Optical element having an integral surface diffuser

• US 6,483,976 B2
• Filed: 05/09/2001
• Issued: 11/19/2002
• Est. Priority Date: 08/25/1998
• Status: Expired due to Term

• Current Assignee: Luminit LLC
• Original Assignee: Physical Optics Corporation
• Inventors: Jannson, Tomasz P., Savant, Gajendra D., Laine, Jeffrey A., Shie, Rick L.
• Primary Examiner(s): Kim, Ellen E.
• Application Number:
  US09/851,815
• Publication Number:
  US 20010017970A1
• Time in Patent Office: 559 Days
• Field of Search: 385/146-147, 385/133, 385/141, 359/443, 359/566, 359/707, 359/742
• US Class Current: 385/133
• CPC Class Codes: F21S 43/237 rod-shaped
• CPC Class Codes: F21S 43/239 plate-shaped
• CPC Class Codes: F21S 43/245 emitting light from one or more of its major surfaces
• CPC Class Codes: F21S 43/249 with two or more light sources being coupled into the light guide
• CPC Class Codes: G02B 5/021 the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
• CPC Class Codes: G02B 5/0221 the surface having an irregular structure G02B5/0226 takes precedence
• CPC Class Codes: G02B 5/0268 characterized by the fabrication or manufacturing method
• CPC Class Codes: G02B 5/0278 used in transmission
• CPC Class Codes: G02B 6/0038 Linear indentations or grooves, e.g. arc-shaped grooves or meandering grooves, extending over the full length or width of the light guide
• CPC Class Codes: Y10S 385/901 Illuminating or display apparatus

Abstract

A monolithic element has a substrate body and at least one macro-optical characteristic integral in a first portion of the optical element. A plurality of surface micro-structures are integral in a portion of the optical element. The micro-structures are designed to homogenize light passing through the optical element to produce a predetermined pattern of smoothly varying, non-discontinuous light exiting the optical element. The light exiting the optical element is therefore altered according to both the macro-optical characteristic of the optical element as well as the homogenizing characteristics of the micro-structures.

Claims

1. A monolithic optical element through which light is able to pass, comprising:

a substrate body through which light is able to pass;

a macro-optical characteristic integral with the substrate body; and

a plurality of micro-structures through which light is able to pass and which are random in nature and which are integral with the substrate body,

wherein the micro-structures are characterized as being able to homogenize light exiting the monolithic optical element via the substrate body,

wherein the micro-structures are further characterized as being able to direct a predetermined distribution of light exiting the monolithic optical element via the substrate body in a manner so as to shape substantially all of a light output of the monolithic optical element into a predetermined direction and distribution pattern,

wherein the substrate body, the macro-optical characteristic integral therewith and the plurality of random micro-structures also integral therewith cooperate thereby to enable the monolithic optical element to produce the light output providing the predetermined direction and distribution pattern of smoothly varying, non-discontinuous light exiting the monolithic optical element,

wherein the substrate body is a total internal reflection lens assembly and wherein the macro-optical characteristic is a total internal reflection capability of the total internal reflection lens assembly, and

wherein the total internal reflection lens assembly includes opposed end surface portions, the opposed end surface portions including the micro-structures from where the light within the total internal reflection lens assembly exits the total internal reflection lens assembly.

2. The optical element according to claim 1, wherein the substrate body is a plastic material and wherein the macro-optical characteristic and the micro-structures are each characterized as having been molded integral with the plastic material.

3. The optical element according to claim 1, wherein the substrate body is a hardened sol-gel solution and wherein the macro-optical characteristic and the micro-structures are each characterized as having been formed integral with the hardened sol-gel solution.

4. The optical element according to claim 1, wherein the substrate body and the macro-optical characteristic integral therewith are of a glass material and wherein the microstructures are characterized as having been formed integral with the macro-optical characteristic.

