminaire arrangement 300 may be performed in a simpler and more time efficient manner.

Referring now to Fig. 6b, the light emitting devices 320 may be arranged in respective light emitting device receiving structures 360. These light emitting device receiving structures 360 may also work as a reflector for directional control of the light emitted by the LEDs 330 of the light emitting devices 320. To achieve this, the light emitting device receiving structures 360 may comprise a reflective coating or layer.

As illustrated in Fig. 6b, the embodiment of the luminaire arrangement 300 further comprises a connector (370) electrically connected to the luminaire arrangement 300 for a supply of power to the plurality of light emitting devices 320.

Referring now to Figs. 7a and 7b which respectively show a bottom view and a cross-sectional view of another embodiment of the optical lens assembly 100 according to the invention. The optical lens assembly 100 comprises a first lens 110a and a second lens 110b, wherein the first lens 110a is arranged with a first lens edge 11 la in a plane P and the second lens 110b is arranged with a second lens edge 11 lb in the plane P. The first 110a and second lens 110b are spaced apart along a first direction LI by a single, elongated connection piece (120), with LI coinciding with plane P. Four support elements 140 extending beyond the plane P by at least a first distance DI in a direction A perpendicular to the plane P. The connection piece 120 is connected at a first connection location 112a to the first lens edge 11 la of the first lens 110a and at a second connection location 112b to the second lens edge 11 lb of the second lens. The connection piece 120 is fully arranged in between the first 100a and second lens 110b. The connection piece 120 has a length Lcp along the first direction LI with a ratio Rlc of the length to a largest cross-sectional dimension CS of the connection piece, wherein Rlc >=3,in the figure Rlc is about 4. The optical lens assembly 100 is injection molded and comprises an injection location 5 which is located on the connection piece 120 in a point of symmetry C diametrically opposed (in the cross-sectional direction) to a first alignment element 150 (i.e. at 180° rotated over the cross-section circumference) of the optical lens assembly 100. Two of the four support elements 140 are essentially completely distributedly, i.e. evenly and diametrically oppositely, arranged on respectively the first Il la and second lens edge 112a. The optical lens assembly 100 further comprises a first 160a and second end piece 160b, the first end piece 160a extends from the first lens edge I lla opposite to the first connection location 112a along the first length direction, Li and the second end piece 160b extends from the second lens edge 111b opposite to the second connection location 112b along the first length direction, Li. The end pieces 160a, 160b may contribute to a further improved alignment of the optical lens assembly 100, for example in that the optical lens assembly 100 may be clamped between a reflector cup of the luminaire and the L2-type LED module (both not shown here).

Referring no to Fig. 8 which shows a bottom view of yet another embodiment of the optical lens assembly 100 according to the invention. The construction is similar to the construction of the optical lens assembly as shown in Figs. 7a-b, yet in the optical lens assembly shown in Fig. 8 two mutually diametrically positioned first alignment elements 150 are located on each respective lens edge Il la, 111b. Two of the four support elements 140 are partially and distributedly, i.e. evenly and diametrically oppositely, arranged on respectively the first I lla and second lens edge 112a. The optical lens assembly 100 is injection molded and comprises an injection location 5 which is located on the connection piece 120 in a plane of symmetry Q and 90° rotated over Li with respect to first alignment elements 150 of the optical lens assembly 100.

Fig. 9 shows a plot of the relative thickness of the frozen layer of molding material as a function of position in a prior art lens 1000 injection molded by injecting the molding material from one side 5000 of the mold. The scale shows the deviation in mm compared with an average thickness of the frozen layer of molding material over the lens.

Generally, areas which are not yet frozen will have a good surface copy quality. Areas which are too far frozen will have a lower copy quality or could even result in less or even no texture on the surface.

It is therefore desired to provide a method for injection molding lenses which results in a symmetrical product as well as a resulting symmetrical injection molded optical lens assembly and a resulting symmetrical light distribution. It is further desired to provide a symmetric injection molded optical lens assembly comprising, in use, a resulting symmetrical light distribution.

Fig. 11 shows a plot of the relative thickness of the frozen layer of molding material as a function of position in an optical lens assembly 100 as shown in Figs. 2b, 3, and 10 and described above. The scale shows the deviation in mm compared with an average thickness of the frozen layer of molding material over the optical lens assembly 100.

As may be seen from Fig. 11 the result is an optical lens assembly 100 which is highly or possibly even fully symmetrical around a symmetry axis S2 which extends perpendicular and transverse to the connection piece 120 and on which the injection location lies.

Fig. 12 shows another embodiment of an optical lens assembly 100' according to the invention. The optical lens assembly 100’ shown in Fig. 12 differs from that described above with reference to Figs. 2b, 3, and 10 in virtue of the following features.

The optical lens assembly 100’ shown in Fig. 12 is manufactured by injection molding and comprises three lenses 110, 110’ and two connection pieces 120. The three lenses 110, 110’ are arranged in series along a length direction Li of the optical lens assembly 100’. The optical lens assembly 100’ thus comprises a middle lens 110’ and two outer lenses 110. The middle lens 110’ is connected to each of the two outer lenses 110 by a connection piece 120 of the two connection pieces 120.

