Optical system

Abstract

The present disclosure provides an optical system including a TIR mother lens and a secondary output lens, preferably for efficiently distributing light out of an LED track lighting system. The optical system of the present disclosure is configured to create variant beam angles from a lens assembly using the same TIR lens. Preferably, by altering the dimensions and focal lengths of the secondary output lens in a single TIR lens, the optical system can create a variety of beam angles, including, but not limited to, Spot (“SP”), Narrow Flood (“NFL”), Flood (“FL”), or Wide Flood (“WFL”) beam angles.

Claims

1. An optical system, comprising: a) a TIR lens having a first end having a first diameter, a second planar end wall opposite the first end that is annularly shaped and perpendicular to a central longitudinal axis of the TIR lens, the second planar end wall having a second diameter larger than the first diameter, an outer tapering peripheral wall connecting the first end and the second planar end wall, and an inner peripheral wall defining a cavity through a central region of the TIR lens from the first end to the second planar end wall and defining a first opening in the first end of the TIR lens and a second opening in the second planar end wall of the TIR lens, the TIR lens being configured to refract light from a light source near the first end of the TIR lens and direct light from the light source through the second planar annularly shaped end wall along an orientation that is parallel to the central longitudinal axis of the TIR lens; and b) a secondary lens removably disposed at least partially over the second planar end wall of the TIR lens and attached to the TIR lens, the secondary lens being configured to redirect the light passing through the secondary lens originating from the second planar end wall of the TIR lens; wherein the secondary lens is removably attached to the second planar end wall of the TIR lens by a plurality of studs extending orthogonally to a plane defined by the secondary lens.

2. The optical system of claim 1, wherein the secondary lens is coaxially co-located with the TIR lens.

3. The optical system of claim 1, wherein the secondary lens covers the second opening in the second planar end wall of the TIR lens.

4. The optical system of claim 1, wherein the secondary lens is a Fresnel lens.

5. The optical system of claim 1, wherein the secondary lens is a micro lens.

6. The optical system of claim 1, wherein the secondary lens is removably attached to the second planar end wall of the TIR lens.

7. A light fixture comprising the optical system of claim 1 disposed in a housing, the light fixture further comprising an operable LED light source disposed proximate a central region of the first end of the TIR lens.

8. An optical system, comprising: a) a TIR lens having a first end having a first diameter, a second planar end wall opposite the first end that is annularly shaped and perpendicular to a central longitudinal axis of the TIR lens, the second planar end wall having a second diameter larger than the first diameter, an outer tapering peripheral wall connecting the first end and the second planar end wall, and an inner peripheral wall defining a cavity through a central region of the TIR lens, the inner peripheral wall having a length from the first end of the TIR lens to the second planar end wall of the TIR lens and surrounding a central cavity inside the TIR lens, the inner peripheral wall further defining a first opening in the first end of the TIR lens and a second opening in the second planar end wall of the TIR lens, wherein the inner peripheral wall is defined at least in part by a plurality of tapering generally conically shaped walls that taper radially outwardly along a direction from the first end of the TIR lens toward the second planar end wall of the TIR lens, the TIR lens being configured to refract light from a light source near the first end of the TIR lens and direct light from the light source through the second planar annularly shaped end wall along an orientation that is parallel to the central longitudinal axis of the TIR lens; and b) a secondary lens attached proximate the second planar end wall of the TIR lens, the secondary lens being configured to redirect the light passing through the secondary lens; wherein the secondary lens is removably attached to the second planar end wall of the TIR lens by a plurality of studs extending orthogonally to a plane defined by the secondary lens.

9. The optical system of claim 8, wherein two of the tapering generally conically shaped walls that define the inner peripheral wall are separated along the length of the inner peripheral wall by an annularly shaped shoulder, wherein a distal end of one of the generally conically shaped walls adjoins a radially inward periphery of the shoulder, and a proximal end of a second one of the generally conically shaped walls adjoins a radially outward periphery of the shoulder.

10. The optical system of claim 8, wherein a first tapering generally conically shaped wall that defines the inner peripheral wall defines an inwardly facing surface.

11. The optical system of claim 10, wherein a proximal end of the first tapering generally conically shaped wall adjoins the first end of the TIR lens.

12. The optical system of claim 11, wherein second and third tapering generally conically shaped walls that define the inner peripheral wall are separated along the length of the inner peripheral wall by an annularly shaped shoulder, wherein a distal end of the second generally conically shaped wall adjoins a radially inward periphery of the shoulder, and a proximal end of the third generally conically shaped wall adjoins a radially outward periphery of the shoulder.

