`
`
`(19) United States
`
`
`
`
`
`
`
`
`
`(12) Patent Application Publication (10) Pub. No.: US 2010/0128488 A1
`
`
`
`
`
`
`
`
` Marcoux (43) Pub. Date: May 27, 2010
`
`US 20100128488A1
`
`
`
`
`(54) SOLID STATE OPTICAL ILLUMINATION
`
`
`
`
`APPARATUS
`
`
`
`
`(52) US. Cl. ................................................... 362811.02
`
`
`
`
`
`
`
`(75)
`
`
`
`Inventor:
`
`
`(73) Assignee:
`
`
`
`
`
`
`
`Eric Marcoux, Laval (CA)
`
`
`Correspondence Address:
`gig-REC&AZ§E3& GOULD PC
`
`
`
`
`MINNEAPOLIS MN 55402_0903 (US)
`’
`
`
`
`
`DBM Reflex Enterprises Inc.
`
`
`Laval (CA)
`
`
`
`
`
`
`
`’
`
`(57)
`
`ABSTRACT
`
`
`
`
`
`
`
`
`
`3131Bptifical system having 1a 2101M sltate light sourcie, such as at:
`a prov1 es an on pu
`0 any spec rum, inc u es a ens
`
`
`
`
`
`
`
`
`illumination pattern ofuniform distribution over a remote and
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`larger target. The lens does not have an ax1s ofrevolution. The
`lens has a generally non-circular outer shape in cross section
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`and on top views, where the outer optical surfaces are angled
`
`
`
`
`
`
`
`
`
`one relative to another. The lens includes refractive and
`
`
`
`
`
`
`
`
`
`reflective active optical surfaces to split, direct and shape the
`
`
`
`
`
`
`
`
`
`
`incoming beam from the light source towards the target in the
`
`
`
`
`
`
`
`form of several angled beams of prescribed energies calcu-
`
`
`
`
`
`
`
`
`
`lated as a function ofthe shape ofthe target and distance to the
`
`
`
`
`
`
`
`
`
`
`target. The lens has an inner primary and partially open opti-
`
`
`
`
`
`
`
`
`
`cal cavity of a polygonal cross section facing the light source.
`
`
`
`
`
`
`
`
`This optical cavity has a number of refractive optical surfaces
`
`
`
`
`
`
`
`whose shape and number is determined by the number of and
`
`
`
`
`
`
`shape of the illumination beams generated in conjunction
`with the other surfaces of the lens. This novel optical system
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`may include an array of white LEDs that generate the input
`
`
`
`
`
`
`
`illumination to an array of these lenses to insure the proper
`
`
`
`
`
`
`
`illumination level and uniformity at particular remote targets.
`
`
`
`
`
`(21) Appl. No.:
`
`
`
`12/624,317
`
`
`
`Filed:
`
`
`
`
`
`
`
`Nov. 23, 2009
`
`
`
`
`Related US. Application Data
`.
`.
`.
`.
`
`
`
`
`
`Prov1s1onal applicatlon No. 61/116,900, filed on Nov.
`
`
`21’ 2008‘
`
`_
`_
`_
`_
`
`
`
`Publication Class1ficat10n
`
`
`
`Int. Cl,
`
`F21 V 5/00
`
`
`
`(2006.01)
`
`
`
`
`
`(22)
`
`
`
`(60)
`
`
`
`(51)
`
`
`
`
`
`
`
`Page 1 of31
`
`SAMSUNG EXHIBIT 1012
`
`Page 1 of 31
`
`SAMSUNG EXHIBIT 1012
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 1 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`
`
`
`Fig. 1a) PRIOR ART
`
`Page 2 of31
`
`Page 2 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 2 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`Page 3 0f31
`
`Page 3 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 3 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`Page 4 of31
`
`Page 4 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 4 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`Page 5 0f31
`
`Page 5 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 5 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`
`
`
`
`
`
`Page 6 0f31
`
`Page 6 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 6 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`Fig.3e)
`
` Fig.3c)Fig.3d)
`
`Page 7 0f31
`
`Page 7 of 31
`
`

`

`
`
`Patent Application Publication
`
`
`
`
`
`
`May 27, 2010 Sheet 7 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`
`
`nnm+<uu«blolnlmyvImmwlnnOum
`
`
`
`
`
`
`
`
`
`
`
`mHOn—w:m+<:mE<mmFoam:0:E<mm
`
`
`
`
`
`2m::<:
`
`
`:m:_>_<mm:<:_>_<mm
`
`
`
`
`
`
`
`
`
`
`
`
`
`Page 8 0f31
`
`Page 8 of 31
`
`
`
`

