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`as) United States
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`a2) Patent Application Publication 10) Pub. No.: US 2010/0128488 Al
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` Marcoux (43) Pub. Date: May 27, 2010
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`US 20100128488A1
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`(54) SOLID STATE OPTICAL ILLUMINATION
`APPARATUS
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`(52) US. CD. vc cceeeccrssenseececeneeeneenseenees 362/311.02
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`(75)
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`(21) Appl. No.:
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`Filed:
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`Erie Marcoux, Laval (CA)
`Inventor:
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`Correspondence Address:
`owakowns GOULD PC
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`MINNEAPOLIS, MN 55402-0903 (US)
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`DBMReflex Enterprises Inc.
`(73) Assignee:
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`Laval (CA)
`12/624,317
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`Nov. 23, 2009
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`Related U.S. Application Data
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`(60) Provisional application No. 61/116,900,filed on Nov.
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`21, 2008.
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`ABSTRACT
`(57)
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`anoptical systemhaving a solid wate pet source. such as an
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`of any spectrum,includesa lens
`that provides an outpu
`illuminationpattern ofuniform distributionover aremote and
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`larger target. The lens does not have an axis ofrevolution. The
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`lens has a generally non-circular outer shape in cross section
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`and on top views, wherethe outer optical surfaces are angled
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`one relative to another. The lens includes refractive and
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`reflective active optical surfaces to split, direct and shape the
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`incoming beam from the light source towards the target in the
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`form of several angled beams ofprescribed energies calcu-
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`lated as a function ofthe shape ofthe target and distance to the
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`target. The lens has an inner primary andpartially open opti-
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`cal cavity ofa polygonalcross section facing the light source.
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`This optical cavity has a numberof refractive optical surfaces
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`whoseshape and numberis determined by the numberof and
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`shape of the illumination beams generated in conjunction
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`with the other surfaces of the lens. This novel optical system
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`mayinclude an array of white LEDsthat generate the input
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`illumination to an array of these lenses to insure the proper
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`illumination level and uniformity at particular remotetargets.
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`Publication Classification
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`Int. Cl.
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`F21V 5/00
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`(51)
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`(2006.01)
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`SOLID STATE OPTICAL ILLUMINATION
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`APPARATUS
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`[0001] This application claims benefit of Ser. No. 61/116,
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`900, filed 21 Nov. 2008 in the U.S. and which application is
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`incorporated herein by reference. To the extent appropriate, a
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`claim ofpriority is madeto the above disclosed applications.
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`FIELD OF INVENTION
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`[0002] The present invention relates to an illumination
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`apparatus including a solid state light source and a lens to
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`provide uniform illumination at a remote target. More par-
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`ticularly, the present invention relates to an illumination appa-
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`ratus including a solid state illumination source and a lens that
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`generates multiple angled beams of a certain shape and
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`energy distribution towards a remote andlargetarget.
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`BACKGROUND
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`Solid state illumination sources and optical systems
`[0003]
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`have been extensively used in many applications, such as in
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`bar code readers, optical communication systems, flat image
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`displays, CD and DVD players.
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`[0004] More recently white LEDs and specially designed
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`lenses have found applications for outdoor illumination sys-
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`tems due to significant savings in energy, easiness of mass
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`production or service and much longerlife expectancy.
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`[0005] Great efforts in the lens design for LED illumination
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`are required to meet more demanding day to day applications
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`wherethe shape andthe illumination level ofthe light beam at
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`a remote target have to meet above normal standards and
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`regulations. Both the patent and technicalliterature provide
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`design and manufacturing solutions for solid state and espe-
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`cially LED remote illumination solutions.
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`[0006] Reference is made in this regard to U.S. Pat. No.
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`7,009,213 to Camras that teaches an LED basedillumination
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`system having a specially designedlens.
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`[0007] Reference is made in this regard to WO 2008/
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`122941 to Montagne that teaches an LED based luminary
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`head to illuminate high aspect ratio rectangular targets such as
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`[0008] One can distinguish here optical systems for solid
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`state illumination applications where the input beam (IB)
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`from the source and the output beam (OB) comingout from a
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`lens facing the LED have axis that are at least partially col-
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`linear and/or parallel.
