LED light assembly having three-part optical elements

• US 9,659,511 B2
• Filed: 07/21/2016
• Issued: 05/23/2017
• Est. Priority Date: 07/30/2012
• Status: Active Grant

• Current Assignee: Ultravision Technologies, LLC (Ultravision International Inc.)
• Original Assignee: Ultravision Technologies, LLC (Ultravision International Inc.)
• Inventors: Hall, William Y., Magarill, Simon, Auyeung, David Siucheong
• Primary Examiner(s): Negron, Ismael
• Application Number:
  US15/216,562
• Publication Number:
  US 20160329004A1
• Time in Patent Office: 306 Days
• CPC Class Codes: F21K 9/60 Optical arrangements integrated in the light source, e.g. for improving the colour rendering index or the light extraction
• CPC Class Codes: F21S 6/006 for direct lighting only, e.g. task lighting
• CPC Class Codes: F21V 19/003 Fastening of light source holders, e.g. of circuit boards or substrates holding light sources
• CPC Class Codes: F21V 21/26 Pivoted arms
• CPC Class Codes: F21V 23/002 Arrangements of cables or conductors inside a lighting device, e.g. means for guiding along parts of the housing or in a pivoting arm
• CPC Class Codes: F21V 29/00 Protecting lighting devices from thermal damage; Cooling or heating arrangements specially adapted for lighting devices or systems lighting fixtures combined with outlets for air-treatment systems F24F13/078
• CPC Class Codes: F21V 29/15 Thermal insulation
• CPC Class Codes: F21V 29/503 of light sources cooling arrangements structurally associated with gas-discharge or vapour-discharge lamps H01J61/52; cooling arrangements structurally associated with electric incandescent lamps H01K1/58; cooling arrangements structurally associated with light-emitting diodes H01L33/64
• CPC Class Codes: F21V 29/70 characterised by passive heat-dissipating elements, e.g. heat-sinks
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/745 the fins or blades being planar and inclined with respect to the joining surface from which the fins or blades extend
• CPC Class Codes: F21V 29/76 with essentially identical parallel planar fins or blades, e.g. with comb-like cross-section
• CPC Class Codes: F21V 29/763 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21V 29/89 Metals
• CPC Class Codes: F21V 31/00 Gas-tight or water-tight arrangements
• CPC Class Codes: F21V 31/005 Sealing arrangements therefor
• CPC Class Codes: F21V 33/00 Structural combinations of lighting devices with other articles, not otherwise provided for
• CPC Class Codes: F21V 5/007 Array of lenses or refractors for a cluster of light sources, e.g. for arrangement of multiple light sources in one plane combination of two or more refractors F21V5/008
• CPC Class Codes: F21W 2131/10 Outdoor lighting
• CPC Class Codes: F21W 2131/40 : Lighting for industrial, commercial, recreational or military use
• CPC Class Codes: F21Y 2105/10 : comprising a two-dimensional array of point-like light-generating elements
• CPC Class Codes: F21Y 2105/12 : characterised by the geometrical disposition of the light-generating elements, e.g. arranging light-generating elements in differing patterns or densities
• CPC Class Codes: F21Y 2105/16 : square or rectangular, e.g. for light panels
• CPC Class Codes: F21Y 2115/10 : Light-emitting diodes [LED]
• CPC Class Codes: G02B 19/0014 : at least one surface having optical power
• 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
• CPC Class Codes: G09F 13/02 : Signs, boards, or panels, illuminated by artificial light sources positioned in front of the insignia
• CPC Class Codes: G09F 13/22 : electroluminescent electroluminescent light sources per se H05B33/00
• CPC Class Codes: G09F 15/00 : Boards, hoardings, pillars, or like structures for notices, placards, posters, or the like
• CPC Class Codes: G09F 15/0037 : supported by a post
• CPC Class Codes: G09F 15/005 : for orientation or public information
• CPC Class Codes: G09F 2013/222 : with LEDs

Abstract

An LED lighting assembly includes a circuit board, a number of light emitting diodes (LEDs) overlying the circuit board, and optical element is proximate each LED and separate from other optical elements. Each optical element includes a first portion and a second portion that intersects with the first portion in a region between the first and second portions. The first and second portions are shaped so that at least one surface normal of the first portion intersects with at least one surface normal of the second portion, and the first and second portions are configured so that light from the associated LED exits the associated optical element through the first and the second portions. Each optical element also includes a third portion extending beyond the region between the first portion and the second portion in a direction away from the associated LED.