`

`
`
`Patent Application Publication
`
`
`
`
`
`
`May 27, 2010 Sheet 8 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
` :U+m+<:
`
`
`
`-m.mm.
`
`.m:EFk..o+o+m+<_.
`
`
`
`
`
`
`
`
`
`._.On_wam:_>_<mmm._.0n_w:D+U+m+<:m_>_<mm
`
`
`
`
`
`5%.:9.52mm
`
`m._.On_w
`
`ms_<mm
`
`RD:
`
`Ev.mmt
`
`
`:0+m+<:
`
`
`
`
`
`
`
`
`
`
`
`
`Page 9 0f31
`
`Page 9 of 31
`
`
`
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 9 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`Figs.5a-b
`SPOTS“A+B+C+D+E”
`
`
`
`
`
`
`
`
`
`
`
`
`Page 10 of31
`
`Page 10 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 10 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`ILLUMINATED
`Non-
`
`(U
`
`
`U
`
`
`
`2C
`
`D
`.“i
`
`<
`
`z
`
`s
`
`:3
`i
`
`
`
`
`
`mum:
`1:
`
`
`
`
`f.
`
`
`:
`2"“
`DE
`
`
`9m
`
`I_cn
`LI.
`LU
`....l
`
`
`2 g
`
`
`
`
`:
`
`'2
`é
`
`m
`
`0-
`
`<“
`
`DE
`
`9:
`
`l—Cfl
`
`
`
`I 9 D
`
`!
`
`
`
`
`
`
`
`
`Page 11 of31
`
`Page 11 of 31
`
`

`

`
`
`Patent Application Publication
`
`
`
`
`
`
`May 27, 2010 Sheet 11 0f 26
`
`M
`
`
`
`
`
`mNif
`
`
`
`
`
`
`
`m1.25.220:
`
`
`
`
`
`$833.2359m
`
`
`
`ULz<mo<=d=ammoncmé:Em...
`
`
`
`
`
`
`
`
`
`
`
`:._.Z<m_n_<30=:._.z<~._n_<30:
`
`
`
`meOQXmFIG—momwOaXm.Em...
`
`
`
`
`
`
`
`Page 12 of31
`
`Page 12 of 31
`
`
`
`

`

`Patent Application Publication
`
`May 27
`
`9
`
`2010 Sheet 12 of 26
`
`US 2010/0128488 A1
`
`
`
`DmmOmeFIG—m
`
`.L.Z<mn_<30:
`
`
`
`meOmxwHum...
`
`:._.Z<N_n_<20=
`
`
`
`DmmOmeiDPIG—m
`
`:._.Z<m_n_<30:
`
`m.mt
`
`
`
`DmmOmeiDFIG—m
`
`:._.Z<w_D<DO:
`
`Page 13 of31
`
`Page 13 of 31
`
`
`
`
`
`

`

`
`
`Patent Application Publication
`
`
`
`
`
`
`May 27, 2010 Sheet 13 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`3.3aif
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Page 14 of31
`
`Page 14 of 31
`
`
`

`

`
`
`Patent Application Publication
`
`
`
`
`
`
`May 27, 2010 Sheet 14 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`:m:w:0:w2<mm
`
`@720m.mmE
`
`
`
`
`
`
`
`m_>_<mm
`
` :Z:
`
`......kiwi»..
`
`
`
`Page 15 of31
`
`Page 15 of 31
`
`
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 15 0f 26
`
`
`
`US 2010/0128488 Al
`
`
`
`x“
`
`,,ssssssmssssss‘
`
`.-
`
`
`
`
`
`”Maui-”H”.-
`
`-.:1-::1-::1g:-.-.-.-.t-.:1-::1:z-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.
`'
`".
`".
`".
`'tfitytywwwvl:-.-.-.-.-.-.-.-.~.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.-.
`
`
`
`'
`'.
`-.-.-.-.-.-.-.-.-.-.-.-.-.-.;..-.-.-.-.-. -.-.-.-.-.-.-.-.-.-.-.-.-.;..;:$;.3'.-.-.-.-.-.-.-.-.-.-.-.-.-.
`
`\2
`
`EKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKKK\.............................................................................................._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._._..
`
`Page 16 of31
`
`Page 16 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 16 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`101a114 100
`
`
`1
`//
`
`101c
`
`
`mm
`
`112a
`
`101f
`112b 102/
`
`11Gb
`
`
`
`101e/
`
`
`
`“’2"
`
`_
`
`"
`
`104b
`
`
`
`
`
`
`
`104a 106
`108
`
`
`
`Isameiric v 'ew \
`
`102C
`
`
`101d
`
`101b
`
`
`
`
`91’ng
`
`
`
`Page 17 of31
`
`Page 17 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 17 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`102 Left V‘iE‘EW
`
`
`
`
`fig )16[
`
`
`
`102 8&3th mi AA
`
`
`
`
`fig. [16
`
`Page 18 of31
`
`Page 18 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 18 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`F
`
`F 1
`
`-
`
`1:
`Q
`.3
`EH
`
`7A
`
`73
`
`—-\‘
`m
`<1-
`
`F
`
`\
`
`no
`
`F F
`
`N oF g
`
`o
`
`Page 19 of31
`
`Page 19 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 19 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`
`
`
`
`
`
`Page 20 of 31
`
`Page 20 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 20 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`Page 21 of31
`
`Page 21 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 21 of 26
`
`
`US 2010/0128488 A1
`
`
`
`
`E: Ii [.1
`
`
`
`
`
`
`
`
`
`IIII...III-IIII-l-IIIIlI-III-
`III-II
`
`IIIIIIIIIIIIIIIIIIIIIIIIIIIII
`I'll-I
`'1III-II'll-III.IIIIIIIIIIIIIIIIIIIIII
`
`"II-II
`Ill-IIIIIIIIIIIIII
`IIIIII
`.I - --—---—----—--g--pg-ggpggqg_!-g ‘!!---I
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Page 22 of 31
`
`Page 22 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 22 of 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`Page 23 of 31
`
`Page 23 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 23 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`fig/3
`
`Page 24 of 31
`
`Page 24 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 24 of 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`108”
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`fl)
`
`
`
`102"
`
`
`
`
`
`
`
`
`
`
`
`
`
`.)
`
`
`avg/3
`
`Page 25 of31
`
`Page 25 of 31
`
`

