OPTICAL ELEMENTS WITH INTERNAL OPTICAL FEATURES AND METHODS OF FABRICATING SAME

• US 20090021841A1
• Filed: 07/16/2008
• Published: 01/22/2009
• Est. Priority Date: 07/17/2007
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: Cree Lighting Company (Ideal Industries Incorporated)
• Inventors: Pickard, Paul Kenneth, Negley, Gerald H.
• Granted Patent: US 8,123,384 B2
• Time in Patent Office: Days
• US Class Current: 359/642
• CPC Class Codes: F21K 9/68 Details of reflectors forming part of the light source
• CPC Class Codes: G02B 1/10 Optical coatings produced by application to, or surface treatment of, optical elements G02B1/08 takes precedence
• CPC Class Codes: G02B 5/021 the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
• CPC Class Codes: G02B 5/0231 the surface having microprismatic or micropyramidal shape macroscopic prism arrays G02B5/045
• CPC Class Codes: G02B 5/0268 characterized by the fabrication or manufacturing method
• CPC Class Codes: G02B 5/0278 used in transmission
• CPC Class Codes: G02B 5/045 Prism arrays
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor

Abstract

An optical element, comprising a substrate and at least one optical film. The substrate is at least partially light-transmissive. The optical film comprises at least a first optical feature and is positioned on a contact surface of the substrate. Also, a lighting device comprising at least one solid state light emitter and such an optical element. Also, methods for making an optical element by molding (e.g., film insert molding), bonding or laminating.

Claims

1. An optical element, comprising:

a substrate, said substrate being at least partially light-transmissive, said substrate comprising a contact surface;

at least one optical film, said optical film being positioned on said contact surface of said substrate, said optical film comprising at least a first optical feature.

2. An optical element as recited in claim 1, wherein said optical film is positioned directly on said contact surface of said substrate.

3. An optical element as recited in claim 1, wherein:

said optical film comprises an optical film first surface and an optical film second surface,

said optical film second surface is in contact with said contact surface of said substrate, and

said optical film second surface is substantially smooth.

4. An optical element as recited in claim 3, wherein said optical film first surface is substantially smooth.

5. An optical element as recited in claim 3, wherein a first region of said optical film second surface is substantially uniformly spaced from said contact surface, said first region comprising at least half of said optical film second surface.

6. An optical element as recited in claim 3, wherein a first region of said optical film second surface is in direct contact with said contact surface, said first region comprising at least half of said optical film second surface.

7. An optical element as recited in claim 3, wherein said optical film first surface is substantially uniformly spaced from said optical film second surface.

8. An optical element as recited in claim 1, wherein:

said optical film comprises an optical film first surface and an optical film second surface,

said optical film second surface is in contact with said contact surface of said substrate,

said optical film comprises at least a first layer and a second layer,

a first layer first surface of said first layer comprises said optical film first surface,

said first layer further comprises a first layer second surface,

said first optical feature is positioned on said first layer second surface,

a second layer second surface of said second layer comprises said optical film second surface,

said second layer further comprises a second layer first surface, and

said first layer second surface is in contact with said second layer first surface.

9. An optical element as recited in claim 8, wherein said optical film further comprises at least one intermediate material positioned between said first layer and said second layer.

10. An optical element as recited in claim 9, wherein said intermediate material comprises a solid material.

11. An optical element as recited in claim 9, wherein said intermediate material comprises air.

12. An optical element as recited in claim 8, wherein said first layer second surface is in direct contact with said second layer first surface.

13. An optical element as recited in claim 8, wherein said second layer second surface is substantially smooth.

14. An optical element as recited in claim 13, wherein said first layer first surface is substantially smooth.

15. An optical element as recited in claim 8, wherein said first layer first surface is substantially smooth.

16. An optical element as recited in claim 8, wherein said second layer first surface comprises at least a second optical feature.

17. An optical element as recited in claim 8, wherein said first layer first surface is opposite said first layer second surface.

18. An optical element as recited in claim 8, wherein said second layer first surface is opposite said second layer second surface.

19. An optical element as recited in claim 1, wherein:

said optical film comprises a first layer,

said first layer comprises a first layer first surface and a first layer second surface

said first layer second surface is in contact with said contact surface of said substrate,

said first optical feature is positioned on said first layer first surface.

