Illumination assembly

• US 6,424,786 B1
• Filed: 04/14/2000
• Issued: 07/23/2002
• Est. Priority Date: 12/02/1996
• Status: Expired due to Term

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Beeson, Karl W., Zimmerman, Scott M., Diaz, Jose C., Maxfield, MacRae, Foley, Michael
• Primary Examiner(s): Spyrou, Cassandra
• Assistant Examiner(s): Maxie, Christopher S.
• Application Number:
  US09/549,665
• Time in Patent Office: 830 Days
• Field of Search: 385/146, 385/43, 385/147, 385/51
• US Class Current: 385/146
• CPC Class Codes: G02B 2006/12195 Tapering
• CPC Class Codes: G02B 3/0031 Replication or moulding, e.g. hot embossing, UV-casting, injection moulding
• CPC Class Codes: G02B 3/0068 arranged in a single integral body or plate, e.g. laminates or hybrid structures with other optical elements G02B5/1885, G02B17/002, G02B30/27 take precedence
• CPC Class Codes: G02B 5/0221 the surface having an irregular structure G02B5/0226 takes precedence
• CPC Class Codes: G02B 5/0231 the surface having microprismatic or micropyramidal shape macroscopic prism arrays G02B5/045
• CPC Class Codes: G02B 5/0242 by means of dispersed particles
• CPC Class Codes: G02B 5/0278 used in transmission
• CPC Class Codes: G02B 5/0289 used as a transflector
• CPC Class Codes: G02B 5/045 Prism arrays
• CPC Class Codes: G02B 6/1221 made from organic materials
• CPC Class Codes: G02B 6/241 Light guide terminations
• CPC Class Codes: G02F 1/133607 the light controlling member including light directing or refracting elements, e.g. prisms or lenses
• CPC Class Codes: G03B 21/625 Lenticular translucent screens

Abstract

An optical illumination assembly comprising an array of optical microprisms and microlenses for redirecting light from a light source. Such displays are used in a wide variety of applications such as backlit flat panel displays requiring a directed light source which provides an efficient output of light. The illumination assembly has a light transmitter optically coupled to an input end of array of microprisms through an optional diffuser, and a microlens on the light output end of each microprism. The microprisms have a light input end optically coupled to the light transmitting means and a light output end spaced from the light input end. Two pairs of oppositely positioned sidewalls having one an edge defined by said light input end and another edge defined by said light output end are positioned for reflecting of transmitted light toward the light output end; When light from the light transmitting means enters each microprism through the light input end, the light is directed by said sidewalls through the microprisms to each light output end and then through the microlenses. Optionally a light diffuser is positioned between the light transmitter and the input end of the microprisms.

Claims

1. An illumination assembly comprising:

(a) a light transmitting means;

(b) an array of microprisms wherein each microprism comprises;

(i) a light input end optically coupled to said light transmitting means;

(ii) a light output end spaced from the light input end;

(iii) a pair of oppositely positioned first sidewalls, each first sidewall having an edge defined by said light input end and an edge defined by said light output end;

at least one of said first sidewalls being positioned for effecting reflection of transmitted light toward the light output end;

(iv) a pair of oppositely positioned second sidewalls, each second sidewall having an edge defined by said light input end and an edge defined by said light output end;

at least one of said second sidewalls being positioned for effecting reflection of transmitted light toward the light output end; and

(c) a microlens on the light output end of each microprism, without an intermediate layer that extends laterally between two adjacent microprisms situated therebetween, such that when light from said light transmitting means enters each microprism through said light input end, the light is directed by said sidewalls through said microprisms and out each light output end.

2. The assembly of claim 1 wherein the microlenses are convex.

3. The assembly of claim 2 wherein the microlenses have a single axis of curvature.

5. The assembly of claim 1 wherein the microlenses are integrally formed with the light output end of each microprism.

9. The assembly of claim 1 further comprising a black colorant between the sidewalls of adjacent microprisms.

10. The assembly of claim 1 further comprising a light diffusing element optically coupled between the light transmitting means and the light input end.

