High efficiency total internal reflection optic for solid state lighting luminaires

• US 8,556,469 B2
• Filed: 12/06/2010
• Issued: 10/15/2013
• Est. Priority Date: 12/06/2010
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Pickard, Paul Kenneth
• Primary Examiner(s): TSO, LAURA K
• Application Number:
  US12/961,380
• Publication Number:
  US 20120140462A1
• Time in Patent Office: 1,044 Days
• Field of Search: 362/311.02
• US Class Current: 362/311.02
• CPC Class Codes: G02B 17/086 wherein the system is made of a single block of optical material, e.g. solid catadioptric systems
• CPC Class Codes: G02B 19/0028 refractive and reflective surfaces, e.g. non-imaging catadioptric systems
• CPC Class Codes: G02B 19/0066 in the form of an LED array

Abstract

Optical elements having components made from high refractive index materials (RI≦1.6) and lamp assemblies incorporating such elements. Various optical elements, such as total internal reflection lenses, can be fabricated from materials having a higher index of refraction than materials typically used in such elements. The compact optical elements have at least one internal reflection surface that directs radiant energy (e.g., light) from a receiving end to a transmitting end. By using a high refractive index material, a lens can be fabricated that directs a greater portion of the light emitted from a source into the lens toward the transmitting end of the lens. Thus, less of the light spills out of the lens at a surface where emission is not intended, reducing the number of lossy bounces needed to direct the light in a particular direction.

Claims

1. An optical element, comprising:

a lens comprising at least one total internal reflection (TIR) surface positioned to internally reflect incident light, said lens further comprising a receiving end with a diffuser;

wherein said lens comprises a polymeric material having a refractive index of 1.6 or greater.

2. The optical element of claim 1, said polymeric material having a refractive index of 1.7 or greater.

3. The optical element of claim 1, said polymeric material having a refractive index of 1.8 or greater.

4. The optical element of claim 1, wherein said lens is symmetrical about a longitudinal axis running through the center of said lens.

5. The optical element of claim 1, said at least one TIR surface having a conical shape.

6. The optical element of claim 1, said at least one TIR surface having an elliptical shape.

7. The optical element of claim 1, said at least one TIR surface having a parabolic shape.

8. The optical element of claim 1, wherein said receiving end comprises at least one zone and said lens further comprises a transmitting end comprising at least one zone.

9. The optical element of claim 8, said at least one receiving end zone having a shape characterized as hemispheric, hyperbolic, inverse parabolic, or conic.

10. The optical element of claim 1, said receiving end comprising at least two zones having, each of said zones having a shape characterized as hemispheric, hyperbolic, inverse parabolic, or conic.

11. The optical element of claim 8, said at least one transmitting end zone having a flat shape.

12. The optical element of claim 8, said at least one transmitting end zone having a dome shape.

13. The optical element of claim 8, said at least one transmitting end zone comprising a Fresnel lens.

14. The optical element of claim 8, said transmitting end comprising a plurality of zones.

15. The optical element of claim 8, said transmitting end comprising a disperser.

16. The optical element of claim 8, said transmitting end comprising a plurality of lenslets.

17. The optical element of claim 8, said transmitting end comprising a diffractive element.

18. The optical element of claim 1, said diffuser comprising surface elements.

19. The optical element of claim 1, said diffuser comprising a volumetric film.

20. The optical element of claim 1, further comprising a wavelength conversion material on a surface of or internal to said optical element.

21. An optical element, comprising:

a lens comprising a plurality of internal surfaces arranged to redirect light entering said lens at a receiving end toward a transmitting end, wherein said receiving end comprises a diffuser;

wherein said lens comprises a material having a refractive index of 1.6 or greater.

22. The optical element of claim 21, said lens comprising a polymer.

23. The optical element of claim 21, said lens comprising poly(methyl methacrylate) (PMMA).

24. The optical element of claim 21, said lens comprising a polycarbonate.

25. The optical element of claim 21, said lens comprising a cyclic olefin copolymer (COC).

26. The optical element of claim 21, said diffuser comprising surface elements on an inner surface of said lens.

27. The optical element of claim 21, said diffuser comprising a diffusive volumetric film on said inner surface.

28. The optical element of claim 21, further comprising a wavelength conversion material on a surface of said lens.

29. An optical assembly, comprising:

a housing;

a light source within said housing;

a lens within said housing arranged to receive a portion of the light emitted from said light source at a receiving end, said lens internally directing light from said light source toward a transmitting end, wherein said receiving end comprises a diffuser;

wherein said lens comprises a material having a refractive index of 1.6 or greater.

30. The optical assembly of claim 29, said lens comprising a polymer.

31. The optical assembly of claim 29, said lens comprising poly(methyl methacrylate) (PMMA).

32. The optical element of claim 29, said lens comprising a polycarbonate.

33. The optical element of claim 29, said lens comprising a cyclic olefin copolymer (COC).

34. The optical assembly of claim 29, said diffuser comprising surface elements on a surface of said lens.

35. The optical assembly of claim 29, said diffuser comprising a diffusive volumetric film on a surface of said lens.

36. The optical assembly of claim 29, said optical assembly further comprising a wavelength conversion material on said inner surface of or internal to said lens.

37. The optical assembly of claim 29, said light source comprising multiple solid state emitters.

38. The optical assembly of claim 29, said light source comprising multiple light emitting diodes (LEDs).

39. The optical assembly of claim 29, said light source comprising at least two light sources emitting different spectra.

40. The optical assembly of claim 29, wherein said housing comprises a thermally conductive component in thermal contact with said light source to draw heat away from said light source.

41. An optical element, comprising:

a lens comprising at least one total internal reflection (TIR) surface positioned to internally reflect incident light and a receiving end that comprises a diffuser.

42. The optical element of claim 41, wherein said lens comprises a polymeric material having a refractive index of b 1.6 or greater.

43. The optical element of claim 41, said diffuser comprising surface elements.

44. The optical element of claim 41, said diffuser comprising a volumetric film.

45. The optical element of claim 41, further comprising a wavelength conversion material on a surface of or internal to said optical element.

46. An optical assembly comprising:

a light source;

a lens arranged to receive a portion of the light emitted from said light source at a receiving end, said lens internally directing light from said light source toward a transmitting end; and

a diffuser comprising a portion that is between said light source and said receiving end of said lens.

47. The optical element of claim 46, wherein said lens comprises a polymeric material having a refractive index of 1.6 or greater.

48. The optical element of claim 46, wherein said lens comprises a polymeric material having a refractive index of 1.7 or greater.

49. The optical element of claim 46, wherein said lens comprises a polymeric material having a refractive index of 1.8 or greater.

50. The optical element of claim 46, said diffuser comprising surface elements.

51. The optical element of claim 46, said diffuser comprising a volumetric film.