13. The optical system of claim 12, wherein a distal end of the first tapering generally conically shaped wall adjoins a proximal end of the second tapering generally conically shaped wall.

14. The optical system of claim 8, wherein the secondary lens is coaxially co-located with the TIR lens.

15. The optical system of claim 8, wherein the secondary lens covers an opening formed in the second planar end wall of the TIR lens defined by a distal end of the inner peripheral wall.

16. The optical system of claim 8, wherein the secondary lens is a Fresnel lens.

17. The optical system of claim 8, wherein the secondary lens is a micro lens.

18. The optical system of claim 8, wherein the secondary lens is removably attached to the TIR lens.

19. A light fixture comprising the optical system of claim 8 disposed in a housing, the light fixture further comprising an operable LED light source disposed proximate a central region of the first end of the TIR lens.

20. A kit for assembling an optical system capable of producing a plurality of different beam patterns, comprising: a) a TIR lens having a first end having a first diameter, a second planar end wall opposite the first end that is annularly shaped and perpendicular to a central longitudinal axis of the TIR lens, the second planar end wall having a second diameter larger than the first diameter, an outer tapering peripheral wall connecting the first end and the second planar end wall, and an inner peripheral wall defining a cavity through a central region of the TIR lens from the first end to the second planar end wall, the TIR lens being configured to refract light from a light source near the first end of the TIR lens and direct light from the light source through the second planar annularly shaped end wall along an orientation that is parallel to the central longitudinal axis of the TIR lens; and b) a plurality of secondary lenses having different focal lengths from each other, each of the secondary lenses being configured to be removably attached to the TIR lens near the second planar end wall of the TIR lens, wherein each combination of the TIR lens and each secondary lens creates a unique beam pattern; wherein the secondary lens is removably attached to the second planar end wall of the TIR lens by a plurality of studs extending orthogonally to a plane defined by the secondary lens.

21. The optical system of claim 20, wherein each secondary lens is coaxially co-located with the TIR lens when removably attached to the TIR lens.

22. The optical system of claim 20, wherein the secondary lens covers an opening formed in the second planar end wall of the TIR lens defined by a distal end of the inner peripheral wall.

23. The optical system of claim 20, wherein at least one of the secondary lenses is a Fresnel lens.

24. The optical system of claim 20, wherein at least one of the secondary lenses is a micro lens.

25. A light fixture comprising the optical system of claim 20 disposed in a housing, the light fixture further comprising an operable LED light source disposed proximate a central region of the first end of the TIR lens.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIG. 1(a) is a side perspective view of the optical system of the present disclosure, containing a TIR lens and a circular Fresnel lens placed therein;

(2) FIG. 1(b) is a cross sectional view of the optical system seen in FIG. 1, showing the ray-tracing of the TIR lens and the Fresnel lens;

(3) FIG. 1(c) is a side perspective view of the optical system seen in FIG. 1, with the Fresnel lens having been removed from the distal end of the central well in the TIR lens;

(4) FIG. 1(d) is a top perspective view of the optical system seen in FIG. 1, showing the central well of the TIR lens and placement of the light source at the proximal end thereof;

(5) FIGS. 1(e)-1(g) are views of a mother TIR lens in combination with a micro lens;

(6) FIG. 2(a) is a side perspective view of an illustrative lens system of the disclosure configured to deliver a spot (SP) beam;

(7) FIG. 2(b) is a plotted graph showing the intensity distribution of the Spot beam;

(8) FIG. 3(a) is a side perspective view of an illustrative lens system of the disclosure configured to deliver a narrow flood (NF) beam;

(9) FIG. 3(b) is a plotted graph showing the intensity distribution of the Narrow Flood beam;

(10) FIG. 4(a) is a side perspective view of an illustrative lens system of the disclosure configured to deliver a flood (FL) beam;

(11) FIG. 4(b) is a plotted graph showing the intensity distribution of the Flood beam;

(12) FIG. 5(a) is a side perspective view of an illustrative lens system of the disclosure configured to deliver a wide flood (WFL) beam;

(13) FIG. 5(b) is a plotted graph showing the intensity distribution of the Wide Flood beam;

(14) FIG. 6(a) is a side perspective view of an exemplary mother TIR lens used in the embodiments of FIGS. 2-5;

(15) FIG. 6(b) is a plotted graph showing the intensity distribution of the mother TIR lens;

(16) FIGS. 7(a)-7(e) illustrate further aspects of the lens assembly of FIG. 2(a);

(17) FIGS. 8(a)-8(e) illustrate further aspects of the lens assembly of FIG. 3(a);

(18) FIGS. 9(a)-9(e) illustrate further aspects of the lens assembly of FIG. 4(a);

(19) FIGS. 10(a)-10(e) illustrate further aspects of the lens assembly of FIG. 5(a); and

(20) FIG. 11 is a cross section of an exemplary light fixture including an embodiment of the disclosure.