11. The assembly of claim 10 wherein the light diffusing element is attached to the light input end.

12. The assembly of claim 1 further comprising a light reflectance coating on the sidewalls.

13. The assembly of claim 1 wherein the light output end has a surface area less than that of the light input end.

14. The assembly of claim 1 wherein the microprisms have inwardly tapered sidewalls, and the light output end has a surface area less than that of the light input end.

15. The assembly of claim 1 wherein said microprisms, microlenses, and light transmitting means have an index of refraction of from about 1.40 and about 1.65.

16. The assembly of claim 1 wherein said light transmitting means is a waveguide.

17. The assembly of claim 1 wherein said microprisms and microlenses are constructed from an organic polymeric material.

18. The assembly of claim 1 wherein said light output end has a surface parallel to a surface of said input end.

19. The assembly of claim 1 wherein selected first and second sidewalls form a tilt angle of from about 2 to about 25 degrees to the normal of the plane of said light input end.

20. The assembly of claim 1 wherein said second sidewalls forms a tilt angle of from about 5 to about 25 degrees to the normal of the plane of said light input end.

4. An illumination assembly comprising:

(a) a light transmitting means;

(b) an array of microprisms wherein each microprism comprises;

(i) a light input end optically coupled to said light transmitting means;

(ii) a light output end spaced from the light input end;

(iii) a pair of oppositely positioned first sidewalls, each first sidewall having an edge defined by said light input end and an edge defined by said light output end;

at least one of said first sidewalls being positioned for effecting reflection of transmitted light toward the light output end;

(iv) a pair of oppositely positioned second sidewalls, each second sidewall having an edge defined by said light input end and an edge defined by said light output end;

at least one of said second sidewalls being positioned for effecting reflection of transmitted light toward the light output end; and

(c) a microlens on the light output end of each microprism, such that when light from said light transmitting means enters each microprism through said light input end, the light is directed by said sidewalls through said microprisms and out each light output end, the microlenses having two perpendicular axes of curvature.

6. An illumination assembly comprising:

(a) a light transmitting means;

(b) an array of microprisms wherein each microprism comprises;

(i) a light input end optically coupled to said light transmitting means;

(ii) a light output end spaced from the light input end;

(iii) a pair of oppositely positioned first sidewalls, each first sidewall having an edge defined by said light input end and an edge defined by said light output end;

at least one of said first sidewalls being positioned for effecting reflection of transmitted light toward the light output end;

(iv) a pair of oppositely positioned second sidewalls, each second sidewall having an edge defined by said light input end and an edge defined by said light output end;

at least one of said second sidewalls being positioned for effecting reflection of transmitted light toward the light output end; and

(c) a microlens on the light output end of each microprism, such that when light from said light transmitting means enters each microprism through said light input end, the light is directed by said sidewalls through said microprisms and out each light output end, the microlenses are directly attached to the light output end of each microprism without an intermediate spacer element.

7. The assembly of claim 6 wherein the microlenses have substantially the same index of refraction as the microprisms.

8. An illumination assembly comprising:

(a) a light transmitting means;

(b) an array of microprisms wherein each microprism comprises;

(i) a light input end optically coupled to said light transmitting means;

(ii) a light output end spaced from the light input end;

(iii) a pair of oppositely positioned first sidewalls, each first sidewall having an edge defined by said light input end and an edge defined by said light output end;

at least one of said first sidewalls being positioned for effecting reflection of transmitted light toward the light output end;

(iv) a pair of oppositely positioned second sidewalls, each second sidewall having an edge defined by said light input end and an edge defined by said light output end;

at least one of said second sidewalls being positioned for effecting reflection of transmitted light toward the light output end; and

(c) a microlens on the light output end of each microprism, such that when light from said light transmitting means enters each microprism through said light input end, the light is directed by said sidewalls through said microprisms and out each light output end, the microlenses are directly attached to the light output end of each microprism by means of an index of refraction matching fluid or adhesive.

