LED lens

• US 9,523,479 B2
• Filed: 01/03/2014
• Issued: 12/20/2016
• Est. Priority Date: 01/03/2014
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Goldstein, Corey
• Primary Examiner(s): Coughlin, Andrew
• Assistant Examiner(s): ULANDAY, MEGHAN K
• Application Number:
  US14/147,268
• Publication Number:
  US 20150192267A1
• Time in Patent Office: 1,082 Days
• US Class Current: 1/1
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 5/08 producing an asymmetric light distribution
• CPC Class Codes: F21V 7/0091 using total internal reflection
• CPC Class Codes: F21Y 2105/10 comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2113/13 comprising an assembly of point-like light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• 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 3/00 Simple or compound lenses
• CPC Class Codes: H01L 33/58 Optical field-shaping elements

Abstract

A lens for distribution of light from a light emitter having an emitter axis. The lens includes an outer surface and a total internal reflection (TIR) surface positioned outwardly of and around the emitter such that light received by the TIR surface is totally internally reflected toward the outer surface. The TIR surface has at least one recessed region extending away from the light emitter, thereby to increase amount of TIR and facilitate lateral diffusion of highest-intensity light in the middle of the light distribution. The lens may further include a base surface adjacent the emitter and an inner surface defining an inner cavity about the emitter axis. In such embodiments, the TIR is positioned and configured for total internal reflection of light received from the inner surface.

Claims

1. A lens for distribution of light from a light emitter having an emitter axis, comprising:

an inner surface defining an inner cavity about the emitter axis; and

a total internal reflection (TIR) surface partially bounding a secondary cavity which is offset from the inner cavity with an intermediate surface therebetween, the intermediate surface including front and rear edges with a pair of side edges therebetween, the TIR surface extending from the rear edge of the intermediate surface the TIR surface and being centered substantially on a non-preferential side outwardly of and around the inner surface and positioned and configured for total internal reflection of light received from the inner surface toward a preferential side, the TIR surface comprising at least one recessed region extending away from the light emitter.

2. The lens of claim 1 wherein the TIR surface is substantially cross-sectionally convex.

3. The lens of claim 2 wherein the TIR surface comprises at least two cross-sectionally convex surface portions with the recessed region therebetween.

4. The lens of claim 3 wherein the recessed region is substantially cross-sectionally smoothly concave.

5. The lens of claim 4 wherein the recessed region smoothly adjoins adjacent convex portions of the TIR surface.

6. The lens of claim 1 wherein the recessed region is substantially cross-sectionally smoothly concave.

7. The lens of claim 6 wherein the recessed region smoothly adjoins adjacent convex portions of the TIR surface.

8. The lens of claim 1 wherein the inner surface is configured for distributing light from the light emitter predominantly toward the preferential side.

9. The lens of claim 8 wherein the TIR surface spans an angle in the range 90-180°

around the emitter axis.

10. The lens of claim 9 wherein the TIR surface spans about 140°

around the emitter axis.

11. The lens of claim 8 further comprising a base surface adjacent the emitter and forming an opening to an inner cavity about the emitter and a second opening to the secondary cavity partially bounded by the TIR surface.

12. The lens of claim 1 further including an outer surface configured for refracting emitter light predominantly toward the preferential side.

13. A lens for distribution of light from a light emitter having an emitter axis, comprising:

an inner surface defining an inner cavity about the emitter axis;

a total internal reflection (TIR) surface partially bounding a secondary cavity outwardly of and around the inner surface and positioned and configured for total internal reflection of light received from the inner surface, the TIR surface comprising at least one recessed region extending away from the light emitter; and

an outer surface comprising a non-convex region substantially over the TIR surface and configured to further refract light received from the TIR surface.

14. The lens of claim 13 further comprising an outward flange extending from the outer surface away from the axis.

15. A lens for distribution of light from a light emitter having an emitter axis, comprising:

an outer surface configured for refracting emitter light predominantly toward the preferential side;

a total internal reflection (TIR) surface positioned outwardly of and around the emitter such that light received by the TIR surface is totally internally reflected toward the outer surface, the TIR surface comprising at least one recessed region extending away from the light emitter; and

a non-convex region of the outer surface substantially over the TIR surface along the emitter axis and configured to further refract light received from the TIR surface.