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`[0009] Reference is made in this regard to U.S. Pat. No.
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`2,254,961 to Harris, U.S. Pat. No. 5,924,788 to Parkyn and
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`USS. Pat. No. 6,896,381 to Benitez.
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`[0010] U.S. Pat. No. ’381 to Benitez teaches an openoptical
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`cavity facing the LED and in the proximity of the LED,this
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`cavity having an axis ofrevolution and a circular cross section
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`in a plane perpendicularto the incoming light beam from the
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`LED. Theoptical cavity has a spherical refractive surface that
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`accepts the incoming beam from the LED.
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`[0011] There are also other applications where the input
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`beam (IB) and the output beam (OB)are at an angle calcu-
`lated to meet certain illuminationcriteria.
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`[0012] Reference is made in this regard to U.S. Pat. No.
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`6,607,286 to West, U.S. Pat. No. 6,674,096 to Sommers, U.S.
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`Pat. No. 7,006,306 to Falicoff, U.S. Pat. No. 7,118,236 to
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`Hahm,U.S. Pat. No. 7,153, 002 to Kim, U.S. Pat. No. 7,390,
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`Page 28 of 31
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`117 to Leatherdale, US Patent Application 2007/0257270 to
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`Lu, US Patent Application 2007/0201225 to Holder and EP
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`1,528,603 to Herbert.
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`Further reference is made here to commercially
`[0013]
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`available LED based illumination systems produced by com-
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`panies such as Led Prescriptions Innovators (LPI), I/Iumina-
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`tion ManagementSolutions (such as LED LightBARS™),
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`Sekonix, Joliet, Led-Spot Ledil (such as Flare lens™ and
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`Snow White lens™).
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`[0014]
`In U.S. Pat. No. 6,674,096 the lens and the LED
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`source form a single package. In U.S. Pat. No. 7,390,117 to
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`Leatherdale the lens and the source LED die are separated. In
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`USS. Pat. No. 6,607,286 to West an optical cavity having an
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`axis of revolution and a circular shape in cross section covers
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`and encapsulates the LED die. Contrary to West ’286 in U.S.
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`Pat. No. 7,153, 002 to Kim the lens has an optical cavity
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`remote from the LED andfully enclosed in the lens body. This
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`cavity provides both reflective and refractive surfaces to
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`direct the beam towardsa direction to a target that is angled
`from an axis that is normal to the LED die. US. Pat. No.
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`5,926,320 to Parkyn also teaches an enclosedair gap cavity
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`Inmost cases disclosed in patentliterature the lenses
`[0015]
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`used in conjunction with solid state light sources, such as
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`LEDs, have a circular perimeter having an axis of reference
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`going through the LED die. Such a circular perimeter lenses
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`are used in street illumination, such as in FIGS. 21-26 of US
`20070201225 to Holder. FIGS. 21-25 of Holder ’225 show a
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`composite lens having several sub-lenses, each having a
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`“blob” or a dome shapedlens portions. This portion can be
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`seen as a sub-lenses that generate several illumination beams
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`upon a target, such as a street. WO 2008122941 to Montagne
`showsa two lobs LEDlensforstreet illumination where each
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`lob has a circular parameter U.S. Pat. No. 7,390,117 to
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`Leatherdale teaches several designs where the LED lens has
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`a single body that has a polygonal perimeter, these lenses
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`being made of two optical materials for use in lateral illumi-
`nation.
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`[0016] There is a need to further improvethe solid state
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`illumination systems for applications where the energy and
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`the shape of the light beams at the level of a target meet
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`increased demanding criteria without complicating the
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`design of the lens or making them more complicated.
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`SUMMARY OF THE INVENTION
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`[0017] The present application teaches an improved solid
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`state illumination system for a variety of applications such as
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`public roads, large billboards, parking areas, gas stations,
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`street signs or sport arenas (tennis courts, hockey rinks, etc.)
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`that require constant or uniform illumination over the entire
`surface with some restrictions to contain the illumination
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`pattern. In someof these applications, such as public roads,
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`billboards and sport arenas the illumination beam has to be
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`limited to a direction or several directions and prevent the
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`illumination over other directions with respect to the illumi-
`nation source.