20. An optical element as recited in claim 19, wherein said first layer second surface is substantially smooth.

21. An optical element as recited in claim 19, wherein said first layer first surface is opposite said first layer second surface.

22. An optical element as recited in claim 1, wherein said substrate is substantially translucent.

23. An optical element as recited in claim 1, wherein said substrate is substantially transparent.

24. An optical element as recited in claim 1, wherein said substrate is lens-shaped.

25. An optical element as recited in claim 1, wherein said substrate comprises a substrate second surface, said substrate second surface comprising at least a third optical feature.

26. An optical element as recited in claim 25, wherein said substrate second surface is opposite from said contact surface.

27. An optical element as recited in claim 26, wherein said substrate second surface is substantially parallel to said contact surface.

28. An optical element as recited in claim 1, wherein said optical film diffuses light passing through said optical film.

29. An optical element as recited in claim 1, wherein said optical film mixes light passing through said optical film.

30. An optical element as recited in claim 1, wherein said optical film and said substrate are adhesively bonded to each other.

31. An optical element as recited in claim 1, wherein said optical film and said substrate are molded together.

32. An optical element as recited in claim 1, wherein said optical film and said substrate are laminated together.

33. An optical element as recited in claim 32, wherein said optical film and said substrate are coextruded

34. An optical element as recited in claim 1, wherein said substrate comprises polycarbonate.

35. An optical element as recited in claim 34, wherein said optical film comprises polycarbonate.

36. An optical element as recited in claim 1, wherein said optical film comprises polycarbonate.

37. A lighting device, comprising:

at least one optical element as recited in claim 1; and

at least one solid state light emitter,

said solid state light emitter and said optical element being positioned and oriented relative to one another such that if light is emitted from said solid state light emitter, at least a portion of said light will pass through said optical element.

38. A lighting device as recited in claim 37, wherein said lighting device comprises a plurality of solid state light emitters, said solid state light emitters and said optical element being positioned and oriented relative to one another such that for each said solid state light emitter, if light is emitted from said solid state light emitter, at least a portion of said light will pass through said optical element.

39. A lighting device as recited in claim 37, wherein said lighting device is in the shape of a light bulb, a conventional reflector light or a downlight.

40. An illuminated enclosure, comprising an enclosed space and at least one lighting device as recited in claim 37, wherein said lighting device illuminates at least a portion of said enclosure.

41. An illuminated surface, comprising a surface and at least one lighting device as recited in claim 37, wherein if said lighting device is illuminated, said lighting device would illuminate at least a portion of said surface.

42. An illuminated area, comprising at least one item selected from among the group consisting of a swimming pool, a room, a warehouse, an indicator, a road, a vehicle, a road sign, a billboard, a ship, a toy, a mirror, a vessel, an electronic device, a boat, an aircraft, a stadium, a computer, a remote audio device, a remote video device, a cell phone, a tree, a window, a yard, a lamppost, an indicator light, or a device or array of devices that illuminate an enclosure, or a device that is used for edge or back-lighting, having mounted therein or thereon at least one lighting device as recited in claim 37.

43. A method of making an optical element, comprising:

positioning within a mold at least one optical film, said optical film comprising at least a first optical feature;

feeding into said mold at least one flowable substrate material;

solidifying said at least one flowable substrate material to form a substrate, said substrate being at least partially light-transmissive and comprising a contact surface which is in contact with said optical film.

44. A method as recited in claim 43, wherein said optical film is in direct contact with said contact surface of said substrate.

45. A method as recited in claim 43, wherein:

said optical film comprises an optical film first surface and an optical film second surface,

said optical film second surface is in contact with said contact surface of said substrate, and

said optical film second surface is substantially smooth.

46. A method as recited in claim 43, wherein:

said optical film comprises an optical film first surface and an optical film second surface,

said optical film second surface is in contact with said contact surface of said substrate,

said optical film comprises at least a first layer and a second layer,

a first layer first surface of said first layer comprises said optical film first surface,

said first layer further comprises a first layer second surface,

said first optical feature is positioned on said first layer second surface,

a second layer second surface of said second layer comprises said optical film second surface,

said second layer further comprises a second layer first surface, and

said first layer second surface is in contact with said second layer first surface.

