Shaped microstructure-based optical diffusers for creating batwing and other lighting patterns

• US 9,765,949 B2
• Filed: 07/25/2014
• Issued: 09/19/2017
• Est. Priority Date: 07/26/2013
• 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., Rinehart, Thomas A., McLaurin, Christopher B.
• Primary Examiner(s): Husar, Stephen F
• Application Number:
  US14/341,125
• Publication Number:
  US 20150029717A1
• Time in Patent Office: 1,152 Days
• CPC Class Codes: F21K 9/65 specially adapted for changing the characteristics or the distribution of the light, e.g. by adjustment of parts
• 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: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A light distribution device includes a light transmissive substrate having first and second opposing faces and a plurality of substantially parallel linear prisms on the second face that extend in a longitudinal direction of the substrate. The light distribution device is configured to connect to a light assembly including a linear light source with the first face of the substrate facing the light source, with the linear prisms substantially parallel to a light source longitudinal axis and with and the substrate having a non-planar cross-sectional shape such that at least a major portion of the substrate is concave relative to the light source. When connected, the light distribution device is configured to receive light from the light source and distribute the light emerging from the second face of the substrate in a batwing distribution pattern in a plane perpendicular to the light source longitudinal axis.

Claims

1. A light distribution device for use with a light assembly including a linear light source having a light source longitudinal axis, the light distribution device comprising:

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

a plurality of substantially parallel linear prisms on the second face that extend in a longitudinal direction of the substrate, a respective prism having a generally triangular cross section in a plane transverse to the longitudinal direction of the substrate;

wherein the light distribution device is configured to connect to the light assembly in a connected position with the first face of the substrate facing the light source, with the linear prisms substantially parallel to the light source longitudinal axis and with and the substrate having a non-planar cross-sectional shape in a plane transverse to the longitudinal direction of the substrate such that at least a major portion of the substrate is concave relative to the light source;

wherein, when connected in the connected position, the light distribution device is configured to receive light from the light source and distribute the light emerging from the second face of the substrate in a batwing distribution pattern in a plane perpendicular to the light source longitudinal axis.

2. The light distribution device of claim 1 wherein the non-planar cross-sectional shape is an arc of a circle.

3. The light distribution device of claim 2 wherein a center of a circle including the arc of the circle is spaced-apart from the light source longitudinal axis.

4. The light distribution device of claim 1 wherein the non-planar cross-sectional shape is an arc of an ellipse.

5. The light distribution device of claim 4 wherein a center of an ellipse including the arc of the ellipse is spaced-apart from the light source longitudinal axis.

6. The light distribution device of claim 1 wherein the non-planar cross-sectional shape is a pointed arch.

7. The light distribution device of claim 1 further comprising first and second reflectors, the first reflector spanning from the light assembly to a first longitudinal edge of the substrate, the second reflector spanning from the light assembly to a second longitudinal edge of the substrate that is opposite the first longitudinal edge of the substrate.

8. The light distribution device of claim 7 wherein the first and second reflectors are specular reflectors.

9. The light distribution device of claim 7 wherein the first and second reflectors are diffuse reflectors.

10. The light distribution device of claim 7 wherein the first and second reflectors define a reflector angle at the light assembly that is at least about 60 degrees to distribute the light emerging from the second face in a wide batwing distribution pattern in a plane perpendicular to the light source longitudinal axis.

11. The light distribution device of claim 7 wherein the first and second reflectors define a reflector angle at the light assembly that is between about 30 and 60 degrees to distribute the light emerging from the second face in a narrow batwing distribution pattern in a plane perpendicular to the light source longitudinal axis.

12. The light distribution device of claim 7 wherein the first reflector spans from the light assembly past the first longitudinal edge of the substrate and the second reflector spans from the light source assembly past the second longitudinal edge of the substrate.

13. The light distribution device of claim 1 wherein the respective prism has an internal angle of about 90 degrees.

14. The light distribution device of claim 1 wherein the respective prism has an internal angle of about 60 degrees.

15. The light distribution device of claim 1 wherein the substrate has a refractive index of about 1.49 or less.

16. The light distribution device of claim 1 wherein the respective prism comprises a base at the second face of the substrate, and wherein substantially none of the prisms have a base that directly faces the light source.

17. The light distribution device of claim 1 wherein the non-planar cross-sectional shape comprises a raised central point with two outwardly-bending curves extending in opposite directions therefrom, and wherein the two outwardly-bending curves are concave relative to the light source.

18. The light distribution device of claim 17 wherein the substrate is a first substrate, the light distribution device further comprising:

a second substrate having first and second opposing faces with a plurality of substantially parallel linear prisms on the second face, the second substrate being concave relative to the light source, a first longitudinal edge of the second substrate positioned at a first longitudinal edge of the first substrate;

a third substrate having first and second opposing faces with a plurality of substantially parallel linear prisms on the second face, the third substrate being concave relative to the light source, a first longitudinal edge of the third substrate positioned at a second longitudinal edge of the first substrate that is opposite the first longitudinal edge of the first substrate;

a first reflector spanning from the light assembly to a second longitudinal edge of the second substrate that is opposite the first longitudinal edge of the second substrate; and

a second reflector spanning from the light assembly to a second longitudinal edge of the third substrate that is opposite the first longitudinal edge of the third substrate.