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`[0018] This is achieved accordingto an aspectofthis inven-
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`tion by using a white LED and a moldedlenses of a complex
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`shape that generate a number of output beams towards the
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`target having prescribed energy levels and shapesat the tar-
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`get. The output beams form an angle with respect to an axis
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`that is perpendicular to the LED die.
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`[0019] According to an aspect of this invention the energy
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`level and the desired shapeat the target is achieved by using
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`an array of LED lenses and an array of complex shaped
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`Page 28 of 31
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`

`

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`US 2010/0128488 Al
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`May 27, 2010
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`FIG. 4 (a-b-c-d-e-f-g-h) show ray tracings through
`[0034]
`lenses, where the lenses has an identical shape and output
`the embodiments of FIG.3.
`beams. In some cases the numberof lenses and the numberof
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`LEDsare not the same, i.e. several lenses are used in con-
`[0035]
`FIG. 5 (a-b) show the illumination pattern at the
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`junction with a single LED, or several LEDs are used in
`target achieved by the lenses shownin FIG.6 (a-b) show the
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`conjunction with a single lens.
`division of light in two quadrants andthe illuminated and non
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`illuminatedareas.
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`[0020] According to an aspectof this invention,the illumi-
`nation lens does not have an axis of revolution. In cross
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`FIG. 7. Shows sections of the illumination area
`[0036]
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`sections the lens has an external polygonal shape in planes
`according to the invention.
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`perpendicular to an axis that is perpendicular to the LED die.
`FIG. 8. Shows sections of the illumination area
`[0037]
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`The lens may have any numberof external surfaces each
`according to the invention.
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`having an optical function and a main direction of illumina-
`FIG. 9 (a-b-c-d-e-f) show another embodiment of
`[0038]
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`the invention.
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`tion towardsatarget.
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`[0021] According to an aspect of this invention, the com-
`[0039]
`FIG. 10 Shows another embodiment of the inven-
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`tion.
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`plex shapelens has an inneroptical cavity in the proximity of
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`the LED die making no contact with the LED. This inner
`FIG. 11 (a-o) show various 2D and 3D schematic
`[0040]
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`views of an embodimentofthe invention.
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`optical cavity is partially open towards the LED die to allow
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`the incoming beam orlight rays from the LED die to travel
`[0041]
`FIG. 12 shows an embodimentof the invention as
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`without any bending towardstherefractive optical surfaces of
`applicable to targets such as roadillumination,billboards and
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`the cavity.
`sport arenas.
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`[0022] According to an aspect of this invention the lens
`[0042]
`FIG. 13 (a-7) show other embodimentsofthe inven-
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`may have oneorseveral air gaps between sub-lens elements
`tion ina 2D and 3D schematic representation for applications
`that form thelens.
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`such as for parking areas andgasstations.
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`[0023] According to an aspect ofthis invention the lens has
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`DETAILED DESCRIPTION OF THE INVENTION
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`anumberofoptical surfaces providingtotal internalreflection
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`(TIR)
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`Stated broadly, the present invention is directed to
`[0043]
`[0024] According to an aspectof this invention the refrac-
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`tive andthe reflective surfaces of the lens can be continuous,
`an optical system havingasolid state light source, such as an
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`LED of any spectrum. The system includes a lens that pro-
`can beflat (i.e. no optical power), can be cylindrical, spherical
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`vides an output illumination pattern of uniform distribution
`or aspherical.
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`over a remote andlarger target. The lens does not have an axis
`[0025] According to an aspect of this invention these opti-
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`cal refractive and reflective surfaces can be further multi-
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`of revolution. The lens has a generally non-circular outer
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`shape in cross section and on top views, where the outer
`facetted or micro-structured to furtheralter the energy and/or
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`optical surfaces are angled one relative to another. The lens
`spatial distribution of the beams.
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`includes refractive and reflective active optical surfaces to
`[0026] According to an aspect of this invention these opti-
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`split, direct and shape the incoming beam from the light
`cal refractive andreflective surfaces have no mirror coatings.
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`source towardsthe target in the form of several angled beams
`[0027] According to an aspect of this invention the LED
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`ofprescribed energies calculated as a function ofthe shape of
`and the lens generate a number of out coming illumination
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`the target and distance to the target. The lens has an inner
`beamsonly from oneside of a plane to preventthe illumina-
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`primary andpartially open optical cavity of a polygonalcross
`tion of an area proximate to the desired illuminationtarget.
