Optical elements with internal optical features and methods of fabricating same

Abstract

An optical element, comprising a substrate and at least one optical film. The substrate is at least partially light-transmissive. The optical film comprises at least a first optical feature and is positioned on a contact surface of the substrate. Also, a lighting device comprising at least one solid state light emitter and such an optical element. Also, methods for making an optical element by molding (e.g., film insert molding), bonding or laminating.

1 . A method of making an optical element, comprising:
 positioning within a mold at least one optical film, the optical film comprising at least a first optical feature;   feeding into the mold at least one flowable substrate material;   solidifying the at least one flowable substrate material to form a substrate, the substrate at least partially light-transmissive and comprising a contact surface which is in contact with the optical film.   
     
     
         2 . A method as recited in  claim 1 , wherein after said solidifying, the optical film is in direct contact with the contact surface of the substrate. 
     
     
         3 . A method as recited in  claim 1 , wherein:
 the optical film comprises an optical film first surface and an optical film second surface,   after said solidifying, the optical film second surface is in contact with the contact surface of the substrate, and   the optical film second surface is substantially smooth.   
     
     
         4 . A method as recited in  claim 1 , wherein:
 the optical film comprises an optical film first surface and an optical film second surface,   after said solidifying, the optical film second surface is in contact with the contact surface of the substrate,   the optical film comprises at least a first layer and a second layer,   a first layer first surface of the first layer comprises the optical film first surface,   the first layer further comprises a first layer second surface,   the first optical feature is on the first layer second surface,   a second layer second surface of the second layer comprises the optical film second surface,   the second layer further comprises a second layer first surface, and   the first layer second surface is in contact with the second layer first surface.   
     
     
         5 . A method as recited in  claim 4 , wherein the second layer second surface is substantially smooth. 
     
     
         6 . A method as recited in  claim 1 , wherein:
 the optical film comprises a first layer,   the first layer comprises a first layer first surface and a first layer second surface   after said solidifying, the first layer second surface is in contact with the contact surface of the substrate,   the first optical feature is on the first layer first surface.   
     
     
         7 . A method as recited in  claim 6 , wherein the first layer second surface is substantially smooth. 
     
     
         8 . A method as recited in  claim 1 , wherein the substrate is substantially translucent. 
     
     
         9 . A method as recited in  claim 1 , wherein the substrate is substantially transparent. 
     
     
         10 . A method as recited in  claim 1 , wherein the substrate is lens-shaped. 
     
     
         11 . A method as recited in  claim 1 , wherein the substrate comprises a substrate second surface, the substrate second surface comprising at least a second optical feature. 
     
     
         12 . A method of making an optical element, comprising:
 applying at least one adhesive to at least one of an optical film and a substrate; and   bringing the optical film and the substrate together so that the optical film and the substrate are in contact with each other and at least a portion of the adhesive is between the optical film and the substrate,   the optical film comprising at least a first optical feature,   the substrate at least partially light-transmissive.   
     
     
         13 . A method as recited in  claim 12 , wherein:
 the optical film comprises an optical film first surface and an optical film second surface,   said bringing the optical film and the substrate together comprises bringing the optical film second surface into contact with the contact surface of the substrate, and   the optical film second surface is substantially smooth.   
     
     
         14 . A method as recited in  claim 12 , wherein:
 the optical film comprises an optical film first surface and an optical film second surface,   said bringing the optical film and the substrate together comprises bringing the optical film second surface into contact with the contact surface of the substrate,   the optical film comprises at least a first layer and a second layer,   a first layer first surface of the first layer comprises the optical film first surface,   the first layer further comprises a first layer second surface,   the first optical feature is on the first layer second surface,   a second layer second surface of the second layer comprises the optical film second surface,   the second layer further comprises a second layer first surface, and   the first layer second surface is in contact with the second layer first surface.   
     
     
         15 . A method as recited in  claim 14 , wherein the second layer second surface is substantially smooth. 
     
     
         16 . A method of making an optical element, comprising:
 laminating an optical film to a substrate such that the optical film is in contact with the substrate,   the optical film comprising at least a first optical feature,   the substrate at least partially light-transmissive.   
     
     
         17 . A method as recited in  claim 16 , wherein:
 the optical film comprises an optical film first surface and an optical film second surface,   said laminating an optical film to a substrate comprises bringing the optical film second surface into contact with the contact surface of the substrate, and   the optical film second surface is substantially smooth.   
     
     
         18 . A method as recited in  claim 16 , wherein:
 the optical film comprises an optical film first surface and an optical film second surface,   said laminating an optical film to a substrate comprises bringing the optical film second surface into contact with the contact surface of the substrate,   the optical film comprises at least a first layer and a second layer,   a first layer first surface of the first layer comprises the optical film first surface,   the first layer further comprises a first layer second surface,   the first optical feature is on the first layer second surface,   a second layer second surface of the second layer comprises the optical film second surface,   the second layer further comprises a second layer first surface, and   the first layer second surface is in contact with the second layer first surface.   
     
     
         19 . A method as recited in  claim 18 , wherein the second layer second surface is substantially smooth. 
     
     
         20 . A method as recited in  claim 16 , wherein:
 the optical film comprises a first layer,   the first layer comprises a first layer first surface and a first layer second surface   said laminating an optical film to a substrate comprises bringing the first layer second surface into contact with the contact surface of the substrate,   the first optical feature is on the first layer first surface.