LED device for wide beam generation

• US 8,511,864 B2
• Filed: 03/16/2012
• Issued: 08/20/2013
• Est. Priority Date: 02/27/2006
• Status: Active Grant

• Current Assignee: Signify Holding B.V. (Signify N.V.)
• Original Assignee: Illumination Management Solutions Incorporated (Eaton Corporation PLC.)
• Inventors: Holder, Ronald G., Rhoads, Greg
• Primary Examiner(s): SEMBER, THOMAS M
• Application Number:
  US13/422,871
• Publication Number:
  US 20120176791A1
• Time in Patent Office: 522 Days
• Field of Search: 362/311.01, 362/311.02, 362/311.06, 362/311.15
• US Class Current: 362/311.02
• CPC Class Codes: F21K 9/60 Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
• CPC Class Codes: F21K 9/69 Details of refractors forming part of the light source
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21W 2131/103 of streets or roads
• 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 19/0071 adapted to illuminate a complete hemisphere or a plane extending 360 degrees around the source
• CPC Class Codes: H01L 33/58 Optical field-shaping elements
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

An apparatus and method is characterized by providing an optical transfer function between a predetermined illuminated surface pattern, such as a street light pattern, and a predetermined energy distribution pattern of a light source, such as that from an LED. A lens is formed having a shape defined by the optical transfer function. The optical transfer function is derived by generating an energy distribution pattern using the predetermined energy distribution pattern of the light source. Then the projection of the energy distribution pattern onto the illuminated surface is generated. The projection is then compared to the predetermined illuminated surface pattern to determine if it acceptably matches. The process continues reiteratively until an acceptable match is achieved. Alternatively, the lens shape is numerically or analytically determined by a functional relationship between the shape and the predetermined illuminated surface pattern and predetermined energy distribution pattern of a light source as inputs.

Claims

1. An apparatus comprising a two-dimensional array of light sources, each light source comprising:

a respective LED comprising a substrate; and

a respective lens coupled to the respective LED and operative to transform a substantially Lambertian output into a light distribution that spreads about an axis,

wherein the axis is substantially perpendicular to the substrate,

wherein a polar candela plot of the light distribution comprises a first peak and a second peak that are disposed at substantially opposing angles relative to a line on the polar candela plot that corresponds substantially to the axis, and

wherein the respective lens comprises an indentation that is disposed entirely on one side of the axis and that divides an outer surface of the respective lens into two subsurfaces.

2. The apparatus of claim 1, wherein the line is at zero degrees on the polar candela plot.

3. The apparatus of claim 1,

wherein the polar candela plot comprises:

a first quadrant;

a second quadrant disposed immediately clockwise from the first quadrant;

a third quadrant disposed immediately clockwise from the second quadrant; and

a fourth quadrant disposed immediately clockwise from the third quadrant,

wherein the first peak is disposed in the second quadrant, and

wherein the second peak is disposed in the third quadrant.

4. The apparatus of claim 1, wherein the respective lens comprises:

a smooth concave surface opposite the respective LED; and

a plurality of refracting lobes protruding relative to the smooth surface, including one on a first side of the indentation and another on a second side of the indentation.

5. The apparatus of claim 1, wherein the respective lens comprises a first refracting lobe operative to form the first peak and a second refracting lobe operative to form the second peak, and wherein the indentation extends between the first refracting lobe and the second refracting lobe.

6. The apparatus of claim 1, wherein the first peak comprises a mirror image of the second peak.

7. The apparatus of claim 1, wherein each of the light sources in the two-dimensional array is attached to a common substrate that is connected to a heat sink, and wherein the apparatus further comprises a light fixture housing the substrate.

8. The apparatus of claim 1, wherein the respective lens is a protective dome of the respective LED.

9. A light module comprising a plurality of light sources arranged on a substrate, each light source comprising:

at least one light emitting diode comprising a substrate; and

a lens coupled to the at least one light emitting diode and operative to distribute light along an axis that is orthogonal to the substrate,

wherein the axis lies in a plane that extends between two subsurfaces of the lens, wherein the lens comprises an indentation that extends between the two subsurfaces and that is offset from the axis,

wherein a polar candela plot of the distributed light comprises two polar regions of elevated intensity exhibiting substantial mirror image symmetry with respect to one another, and

wherein approximately zero degrees on the polar candela plot represents the axis.

10. The light module of claim 9, wherein the at least one light emitting diode comprises a protective dome that is distinct from the lens.

11. The light module of claim 9,

wherein the polar candela plot comprises:

a first quadrant;

a second quadrant disposed immediately clockwise from the first quadrant;

a third quadrant disposed immediately clockwise from the second quadrant; and

a fourth quadrant disposed immediately clockwise from the third quadrant,

wherein a first of the two polar regions of elevated intensity is disposed in the second quadrant, and

wherein a second of the two polar regions of elevated intensity is disposed in the third quadrant.

12. The light module of claim 9, wherein the two polar regions of elevated intensity comprise a first peak displaced clockwise relative to said zero degrees and a second peak displaced counterclockwise relative to said zero degrees.

13. The light module of claim 9, wherein the two polar regions of elevated intensity comprise:

a first peak located between approximately 40 and approximately 60 degrees clockwise from said zero degrees; and

a second peak located between approximately 40 and approximately 60 degrees counterclockwise from said zero degrees.

14. The light module of claim 9, wherein the lens comprises a prism jutting from a surface of the lens.

15. The light module of claim 9, wherein the lens comprises a complex prism.

16. The light module of claim 9, wherein the lens comprises a plurality of refracting lobes, defined at least in part by the indentation, for forming the two polar regions of elevated intensity.

17. The light module of claim 9, wherein the two polar regions of elevated intensity are substantially symmetrical about a line extending between zero degrees and 180 degrees on the polar candela plot.

18. The light module of claim 9, wherein a luminaire heat sink is in thermal communication with the substrate.

19. A light module comprising a plurality of light sources arranged on a substrate, each light source comprising:

at least one light emitting diode; and

a lens coupled to the at least one light emitting diode and operative to distribute light along an axis that is perpendicular to the substrate,

wherein the lens comprises;

a plane of symmetry that comprises the axis, wherein a second plane is perpendicular to the plane of symmetry, is perpendicular to the substrate, and comprises the axis; and

a surface region disposed at a location that is offset from the second plane, the surface region comprising an indentation disposed at an intersection between the plane of symmetry and the surface region,

wherein a polar candela plot of the distributed light comprises two polar regions of elevated intensity exhibiting substantial mirror image symmetry with respect to one another, and

wherein approximately zero degrees on the polar candela plot represents the axis.

20. The light module of claim 19, wherein the indentation divides the outer surface region into two protruding subregions.