Light panel, optical assembly with improved interface and light panel with improved manufacturing tolerances

• US 9,464,782 B2
• Filed: 03/04/2014
• Issued: 10/11/2016
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Morgan Innovation Incorporated
• Original Assignee: Morgan Solar Inc.
• Inventors: Morgan, John Paul, Myrskog, Stefan, Barnes, Brett, Sinclair, Michael, Morris, Nigel
• Primary Examiner(s): Sohn, Seung C
• Application Number:
  US14/196,291
• Publication Number:
  US 20150083899A1
• Time in Patent Office: 952 Days
• Field of Search: 250/216
• US Class Current: 1/1
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: F21V 17/02 with provision for adjustment F21V17/04 - F21V17/08 take precedence
• CPC Class Codes: F21V 29/502 characterised by the adaptation for cooling of specific components
• CPC Class Codes: F21V 7/00 Reflectors for light sources characterised by cooling arrangements F21V29/505
• CPC Class Codes: F21V 7/04 Optical design
• CPC Class Codes: G01J 1/0414 using plane or convex mirrors, parallel phase plates, or plane beam-splitters
• CPC Class Codes: G01J 1/42 using electric radiation detectors optical or mechanical part G01J1/04; by comparison with a reference light or electric value G01J1/10
• CPC Class Codes: H01L 31/02013 comprising output lead wires elements
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/0508 the interconnection means having a particular shape
• CPC Class Codes: H01L 31/052 Cooling means directly associated or integrated with the PV cell, e.g. integrated Peltier elements for active cooling or heat sinks directly associated with the PV cells cooling means in combination with the PV module H02S40/42
• CPC Class Codes: H01L 31/0543 comprising light concentrating means of the refractive type, e.g. lenses
• CPC Class Codes: H01L 31/0547 comprising light concentrating means of the reflecting type, e.g. parabolic mirrors, concentrators using total internal reflection
• CPC Class Codes: H01L 31/0687 Multiple junction or tandem solar cells
• CPC Class Codes: H02S 40/22 Light-reflecting or light-concentrating means directly associated with the PV cell or integrated with the PV cell H01L31/054
• CPC Class Codes: Y02E 10/52 PV systems with concentrators
• CPC Class Codes: Y02E 10/544 Solar cells from Group III-V materials
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

Light panels, and methods of providing the light panels, are described. The described light panels are substantially transparent and can operate as an illumination device or as a solar panel. An example light panel includes a first optic layer for transmitting light; a second optic layer with a reflective surface configured for one of directing light from the first optic layer and directing light to the first optic layer; and a receiving assembly disposed between the first optic layer and the second optic layer. The receiving assembly includes a first receiving layer adjacent to the first optic layer; a second receiving layer adjacent to the second optic layer and separated from the first receiving layer; and a light device coupled to the first receiving layer. The light device can be configured to receive light from the reflective surface or to provide light to the reflective surface.

Claims

1. A light panel comprising:

a first optic layer for transmitting light;

a second optic layer having a reflective surface configured for one of directing light from the first optic layer and directing light to the first optic layer; and

a receiving assembly disposed between the first optic layer and the second optic layer, the receiving assembly having;

a first receiving layer adjacent to the first optic layer;

a second receiving layer adjacent to the second optic layer and separated from the first receiving layer; and

a light device coupled to the first receiving layer, the light device being operable to receive light from the reflective surface via the second receiving layer when the reflective surface is configured to direct light from the first optic layer; and

the light device being operable to provide light to the reflective surface via the second receiving layer when the reflective surface is configured to direct light to the first optic layer;

wherein each of the first optic layer, the second optic layer and the receiving assembly is substantially transparent.

2. The light panel of claim 1, wherein the second optic layer is substantially parallel to the first optic layer.

3. The light panel of any one of claims 1 and 2, wherein the receiving assembly is substantially rigid.

4. The light panel of claim 1, wherein the light device is coupled to the first receiving layer such that an opening of the light device faces the reflective surface of the second optic layer and faces away from the first optic layer.

5. The light panel of claim 1, wherein the reflective surface directs light from one of the first optic layer and the light device to the other one of the first optic layer and the light device by reflecting the light.

6. The light panel of claim 5, wherein the reflective surface directs light from one of the first optic layer and the light device to the other one of the first optic layer and the light device within two reflections.

7. The light panel of claim 1, wherein:

the reflective surface comprises a primary reflective area and a secondary reflective area; and

one of the primary reflective area and the secondary reflective area directs light to the other one of the primary reflective area and the secondary reflective.

8. The light panel of claim 1, wherein the light device comprises a photovoltaic cell for collecting the light transmitted from the first optic layer and reflected from the reflective surface of the second optic layer.