`

`
`
`Patent Application Publication
`
`
`
`
`
`
`May 27, 2010 Sheet 25 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`fiflfij-
`
`
`K
`
`Page 26 of 31
`
`Page 26 of 31
`
`

`

`
`
`
`
`
`
`Patent Application Publication May 27, 2010 Sheet 26 0f 26
`
`
`US 2010/0128488 A1
`
`
`
`
`
`
`
`
`
`
`
`
`.$ection cut D-fi
`
`
`3:1
`
`Scale:
`
`
`
`
`
`.Section cut E-E
`
`
`‘Scale:
`
`
`3:1
`
`
`
`91313 [-m-n
`
`Page 27 of 31
`
`Page 27 of 31
`
`

`

`
`
`US 2010/0128488 A1
`
`
`May 27, 2010
`
`
`
`SOLID STATE OPTICAL ILLUMINATION
`
`
`
`APPARATUS
`
`
`
`
`
`
`
`
`
`
`
`
`
`[0001] This application claims benefit of Ser. No. 61/116,
`
`
`
`
`
`
`
`
`
`900, filed 21 NOV. 2008 in the US. and which application is
`
`
`
`
`
`incorporated herein by reference. To the extent appropriate, a
`
`
`
`
`
`
`
`claim of priority is made to the above disclosed applications.
`FIELD OF INVENTION
`
`
`
`
`
`
`
`
`
`
`
`[0002] The present invention relates to an illumination
`
`
`
`
`
`
`
`
`apparatus including a solid state light source and a lens to
`
`
`
`
`
`
`
`provide uniform illumination at a remote target. More par-
`
`
`
`
`
`
`
`ticularly, the present invention relates to an illumination appa-
`
`
`
`
`
`
`
`
`
`ratus including a solid state illumination source and a lens that
`
`
`
`
`
`
`
`generates multiple angled beams of a certain shape and
`
`
`
`
`
`
`
`energy distribution towards a remote and large target.
`BACKGROUND
`
`
`
`
`
`
`
`
`
`
`Solid state illumination sources and optical systems
`[0003]
`
`
`
`
`
`
`
`have been extensively used in many applications, such as in
`
`
`
`
`
`
`
`
`bar code readers, optical communication systems, flat image
`
`
`
`displays, CD and DVD players.
`
`
`
`
`
`
`
`
`[0004] More recently white LEDs and specially designed
`
`
`
`
`
`
`
`
`lenses have found applications for outdoor illumination sys-
`
`
`
`
`
`
`
`tems due to significant savings in energy, easiness of mass
`
`
`
`
`
`
`
`production or service and much longer life expectancy.
`[0005] Great efforts in the lens design for LED illumination
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`are required to meet more demanding day to day applications
`where the shape and the illumination level ofthe light beam at
`
`
`
`
`
`
`
`
`a remote target have to meet above normal standards and
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`regulations. Both the patent and technical literature provide
`
`
`
`
`
`
`
`
`
`design and manufacturing solutions for solid state and espe-
`cially LED remote illumination solutions.
`
`
`
`
`
`[0006] Reference is made in this regard to US. Pat. No.
`
`
`
`
`
`
`
`
`7,009,213 to Camras that teaches an LED based illumination
`
`
`
`
`
`
`
`
`
`
`
`
`system having a specially designed lens.
`[0007] Reference is made in this regard to WC 2008/
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`122941 to Montagne that teaches an LED based luminary
`
`
`
`
`
`
`
`
`head to illuminate high aspect ratio rectangular targets such as
`
`
`public roads.
`
`
`
`
`
`
`
`
`[0008] One can distinguish here optical systems for solid
`
`
`
`
`
`
`
`
`state illumination applications where the input beam (IB)
`
`
`
`
`
`
`
`
`
`from the source and the output beam (OB) coming out from a
`
`
`
`
`
`
`
`
`
`
`
`lens facing the LED have axis that are at least partially col-
`
`
`
`linear and/or parallel.
`[0009] Reference is made in this regard to US. Pat. No.
`
`
`
`
`
`
`
`
`2,254,961 to Harris, US. Pat. No. 5,924,788 to Parkyn and
`
`
`
`
`
`
`
`
`US. Pat. No. 6,896,381 to Benitez.
`
`
`
`
`
`[001 0] U. S. Pat. No. ’ 3 81 to Benitez teaches an open optical
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`cavity facing the LED and in the proximity of the LED, this
`cavity having an axis ofrevolution and a circular cross section
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`in a plane perpendicular to the incoming light beam from the
`
`
`
`
`
`
`
`
`
`LED. The optical cavity has a spherical refractive surface that
`
`
`
`
`
`
`
`accepts the incoming beam from the LED.
`
`
`
`
`
`
`
`
`[0011] There are also other applications where the input
`beam (IB) and the output beam (OB) are at an angle calcu-
`
`
`
`
`
`
`
`
`lated to meet certain illumination criteria.
`
`
`
`
`
`[0012] Reference is made in this regard to US. Pat. No.
`
`
`
`
`
`
`
`
`6,607,286 to West, US. Pat. No. 6,674,096 to Sommers, US.
`
`
`
`
`
`
`
`
`Pat. No. 7,006,306 to Falicoff, US. Pat. No. 7,118,236 to
`
`
`
`
`
`
`
`
`Hahm, US. Pat. No. 7,153, 002 to Kim, US. Pat. No. 7,390,
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Page 28 of31
