WO2018032994A1 - 条状异形透镜及基于该条状异形透镜的led灯光源组件 - Google Patents

条状异形透镜及基于该条状异形透镜的led灯光源组件 Download PDF

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WO2018032994A1
WO2018032994A1 PCT/CN2017/096252 CN2017096252W WO2018032994A1 WO 2018032994 A1 WO2018032994 A1 WO 2018032994A1 CN 2017096252 W CN2017096252 W CN 2017096252W WO 2018032994 A1 WO2018032994 A1 WO 2018032994A1
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cylinder
strip
shaped lens
curved
shaped
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PCT/CN2017/096252
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English (en)
French (fr)
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王安
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江苏恒鹏智能电气有限公司
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Publication of WO2018032994A1 publication Critical patent/WO2018032994A1/zh

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/60—Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/04—Refractors for light sources of lens shape
    • F21V5/043—Refractors for light sources of lens shape the lens having cylindrical faces, e.g. rod lenses, toric lenses
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V31/00—Gas-tight or water-tight arrangements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/04—Refractors for light sources of lens shape

Definitions

  • the present invention relates to a shaped lens and a light source assembly using the same, and more particularly to a shaped lens and an LED light source assembly for use with an LED lamp.
  • the assembly is more complicated; there is also a common way to fix a separate lens on each LED bead to achieve optical requirements by changing the refracted light, but the fixed lens often uses glue or glue, etc., after two or three years, Especially in areas where the heat and cold are very strong, reliability will be very challenging. More importantly, the two methods can not solve the waterproof problem of the PCB regardless of the reflector or the lens itself. In actual use, a transparent cover must be added. To achieve a certain anti-collision level, a certain thickness is required. Refraction greatly reduces overall light efficiency.
  • This traditional LED lamp structure determines the complexity of the production process.
  • the lens or reflector on each lamp bead is assembled separately, the efficiency is low and the assembly precision is not high, and the overall cost is raised again.
  • the design structure is basically one-to-one for the matching of the LED lamp bead to the lens or the reflector, so when the LED lamp bead is replaced, basically the lens should be redesigned and opened, and the versatility is not good enough.
  • the object of the present invention is to provide a strip-shaped shaped lens for the shortcoming of the existing LED light distribution scheme.
  • the shaped lens cooperates with the waterproof ring to directly solve the waterproof problem of the PCB board, and the one for the lamp bead does not need to be one-to-one. Separate lens installation, and any number of LED lamp bead boards of any manufacturer can be applied. Because the lens itself and the waterproof ring can play a waterproof role, as long as one refraction can achieve optical requirements, the light effect will be greatly improved.
  • the strip-shaped shaped lens of the present invention comprises a curved surface cylinder, the bottom surface of the curved surface cylinder is a horizontal structure, and one side of the central axis of the bottom surface is provided with a circular arc surface cavity, A snap is provided on both sides of the curved cylinder.
  • the arc surface of the curved surface cylinder is defined by the lamp bead, the arc surface cavity and the light exiting requirement. According to the requirements of light emission and the properties of the lamp bead, an appropriate arc surface cavity can be selected, and the curve of the smooth surface can be obtained by optical calculation formula.
  • the curved cylinder and the buckle are integrally formed by an extrusion process.
  • the extrusion process it is possible to achieve products of any length, and the cost of producing molds and parts is reduced by more than 30%.
  • the distance between the top surface of the curved surface of the curved surface cylinder and the bottom surface of the curved surface cylinder is 11.4 mm to 12.4 mm
  • the distance between the central axis of the curved surface cylinder and the central axis of the circular surface cavity is 6.5 mm to 7.5 mm
  • the radius of the circular arc cavity is 5 mm to 6 mm.
