Methods and apparatus for intrinsically safe laser sourced illumination

Abstract

Intrinsically safe laser sourced illumination. A system for illumination is disclosed, including a plurality of laser illumination sources configured to transmit laser beams; a dichroic mirror spaced from the plurality of laser illumination sources and having an aperture configured to allow the laser beams to pass through the dichroic mirror, the remaining surfaces of the dichroic mirror configured to reflect the laser beams; a phosphor element spaced from the dichroic mirror and coated with a substance to fluoresce when struck by the laser beams and configured to disperse the laser beams and to output combined light that includes fluorescent light and the dispersed laser beams; and an illumination output arranged to receive the combined light from the phosphor element and to output illuminating light containing both the fluorescent light and the dispersed laser beams. Methods are also disclosed.

Claims

1. A system comprising: illumination sources configured to produce illuminated light having a first color; a first dichroic mirror having a first surface portion and a second surface portion, the first surface portion configured to reflect light having the first color and to reflect light having a second color, and the second surface portion configured to transmit at least a portion of the illuminated light having the first color as transmitted light and to reflect light having the second color; a phosphor element configured to produce fluorescent light having the second color responsive to receiving the transmitted light having the first color, and to disperse a portion of the transmitted light, to produce dispersed light having the first color; and a second dichroic mirror having a third surface portion and a fourth surface portion, the phosphor element optically coupled between the first dichroic mirror and the second dichroic mirror, the third surface portion configured to reflect the dispersed light of the first color, and the fourth surface portion configured to transmit at least a portion of the fluorescent light of the second color and to transmit light of the first color.

2. The system of claim 1, wherein the illumination sources include laser diodes.

3. The system of claim 2, wherein the laser diodes are configured to output blue light or violet light.

4. The system of claim 2, wherein the laser diodes are configured to output light having a wavelength between 400 nanometers and 460 nanometers.

5. The system of claim 1, wherein the second color is yellow.

6. The system of claim 5, wherein the phosphor element is configured to not reflect the illuminated light responsive to the phosphor element being displaced from its original position.

7. The system of claim 1, wherein a substrate of the phosphor element is configured to reflect the illuminated light back to the second surface portion, responsive to a phosphor coating on the phosphor element being dislocated.

8. The system of claim 1, wherein the illumination sources are configured to transmit the illuminated light to strike the first surface portion, responsive to the illumination sources being displaced from their original position.

9. The system of claim 1, wherein the first color is blue, and the second color is yellow.

10. The system of claim 1, further comprising: a condensing lens optically coupled between the first dichroic mirror and the phosphor element; and a collimating lens optically coupled between the phosphor element and the second dichroic mirror.

11. The system of claim 1, the second surface portion having an inner edge and an outer edge, the outer edge having an oval shape, a circular shape, a rectangular shape, or a square shape.

12. A method, comprising: producing, by illumination sources, illuminated light having a first color; reflecting, by a first surface portion of a first dichroic mirror, the illuminated light having the first color, the first surface portion configured to reflect light having a second color; transmitting, by a second surface portion of the first dichroic mirror, at least a portion of the illuminated light having the first color as transmitted light, the second surface portion configured to reflect light having the second color; producing, by a phosphor element, fluorescent light having the second color, responsive to receiving the transmitted light; dispersing, by the phosphor element, a portion of the transmitted light, to produce dispersed light having the first color; reflecting, by a third surface portion of a second dichroic mirror, the dispersed light of the first color; and transmitting, by a fourth surface portion of the second dichroic mirror, at least a portion of the fluorescent light, wherein the fourth surface portion is configured to transmit light having the first color.

13. The method of claim 12, wherein when the illumination sources are dislocated, the illuminated light strikes the first surface portion.

14. The method of claim 12, wherein when the phosphor element loses a phosphor coating, a substrate of the phosphor element is configured to reflect the illuminated light back to the second surface portion.

15. The method of claim 12, wherein the first color is blue and the second color is yellow.

16. The method of claim 12, further comprising: focusing, by a condensing lens, the illuminated light on the phosphor element; and collimating, by a collimated lens, the fluorescent light and the dispersed light.

