Method and apparatus for a light collection and projection system

• US 10,018,341 B2
• Filed: 08/29/2016
• Issued: 07/10/2018
• Est. Priority Date: 07/31/2014
• Status: Active Grant

• Current Assignee: JST Performance Incorporated (Truck-Lite Holdings 2 Corp.)
• Original Assignee: JST Performance Incorporated (Truck-Lite Holdings 2 Corp.)
• Inventors: Madril, Edgar A.
• Primary Examiner(s): Garlen, Alexander
• Application Number:
  US15/250,055
• Publication Number:
  US 20160363302A1
• Time in Patent Office: 680 Days
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• 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 3/02 characterised by the shape
• 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: F21V 5/04 of lens shape
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A method and apparatus for collecting and projecting light into a specified target illuminance. A lens may be mounted or otherwise paired to a carrier to form a lens/carrier combination, which may then be mounted to a printed circuit board assembly (PCBA) containing a light emitting diode (LED). The lens/carrier combination may establish an optimum optical relationship between the LED and the lens, such that a predetermined photometric distribution of the LED is collected by the lens, while the remaining photometric distribution of the LED is rejected by the carrier. The lens may include a first pair of opposing surfaces forming a first focus and a second pair of opposing surfaces forming a second focus. The first and second foci may cause light to be subtended into one or more of collimated light focused light, diffused light, and shifted light. The carrier may include an obstruction extending toward the PCBA.

Claims

1. An LED-based lighting system, comprising:

a PCBA having an LED; and

a lens configured over the LED to subtend light from the LED, the lens including a first discrete region formed of a first convex inner surface and a first convex outer surface, the first discrete region forming a first focus, the lens including a second discrete region formed of a second convex inner surface and a second convex outer surface, the second discrete region forming a second focus, wherein the first inner surface is out of alignment with the second inner surface forming an overhang, the first outer surface is out of alignment with the second outer surface forming an underhang, and wherein the overhang and underhang extend along a plane extending at an incline to a central axis of the lens.

2. The LED-based lighting system of claim 1, wherein the first focus of the first discrete region causes light to be subtended into a first subtended span of collimated light.

3. The LED-based lighting system of claim 2, wherein the collimated light travels in a direction substantially parallel to a central axis of the lens.

4. The LED-based lighting system of claim 2, wherein the collimated light travels in a direction substantially parallel to an axis of symmetry of light emitted by the LED.

5. The LED-based lighting system of claim 1, wherein the second focus of the second discrete region causes light to be subtended into a second subtended span of focused light.

6. The LED-based lighting system of claim 5, wherein the focused light travels in a direction substantially non-parallel to a central axis of the lens.

7. The LED-based lighting system of claim 5, wherein the focused light travels in a direction substantially non-parallel to an axis of symmetry of light emitted by the LED.

8. The LED-based lighting system of claim 1, wherein a central axis of the lens is offset from and parallel to an axis of symmetry of light emitted by the LED.

9. The LED-based lighting system of claim 1, wherein the lens is spaced from the LED to achieve a target illuminance.

19. The LED-based lighting system of claim 1, wherein the first focus is different from the second focus.

10. A method, comprising:

emitting light from an LED in an effective span of emission;

forming a lens with a first discrete region out of alignment with a second discrete region along a plane extending at an incline with respect to a central axis of the lens, wherein the first and second discrete regions form one or more of an overhang and an underhang, wherein the first discrete region is formed by a first convex inner surface and a first convex outer surface, wherein the second discrete region is formed by a second convex inner surface and a second convex outer surface;

passing a first portion of the effective span through the first discrete region to produce a first subtended span of light; and

passing a second portion of the effective span through the second discrete region to produce a second subtended span of light.

11. The method of claim 10, wherein the first subtended span of light is collimated light, and the second subtended span of light is focused light.

12. The method of claim 10, further including:

passing the first subtended span of light in a direction substantially parallel to a central axis of the lens, and

passing the second subtended span of light in a direction substantially non-parallel to a central axis of the lens.

13. The method of claim 10, further including:

passing the first subtended span of light in a direction substantially parallel to the axis of symmetry of the effective span of emission, and

passing the second subtended span of light in a direction substantially non-parallel to the axis of symmetry of the effective span of emission.

14. The method of claim 10, further including:

subtending the emitted light from the LED through a first inner surface of the first discrete region to produce first refracted light; and

subtending the first refracted light through a first outer surface of the first discrete region to produce the first subtended span of light.

15. The method of claim 14, further including:

subtending the emitted light from the LED through a second inner surface of the second discrete region to produce second refracted light; and

subtending the second refracted light through a second outer surface of the second discrete region to produce the second subtended span of light.

16. An LED-based lighting system, comprising:

a PCBA having an LED; and

a lens configured over the LED to subtend light from the LED, the lens including a first convex inner surface and a first convex outer surface, and a second convex inner surface and a second convex outer surface;

wherein the first inner surface is out of alignment with the second inner surface forming an overhang, and the first outer surface is out of alignment with the second outer surface forming an underhang; and

wherein the overhang and underhang extend along a plane extending at an incline to a central axis of the lens.

17. The LED-based lighting system of claim 16, wherein the first inner surface and the first outer surface form a first discrete region exhibiting a first focus, and wherein the second inner surface and the second outer surface form a second discrete region exhibiting a second focus.

18. The LED-based lighting system of claim 17, wherein the first focus of the first discrete region causes light to be subtended into a first subtended span traveling in a first direction, and wherein the second focus of the second discrete region causes light to be subtended into a second subtended span travelling in a second direction different from the first direction.

20. The LED-based lighting system of claim 17, wherein the first focus is different from the second focus.