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`117 to Leatherdale, US Patent Application 2007/0257270 to
`
`
`
`
`
`
`Lu, US Patent Application 2007/0201225 to Holder and EP
`1,528,603 to Herbert.
`
`
`
`
`
`
`
`Further reference is made here to commercially
`[0013]
`
`
`
`
`
`
`available LED based illumination systems produced by com-
`
`
`
`
`
`
`panies such as Led Prescriptions Innovators (LPI), Illumina-
`
`
`
`
`
`tion Management Solutions (such as LED LightBARSTM),
`
`
`
`
`
`
`
`Sekonix, Joliet, Led-Spot Ledil (such as Flare lensTM and
`Snow White lensTM).
`
`
`
`[0014]
`In US. Pat. No. 6,674,096 the lens and the LED
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`source form a single package. In US. Pat. No. 7,390,117 to
`
`
`
`
`
`
`
`
`Leatherdale the lens and the source LED die are separated. In
`
`
`
`
`
`
`
`
`US. Pat. No. 6,607,286 to West an optical cavity having an
`axis of revolution and a circular shape in cross section covers
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`and encapsulates the LED die. Contrary to West ’286 in US.
`
`
`
`
`
`
`
`
`Pat. No. 7,153, 002 to Kim the lens has an optical cavity
`
`
`
`
`
`
`
`
`
`remote from the LED and fully enclosed in the lens body. This
`
`
`
`
`
`
`
`
`cavity provides both reflective and refractive surfaces to
`
`
`
`
`
`
`
`
`direct the beam towards a direction to a target that is angled
`from an axis that is normal to the LED die. US. Pat. No.
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`5,926,320 to Parkyn also teaches an enclosed air gap cavity
`[0015]
`In most cases disclosed inpatent literature the lenses
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`used in conjunction with solid state light sources, such as
`
`
`
`
`
`
`
`LEDs, have a circular perimeter having an axis of reference
`
`
`
`
`
`
`
`
`going through the LED die. Such a circular perimeter lenses
`are used in street illumination, such as in FIGS. 21-26 of US
`
`
`
`
`
`
`
`20070201225 to Holder. FIGS. 21-25 of Holder ’225 show a
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`composite lens having several sub-lenses, each having a
`
`
`
`
`
`
`
`
`“blob” or a dome shaped lens portions. This portion can be
`seen as a sub-lenses that generate several illumination beams
`
`
`
`
`
`
`
`
`
`
`
`
`
`upon a target, such as a street. WO 2008122941 to Montagne
`shows a two lobs LED lens for street illumination where each
`
`
`
`
`
`
`
`
`
`lob has a circular parameter US. Pat. No. 7,390,117 to
`
`
`
`
`
`
`
`
`Leatherdale teaches several designs where the LED lens has
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`a single body that has a polygonal perimeter, these lenses
`being made of two optical materials for use in lateral illumi-
`
`
`
`
`
`
`
`
`
`nation.
`
`[0016] There is a need to further improve the solid state
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`illumination systems for applications where the energy and
`
`
`
`
`
`
`
`the shape of the light beams at the level of a target meet
`
`
`
`
`
`increased demanding criteria without complicating the
`
`
`
`
`
`
`design of the lens or making them more complicated.
`SUMMARY OF THE INVENTION
`
`
`
`
`
`
`
`
`
`
`[0017] The present application teaches an improved solid
`
`
`
`
`
`
`
`state illumination system for a variety of applications such as
`
`
`
`
`
`
`
`
`public roads, large billboards, parking areas, gas stations,
`
`
`
`
`
`
`
`
`
`street signs or sport arenas (tennis courts, hockey rinks, etc.)
`that require constant or uniform illumination over the entire
`
`
`
`
`
`
`
`
`surface with some restrictions to contain the illumination
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`pattern. In some of these applications, such as public roads,
`billboards and sport arenas the illumination beam has to be
`
`
`
`
`
`
`
`
`limited to a direction or several directions and prevent the
`
`
`
`
`
`
`
`illumination over other directions with respect to the illumi-
`
`
`
`
`
`
`
`
`nation source.
`
`
`
`
`
`
`
`
`[0018] This is achieved according to an aspect ofthis inven-
`
`
`
`
`
`
`tion by using a white LED and a molded lenses of a complex
`
`
`
`
`
`
`
`shape that generate a number of output beams towards the
`
`
`
`
`
`
`
`
`target having prescribed energy levels and shapes at the tar-
`
`
`
`
`
`
`
`
`get. The output beams form an angle with respect to an axis
`
`
`
`
`that is perpendicular to the LED die.
`
`
`
`
`
`
`[0019] According to an aspect of this invention the energy
`
`
`
`
`
`
`
`level and the desired shape at the target is achieved by using
`
`
`
`
`
`
`
`
`
`an array of LED lenses and an array of complex shaped
`
`
`
`
`
`
`
`
`
`
`
`Page 28 of 31
`
`

