Hybrid lens for controlled light distribution

• US 10,468,566 B2
• Filed: 04/10/2017
• Issued: 11/05/2019
• Est. Priority Date: 04/10/2017
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Inventors: Tarsa, Eric, Wilcox, Kurt, Hou, Bin, Lowes, Ted
• Primary Examiner(s): Tumebo, Tsion
• Application Number:
  US15/483,096
• Publication Number:
  US 20180294389A1
• Time in Patent Office: 939 Days
• CPC Class Codes: F21V 5/007 Array of lenses or refractors for a cluster of light sources, e.g. for arrangement of multiple light sources in one plane combination of two or more refractors F21V5/008
• CPC Class Codes: F21V 5/045 the lens having discontinuous faces, e.g. Fresnel lenses
• CPC Class Codes: F21V 7/0091 using total internal reflection
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G02B 19/0028 refractive and reflective surfaces, e.g. non-imaging catadioptric systems
• CPC Class Codes: G02B 19/0061 the light source comprising a LED semiconductor devices with at least one potential-jump barrier or surface barrier specially adapted for light emission H01L33/00
• CPC Class Codes: G02B 19/0066 in the form of an LED array
• CPC Class Codes: G02B 19/0071 adapted to illuminate a complete hemisphere or a plane extending 360 degrees around the source
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 33/58 Optical field-shaping elements

Abstract

A lens for distribution of light predominantly toward a preferential side from a light emitter having an emitter axis. The lens has a faceted output region, a smooth output surface and at least one reflective surface which reflects light through total-internal-reflection (TIR) toward the faceted output region. The faceted output region is formed by pairs of transverse surfaces each surface of which redirects the received light to provide a composite illuminance pattern. The lens may further have faceted input surfaces at least partially defining a light-input cavity about the emitter axis. The faceted input region is formed by pairs of transverse surfaces each surface of which redirects the received light.

Claims

1. A lens for distribution of light from a light emitter having an emitter axis, the lens comprising an inner surface defining an inner cavity about the emitter axis, the inner surface comprising at least two distinct inner-surface stepwise discontinuities, one formed by a plurality of pairs of transverse inner regions having substantially curved projections on planes orthogonal to the emitter axis and the other formed by a plurality of pairs of transverse inner regions having substantially straight projections on planes orthogonal to the emitter axis.

2. The lens of claim 1 further comprising a secondary surface offset from the inner surface, the secondary surface being configured for total internal reflection (TIR) of light received from the inner surface.

3. The lens of claim 1 further comprising an outer surface including outer-surface stepwise discontinuities formed by a plurality of transverse outer regions.

4. The lens of claim 2 wherein at least some of the outer stepwise discontinuities are optically aligned over the secondary surface for receiving and redirecting light reflected by the secondary surface.

5. The lens of claim 3 wherein the outer surface comprises at least one smooth outer region adjacent to the outer stepwise discontinuities.

6. The lens of claim 4 wherein the outer-surface stepwise discontinuities are between a pair of smooth outer regions which are non-planar.

7. The lens of claim 5 wherein adjacent transverse inner and outer regions extend to substantially parallel intersection regions therebetween, the intersection regions of some of the outer-surface stepwise discontinuities are transverse to at least one intersection region of another outer-surface stepwise discontinuity.

8. The lens of claim 7 wherein at least some of the transverse inner regions are configured for total internal reflection (TIR) of the light received from the emitter.

9. The lens of claim 1 wherein:

the inner stepwise discontinuities comprise longitudinally substantially straight intersection regions each adjoining a pair of the substantially planar inner regions; and

the inner stepwise discontinuities comprise intersection regions extending along a curve between adjacent transverse curved inner regions.

10. The lens of claim 1 wherein the transverse inner regions proximal the emitter axis have smaller cross-sectional dimensions than the transverse inner regions distal from the light emitter.

11. The lens of claim 2 wherein the secondary surface at least partially bounds a secondary cavity offset from the inner cavity.

12. The lens of claim 3 wherein:

the outer surface comprises a smooth outer region; and

at least one of the sets of the inner stepwise discontinuities redirects emitter light toward a smooth outer region.