16. The lens of claim 15 wherein the TIR surface is substantially cross-sectionally convex.

17. The lens of claim 16 wherein the TIR surface comprises at least two cross-sectionally convex surface portions with the recessed region therebetween.

18. The lens of claim 17 wherein the recessed region is substantially cross-sectionally smoothly concave and smoothly adjoins adjacent convex portions of the TIR surface.

19. The lens of claim 15 configured for distributing light from the light emitter predominantly toward a preferential side, the TIR surface being centered substantially on the non-preferential side to redirect light therefrom toward the preferential side.

20. The lens of claim 19 further including a refracting inner surface configured for refracting light from the light emitter predominantly toward a preferential side, the refracting inner surface having:

a front sector centered on the preferential side and refracting emitter light predominantly toward the outer surface; and

a back sector centered on the non-preferential side radially opposite the preferential side and having a back-sector surface configuration differing from the surface configuration of the front sector.

21. The lens of claim 20 wherein the TIR surface spans an angle in the range 90-180°

around the emitter axis.

22. The lens of claim 21 wherein the TIR surface spans about 140°

around the emitter axis.

23. The lens of claim 19

further comprising an inner surface defining an inner cavity about the emitter axis,

the TIR surface partially bounding a secondary cavity partially bounded by the TIR surface.

24. The lens of claim 23 wherein the secondary cavity is offset from the inner cavity with an intermediate surface therebetween, the intermediate surface including front and rear edges with a pair of side edges therebetween, the TIR surface extending from the rear edge of the intermediate surface.

25. The lens of claim 24 wherein the intermediate surface is substantially orthogonal to the emitter axis.

26. The lens of claim 24 wherein the rear edge of the intermediate surface is shaped by at least two convex edge portions each extending from the respective side edge toward a front-to-rear centerline and inwardly toward the emitter axis, thereby forming a recessed edge portion on the centerline.

27. The lens of claim 26 wherein the convex edge portions define two central tangent lines transverse to the centerline, the angle between the central tangent lines being less than 180°

.

28. The lens of claim 27 wherein the convex edge portions define two side tangent lines transverse to the centerline, the angle between the side tangent lines being less than the angle between the central tangent lines.

29. The lens of claim 28 wherein the recessed edge portion is substantially smoothly concave and smoothly adjoins adjacent convex edge portions.

30. The lens of claim 24 wherein:

the TIR surface terminates remotely from the base surface at a distal edge of substantially continuous convex configuration; and

the secondary cavity is further partially bounded by an axially-remote surface extending from the base surface toward the TIR surface and offset therefrom by an end surface which extends from the distal edge of the TIR surface to an axially-remote surface.

31. The lens of claim 24 wherein the inner surface is configured for refracting light from the light emitter predominantly toward a preferential side, the inner surface including:

a front sector centered on the preferential side and having a first configuration for refracting light from the emitter predominantly toward the preferential side; and

a back sector centered on the non-preferential side radially opposite the preferential side and having a second configuration for refracting light from the emitter, the second configuration differing from the first configuration, the back sector extending from the front edge of the intermediate surface.

32. The lens of claim 31 wherein the intermediate surface portion is substantially orthogonal to the emitter axis.

33. The lens of claim 31 wherein the front edge of the intermediate surface is shaped by at least two convex front-edge portions each extending from the respective side edge toward a front-to-rear centerline and inwardly toward the emitter axis, thereby forming a recessed front-edge portion on the centerline.

34. The lens of claim 33 wherein the front edge of the intermediate surface is substantially equidistant from the rear edge at positions along radii from the emitter axis.

35. The lens of claim 15 further comprising a base surface adjacent the emitter and forming an opening to an inner cavity about the emitter and a second opening to a secondary cavity which is offset from the inner cavity and is partially bounded by the TIR surface.

36. The lens of claim 35 wherein the secondary cavity is further bounded by an axially-remote surface with an end surface adjoining the TIR surface and the axially-remote surface.