  • the invention relates to an LED lamp light source assembly based on a strip-shaped shaped lens, comprising a substrate, a PCB board with LED lamp beads, a strip-shaped shaped lens, and a fixed card, wherein the PCB board with the LED lamp bead is disposed on the substrate,
  • the strip-shaped shaped lens is disposed on the PCB board with the LED lamp bead and the substrate, the fixed card is disposed at two ends of the substrate, and the strip-shaped shaped lens comprises a curved column body, and the bottom surface of the curved surface cylinder a horizontal structure; one side of the central axis of the bottom surface is provided with a circular arc surface cavity, and the two sides of the curved surface cylinder are provided with a buckle; the arc surface of the curved surface cylinder passes through the lamp bead and the circle
  • the curved cavity and the light output requirements are jointly defined.
  • a further improvement of the above technical solution further includes a waterproof strip and a waterproof card disposed between the base material and the bottom surface of the curved cylinder, at both ends of the bottom surface of the curved cylinder and the curved cylinder Inside the buckle on both sides, the waterproof card is disposed at both ends of the substrate and is located inside the fixed card.
  • the curved cylinder and the buckle are integrally formed by an extrusion process.
  • the distance between the top surface of the curved surface of the curved surface cylinder and the bottom surface of the curved surface cylinder is 11.4 mm to 12.4 mm
  • the distance between the central axis of the curved surface cylinder and the central axis of the circular surface cavity is 6.5.
  • the radius of the arcuate cavity is 5 mm to 6 mm.
  • the distance between the top of the light-emitting surface of the curved cylinder and the bottom surface of the curved cylinder is 11.9 mm, and the distance between the central axis of the curved cylinder and the central axis of the circular arc cavity is 7 mm.
  • the radius of the arc surface cavity is 5.5 mm. This structure is most suitable for guardrail lamp module products.
  • the strip-shaped shaped lens of the invention and the LED light source assembly based on the strip-shaped shaped lens design a novel strip-shaped shaped lens, which is different from the lens of the conventional injection molding process, and the new lens can be extruded, possibly
  • the cost of producing molds and parts can be reduced by more than 30%, and the two-layer optical structure in the traditional product can be changed to one layer, and the overall lighting effect can be increased by 10-15% under the same light source.
  • This special-shaped lens is applied to the guardrail lamp and conforms to the size of the outer steel tube. It can be combined with other parts such as the light board to form a separate light source component, or an independent module product for realizing light distribution, heat dissipation, waterproof, etc.
  • the two-core waterproof connector is electrically connected to the general-purpose power supply of the market, thus becoming a general-purpose guardrail lamp module product in the market.
  • Figure 1 is a cross-sectional structural view of a strip-shaped shaped lens
  • FIG. 2 is an assembled view of an embodiment based on a strip-shaped shaped lens
  • FIG. 3 is an enlarged view showing a state of use of a strip-shaped shaped lens
  • FIG. 4 is a distribution diagram of a light distribution block simulated by a luminaire based on a strip-shaped shaped lens in a two-way environment
  • Figure 5 is a distribution diagram of light distribution data simulated in a two-way environment using a strip-shaped shaped lens-based luminaire
  • FIG. 6 is a distribution diagram of a light distribution color block simulated in a three-way environment using a strip-shaped shaped lens-based luminaire
  • Figure 7 is a distribution of light distribution data simulated in a three-way environment using a strip-shaped shaped lens-based luminaire.
  • the strip-shaped shaped lens includes a curved cylinder 1 , the bottom surface 2 of the curved cylinder is a horizontal structure, and one side of the central axis of the bottom surface is provided with a circular arc cavity 3 , the arc A buckle 4 is disposed on both sides of the face cylinder.
  • the distance between the top of the light exit surface 5 of the curved surface cylinder and the bottom surface 2 of the curved surface cylinder is 11.9 mm
  • the distance between the central axis of the curved surface cylinder and the central axis of the arc surface cavity is 7 mm.
  • the radius of the face cavity is 5.5 mm.
  • This structure size is most suitable for the light distribution requirements on the LED guardrail lamp. According to the actual needs and the application of other occasions, the selection interval of ⁇ 0.5mm can be performed on the basis of the above parameters to adapt to different light distribution requirements. .
