LED array systems

• US 8,246,220 B2
• Filed: 07/12/2011
• Issued: 08/21/2012
• Est. Priority Date: 06/01/2004
• Status: Expired due to Fees

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Epstein, Kenneth A., Tran, Hung T., Schultz, John C., Emmons, Robert M.
• Primary Examiner(s): Ward, John A
• Application Number:
  US13/180,876
• Publication Number:
  US 20110267799A1
• Time in Patent Office: 406 Days
• Field of Search: 362/19, 362/231, 362/241, 362/246, 362/330, 362/339, 362/619, 362/625, 362/632, 385/31, 385/125, 385/901
• US Class Current: 362/339
• CPC Class Codes: G02B 3/0056 arranged along two different directions in a plane, e.g. honeycomb arrangement of lenses G02B3/0043 takes precedence; miniaturised objectives for electronic devices employing wafer level optics G02B13/0085
• CPC Class Codes: G02B 6/0018 Redirecting means on the surface of the light guide
• CPC Class Codes: G02B 6/0021 for housing at least a part of the light source, e.g. by forming holes or recesses
• CPC Class Codes: G02B 6/0053 Prismatic sheet or layer; Brightness enhancement element, sheet or layer
• CPC Class Codes: G02B 6/0055 Reflecting element, sheet or layer
• CPC Class Codes: G02B 6/0068 Arrangements of plural sources, e.g. multi-colour light sources
• CPC Class Codes: G02F 1/133603 with LEDs
• CPC Class Codes: G09F 9/3026 Video wall, i.e. stackable semiconductor matrix display modules video wall control systems G06F3/1446, G09G2300/026
• CPC Class Codes: G09F 9/33 being semiconductor devices, e.g. diodes
• CPC Class Codes: G09F 9/35 being liquid crystals G09F9/302 takes precedence; liquid crystal materials C09K19/00; liquid crystal panels comprising a number of electrodes in a single cell per se G02F1/13

Abstract

A light emitting diode (LED) array comprises an array of LEDs mounted to a substrate. The LEDs emit light in a direction generally perpendicular to the substrate. An optical sheet is disposed over the LEDs. At least a portion of light entering one side of the optical sheet from the LEDs is guided within the optical sheet in a direction generally parallel to the substrate. Light extraction features direct light from the optical sheet in a generally forward direction. Such an array is useful for several applications, including space lighting, direct information display and backlighting of liquid crystal displays. The light spreading effect of the optical sheet reduces the amount of black space between LED pixels.

Claims

1. An optical assembly for emitting light, comprising:

an array of inorganic light emitting diodes (LEDs) mounted to a substrate, the LEDs emitting light in a direction generally perpendicular to the substrate; and

an optical sheet disposed over the LEDs, at least a portion of light entering one side of the optical sheet from the LEDs being guided within the optical sheet in a direction generally parallel to the substrate,

wherein the optical sheet comprises a first side facing towards the substrate and a second side facing away from the substrate, at least one light extraction feature being provided with the optical sheet to extract light, that has been guided along the optical sheet from the LEDs, through one of the first and second sides,

wherein the light extraction feature comprises a structure on one surface of the optical sheet.

2. The optical assembly of claim 1 wherein the light extraction feature structure comprises one or more patches of diffusely reflecting material on at least one of the first and second sides of the optical sheet.

3. The optical assembly of claim 1 wherein the light extraction feature structure comprises one or more light extraction prisms having prism bases disposed on the second side of the optical sheet.

4. The optical assembly of claim 3, wherein the light extraction prisms are arranged on the second side of the optical sheet as one or more Fresnel lenses.

5. The optical assembly of claim 3, wherein the light extraction prisms on the second side are substantially linear.

6. The optical assembly of claim 3, wherein the light extraction prisms on the second side are curved.

7. The optical assembly of claim 1 further comprising an intermediate layer disposed between the optical sheet and the substrate.

8. The optical assembly of claim 7 wherein the intermediate layer is a reflective intermediate layer.

9. An assembly as recited in claim 1, wherein the extraction feature structure comprises an array of light extraction prisms disposed with respective prism apexes directed towards the optical sheet.

10. An assembly as recited in claim 9, further comprising a coupling layer on the second side of the optical sheet, wherein the guided light passes into the coupling layer and the prism apexes extend into the coupling layer.

11. An assembly as recited in claim 9, wherein light that has coupled from the optical sheet into the light extraction prisms is totally internally reflected by the prisms in a direction away from the optical sheet.

12. An assembly as recited in claim 9, further comprising an optical diffuser, light that has passed through the light extraction prisms from the optical sheet being passed through the optical diffuser.

13. An assembly as recited in claim 9, further comprising a filter, light that has passed through the light extraction prisms from the optical sheet being passed through the filter.

14. An assembly as recited in claim 13, wherein the filter comprises a projection screen.

15. An assembly as recited in claim 13, wherein the filter comprises a polarizer.

16. An assembly as recited in claim 9, wherein the light extraction prisms are substantially linear.

17. An assembly as recited in claim 9, wherein the light extraction prisms are curved.

18. An assembly as recited in claim 17, wherein the curved light extraction prisms are curved in patterns centered on respective LEDs.