The injection location 5 is located on the middle lens 110’ in a position corresponding to an injection location at which molding material was injected during injection molding of the optical lens assembly 100’. Generally, the injection location 5 is located centrally on the middle lens 110’. More particularly, the injection location 5 is located equidistant from each of the two outer lenses 110. For instance, the injection location 5 may be arranged on an axis of symmetry S2 of the optical lens assembly 100’, or in a point of symmetry C of the optical lens assembly 100’. The injection location 5 may additionally or alternatively also be arranged equidistant from mutually opposite sides 21 and 22 of the middle lens 110’, such as on the axis of symmetry S2 and equidistant from the mutually opposite sides 21 and 22. Alternatively, or additionally, the injection location 5 may also be arranged on an axis of symmetry Si of the optical lens assembly 100’ extending in the width direction W of the optical lens assembly 100’.

Fig. 13 shows another embodiment of an optical lens assembly 100” according to the invention. The optical lens assembly 100” shown in Fig. 13 differs from those described above with reference to Figs. 2b, 3, and 10 and 12 in virtue of the following features.

The optical lens assembly 100” shown in Fig. 13 is manufactured by injection molding and comprises four lenses 110, 110’ and four connection pieces 120, 120’. The four lenses 110, 110’ are arranged in a 2x2 array. The optical lens assembly 100” thus comprises an upper row of lenses 110 and a lower row of lenses 110’. The two lenses 110 of the upper row of lenses 110 are connected to each other by a connection piece 120. Likewise, the two lenses 110’ of the lower row of lenses 110’ are connected to each other by a connection piece 120. The connection pieces 120’ are diagonally extending connection pieces 120’ crossing at a center P of the optical lens assembly 100”. Thus, one of the connection pieces 120’ connects the upper left lens 110 and the lower right lens 110’ of the optical lens assembly 100”, while the other one of the connection pieces 120’ connects the upper right lens 110 and the lower left lens 110’ of the optical lens assembly 100”.

The injection location 5 is located on the optical lens assembly 100" in a position corresponding to an injection location at which molding material was injected during injection molding of the optical lens assembly 100”. Generally, the injection location 5 is located centrally on the optical lens assembly 100”. More particularly, the injection location 5 is located equidistant from each of the four lenses 110, 110’. The injection location 5 is located on the connection pieces 120’ where the connection pieces 120’ cross or intersect each other. For instance, the injection location 5 may be arranged on an axis of symmetry or in a plane of symmetry R (perpendicular to plane P) of the optical lens assembly 100” extending in the length direction Li of the optical lens assembly 100”, or in a point of symmetry C of the optical lens assembly 100”. Alternatively, or additionally, the injection location 5 may also be arranged on an axis of symmetry or in a plane of symmetry Q (perpendicular to plane p and plane R) of the optical lens assembly 100” extending in the width direction W of the optical lens assembly 100”.

Finally, Fig. 14 shows a flow diagram illustrating a method according to the invention for injection molding an optical lens assembly 1 as described above.

The method generally comprises providing 501 a mold comprising two lens compartments. Each of the two lens compartments comprise a plurality of lens cups. Each of the two lens compartments further comprise a connection piece connecting the two lens compartments. The mold comprises an injection location configured for receiving molding material to be injected into the mold. The injection location is arranged on the mold in a position being central with respect to the plurality of lens compartments. More particularly, the injection location is arranged equidistant from each of the plurality of lens compartments of the mold.

The injection location may be arranged on the mold in a position being in one or more of a geometrical center point of the plurality of lens compartments, in a point of symmetry of the plurality of lens compartments, on at least one of a first axis of symmetry of the plurality of lens compartments and a second axis of symmetry of the plurality of lens compartments, and on at least one of a first plane of symmetry of the plurality of lens compartments and second plane of symmetry of the plurality of lens compartments.

The method further generally comprises injecting 502 a molding material into the mold at the injection location. The molding material may be a transparent material, such as PMMA, PC, Silicone, Transparent Casting Plastics or PET.

The method may further comprise any one or more of the following optional steps: hardening 503 the molding material over a predetermined period of time, At, hardening 504 the molding material at one or more predetermined temperature, T, and removing 505 the optical lens assembly 100 from the mold.

The mold used in the method further comprises a length direction and a width direction both lying in a plane intersecting all lens compartments of the plurality of lens compartments in the same height. The length direction and the width direction extend perpendicular to one another. The mold also comprises a height direction H extending perpendicular to both the length direction and the width direction.

The mold used in the method may further comprise a plurality of support element recesses extending in the height direction. The support element recesses may be arranged between each two lens cups of the plurality of lens cups. Thereby, the resulting optical lens assembly 100 may be provided with support elements 140.

At least one of the lens compartments of the mold used in the method may further comprise a positioning element recess. The positioning element recess may be arranged centrally on the lens compartment. Thereby, the resulting optical lens assembly 100 may be provided with positioning elements 150.

