WO2016149900A1 - Lentille optique et projecteur la comprenant - Google Patents

Lentille optique et projecteur la comprenant Download PDF

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Publication number
WO2016149900A1
WO2016149900A1 PCT/CN2015/074916 CN2015074916W WO2016149900A1 WO 2016149900 A1 WO2016149900 A1 WO 2016149900A1 CN 2015074916 W CN2015074916 W CN 2015074916W WO 2016149900 A1 WO2016149900 A1 WO 2016149900A1
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WO
WIPO (PCT)
Prior art keywords
optical lens
conical frustum
shaped optical
frustum shaped
light
Prior art date
Application number
PCT/CN2015/074916
Other languages
English (en)
Inventor
Hong Xu
Original Assignee
Hong Xu
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hong Xu filed Critical Hong Xu
Priority to PCT/CN2015/074916 priority Critical patent/WO2016149900A1/fr
Publication of WO2016149900A1 publication Critical patent/WO2016149900A1/fr

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Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G02B3/02—Simple or compound lenses with non-spherical faces
    • G02B3/04—Simple or compound lenses with non-spherical faces with continuous faces that are rotationally symmetrical but deviate from a true sphere, e.g. so called "aspheric" lenses
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/04—Refractors for light sources of lens shape
    • F21V5/048—Refractors for light sources of lens shape the lens being a simple lens adapted to cooperate with a point-like source for emitting mainly in one direction and having an axis coincident with the main light transmission direction, e.g. convergent or divergent lenses, plano-concave or plano-convex lenses
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00—Reflectors for light sources
    • F21V7/0091—Reflectors for light sources using total internal reflection
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]