DETAILED DESCRIPTION

(21) Descriptions herein of the optical systems and lenses of the present disclosure shown in FIGS. 1-11 represent conceptual embodiments of systems embodying the principles of the disclosed embodiments. It should be understood that these figures and embodiments are exemplary in nature and in no way serve to limit the scope of the disclosure.

(22) As can be seen in FIGS. 1(a)-(d), one illustrated embodiment 10 includes a TIR lens 20 which is preferably conically shaped. At the flat proximal surface 22 of the TIR lens, there is a light source 30, which is preferably an LED light source. Light source 30 is positioned to refract light into the TIR lens which can then provide symmetrical light distribution.

(23) Extending within the TIR lens, and coaxially located with respect to the light source 30 placed at the flat proximal surface 22, is a cut-out segment 24 of the TIR lens, which is more preferably filled with air, through which light can be passed from the light source 30. At the opposite distal end 26 of the cut-out segment 24, and a Fresnel lens 40 can be placed so that it falls within the surface area of TIR lens 20 and spaced a distance apart from the light source 30. Preferably, the Fresnel lens 40 can be interchangeable within a single TIR lens 20. By combining the TIR lens 20 with the Fresnel lens 40, the system can emit a strong central beam. This provides an improvement over the use of a TIR lens individually, which lacks refractive collimating power, and over the use of a Fresnel lens individually, which lacks reflective collimating power.

(24) FIGS. 1e-1g similarly illustrate a system that places a micro lens 45 at the opposite distal end 26 of the cut-out segment 24 rather than a Fresnel lens so that it falls within the surface area of TIR lens 20 and spaced a distance apart from the light source 30. Preferably, the micro lens 45 can be interchangeable within a single TIR lens 20. By combining the TIR lens 20 with the micro lens 45, the light source can emit a desired wider beam.

EXAMPLES

(25) The presently provided examples presented below in FIGS. 2-10 are intended to be non-limiting and are presented to illustrate aspects of inventions provided in accordance with the disclosure.

(26) As can be seen in FIGS. 2(a)-5(a), the optical system 10 preferably provides the additional benefit of enabling a single TIR lens 20 to be used with a variety of secondary (e.g., Fresnel type or other) lenses to create different beam angles of projected light. Preferably, using a single TIR lens 20 and light source 30, at least four different inserted lenses 50, 52, 54, and 56—each with a different diameter, focal length and surface geometries—can be used to create Spot beam (e.g., at an angle of 0-17°, or any angular increment therebetween of 0.1 degrees), a Narrow Flood beam (e.g., at an angle of 18-25°, or any angular increment therebetween of 0.1 degrees), a Flood beam (e.g., with an angle of 26-39°, or any angular increment therebetween of 0.1 degrees), and a Wide Flood beam angle (e.g., with an angle of 40° or greater in any angular increment above) 40°), respectively. Of the aforementioned embodiments, the embodiments of FIGS. 2 and 3 use a Fresnel lens insert, while the embodiments of FIGS. 4 and 5 use a micro lens insert, which uses a pattern of (e.g., hexagonal or other shaped) elements to spread out the resulting beam.

(27) A cross sectional side schematic of a secondary micro lens installed over a mother TIR lens is presented in FIG. 1(f). The illustrated micro lens insert is a flat lens element that can have micro geometries on one-side or both sides of the lens. Such a lens can be used for spreading out a collimated beam into a wide-distribution beam such as Flood (FL) or Wide Flood (WFL). Its role as opposed to the aforementioned Fresnel secondary lens can be compared to a concave lens vs. a convex lens, where the former spreads out a collimated beam while the latter takes a natural beam at focus and collimate it.

(28) As disclosed herein, the micro-lens insert has micro-lens geometries only on the perimeter that covers the output surface of the mother TIR lens where the collimated beam comes out but leaves the center that covers the air-well of the TIR lens transparent, or with slight surface treatment such as frosting to soften the beam. Therefore, the collimated beam is spread wider by the micro-lens while the direct light from the LED source comes out without collimation to also serve as part of the wider beam.

