Optical element for a light source and lighting system using same

• US 9,157,602 B2
• Filed: 05/10/2010
• Issued: 10/13/2015
• Est. Priority Date: 05/10/2010
• 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): May, Robert
• Assistant Examiner(s): Gyllstrom, Bryon T
• Application Number:
  US12/776,799
• Publication Number:
  US 20110273882A1
• Time in Patent Office: 1,982 Days
• Field of Search: 362/237, 362/296.08, 362/311.01, 362/311.02, 362/3, 362/11.06, 362/326, 362/334, 362/335
• US Class Current: 1/1
• CPC Class Codes: F21K 9/23 Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
• CPC Class Codes: F21K 9/68 Details of reflectors forming part of the light source
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 7/0091 using total internal reflection
• 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 19/0066 in the form of an LED array

Abstract

An optical element for a light source and a lighting system using the optical element are disclosed. In example embodiments, the optical element includes an entry surface and an exit surface opposite the entry surface. The entry surface includes at least three subsurfaces, wherein each subsurface is disposed to receive light rays leaving light source. Each of the three subsurfaces is geometrically shaped and positioned to receive light rays entering the optical element through that subsurface in order to direct the light passing through the optical element. In some embodiments the optical element includes a concentrator lens disposed in the exit surface. The optical element can also include a mixing treatment. A lighting system can include multiple optical elements, each paired with a light source such as an LED or LED package.

Claims

1. An optical element for a lighting system, the optical element comprising:

a flat, annular bottom surface;

an entry surface comprising at least three subsurfaces including an inverted conic subsurface and a spherical subsurface that joins the flat, annular bottom surface at a normal angle at a first corner, wherein each subsurface is disposed to receive light rays from a light source in a different direction;

an exit surface opposite the entry surface;

a Fresnel concentrator lens disposed in or on the exit surface to receive the light rays from the inverted conic subsurface near the center of the exit surface and direct the light rays towards the normal; and

an outer surface disposed between the exit surface and the flat, annular bottom surface that joins the flat annular bottom surface at a second corner;

wherein each of the three subsurfaces is shaped and positioned to direct light rays through the optical element so that many light rays exit the optic at a normal angle relative to the exit surface.

2. The optical element of claim 1 wherein the at least three subsurfaces further comprise a flat conic subsurface.

3. The optical element of claim 2 wherein the outer surface is a conic surface.

4. The optical element of claim 3 wherein the outer surface is a parabolic surface that provides for all incident light rays received through the entry surface to be totally internally reflected.

5. The optical element of claim 4 further comprising a mixing treatment.

6. The optical element of claim 5 wherein the mixing treatment comprises a diffractive surface treatment in the exit surface.

7. The optical element of claim 5 wherein the mixing treatment comprises a patterned lens treatment in the exit surface.

8. The optical element of claim 5 wherein the mixing treatment comprises faceting in one of the entry surface and the outer surface.

9. The optical element of claim 1, wherein the exit surface further comprises a concentrator lens and wherein:

a first of the three subsurfaces directs a first portion of light from the light source to the outer surface; and

a second of the three subsurfaces directs a second portion of light from the light source to the outer surface.

10. A lighting system comprising:

a light source; and

an optical element further comprising,

a flat, annular bottom surface;

an entry surface near the light source, the entry surface comprising at least three subsurfaces including an inverted conic subsurface and a spherical subsurface that joins the flat, annular bottom surface at a normal angle at a first corner, wherein each subsurface is disposed to receive light rays leaving the light source in a different direction;

an exit surface opposite the entry surface;

a Fresnel concentrator lens disposed in or on the exit surface to receive the light rays from the inverted conic subsurface near the center of the exit surface and direct the light rays towards the normal; and

an outer surface disposed between the exit surface and the flat, annular bottom surface that joins the flat annular bottom surface at a second corner;

wherein each of the three subsurfaces is shaped and positioned to direct light rays through the lighting system so that many light rays exit the optic at a normal angle relative to the exit surface.

11. The lighting system of claim 10 wherein the at least three subsurfaces further comprise a flat conic subsurface.

12. The lighting system of claim 11 wherein the outer surface is a conic surface.

13. The lighting system of claim 12 wherein the outer surface is a parabolic surface that provides for all incident light rays received through the entry surface to be totally internally reflected.

14. The lighting system of claim 13 wherein the light source is a light emitting diode (LED).

15. The lighting system of claim 14 wherein:

the light source comprises a plurality of LED packages arranged in an array; and

the optical element comprises a plurality of optical elements, each with the entry surface near one of the plurality of the LEDs.

16. The lighting system of claim 14 further comprising a mixing treatment.

17. The lighting system of claim 16 wherein the mixing treatment comprises a diffractive surface treatment in the exit surface.

18. The lighting system of claim 16 wherein the mixing treatment comprises a patterned lens treatment in the exit surface.

19. The lighting system of claim 16 wherein the mixing treatment comprises faceting in one of the entry surface and the outer surface.

20. The lighting system of claim 10, wherein the exit surface further comprises a concentrator lens and wherein:

a first of the three subsurfaces directs a first portion of light from the light source to the outer surface;

a second of the three subsurfaces directs a second portion of light from the light source to the outer surface.

21. A method of assembling a lighting system, the method comprising:

arranging a plurality of light sources in a pattern; and

placing an optical element at each light source to receive light rays through an entry surface of the optical element comprising at least three subsurfaces including an inverted conic subsurface and a spherical subsurface that joins a flat, annular bottom surface of the optical element at a normal angle at a first corner, wherein each subsurface is disposed to receive light rays leaving the light source in a different direction, and wherein each optical element further comprises,

an exit surface opposite the entry surface;

a Fresnel concentrator lens disposed in or on the exit surface to receive the light rays from the inverted conic subsurface near the center of the exit surface and direct the light rays towards the normal; and

an outer surface disposed between the exit surface and the flat, annular bottom surface that joins the flat annular bottom surface at a second corner, so that the three subsurfaces direct light rays entering the optical element through the lighting system to cause many light rays to exit the optic at a normal angle relative to the exit surface.

22. The method of claim 21 wherein each light source is a light emitting diode (LED).

23. The method of claim 22 wherein each optical element further comprises a diffractive surface treatment in the exit surface.

24. The method of claim 22 wherein each optical element further comprises a patterned lens treatment in the exit surface.

25. The method of claim 22 wherein each optical element further comprises faceting in one of the entry surface and the outer surface.