OPTICAL ELEMENT COMBINABLE WITH A SOLID-STATE LIGHT SOURCE, AND RELATIVE PRODUCTION METHOD
TECHNICAL FIELD
The present invention relates to an optical element combinable with a solid-state light source, and to the relative production method. BACKGROUND ART As described, for example, in Japanese Patent Application JP 61-147585, integrated lighting modules are known comprising a solid-state light source (in particular, a LED) combined with an optical element, e.g. a total-internal-reflection lens or coUimator. The optical element is normally defined by a monolithic body extending along an axis and having a recess for housing the light source. At respective opposite axial ends, the body has an entry surface facing the light source in use, and an exit surface. The optical element is molded in one piece from plastic material in a special mold, and, being relatively thick, with an axial dimension comparable (i.e. substantially equal to or greater than) its transverse
dimension, takes a relatively long time to mold.
Moreover, a light beam of predetermined characteristics can only be obtained from the optical element by working, at the design stage, on the shape of optical element and that of its boundary surfaces, in particular the entry and exit surfaces. Consequently, the types of beams obtainable are limited.
DISCLOSURE OF INVENTION
It is an object of the present invention to provide an optical element combinable with a solid-state light source (LED) , and a method of producing such an optical element, which provide for solving the aforementioned problems of the known art .
According to the present invention, there are provided an optical element combinable with a solid-state light source, and a method of producing such an optical element, as claimed in the accompanying Claims 1 and 11 respectively.
Preferred embodiments of the optical element and production method according to the invention are defined in the dependent Claims 2 to 10 and 12 to 22 respectively.
In accordance with the invention, the optical element is divided into two or more portions formed at respective separate molding steps. Each molding step produces a portion of a thickness smaller than the overall thickness of the body, and which is therefore faster to mold. The total time required to produce the
optical element is thus greatly reduced. One material may be used to form all the portions of the optical element, or the various portions may be made of different materials . In the latter case, dividing the optical element into portions allows considerable freedom in the design of the characteristics of the beam emitted by the optical element. That is, in addition to working on the overall shape of the optical element and its entry and exit surfaces, an auxiliary optical surface may be formed inside the optical element, at the boundary of adjacent portions made of respective materials having at least one different optical characteristic; and the auxiliary- optical surface may be appropriately designed to obtain given characteristics of the beam.
Body portions of different materials may also be used for specific functions (as a filter, protective covering, yellowing shield, etc.).
BRIEF DESCRIPTION OF THE DRAWINGS A number of non-limiting embodiments of the present invention will be described by way of example with reference to the accompanying drawings, in which:
Figure 1 shows a schematic view in perspective of an optical element in accordance with the present invention; Figure 2 shows a section along line II-II of the Figure 1 optical element;
Figures 3 and 4 show, schematically, respective steps in the method of producing the Figure 1 optical
element ;
Figures 5, 6 and 7 show schematic views in perspective of respective variations of the optical element according to the present invention; Figures 8 and 9 show a schematic view in perspective and a longitudinal section respectively of a further variation of the optical element according to the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION Number 1 in Figures 1 and 2 indicates as a whole an optical element combinable with a solid-state light source (in particular a LED) to define, for example, a known integrated lighting module.
Optical element 1 comprises a body 2 made of substantially transparent plastic (polymer) material, extending along an axis A, and shaped in substantially known manner, e.g. to define a high-efficiency, total- internal-reflection lens or coUimator.
In the non-limiting example referred to, body 2 is a rotationally symmetrical body of revolution, and axis A defines a central axis of body 2 and an optical axis of optical element 1. It is understood, however, that body 2 may be shaped otherwise than as described and illustrated herein purely by way of example . At one axial end 4, body 2 comprises a recess 5 for housing the light source, and which is bounded by an entry surface 7 facing the light source, in use, to intercept the beam emitted by the light source. The axial
end 8 of body 2 opposite end 4 has an exit surface 9, through which the beam travelling through optical element 1 is emitted.
In the purely non-limiting example shown in Figures 1 and 2, entry surface 7 comprises a convex peripheral portion 10 connected by a substantially cylindrical collar 11 to a concave portion 12, while exit surface 9 is substantially flat. It is understood, however, that both entry surface 7 and exit surface 9 may be shaped otherwise than as shown, depending on the desired characteristics of the beam emitted by optical element 1. Body 2 comprises a dead hole 15, e.g. substantially cylindrical or truncated-cone-shaped, which extends along axis A from exit surface 9 towards end 4, and has a substantially flat bottom surface 16.