37. The lens of claim 15 further comprising an outward flange extending from the outer surface away from the axis.

38. A lens for distribution of light from a light emitter having an emitter axis, comprising:

an outer surface;

an inner surface defining an inner cavity about the emitter axis; and

a total internal reflection (TIR) surface partially bounding a secondary cavity which is offset from the inner cavity and centered substantially on a non-preferential side, the TIR surface being positioned outwardly of and around the emitter such that light received by the TIR surface is totally internally reflected toward a preferential side, the TIR surface comprising at least one recessed region extending away from the light emitter, the secondary cavity being offset from the inner cavity with an intermediate surface therebetween, the intermediate surface including front and rear edges with a pair of side edges therebetween,

the TIR surface extending from the rear edge of the intermediate surface, the rear edge of the intermediate surface being shaped by at least two convex edge portions each extending from the respective side edge toward a front-to-rear centerline and inwardly toward the emitter axis, thereby forming a recessed edge portion on the centerline.

39. The lens of claim 38 wherein the intermediate surface is substantially orthogonal to the emitter axis.

40. The lens of claim 38 wherein the recessed edge portion is substantially smoothly concave and smoothly adjoins adjacent convex edge portions.

41. The lens of claim 38 wherein the back sector of the inner surface extends from the front edge of the intermediate surface, the front edge of the intermediate surface is shaped by at least two convex front-edge portions each extending from the respective side edge toward a front-to-rear centerline and inwardly toward the emitter axis, thereby forming a recessed front-edge portion on the centerline.

42. The lens of claim 38 wherein the outer surface is configured for refracting emitter light predominantly toward the preferential side, the outer surface comprising a non-convex region substantially over the TIR surface configured to further refract light received from the TIR surface.

43. A light fixture comprising:

a heat-sink structure having a mounting surface;

a circuit board on the mounting surface and having a plurality of light emitters spaced thereon; and

an optical member over the circuit board and having a plurality of lenses each in alignment with a corresponding one of the emitters, each lens comprising an outer surface and a total internal reflection (TIR) surface positioned outwardly of and around the emitter such that light received by the TIR surface is totally internally reflected toward the outer surface, the TIR surface comprising at least one recessed region extending away from the light emitter, the outer surface being configured for refracting emitter light predominantly toward a preferential side and comprising a non-convex region which is substantially over the TIR surface along the emitter axis and is configured to refract light received from the TIR surface.

44. The light fixture of claim 43 wherein:

the TIR surface comprises at least two cross-sectionally convex surface portions with the recessed region therebetween; and

the recessed region is substantially cross-sectionally smoothly concave and smoothly adjoins adjacent convex portions of the TIR surface.

45. A light fixture comprising:

a heat-sink structure having a mounting surface;

a circuit board on the mounting surface and having a plurality of light emitters spaced thereon;

an optical member over the circuit board and having a plurality of lenses each in alignment with a corresponding one of the emitters, each lens comprising an outer surface, a refracting inner surface and a total internal reflection (TIR) surface positioned outwardly of and around the refracting inner surface being configured for refracting light from the light emitter predominantly toward a preferential side, the refracting inner surface defining an inner cavity about the emitter axis, the TIR surface partially bounding a secondary cavity which is offset from the inner cavity and comprising at least one recessed region extending away from the light emitter.

46. The light fixture of claim 45 wherein:

the secondary cavity is offset from the inner cavity with an intermediate surface therebetween, the intermediate surface including front and rear edges with a pair of side edges therebetween;

the TIR surface extends from the rear edge of the intermediate surface, the rear edge of the intermediate surface being shaped by at least two convex edge portions each extending from the respective side edge toward a front-to-rear centerline and inwardly toward the emitter axis, thereby forming a recessed edge portion on the centerline; and

a back sector of the inner surface extends from the front edge of the intermediate surface, the front edge of the intermediate surface is shaped by at least two convex front-edge portions each extending from the respective side edge toward a front-to-rear centerline and inwardly toward the emitter axis, thereby forming a recessed front-edge portion on the centerline.

47. The light fixture of claim 45 wherein the outer surface is configured for refracting emitter light predominantly toward the preferential side, the outer surface comprising a non-convex region substantially over the TIR surface configured to further refract light received from the TIR surface.