Reshaping light source modules and illumination systems using the same

• US 7,246,923 B2
• Filed: 02/11/2004
• Issued: 07/24/2007
• Est. Priority Date: 02/11/2004
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Conner, Arlie R.
• Primary Examiner(s): Luebke; Renee
• Assistant Examiner(s): DZIERZYNSKI, EVAN P
• Application Number:
  US10/776,155
• Publication Number:
  US 20050174771A1
• Time in Patent Office: 1,259 Days
• Field of Search: 362/800, 362/551, 362/555, 362/561, 362/227, 362/257, 362/268, 362/291, 362/317, 362/329, 362/331, 362/332, 362/309
• US Class Current: 362/309
• 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: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G02B 27/0961 Lens arrays lens arrays per se G02B3/0006
• CPC Class Codes: G02B 27/0994 Fibers, light pipes optical fibers per se G02B6/02

Abstract

Light source modules are disclosed, which include an emitter having a light-emitting surface and a pyramid collector mounted onto the emitter over the emitting surface. Also disclosed are illumination systems, including a plurality of light source modules, each light source module comprising an emitter having a light-emitting surface and a pyramid collector mounted onto the emitter over the emitting surface. The illumination systems further include an illumination target and a system of optical elements disposed between the at least one light source module and the illumination target.

Claims

1. A light source module comprising an emitter having a light-emitting surface and a pyramid collector made of a substantially optically clear material mounted onto one emitter over its emitting surface and having sides which operate as simple reflectors for light emanating from the emitting surface at angles that are sufficiently large to result in total internal reflection of such light within the pyramid collector, said pyramid collector having a proximal end facing the emitting surface and a distal end facing away from the emitting surface;

wherein the shape and size of the proximal end are different from the shape and size of the distal end, and wherein a geometrical figure having the shape and size of the proximal end can be completely enclosed within a geometrical figure having the shape and size of the distal end.

2. The light source module as recited in claim 1, wherein the proximal end of the pyramid collector is in contact with the light-emitting surface.

3. The light source module as recited in claim 1, wherein the proximal end of the pyramid collector has dimensions and shape that are approximately the same as dimensions and shape of the emitting surface.

4. The light source module as recited in claim 1, wherein the proximal end has a generally square shape and the distal end has a generally rectangular shape.

5. The light source module as recited in claim 1, wherein the proximal end of the pyramid collector is fitted around the emitting surface.

6. The light source module as recited in claim 1, further comprising a straight rectangular pipe section disposed adjacent to the distal end of the pyramid collector.

7. The light source module as recited in claim 1, further comprising a dome portion.

8. The light source module as recited in claim 7, further comprising a straight pipe portion disposed between the dome portion and the pyramid collector.

9. The light source module as recited in claim 7, further comprising a generally disk-shaped flange disposed between the dome portion and the pyramid collector.

10. The light source module as recited in claim 1, wherein the distal end of the pyramid collector has a generally pincushioned configuration.

11. The light source module as recited in claim 1, wherein the pyramid collector collects at least about 70 percent of light emitted by the emitter.

12. The light source module as recited in claim 1, wherein a distance between the proximal and distal ends of the pyramid collector is about 3 to 5 times longer than a largest diagonal of its distal end.

13. The light source module as recited in claim 1, wherein the pyramid collector has sides that taper from about 2 to about 6 degrees from the distal to the proximal end.

14. The light source module as recited in claim 1, wherein the pyramid collector has sides that taper no more than about 10 degrees from the distal to the proximal end.

15. An illumination system, comprising:

a plurality of light source modules, each light source module comprising an emitter having a light-emitting surface and a pyramid collector made of a substantially optically clear material mounted onto one emitter over its emitting surface and having sides which operate as simple reflectors for light emanating from the emitting surface at angles that are sufficiently large to result in total internal reflection of such light within the pyramid collector, each pyramid collector having a proximal end facing the emitting surface and a distal end facing away from the emitting surface;

wherein the shape and size of the proximal end are different from the shape and size of the distal end;

an illumination target; and

a system of optical elements disposed between the at least one light source module and the illumination target.

16. The illumination system as recited in claim 15, wherein the plurality of the light source modules is disposed in an array within a non-radially symmetrical aperture.

17. The illumination system as recited in claim 16, wherein the illumination target is an image-forming device disposed for being illuminated at an angle and having a plurality of mirrors rotatable about a pivot axis, and wherein the non-radially symmetrical aperture has a long dimension and a short dimension and is oriented so that the long dimension is aligned with the pivot axis of the mirrors of the image-forming device.

18. The illumination system as recited in claim 15, wherein the light source modules and the system of optical elements are configured to form a plurality of channels aimed substantially into the illumination target.

19. The illumination system as recited in claim 18, wherein the light source modules are disposed tangentially to and along a spherical surface.

20. The illumination system as recited in claim 15, wherein the proximal end of each pyramid collector is in contact with the emitting surface of the emitter the pyramid collector is mounted on.

21. The illumination system as recited in claim 15, wherein proximal end of each pyramid collector has dimensions and shape that are approximately the same as dimensions and shape of the emitting surface of the emitter the pyramid collector is mounted on.

22. The illumination system as recited in claim 15, wherein the proximal end of each pyramid collector is fitted around the emitting surface of the light source module the pyramid collector is mounted on.

23. The illumination system as recited in claim 15, wherein each light source module further comprises a straight rectangular pipe section disposed adjacent to the distal end of each pyramid collector.

24. The illumination system as recited in claim 15, wherein each light source module further comprises a dome portion.

25. The illumination system as recited in claim 24, wherein each light source module further comprises a straight pipe portion disposed between the dome portion and the pyramid collector.

26. The illumination system as recited in claim 24, wherein each light source module further comprises a generally disk-shaped flange disposed between the dome portion and the pyramid collector.

27. The illumination system as recited in claim 15, wherein the distal end of each pyramid collector has a generally pincushioned configuration.

28. The illumination system as recited in claim 15, wherein each pyramid collector collects at least about 70 percent of light emitted by the emitter the pyramid collector is mounted on.

29. The illumination system as recited in claim 15, wherein a distance between the proximal and distal ends of each pyramid collector is about 3 to 5 times longer than a largest diagonal of that pyramid collector'"'"'s distal end.

30. The illumination system as recited in claim 15, wherein each pyramid collector has sides that taper from about 2 to about 6 degrees from the distal to the proximal end of that pyramid collector.

31. The illumination system as recited in claim 15, wherein each pyramid collector has sides that taper no more than about 10 degrees from the distal to the proximal end of that pyramid collector.

32. The illumination system as recited in claim 15, wherein the proximal end of each pyramid collector has a generally square shape and the distal end of each collector has a generally rectangular shape.

33. The illumination system as recited in claim 15, wherein the system of optical elements is configured to image the distal end of each pyramid collector onto the illumination target.

34. The illumination system as recited in claim 33, wherein the images of the emitting surfaces are substantially superimposed to form an illumination patch, said illumination patch substantially filling the illumination target.

35. The illumination system as recited in claim 33, wherein the images of the emitting surfaces are closely packed to form an illumination patch, said illumination patch substantially filling the illumination target.

36. The illumination system as recited in claim 33, wherein the images of the emitting surfaces overlap to form an illumination patch, said illumination patch substantially filling the illumination target.

37. The illumination system as recited in claim 15, wherein a shape of at least one of the distal ends of the pyramid collectors substantially matches a shape of the illumination target.

38. The illumination system as recited in claim 37, wherein the shape of the illumination target is substantially square.

39. The illumination system as recited in claim 37, wherein the shape of the illumination target is substantially rectangular.