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`section facing the light source. This optical cavity has a num-
`[0028] According to an aspect of this invention the LED
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`berofrefractive optical surfaces whose shape and numberis
`and lens illumination system is used for a novelstreet illumi-
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`determined by the number of and shape ofthe illumination
`nation apparatus that provides reduced energy consumption
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`beamsgenerated in conjunction with the other surfaces ofthe
`and improved illumination uniformity at the street level.
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`lens. This novel optical system may include an array of white
`[0029] According to an aspect of this invention the LED
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`LEDsthat generate the input illuminationto an array ofthese
`and lens illumination system is used for a novel (indoor or
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`lenses to insure the properillumination level and uniformity
`outdoor) billboard illumination apparatus that provides
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`at particular remote targets.
`reduced energy consumption and improvedillumination uni-
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`[0044] Referring now to the Figures, and moreparticularly
`formity at the billboard level without affecting adjacent areas
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`FIGS. 2a and 28,there is shown an array of four illumination
`that have to be protected from the illumination.
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`apparatuses 10 according to the invention.
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`[0045] Each apparatus 10 lies on support 12. In some cases,
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`dependingonthe illumination requirements, a single appara-
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`tus may nobesufficient, and therefore the present invention
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`contemplates an array of such apparatuses.
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`[0046] As shown in FIG.2a bythe large arrows, the light
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`emitted by the apparatus can exit from any numberoffacets
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`of the lenses which form part of the apparatus, as will be
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`apparent hereinafter.
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`[0047] The lens of FIG. 2a permits illumination along pre-
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`determined regions. More particularly,
`the lenses are so
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`arranged to permit an illumination pattern shown in FIG.2d:
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`two shorter patterns 14a and 14d, and a longer pattern 14,
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`whichis adjacent the patterns 14a and 148. The illumination
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`pattern values are shown in FIG.2c.
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`[0030] The invention can be more understood from the
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`following drawingsthat are intended to provide stand alone or
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`additional and specific design details that do not limit the
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`scope ofthe invention. Sizes and shapesofthe elements ofthe
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`lens and LED dies in the drawings are approximate and may
`notbe at scale.
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`[0031]
`FIG. 1 (a-b-c-d) show prior art designs used for
`street illumination.
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`[0032]
`FIG. 2 (a-b-c-d) show embodimentsof the lens and
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`the illumination pattern as disclosed in the current invention.
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`[0033]
`FIG. 3 (a-b-c-d-e) show other views of the embodi-
`ments shown in FIG.2 of the currentinvention.
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`Page 29 of 31
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`Page 29 of 31
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`

`

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`US 2010/0128488 Al
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`May 27, 2010
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`[0058] The combinationofall of the rays of light produces
`FIGS. 3a-3e show the apparatus accordingto a pre-
`[0048]
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`ferred embodimentof the invention. The LED2lies on a die
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`the pattern shown in FIGS. 5a and 5d,the difference between
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`(not shownin this Figure). The LED is physically separated
`the twofigures being the fact that 5a shows the apparatus 10
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`from the lens by cavity 9 (FIG. 3e) which has a surface 11 for
`as well as planes 101 and 103. Plane 101 separates the light
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`refracting the beam coming from the LED 2.
`pattern into left and right quadrants, whereas plane 103 limits
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`the lighted area along a predetermined path delimited by the
`Thelensitself is made of a plurality of sub-lenses
`[0049]
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`rear of the apparatus (as seen from the side view of FIG.65,
`20, 22, 24, 26 and 28, which cooperate together to achieve the
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`and is actually parallel to the reference axis, and offset thereto
`objects of the invention. Lenses 20 and 22 are mirror images
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`(see the z-axis label in FIG. 65). FIGS. 7 and 8 are different
`of each other about a median plane or axis 32. One aspect of
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`representations ofthis effect.
`the invention also lies in the quasi-square outline ofthe lens
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`(or rectangular), as opposedto circular or oval lenses. This
`FIGS. 9a-9fand 10 are different embodiments ofthe
`[0059]
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`permits a more precise beam shaping, allowing rectangular
`invention, showing alternative shapes for the lenses, resulting
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`illumination patterns.