`

`
`
`US 2010/0128488 A1
`
`
`May 27, 2010
`
`
`
`
`
`
`
`
`
`
`
`
`lenses, where the lenses has an identical shape and output
`beams. In some cases the number of lenses and the number of
`
`
`
`
`
`
`
`
`LEDs are not the same, i.e. several lenses are used in con-
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`junction with a single LED, or several LEDs are used in
`
`
`
`
`conjunction with a single lens.
`
`
`
`
`
`
`
`[0020] According to an aspect of this invention, the illumi-
`nation lens does not have an axis of revolution. In cross
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`sections the lens has an external polygonal shape in planes
`
`
`
`
`
`
`perpendicular to an axis that is perpendicular to the LED die.
`
`
`
`
`
`
`
`
`
`The lens may have any number of external surfaces each
`
`
`
`
`
`
`
`having an optical function and a main direction of illumina-
`
`
`
`tion towards a target.
`
`
`
`
`
`
`
`[0021] According to an aspect of this invention, the com-
`
`
`
`
`
`
`
`
`
`plex shape lens has an inner optical cavity in the proximity of
`
`
`
`
`
`
`
`
`
`the LED die making no contact with the LED. This inner
`
`
`
`
`
`
`
`
`optical cavity is partially open towards the LED die to allow
`
`
`
`
`
`
`
`
`
`the incoming beam or light rays from the LED die to travel
`
`
`
`
`
`
`
`
`without any bending towards the refractive optical surfaces of
`
`
`the cavity.
`
`
`
`
`
`
`[0022] According to an aspect of this invention the lens
`
`
`
`
`
`
`
`
`may have one or several air gaps between sub-lens elements
`that form the lens.
`
`
`
`
`
`
`
`
`
`
`
`
`[0023] According to an aspect ofthis invention the lens has
`
`
`
`
`
`
`
`
`a number ofoptical surfaces providing total internal reflection
`(TIR)
`
`
`
`
`
`
`
`[0024] According to an aspect of this invention the refrac-
`tive and the reflective surfaces of the lens can be continuous,
`
`
`
`
`
`
`
`
`
`
`
`
`
`can be flat (i.e. no optical power), can be cylindrical, spherical
`
`
`or aspherical.
`
`
`
`
`
`
`
`[0025] According to an aspect of this invention these opti-
`cal refractive and reflective surfaces can be further multi-
`
`
`
`
`
`
`
`
`facetted or micro-structured to further alter the energy and/or
`
`
`
`
`
`
`
`spatial distribution of the beams.
`
`
`
`
`
`
`
`
`
`
`[0026] According to an aspect of this invention these opti-
`cal refractive and reflective surfaces have no mirror coatings.
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`[0027] According to an aspect of this invention the LED
`
`
`
`
`
`
`
`
`and the lens generate a number of out coming illumination
`
`
`
`
`
`
`
`
`
`beams only from one side of a plane to prevent the illumina-
`
`
`
`
`
`
`
`tion of an area proximate to the desired illumination target.
`
`
`
`
`
`
`
`[0028] According to an aspect of this invention the LED
`and lens illumination system is used for a novel street illumi-
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`nation apparatus that provides reduced energy consumption
`
`
`
`
`
`
`
`and improved illumination uniformity at the street level.
`
`
`
`
`
`
`
`[0029] According to an aspect of this invention the LED
`and lens illumination system is used for a novel (indoor or
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`outdoor) billboard illumination apparatus that provides
`
`
`
`
`
`
`
`reduced energy consumption and improved illumination uni-
`
`
`
`
`
`
`
`
`formity at the billboard level without affecting adjacent areas
`that have to be protected from the illumination.
`
`
`
`
`
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`
`
`
`
`
`
`
`
`
`
`
`
`[0030] The invention can be more understood from the
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`following drawings that are intended to provide stand alone or
`
`
`
`
`
`
`
`
`
`additional and specific design details that do not limit the
`scope ofthe invention. Sizes and shapes ofthe elements ofthe
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`lens and LED dies in the drawings are approximate and may
`not be at scale.
`
`
`
`
`
`
`
`
`
`
`[0031]
`FIG. 1 (a-b-c-d) show prior art designs used for
`street illumination.
`
`
`[0032]
`FIG. 2 (a-b-c-d) show embodiments of the lens and
`
`
`
`
`
`
`
`the illumination pattern as disclosed in the current invention.
`
`
`
`
`
`
`
`[0033]
`FIG. 3 (a-b-c-d-e) show other views ofthe embodi-
`
`
`
`
`
`
`