(29) Plotted graphs showing the intensity distributions emitted through the different lenses 50, 52, 54, and 56 inserted into a mother TIR lens 20 can be seen in FIGS. 2(b)-5(b), corresponding with the inserted lenses seen in FIGS. 2(a)-5(a), respectively. This allows the optical system 10 of the present disclosure to be used in a variety of applications and products, while using a single housing 12 (e.g., FIG. 11), the same TIR lens 20, and the same light source 30, despite the need for variation in central beam intensity.

(30) It will be appreciated that the focal length of the secondary lens insert can be any desired distance, to produce beam angle from about 5° to about 150°, in any desired increment there between, for example, of one degree. Moreover, the ratio of the radius Ri of the secondary lens (e.g., 50) to that of the TIR lens (e.g., 20) at the distal face of the assembly Ro can range, for example, from about 0.01 to about 1.0 and in any desired increment there between of about 0.01. At the same time, the ratio of the height H of the TIR lens to its Radius Ro can vary from about 0.1 to about 10.0 and in any desired increment there between of about 0.1. Moreover, the distance between the LED and the TIR lens entrance 22 can be varied from about 1 mm to about 20 mm and in any desired increment there between of about 0.1 mm.

(31) In some embodiments, spot beams can be used for illuminating an object on a wall, a flood beam can be used for ceiling light, and a wide flood beam can be used to light a hallway. As can be seen in FIG. 1(c), a Fresnel lens 40 can be removed from the TIR lens 20 to be replaced with another Fresnel or other lens of varying specifications to create different beam angles. Thus, as can be seen in FIGS. 2(a)-5(a), lenses 50, 52, 54, and 56 can be interchanged within the same TIR lens 20 for creation of SP, NFL, FL, and WFL beam angles, respectively. It will also be appreciated that the diameter of the secondary lens can be any suitable diameter and may overlap the surface of the mother TIR lens to any desired extent as is needed to effectuate the desired design.

(32) A non-limiting example of an illustrative mother TIR lens and corresponding polar plot are presented in FIGS. 6(a)-6(b), respectively. As can be seen, six receiving apertures 60 are symmetrically positioned about a central orifice 62 for receiving corresponding alignment and fixation pegs 64 from a corresponding lens insert. As will be appreciated by those of skill in the art, other retaining structures may be used instead of the disclosed peg/orifice combination, such as snap fit connections, threaded connections, adhesive and the like.

(33) FIGS. 7(a)-7(e) illustrate the lens system illustrated in FIG. 2A in further detail. As can be seen in FIG. 7(a), a mother TIR lens 20 is presented with the aforementioned receiving apertures. Also presented is a central Fresnel lens 50 with three symmetrically spaced fixation pegs 64 for insertion into three of the receiving apertures 60. While any method of joining can be accomplished (threaded connection, snap fit, etc.), the illustrated technique can provide for a removable lens insert that can be substituted with other inserts if a user's preference changes or simply to provide versatility. The extra three orifices are provided for substitution if any pegs were broken in the first three orifices when removing a previous insert.

(34) FIG. 7(b) presents an end view of the lens assembly 10, whereas FIG. 7(c) presents a central longitudinal cross sectional view of the lens assembly 10, illustrating the mother TIR lens 20, and the central Fresnel lens 50 attached to the mother TIR lens 20 via fixation pegs 64. Also present in FIG. 7(c) is a stepped central aperture 24 defined through the mother TIR lens 20 including a distal-most chamber adjacent the Fresnel lens 50 that steps radially inward at its proximal end to form a central generally cylindrical chamber that is joined to a conical chamber with a slight taper that terminates at a proximal opening defined into the mother TIR lens 20. FIG. 7(d) presents an exploded view of the lens assembly 10, illustrating the mother TIR lens 20, and the Fresnel lens 50, wherein the detail illustrates a prismatic patterning 28 around an annularly shaped distal face of the mother TIR lens. The patterning 28 is for maximizing beam uniformity without sacrificing central beam and beam angle. FIG. 7(e) presents a rear facing exploded view of the lens assembly, again illustrating the mother TIR lens 20 and the Fresnel lens 50.

(35) FIGS. 8(a)-8(e) illustrate the lens system illustrated in FIG. 3A in further detail. As can be seen, a mother TIR lens 20 is presented with the aforementioned receiving apertures. Also presented is a central Fresnel lens 52 with three symmetrically spaced fixation pegs 64 for insertion into three of the receiving apertures. It will be appreciated that the diameter can be any suitable diameter and may overlap the surface of the mother TIR lens to any desired extent as is needed to effectuate the desired design.

