High efficiency non-imaging optics

• US 6,639,733 B2
• Filed: 03/16/2001
• Issued: 10/28/2003
• Est. Priority Date: 03/16/2000
• Status: Expired due to Term

• Current Assignee: Light Prescriptions Innovators, LLC
• Original Assignee: Light Prescriptions Innovators, LLC
• Inventors: Falicoff, Waqidi, Caulfield, H. J., Benitez, Pablo, Minano, Juan C., Gonzalez, Juan C.
• Primary Examiner(s): Spector, David N.
• Application Number:
  US09/810,959
• Publication Number:
  US 20030016539A1
• Time in Patent Office: 956 Days
• Field of Search: 359/708, 359/718, 359/726, 359/728, 362/327, 362/347
• US Class Current: 359/728
• CPC Class Codes: F21V 7/04 Optical design
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: F24S 23/00 Arrangements for concentrating solar-rays for solar heat collectors
• CPC Class Codes: G02B 19/0028 refractive and reflective surfaces, e.g. non-imaging catadioptric systems
• CPC Class Codes: G02B 19/0042 for use with direct solar radiation
• 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: H01L 2224/48091 Arched
• CPC Class Codes: H01L 2224/48247 connecting the wire to a bond pad of the item
• CPC Class Codes: H01L 2924/00012 Relevant to the scope of the group, the symbol of which is combined with the symbol of this group
• CPC Class Codes: H01L 2924/00014 the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
• CPC Class Codes: H01L 2924/181 Encapsulation
• CPC Class Codes: H01L 33/54 having a particular shape
• CPC Class Codes: Y02E 10/44 Heat exchange systems

Abstract

A highly efficient optical device comprises two opposing active non-spherical optical surfaces defined by a two-dimensional representation that is symmetrically extended to provide a three-dimensional device. A focal area, spaced apart from the optical surface and non-contiguous therewith, is defined by the two opposing active optical surfaces. The active optical surfaces each have a continuous second derivative, and the optical surfaces are defined by a polynomial with an order of at least about twenty. The optical device may comprise a transparent dielectric core, and the optical surfaces may be formed on the core. A receiver may be situated at the focal area to provide a concentrator. An extended light source such as an LED may be situated at the focal area, to provide a collimator. Faceted embodiments can provide a low aspect optical device. In some embodiments a diffuser may be used to transform incident radiation into a predetermined shape.

Claims

1. A method of manufacturing an optical device having two opposing active optical surfaces that convert a first distribution of an input radiation to a second distribution of output radiation, comprising:

providing a two-dimensional mathematical model that describes the first distribution of radiation as an input bundle of edge rays and the second distribution of radiation as an output bundle of edge rays, and representing the input and output edge ray bundles each in a phase-space representation in terms of the position of each ray in space and its associated optical cosine, where the locus of the edge rays in the phase-space for the input bundle defines a closed boundary of a first planar shape, and the locus of the edge rays in the phase-space for the output bundle defines a closed boundary of a second planar shape, wherein these two planar shapes have a substantially equal area;

approximating the two-dimensional shape of the outer caustic of said input and output radiation distribution ray bundles, where the outer caustic is defined such that it does not touch any of said active optical surfaces;

defining a two-dimensional representation of said active optical surfaces responsive to the boundary conditions of the phase-space representations and the outer caustics, including defining a focal area spaced apart from, and noncontiguous with, said optical surfaces, said active optical surfaces each having a continuous second derivative, said optical surfaces further formed so that the theoretical transmission efficiency of the said first input radiation distribution to said second input radiation distribution, neglecting attenuation losses in the processing path, is greater than about 80% of the maximum transmission efficiency; and

symmetrically extending said two-dimensional representation of said optical surfaces to provide a three-dimensional optical device.

2. The method of claim 1 wherein one of said active optical surfaces is substantially flat.

3. The method of claim 1 further comprising forming said optical surfaces on a transparent dielectric core.

4. The method of claim 1 further comprising situating a receiver approximately at the focal area, thereby providing a concentrator.

5. The method of claim 1 wherein said theoretical transmission efficiency of the said first input radiation distribution to said second input radiation distribution, neglecting attenuation losses in the processing path, is greater than about 90% of the maximum transmission efficiency.

6. The method of claim 1 further comprising forming a diffuser on at least one of said optical surfaces.

7. The method of claim 6 wherein said diffuser transforms incident radiation into a predetermined shape.

8. The method of claim 1 wherein said step of symmetrically extending said two-dimensional representation includes extruding said two-dimensional representation to provide a linearly-symmetric optical device.

9. The method of claim 8 further comprising situating an extended linearly extruded light source approximately at the focal area, thereby providing a collimator with an approximately rectangular cross-sectional output.

10. The method of claim 1 wherein said optical surfaces are formed to define an RR device.

11. The method of claim 1 further comprising forming said optical surfaces to form a folded edge ray device.

12. The method of claim 11 wherein said optical surfaces are formed to define an RX device.

13. The method of claim 11 wherein said optical surfaces are formed to define an RXI device.

14. The method of claim 11 wherein said optical surfaces are formed to define an XX device.

15. The method of claim 11 wherein said optical surfaces are formed to define an XR device.

16. The method of claim 1 wherein said step of symmetrically extending said two-dimensional representation includes rotating said two-dimensional representation so that said optical device is rotationally symmetric about a central axis.