Claims

1. An apparatus comprising a lighting assembly for illumination of an area, the lighting assembly comprising:

a circuit board;

a plurality of light emitting diodes (LEDs) overlying the circuit board; and

a plurality of optical elements, wherein each optical element of the plurality of optical elements is proximate an associated LED of the plurality of LEDs, wherein each optical element of the plurality of optical elements is separate from other optical elements of the plurality of optical elements, and wherein each optical element of the plurality of optical elements comprises a single optical element that includes a first portion, a second portion and a third portion

wherein the first portion of the optical element comprises a first curved surface;

wherein the second portion of the optical element comprising a second curved surface that intersects with the first portion of the optical element in a region between the first portion of the optical element and the second portion of the optical element, wherein the first portion of the optical element and the second portion of the optical element are shaped so that at least one surface normal of the first portion of the optical element intersects with at least one surface normal of the second portion of the optical element and wherein the first and second portions of the optical element are configured so that light from the associated LED exits the associated optical element through the first and the second portions of the optical element;

wherein the third portion of the optical element extends beyond the region between the first portion of the optical element and the second portion of the optical element in a direction away from the associated LED;

wherein the LEDs and optical elements are arranged over the circuit board so that, during operation, light from light assembly does not create hot spots or result in dead spots on the area so long as some of the LEDs are functional.

2. The apparatus of claim 1, further comprising a heat sink comprising a plurality of fins thermally coupled to the plurality of LEDs.

3. The apparatus of claim 1, further comprising a billboard comprising the area, wherein the lighting assembly is located adjacent the billboard to illuminate the area.

4. The apparatus of claim 1, further comprising a billboard comprising the area, wherein the lighting assembly is located adjacent the billboard to illuminate the area when a subset of the LEDs is not generating any light.

5. The apparatus of claim 1, wherein the LEDs are arranged in two rows that extend along a longitudinal axis of the circuit board.

6. The apparatus of claim 5, further comprising a heat sink thermally coupled to a lower surface of the circuit board so that the circuit board is between the LEDs and the heat sink, wherein the heat sink comprises a first section substantially parallel to the lower surface of the circuit board and a plurality of fins extending away from the first section and substantially perpendicular thereto, a longitudinal axis of each fin being substantially perpendicular to the longitudinal axis of the circuit board.

7. The apparatus of claim 6, wherein the LEDs are arranged in only the two rows.

8. A lighting assembly for illumination of an area, the lighting assembly comprising:

a circuit board;

a plurality of light emitting diodes (LEDs) overlying the circuit board; and

a plurality of optical elements, wherein each optical element of the plurality of optical elements is proximate an associated LED of the plurality of LEDs, wherein each optical element of the plurality of optical elements is separate from other optical elements of the plurality of optical elements, and wherein each optical element of the plurality of optical elements comprises a single lens that includes a first portion, a second portion and a third portion

wherein the first portion of the lens comprises a first curved surface;

wherein the second portion of the lens comprising a second curved surface that intersects with the first portion of the lens in a region between the first portion of the lens and the second portion of the lens, wherein the first portion of the lens and the second portion of the lens are shaped so that at least one surface normal of the first portion of the lens intersects with at least one surface normal of the second portion of the lens, and wherein the first and second portions of the lens are configured so that light from the associated LED exits the associated optical element through the first and the second portions of the lens;

wherein the third portion of the lens extends beyond the region between the first portion of the lens and the second portion of the lens in a direction away from the associated LED; and

wherein each optical element of the plurality of optical elements is associated with only one LED of the plurality of LEDs and is configured to direct light from that one LED toward the area such that the light from each optical element of the plurality of optical elements is directed across all of the area, wherein the light from each optical element of the plurality of optical elements is directed across all of the area so that the area is illuminated without hot spots or dead spots.