9. The light panel of claim 8, wherein:

the first optic layer receives the light from an external light source and transmits the light to the second optic layer; and

the reflective surface of the second optic layer directs the light from the first optic layer to the light device using one or more reflections.

10. The light panel of claim 1, wherein the light device comprises a light source for providing the light to be transmitted, by the first optic layer, externally away from the light panel.

11. The light panel of claim 10, wherein:

the reflective surface of the second optic layer receives the light from the light source and directs the light to the first optic layer using one or more reflections; and

the first optic layer transmits the reflected light from the second optic layer externally away from the light panel.

12. The light panel of claim 1, wherein:

one of the first optic layer and the second optic layer comprises a first material associated with a first coefficient of thermal expansion; and

one of the first receiving layer and the second receiving layer comprises a second material associated with a second coefficient of thermal expansion, wherein the first coefficient of thermal expansion and the second coefficient of thermal expansion are different.

13. The light panel of claim 12, wherein the first coefficient of thermal expansion is greater than the second coefficient of thermal expansion.

14. The light panel of claim 12, wherein the first material comprises a polymer-based material and the second material comprises glass.

15. The light panel of claim 14, wherein the polymer-based material comprises poly(methyl methacrylate) (PMMA).

16. The light panel of claim 1, further comprising an elastomeric interface disposed between the first optic layer and the first receiving layer, wherein the elastomeric interface physically adjusts with at least physical changes at the first optic layer.

17. The light panel of claim 16, wherein the elastomeric interface comprises at least one of silicone, ethylene-vinyl acetate and ionomer.

18. The light panel of claim 1, wherein the first optic layer comprises an annular lens.

19. The light panel of claim 18, wherein the light device is coupled to the first receiving layer relative to the annular lens to facilitate a light path between the annular lens and the light device via the reflective surface.

20. The light panel of claim 18, wherein:

the first optic layer further comprises an outer annular lens concentric with the annular lens, wherein an inner edge of the outer annular lens is coupled to an exterior edge of the annular lens; and

the light device is mounted to the first receiving layer relative to the annular lens and the outer annular lens to facilitate a light path between the first optic layer and the light device via the reflective surface.

21. The light panel of claim 1, wherein the receiving assembly further includes a heat spreader disposed between the first receiving layer and the second receiving layer.

22. The light panel of claim 21, wherein the light device is mounted to a portion of the heat spreader.

23. The light panel of claim 21, wherein the heat spreader is provided in a configuration that minimally interferes with transmission of light between the first optic layer and the second optic layer.

24. The light panel of claim 21, wherein the heat spreader is provided in a hub and spoke configuration.

25. The light panel of claim 21, wherein the heat spreader is provided in a planar configuration.

26. The light panel of claim 1, wherein the first receiving layer and the second receiving layer are separated by an encapsulant.

27. The light panel of claim 26, wherein the encapsulant comprises silicone.

28. A light panel array comprising a series of at least two light panels defined in accordance with claim 1.

29. A method of providing a light panel by an assembler comprising:

providing a receiving assembly, the receiving assembly having;

a first receiving layer;

a second receiving layer separated from the first receiving layer; and

a light device coupled to the first receiving layer;

scanning, with an optical module, the receiving assembly to determine a position of the light device;

placing a first optic layer adjacent to the first receiving layer based on the position of the light device; and

placing a second optic layer adjacent to the second receiving layer based on the placement of the first optic layer;

wherein each of the first optic layer, the second optic layer and the receiving assembly is substantially transparent.

30. The method of providing the light panel of claim 29, wherein scanning the receiving assembly further comprises storing the position of the light device.

31. The method of providing the light panel of any one of claims 29 and 30, wherein:

the first optic layer comprises at least one lens; and

placing the first optic layer adjacent to the first receiving layer further comprises aligning each lens with the light device to facilitate a light path between the lens and the light device.

32. The method of providing the light panel of claim 29, wherein placing the first optic layer adjacent to the first receiving layer further comprises mounting the first optic layer to the first receiving layer using an adhesive material.

33. The method of providing the light panel of claim 32, wherein the adhesive material forms an elastomeric interface that physically adjusts with at least physical changes at the first optic layer.

34. The method of providing the light panel of claim 29 further comprising:

flipping the receiving assembly prior to placing the second optic layer adjacent to the second receiving layer.

35. The method of providing the light panel of claim 29, wherein placing the second optic layer adjacent to the second receiving layer further comprises:

after placing the first optic layer adjacent to the first receiving layer, scanning, with the optical module, an initial light panel composed of the first optic layer and the receiving assembly to determine a position of the first optic layer relative to the receiving assembly.

36. The method of providing the light panel of claim 29, wherein placing the second optic layer adjacent to the second receiving layer further comprises mounting the second optic layer to the second receiving layer using an adhesive material.