Microstructure-based optical diffusers for creating batwing and other lighting patterns

• US 10,072,816 B2
• Filed: 06/18/2014
• Issued: 09/11/2018
• Est. Priority Date: 06/19/2013
• Status: Active Grant

• Current Assignee: Bright View Technologies Corporation (Tredegar Corporation)
• Original Assignee: Bright View Technologies Corporation (Tredegar Corporation)
• Inventors: Shen, Bing, Purchase, Ken G.
• Primary Examiner(s): Truong, Bao Q
• Assistant Examiner(s): Fallahkhair, Arman B
• Application Number:
  US14/308,293
• Publication Number:
  US 20140376220A1
• Time in Patent Office: 1,546 Days
• Field of Search: 362235, 362330, 362620, 362339, 362626, 362337
• CPC Class Codes: B29D 11/0074 Production of other optical elements not provided for in B29D11/00009- B29D11/0073
• CPC Class Codes: B29L 2011/00 Optical elements, e.g. lenses, prisms
• CPC Class Codes: F21S 11/00 Non-electric lighting devices or systems using daylight roofs with sky-light opening E04D13/03; sun blinds for windows with means for redirecting light onto ceiling of a room E06B9/00; hybrid lighting devices combining artificial and natural light F21S19/00; solar heat collectors F24S; solar cells or solar cell modules H01L31/00
• CPC Class Codes: F21V 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 5/005 using microprisms
• CPC Class Codes: F21V 5/02 of prismatic shape F21V5/04 takes precedence
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G02B 5/0231 the surface having microprismatic or micropyramidal shape macroscopic prism arrays G02B5/045

Abstract

A light transmissive structure includes a light transmissive substrate having first and second opposing faces and array of microprism elements on the first face, with a respective microprism element including a plurality of concentric microprisms. The light transmissive structure is configured to receive light from a light source facing the first face and distribute the light emerging from the second face in a 2D batwing distribution.

Claims

1. A light transmissive structure comprising:

a light transmissive substrate having first and second opposing faces; and

an array of microprism elements on the first face,

wherein;

(i) the light transmissive structure is configured to receive light from a light source facing and spaced apart from the first face in a direction perpendicular to the substrate and positioned independent of any particular one of the microprism elements in a plane parallel to the substrate; and

(ii) the array of microprism elements are configured to distribute the light emerging from the second face in a 2D batwing distribution;

wherein a respective microprism element comprises a plurality of concentric circular microprisms;

wherein the array of microprism elements substantially covers the first face of the substrate.

2. The light transmissive structure of claim 1 in combination with at least one light source and a housing that is configured to hold the at least one light source and the light transmissive substrate so that light from the light source impinges on the first face of the substrate and emerges from the second face of the substrate in a 2D batwing distribution.

3. The combination of claim 2 wherein the housing defines a light exit surface area where the substrate is held, and wherein a respective microprism element has an area on the first face of the substrate that is at least one order of magnitude smaller than the light exit surface area.

4. The combination of claim 3 wherein a respective microprism element has an area on the first face of the substrate that is at least two orders of magnitude smaller than the light exit surface area.

5. The combination of claim 3 wherein a respective microprism element has an area on the first face of the substrate that is at least four orders of magnitude smaller than the light exit surface area.

6. The combination of claim 2 wherein the housing defines a light exit surface area where the substrate is held, and wherein the array of microprism elements on the first face of the substrate extends over substantially the entire light exit surface area.

7. The combination of claim 2 wherein the light source is an array of LEDs with a spacing between adjacent LEDs, and wherein a respective microprism element has a size that generally corresponds to the spacing between adjacent LEDs.

8. The light transmissive structure of claim 1 wherein at least some of the microprisms have a generally triangular cross section with a peak, the cross section taken in a plane perpendicular to the first face of the substrate.

9. The light transmissive structure of claim 8 wherein the peak is generally parallel to the first face of the substrate.

10. The light transmissive structure of claim 8 wherein the peak is a sharp peak.

11. The light transmissive structure of claim 8 wherein the peak is a rounded peak.

12. The light transmissive structure of claim 8 wherein:

a respective microprism has an internal angle defined by the peak of between about 60 and 100 degrees; and

a respective microprism has a pitch of between about 10 microns and 3 mm.

13. The light transmissive structure of claim 8 wherein:

a respective microprism has an internal angle of between about 70 and 90 degrees; and

a respective microprism has a pitch of between about 10 microns and 1 mm.

14. The light transmissive structure of claim 1 further comprising at least one diffusion feature.

15. The light transmissive structure of claim 14 wherein the diffusion feature comprises surface roughness on at least some of the microprisms.

