Optic and Apparatus for Making an Optic

• US 20160320018A1
• Filed: 05/01/2015
• Published: 11/03/2016
• Est. Priority Date: 05/01/2015
• Status: Active Grant

• Current Assignee: Signify Holding B.V. (Signify N.V.)
• Original Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Inventors: Gibbs, Anthony Ryan
• Granted Patent: US 10,041,646 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 2045/2677 The exchangeable mould parts being combinable or rearrangeable in different ways
• CPC Class Codes: B29C 39/00 Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor B29C41/00 takes precedence
• CPC Class Codes: B29C 45/2673 with exchangeable mould parts, e.g. cassette moulds B29C45/1756 takes precedence
• CPC Class Codes: B29D 11/00298 Producing lens arrays
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2011/0016 Lenses
• CPC Class Codes: B29L 2011/0075 Light guides, optical cables
• CPC Class Codes: B29L 2031/747 Lightning equipment
• 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 5/02 of prismatic shape F21V5/04 takes precedence
• CPC Class Codes: F21V 5/046 the lens having a rotationally symmetrical shape about an axis for transmitting light in a direction mainly perpendicular to this axis, e.g. ring or annular lens with light source disposed inside the ring
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G02B 19/0014 at least one surface having optical power
• 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

Abstract

An optic can manage light emitted by a light emitting diode. The optic can comprise a backside that faces the light emitting diode and a front side opposite the backside. The front side can be convex. The backside can have a central region that is adjacent the light emitting diode and that is either concave or convex. One or more grooves can extend peripherally about the central region. An injection molding system can produce optics in which the backside comprises the concave central region as well as optics in which the backside comprises the convex central region. The molding system can utilize one molding member shaped according to the front side of the optic. That molding member can be compatible with two other molding members that are shaped according to the different backsides of the optic. Thus, two different optic forms can be produced with three molding members.

Claims

1. A lighting system comprising:

a light emitting diode; and

an optic comprising;

a backside positioned to receive light from the light emitting diode; and

a front side that is opposite the backside and that is convex,

wherein the backside comprises;

a convex region disposed adjacent the light emitting diode;

a first groove circumscribing the convex region; and

a second groove circumscribing the convex region and the first groove.

2. The lighting system of claim 1, the optic comprising a protrusion that is disposed between the first groove and the second groove and that circumscribes the first groove and the convex region.

3. The lighting system of claim 2, wherein the protrusion comprises:

a first surface oriented towards the convex region; and

a second surface oriented away from the convex region, and

wherein the first groove provides space for peripheral light emitted by the light emitting diode to enter the optic through the first surface of the protrusion.

4. The lighting system of claim 3, wherein the second surface of the protrusion is operative to internally reflect the peripheral light that enters the optic through the first surface of the protrusion.

5. The lighting system of claim 4, wherein the second surface comprises a totally internally reflective surface.

6. The lighting system of claim 1, wherein the second groove is deeper than the first groove.

7. The lighting system of claim 1, wherein the light emitting diode comprises an array of light emitting diodes that the lighting system comprises, and

wherein the optic comprises an optical array aligned to the array of light emitting diodes.

8. A lighting system comprising:

a light emitting diode; and

an optic comprising;

a backside positioned to receive light from the light emitting diode; and

a front side that is opposite the backside and that comprises a convex region,

wherein the backside comprises;

a concave region disposed adjacent the light emitting diode; and

a groove circumscribing the concave region.

9. The lighting system of claim 8, wherein the optic comprises a protrusion that circumscribes the concave region and that is formed between the groove and the concave region.

10. The lighting system of claim 9, wherein the concave region comprises a first surface extending peripherally with respect to the concave region, and

wherein the protrusion comprises:

the first surface; and

a second surface oriented away from the concave region.

11. The lighting system of claim 10, wherein the second surface is totally internally reflective with respect to light that is produced by the light emitting diode and that enters the optic through the first surface.

12. The lighting system of claim 10, wherein the second surface is internally reflective.

13. The lighting system of claim 8, wherein the light emitting diode comprises an array of light emitting diodes that the lighting system comprises, and

wherein the optic comprises an optical array aligned to the array of light emitting diodes.

14. The lighting system of claim 8, wherein the concave region has a first depth,

wherein the groove has a second depth, and

wherein the first depth is within approximately thirty-five percent of the second depth.

15. The lighting system of claim 8, wherein the convex region of the front side is disposed to receive and refract light internally reflected from a surface of the groove.

16. The lighting system of claim 8, wherein the backside of the optic further comprises a flat surface that extends peripherally with respect to the groove.

17. A system for fabricating optics, the system comprising:

a first member;

a second member; and

a third member,

wherein the first member and the second member comprise a first injection mold for molding a first type of optic,

wherein the first member and the third member comprise a second injection mold for molding a second type of optic,

wherein the first type of optic and the second type of optic have a common front side form, and

wherein the first type of optic and the second type of optic have different backside forms for providing two different light distributions.

18. The system of claim 17, wherein the first type of optic comprises a first array of first optical elements, and

wherein the second type of optic comprises a second array of second optical elements.

19. The system of claim 17, further comprising a fourth member,

wherein the first member and the fourth member comprise a third injection mold for molding a third type of optic,

wherein the first type of optic, the second type of optic, and the third type of optic have the common front side form, and

wherein the first type of optic, the second type of optic, and the third type of optic have different backside forms for providing three different light distributions.

20. The system of claim 19, wherein the first type of optic comprises a first array of first optical elements,

wherein the second type of optic comprises a second array of second optical elements, and

wherein the third type of optic comprises a third array of third optical elements.