  • an embodiment of the above-mentioned strip-shaped shaped lens applied to an LED guardrail lamp comprises a substrate 6, a PCB board 7 with LED lamp beads, a strip-shaped shaped lens 8, a fixed card 9, and a waterproof strip.
  • the waterproof card 11, the PCB board 7 with the LED lamp bead is disposed on the substrate 6, and the strip-shaped shaped lens 8 is disposed on the PCB board 7 with the LED lamp bead and the substrate 6, the LED with the LED
  • the PCB board 7 of the lamp bead is disposed directly below the arcuate surface cavity 3.
  • the waterproof strip 10 is disposed between the substrate 6 and the bottom surface 2 of the curved cylinder, at both ends of the bottom surface 2 of the curved cylinder and the inside of the buckle 4 on both sides of the curved cylinder;
  • the card 11 is disposed at both ends of the substrate, and the fixed card 9 is disposed outside the waterproof card 11, and the waterproof card 11 and the fixed card 9 are both fixed to the substrate 6 by screws.
  • the strip-shaped shaped lens 8 is realized by an extrusion process, and the length of the product can be set by the length of the extruded substrate 6 and the lens, and can be completely made by the customer. It can be 1200mm, or 600mm, or even 300mm, any length can be customized. .
  • the power of the product is determined by the number of lamp beads. The number of wires can be easily increased or decreased by a certain length. Just replace the PCB aluminum substrate, that is, the PCB board with LED lamp beads, and even wire the aluminum substrate to the maximum possible number.
  • the customer power requirement patch can control the number of patches required; on the PCB board 7 with LED lamp beads, different types of LED lamp beads can be set, that is to say, LED lamp beads of different manufacturers can be realized universally, which is The existing market's guardrail lamp products are basically impossible; for red, green, blue and other color light beads, to achieve urban lighting, as long as the different color beads are connected to the DMX control power supply, it is very convenient to implement;
  • the waterproof connector is connected to the power supply of many manufacturers, and the whole lamp assembly will be standardized and standardized, which can greatly reduce the cost and simplify the final design and production of the entire lamp.
  • the single-shaped lens with the strip-shaped shaped lens 8 realizes the secondary light distribution and the waterproof new LED guardrail lamp, has a reasonable structure, can greatly improve the overall light effect of the lamp, and is easier to control.
  • Light distribution for better uniformity, different LED lamp beads can be used for the entire light source assembly, and easily extended to such as wall washers Lighting fixtures, etc., while the overall lighting components are much less than the current market products, parts costs and assembly costs are greatly reduced, directly through the design of new lenses to achieve the replacement of such products.
  • the method for assembling the strip-shaped shaped lens 8 on the guardrail lamp module is as follows: the lamp bead is attached to the PCB aluminum substrate 7 as required, and the PCB aluminum substrate is mounted on the groove of the substrate 6 of the extruded profile.
  • the waterproof groove on the substrate 6 is placed in the waterproof strip 10; the strip-shaped shaped lens 8 is mounted on the substrate 6, and the waterproof strip 10 is pressed to achieve lateral waterproofing; at both ends, it can be treated like a general-purpose product in the market.
  • the waterproof card 11 and the fixed card 9 are directly fixed to both ends of the substrate 6 by screws, because the center parts are less, and it is relatively easier to ensure that the ends are flush during the assembly process than the general products of the market.
  • the whole lamp installation process does not have the process of filling glue, adding glue, etc., which greatly improves the production efficiency, facilitates the installation of the lamp supplier, and avoids the problem of easy to dirty and affect the appearance.
  • the strip-shaped shaped lens 8 of the present invention uses a tunnel shape in combination with any number of lamp beads in a key optical solution, and changes the thickness of different regions of the lens in the cross section of the tunnel to change the direction of the refracted light. Symmetrical shape, and in the direction of the tunnel, by adjusting the height of the tunnel and the shape of the arc to reach the beam angle of the actual light distribution along the road direction, this direction is completely symmetrical, because the general light beam curve of the lamp bead is a standard Lang wave curve.