5. A total internal reflection lens assembly through which light is able to pass, comprising:

a total internal reflection lens having an entrance surface that is adapted to;

(i) permit light initially to pass through said entrance surface into the lens, and

(ii) reflect light away from the entrance surface as soon as the light is inside of the lens,

wherein the total internal reflection lens is elongated and has opposite end surface portions from where the light within the total internal reflection lens exits the lens;

a light-reflective surface that is integral with the total internal reflection lens and that is spaced from and disposed toward the entrance surface for reflecting the light entering the lens back toward the entrance surface at a predetermined angle; and

a plurality of micro-structures through which light is able to pass and which are random in nature and which are integral with the opposite end surface portions of the total internal reflection lens,

wherein the micro-structures are characterized as being not only able to homogenize light exiting the total internal reflection lens via the opposite end surface portions but also able to diffuse and shape the light,

wherein the micro-structures are further characterized as being able to direct a predetermined distribution of light exiting the total internal reflection lens via the opposite end surface portions in such a manner as to shape substantially all of a light output of the total internal reflection lens into a predetermined direction and distribution pattern, and

wherein the entrance surface, the light-reflective surface, the lens end portions and the plurality of random micro-structures integral therewith cooperate thereby to enable the total internal reflection lens to produce the light output having the predetermined direction and distribution pattern of smoothly varying, non-discontinuous light exiting the total internal reflection lens assembly.

6. The total internal reflection lens assembly according to claim 5, further comprising a light source disposed adjacent the entrance surface for directing light toward and into the total internet reflection lens.

7. The total internal reflection lens assembly according to claim 5, herein the entrance surface is a curved entrance surface.

8. The total internal reflection lens assembly according to claim 5, wherein the assembly is substantially a plastic material and wherein the micro-structures are characterized as having been molded integral with the plastic material.

9. The total internal reflection lens assembly according to claim 5, wherein the assembly is substantially a hardened sol-gel solution and wherein the micro-structures are each characterized as having been formed integral with the hardened sol-gel solution.

10. The total internal reflection lens assembly according to claim 5, wherein the assembly is substantially of a glass material and wherein the micro-structures are characterized as having been formed integral with the macro-optical characteristic.

11. A light pipe comprising:

an elongated substrate body through which light is able to pass,

wherein the elongated substrate body has opposed longitudinal edge margins and opposite end portions, and

wherein at least one of said opposite end portions is characterized as being able to receive light;

a plurality of light-reflective facet structures integral with a first of said substrate body longitudinal edge margins; and

a plurality of micro-structures which are random in nature and integral with a second of said substrate body longitudinal edge margins,

wherein the micro-structures are characterized as being not only able to homogenize light exiting the second substrate body longitudinal end margin but also able to diffuse and shape the light,

wherein the micro-structures are further characterized as being able to direct a predetermined distribution of light exiting the second substrate body longitudinal end margin in such a manner as to shape substantially all of a light output of the elongated substrate body into a predetermined direction and distribution pattern,

wherein the light-reflective facet structures and the plurality of random micro-structures cooperate thereby to enable the elongated substrate body to produce the light output providing the predetermined direction and distribution pattern of smoothly varying, non-discontinuous light exiting the second substrate body longitudinal end margin; and

wherein the random micro structures have a primary axis perpendicular to the mean propagation of light exiting the second substrate body longitudinal end margin.

12. The light pipe according to claim 11, further comprising a light source in contact with the one substrate body end portion.

13. The light pipe according to claim 11, wherein the substrate body is a plastic material and wherein the light-reflective facet structures and the micro-structures are each characterized as having been molded integral with the plastic material.

14. The light pipe according to claim 11, wherein the substrate body is a hardened sol-gel solution and wherein the light-reflective facet structures and the micro-structures are each characterized as having been formed integral with the hardened sol-gel solution.

15. The light pipe according to claim 11, wherein the substrate body and the light-reflective facet structures are of a glass material and wherein the micro-structures are characterized as having been formed integral with the macro-optical characteristic.