17. A headlight comprising: laser diodes configured to produce illuminated light having a first color; a first dichroic mirror having a first surface portion and a second surface portion, the first surface portion configured to reflect light having the first color and to reflect light having a second color, the second surface portion configured to transmit at least a portion of the illuminated light having the first color as transmitted light and to reflect light having the second color; a phosphor element configured to produce fluorescent light having the second color responsive to receiving the transmitted light having the first color and to disperse a portion of the transmitted light to produce dispersed light having the first color; a second dichroic mirror having a third surface portion and a fourth surface portion, the phosphor element optically coupled between the first dichroic mirror and the second dichroic mirror, the third surface portion configured to reflect light of the first color, and the fourth surface portion configured to transmit light of the first color and to transmit at least a portion of the fluorescent light of the second color; a condensing lens optically coupled between the first dichroic mirror and the phosphor element; and a collimating lens optically coupled between the phosphor element and the second dichroic mirror.

18. The headlight of claim 17, wherein a substrate of the phosphor element is configured to reflect the illuminated light back through the second surface portion, responsive to the phosphor element losing a phosphor coating.

19. The headlight of claim 17, wherein the first color is blue and the second color is yellow.

20. The headlight of claim 17, the second surface portion having an inner edge and an outer edge, the outer edge having an oval shape, a circular shape, a rectangular shape, or a square shape.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For a more complete understanding of the illustrative examples of aspects of the present application that are described herein and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

(2) FIG. 1 depicts a top view of a prior art laser sourced headlight assembly;

(3) FIG. 2 depicts a top view of an intrinsically safe laser illumination system of the present application utilizing a folded light path;

(4) FIGS. 3A and 3B each depict in a front view a pair of laser diode arrays and dichroic mirrors for an intrinsically safe laser illumination system for use in arrangements of the present application;

(5) FIG. 4 depicts in another top view the intrinsically safe illumination system of FIG. 2 with an example shifted laser diode array failure;

(6) FIG. 5 depicts in yet another top view the intrinsically safe illumination system of FIG. 2 with missing yellow phosphor substrate failure;

(7) FIG. 6 depicts in a top view the intrinsically safe laser illumination system of FIG. 2 with an example phosphor element coating failure;

(8) FIG. 7 depicts a top view of another example of an intrinsically safe laser illumination arrangement of the present application utilizing a linear light path;

(9) FIGS. 8A-8B each depict a front view of laser diode arrays and dichroic mirrors for use in the intrinsically safe laser illumination system arrangement of FIG. 7;

(10) FIG. 9 depicts in a top view the intrinsically safe illumination system of FIG. 7 with an example shifted laser diode array failure;

(11) FIG. 10 depicts in another top view the intrinsically safe illumination system of FIG. 7 with an example phosphor coating failure; and

(12) FIG. 11 depicts a flow diagram illustrating a method of creating an intrinsically safe illumination system.

(13) Corresponding numerals and symbols in the different figures generally refer to corresponding parts unless otherwise indicated. The figures are drawn to clearly illustrate the relevant aspects of the illustrative example arrangements and are not necessarily drawn to scale.

DETAILED DESCRIPTION

(14) The making and using of various example illustrative arrangements that incorporate aspects of the present application are discussed in detail below. It should be appreciated, however, that the illustrative examples disclosed provide many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific examples and arrangements discussed are merely illustrative of specific ways to make and use the various arrangements, and the examples described do not limit the scope of the specification, nor do they limit the scope of the appended claims.

(15) For example, when the term “coupled” is used herein to describe the relationships between elements, the term as used in the specification and the appended claims is to be interpreted broadly, and while the term “coupled” includes “connected”, the term “coupled” is not to be limited to “connected” or “directly connected” but instead the term “coupled” may include connections made with intervening elements, and additional elements and various connections may be used between any elements that are described as “coupled.”