16. The light transmissive structure of claim 14 wherein the diffusion feature comprises a diffuser on the second face of the substrate.

17. The light transmissive structure of claim 14 wherein the diffusion feature comprises a light scattering agent in at least some of the microprisms and/or in the substrate.

18. The light transmissive structure of claim 14 wherein the diffusion feature comprises a diffusive coating on at least some of the microprisms.

19. The light transmissive structure of claim 1 wherein at least some of the microprisms have a generally triangular cross section with a peak, the cross section taken in a plane perpendicular to the first face of the substrate, and have a prism internal angle defined by the peak with the prism internal angle varying as a function of a prism orientation angle that is measured relative to an edge of the substrate in a plane defined by the substrate.

20. The light transmissive structure of claim 6 wherein portions of the microprisms having prism orientation angles of about 45 degrees and 135 degrees have a first prism internal angle that is less than a second prism internal angle of portions of the microprisms having prism orientation angles of about 0 degrees and 90 degrees.

21. The light transmissive structure of claim 1 wherein a respective microprism element is generally hexagonal.

22. The light transmissive structure of claim 1 wherein a respective microprism element is generally square.

23. The light transmissive structure of claim 1 wherein a respective microprism element has an area of less than about 1 square centimeter on the second face of the substrate.

24. The light transmissive structure of claim 1 wherein a respective microprism element has an area of about 0.1 square centimeters or less on the second face of the substrate.

25. The light transmissive structure of claim 1 wherein a respective microprism is undetectable by the naked eye.

26. The light transmissive structure of claim 1 wherein adjacent microprism elements are in contact with one another.

27. The light transmissive structure of claim 1 wherein the array of microprism elements comprises gaps between at least some of the microprism elements, the light transmissive structure further comprising gap-filling microstructures in at least some of the gaps.

28. The light transmissive structure of claim 1 wherein at least some of the microprisms have a generally triangular cross section with a peak, the cross section taken in a plane perpendicular to the first face of the substrate, the peak having a height relative to the first face of the substrate that varies as a function of a prism orientation angle that is measured relative to an edge of the substrate.

29. The light transmissive structure of claim 1 wherein the light transmissive structure is configured to receive light having a Lambertian distribution from a light source facing the first face and distribute the light emerging from the second face in a 2D batwing distribution.

30. The light transmissive structure of claim 1 wherein the light transmissive structure is configured to receive light having a light distribution having a Full Width at Half Maximum (FWHM) of at least about 30 degrees from a light source facing the first face and distribute the light emerging from the second face in a 2D batwing distribution.

31. The light transmissive structure of claim 1 wherein the light transmissive structure is configured to receive light having a light distribution having a Full Width at Half Maximum (FWHM) of at least about 40 degrees from a light source facing the first face and distribute the light emerging from the second face in a 2D batwing distribution.

32. The light transmissive structure of claim 1 wherein the light transmissive structure is configured to receive light having a light distribution having a Full Width at Half Maximum (FWHM) of at least about 60 degrees from a light source facing the first face and distribute the light emerging from the second face in a 2D batwing distribution.

33. The light transmissive structure of claim 1 wherein the light transmissive structure is configured to receive light having a light distribution having a Full Width at Half Maximum (FWHM) of at least about 80 degrees from a light source facing the first face and distribute the light emerging from the second face in a 2D batwing distribution.

34. The light transmissive structure of claim 1, wherein a respective microprism follows a prism path along the first face of the substrate, wherein the microprism has a generally triangular cross section with a peak and a pitch, the cross section taken in a plane perpendicular to the first face of the substrate, and wherein:

(i) the peak has a height relative to the first face of the substrate that varies along the prism path; and

/or (ii) the pitch varies along the prism path.

35. The light transmissive structure of claim 1 in combination with at least one light source wherein the light transmissive substrate is suspended under the light source so that light from the light source impinges on the first face of the substrate and emerges from the second face of the substrate in a 2D batwing distribution.

36. The light transmissive structure of claim 1 wherein the second face is smooth.

37. The light transmissive structure of claim 1 wherein the second face is planar.

38. A luminaire comprising:

a housing;

a light source held in the housing;

a light transmissive structure held in the housing, the light transmissive structure comprising;

a light transmissive substrate having first and second opposing faces; and

an array of microprism elements on the first face,

wherein the light transmissive structure is configured to receive light from the light source facing the first face and distribute the light emerging from the second face in a 2D batwing distribution;

wherein the light source is spaced apart from the first face in a direction perpendicular to the substrate and is positioned independent of any particular one of the microprism elements in a plane parallel to the substrate;

wherein a respective microprism element comprises a plurality of concentric circular microprisms;

wherein the array of microprism elements substantially covers the first face of the substrate.