9. An apparatus comprising a lighting assembly for illumination of an area, the lighting assembly comprising:

a circuit board;

a plurality of light emitting diodes (LEDs) overlying the circuit board; and

a plurality of optical elements, wherein each optical element of the plurality of optical elements is proximate a respective LED of the plurality of LEDs, wherein each optical element of the plurality of optical elements is separate from other optical elements of the plurality of optical elements, wherein each optical element of the plurality of optical elements comprises a lens that includes;

a first outer boundary, a second outer boundary opposite the first outer boundary, a third outer boundary connecting the first outer boundary and the second outer boundary, a fourth outer boundary opposite the third outer boundary, and a central region halfway between the first outer boundary and the second outer boundary;

a first lens portion with an outer surface extending from the first outer boundary toward the central region and having a first peak located between the central region and the first outer boundary, the first peak being spaced from the central region, and the first peak being vertically spaced from the circuit board on which the respective LED is arranged by a first distance;

a second lens portion with an outer surface extending from the second outer boundary toward the central region and having a second peak located between the central region and the second outer boundary, the second peak being spaced from the central region, and the second peak being vertically spaced from the circuit board on which the respective LED is arranged by the first distance, wherein the first lens portion intersects with the second lens portion at a region between the first lens portion and the second lens portion, and wherein the first lens portion and the second lens portion are shaped so that at least one surface normal of the first lens portion intersects with at least one surface normal of the second lens portion; and

a third lens portion disposed between the first outer boundary and the second outer boundary and having a third peak located between the third outer boundary and a region halfway between the third outer boundary and the fourth outer boundary, the third peak spaced from the region halfway between the third outer boundary and the fourth outer boundary, the third peak being vertically spaced from the circuit board on which the respective LED is arranged by a second distance that is greater than the first distance.

10. The apparatus of claim 9, further comprising a billboard comprising the area, wherein the lighting assembly is located adjacent the billboard to illuminate the area.

11. The apparatus of claim 9, further comprising a billboard comprising the area, wherein the lighting assembly is located adjacent the billboard to illuminate the area without hot spots or dead spots when a subset of the LEDs is not generating any light.

12. The apparatus of claim 9, wherein each optical element of the plurality of optical elements is associated with only one LED of the plurality of LEDs and is configured to direct light from that one LED toward the area such that the light from each optical element of the plurality of optical elements is directed across the area, wherein light from each optical element of the plurality of optical elements is directed so that the area is illuminated without hot spots or dead spots.

13. The apparatus of claim 9, wherein the LEDs are arranged in two rows that extend along a longitudinal axis of the circuit board.

14. The apparatus of claim 13, further comprising a heat sink thermally coupled to a lower surface of the circuit board so that the circuit board is between the LEDs and the heat sink, wherein the heat sink comprises a first section substantially parallel to the lower surface of the circuit board and a plurality of fins extending away from the first section and substantially perpendicular thereto, a longitudinal axis of each fin being substantially perpendicular to the longitudinal axis of the circuit board.

15. A lighting assembly comprising:

a carrier;

a first substrate attached to the carrier;

a first plurality of light emitting diodes (LEDs) arranged at a surface of the first substrate;

a first plurality of optical elements, wherein each optical element of the first plurality of optical elements is proximate an associated LED of the first plurality of LEDs such that each optical element overlies a single LED and each LED underlies a single optical element;

a second substrate attached to the carrier;

a second plurality of light emitting diodes (LEDs) arranged at a surface of the second substrate;

a second plurality of optical elements, wherein each optical element of the second plurality of optical elements is proximate an associated LED of the second plurality of LEDs such that each optical element overlies a single LED and each LED underlies a single optical element;

wherein each optical element of the first plurality and the second plurality of optical elements comprises a lens with a first part, a second part, and a third part, wherein the first part comprises a first curved surface, wherein the second part comprises a second curved surface that intersects with the first curved surface at a region between the first part and the second part, wherein the first part and the second part each have a peak relative to the respective first or second substrate, the peak being spaced from the region between the first part and the second part, and wherein the third part extends beyond the region between the first part and the second part in a direction away from the associated LED;

wherein each optical element of the first plurality of optical elements is configured to direct light from the associated LED so that the lighting assembly can illuminate a substantially rectangular region; and

wherein each optical element of the second plurality of optical elements is configured to direct light from the associated LED so that the lighting assembly can illuminate the substantially rectangular region.

16. The lighting assembly of claim 15, wherein the LEDs of the first plurality of LEDs are arranged in rows that extend along a longitudinal axis in a plane of the surface of the first substrate, the lighting assembly further comprising a heat sink thermally coupled to a second surface of the first substrate, the second surface opposite the surface, the heat sink comprising a first section substantially parallel to the surface of the first substrate so that each and every LED of the first plurality of LEDs is separated from the heat sink by the first substrate, the heat sink further comprising a plurality of fins extending away from the first section and substantially perpendicular thereto, each fin extending along an axis in the plane of the surface of the first substrate, the axis for each fin being substantially perpendicular to the longitudinal axis of the surface of the first substrate, wherein the fins are substantially flat.

