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Proceedings Paper

Replicative manufacturing of complex lighting optics by non-isothermal glass molding
Author(s): Holger Kreilkamp; Anh Tuan Vu; Olaf Dambon; Fritz Klocke
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Paper Abstract

The advantages of LED lighting, especially its energy efficiency and the long service life have led to a wide distribution of LED technology in the world. However, in order to make fully use of the great potential that LED lighting offers, complex optics are required to distribute the emitted light from the LED efficiently. Nowadays, many applications use polymer optics which can be manufactured at low costs. However, due to ever increasing luminous power, polymer optics reach their technological limits. Due to its outstanding properties, especially its temperature resistance, resistance against UV radiation and its long term stability, glass is the alternative material of choice for the use in LED optics. This research is introducing a new replicative glass manufacturing approach, namely non-isothermal glass molding (NGM) which is able to manufacture complex lighting optics in high volumes at competitive prices. The integration of FEM simulation at the early stage of the process development is presented and helps to guarantee a fast development cycle. A coupled thermo-mechanical model is used to define the geometry of the glass preform as well as to define the mold surface geometry. Furthermore, simulation is used to predict main process outcomes, especially in terms of resulting form accuracy of the molded optics. Experiments conducted on a commercially available molding machine are presented to validate the developed simulation model. Finally, the influence of distinct parameters on important process outcomes like form accuracy, surface roughness, birefringence, etc. is discussed.

Paper Details

Date Published: 27 September 2016
PDF: 13 pages
Proc. SPIE 9949, Polymer Optics and Molded Glass Optics: Design, Fabrication, and Materials 2016, 99490B (27 September 2016); doi: 10.1117/12.2235848
Show Author Affiliations
Holger Kreilkamp, Fraunhofer-Institut für Produktionstechnologie IPT (Germany)
Anh Tuan Vu, Fraunhofer-Institut für Produktionstechnologie IPT (Germany)
Olaf Dambon, Fraunhofer-Institut für Produktionstechnologie IPT (Germany)
Fritz Klocke, Fraunhofer-Institut für Produktionstechnologie IPT (Germany)

Published in SPIE Proceedings Vol. 9949:
Polymer Optics and Molded Glass Optics: Design, Fabrication, and Materials 2016
David H. Krevor; William S. Beich; Michael P. Schaub; Alan Symmons, Editor(s)

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