Multi-lens LED-array optic system

• US 9,689,552 B2
• Filed: 01/04/2016
• Issued: 06/27/2017
• Est. Priority Date: 05/29/2009
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Wilcox, Kurt S., Keller, Bernd, Andrews, Peter S., Strom, Christopher, Lowes, Ted
• Primary Examiner(s): Breval, Elmito
• Application Number:
  US14/987,199
• Publication Number:
  US 20160116135A1
• Time in Patent Office: 540 Days
• CPC Class Codes: F21V 13/02 Combinations of only two kinds of elements
• CPC Class Codes: F21V 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 5/008 Combination of two or more successive refractors along an optical axis
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 7/0091 using total internal reflection
• CPC Class Codes: F21W 2131/103 of streets or roads
• 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 19/0014 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 19/0057 in the form of a laser diode array, e.g. laser diode bar semiconductor laser arrays with beam combining arrangement H01S5/4012
• CPC Class Codes: G02B 19/0066 in the form of an LED array
• CPC Class Codes: H01L 25/0753 the devices being arranged next to each other
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H01L 33/54 having a particular shape

Abstract

A lighting apparatus including an LED light emitter having an axis. The apparatus comprising a first lens over the emitter a second lens spaced over the first lens. The first lens is configured to direct LED-emitted light primarily toward a preferential radial side with respect to the emitter axis. The first lens may be an asymmetric primary lens. The first lens may have a centerline which is offset from the emitter axis toward the preferential radial side. Alternatively or in addition, the first lens may have an outer surface configured to direct LED-emitted light primarily toward the preferential radial side. The second lens may be asymmetric and be configured to further direct the light primarily toward the preferential radial side. The secondary lens may include inner and outer surfaces each shaped to direct received light primarily toward the preferential side.

Claims

1. A lighting apparatus including an LED light emitter having an axis, the apparatus comprising:

an asymmetric first lens over the emitter and having an asymmetric outer surface configured to direct LED-emitted light primarily toward a preferential radial side with respect to the emitter axis; and

a second lens spaced over the first lens and configured to further direct the light primarily toward the preferential radial side.

2. The lighting apparatus of claim 1 wherein the first lens has a centerline which is offset forwardly from the emitter axis.

3. The lighting apparatus of claim 2 wherein the first lens has an outer surface configured to direct LED-emitted light primarily toward the preferential radial side.

4. The lighting apparatus of claim 1 wherein the second lens includes:

an inner surface configured to direct light from the first-lens outer surface primarily toward the preferential radial side; and

an outer surface configured to direct light primarily toward the preferential radial side from the inner surface.

8. The lighting apparatus of claim 1 wherein:

the emitter includes an LED light source which includes a submount having an LED-populated area which has an aspect ratio greater than 1, and an array of LEDs on the LED-populated area; and

the first lens is on the submount over the LED-populated area.

9. The lighting apparatus of claim 8 wherein the aspect ratio is at least about 1.25.

10. The lighting apparatus of claim 9 wherein the aspect ratio is at least about 1.5.

11. The lighting apparatus of claim 10 wherein the aspect ratio is at least about 2.

5. A lighting apparatus including an LED light emitter having an axis, the apparatus comprising:

a first lens over the emitter and configured to direct LED-emitted light primarily toward a preferential radial side with respect to the emitter axis; and

a second lens spaced over the first lens and configured to further direct the light primarily toward the preferential radial side, the second lens including;

an inner refracting surface surrounding the first lens and including front and back sectors configured differently from one another for receiving and directing light from the first-lens outer surface primarily toward the preferential radial side;

a reflecting surface around the back sector, the reflecting surface being positioned to receive light refracted by the back sector for total internal reflection (TIR) toward the preferential side; and

an outer refracting surface configured to direct received light primarily toward the preferential radial side.

6. The lighting apparatus of claim 5 wherein the back sector of the refracting portion of the second lens includes at least a pair of surface portions transverse to each other.

7. The lighting apparatus of claim 6 wherein the front sector of the refracting portion of the second lens has a substantially smooth surface configuration extending to the juncture of the front and back sectors.

12. A lighting apparatus for primarily preferential-side illumination, the apparatus including an LED light emitter having an axis, the apparatus comprising:

an asymmetric primary lens over the LED light emitter and configured to direct LED-emitted light primarily toward the preferential radial side, the primary lens having a centerline which is offset from the axis toward the preferential radial side; and

an asymmetric secondary lens spaced over the primary lens and configured to further direct the light primarily toward the preferential side.

13. The lighting apparatus of claim 12 wherein the secondary lens includes:

an inner surface shaped to direct light from the first-lens outer surface primarily toward the preferential side; and

an outer surface shaped to direct light from the inner surface primarily toward the preferential side.

14. The lighting apparatus of claim 12 wherein the primary lens is overmolded on a submount.

15. The lighting apparatus of claim 12 wherein:

the LED emitter comprises an LED light source which includes a submount having an LED-populated area which has an aspect ratio greater than 1, and an array of LEDs on the LED-populated area; and

the primary lens is on the submount over the LED-populated area.

16. The lighting apparatus of claim 15 wherein the aspect ratio is at least about 1.25.

17. The lighting apparatus of claim 16 wherein the aspect ratio is at least about 1.5.

18. A lighting apparatus including an LED light emitter having an axis, the apparatus comprising:

an asymmetric primary lens over the LED light emitter and configured to direct LED-emitted light primarily toward the preferential side; and

an asymmetric secondary lens spaced over the primary lens and configured to further direct the light primarily toward the preferential side, the secondary lens including an inner surface shaped to direct light from the first-lens outer surface primarily toward the preferential side and an outer surface shaped to direct light from the inner surface primarily toward the preferential side, the inner surface comprising;

a refracting portion surrounding the primary lens and including front and back sectors configured differently from one another; and

a reflecting portion around the back sector, the reflecting portion positioned to receive light refracted by the back sector for total internal reflection (TIR) toward the preferential side.