`ments shown in FIG. 2 of the current invention.
`
`
`
`
`
`
`
`
`Page 29 of 31
`
`
`
`
`
`
`
`FIG. 4 (a-b-c-d-e-f—g-h) show ray tracings through
`[0034]
`the embodiments of FIG. 3.
`
`
`
`
`
`
`
`
`
`
`
`[0035]
`FIG. 5 ((1-1)) show the illumination pattern at the
`
`
`
`
`
`
`
`target achieved by the lenses shown in FIG. 6 ((1-1)) show the
`
`
`
`
`
`
`
`
`division of light in two quadrants and the illuminated and non
`illuminated areas.
`
`
`FIG. 7. Shows sections of the illumination area
`[0036]
`
`
`
`
`
`
`
`
`
`
`according to the invention.
`FIG. 8. Shows sections of the illumination area
`[0037]
`
`
`
`
`
`
`
`
`
`
`according to the invention.
`FIG. 9 (a-b-c-d-e-f) show another embodiment of
`[0038]
`
`
`
`
`
`
`the invention.
`
`
`[0039]
`FIG. 10 Shows another embodiment of the inven-
`
`
`
`
`
`
`tion.
`
`FIG. 11 ((1-0) show various 2D and 3D schematic
`[0040]
`
`
`
`
`
`
`views of an embodiment of the invention.
`
`
`
`[0041]
`FIG. 12 shows an embodiment of the invention as
`
`
`
`
`
`
`
`
`
`
`
`
`applicable to targets such as road illumination, billboards and
`sport arenas.
`
`
`[0042]
`FIG. 13 ((1-11) show other embodiments ofthe inven-
`
`
`
`
`
`
`
`
`
`
`
`tion in a 2D and 3D schematic representation for applications
`
`
`
`
`
`
`
`such as for parking areas and gas stations.
`DETAILED DESCRIPTION OF THE INVENTION
`
`
`
`
`
`
`
`
`
`
`
`Stated broadly, the present invention is directed to
`[0043]
`
`
`
`
`
`
`
`
`
`an optical system having a solid state light source, such as an
`
`
`
`
`
`
`
`
`
`LED of any spectrum. The system includes a lens that pro-
`
`
`
`
`
`
`vides an output illumination pattern of uniform distribution
`over a remote and larger target. The lens does not have an axis
`
`
`
`
`
`
`
`
`
`
`
`of revolution. The lens has a generally non-circular outer
`
`
`
`
`
`
`
`
`shape in cross section and on top views, where the outer
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`optical surfaces are angled one relative to another. The lens
`includes refractive and reflective active optical surfaces to
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`split, direct and shape the incoming beam from the light
`source towards the target in the form of several angled beams
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`ofprescribed energies calculated as a function ofthe shape of
`the target and distance to the target. The lens has an inner
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`primary and partially open optical cavity of a polygonal cross
`
`
`
`
`
`
`
`
`
`
`section facing the light source. This optical cavity has a num-
`ber of refractive optical surfaces whose shape and number is
`
`
`
`
`
`
`
`
`determined by the number of and shape of the illumination
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`beams generated in conjunction with the other surfaces ofthe
`
`
`
`
`
`
`
`
`
`lens. This novel optical system may include an array of white
`
`
`
`
`
`
`
`LEDs that generate the input illumination to an array ofthese
`
`
`
`
`
`
`
`
`lenses to insure the proper illumination level and uniformity
`
`
`
`
`at particular remote targets.
`
`
`
`
`
`
`
`[0044] Referring now to the Figures, and more particularly
`FIGS. 2a and 2b, there is shown an array of four illumination
`
`
`
`
`
`
`
`
`
`
`apparatuses 10 according to the invention.
`
`
`
`
`
`
`
`[0045] Each apparatus 10 lies on support 12. In some cases,
`
`
`
`
`
`depending on the illumination requirements, a single appara-
`tus may no be suflicient, and therefore the present invention
`
`
`
`
`
`
`
`
`
`
`
`contemplates an array of such apparatuses.
`[0046] As shown in FIG. 2a by the large arrows, the light
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`emitted by the apparatus can exit from any number of facets
`
`
`
`
`
`
`
`
`of the lenses which form part of the apparatus, as will be
`
`
`apparent hereinafter.
`
`
`
`
`
`
`
`
`[0047] The lens of FIG. 2a permits illumination along pre-
`
`
`
`
`
`
`
`
`determined regions. More particularly,
`the lenses are so
`
`
`
`
`
`
`
`arranged to permit an illumination pattern shown in FIG. 2d:
`
`
`
`
`
`
`
`
`
`
`two shorter patterns 14a and 14b, and a longer pattern 14,
`
`
`
`
`
`
`
`
`
`which is adjacent the patterns 14a and 14b. The illumination
`pattern values are shown in FIG. 20.
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Page 29 of 31
`
`