(16) An intrinsically safe laser illumination system is one where additional control systems are not required to sequester or contain the collimated laser light from exiting the illumination system. The following paragraphs will illustrate a safe laser illumination system that operates safely without the need for additional safety systems. However, in alternative arrangements that are contemplated by the inventors, a sensor such as described above with respect to prior known arrangements can be used in conjunction with the intrinsically safe laser illumination system and the benefits of the use of the arrangements would still accrue in such an alternative arrangement.

(17) FIG. 2 depicts a top view of an intrinsically safe laser illumination system 200 utilizing a folded light path. In FIG. 2, a laser illumination headlamp 202 contains a laser array 210 whose laser beams 230 are directed through apertures in a dichroic mirror 212 and through a focusing and collimating lens set 214 to focus on a reflective yellow phosphor element 218. The light from the phosphor substrate travels back through the lens set 214 and is reflected off the dichroic mirror 212 and out of the headlamp or illumination system 202 as depicted by light rays 250. The lens set 214 may contain one or more lenses to achieve its purpose of collimating and focusing the laser beams on the reflective phosphor substrate. Of special interest in this example of the present application is the function of the dichroic mirror 212 which is mounted at an angle 232 to the laser diode array 212. The approximate angle of the mirror in one example arrangement would be 45 degrees, however the mirror 212 can be arranged at other angles in such a manner that the light paths depicted are accomplished with the intent of reflecting laser beams 230 to a safe location in the case where the laser array 210 and dichroic mirror 212 become misaligned, as is further described below. The dichroic mirror 212 reflects yellow and blue light on the front and back surfaces. The exception is that there is aperture area that is aligned to the laser diode array 210 which still reflects yellow light, but allows blue laser beams 230 to pass either direction through the mirror. A better understanding of the laser diode array and dichroic mirror may be attained by examining the further details presented in FIGS. 3A and 3B.

(18) FIGS. 3A-3B each depict in aspects of the present application a front view of a pair of arrangements for laser diode arrays and dichroic mirrors for an intrinsically safe laser illumination system. FIG. 3A illustrates a laser array 310 which contains, in a non-limiting example, eight laser diode sources 312 that are arranged in a square pattern. Element 320 is a dichroic mirror with a rectangular aperture 324. Dichroic mirror 320 is designed to reflect blue and yellow light on front and back surfaces. An exception is the aperture area 324 which will allow blue light to pass in either direction. The size and position of the aperture 324 will coincide with the laser array 310 in such a manner that when the mirror 320 is aligned, in an example arrangement to illustrate the features, at about 45 degrees to the array, the mirror aperture 324 will allow the blue laser beams to pass through the mirror 320. Laser array 310 is depicted with the laser sources 312 in a square pattern that corresponds to the mirror aperture 324 in the mirror 320 that is rectangular when viewed directly from the front as illustrated, but not necessarily to scale.

(19) FIG. 3B depicts a second example arrangement of the present application with a laser array 316 where the laser diode sources 318 are arranged in a circular pattern. Element 330 is another dichroic mirror with an oval aperture 334. This mirror 330 is designed to reflect blue and yellow light on front and back surfaces. An exception is the aperture area 334 which will allow blue light to pass in either direction. Laser array 316 depicted with the laser sources 318 in a circular pattern corresponds to the mirror aperture 334 in the mirror 330 being an oval shape when viewed directly from the front as illustrated, but is not necessarily drawn to scale. The inventor contemplates additional laser diode layout patterns and corresponding dichroic mirror arrangements that form further aspects of the present application, each of these arrangements will allow laser light to pass through one or more apertures in a mirror while reflecting light in other areas of the mirror. Example arrangement that are contemplated as providing additional aspects of the present application includes arrangements with multiple apertures in the mirror with corresponding laser layouts.

(20) In both of the non-limiting illustrative example arrangements shown in FIG. 3A and FIG. 3B, the mirror apertures are symmetric to allow the laser beams to pass back to front through the mirror and also front to back through the mirror. In the event of a partial or total failure of the phosphor coating in a system incorporating the mirrors of FIG. 3A or 3B, the laser beams would be reflected off the substrate surface of the phosphor and then would be directed back through the symmetric aperture of the mirror, preventing collimated laser light from exiting the headlight system. The following examples illustrate the intrinsically safe nature of this illumination system in view of different possible failure mechanisms.

