Thin-sheet collimation optics for diode laser illumination systems for use in night vision and exterior lighting applications

• US 6,422,713 B1
• Filed: 10/17/2000
• Issued: 07/23/2002
• Est. Priority Date: 10/17/2000
• Status: Expired due to Term

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Weber, Willes H., Fohl, Timothy, Remillard, Jeffrey Thomas
• Primary Examiner(s): Sember, Thomas M.
• Assistant Examiner(s): DELGIZZI, RONALD ERNEST
• Application Number:
  US09/688,992
• Time in Patent Office: 644 Days
• Field of Search: 362/31, 362/26, 362/297, 362/339, 385/146
• US Class Current: 362/600
• CPC Class Codes: G02B 27/09 Beam shaping, e.g. changing the cross-sectional area, not otherwise provided for adapting the beam shape of a laser diode G02B19/0052; adapting the beam shape of an LED G02B19/0061; coupling into light guides using intermediate optical elements G02B6/4204; beam shaping specially adapted for lasers H01S3/005

Abstract

An optical element, a lighting system utilizing the optical element and a method of manipulating light from a source to provide an illumination pattern suitable for use in a night vision system and exterior lighting applications is disclosed. The optical element has an input surface and an output surface disposed at approximately perpendicular to the input surface. A stepped surface angles between the input surface and the output surface intersecting the light inside the optical element. Multiple facets are formed in the stepped surface to reflect the light towards the output surface. The input, stepped and output surfaces are arranged such that the light reflects only from the stepped surface. The optical element has a rectangular shape in one embodiment and a wedge shape in a second embodiment.

Claims

1. An optical element for directing a light, the optical element comprising:

an input surface for receiving the light;

an output surface generally perpendicular to the input surface for emitting the light; and

a stepped surface angling between the input surface and the output surface, the stepped surface having a plurality of reflecting facets arranged so that the light is reflected only by the plurality of reflecting facets in passing from the input surface to the output surface.

2. The optical element of claim 1 further comprising a curvilinear shape of the input surface for collimating the light in a first plane parallel to the output surface.

3. The optical element of claim 2 wherein the curvilinear shape diverges the light in a second plane perpendicular to the output surface.

4. The optical element of claim 2 wherein the curvilinear shape collimates the light in a second plane perpendicular to the output surface.

5. The optical element of claim 1 further comprising a curvilinear shape of the input surface for diverging the light in a first plane parallel to the output surface.

6. The optical element of claim 1 wherein the plurality of facets arc about an axis normal to the output surface.

7. The optical element of claim 1 further comprising:

an output area of the output surface; and

an input area of the input surface, the input area being no greater than ten percent of the output area.

8. A lighting system comprising:

a source of a light, the light being divergent in an emission pattern; and

an optical element disposed a predetermined distance from the source, the optical element having an input surface for receiving the light from the source, an output surface approximately perpendicular to the input surface for emitting the light, and a stepped surface angled between the input surface and the output surface, the stepped surface having a plurality of reflecting facets arranged so that the light is reflected only by the plurality of reflecting facets in passing from the input surface to the output surface, the predetermined distance for spatially expanding the emission pattern of the light prior to the input surface.

9. The lighting system of claim 8 further comprising a first dimension of the input surface such that the emission pattern approximately fills the first dimension at the input surface.

10. The lighting system of claim 9 further comprising a second dimension of the input surface such that the emission pattern approximately fills the second dimension at the input surface.

11. The lighting system of claim 8 further comprising a second optical element disposed between the source and the optical element for broadening the emission pattern in a plane parallel to the output surface.

12. The lighting system of claim 8 wherein the plurality of facets arc about an axis normal to the output surface.

13. The lighting system of claim 12 further comprising:

the source being positioned at approximately the axis, and the source having an emission divergent angle measured normal to the axis; and

the plurality of facets arcing through an angle measured normal to the axis, the angle of the plurality of facets being at least as great as the emission divergence angle of the source.

14. A method for manipulating a light emitted from a source, the light being divergent in an emission pattern from the source, the method comprising:

spatially expanding the emission pattern of the light over a predetermined distance between the source and an optical element;

inserting the light into an input surface of the optical element in response to spatially expanding the emission pattern;

reflecting the light only from a plurality of facets formed in a stepped surface of the optical element in response to inserting the light; and

emitting the light from an output surface of the optical element in response to reflecting the light.

15. The method of claim 14 further comprising collimating the light in a first plane parallel to the output surface in response to spatially expanding the light.

16. The method of claim 15 further comprising diverging the light in a second plane perpendicular to the output surface in response to spatially expanding the light.

17. The method of claim 15 further comprising collimating the light in a second plane perpendicular to the output surface in response to spatially expanding the light.

18. The method of claim 14 further comprising broadening the emission pattern in a plane parallel to the output surface while spatially expanding the emission pattern.

19. A thin sheet optical element comprising:

an aspherical entrance surface for collimating light passing through the entrance surface;

a substantially planar exit surface generally perpendicular to an axis of symmetry of the entrance surface; and

a stepped surface opposing the substantially planar exit surface having a plurality of steps generally parallel to the exit surface separated by associated angled facets disposed at an angle to reflect the light passing through the entrance surface through the optical element and out the exit surface.

20. The optical element of claim 19 wherein at least one of the angled facets is disposed at an angle to provide total internal reflection of light from the entrance surface through the optical element and out the exit surface.

21. The optical element of claim 20 wherein the at least one angled facet is disposed at an angle of about forty-five degrees.

22. The optical element of claim 19 wherein the aspherical entrance surface, the exit surface, and the stepped surface are fabricated from plastic.

23. The optical element of claim 22 wherein the aspherical entrance surface, the exit surface, and the stepped surface are fabricated from polycarbonate.

24. The optical element of claim 19 wherein the angled facets are disposed at different angles to disperse reflected light.

25. The optical element of claim 19 wherein at least one of the angled facets is disposed at an angle to provide internal reflection of light from the entrance surface through the optical element and out the exit surface.

26. The optical element of claim 19 wherein the stepped surface includes a reflective material disposed on the angled facets to reflect light through the optical element and out the exit surface.

27. The optical element of claim 19 wherein the angled facets are skew relative to the output surface.