(36) FIG. 8(b) presents an end view of the lens assembly 10, whereas FIG. 8(c) presents a central longitudinal cross sectional view of the lens assembly 10, illustrating the mother TIR lens 20, and the central Fresnel lens 52 attached to the mother TIR lens 20 via fixation pegs 64. Also present in FIG. 8(c) is a stepped central aperture 24 defined through the mother TIR lens 20 including a distal-most chamber adjacent the Fresnel lens 52 that steps radially inward at its proximal end to form a central generally cylindrical chamber that is joined to a conical chamber with a slight taper that terminates at a proximal opening defined into the mother TIR lens 20. FIG. 8(d) presents an exploded view of the lens assembly 10, illustrating the mother TIR lens 20, and the Fresnel lens 52, wherein the detail illustrates a hexagonal patterning 28 around an annularly shaped distal face of the mother TIR lens. The patterning 28 is for maximizing beam uniformity without sacrificing central beam and beam angle. FIG. 8(e) presents a rear facing exploded view of the lens assembly, again illustrating the mother TIR lens 20 and the Fresnel lens 52. As further illustrated in FIG. 8(e), lens 52 also includes a patterned portion molded therein in a grid pattern for the best beam uniformity.

(37) FIGS. 9(a)-9(e) illustrate the lens system illustrated in FIG. 4(a) in further detail. As can be seen, a mother TIR lens 20 is presented with the aforementioned receiving apertures. Also presented is a micro lens 54 with three symmetrically spaced fixation pegs 64 for insertion into three of the receiving apertures, as with the two preceding embodiments.

(38) FIG. 9(b) presents an end view of the lens assembly 10, whereas FIG. 9(c) presents a central longitudinal cross sectional view of the lens assembly 10, illustrating the mother TIR lens 20, and the central micro lens 54 attached to the mother TIR lens 20 via fixation pegs 64. Also present in FIG. 9(c) is a stepped central aperture 24 defined through the mother TIR lens 20 including a distal-most chamber adjacent the micro lens 54 that steps radially inward at its proximal end to form a central generally cylindrical chamber that is joined to a conical chamber with a slight taper that terminates at a proximal opening defined into the mother TIR lens 20. FIG. 9(d) presents an exploded view of the lens assembly 10, illustrating the mother TIR lens 20, and the micro lens 54, wherein the detail illustrates a hexagonal prismatic patterning 28 around an annularly shaped distal face of the mother TIR lens 20. The patterning 28 is for maximizing beam uniformity without sacrificing central beam and beam angle. FIG. 9(e) presents a rear facing exploded view of the lens assembly, again illustrating the mother TIR lens 20 and the micro lens 54. FIG. 9(e) shows the micro lens structure details on lens 54.

(39) FIGS. 10(a)-10(e) illustrate the lens system illustrated in FIG. 5(a) in further detail. As can be seen, a mother TIR lens 20 is presented with the aforementioned receiving apertures. Also presented is a micro lens 56 with three symmetrically spaced fixation pegs 64 for insertion into three of the receiving apertures, as with the three preceding embodiments.

(40) FIG. 10(b) presents an end view of the lens assembly 10, whereas FIG. 10(c) presents a central longitudinal cross sectional view of the lens assembly 10, illustrating the mother TIR lens 20, and the central micro lens 56 attached to the mother TIR lens 20 via fixation pegs 64. Also present in FIG. 10(c) is a stepped central aperture 24 defined through the mother TIR lens 20 including a distal-most chamber adjacent the micro lens 56 that steps radially inward at its proximal end to form a central generally cylindrical chamber that is joined to a conical chamber with a slight taper that terminates at a proximal opening defined into the mother TIR lens 20. FIG. 10(d) presents an exploded view of the lens assembly 10, illustrating the mother TIR lens 20, and the micro lens 56, wherein the detail illustrates a patterning 28 around an annularly shaped distal face of the mother TIR lens 20. The patterning 28 is for maximizing beam uniformity without sacrificing central beam and beam angle. FIG. 10(e) presents a rear facing exploded view of the lens assembly, again illustrating the mother TIR lens 20 and the micro lens 56. FIG. 10(e) shows the micro lens structure details on lens 56.

(41) FIG. 11 presents a cross section of an example of a light fixture 100 including a lens element 10 as described herein, operably positioned with respect to one or more LED elements 30, which in turn are operably coupled to a LED driver and/or power supply 60.

(42) Although the present disclosure herein has been described with reference to particular preferred embodiments thereof, it is to be understood that these embodiments are merely illustrative of the principles and applications of the disclosure. Therefore, modifications may be made to these embodiments and other arrangements may be devised without departing from the spirit and scope of the disclosure.