19. The light distribution device of claim 1 wherein a first longitudinal edge of the substrate is connected to the light assembly on one side of the light source and a second longitudinal edge of the substrate that is opposite the first longitudinal edge of the substrate is connected to the light assembly on an opposite side of the light source.

20. The light distribution device of claim 1 further comprising first and second end caps, the first end cap at a first transverse edge of the substrate and the second end cap at a second transverse edge of the substrate that is opposite the first transverse edge of the substrate.

21. The light distribution device of claim 1 wherein the plurality of substantially parallel linear prisms are on a central longitudinal portion of the substrate, the light distribution device further comprising a first outer longitudinal light-blocking portion of the substrate and a second outer longitudinal light-blocking portion of the substrate that is opposite the first outer longitudinal light-blocking portion.

22. The light distribution device of claim 1 wherein the plurality of substantially parallel linear prisms are substantially uniformly distributed on the second face of the substrate.

23. The light distribution device of claim 1 wherein the substrate is a monolithic member.

24. The light distribution device of claim 1 wherein the substrate comprises a film comprising the plurality of substantially parallel linear prisms on a rigid or semi-rigid translucent or transparent member.

25. The light distribution device of claim 24 wherein the film has a thickness of about 0.2 mm or less.

26. The light distribution device of claim 1 wherein the respective prism has a pitch of about 100 microns or less.

27. The light distribution device of claim 1 further comprising a microstructure or holographic diffuser on the first face of the substrate.

28. The light distribution device of claim 1 further comprising at least one diffusion feature, the at least one diffusion feature comprising:

surface roughness on at least some of the prisms;

rounding of at least some of the peaks of the prisms;

rounding of at least some valleys that are between adjacent prisms;

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

/or

a diffusive coating on at least some of the prisms.

29. The light distribution device of claim 1 wherein the substrate is configured to be curved and/or bent to form the non-planar cross-sectional shape.

30. The light distribution device of claim 1 wherein the respective prism has an internal angle of between about 45 and 90 degrees.

31. The light distribution device of claim 1 in combination with the light assembly including the linear light source.

32. The combination of claim 31 wherein the linear light source comprises an array of spaced-apart LEDs.

33. The combination of claim 31 wherein the linear light source comprises a fluorescent lamp.

34. The light distribution device of claim 1 wherein the first face is smooth.

35. A light distribution device for use with first and second light assemblies, the first light assembly including a first linear light source having a first light source longitudinal axis, the second light assembly including a second linear light source having a second light source longitudinal axis, the light distribution device comprising:

a first light transmissive substrate having first and second opposing faces with a plurality of substantially parallel linear prisms on the second face that extend in a longitudinal direction of the first substrate;

a second light transmissive substrate having first and second opposing faces with a plurality of substantially parallel linear prisms on the second face that extend in a longitudinal direction of the second substrate,

wherein the first light transmissive substrate is configured to connect to the first light assembly in a connected position with the first face of the first substrate facing the first light source, with the linear prisms substantially parallel to the first light source longitudinal axis and with the first substrate concave relative to the first light source;

wherein the second light transmissive substrate is configured to connect to the second light assembly in a connected position with the first face of the second substrate facing the second light source, with the linear prisms substantially parallel to the second light source longitudinal axis and with the second substrate concave relative to the second light source;

wherein, when connected in the connected position, the first light transmissive substrate is configured to receive light from the first light source and distribute the light emerging from the second face of the first substrate in a first one-sided distribution pattern in a plane perpendicular to the first light source longitudinal axis;

wherein, when connected in the connected position, the second light transmissive substrate is configured to receive light from the second light source and distribute the light emerging from the second face of the second substrate in a second one-sided distribution pattern in a plane perpendicular to the second light source longitudinal axis; and

wherein the first and second one-sided distributions patterns combine to form a batwing distribution pattern in a plane perpendicular to the first and second light source longitudinal axes.

36. The light distribution device of claim 35 further comprising:

a first reflector spanning from the first light assembly to a first longitudinal edge of the first substrate;

a second reflector spanning from the first light assembly to a second longitudinal edge of the first substrate that is opposite the first longitudinal edge of the first substrate;

a third reflector spanning from the second light assembly to a first longitudinal edge of the second substrate; and

a fourth reflector spanning from the second light assembly to a second longitudinal edge of the second substrate that is opposite the first longitudinal edge of the second substrate.

37. The light distribution device of claim 35 further comprising:

a first reflector spanning from the first light assembly to a first longitudinal edge of the first substrate;

a second reflector spanning from the second light assembly to a first longitudinal edge of the second substrate; and

a third reflector spanning from the first light assembly to the second light assembly;

wherein the third reflector is positioned and configured such that the first light source does not directly illuminate the second substrate and such that the second light source does not directly illuminate the first substrate.

38. The light distribution device of claim 37 further comprising a diffuser spanning from a second longitudinal edge of the first substrate that is opposite the first longitudinal edge of the first substrate to a second longitudinal edge of the second substrate that is opposite the first longitudinal edge of the second substrate.