Harold Brunt Optomechanical Designer, Corporate Officer, VP LumenFlow Corp. Board Member, United Lumen, LLC

Transcription

1 6/22/ Harold Brunt Optomechanical Designer, Corporate Officer, VP LumenFlow Corp. Board Member, United Lumen, LLC LumenFlow Corp. is a Photonics Engineering, Consulting and small manufacturing company located in Wyoming, Michigan. We offer an interdisciplinary approach to photonics problem solving specializing in: Precision Optics Visible, NIR & IR Lens Assemblies Instrument Grade Lasers Machine Vision Illumination LED Optics & Systems Engineering LumenFlow Corp. sits on the Board for the MSSLA and MI-Light. LumenFlow s Patented 360 View Lens

2 6/22/ Harold Brunt Optomechanical Designer, Corporate Officer, VP LumenFlow Corp. Board Member, United Lumen, LLC LumenFlow Corp. is a Photonics Engineering, Consulting and small manufacturing company located in Wyoming, Michigan. We offer an interdisciplinary approach to photonics problem solving specializing in: Precision Optics Visible, NIR & IR Lens Assemblies Instrument Grade Lasers Machine Vision Illumination LED Optics & Systems Engineering LumenFlow Corp. sits on the Board for the MSSLA and MI-Light. LumenFlow s Patented 360 View Lens

3 6/22/ For Optical Engineering, Ray Trace, and Lighting Simulation LumenFlow Corp. utilizes: Zemax OpticStudio 16.5 Zemax LensMechanix Add-In for SolidWorks OptisWorks 2016 Add-In for SolidWorks 2016 with: ODESIS (Optical Design) package SPEOS for SolidWorks 2017 Add-In with: Photometry Package Colorimetry Analyzer Option Mass Fluorescent Materials Generator Option 3D Texture Option Multi-Threading 16 Threads Option LumenFlow has been a licensed Zemax user since 2000, a SolidWorks user since 2002, and an OptisWorks user since 2005.

4 6/22/ A product does not need to be complex to benefit from the investment in simulation even after initial prototype. Simulation of the performance and making corrections in the design prior to making tooling commitments saves significant time and money. The ClipCleany Pet Product Simulation after optimization The ClipCleany Pet Product As it appeared on ABC News

5 6/22/ LumenFlow can optimize a simple consumer LED lighting design or take a complex laser based instrument from concept prototype to manufacturing. Laser Based cylindrical object measurement System concept ray trace, casting print, assembly & alignment

6 6/22/ LumenFlow produces a series of VIS, NIR and IR lenses for instrumentation. The Lens elements and machined components are all sourced in the USA. LumenFlow VIS, NIR & IR Lenses for Instrumentation from ray trace, to component sourcing to manufacturing

7 6/22/ LumenFlow designed a unique Machine Vision Lens System which will allow a user to view a cylindrical surface as a flat image in one view with one camera. Optional optics create the flexibility of internal or external surface inspection with up to 40μm resolution. LumenFlow 360 External View Lens System The Sample as viewed on screen (left) Etching Detail analyzed by third party software

8 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: Our work with Dow Corning Corporation Moldable Optical Silicones started with the development of our LED remote phosphor technology in LumenFlow LED on Display in Dow Corning Corporation s LightFair International 2013 Booth (Left), LumenFlow Mini HEOC Sample for 2014 Booth (Right)

9 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: LumenFlow has been a technical resource at LightFair International for Dow Corning Corporation from 2013 through 2016 and was a co-exhibitor in LumenFlow Compound Optic Kiosk for Dow Corning Corporation s LightFair International 2015 Booth

10 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: LumenFlow has characterized Dow Corning Moldable Optical Silicones to generate material and surface definition files for SPEOSsoftware: Materials such as MS-1002 and MS-4007, and surfaces for multiple cross-sections and specular and matte finishes of MS LumenFlow designed the Wide Angle Reflector using Dow Corning MS-2002 moldable White Reflector Silicone. Wide Angle Reflector Design, Molded Part, and output with LED source

11 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: LumenFlow designed the Compound Optic using ODESIS (Optical Design) package and SPEOS for SolidWorks The Compound Optic is molded using Dow Corning MS-1002 and is a replacement for a thermoplastic TIR in a machine vision application. Design features: Two lenses joined along the center by a light pipe. Narrow angle output from the source along the center of the optic is shaped by a single lens (two surfaces). Wide angle output is shaped by two lenses (four surfaces).