`

`
`
`US 2010/0128488 A1
`
`
`May 27, 2010
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`FIGS. 3a-3e show the apparatus according to a pre-
`[0048]
`ferred embodiment of the invention. The LED 2 lies on a die
`
`
`
`
`
`
`
`
`
`
`
`
`
`(not shown in this Figure). The LED is physically separated
`
`
`
`
`
`
`
`
`from the lens by cavity 9 (FIG. 36) which has a surface 11 for
`
`
`
`
`
`
`
`refracting the beam coming from the LED 2.
`
`
`
`
`
`
`
`[0049] The lens itself is made of a plurality of sub-lenses
`
`
`
`
`
`
`
`
`
`20, 22, 24, 26 and 28, which cooperate together to achieve the
`
`
`
`
`
`
`
`objects of the invention. Lenses 20 and 22 are mirror images
`
`
`
`
`
`
`
`
`
`
`of each other about a median plane or axis 32. One aspect of
`
`
`
`
`
`
`
`
`the invention also lies in the quasi-square outline of the lens
`
`
`
`
`
`
`
`(or rectangular), as opposed to circular or oval lenses. This
`
`
`
`
`
`
`
`permits a more precise beam shaping, allowing rectangular
`
`
`illumination patterns.
`
`
`
`
`
`
`FIG. 3b is a top view of the apparatus, showing how
`[0050]
`
`
`
`
`
`
`
`
`
`it is separated by plane 32 into two portions, 34 and 36.
`
`
`
`
`
`
`[0051]
`FIG. 30 is a top perspective view of the apparatus.
`
`
`
`
`
`
`
`[0052]
`FIG. 3d is a side view of the apparatus, rotated 90°
`clockwise, whereas FIG. 36 is a sectional view of the appa-
`
`
`
`
`
`
`
`
`
`
`
`
`
`ratus, taken along line A-A of FIG. 3b.
`
`
`
`
`
`
`
`[0053] The lenses are so designed to provide an illumina-
`
`
`
`
`
`
`
`
`
`
`tion pattern along a target area that is remote from the appa-
`ratus 10 along a reference axis. This reference axis is not
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`illustrated, but canbe thought ofbeing towards top ofFIG. 3a,
`
`
`
`that is straight up.
`
`
`
`
`
`
`
`
`[0054] The light beam emerging from LED die 2 is received
`
`
`
`
`
`
`
`
`
`by optical cavity 9 whose function is to split the beam into a
`
`
`
`
`
`
`
`
`
`plurality of beams via optical refraction as the light travels
`
`
`
`
`
`
`
`
`
`
`from an air space into the lens body and it goes through
`
`
`
`
`
`
`
`
`refractive surfaces 11. The complex shape of surface 11 gen-
`
`
`
`
`
`
`
`
`erates a plurality of beams such as beams that make an angle
`
`
`
`
`
`
`
`
`with respect to a normal axis perpendicular to the plane of the
`LED die. This is done purposely to achieve a beam restricted
`
`
`
`
`
`
`
`illumination over a target. In other words, the illumination
`
`
`
`
`
`
`
`
`system 10 consists of an array of lenses and LEDs that create
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`a uniform beam of light over a target (see for example FIGS.
`5a and 5b). The current design achieves an illumination ratio
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`between various adjacent areas at the target level that is in the
`
`
`
`
`
`
`
`
`range of 3 : 1, 2:1 or even better as a function ofthe specifics of
`
`
`
`
`
`
`
`
`
`the lens design. In order to compensate for the inherent dif-
`
`
`
`
`
`
`
`ference of the light beam uneven projection that creates a AL
`path difference that translates into a difference in the intensity
`
`
`
`
`
`
`
`
`of light, the lenses covered by the current inventions have
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`been designed to manage the light flux in a manner that
`ensures not only a uniform illumination at the target but also