21. An illumination assembly comprising:

(a) a light transmitting means;

(b) an array of microprisms wherein each microprism comprises;

(i) a light input end optically coupled to said light transmitting means;

(ii) a light output end spaced from the light input end;

(iii) a pair of oppositely positioned first sidewalls, each first sidewall having an edge defined by said light input end and an edge defined by said light output end;

at least one of said first sidewalls being positioned for effecting reflection of transmitted light toward the light output end;

(iv) a pair of oppositely positioned second sidewalls, each second sidewall having an edge defined by said light input end and an edge defined by said light output end;

at least one of said second sidewalls being positioned for effecting reflection of transmitted light toward the light output end;

(c) a microlens on the light output end of each microprism, such that when light from said light transmitting means enters each microprism through said light input end, the light is directed by said sidewalls through said microprisms and out each light output end; and

(d) an array of second microprisms attached between the array of microprisms and the microlenses, wherein each second microprism comprises;

(i) a second light input end optically coupled to said light transmitting means;

(ii) a second light output end;

(iii) a second pair of oppositely positioned first sidewalls, each first sidewall having an edge defined by said second light input end and an edge defined by said second light output end;

at least one of said first sidewalls being positioned for effecting reflection of transmitted light toward the second light output end;

(iv) a pair of oppositely positioned second sidewalls, each second sidewall having an edge defined by said second light input end and an edge defined by said second light output end;

at least one of said second sidewalls being positioned for effecting reflection of transmitted light toward the second light output end and the microlenses.

22. The assembly of claim 21 further comprising a light diffusing element optically coupled between the light transmitting means and the light input end.

23. An illumination assembly comprising:

(a) a light transmitting means;

(b) an array of microprisms wherein each microprism comprises;

(i) a light input end optically coupled to said light transmitting means;

(ii) a light output end spaced from the light input end;

(iii) a pair of oppositely positioned first sidewalls, each first sidewall having an edge defined by said light input end and an edge defined by said light output end;

at least one of said first sidewalls being positioned for effecting reflection of transmitted light toward the light output end;

(iv) a pair of oppositely positioned second sidewalls, each second sidewall having an edge defined by said light input end and an edge defined by said light output end;

at least one of said second sidewalls being positioned for effecting reflection of transmitted light toward the light output end;

(c) a microlens on the light output end of each microprism, without an intermediate layer that extends laterally between two adjacent microprisms situated therebetween, such that when light from said light transmitting means enters each microprism through said light input end, the light is directed by said sidewalls through said microprisms and out each light output end; and

(d) a light diffusing element optically coupled between the light transmitting means and the light input end.

24. The assembly of claim 23 wherein the light diffusing element is attached to the light input end.

25. The assembly of claim 23 wherein the light diffusing element comprises a transparent or translucent substrate having smooth bumps on a substrate surface, said bumps ranging from about 1 micron to about 20 microns in both height and width.

26. The assembly of claim 23 wherein the bumps comprise a polymerized material on the surface of the substrate.

27. The assembly of claim 23 wherein the bumps are in juxtaposition with the light input end of the microprisms.

28. An illumination assembly having an array of microprisms, wherein each microprism comprises:

(a) a light input end for receiving light;

(b) a light output end spaced from the light input end;

(c) one or more sidewalls, wherein each sidewall has an edge defined by said light input end and an edge defined by said light output end;

at least one of said one or more sidewalls being positioned for effecting reflection of transmitted light toward the light output end; and

(d) a microlens on the light output end of each microprism, without an intermediate layer that extends laterally between two adjacent microprisms situated therebetween, such that when light from said light transmitting means enters each microprism through said light input end, the light is directed by said one or more sidewalls through said microprisms and out each light output end.

29. An illumination assembly comprising:

(a) a light transmitting means;

(b) an array of microprisms wherein selected microprisms comprise;

(i) a light input end optically coupled to said light transmitting means;

(ii) a light output end spaced from the light input end;

(iii) one or more sidewalls, wherein each sidewall has an edge defined by said light input end and an edge defined by said light output end;

at least one of said one or more sidewalls being positioned for effecting reflection of transmitted light toward the light output end; and

(iv) said light output end is shaped to define a microlens, without an intervening layer in between said microlens and said light output end.