47. A method as recited in claim 46, wherein said second layer second surface is substantially smooth.

48. A method as recited in claim 43, wherein:

said optical film comprises a first layer,

said first layer comprises a first layer first surface and a first layer second surface

said first layer second surface is in contact with said contact surface of said substrate,

said first optical feature is positioned on said first layer first surface.

49. A method as recited in claim 48, wherein said first layer second surface is substantially smooth.

50. A method as recited in claim 43, wherein said substrate is substantially translucent.

51. A method as recited in claim 43, wherein said substrate is substantially transparent.

52. A method as recited in claim 43, wherein said substrate is lens-shaped.

53. A method as recited in claim 43, wherein said substrate comprises a substrate second surface, said substrate second surface comprising at least a third optical feature.

54. A method of making an optical element, comprising:

applying at least one adhesive to at least one of an optical film and a substrate; and

bringing said optical film and said substrate together so that said optical film and said substrate are in contact with each other and at least a portion of said adhesive is positioned between said optical film and said substrate,

said optical film comprising at least a first optical feature,

said substrate being at least partially light-transmissive.

55. A method as recited in claim 54, wherein:

said optical film comprises an optical film first surface and an optical film second surface,

said optical film second surface is in contact with said contact surface of said substrate, and

said optical film second surface is substantially smooth.

56. A method as recited in claim 54, wherein:

said optical film comprises an optical film first surface and an optical film second surface,

said optical film second surface is in contact with said contact surface of said substrate,

said optical film comprises at least a first layer and a second layer,

a first layer first surface of said first layer comprises said optical film first surface,

said first layer further comprises a first layer second surface, said first optical feature is positioned on said first layer second surface,

a second layer second surface of said second layer comprises said optical film second surface,

said second layer further comprises a second layer first surface, and

said first layer second surface is in contact with said second layer first surface.

57. A method as recited in claim 56, wherein said second layer second surface is substantially smooth.

58. A method as recited in claim 54, wherein:

said optical film comprises a first layer,

said first layer comprises a first layer first surface and a first layer second surface

said first layer second surface is in contact with said contact surface of said substrate,

said first optical feature is positioned on said first layer first surface.

59. A method as recited in claim 58, wherein said first layer second surface is substantially smooth.

60. A method as recited in claim 54, wherein said substrate is substantially translucent.

61. A method as recited in claim 54, wherein said substrate is substantially transparent.

62. A method as recited in claim 54, wherein said substrate is lens-shaped.

63. A method as recited in claim 54, wherein said substrate comprises a substrate second surface, said substrate second surface comprising at least a third optical feature.

64. A method of making an optical element, comprising:

laminating an optical film to a substrate such that said optical film is in contact with said substrate,

said optical film comprising at least a first optical feature,

said substrate being at least partially light-transmissive.

65. A method as recited in claim 64, wherein:

said optical film comprises an optical film first surface and an optical film second surface,

said optical film second surface is in contact with said contact surface of said substrate, and

said optical film second surface is substantially smooth.

66. A method as recited in claim 64, wherein:

said optical film comprises an optical film first surface and an optical film second surface,

said optical film second surface is in contact with said contact surface of said substrate,

said optical film comprises at least a first layer and a second layer,

a first layer first surface of said first layer comprises said optical film first surface,

said first layer further comprises a first layer second surface,

said first optical feature is positioned on said first layer second surface,

a second layer second surface of said second layer comprises said optical film second surface,

said second layer further comprises a second layer first surface, and

said first layer second surface is in contact with said second layer first surface.

67. A method as recited in claim 66, wherein said second layer second surface is substantially smooth.

68. A method as recited in claim 64, wherein:

said optical film comprises a first layer,

said first layer comprises a first layer first surface and a first layer second surface

said first layer second surface is in contact with said contact surface of said substrate,

said first optical feature is positioned on said first layer first surface.

69. A method as recited in claim 68, wherein said first layer second surface is substantially smooth.

70. A method as recited in claim 64, wherein said substrate is substantially translucent.

71. A method as recited in claim 64, wherein said substrate is substantially transparent.

72. A method as recited in claim 64, wherein said substrate is lens-shaped.

73. A method as recited in claim 64, wherein said substrate comprises a substrate second surface, said substrate second surface comprising at least a third optical feature.