Compact folded-optics illumination lens

• US 7,181,378 B2
• Filed: 02/13/2004
• Issued: 02/20/2007
• Est. Priority Date: 10/11/2002
• Status: Active Grant

• Current Assignee: Light Engine Limited
• Original Assignee: Light Prescriptions Innovators, LLC
• Inventors: Benitez, Pablo, Munoz, Fernando, Minano, Juan C.
• Primary Examiner(s): Rodriguez; Paul
• Assistant Examiner(s): CRAIG, DWIN M
• Application Number:
  US10/779,259
• Publication Number:
  US 20040252390A1
• Time in Patent Office: 1,103 Days
• Field of Search: 703/2, 703/1, 359/737, 359/708, 359/718, 359/726, 359/728, 362/327, 362/347, 700/98
• US Class Current: 703/2
• CPC Class Codes: F21V 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 7/0091 using total internal reflection
• CPC Class Codes: F21Y 2101/00 Point-like light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• 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
• CPC Class Codes: G02B 27/0012 Optical design, e.g. procedures, algorithms, optimisation routines
• CPC Class Codes: G02B 3/02 with non-spherical faces G02B3/10 takes precedence

Abstract

The present embodiments provide for apparatuses, and methods for manufacturing apparatuses to convert a first distribution of an input radiation to a second distribution of output radiation. The apparatus can be defined in some embodiments by generating a two-dimensional representation of three active optical surfaces including calculating a segment of first, entry and second surfaces based on first second, and third generalized Cartesian ovals, respectively, and successively repeating the calculating of the segments of the first and second surfaces, and rotationally sweeping the two-dimensional representation about a central axis providing a three-dimensional representation. In some embodiments, portion of the first and/or second surfaces can be totally internally reflective.

Claims

1. A method of manufacturing an optical device, comprising:

generating a two-dimensional representation of at least three active optical surfaces of an optical device, comprising;

defining a perimeter;

calculating a segment of a first surface, an entry surface and a second surface based on an edge ray set according to generalized Cartesian ovals; and

successively repeating the steps of calculating the segments of the first and second surface; and

rotationally sweeping the two-dimensional representation about a central axis providing a three-dimensional representation of optical device; and

utilizing the three-dimensional representation to make the optical device.

2. The method of claim 1, wherein the calculating further comprises:

calculating a segment of the first surface based on edge ray set as a first generalized Cartesian oval;

calculating a segment of the entry surface based on the edge ray set as a second generalized Cartesian oval; and

calculating a segment of the second surface based on the edge ray set as a third generalized Cartesian oval.

3. The method of claim 2, wherein the calculating the segment of the second surface comprises calculating the segment of the second surface such that the second surface is totally internally reflective.

4. The method of claim 3, wherein the step of calculating the segment of the entry surface includes determining a position of a first end of the segment of the entry surface including the steps of:

determining a flux weighting for edge rays intercepting the first segment of the entry surface;

determining a flux weighting for all edge rays of the edge ray sets; and

determining a resultant sum of the flex weighting for the edge rays intercepting the first segment of the entry surface as a fraction of the flux weighting for all the edge-rays of the edge ray sets.

5. The method of claim 3, wherein the successively repeating the calculating the segment of the first surface comprises calculating a second segment of the first surface as a fourth generalized Cartesian oval based on a far edge ray set;

and

wherein the calculating the second segment of the first surface comprises calculating the second segment such that the far edge ray set intercepts the perimeter segment of the second surface after reflecting from the second segment of the first surface.

6. The method of claim 1, further comprising:

molding material to have dimensions equal to the three-dimensional representation of the optical device.

7. A method of designing an optical device, comprising:

generating a two-dimensional representation of at least three active optical surfaces of an optical device, comprising;

defining a perimeter;

calculating a segment of a first surface, an entry surface and a second surface based on an edge ray set according to generalized Cartesian ovals; and

successively repeating the steps of calculating the segments of the first and second surface; and

rotationally sweeping the two-dimensional representation about a central axis providing a three-dimensional representation of the optical device; and

utilizing the three-dimensional representation to make the optical device.

8. The method of claim 7, wherein the calculating further comprises:

calculating a segment of the first surface based on edge ray set as a first generalized Cartesian oval;

calculating a segment of the entry surface based on the edge ray set as a second generalized Cartesian oval; and

calculating a segment of the second surface based on the edge ray set as a third generalized Cartesian oval.

9. The method of claim 8, wherein the calculating the segment of the second surface comprises calculating the segment of the second surface such that the second surface is totally internally reflective.

10. The method of claim 9, wherein the step of calculating the segment of the entry surface includes determining a position of a first end of the segment of the entry surface including the steps of:

determining a flux weighting for edge rays intercepting the first segment of the entry surface;

determining a flux weighting for all edge rays of the edge ray sets; and

determining a resultant sum of the flex weighting for the edge rays intercepting the first segment of the entry surface as a fraction of the flux weighting for all the edge-rays of the edge ray sets.

11. The method of claim 9, wherein the successively repeating the calculating the segment of the first surface comprises calculating a second segment of the first surface as a fourth generalized Cartesian oval based on a far edge ray set;

and

wherein the calculating the second segment of the first surface comprises calculating the second segment such that the far edge ray set intercepts the perimeter segment of the second surface after reflecting from the second segment of the first surface.