`in different illumination patterns all the while respecting the
`invention.
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`FIG. 3d is a top view of the apparatus, showing how
`[0050]
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`it is separated by plane 32 into twoportions, 34 and 36.
`[0060] As shown in all the embodiments of the invention
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`the lens is characterized by a polygonal external shape, an
`[0051]
`FIG. 3c is a top perspective view of the apparatus.
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`inner optical cavity facing the LED die having a polygonal
`[0052]
`FIG. 3d is a side view of the apparatus, rotated 90°
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`cross section to provide multiple beam illumination under an
`clockwise, whereas FIG. 3¢ is a sectional view of the appa-
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`angle with respect to an axis perpendicular to the LED die.
`ratus, taken along line A-A of FIG. 34.
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`[0061] Referring now to FIG. 11 (a-o), there is shown an
`[0053] The lenses are so designed to provide an illumina-
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`embodimentof the invention showing in 2D and 3D repre-
`tion pattern along a target area that is remote from the appa-
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`sentations. The optical apparatus 100 consists of a solid state
`ratus 10 along a reference axis. This reference axis is not
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`light source 106 and a complex shapedlens 101. Light source
`illustrated, but can be thought ofbeing towardstop ofFIG.3a,
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`101 can have any spectrum inthe visible andinvisible range.
`that is straightup.
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`In the embodimentof FIG. 11, light source 1 is a white LED.
`[0054] The light beam emerging from LEDdie 2 is received
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`Lens 101 can be made of any suitable optical material to
`by optical cavity 9 whose function is to split the beam into a
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`match the optical characteristics of light source 106. In the
`plurality of beamsvia optical refraction as the light travels
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`embodiment of FIG. 11, the lens is injection molded from a
`from an air space into the lens body and it goes through
`suitable moldable material. Lens 101 includes an enclosed
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`refractive surfaces 11. The complex shape of surface 11 gen-
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`optical cavity 108 that faces LED source 106. As shown in
`erates a plurality of beams such as beamsthat make an angle
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`FIG. 11 the light beam emerging from LED die 106 is
`with respect to a normal axis perpendicular to the plane of the
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`received by optical cavity 108 whose function is to split the
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`LEDdie. This is done purposely to achieve a beam restricted
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`beam into a plurality of beams via optical refraction as the
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`illumination over a target. In other words, the illumination
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`light travels from an air space into the lens body and goes
`system 10 consists of an array of lenses and LEDsthat create
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`through refractive surfaces 114. Complex shape 101 gener-
`a uniform beam oflight over a target (see for example FIGS.
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`ates a plurality ofbeams such as beams A-B-C shown in FIG.
`5a and 5d). The current design achieves an illuminationratio
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`11 f-g-h that all make an angle with respect to a normal axis
`between various adjacentareas at the target level that is in the
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`perpendicular to the plane ofthe LED die. As shownin the 3D
`range of 3:1, 2:1 or even better as a function ofthe specifics of
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`representation of lens 101 all the emerging beams from lens
`the lens design. In order to compensate for the inherent dif-
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`101 are directed solely towards directions that prevent the
`ference of the light beam unevenprojection that creates a AL
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`light beamsto illuminate an area defined by a plane defined by
`path difference that translates into a difference in the intensity
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`the back plane of the lens 101 as shownas item 101c in FIG.
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`of light, the lenses covered by the current inventions have
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`11a. This is done purposely to achieve a beam restricted
`been designed to manage the light flux in a manner that
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`illumination over a target that is placed at one side of the
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`ensures not only a uniform illuminationat the target but also
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`illumination system. This is better illustrated in FIG. 12
`a light pattern that is either rectangular or square.
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`where the illumination system 100 consists of an array of
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`[0055] The optical cavity can be of various shapes, such as
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`lenses and LEDs that create a uniform beam of light over
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`domed or circular, or even rectangular. The cavity allows a
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`target 210. The current design achieves an illuminationratio
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`better manipulation of the beam emitted by the LED, and
`between various adjacent areas 206-208at the target level that
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`therefore allows greater freedom in the design of the lenses
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`is in the range of 3:1, 2:1 or even better, as a function of the
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