Definitions

  • the present application relates to the field of spotlights and, more specifically, to an optical lens and a spotlight including the same.
  • LED Light-emitting diode
  • LED based lamps can save a significant amount of energy than both fluorescent lamps and incandescent lamps for producing the same amount of luminous flux. Because of this advantage, people have been trying to replace the conventional light sources with LED chips in many lamp applications including spotlights.
  • Conventional optical lenses used for spotlights usually have a single curved reflection surface for increasing the central luminous intensity of a region targeted by a spotlight.
  • One aspect of the present application involves a conical frustum shaped optical lens made of transparent material, the conical frustum shaped optical lens having a long diameter at a first end and a short diameter at a second end and the conical frustum shaped optical lens defined by multiple rotational surfaces and a flat fifth surface.
  • the multiple rotational surfaces include a first surface, a second surface, a third surface, and a fourth surface.
  • the conical frustum shaped optical lens has a cavity located near the second end and defined by the first surface and the second surface for engaging a light source.
  • the first surface is configured such that at least a portion of light striking the first surface from the light source is refracted by the first surface onto the flat fifth surface.
  • the second and third surfaces are configured such that a first portion of light striking the second surface from the light source is refracted by the second surface onto the third surface and then reflected by the third surface onto the flat fifth surface.
  • the second and fourth surfaces are configured such that a second portion of light striking the second surface from the light source is refracted by the second surface onto the flat fifth surface and then entirely reflected by the flat fifth surface onto the fourth surface and then reflected by the fourth surface back onto the flat fifth surface.
  • the first surface includes a conical frustum portion and a spherical portion and it is configured to refract at least a portion of the light onto the flat fifth surface at an incidence angle of not great than 4-degree.
  • the second surface includes a first multifaceted portion near the bottom of the cavity and the first multifaceted portion is configured to refract, partially, the second portion of the light onto the flat fifth surface at an incidence angle greater than a critical angle between the transparent material and the air.
  • the second surface further includes a second multifaceted portion near the opening of the cavity and the second multifaceted portion is configured to refract, partially, the second portion of the light onto the third surface at an incidence angle greater than a critical angle between the transparent material and the air.
  • the fourth surface is covered with a reflective coating.
  • the conical frustum shaped optical lens is made from a UV-resistant transparent material selected from the group consisting of glass and polycarbonate material.
  • the conical frustum shaped optical lens is used in an MR16 form factor spotlight.
  • a spotlight including the conical frustum shaped optical lens described above.
  • the spotlight further includes a lens support made of plastic material and an LED chip.
  • the lens support has a top surface covered with a reflective coating and the top surface is configured to tightly engage the fourth surface of the conical frustum shaped optical lens.
  • the spotlight is an MR16 form factor spotlight.
  • FIG. 1 is an exploded schematic view of an LED spotlight including an optical lens, a lens support, and an LED chip according to some embodiments of the present application;
  • FIGS. 2A through 2D are multiple perspective schematic views of the optical lens and the lens support according to some embodiments of the present application.
  • FIG. 3 is a cross-sectional schematic view of the optical lens according to some embodiments of the present application.
  • FIGS. 4A through 4D are multiple cross-sectional schematic views illustrative of different light paths in the optical lens according to some embodiments of the present application.
  • FIG. 5 is a cross-sectional schematic view of dimensions of the optical lens according to some embodiments of the present application.
  • FIGS. 6A and 6B are cross-sectional schematic views illustrative of dimensional constraints over certain portions of the optical lens according to some embodiments of the present application.
  • FIG. 1 is an exploded schematic view of an MR16 form factor LED spotlight 100 including an optical lens 110, a lens support 120, and an LED chip 130 according to some embodiments of the present application.
  • FIG. 5 is a cross-sectional schematic view of various dimensions of the optical lens 110 according to some embodiments of the present application.
  • the optical lens 110 has a conical frustum shaped optical lens having a long diameter at its top surface and a short diameter at its bottom.
  • the long diameter of an optical lens used in the MR16 form factor LED spotlight is 46.0 mm and the short diameter of the optical lens is 9.7 mm.
  • the height of the optical lens is 9.8 mm.
  • the optical lens 110 is made from a UV-resistant transparent material, such as glass, polycarbonate material, or the like.
  • LEV170 is a transparent polycarbonate (PC) material made by Idemitsu Kosan of Japan with a refractive index of 1.59 relative to the air that can be used for forming the optical lens of the present application.
  • the optical lens 110 sits on top of the lens support 120.
  • a cavity for engaging the LED chip 130 such that light from the LED chip 130 passes through the optical lens 110 and exits the optical lens 110 from its top flat surface.
  • the lens support 120 is typically made of plastic materials that can sustain a temperature of 100°C or higher.
  • the lens support 120 has a reflective coating on its top surface that tightly engages the bottom surface of the optical lens 110 for reflecting light back to the top surface of the optical lens 110. In other words, folded light paths are created within the optical lens 110 such that a majority of light from the LED chip 130 is reflected twice within the optical lens 110 before being output.