(21) FIG. 4 depicts in a top view the intrinsically safe illumination system of FIG. 2 with a shifted laser diode array failure. Depicted in 400 is an intrinsically safe illumination headlight or headlamp assembly 402 similar to 202 depicted in FIG. 2, retaining the numerical assignments, only now in the 400 series. Assembly 402 includes the laser source 410, laser beams 430, dichroic mirror 412, phosphor element 418 and the light output 450. In this illustration, the laser array 410 is shown shifted or rotated in position with respect to the dichroic mirror 412 in such a manner that the laser beams 430 are now not aligned with the apertures in the dichroic mirror 412.

(22) In this example, the laser beams 430 are reflected away from the normal output direction 450 of the illumination system and do not exit the illumination system. This is an intrinsic safety feature of this arrangement and does not require any detectors, ECUs nor power interrupt systems to contain the laser beams. Power can remain on for the laser diodes 410 without endangering human or animal observers as no laser energy is emitted from assembly 402 at output 450 in this example failure.

(23) FIG. 5 depicts in another example the intrinsically safe illumination system of FIG. 2 with a missing yellow phosphor substrate failure. Depicted in FIG. 5 is an intrinsically safe illumination arrangement 502 such as was depicted in FIG. 2 as 202, retaining the numerical assignments, only in the 500 series. The assembly 502 includes the laser source 510, laser beams 530, dichroic mirror 512, lens set 514, phosphor element 518 and the light output 550.

(24) In this example, the yellow phosphor substrate 518 is not in its proper location. Laser array 510 supplies laser beams 530 which are in alignment with the dichroic mirror 512. The laser beams pass thru the lens set 514 but do not energize the dislocated yellow phosphor substrate 518. Without striking the substrate 518 (which is now out of the designed position), the laser beams cross and are not reflected and are thus contained within the illumination system. In this example, the laser beams are contained away from the normal output direction 550 of the illumination system 500 and do not exit the illumination system. The system 500 is thus intrinsically safe. The safety features do not require any detectors, ECUs nor power interrupt systems to contain the laser beams. Power can remain on to the laser diode array 510 without risk that any laser energy is emitted from the assembly 502.

(25) In yet another example, FIG. 6 depicts in a top view an intrinsically safe laser illumination system 600 such as that of FIG. 2 illustrating an example of a yellow phosphor coating failure. Depicted in FIG. 6 is an intrinsically safe illumination assembly 602 as depicted in FIG. 2 retaining the numerical assignments, only now with numbers in the 600 series. The arrangement 602 of FIG. 6 includes the laser source 610, laser beams 630, dichroic mirror 612, lens set 614, phosphor element 618 and has the light output 650.

(26) In this example illustration, the phosphor coating on element 618 has fully or partially delaminated exposing the reflective substrate of the phosphor element 618 in whole or part. In the example of FIG. 6, the laser array 610 produces laser beams 630 which pass thru an aperture in the dichroic mirror 612. The laser beams then pass through lens set 614 and are focused on the yellow phosphor element 618. In this failure example, all or part of the laser beams will be reflected by the reflective substrate of the phosphor element 618. With the symmetric nature of the laser array 610 and aperture on the dichroic mirror 612, the non-disbursed portion of the beams are simply reflected off the substrate and back to the original laser diodes as shown by the double ended beam arrow 630. Without the phosphor coating the beams are simply reflected and contained within the illumination system housing. This is an intrinsic safety feature of this arrangement and does not require any detectors, ECUs nor power interrupt systems to contain the laser beams.

(27) FIG. 7 depicts in a top view another example arrangement of an intrinsically safe laser illumination system 700 utilizing a linear light path. Illustrated in FIG. 7 is a top view of an intrinsically safe lighting assembly 702 which contains a laser light source 710 coupled to a condensing lens system 714 through a dichroic mirror 712. The focusing lens directs light energy to a light dispersing element 718. Following the dispersing element 718 s a collimating lens set 716 which directs the light energy 750 out of the lighting assembly 702 thru a second dichroic mirror 722.

