Faceted optics for illumination devices

• US 9,347,642 B2
• Filed: 09/07/2012
• Issued: 05/24/2016
• Est. Priority Date: 09/07/2011
• Status: Active Grant

• Current Assignee: LEDVANCE LLC (MLS Co. Ltd.)
• Original Assignee: TerraLUX Incorporated
• Inventors: Catalano, Anthony
• Primary Examiner(s): Gramling, Sean
• Application Number:
  US13/606,106
• Publication Number:
  US 20130058104A1
• Time in Patent Office: 1,355 Days
• Field of Search: 362/335, 362/361
• US Class Current: 1/1
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 7/0091 using total internal reflection
• CPC Class Codes: F21V 7/06 with parabolic curvature
• 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]
• CPC Class Codes: G02B 19/0009 having refractive surfaces only
• CPC Class Codes: G02B 19/0066 in the form of an LED array
• CPC Class Codes: H01L 33/58 Optical field-shaping elements

Abstract

Faceted optics for use in conjunction with (typically planar) arrangements of discrete light sources (e.g., an array of multiple LED dies) improve or optimize the trade-off between beam divergence and beam non-uniformity, and between non-uniformities resulting from the imaging of the extended light source and artifacts introduced by the optic itself.

Claims

1. An optic for use in conjunction with an extended light source comprising a plurality of discrete light sources, the optic comprising:

a solid paraboloid structure formed of a substantially transparent material and having;

a first end comprising an exit surface at which a light beam generated by the plurality of discrete light sources exits the optic and a second end at which the plurality of discrete light sources are disposed, and

an outer surface comprising a plurality of planar quadrilateral facets;

a convex lens structure disposed on the exit surface of the solid paraboloid structure, the convex lens structure being centered on an axis of the solid paraboloid structure at a length from the second end such that a plurality of rows of facets are disposed on the solid paraboloid structure along the length between the second end and the entire convex lens structure;

wherein the facets are sized and arranged such that a light beam exiting the first end of the optic, is substantially free of images of the discrete light sources and artifacts resulting from faceting.

2. The optic of claim 1, wherein the brightness of the beam varies locally by less than 3%.

3. The optic of claim 1, wherein the brightness of the beam varies locally by less than 1%.

4. The optic of claim 1, wherein the brightness of the beam varies locally by 0.3%.

5. The optic of claim 1, wherein a beam divergence angle exceeds a baseline beam divergence angle by less than 5%.

6. The optic of claim 1, wherein, when the optic is used in conjunction with an extended light source that does not emit at the symmetry axis of the paraboloid, the brightness of the beam is not substantially lower in a center than in regions surrounding the center.

7. The optic of claim 1, wherein, when the optic is used in conjunction with an extended light source that does not emit light at the symmetry axis of the paraboloid, the beam comprises a substantially uniform center portion.

8. The optic of claim 1, wherein the convex lens surface is recessed from the first end.

9. The optic of claim 1, wherein the convex lens surface protrudes from the first end.

10. The optic of claim 1, wherein the convex lens surface is faceted.

11. The optic of claim 10, wherein the convex lens surface divided into two facets in a vertical direction.

12. The optic of claim 1, wherein a total angular coverage of the convex lens and the paraboloid exceeds 75°

.

13. The optic of claim 1, wherein a total angular coverage of the convex lens and the paraboloid exceeds 80°

.

14. The optic of claim 1, wherein a total angular coverage of the convex lens and the paraboloid exceeds 85°

.

15. The optic of claim 1, wherein the outer surface is divided into at least thirty and no more than sixty facets in an azimuthal direction.

16. The optic of claim 1, wherein a vertical angular extent of the planar facets of the outer surface is in the range from about 5°

to about 10°

.

17. The optic of claim 1, wherein all of the facets have substantially the same vertical angular extent.

18. The optic of claim 1, wherein the extended light source comprises twelve light-emitting diodes and the outer surface of the optic has an angular extent of about 50.5°

and is divided into eleven facets into a vertical direction and into 54 facets in an azimuthal direction.

19. The optic of claim 1, wherein a total number of facets of the optic is in the range from about fifty times to about one hundred times the number of discrete light sources within the extended light source.

20. The optic of claim 1, wherein the second end of the optic coincides with the focal plane of the paraboloid.

21. The optic of claim 1, wherein the paraboloid is truncated at the second end.

22. The optic of claim 1, wherein the solid structure further has a concave entrance face recessed from the second end for receiving light from the plurality of discrete light sources.

23. An optic for use in conjunction with an extended light source comprising a plurality of discrete light sources, the optic comprising:

a solid paraboloid structure formed of a substantially transparent material and having;

an outer surface comprising a plurality of planar quadrilateral facets having vertices that collectively define a faceted paraboloid,

a first end comprising an exit surface at which a light beam generated by the plurality of discrete light sources exits the optic and a second end at which the plurality of discrete light sources are disposed,

a convex lens structure disposed on the exit surface of the solid paraboloid structure, the convex lens structure being centered on an axis of the solid paraboloid structure at a length from the second end such that a plurality of rows of facets are disposed on the solid paraboloid structure along the length between the second end and the entire convex lens structure;

wherein the facets are sized and arranged such that a light beam exiting a first end of the optic, opposite a second end of the optic at which the extended light source is disposed, is substantially uniform in brightness and has a beam divergence angle that exceeds a baseline beam divergence by less than 10%.

24. The optic of claim 23, wherein the beam divergence exceeds the baseline beam divergence by less than 5%.

25. An optic for use in conjunction with a plurality of discrete light sources collectively forming an extended light-emitting surface, the optic comprising:

a solid structure formed of a substantially transparent material and defining a truncated paraboloid having;

a first end comprising an exit surface at which a light beam generated by the plurality of discrete light sources exits the optic and a second end at which the plurality of discrete light sources are disposed, and

a convex lens structure disposed on the exit surface the convex lens structure being centered on an axis of the truncated paraboloid at a length from the second end such that a plurality of rows of facets are disposed on the truncated paraboloid along the length between the second end and the entire convex lens structure;

a surface of the truncated paraboloid comprising a plurality of planar quadrilateral facets having vertices that collectively define the truncated paraboloid, and the surface of the convex lens structure being faceted so as to substantially eliminate non-uniformities of the extended light-emitting surface in a beam exiting the solid structure at the exit surface.