Beam shaping lens and LED lighting system using same

• US 9,134,006 B2
• Filed: 10/22/2012
• Issued: 09/15/2015
• Est. Priority Date: 10/22/2012
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Rodgers, Elizabeth, Pickard, Paul Kenneth
• Primary Examiner(s): Bowman, Mary Ellen
• Application Number:
  US13/657,421
• Publication Number:
  US 20140111984A1
• Time in Patent Office: 1,058 Days
• Field of Search: 362/231, 362/244, 362/362, 313/113, 313/493
• US Class Current: 1/1
• CPC Class Codes: F21K 9/62 using mixing chambers, e.g. housings with reflective walls
• CPC Class Codes: F21S 8/026 intended to be recessed in a ceiling or like overhead structure, e.g. suspended ceiling
• CPC Class Codes: F21V 17/164 the parts being subjected to bending, e.g. snap joints
• CPC Class Codes: F21V 5/005 using microprisms
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A beam shaping lens and an LED lighting system are disclosed. The lens according to example embodiments can concentrate or spread light, depending on the specific embodiment used. The lens according to example embodiments of the invention includes repeated concentric rings of refractive features, with either a constant or gradient feature angle. These features may include substantially triangular concentric rings. These features are located on the interior face of the lens, facing the LED source. In some embodiments, the exterior or exit surface of the lens includes texturing. A lens according to example embodiments of the invention can be used with various fixtures. Light enters the lens through the entry surface including the concentric rings, and exits the fixture through a textured exit surface opposite the entry surface.

Claims

1. A light engine for a lighting system, the light engine comprising:

an LED light source of size S;

a reflector comprising a bottom portion that is near the LED light source; and

a lens attached to the reflector, the lens further comprising,

an entry surface including a plurality of concentric rings, each having a substantially triangular cross-section with no side that is parallel to an axis of the lens, wherein the lens has a diameter LD, where the ratio LD/S is between about 8;

1 and 4;

1; and

an exit surface that is textured to provide diffusion.

2. The light engine of claim 1 wherein the concentric rings are spaced at an interval between 0.1 and 5 mm.

3. The light engine of claim 2 wherein the concentric rings are spaced at an interval between 0.2 and 3 mm.

4. The light engine of claim 3 wherein the concentric rings are spaced at an interval between 0.3 and 2 mm.

5. The light engine of claim 4 wherein the exit surface further comprises at least one of roughening and textured features.

6. The light engine of claim 2 wherein each of the concentric rings has a vertex angle of from about 35 degrees to about 90 degrees.

7. The light engine of claim 6 wherein a vertex angle is substantially the same for each of the concentric rings.

8. The light engine of claim 6 wherein a gradient is applied to the vertex angle of the concentric rings so that the vertex angle varies across a radius of the lens.

9. The light engine of claim 8 wherein the exit surface further comprises at least one of roughening and textured features.

10. The light engine of claim 9 wherein the interval of the concentric rings varies across the radius of the lens.

11. The light engine of claim 10 wherein each of the concentric rings has a vertex angle of from about 40 degrees to about 65 degrees.

12. A lighting system comprising:

an LED light source of size S;

a reflector to reflect at least a portion of the light from the LED light source, the reflector including a bottom portion that is near the LED light source; and

a lens disposed to receive the light from the LED light source, the lens further including an entry surface comprising a plurality of concentric rings, each having a substantially triangular cross-section with no side that is parallel to an axis of the lens and a textured exit surface to provide diffusion, wherein the lens has a diameter LD, where the ratio LD/S is between about 8;

1 and 4;

1.

13. The lighting system of claim 12 wherein the concentric rings are spaced at an interval between 0.1 and 5 mm.

14. The lighting system of claim 13 wherein the concentric rings are spaced at an interval between 0.2 and 3 mm.

15. The lighting system of claim 14 wherein the concentric rings are spaced at an interval of about 0.5 mm.

16. The lighting system of claim 13 wherein each of the concentric rings has a vertex angle of from about 35 degrees to about 90 degrees.

17. The lighting system of claim 16 wherein a vertex angle is substantially the same for each of the concentric rings.

18. The lighting system of claim 16 wherein a gradient is applied to the vertex angle of the concentric rings so that the vertex angle varies across a radius of the lens.

19. The lighting system of claim 18 wherein the LED light source further comprises at least first and second LEDs which, when illuminated, emit light having a dominant wavelength from 435 to 490 nm and a dominant wavelength from 600 to 640 nm, respectively, and a phosphor, when excited, emits light having a dominant wavelength from 540 to 585 nm.

20. The lighting system of claim 19 wherein the textured exit surface further comprises at least one of roughening and textured features.

21. The lighting system of claim 20 wherein the interval of the concentric rings varies across the radius of the lens.

22. A method of assembling an LED light fixture, the method comprising:

providing a reflector;

arranging an LED light source of size S proximate to the reflector so that a bottom portion of the reflector is near the LED light source;

connecting the LED light source to a power supply to enable the power supply to energize the LED light source; and

attaching a lens to the reflector to receive light from the LED light source at least one of directly or as reflected by the reflector, wherein the lens further comprises an entry surface including a plurality of concentric rings, each having a substantially triangular cross-section with no side that is parallel to an axis of the lens and a textured exit surface to provide diffusion and wherein the lens has a diameter LD, where the ratio LD/S is between about 8;

1 and 4;

1 and the lens has a beam angle from about 10°

to about 15°

.

23. The method of claim 22 wherein the concentric rings are spaced at an interval between 0.1 and 5 mm.

24. The method of claim 23 wherein the concentric rings are spaced at an interval between 0.2 and 3 mm.

25. The method of claim 24 wherein the concentric rings are spaced at an interval of about 0.5 mm.

26. The method of claim 25 wherein the textured exit surface further comprises at least one of roughening and textured features.

27. The method of claim 23 wherein each of the concentric rings has a vertex angle of from about 35 degrees to about 90 degrees.

28. The method of claim 27 wherein a gradient is applied to the vertex angle of the concentric rings so that the vertex angle varies across a radius of the lens.

29. The method of claim 28 further comprising assembling the LED light source from at least first and second LEDs which, when illuminated, emit light having a dominant wavelength from 435 to 490 nm and a dominant wavelength from 600 to 640 nm, respectively, and a phosphor, when excited, emits light having a dominant wavelength from 540 to 585 nm.

30. A lighting system comprising:

an LED light source of size S;

a reflector to reflect at least a portion of the light from the LED light source positioned so that a bottom portion of the reflector is near the LED light source; and

a lens disposed to receive the light from the LED light source, the lens having a plurality of concentric features on an entry surface, each with non-vertical sides so that an effective surface area of the lens is increased by a surface space of the non-vertical sides and the lens has a diameter LD, where the ratio LD/S is between about 8;

1 and 4;

1 for a beam angle from about 10°

to about 15°

.

31. The lighting system of claim 30 wherein the ratio is between about 6:

1 and 4;

1.

32. The lighting system of claim 30 wherein the ratio is between about 5:

1 and 4;

1.