  • the spotlight 100 can achieve a tighter columniation of light than is normally available from a conventional lamp design of equivalent depth.
  • the LED chip 130 has a circular lighting surface of 5.0 mm in diameter and a light beam angle of 120-degree.
  • the circular lighting surface is located on the same surface as the bottom of the optical lens 110.
  • the optical lens 110, the lens support 120, and the LED chip 130 are centered along the axis 140 with their top surfaces being perpendicular to the axis 140, respectively.
  • the spotlight can achieve a light beam angle of 8-degree and a central luminous intensity of approximately 10,000 candela (cd) .
  • FIGS. 2A through 2D are multiple perspective schematic views of the optical lens 110 and the lens support 120 according to some embodiments of the present application.
  • the conical frustum shaped optical lens has a cavity with an opening near the bottom of the lens body.
  • the bottom of the cavity is a curved surface 210 for collecting some light from the LED chip located near the opening of the cavity (not shown in FIG. 2A) .
  • FIG. 2B depicts the surrounding surface 220 of the cavity.
  • FIG. 2C depicts two bottom surfaces 230 and 240 of the conical frustum shaped optical lens.
  • the surface 230 is closer to the surface 220 than the surface 240. Both surfaces are responsiblefor reflecting incident light onto the top surface of the optical lens (not shown in FIG. 2C) .
  • FIG. 2D depicts a portion of a lens support supporting the optical lens as shown in FIG. 1.
  • the lens support has a surface 260 that engages the surface 240 of the optical lens seamlessly.
  • at least one of the surface 260 and the surface 240 is covered with a reflective coating for reflecting incident light.
  • FIG. 3 is a 2-D cross-sectional schematic view of the optical lens 110 according to some embodiments of the present application.
  • the optical lens 110 has a conical frustum shaped optical lens with a cavity 260 near its bottom.
  • the conical frustum shaped optical lens is defined by multiple rotational surfaces and a flat top surface 250.
  • the multiple rotational surfaces include a surface 210 and a surface 220 that collectively define the cavity 210 (which is open-ended) and a surface 230 and a surface 240 defining the bottom surface of the optical lens 110.
  • some light from an LED chip located near the opening of the cavity 260 (not shown in FIG.
  • the surface 220 By carefully designing the shape and dimension of the surface 220, a significant portion of light refracted by the surface 220 strikes the top surface 250 at an angle greater than the critical angle of the material used for making the optical lens (e.g., LEV170) .
  • the critical angle of the material used for making the optical lens e.g., LEV170
  • a propagating wave (including light) within a first medium strikes a boundary between the first medium and a second medium at an angle larger than a particular critical angle with respect to the normal to the boundary, a phenomenon called “total internal reflection” occurs.
  • the refractive index of the first medium e.g., LEV170
  • the second medium e.g., air
  • the wave whose incidence angle is greater than the critical angle cannot pass through the boundary and is entirely reflected.
  • a majority of light striking the top surface at an angle greater than the critical angle of the material used for making the optical lens is entirely reflected onto the surface 240.
  • the shape and dimension of the surface 240 most of the light is reflected back onto the top surface 250 at an angle much smaller than the critical angle.
  • Such light is then refracted out of the top surface 250 at a small angle (e.g., no greater than 5-degree) relative to the central axis 140.
  • optical lens 110 when different portions of the optical lens 110 have predefined shapes and dimensions, light emitted by the LED chip, enters into the optical lens 110 through different surfaces, is reflected once or multiple times inside the conical frustum shaped optical lens, and finally exits the optical lens 110 from its top surface 250 at a relatively small angle with respect to the central axis 140.
  • FIGS. 4A through 4C depict multiple cross-sectional schematic views of representative light paths in the optical lens 110 according to some embodiments of the present application. Since the optical lens 110 has a conical frustum shaped optical lens, only the left half of the lens body is depicted in FIGS. 4A through 4D for brevity. One skilled in the art would understand that the right half of the lens body is symmetrical to the left half with respect to the central axis 140.
  • FIG. 4A depicts two light paths 410 and 420 from the LED chip 130.
  • the two light paths strike the surface 210 at two different incidence angles.
  • the incidence angle of the light path 410 (which is probably the largest among all the light paths striking the surface 210) is significantly greater than that of the light path 420 (which is close to the smallest incidence angle among all the light paths striking the surface 210) .
  • both light paths exit the top surface 250 of the optical lens 110, they almost have the same angle with respect to the central axis 140.
  • the angle between the light path 410 and the central axis 140 is 3.9-degree and the angle between the light path 420 and the central axis 140 (or its parallel line) is 3.8-degree.
  • the surface 210 is configured to be comprised of two portions as shown in FIG. 4B, which is an enlarged view of the portion 430 in FIG. 4A. As shown in FIG. 4B, the surface 210 includes a conical frustum portion 210-1 and a spherical portion 210-2. As shown in FIG. 4B
  • the conical frustum portion 210-1 has a conical angle of 124-degree and a diameter of 4.8 mm at its top.
  • the spherical portion 210-2 has a diameter of 3.0 mm.
  • the total volume of the surface 210 is 4.8 mm x 4.8 mm x 0.88 mm.
  • the surface 220 is comprised of two conical frustum portions 220-1 and 220-2.
  • the conical frustum portion 220-1 has a diameter of 4.8 mm at its top, a diameter of 6.7 mm at its bottom, a height of 3.4 mm, and a conical angle of 32-degree.