  • the optical design method can be applied to most lamp beads, and the process adjustment in the actual lens production, such as adjusting the product profile curve according to the actual distributed photometer to adjust the shape of a certain partial curve of the lens cross section is also very targeted, also Very convenient.
  • the strip-shaped shaped lens 8 is provided with a convex special curved surface shape, and optically combined with the inner circular arc surface cavity 3 to form a light passage, and the light emitted by the light bulb passes through the integral light passage, and is obtained.
  • the shape of the light curve is usually required for the guardrail lamp.
  • This light channel is only an optical loss, according to the general PC lens light transmittance of about 89%, plus we can use a high reflectivity PCB inkjet material to reflect a part of the lens back light to the lens for refraction to increase light efficiency, In addition to the power conversion efficiency, the optical efficiency of the overall light source module can reach about 90%.
  • the light effect of the light source can reach 144lm/W, which is absolutely unique in the existing guardrail lamp. .
  • this structure is also suitable for medium-power LED lamp beads.
  • medium-power LEDs with higher performance and higher cost performance than high-power LED lamp beads the feasibility of this solution will be further improved. It is believed that this solution will be applied in the near future. The medium power LED lamp beads will soon appear to replace the existing high power LED lamp beads.
  • each manufacturer is different from each other, corresponding to the only selected LED light bead, the corresponding power is basically fixed, and the connected power source is also the lamp manufacturer alone.