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`a light pattern that is either rectangular or square.
`
`
`
`
`
`
`
`
`[0055] The optical cavity can be of various shapes, such as
`
`
`
`
`
`
`
`domed or circular, or even rectangular. The cavity allows a
`
`
`
`
`
`
`
`better manipulation of the beam emitted by the LED, and
`
`
`
`
`
`
`
`therefore allows greater freedom in the design of the lenses
`
`
`
`
`
`for the specific purposes of the apparatus.
`[0056] Referring now to FIGS. 4a-4h, there is shown the
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`various ray tracings ofthe light as it exits the lens. In FIG. 4a,
`
`
`
`
`
`
`
`
`
`
`
`the light exits along surface 26. In FIG. 4b, light exits along
`surface 28. In FIG. 40, light exits along surface 22 or 20. To
`
`
`
`
`
`
`
`
`
`the right of each of these figures, there is shown the illumi-
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`nation spot of the beam. FIG. 4d shows the ray tracing for the
`
`
`
`
`
`
`
`combination of FIGS. 4a and 4b, and its resulting pattern.
`FIG. 46 shows the ray tracing of the combination of FIGS.
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`4a-4c. These are all figures taken along the side of the appa-
`ratus.
`
`FIG. 4fis a front view of the apparatus, and shows
`[0057]
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`the light exiting along surface 30, whereas FIG. 4h shows the
`
`
`
`
`
`light exiting from surface 24.
`
`
`
`
`
`
`
`[0058] The combination of all of the rays of light produces
`
`
`
`
`
`
`
`
`the pattern shown in FIGS. 5a and 5b, the difference between
`
`
`
`
`
`
`
`
`
`
`the two figures being the fact that 5a shows the apparatus 10
`
`
`
`
`
`
`
`
`
`
`
`as well as planes 101 and 103. Plane 101 separates the light
`
`
`
`
`
`
`
`
`
`
`pattern into left and right quadrants, whereas plane 103 limits
`
`
`
`
`
`
`
`the lighted area along a predetermined path delimited by the
`
`
`
`
`
`
`
`
`
`
`rear of the apparatus (as seen from the side view of FIG. 6b,
`
`
`
`
`
`
`
`
`
`and is actually parallel to the reference axis, and offset thereto
`(see the Z-axis label in FIG. 6b). FIGS. 7 and 8 are different
`
`
`
`
`
`
`
`
`
`
`
`
`representations of this effect.
`FIGS. 9a-9fand 10 are different embodiments ofthe
`[0059]
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`invention, showing alternative shapes for the lenses, resulting
`
`
`
`
`
`
`
`
`
`in different illumination patterns all the while respecting the
`invention.
`
`[0060] As shown in all the embodiments of the invention
`
`
`
`
`
`
`
`
`
`
`
`
`
`the lens is characterized by a polygonal external shape, an
`
`
`
`
`
`
`
`
`inner optical cavity facing the LED die having a polygonal
`
`
`
`
`
`
`
`cross section to provide multiple beam illumination under an
`
`
`
`
`
`
`
`angle with respect to an axis perpendicular to the LED die.
`
`
`
`
`
`
`
`[0061] Referring now to FIG. 11 ((1-0), there is shown an
`
`
`
`
`embodiment of the invention showing in 2D and 3D repre-
`
`
`
`
`
`
`
`
`sentations. The optical apparatus 100 consists of a solid state
`
`
`
`
`
`
`
`
`
`
`light source 106 and a complex shaped lens 101. Light source
`
`
`
`
`
`
`
`
`
`
`101 can have any spectrum in the visible and invisible range.
`In the embodiment of FIG. 11, light source 1 is a white LED.
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Lens 101 can be made of any suitable optical materi