17. The lighting assembly of claim 15, wherein the optical elements of the first plurality and the second plurality of optical elements are configured so that failure of one or more of the LEDs will cause an illumination level of light impinging the substantially rectangular region to decrease while a uniformity of light impinging the substantially rectangular region remains substantially the same.

18. The lighting assembly of claim 15, wherein the lighting assembly is configured to illuminate the substantially rectangular region such that light from each optical element of the first plurality of optical elements is directed across all of the substantially rectangular region.

19. The lighting assembly of claim 15, wherein the lighting assembly is configured so that light emitted from the lighting assembly does not create hot spots or result in dead spots on the substantially rectangular region.

20. The lighting assembly of claim 19, wherein the lighting assembly is configured so that light emitted from the lighting assembly does not create hot spots or result in dead spots on the substantially rectangular region even upon failure of one or more of the LEDs of the first plurality of LEDs.

21. The lighting assembly of claim 20, wherein the lighting assembly is configured so that light emitted from the lighting assembly does not create hot spots or result dead spots on the substantially rectangular region even upon failure of one or more of the LEDs of the first plurality of LEDs and failure of one or more of the LEDs of the second plurality of LEDs.

22. A lighting assembly comprising:

a substrate;

a plurality of light emitting diodes (LEDs) arranged at a surface of the substrate; and

a plurality of optical elements, wherein each optical element of the plurality of optical elements is proximate an associated LED of the plurality of LEDs such that each optical element overlies a single LED and each LED underlies a single optical element, each optical element comprising a lens with a first part, a second part, and a third part, wherein the first part comprises a first curved surface, wherein the second part comprises a second curved surface that intersects with the first curved surface at a region between the first part and the second part, wherein the first part and the second part each have a peak relative to the substrate, the peak being spaced from the region between the first part and the second part, and wherein the third part extends beyond the region between the first part and the second part in a direction away from the associated LED, wherein the optical elements are configured so that failure of one or more of the LEDs will cause an illumination level of light emitted from the lighting assembly to decrease while a uniformity of the light emitted from the lighting assembly remains substantially the same.

23. The lighting assembly of claim 22, wherein the LEDs are arranged in rows that extend along a longitudinal axis in a plane of the surface of the substrate, the lighting assembly further comprising a heat sink thermally coupled to a second surface of the substrate, the second surface opposite the surface, the heat sink comprising a first section substantially parallel to the surface of the substrate so that each and every LED is separated from the heat sink by the substrate, the heat sink further comprising a plurality of fins extending away from the first section and substantially perpendicular thereto, each fin extending along an axis in the plane of the surface of the substrate, the axis for each fin being substantially perpendicular to the longitudinal axis of the surface of the substrate, wherein the fins are substantially flat.

24. The lighting assembly of claim 22, further comprising a second substrate adjacent the substrate, a second plurality of LEDs arranged at a surface of the second substrate, and a second plurality of optical elements, wherein each optical element of the second plurality of optical elements is proximate an associated LED of the second plurality of LEDs, wherein each optical element of the second plurality of optical elements has substantially the same structure as each optical element of the plurality of optical elements.

25. The lighting assembly of claim 22, wherein each optical element of the plurality of optical elements is separate from other optical elements of the plurality of optical elements.

26. The lighting assembly of claim 22, wherein the optical elements of the plurality of optical elements are integrated in a single optical panel that overlies the substrate.

27. The lighting assembly of claim 22, wherein the substrate comprises a single substrate.

28. The lighting assembly of claim 22, wherein the LEDs are arranged over the substrate so that, during operation, the light emitted from the lighting assembly does not create hot spots or result in dead spots on an area being illuminated.

29. The lighting assembly of claim 22, wherein the LEDs and optical elements are configured so that, during operation, the light emitted from the lighting assembly does not create hot spots or result in dead spots on an area being illuminated when one or more of the LEDs is not functioning.

30. The lighting assembly of claim 22, wherein the lighting assembly is configured to illuminate an area such that light from each optical element of the plurality of optical elements is directed across all of the area.