17. The method of claim 16 further comprising forming said optical surfaces on a transparent dielectric core, and forming a cylindrical hole substantially centered about said central axis.

18. The method of claim 17 further comprising the step of inserting a receiver into said cylindrical hole and positioning said receiver approximately at said focal area.

19. The method of claim 18 further comprising the step of attaching said receiver to said dielectric core using a material that has a substantially different index of refraction than said dielectric core.

20. The method of claim 17 further comprising the step of inserting an extended source into said cylindrical hole and positioning said source approximately at said focal area.

21. The method of claim 20 further comprising the step of attaching said source to said dielectric core using a material that has a substantially different index of refraction than said dielectric core.

22. The method of claim 1 wherein at least one of said optical surfaces is formed to comprise facets including an active facet and an inactive facet.

23. The method of claim 22 wherein the optical surfaces are formed to define an aspect ratio that is within a range of about 0.65 to about 0.1.

24. The method of claim 22 wherein one of said active optical surfaces comprises a cuspoid shape that approaches said focal area.

25. The method of claim 1 further comprising situating an extended light source approximately at the focal area, thereby providing a collimator.

26. The method of claim 25 wherein said optical surfaces are formed so that the average angle of the output distribution of radiation is less than about ±

15°

from normal incidence.

27. The method of claim 25 comprising situating an LED light source approximately at said focal area.

28. The method of claim 25 comprising situating an array of LED light sources approximately at said focal area.

29. An optical device that converts a first distribution of an input radiation to a second distribution of output radiation, comprising:

two opposing active non-spherical optical surfaces defined by a two-dimensional representation that is symmetrically extended to provide a three-dimensional device;

a focal area defined by said two opposing active optical surfaces, said

said active optical surfaces each having a continuous second derivative;

said optical surfaces being defined by a polynomial with an order of at least about twenty; and

said optical surfaces further providing a theoretical transmission efficiency of said first input radiation distribution to said second input radiation distribution, neglecting attenuation losses in the processing path, of greater than about 80% of the maximum transmission efficiency.

30. The optical device of claim 29 wherein said optical device is rotationally-symmetric.

31. The optical device of claim 29 further comprising a transparent dielectric core, and wherein said optical surfaces are formed on said optical core.

32. The optical device of claim 29 further a receiver situated approximately at the focal area, thereby providing a concentrator.

33. The optical device of claim 29 wherein said theoretical transmission efficiency of said first input radiation distribution to said second input radiation distribution, neglecting attenuation losses in the processing path, is greater than about 90% of the maximum transmission efficiency.

34. The optical device of claim 29 wherein one of said optical surfaces is substantially flat.

35. The optical device of claim 29 wherein said optical device is linearly-symmetric, so that said focal area comprises a linear shape.

36. The optical device of claim 29 further comprising a linear extended light source that extends along said focal area, thereby providing a collimator with an approximately rectangular cross-sectional output.

37. The optical device of claim 29 wherein said optical surfaces define an RR device.

38. The optical device of claim 29 wherein said optical surfaces define a folded edge ray device.

39. The optical device of claim 38 wherein said optical surfaces define an RX device.

40. The optical device of claim 38 wherein said optical surfaces define an RXI device.

41. The optical device of claim 38 wherein said optical surfaces define an XX device.

42. The optical device of claim 38 wherein said optical surfaces define an XR device.

43. The optical device of claim 29 wherein at least one of said optical surfaces comprises facets including an active facet and an inactive facet.

44. The optical device of claim 43 wherein the optical surfaces define an aspect ratio within a range of about 0.65 to about 0.1.

45. The optical device of claim 43 wherein one of said active surfaces comprises a cuspoid shape that approaches said focal area.

46. The optical device of claim 29 wherein at least one of said optical surfaces comprises a diffuser formed thereon.

47. The optical device of claim 46 wherein said diffuser transforms incident radiation into a predetermined shape.

48. The optical device of claim 29 further comprising a light source situated approximately at the focal area, thereby providing a collimator.

49. The optical device of claim 48 wherein said optical surfaces define an average angle of the output distribution of radiation that is less than about ±

15°

from normal incidence.

50. The optical device of claim 48 wherein said light source comprises an LED.

51. The optical device of claim 48 wherein said light source comprises an array of LEDs.

52. The optical device of claim 29 wherein said optical device comprises a transparent dielectric core and said optical device is rotationally symmetric so that said optical device is rotationally symmetric around a central axis.

53. The optical device of claim 52 wherein said optical device further comprises:

a cylindrical hole centered about said central axis; and

a receiver positioned in said cylindrical hole approximately at said focal area.

54. The optical device of claim 53 further comprising an attaching material for attaching said receiver to said dielectric, and wherein said attaching material has a substantially different index of refraction than said dielectric.

55. The optical device of claim 52 wherein said optical device further comprises:

a cylindrical hole centered about said central axis; and

an extended light source positioned in said cylindrical hole approximately at said focal area.

56. The optical device of claim 55 further comprising an attaching material for attaching said light source to said dielectric, and wherein said attaching material has a substantially different index of refraction than said dielectric.