The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims. For example, optical lens assembly 100, the plurality of lenses 110, the at least one first and second alignment elements 150, 340, etc., may have different shapes, dimensions and/or sizes than those depicted/described. Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage.

Claims

CLAIMS:

1. An optical lens assembly (100) comprising: a first lens (110a) connected to a second lens (110b) wherein i) the first lens is arranged with a first lens edge (11 la) in a plane P and the second lens is arranged with a second lens edge (11 lb) in the plane P, and ii) the first and second lens are spaced apart along a first direction Li by a single, elongated connection piece (120), with Li coinciding with plane P, at least one support element (140) extending beyond the plane P by at least a first distance Di in a direction A perpendicular to the plane P, wherein i) the connection piece is connected at a first connection location (112a) to the first lens edge of the first lens and at a second connection location (112b) to the second lens edge of the second lens, ii) the connection piece is fully arranged in between the first and second lens, and iii) the connection piece has a length L_cp along the first direction Li with a ratio Ric of the length to a largest cross-sectional dimension CS of the connection piece, wherein Ric >=3, wherein at least one of the at least one support element is at least partially arranged on the first and/or second lens edge.

2. The optical lens assembly according to claim 1, wherein the first and second connection location are each provided with one of the at least one support element.

3. The optical lens assembly according to any one of the preceding claims, wherein the connection piece is at least partially flexible.

4. The optical lens assembly according to any one of the preceding claims, further comprising a first and second end piece (160a, 160b), the first end piece extending from the first lens edge opposite to first connection location along the first length direction, Li and the second end piece extending from the second lens edge opposite to second connection location along the first length direction, Li.

5. The optical lens assembly according to any one of the preceding claims, wherein each of the first and second lens comprises at least two neighboring lens elements (130) with respective lens element edges (131a, 131b), and at least one of the at least one support element is arranged between the two neighboring lens elements on a respective lens element edge.

6. The optical lens assembly according to any one of the preceding claims, wherein at least two support elements (140) are arranged equidistant on at least one of the first (I l la) and second lens edge (111b) from a respective first geometrical center point, Ci, of respectively the first (110a) and second lens (110b), wherein the plane P, comprises the first geometrical center point, Ci.

7. The optical lens assembly according to any one of the preceding claims, further comprising at least one first alignment element (150).

8. The optical lens assembly according to claim 7, wherein at least one of the at least one first alignment element is arranged on at least one of: i) the at least first and second lens of a plurality of lenses at a first geometrical center point, Ci, of the at least first and second lens of the plurality of lenses, wherein the plane, P, comprises the first geometrical center point, Ci, and ii) on at least two mutually distributedly arranged locations on the edge of each lens.

9. The optical lens assembly according to any one of the preceding claims, wherein the optical lens assembly comprises an injection location and is injection molded.

10. The optical lens assembly according to claim 9, wherein the injection location (5) is arranged in at least one of: in a geometrical center point of the optical lens assembly, in a point of symmetry (C) of the optical lens assembly, on at least one of a first axis of symmetry (Si) of the optical lens assembly and a second axis of symmetry (S2) of the optical lens assembly, and on a plane of symmetry (Q; R) of the optical lens assembly (1).

11. The optical lens assembly according to claims 7 and 9 or 7 and 10, wherein the at least one first alignment element is arranged centrally on the connection piece, preferably opposite or at 90 ° with the injection location.

12. A luminaire arrangement (300) comprising: a housing (310) extending in a second length direction, L2, a plurality of light emitting devices (320) arranged inside the housing, comprising at least one light emitting diode, LED (330), arranged to emit LED light, and at least one optical lens assembly according to any one of claims 1-11 arranged to optically influence the LED light, wherein the second length direction, L2, is parallel to the first length direction, Li, wherein the at least one support element of the at least one optical lens assembly is configured to define a separation between the first and second lens and the at least one LED by at least a second distance, D2.

13. The luminaire arrangement according to claim 12 comprising at least one optical lens assembly according to claim 7, wherein each of the first and second comprises at least one first alignment element and wherein the luminaire arrangement further comprises at least one second alignment element (340) arranged on each of the plurality of lighting emitting devices, wherein the at least one first alignment element and the at least one second alignment element are configured for mating positional alignment engagement of the at least one optical lens assembly and the housing.

14. The luminaire arrangement according to claims 12 or 13, further comprising at least one engagement structure (350) configured for mating attachment with the at least one optical lens assembly for positional fastening of the at least one optical lens assembly.

15. A method for injection molding optical lenses, the method comprising:

- providing a mold, the mold comprising: i) at least a first and second lens compartment, each lens compartment of the plurality of lens compartments comprising at least one lens cup, ii) at least one connection piece connecting via respective edge portions of the first and second lens compartments of the plurality of lens compartments, the connection piece comprising a support element compartment at an edge portion and being elongated having a length L_cp with a ratio Ric of the length to a largest cross-sectional dimension CS of the connection piece, wherein Ric >=3, and iii) an injection location configured for receiving molding material to be injected into the mold, wherein the injection location is arranged on the mold on the connection piece and in a position being equidistantly with respect to the plurality of lens compartments, and - injecting a molding material into the mold at the injection location.