12 6/22/ LumenFlow and Dow Corning Corporation Moldable Optical Silicones: Predicting the performance of complex structures is made possible by creating those features in the CAD model. LumenFlow designed a Reflector Array for an Acorn Style Street Light using Dow Corning MS-2002 moldable White Reflector Silicone. The Brandon Industries, Inc. Acorn Street Light Product

13 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: Dow Corning Optical Silicone is capable of replicating very fine features. Small features are useful as diffusors for example but will severely tax CAD system resources. LumenFlow has been working with Dow Corning and Tenibac Graphionto model, simulate and measure several available textures. Existing textures are measured and then modeled using the SPEOS for SolidWorks D Texture Option. MaxIM DL Image of Tenibac Graphion tif file (Left), Multiple profile cross sections (Right)

14 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: The profile cross sections exported from the image processing software are scaled using data from measurements made using a Keyence optical microscope system. Keyence Image of Tenibac Graphion textured tool (Left), Molded Silicone part (Right)

15 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: The profile cross sections exported from the image processing software are scaled using data from measurements made using a Keyence optical microscope system. SPEOS for SolidWorks D Texture (Left), SPEOS simulation output at 10mm (Right)

16 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: The goal for the demonstration textures is to provide lighting designers the opportunity to trial optical silicone and known existing textures in their designs. As files are verified and measured the textures will be made available as BSDF surface files. The idea is to: Model an existing texture Test and verify the model Create a BSDF file for customers Also providing the option so that: If a customer does not have the 3D Texture Option, LumenFlow will create a texture Dow Corning will prototype, test and measure Create a BSDF file for the customer Watch this space for a white paper describing the process and for more moldable optical silicone designs:

17 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: The LumenFlow Under Cabinet Strip Lightincludes a design that minimizes the optic size while directing the light where needed. Traditional thermoplastic diffusors will often introduce a shift in color temperature as well as a significant loss in output. Injection moldable optical silicone from Dow Corning Corporation also allows the design to incorporate robust snap assembly and sealing features. Tenibac-Graphion texture designed in SPEOS for SolidWorks (Left), Detail of Strip Light Optic (Center), Output pattern, measured for eight (8) LED single Optic section (Right)

18 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: The desires for low glare and reduced hot spots are realized with a low-profile design that introduces no changes to the LED output such as color separation or change in color temperature. SPEOS for SolidWorks 2017 Simulation (Left), Detail of Strip Light Glare (Right): LumenFlow Corp. Optic Design (Left), Diffusing Thermoplastic (Center), Clear Thermoplastic (Right).

19 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: Often there are applications for fixture designers creating low cost LED linear lighting where the challenge of putting light where it is needed is compounded with the requirement of directing the light away from where it is not wanted. Asymmetric undercut features and unique textures were utilized by LumenFlow Corp. in a design made possible using Dow Corning moldable optical silicone for a low-profile Wall Wash. Tenibac-Graphion texture designed in SPEOS for SolidWorks (Left), Output pattern, measured for eight (8) LED single Optic section (Right)

20 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: Information such as product identification, branding, or ownership is often communicated using low cost LED illumination and projection. LumenFlow designed the Projector Optics using SPEOS for SolidWorks The Optics are molded using Dow Corning MS-1002 and the projector is an exterior automotive application. Basic User generated file (Left), Complete User generated file (Right)

21 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: To compare the simulation results and to assess the differences for material definitionsfor Dow Corning MS-1002 our projector was used consisting of a commercially available LED, and a grid pattern film. Image and Detail from: Basic User generated file (Left), Complete User generated file (Right)

22 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: Projected Image from Prototype (Left), RGB Profile (Center), Monochromatic (Right)

23 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: How accurate is accurate enough?does it really matter all that much? Basic User generated file (Left), Complete User generated file (Right) Normalized Cross Correlation (NCC) and Root Mean Square Error (RMS): Basic User generated file: NCC = 86.2%, RMS = 12.1% Complete User generated file: NCC = 97.4%, RMS = 8.0%

24 6/22/ Material Definition Refractive Index (Index Variation) The Index Variation data field is completed using the index of refraction as measured by Dow Corning using a Varian Cary 5000 UV-Vis-NIR spectrophotometer re-ordered from the provided 850nm 300nm to 400nm 700nm. Absorption & Scattering Properties To complete the Absorption Variation and Scattering Variation data fields, throughput data at multiple wavelengths was used as the fixed points in a curve fitting algorithm to generate the absorption and scatter coefficients from 400nm to 700nm. For each wavelength (λ), measure the output of a laser source at the input (T 0 ) and in the far field (T 1 ) after exiting a sample material rod in multiple lengths (x). Calculate the transmission T for each wavelength for the rod samples. For each length and wavelength: T = T 1 /T 0. Calculate the extinction coefficient α T for each wavelength and sample, where T 1 /T 0 = T = exp(-α T x), and α T = - ln(t)/x