Optical element 1 comprises a number of adjacent portions 17 which together form body 2. More specifically, body 2 is defined by a radially outer shell portion 17a having an inner cavity 18, and by a core portion 17b inside cavity 18.
Shell portion 17a and core portion 17b are coaxial about axis A, and are made of respective different plastic (polymer) materials, i.e. having at least one different physical or optical characteristic, e.g. refraction index. For example, the respective materials from which shell portion 17a and core portion 17b are made may differ as to chemical nature, or may be of the same nature but with different additives (e.g. to obtain
a different colour, act as a specific light filter, impart mechanical strength or chemical protection, etc.). In one variation, portions 17 are made of the same material, e.g. polycarbonate or polymethyl methacrylate. Shell portion 17a and core portion 17b are joined along a boundary surface 20, which comprises a lateral portion 21 coaxial with axis A, and a bottom portion 22 substantially perpendicular to axis A and interposed, along axis A, between entry surface 7 and exit surface 9. Boundary surface 20 defines an auxiliary optical surface 23, which may be appropriately shaped, in particular as regards portion 22, to impart predetermined characteristics to the beam travelling through optical element 1. The method of producing optical element 1 will now be described with reference also to Figures 3 and 4, which show two schematic, simplified longitudinal sections of a mold 25 used in the production method and shown at respective steps in the method. Being substantially known, mold 25 is not described or illustrated in detail for the sake of simplicity. Mold 25 normally comprises two half-molds 26, 27, which mate to define a chamber 28 of the same shape as body 2 of optical element 1 being produced, and which can be parted to open mold 25.
Inside, mold 25 has inserts 29 defining, inside chamber 28, adjacent cavities 30 of the same shape as respective portions 17 of body 2. Optical element 1 is
formed in successive molding steps, in which portions 17 are molded one after the other by feeding respective quantities of plastic (polymer) material successively into cavities 30. In the example shown, shell portion 17a is first molded : as shown in Figure 3, an insert 29a is inserted inside chamber 28 to define a cavity 30a of the same shape as portion 17a of body 2, and a first plastic (polymer) material in the fluid state is injected into cavity 30a along a known feed conduit not shown. Core portion 17b is then molded : as shown in Figure 4, after removing insert 29a, an insert 29b defining hole 15 is inserted inside chamber 28 to define, between insert 29b and shell portion 17a, a cavity 30b of the same shape as core portion 17b; and a second plastic (polymer) material in the fluid state is injected into cavity 30b along a known feed conduit not shown.
The steps in the molding of portions 17 of body 2 may be performed using respective different materials having at least one different physical or optical characteristic, e.g. refraction index, or using respective quantities of the same material. Body 2 is eventually extracted from mold 25 in known manner.
In the Figure 5 variation, shell portion 17a and core portion 17b described with reference to Figures 1 and 2 are further divided into two half-shell portions 17c and two half-core portions 17d respectively. Half- shell portions 17c define two adjacent, symmetrical longitudinal halves, joined along a centreline plane M of
20
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body 2, of radially outer shell portion 17a; half-core portions 17d define two adjacent, symmetrical longitudinal halves, joined along the centreline plane M of body 2, of core portion 17b located radially inwards of shell portion 17a; and hole 15 is formed by joining two communicating recesses 31 formed in half-core portions 17d.
The method of producing the Figure 5 variation is the same as described above : mold 25 and inserts 29 again define cavities 30 shaped to mold portions 17, which are molded in respective successive molding steps from the same or different plastic (polymer) materials.
In the Figure 6 variation, only shell portion 17a is divided into two half-shell portions 17c. Body 2 is thus defined by two half-shell portions 17c and a core portion 17b, which are molded in respective separate successive molding steps .
In the Figure 7 variation, body 2 is divided into two portions 17e, 17f, defining two symmetrical longitudinal halves of body 2. Portions 17e, 17f are adjacent, are joined along the centreline plane M of body 2, and are molded in respective successive molding steps; and, in this case, too, hole 15 is formed by joining two communicating recesses 31 formed in portions 17e, 17f . In the Figure 8 and 9 variation, two adjacent portions 17g, 17h, substantially aligned along axis A, are molded successively. Portions 17g, 17h are joined along a boundary surface 20 substantially perpendicular
to axis A and defining the auxiliary optical surface, which may be appropriately shaped to impart predetermined characteristics to the beam travelling through optical element 1. Portion 17g has recess 5 defined by entry surface 7, and portion 17h has hole 15 and exit surface 9.
Clearly, changes may be made to the optical element and production method as described and illustrated herein without, however, departing from the scope of the present invention.