To see the complete range of POL Hybrid Reflector Optics for specific LED packages
|Conventional reflectors manage to control the off-axis light from the source, but don’t control the light that misses the top edge of the reflector, so a lot of light is wasted into a halo around the central spot beam.|
|The POL Hybrid Reflector design uses a central lens to collect and collimate the on-axis light from the LED.In this way, the light collection efficiency can be driven up to >90% with a more controlled, narrower, higher intensity beam.|
To make the Hybrid Reflector products, POL has developed a novel in-mould production process to make the reflector and integration features in one process and provide easy assembly of the central lens and modular LED mounting.
Highly reflective metal shim used with 95-98% reflectivity.
Hard anodized metal has very good chemical resistance and scratch resistance.
|Flat die-cut reflective metal||Metal shim pressed into shape in mould tool||Support frame and mounting features injection moulded around metal||Central lens clipped in place and LED mounting assembled|
|The perfect colour mixing can be achieved with the POL Colour Mixer Hybrid Reflector optics, allowing an infinite range of illumination colours to be produced with a constant and stable beam geometry.An additional advantage is that the appearance of the emitted light from the optic is a uniform mixed colour too, removing the usual visible spots of RGB seen in other colour mixing approaches.|
|POL also produce reflector products by conventional metal spinning and using vacuum metallisation of plastic moulded reflector substrates, but similarly POL can integrate the Hybrid Reflector central lens component into these other production routes.|
An additional modular design approach is to use beam converter optics fitted over the standard reflectors to give different beam angles . This approach gives a modular, flexible product design with the minimum number of component parts. The beam converter optics are either supplier pre-assembled to the base reflector product or can be supplied separately, so that customers can customise product assemblies at point of manufacture or point of installation.
The POL Hybrid Reflector products can also be fitted with a novel optical integrator design to provide beam smoothing and colour variation mixing with multi-die and COB LED arrays.
This technique can also give a constant beam angle using the same 60mm reflector form factor, with which ever LED array size is used or can give different beam angles with the same 60mm reflector form factor, using the same LED array size. In this way very versatile and modular lighting systems can be produced.
|The novel POL optical integrator design approach also allows simple modular lighting products to be developed:Components snap-fit together to produce a modular assembly
Allows point of assembly or point of installation customisation
Range of beam angles and system powers made from same base parts – same reflector, light engine format and adaptor
The only component that has to be changed to produce different beam angles and beam shapes is the integrator-converter
The latest computer optical design and ray trace programs with optomechanical innovation are used to take full advantage of plastics materials. Complex optical surfaces combined with integral low cost assembly features.
SLA (Stereolithography), SLS (Selective Laser Sintering), Clear SLA, SLA to Vacuum Casting, Direct Machining and Tooling options.
Proven optical quality toolmakers are chosen and assisted by mould flow analysis to optimize the tool. Our specialist toolmakers are skilled in optical surface generation and polishing.
Our moulders are trained in the art of optical moulding. Mould flow process analysis and thorough F.M.E.A. is controlled by the Project Manager to ensure quality and quantity.
Our integrated approach to design enables optical components to become part of the total solution, including how they interface with the other non-optical components.
Plastics optical components can be coated in poly-siloxane and acrylate based resin blends to impart more robust properties.
Polymer Optics Limited
The Hall, Priory Hill, Rugby Road, Wolston, Coventry CV8 3FZ
+44 (0)2476 937394
Polymer Optics “Modular LED Optics”® design, based on a patented hexagonal format, allows maximum packing density and assembly flexibility for a wide range of applications.
We have also developed specialist optics for the latest range of high power UV LEDs emerging onto the market. These are made from high quality optical silicone to give excellent UV transmission with no long term degradation. See POL’s Silicone Optics page for further details.
We design and supply a comprehensive range of high quality, standard products for use with most world-leading LED devices
Hybrid Reflector design uses a central lens to collect and collimate the on-axis light from the LED.
Our expertise in efficient light control in Lightguide assemblies, enables a lower number of LEDs to achieve the maximum performance.
Free-Form optics are a relatively recent development which offer a step change in the way wide areas are illuminated by LEDs.
Our "engineering with light" approach allows us to provide product solutions for all applications across the whole spectrum from Visible to Infrared.
Developed tooling techniques enable us to produce precision optical surfaces with optical apertures of less than 1mm in diameter, required for miniature camera lens applications.
Our design approach, using light scattering pattern techniques, have enabled us to provide high efficiency display illuminations with very compact space envelopes, which use the minimum of light sources and electrical power consumption.
Our experience in designing and developing ophthalmic products, enables us to provide precision, impact resistant, eye protection optics for applications such as: fire protection, motor cycle visors, industrial PPE and military systems.
Polymer Optics have designed and manufactured a range of optics for street lighting, to meet both the ME and S class regimes of EN13201-2 in Europe and the requirements of IESNA RP-8-00 in the USA.
Emergency Lighting and Visual Alarm Devices are applications where light from an LED has to be efficiently distributed over a wide area. POL’s free form optics technology is particularly suited for applications which require wide area illumination.
POL can now provide advanced optical product design and rapid manufacture in the latest silicone resins to gain design and cost advantages in our customers’ applications.
Our patented prismatic colour mixing optic was introduced to enable good colour mixing, for narrow beam angle systems, using three discrete LED sources.
Brand named “GloWorm®”, the novel lightguide technology enables the light projected from a simple lightguide to be redirected and shaped