  • the conical frustum portion 220-2 has a diameter of 6.7 mm at its top, a diameter of 8.5 mm at its bottom, a height of 5.0 mm, and a conical angle of 20-degree.
  • each of the two conical frustum portions is approximated by a plurality (e. g., 50) of facets, each facet is a small flat surface (not a curved surface) .
  • These facets provide optical control by gathering the light from different directions to create a concentrated light beam. It should be noted that the shape and dimension of the surface 220 as described above is only for illustrative purpose.
  • FIG. 4C depicts that two light path 440 and 450 depart from different parts of the LED chip 130 at different angles.
  • the light path 440 first strikes the lower portion 220-2 of the surface 220 and is then reflected by the top surface 250 and the surface 240 and finally departs from the top surface 250 in a nearly vertical direction (0.71-degree) .
  • the light path 450 first strikes the upper portion 220-1 of the surface 220 and is then reflected by the top surface 250 and the surface 240 and finally departs from the top surface 250 at a small refraction angle (4-degree) .
  • the top surface 250 has a diameter of 46 mm.
  • the critical angle at the top surface is therefore arcsin (1/1.59) ⁇ 39-degree. In other words, it is likely that a lot of light paths like the light path 430 are entirely reflected because their incidence angles are greater than 39-degree. In other words, there is very little light passing through the top surface 250 when it is refracted onto the top surface 250 by the surface 220.
  • the surface 240 is a special curved rotational surface such that it can reflect most of the light paths reflected by the top surface 250 like the light paths 440 and 450 onto the top surface with a small incidence angle, which is important for reducing the spotlight’s light beam angle and increasing the central luminous intensity.
  • the light that is twice reflected by the top surface 250 and the surface 240 makes the primary contribution to the high central luminous intensity.
  • approximately 94%of the central luminous intensity may be contributed by light that is twice reflected between the top surface 250 and the surface 240 before being output.
  • FIG. 4D depicts a light path 430 that first strikes the surface 220 and is then reflected by the surface 230 onto the top surface 250.
  • the light path 430 has a near zero incidence angle on the top surface 250 and a refraction angle of 3.2-degree when departing from the top surface 250.
  • the surface 230 is a special curved rotation surface.
  • the surface 230 has a diameter of 12.2 mm at its top, a diameter of 9.7 mm at its bottom and a height of 3.1 mm. It is estimated that approximately 26%of the light from the LED chip 130 follows the light path that is similar to the light path 430, which contributes approximately 3%of the central luminous intensity.
  • FIG. 6A depicts one light path 610 originating from the LED chip 130 and striking the top surface 250 at an angle above the critical angle.
  • the light path 610 has two segments 610-1 and 610-2.
  • the segment 610-1 is located within the cavity before striking the surface 220 at the point A.
  • the segment 610-2 is located within the optical lens 110 and between the point A on the surface 220 and the point B on the surface 250.
  • n is the refraction index of the material for making the optical lens.
  • the trajectory of the surface 220 at the point A should form an angle with the horizontal axis 150 between 73-degree and 90-degree in order for the corresponding light path to strike the top surface 250 at an angle above the critical angle.
  • the twice-reflected light between the top surface 250 and the surface 240 contributes more than 90%of the central luminous intensity.
  • the formula above ensures that light should strike the top surface 250 at an angle above the critical angle to the extent possible. Once the light is entirely reflected by the top surface 250, the shape and curvature of the surface 240 should be carefully designed such that light should be reflected back to the top surface 250 to the extent possible.
  • FIG. 6B depicts that the light path 610 after the first total internal reflection by the top surface 250 at point B.
  • the light path 610 is reflected by the surface 240 at the point C back to the top surface 250 and then refracted out of the optical lens 110.
  • the light path associated with the second reflection within the optical lens 110 also has two segments 610-3 and 610-4.
  • the segment 610-3 is located within the optical lens 110 and between the point B on the surface 250 and the point C on the surface 240.
  • the segment 610-4 is located within the optical lens 110 and between the point C on the surface 240 and the surface 250.
  • ⁇ should satisfy the following constraint in order for ⁇ to meet the desired value:
  • Embodiments of the present application include an MR16 form factor spotlight.
  • An LED chip includes from 20 to 110 LEDs arrayed in series upon a thermally conductive substrate.
  • the substrate is soldered to a flexible printed circuit substrate (FPC) having a pair of input power connectors.
  • FPC flexible printed circuit substrate
  • the silicon substrate is physically bonded to an MR16 form factor heat sink via thermal epoxy.
  • a driving module including a high-temperature operating driving circuit is attached to a rigid printed circuit board or a flexible printed circuit substrate. Both the driving circuit and FPC are encased in a thermally conductive plug base that is compatible with an MR16 plug, forming the base assembly module.
  • a potting compound facilitating heat transfer from the driving circuit to the thermally conductive plug case is typically used.
  • the driving circuits are coupled to input power contacts (e.
  • the base assembly module is inserted into and secured within an interior channel of the MR16 form factor heat sink.
  • the input power connectors are coupled to the output power connectors.
  • An optical lens according to the present application is then secured to the heat sink.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Lenses (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