25 6/22/ Absorption & Scattering Properties, continued Generate the extinction coefficient relation for the wavelengths between 400nm and 700nm using a curve fit function, whereby the goodness of fit was maximized by the optimization of NCC and RMS values for light intensity over the length of the sample rod. The extinction coefficient equals the sum of the absorption (α ) and scatter (μ) coefficients so that: α T (λ) = α (λ) + μ(λ). The curve fit function approximates α using C 1 /λ n1 and μ using C 2 /λ n2 where C is a constant and n is the exponent of the wavelength. Note that the scatter relation and phase angles will be a mix between Rayleigh and Mie, due to the complex nature of this material, therefore it is necessary to use a 1/ λ n relation, where n 1 = 1 and 2 n 2 4 and is determined by a best fit. The Henyey-Greenstein formula is selected over Mie in the OptisWorks Scattering properties Tab in order to minimize simulation times. The curve fit variables are calculated for best fit for the formula: (C 1 /λ n1 ) + (C 2 /λ n2 )

26 6/22/ Absorption and Scattering Properties, continued Measurement data for scatter from the side surface of a 50mm rod, in addition to the near and far field throughput data, was used to calculate the ratio between scatter and absorption. The extinction coefficient curve is multiplied by the calculated ratio to generate the absorption (α ) and scatter (μ) coefficient curves. Selecting the Henyey-Greenstein formula option automatically populates the table with the Anisotropy Factor setting of.900. Surface Definitions Scatter & Reflectivity To populate the advanced scattering surface data field, the surface reflectivity from 300nm to 800nm in 25nm increments are generated using a best fit curve Fresnel calculator to generate the Real and imaginary components of the Reflection Coefficient referencing the reflectivity for the given wavelength at 5 as measured by Dow Corning using a Varian Cary 5000 UV-Vis-NIR spectrophotometer.

27 6/22/ Scatter & Reflectivity, continued The values for n and k are assigned as variables and are adjusted so that the difference squared between the measured reflectivity at 5 and the calculated reflectivity is minimized. The calculator is an excel spreadsheet using the formulas: R p = [((n 2 +k 2 )cosθ 2 )-(2ncosΘ 2 +1)] / [((n 2 +k 2 )cosθ 2 )+(2ncosΘ 2 +1)] 2 R s = [(n 2 +k 2 )-(2ncosΘ)+cosΘ 2 ] / [(n 2 +k 2 )-(2ncosΘ)+cosΘ 2 ] 2 R = (R p + R s )/2 Where: R p = Reflection Coefficient of p polarized light R s = Reflection Coefficient of s polarized light R = Random Reflection Coefficient of the averaged R p andr s values.

28 6/22/ The Normalized Cross Correlation (NCC) and the Root Mean Square (RMS) error The NCC is calculated using the formula: NCC = [I Θsn - Ī sn ][I Θen - Ī en ] / ( [I Θsn - Ī sn ] 2 [I Θen - Ī en ] 2 ) Where: I Θsn is the simulated data and I Θen is the measured data, and Ī sn is the simulated data and Ī en is the measured data Mean value. The NCC% is considered acceptable when the value exceeds 99%. The RMS error is calculated using the formula: RMS = ((1/M) (I Θen - I Θsn ) 2 ) Where: M is the number of data points. The RMS% is considered acceptable when the value is less than 5%.

29 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: When the desired image is a bright white projection the edge is usually separated into a rainbow which can cause an image to appear to be out of focus. LumenFlow Corp. is developing an all silicone design that reduces chromatic aberrations which are normally seen as color separation at the edge of the image. Detail of color separation, 0.01mm projected feature: Polycarbonate system (Top), all silicone Design (Bottom)

30 6/22/ LumenFlowand Dow Corning Corporation Moldable Optical Silicones: LumenFlow continues to design demonstration optics and characterize materials for Dow Corning Corporation and Dow Corning Corporation continues to display and mold our proprietary designs for the benefit of their customers. More moldable optical silicone designs:

31 6/22/ The software and what it enables us to accomplish continues to be a major part of our business for our own product development and the services we offer our clients. There are several simulation software packages on the market but it has been the exceptional technical support we have received over the years in addition to the software s capabilities that insures that we will remain an Optis customer.

32 6/22/ THANK YOU! 3685 Hagen Drive SE Suite B, Wyoming, MI