  • Customized the function of the whole luminaire is not well modularized, no matter the actual assembly process, the analysis of future product performance problems, the actual use of product maintenance, etc. will have great difficulties. If this light source component is standardized, standard power supplies from different manufacturers are introduced. The power and length can be adjusted at will, and the universal light source module unit suitable for different lamp tube brackets will be the trend of the market.
  • the strip-shaped shaped lens 8 of the present invention, as well as the design of a standard barrier light source assembly using the lens combined into a universal ultra-high light effect, can perfectly achieve the above requirements.
  • the designed light distribution file is simulated by software, and the two roads are used as simulation conditions.
  • the average illuminance can be more than 40lx and the uniformity is above 0.7. It is much better than the mainstream products in the market (the general illumination is only 30lx, the uniformity is 0.4).
  • the illuminance is also 31lx, and the uniformity is above 0.5.
  • this new light source module has a much higher luminous efficiency
  • the single lens controls the light more easily and accurately, so the ground effect is better.
  • the design scheme of the light distribution can start from the guardrail lamp in outdoor applications, and has a very broad application prospect due to the very universality and more and more applications.

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  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Optics & Photonics (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

一种条状异形透镜（8）及基于条状异形透镜（8）的LED灯光源组件，带LED灯珠的PCB板（7）设置在基材（6）上，条状异形透镜（8）设置在带LED灯珠的PCB板（7）及基材（6）上，固定卡片（9）设置在基材（6）的两端，条状异形透镜（8）包括弧面柱体（1），弧面柱体（1）的底面为水平结构；底面中心轴的一侧设置有圆弧面空腔（3），弧面柱体（1）的两侧边设置有卡扣（4）；弧面柱体（1）的出光面弧度通过灯珠、圆弧面空腔（3）及出光要求共同限定，带LED灯珠的PCB板（7）设置在圆弧面空腔（3）下方。条状异形透镜（8）可以用挤压工艺，能实现任意长度产品，生产模具与零件成本降低30％以上，将传统产品中两层光学结构改为一层，同等光源下整灯光效可提高10-15％。

Description

