Compact folded-optics illumination lens

• US 6,896,381 B2
• Filed: 10/11/2002
• Issued: 05/24/2005
• Est. Priority Date: 10/11/2002
• Status: Active Grant

• Current Assignee: Light Engine Limited
• Original Assignee: Light Prescriptions Innovators, LLC
• Inventors: Miñano, Juan C, Benitez, Pablo, Muñoz, Fernando
• Primary Examiner(s): SIKDER, MOHAMMAD YUNUS
• Application Number:
  US10/269,479
• Publication Number:
  US 20040070855A1
• Time in Patent Office: 956 Days
• Field of Search: 359858-861, 359856-857, 359838-839, 359631-633, 359726-729, 359362-366
• US Class Current: 359/858
• CPC Class Codes: F21V 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 5/04 of lens shape
• CPC Class Codes: F21V 7/0091 using total internal reflection
• CPC Class Codes: F21Y 2101/00 Point-like light sources
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• 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 27/0012 Optical design, e.g. procedures, algorithms, optimisation routines
• CPC Class Codes: G02B 3/02 with non-spherical faces G02B3/10 takes precedence

Abstract

A method for manufacturing an apparatus and the apparatus being configured to convert a first distribution of an input radiation to a second distribution of output radiation. The method consists of the steps of generating a two-dimensional representation of at least three active optical surfaces of an optical device including calculating a segment of a first surface based on edge ray sets as a first generalized Cartesian oval, calculating a segment of an entry surface based on the edge ray set as a second generalized Cartesian oval, calculating a segment of a second surface based on the edge ray set as a third generalized Cartesian oval, and successively repeating the steps of calculating the segment of the first surface and calculating the segment of the second surface in a direction towards a source, and rotationally sweeping the two-dimensional representation about a central axis providing a three-dimensional representation of the optical device.

Claims

1. A folded-optics apparatus, comprising:

a transparent body including a first surface, a second surface and a cavity formed within at least the second surface;

the cavity having a third surface;

the second surface comprising a reflective region extending radially away from the cavity; and

the first surface comprising an annular zone configured to provide internal reflection folding and a refractive transition between the transparent body and an exterior of the transparent body.

2. The apparatus as claimed in claim 1, wherein the cavity is configured to be positioned about an optical device such that the third surface is proximate the optical device and the first surface emits an output optical beam.

3. The apparatus as claimed in claim 2, further comprising a gap defined between the optical device and the third surface.

4. The apparatus as claimed in claim 2, wherein the optical device is a light source, and the third surface is an entry surface allowing light emitted from the light source to pass through the third surface to enter the transparent body.

5. The apparatus as claimed in claim 1, wherein the first, second and third surfaces are optically active surfaces.

6. The apparatus as claimed in claim 5, wherein the first surface internally reflects an optical beam propagating within the body and to refract the optical beam as the beam passes through the first surface;

the second surface reflects the optical beam propagating within the body; and

the third surface refractively redistributes the optical beam as the beam passes through the third surface.

7. The apparatus as claimed in claim 1, wherein the cavity extends through the body to the first surface forming a through hole.

8. The apparatus as claimed in claim 1, wherein a beam exits the first surface and the exiting beam is collimated to an etendue limit set by a relative size of aperture to effective source-diameter.

9. The apparatus as claimed in claim 1, further comprising a light detecting device positioned at least partially within the cavity proximate the third surface of the cavity such that light received by the first surface of the transparent body passes through the third surface of the cavity to impinge on the light detecting device.

10. The apparatus as claimed in claim 1, wherein the cavity is configured to be positioned about an incandescent lamp light source such that the third surface is proximate the light source allowing light emitted from the light source to pass through the third surface to enter the transparent body.

11. The apparatus as claimed in claim 1, wherein the first surface further comprises a central region that is absorptive.

12. The apparatus as claimed in claim 11, wherein the first surface further comprises a central region that is reflective.

13. The apparatus as claimed in claim 11, wherein the first surface further comprises a central region that is refractive.

14. The apparatus as claimed in claim 1, wherein the first surface is planar.

15. The apparatus as claimed in claim 1, wherein the first surface has a reflective central cuspoid depression.

16. The apparatus as claimed in claim 1, wherein the transparent body includes a central zone, the central zone comprising an unfolded beam-forming reflector.

17. The apparatus as claimed in claim 1, wherein the transparent body is configured from a plurality of non-symmetric portions, wherein the plurality of non-symmetric portions provide bilaterally asymmetric distributions.

18. The apparatus as claimed in claim 1, wherein the first, second and third surfaces form a folded edge ray device.

19. The apparatus as claimed in claim 18, wherein the first, second and third surfaces are formed to define an RXIR device.

20. The apparatus as claimed in claim 1, wherein the cavity comprises a bell shape that compresses an angular range of a light source.

21. The apparatus as claimed in claim 1, wherein the cavity comprises a pointed arch configured such that light is deflected away from a central zone of the first surface.

22. The apparatus as claimed in claim 1, wherein the first, second and extended surfaces are configured such that an output light beam has a variable collimation across an exit diameter so as to conform to a particular illumination prescription.

23. The apparatus as claimed in claim 1, wherein the transparent body is formed of glass, silicone or injection-molded plastic.

24. The apparatus as claimed in claim 1, wherein the third surface includes an anti-reflection coating.

25. The apparatus as claimed in claim 1, wherein the transparent body includes a peripheral portion having a means for snap-fitting.