Microstructure-based diffusers for creating batwing lighting patterns

• US 10,302,275 B2
• Filed: 12/16/2014
• Issued: 05/28/2019
• 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: Purchase, Ken G.
• Primary Examiner(s): Harris, William N
• Application Number:
  US15/318,765
• Publication Number:
  US 20170146214A1
• Time in Patent Office: 1,624 Days
• CPC Class Codes: B29D 11/0074 Production of other optical elements not provided for in B29D11/00009- B29D11/0073
• CPC Class Codes: B29D 11/00798 Producing diffusers
• 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 3/049 Patterns or structured surfaces for diffusing light, e.g. frosted surfaces
• CPC Class Codes: F21V 5/005 using microprisms
• CPC Class Codes: F21V 5/02 of prismatic shape F21V5/04 takes precedence
• CPC Class Codes: F21V 7/06 with parabolic curvature
• CPC Class Codes: F21V 7/08 with elliptical curvature
• CPC Class Codes: F21Y 2105/16 square or rectangular, e.g. for light panels
• 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. A respective microprism element includes at least one ring comprising a plurality of microstructure pyramids that is rotated randomly and/or pseudorandomly on the first face about an axis that is orthogonal to the substrate relative to at least one other microprism element. 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, a respective microprism element comprising at least one ring comprising a plurality of microstructure pyramids that is rotated randomly and/or pseudorandomly on the first face about an axis that is orthogonal to the substrate relative to at least one other microprism element;

wherein 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.

2. The light transmissive structure of claim 1 wherein a respective microprism element comprises first and second concentric rings each comprising a plurality of microstructure pyramids, and wherein the first and second rings are each rotated randomly and/or pseudorandomly on the first face relative to one another.

3. The light transmissive structure of claim 1 wherein a respective microprism element comprises a plurality of concentric rings, a respective ring comprising a plurality of microstructure pyramids.

4. The light transmissive structure of claim 3 wherein a respective ring is rotated randomly and/or pseudorandomly on the first face relative to the other rings in a respective microprism element.

5. The light transmissive structure of claim 3 wherein a majority of and/or substantially all of the microstructure pyramids in a respective ring comprise a face that is oriented at a specific angle relative to a center of the plurality of concentric rings.

6. The light transmissive structure of claim 3 wherein the plurality of concentric rings comprises at least 5 rings.

7. The light transmissive structure of claim 1 wherein a respective microstructure pyramid is a triangular pyramid.

8. The light transmissive structure of claim 1 wherein the array of microprism elements extends over substantially the entire first face of the substrate.

9. The light transmissive structure of claim 1 wherein a respective microstructure pyramid and/or ring is substantially undetectable by the naked eye at a viewing distance of about three feet.

10. The light transmissive structure of claim 1 wherein the light transmissive structure is configured to produce a visible pattern to a viewer of the light transmissive structure at a viewing distance of about three feet, the visible pattern corresponding to the array of microprism elements on the first face.

11. 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.

12. 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.

13. 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 30 degrees from a light source facing the first face and distribute the light emerging from the second face in a 2D batwing distribution.

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

surface roughness on at least some of the microstructure pyramids;

a diffuser on the second face of the substrate;

a light scattering agent in at least some of the microstructure pyramids and/or in the substrate; and

/or

a diffusive coating on at least some of the microstructure pyramids.

15. 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.

16. A light transmissive structure comprising:

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

a plurality of pyramid microprisms on the first face, wherein the microprisms are distributed on the first face of the substrate with a plurality of different pyramid face orientation angles measured from an edge of the substrate;

wherein 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;

wherein a respective pyramid microprism is rotated randomly and/or pseudorandomly on the first face relative to at least one other pyramid microprism.

17. The light transmissive structure of claim 16 wherein the microprisms are distributed on the first face of the substrate in equal measure for each of the plurality of pyramid face orientation angles.

18. 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, a respective microprism element comprising a plurality of concentric microprism patterns, a respective microprism pattern comprising a plurality of triangular pyramids arranged in an elliptical configuration;

wherein 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;

wherein a respective microprism element comprises a microprism pattern that is rotated randomly and/or pseudorandomly on the first face relative to at least one other microprism element.

19. The light transmissive structure of claim 18 wherein a respective pyramid comprises a face that is oriented at a specific angle relative to a center of the plurality of concentric microprism patterns.