条状异形透镜及基于该条状异形透镜的LED灯光源组件 技术领域
本发明涉及异形透镜及使用该异形透镜的灯光源组件，尤其针对LED灯使用的异形透镜及LED灯光源组件。
背景技术
LED灯在使用过程如果需要将灯珠的光线打到特定区域时都需要进行配光，配光的方式有两种：一种是通过在每个LED灯珠引入独立的反射杯，通过对反射光线进行再次配光达到相关配光曲线形状，从而实现照(亮)度与照(亮)均匀性，这种方式因为反射器本身经过一次吸收，光效降低很多，而且反射器本身成本高，装配较复杂；还有一种通用的方式是在每一颗LED灯珠上固定一个独立的透镜，通过改变折射光线达到光学要求，但固定透镜经常利用胶水或灌胶等等，经过两三年，尤其冷热交变很强烈的区域，可靠性会有很大的挑战。更重要的是，这两种方式无论反射器还是透镜自身都解决不了PCB的防水问题，在实际使用中，都必须再加上一个透明罩，要达到一定防撞级别还需要一定厚度，二次折射使整体光效大大降低。
这种传统的LED灯结构决定了生产工艺的复杂，每个灯珠上透镜或反射器要单独装配，效率低而且装配精度不高，整体成本再次抬高。同时这种设计结构对于LED灯珠与透镜或反射器的匹配基本是一对一的，所以要换一种LED灯珠时，基本上透镜都要重新设计与开模，通用性不够好。
发明内容
本发明的目的是针对现有LED灯配光方案的不足，提供一种条状异形透镜，这种异形透镜与防水圈配合可以直接解决PCB板防水问题，再者对于灯珠无需一对一的单独透镜安装，且任意数量任意厂家不同LED灯珠的灯板均可以适用，由于这个透镜本身与相配合防水圈可以起到防水作用，只要一次折射就可以达到光学要求，光效将大大提高。
为了解决上述技术问题，本发明的条状异形透镜，包括弧面柱体，所述弧面柱体的底面为水平结构，所述底面中心轴的一侧设置有圆弧面空腔，所述弧面柱体的两侧边设置有卡扣。
上述技术方案中，所述弧面柱体的出光面弧度通过灯珠、圆弧面空腔及出光要求共同限定。根据出光要求及灯珠的属性，可以选择一个适当的圆弧面空腔，再通过光学计算公式可以获得出光面弧度曲线。
上述技术方案中，所述弧面柱体及卡扣通过挤出工艺一体成型。采用挤压工艺，可能实现任意长度产品，生产模具与零件成本降低30％以上。
上述技术方案中，所述弧面柱体的出光面顶部与弧面柱体的底面距离为11.4mm至12.4mm,所述弧面柱体中心轴与圆弧面空腔中心轴之间距离是6.5mm至7.5mm,所述圆弧面空腔的半径为5mm至6mm。
本发明基于条状异形透镜的LED灯光源组件，包括基材、带LED灯珠的PCB板、条状异形透镜、固定卡片，所述带LED灯珠的PCB板设置在基材上，所述条状异形透镜设置在带LED灯珠的PCB板及基材上，所述固定卡片设置在基材的两端，所述条状异形透镜包括弧面柱体，所述弧面柱体的底面为水平结构；所述底面中心轴的一侧设置有圆弧面空腔，所述弧面柱体的两侧边设置有卡扣；所述弧面柱体的出光面弧度通过灯珠、圆弧面空腔及出光要求共同限定。
上述技术方案的进一步改进方案，还包括防水条和防水卡片，所述防水条设置在基材和弧面柱体的底面之间，位于弧面柱体的底面的两端及弧面柱体的两侧边的卡扣内侧，所述防水卡片设置在基材的两端，位于固定卡片的内侧。
上述方案中，所述弧面柱体及卡扣通过挤出工艺一体成型。
上述方案中，所述弧面柱体的出光面顶部与弧面柱体的底面距离为11.4mm至12.4mm,所述弧面柱体中心轴与圆弧面空腔中心轴之间距离是6.5mm至7.5mm,所述圆弧面空腔的半径为5mm至6mm。
上述方案中，所述弧面柱体的出光面顶部与弧面柱体的底面距离为11.9mm,所述弧面柱体中心轴与圆弧面空腔中心轴之间距离是7mm,所述圆弧面空腔的半径为5.5mm。这一结构最适宜护栏灯模组产品。
本发明的条状异形透镜及基于该条状异形透镜的LED灯光源组件，设计了一款全新的条状异形透镜，与传统注塑工艺的透镜不同，这款新型透镜可以用挤压工艺，可能实现任意长度产品，生产模具与零件成本降低30％以上，将传统产品中两层光学结构改为一层，同等光源下整灯光效可提高10-15％。这款异形透镜应用在护栏灯上，符合外部钢管尺寸，与灯板等等其它零件可以组合成独立光源组件，或者称为实现配光、散热、防水等等独立的模组产品，可以通过标准两芯防水接头与市场通用电源电气连接，从而成为一款市场通用护栏灯模组产品。
附图说明
图1为条状异形透镜剖面结构图；
图2为基于条状异形透镜一种实施方式的装配图；
图3为条状异形透镜使用状态结构放大图；
图4为使用基于条状异形透镜的灯具在两条路环境下模拟的配光色块分布图；
图5为使用基于条状异形透镜的灯具在两条路环境下模拟的配光数据分布图；