La présente invention concerne une lentille optique (110) en forme de tronc conique constituée d'un matériau transparent, la lentille optique (110) en forme de tronc conique affichant un grand diamètre au niveau d'une première extrémité et un petit diamètre au niveau d'une seconde extrémité et la lentille optique (110) en forme de tronc conique est définie par de multiples surfaces de rotation (210, 220, 230, 240) et une cinquième surface plate (250). La lentille optique (110) en forme de tronc conique est conçue de manière à créer des chemins de lumière pliés à l'intérieur de la lentille optique (110) en forme de tronc conique, de sorte qu'une majeure partie de la lumière provenant d'une source de lumière soit réfléchie deux fois à l'intérieur de la lentille optique (110) en forme de tronc conique avant d'être délivrée en sortie. Un projecteur à DEL à facteur de forme MR16 comprenant la lentille optique (110) en forme de tronc conique peut permettre d'obtenir un angle de faisceau de lumière réduit et une plus grande intensité lumineuse centrale.
PCT/CN2015/074916 2015-03-24 2015-03-24 Lentille optique et projecteur la comprenant WO2016149900A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/CN2015/074916 WO2016149900A1 (fr) 2015-03-24 2015-03-24 Lentille optique et projecteur la comprenant

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/CN2015/074916 WO2016149900A1 (fr) 2015-03-24 2015-03-24 Lentille optique et projecteur la comprenant

Publications (1)

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WO2016149900A1 true WO2016149900A1 (fr) 2016-09-29

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH05281402A (ja) * 1992-03-31 1993-10-29 Sunx Ltd 光学装置
JP2005197320A (ja) * 2003-12-26 2005-07-21 Omron Corp 発光光源および当該発光光源を用いた光学装置
US20090213607A1 (en) * 2008-02-22 2009-08-27 Koito Manufacturing Co., Ltd. Vehicle lighting device
CN103133964A (zh) * 2011-11-29 2013-06-05 株式会社小糸制作所 车辆用照明灯具

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH05281402A (ja) * 1992-03-31 1993-10-29 Sunx Ltd 光学装置
JP2005197320A (ja) * 2003-12-26 2005-07-21 Omron Corp 発光光源および当該発光光源を用いた光学装置
US20090213607A1 (en) * 2008-02-22 2009-08-27 Koito Manufacturing Co., Ltd. Vehicle lighting device
CN103133964A (zh) * 2011-11-29 2013-06-05 株式会社小糸制作所 车辆用照明灯具

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