LIGHT DIFFUSERS AND METHODS FOR MANUFACTURING
A linear light module having an optical coupling element and a light pipe is described. The optical coupling element receives light emitted by multiple light emitting diodes (LEDs) having different emission wavelengths and couples the light efficiently to a linear light pipe. The light from the LEDs is efficiently mixed by the optical coupling element and the light pipe to produce a linear light output that is uniform in color and intensity. Light diffusers can be used with the optical coupling element and light pipe at various locations to further enhance the uniformity of the emitted light. Novel techniques for manufacturing the light diffusers that use patterning of a suspension solution or injection molding are described.
1 . A method of manufacturing a light diffuser comprising:
mixing scattering particles in a suspension solution;
applying controlled amounts of the mixture to a substrate having low losses at a wavelength of light to be diffused;
heating the substrate until the solution is cured,
wherein light striking the cured mixture on the substrate is scattered, and light striking the substrate without the mixture is transmitted with low loss.
2 . The method of claim 1 , wherein the scattering particles are approximately less than two microns in diameter.
3 . The method of claim 1 , wherein the scattering particles are Kaolin clay particles.
4 . The method of claim 1 , wherein the suspension solution is a silicone adhesive.
5 . The method of claim 1 , wherein applying controlled amounts of the mixture to the substrate comprises squeezing the mixture through a pattern of holes to deposit drops of the mixture onto the substrate.
6 . The method of claim 1 , wherein the substrate is a glass substrate.
7 . The method of claim 1 , wherein applying controlled amounts of the mixture to the substrate comprises spin-coating the mixture onto the substrate.
8 . The method of claim 1 , wherein applying controlled amounts of the mixture to the substrate comprises spraying the mixture onto the substrate.
9 . A light diffuser comprising:
a substrate;
a cured mixture cured on the substrate, wherein the mixture is applied to the substrate prior to curing, wherein the mixture comprises scattering particles dispersed in a suspension solution.
10 . The light diffuser of claim 9 , wherein the scattering particles are Kaolin clay particles.
11 . The light diffuser of claim 9 , wherein the suspension solution is silicone adhesive.
12 . The light diffuser of claim 9 , wherein the scattering particles are approximately less than two microns in diameter.
13 . The light diffuser of claim 9 , wherein the substrate is a glass substrate.
14 . A method of manufacturing a light diffuser, the method comprising:
mixing an injection moldable silicone with scattering particles to produce a resin;
injection molding the resin.
15 . The method of claim 14 , wherein the scattering particles are Kaolin clay particles.
16 . The method of claim 14 , wherein the scattering particles are approximately less than two microns in diameter.
17 . The diffuser manufactured by the method of claim 14 .