图6为使用基于条状异形透镜的灯具在三条路环境下模拟的配光色块分布图；
图7为使用基于条状异形透镜的灯具在三条路环境下模拟的配光数据分布图。
具体实施方案
由图1可知，条状异形透镜，包括弧面柱体1，所述弧面柱体的底面2为水平结构，所述底面中心轴的一侧设置有圆弧面空腔3，所述弧面柱体的两侧边设置有卡扣4。所述弧面柱体的出光面5顶部与弧面柱体的底面2距离为11.9mm,所述弧面柱体中心轴与圆弧面空腔中心轴之间距离是7mm,所述圆弧面空腔的半径为5.5mm。这一结构尺寸最适宜用在LED护栏灯上的配光要求，根据实际的需要及其他场合的应用情况，在上述参数的基础上可以进行±0.5mm的选择区间，以适应不同的配光要求。
结合图2和3，将上述条状异形透镜应用于LED护栏灯灯具的一种实施方式，包括基材6、带LED灯珠的PCB板7、条状异形透镜8、固定卡片9、防水条10、防水卡片11，所述带LED灯珠的PCB板7设置在基材6上，所述条状异形透镜8设置在带LED灯珠的PCB板7及基材6上，所述带LED灯珠的PCB板7设置在圆弧面空腔3的正下方。
所述防水条10设置在基材6和弧面柱体的底面2之间，位于弧面柱体的底面2的两端及弧面柱体的两侧边的卡扣4内侧；所述防水卡11设置在基材的两端，所述固定卡片9设置在防水卡11外侧，防水卡11和固定卡片9均通过螺丝固定在基材6上。
条状异形透镜8采用挤压工艺来实现，产品长度可以由挤出基材6与透镜长度为设定，可以完全由客户要求制作，可以是1200mm，或者600mm，甚至300mm任何长度都可以随意定制。产品功率由灯珠颗数来定，一定长度下数量可以很容易增减，只要换下PCB铝基板也就是带LED灯珠的PCB板7，甚至将铝基板布线成最多可能颗数情况，根据客户功率要求贴片中控制需要贴片的数量即可；在带LED灯珠的PCB板7上可以设置不同型号的LED灯珠，也就是说对不同厂家的LED灯珠可以实现通用，这对于现有市场的护栏灯产品基本上不可能的；对于红绿蓝及其它颜色灯珠，实现城市亮化，只要换上不同颜色灯珠接入DMX控制电源，实现起来非常方便；还有通过通用防水接头与很多厂家的电源相连接，整灯装配将标准化通用化，能大幅度降低成本并能简化最终的整个灯具设计与生产。
上述的应用于LED护栏灯灯具的实施方式，用条状异形透镜8这种单一异形透镜实现二次配光与防水的全新LED护栏灯，结构合理，可以大大提高灯具整体光效，更加容易控制配光实现更好的均匀性，可以将不同LED灯珠用于整个光源组件，并容易拓展到诸如洗墙灯亮 化灯具等等，同时整体灯具的零部件比现行市场产品少很多，零件成本以及装配成本大大降低，直接通过设计全新透镜实现此类产品的更新换代。
这种应用条状异形透镜8于护栏灯模组上的组装方法如下：将灯珠按照要求贴片到PCB铝基板7上，将PCB铝基板安装在挤出型材的基材6上的沟槽内；在基材6上的防水沟槽放入防水条10；将条状异形透镜8装上基材6，同时压紧防水条10实现横向防水；在两端可以如市场通用产品一样处理，直接用螺丝将防水卡片11和固定卡片9固定在基材6的两端，因为中心零件更少，比市场通用产品对于装配过程中保证两端齐平将更加相对容易些。
这种结构对于灯珠的选择将大大增加，无论小尺寸的大功率灯珠如Cree的2525 XBD,飞利浦3030 2D,3535，欧司朗的Duris各种颜色灯珠等等。
整个灯具安装过程没有灌胶、加胶水等等工艺，大大提高生产效率，方便灯具供应商安装，避免容易脏乱影响外观的问题
本发明的条状异形透镜8，在关键的光学解决方案上，利用隧道形状与任意数量灯珠相组合，在隧道的横截面上透镜不同区域厚度变化来达到折射光线的方向改变，这个方向非对称形，而在沿隧道方向通过调整隧道高低与弧面形状达到实际沿道路方向配光的光束角大小，这个方向为完全对称形，因为一般灯珠出光光线曲线为标准朗波曲线，这种光学设计方法对于大多数灯珠都能适用，而且实际透镜生产中工艺调整，如根据实际分布式光度计测得产品配光曲线来调整透镜横截面某个局部区域曲线形状很有针对性，也非常方便。
如图3，所述的条状异形透镜8上设有凸起的特殊曲面形状，与其内圆弧面空腔3形成光学组合成光线通道，灯珠所发出的光线经过这个整体光线通道，得到护栏灯通常要求的特定形状配光曲线形状。这个光线通道只是一次光学损失，根据一般PC透镜透光率89％左右，再加上我们可以用高反射率的PCB喷墨材料使一部分透镜反射回来的光线再次反射到透镜进行折射增加光效，所有除电源转换效率外，整体光源模组的光学效率可达90％左右，对于光源160lm/W的灯珠来说，光源部分光效可达到144lm/W，在现有护栏灯是绝对独一无二的。而且此结构也适用于中功率LED灯珠，对于相对于大功率LED灯珠来说，性能发展更快性价比更高的中功率LED将更加提高此方案的可行性，相信不久将来应用这种方案的中功率LED灯珠会很快出现来替代现有大功率LED灯珠。