13. A lens for distribution of light from a light emitter having an emitter axis, the lens comprising:

an inner surface defining an inner cavity about the emitter axis, the inner surface comprising inner-surface stepwise discontinuities formed by a plurality of transverse inner regions each redirecting light received from the emitter;

a secondary surface offset from the inner surface, the secondary surface being configured for total internal reflection (TIR) of light received from the inner surface the secondary surface comprising a plurality of transverse reflecting regions forming reflecting stepwise discontinuities; and

an outer surface receiving redirected emitter light and comprising outer-surface stepwise discontinuities formed by a plurality of transverse outer regions each redirecting the received light.

14. The lens of claim 13 wherein the plurality of transverse outer regions extend to substantially parallel intersection regions therebetween.

15. A lens for distribution of light from a light emitter having an emitter axis, the lens comprising:

an inner surface defining an inner cavity about the emitter axis, the inner surface comprising inner-surface stepwise discontinuities formed by a plurality of pairs of transverse inner regions with intersection regions therebetween, each of the transverse inner regions redirecting light received from the emitter; and

at least two secondary surface portions spaced apart and extending along opposite sides of the inner surface transversely to the intersection regions of the inner-surface stepwise discontinuities, the secondary surface portions being configured for total internal reflection (TIR) of light received from the inner surface.

16. The lens of claim 15 wherein the secondary surface portions are separate surfaces substantially opposite each other.

17. The lens of claim 15 further comprising an outer surface comprising outer-surface stepwise discontinuities formed by a plurality of transverse outer regions.

18. The lens of claim 17 wherein the outer surface comprises outer stepwise discontinuities corresponding to each of the secondary surfaces for receiving and further redirecting light reflected by the corresponding secondary surfaces.

19. The lens of claim 17 wherein the outer surface comprises at least two sets of transverse outer regions forming a corresponding number of distinct outer stepwise discontinuities, one of the sets being outward of the other for receiving light from corresponding regions of the corresponding secondary surface portion.

20. The lens of claim 19 wherein the outer surface comprises at least one smooth outer region between a pair of the outer-surface stepwise discontinuities.

21. The lens of claim 19 wherein at least two of the distinct outer stepwise discontinuities are optically aligned over each of the at least two of the secondary surface portions.

22. An LED light fixture comprising a heat-sink structure having a mounting surface supporting an LED arrangement which comprises plurality of spaced apart LED light sources and a plurality of lenses each optically coupled with a corresponding one of the light sources, the lens comprising an outer light-output surface and an inner light-input surface which defines an inner cavity about the emitter axis, the inner surface comprising at least two sets of distinct inner-surface stepwise discontinuities each formed by a plurality of pairs of transverse inner surfaces with intersection regions therebetween, the intersection regions of at least one of the sets having curved projections, and at least one other of the sets having substantially straight projections, the projections being on planes orthogonal to the emitter axis.

23. The light fixture of claim 22 wherein each lens further comprises at least one secondary surface offset from the inner surface, the at least one secondary surface being configured for total internal reflection (TIR) of light received from the inner surface and comprising a plurality of transverse reflecting regions forming reflecting stepwise discontinuities.

24. The lens of claim 23 wherein the outer surface comprises outer-surface stepwise discontinuities formed by a plurality of transverse outer regions each redirecting the received light.

25. A lens for distribution of light from a light emitter having an emitter axis, the lens comprising at least two distinct sets of faceted input regions each passing received light therethrough and each being formed by a plurality of pairs of adjacent transverse surfaces extending to elongate adjoining regions, at least one set of the elongate adjoining regions having curved projections, and at least one other set having substantially straight projections, the projections being on planes orthogonal to the emitter axis.

26. The lens of claim 25 further comprising faceted and smooth output regions, each of the faceted input regions being axially aligned with one of the smooth and faceted output regions.

27. The lens of claim 26 further comprising at least one reflective surface reflecting light through total-internal-reflection (TIR).

28. The lens of claim 27 wherein the at least one reflective surface at least partially bounds a reflection cavity offset from the light-input cavity.

29. The lens of claim 26 wherein the faceted output regions comprise major and minor surfaces.

30. The lens of claim 29 wherein the minor surfaces are formed by transverse surface portions with cross-sectional dimensions smaller than cross-sectional dimensions of transverse surface portions of the major surfaces.

31. The lens of claim 26 wherein each faceted output region is formed by pairs of adjacent transverse surfaces each of which redirects the received light to provide a composite illuminance pattern, the pairs of adjacent transverse surfaces of the faceted output regions extending to substantially straight intersection regions substantially parallel to each other.

32. The lens of claim 25 wherein the pairs of adjacent transverse surfaces of the at least two faceted input regions extend to substantially curved intersection regions substantially parallel to each other.