现有各种护栏灯灯具对应的光源尺寸与结构下，基本上每个厂家互不相同，对应选定的唯一一种LED灯珠，对应的功率大小基本固定，连接的电源也是灯具厂家单独定制的，对于整个灯具的功能模组化效果不好，无论实际组装过程中，将来产品性能问题分析，实际使用产品维护等等都会有很大的困难。如果将这种光源组件标准化，引入不同厂家的标准电源， 功率与长度可以随意调整，适用于不同的灯具灯管支架的通用光源模组单元将是市场大势所趋。而本发明的条状异形透镜8，以及应用这款透镜组合成通用超高光效的标准护栏灯光源组件设计，可以完美实现上述需求。
根据以上光学设计的方案，将设计出的配光文件进行软件模拟,以两条道路为模拟条件，如图4和5所示的模拟结果，可达到平均照度40lx以上,均匀度0.7以上的，比市场主流产品(一般照度只有30lx,均匀度0.4)效果要好很多。以三条道路为模拟条件，如图6和7所示的模拟结果，照度也31lx，均匀度0.5以上的表现。一方面因为这种全新光源模组光效高出很多，另一方面单一透镜对光线的控制要容易更精准，所以地面效果更好。
在实施例中，只列举了一种利用该种条状异形透镜的应用领域，在完全不用改动任何其它零件达到其它配光的要求，其可以适应其它应用领域如洗墙灯、工矿灯、投光灯等等。甚至因为路灯的蝙蝠翼配光本身也是沿道路方向为对称形，垂直道路为非对称形，完全也有可能用这种挤出式透镜实现，那样灯珠颗数与功率将更有灵活性，也是本技术方案的拓展领域，相信这种配光的设计方案在室外应用中可以从这款护栏灯开始，由于非常有普遍性，带来越来越多的应用，具有非常广阔的应用前景。

Claims (10)

  1. 条状异形透镜，包括弧面柱体，其特征在于：所述弧面柱体的底面为水平结构，所述底面中心轴的一侧设置有圆弧面空腔，所述弧面柱体的两侧边设置有卡扣。
  2. 如权利要求1所述的条状异形透镜，其特征在于：所述弧面柱体的出光面弧度通过灯珠、圆弧面空腔及出光要求共同限定。
  3. 如权利要求1或2所述的条状异形透镜，其特征在于：所述弧面柱体及卡扣通过挤出工艺一体成型。
  4. 如权利要求3所述的条状异形透镜，其特征在于：所述弧面柱体的出光面顶部与弧面柱体的底面距离为11.4mm至12.4mm,所述弧面柱体中心轴与圆弧面空腔中心轴之间距离是6.5mm至7.5mm,所述圆弧面空腔的半径为5mm至6mm。
  5. 如权利要求3所述的条状异形透镜，其特征在于：所述弧面柱体的出光面顶部与弧面柱体的底面距离为11.9mm,所述弧面柱体中心轴与圆弧面空腔中心轴之间距离是7mm,所述圆弧面空腔的半径为5.5mm。
  6. 基于该条状异形透镜的LED灯光源组件，包括基材、带LED灯珠的PCB板、条状异形透镜、固定卡片，所述带LED灯珠的PCB板设置在基材上，所述条状异形透镜设置在带LED灯珠的PCB板及基材上，所述固定卡片设置在基材的两端，其特征在于：所述条状异形透镜包括弧面柱体，所述弧面柱体的底面为水平结构；所述底面中心轴的一侧设置有圆弧面空腔，所述弧面柱体的两侧边设置有卡扣；所述弧面柱体的出光面弧度通过灯珠、圆弧面空腔及出光要求共同限定，所述带LED灯珠的PCB板设置在圆弧面空腔的正下方。
  7. 如权利要求6所述的基于该条状异形透镜的LED灯光源组件，其特征在于：还包括防水条和防水卡片，所述防水条设置在基材和弧面柱体的底面之间，位于弧面柱体的底面的两端及弧面柱体的两侧边的卡扣内侧，所述防水卡片设置在基材的两端，位于固定卡片的内侧。
  8. 如权利要求6或7所述的基于该条状异形透镜的LED灯光源组件，其特征在于：所述弧面柱体及卡扣通过挤出工艺一体成型。
  9. 如权利要求8所述的基于该条状异形透镜的LED灯光源组件，其特征在于：所述弧面柱体的出光面顶部与弧面柱体的底面距离为11.4mm至12.4mm,所述弧面柱体中心轴与圆弧面空腔中心轴之间距离是6.5mm至7.5mm,所述圆弧面空腔的半径为5mm至6mm。
  10. 如权利要求9所述的基于该条状异形透镜的LED灯光源组件，其特征在于：所述弧面柱体的出光面顶部与弧面柱体的底面距离为11.9mm,所述弧面柱体中心轴与圆弧面空腔中心轴之间距离是7mm,所述圆弧面空腔的半径为5.5mm。
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