(28) In this example arrangement of the present application, a laser light source 710, which has laser diodes arranged in a symmetric pattern, is aligned so that the laser beams 730 pass through an aperture in a dichroic mirror manufactured to pass the laser light. The laser light beams 730 are then focused by the condensing lens set 714 and directed to a yellow phosphor coated element 718. When the laser light 730 hits the element 718, the yellow phosphor fluoresces emitting a bright, dispersed light. That light consists of yellow and blue light and appears as white light. Following element 718 is a collimating lens set 716 which gathers the emitted light and directs it out the front of the lamp system through a second dichroic mirror 722 as depicted by beams 750. For better explanation, the laser diode array and dichroic mirror of FIG. 7 are also detailed in FIGS. 8A-8B.

(29) FIGS. 8A-8B each depict in a front view of a pair of laser diode arrays and a pair of dichroic mirrors that can be used in the arrangements such as for the intrinsically safe laser illumination system of FIG. 7. FIG. 8A depicts a laser array 810 which contains, in this non-limiting illustrative example, eight laser diode sources 812 that are arranged in a symmetric pattern as a square or rectangle. More, or fewer, laser diode sources can be used in forming alternative arrangements. Element 820 is a dichroic mirror with a square aperture 824. Dichroic mirror 820 is designed to reflect blue and yellow light on front and back surfaces except in area 824 where blue light can pass in either direction through the dichroic mirror. The size of the aperture 824 will correspond with the laser array 810 in such a manner that when the mirror is aligned perpendicular to the laser light array, the mirror's aperture 824 will allow the blue laser beams to pass through the mirror. Element 822 is a second dichroic mirror with a square aperture 826. Dichroic mirror 822 is designed to reflect blue light in the square area 826 and pass light in all other areas. The size of the reflective area 826 will correspond with the laser array 810.

(30) FIG. 8B depicts another example of a laser diode light source 816 and mirrors 830 and 832 which can be used with the laser light illumination system in FIG. 7. Laser light source 816 is illustrated with, in this example, six laser diodes sources 818 arranged in a symmetric circular pattern. Dichroic mirror 830 is provided with a circular shaped aperture 834. The mirror 830 reflects blue and yellow light on both surfaces except in the aperture area 834 where blue light is allowed to pass in either direction thru the mirror. The aperture 834 is designed and sized so that when the mirror 830 is positioned perpendicular to the laser light source 816, the laser sources 818 are aligned with the aperture with their light passing through the aperture. Dichroic mirror 832 is provided with a circular shaped area 834. The mirror 832 reflects blue and yellow light in the circular area 836 and passes light in all other areas. The size of the reflective area 836 will correspond with the laser array 816.

(31) In both example arrangements depicted in FIGS. 8A and 8B, the area 824, 826 are symmetric to allow the laser beams to pass through the mirror in both directions. The intrinsically safe features of the arrangements are discussed with respect to the following figures. In addition to these example arrangements, many other laser diode patterns can be used, and corresponding shapes can be formed on the dichroic mirrors as shown in the examples. Alternative arrangements can be formed by using various patterns for the laser diodes and the mirrors as shown above.

(32) FIG. 9 depicts in a top view an intrinsically safe illumination system 900 with an example shifted laser diode array failure. Depicted in FIG. 9 is an intrinsically safe illumination assembly 902 corresponding to the assembly 702 from FIG. 7. In FIG. 9, the numerical assignments from FIG. 7 are retained, only now in the 900 series. Assembly 902 includes the laser light source 910, the dichroic mirror 912, the condensing lens set 914, the dispersing element 918, collimating lens set 916, second dichroic mirror 922 and the final light output 950. In this example which is used to illustrate an intrinsically safe feature, the laser light source 910 is depicted as being shifted with respect to the dichroic mirror 912, so that the laser light 930 is no longer aligned with the aperture in the dichroic mirror 912. Since the dichroic mirror 912 reflects both blue and yellow light in the areas where the aperture is not located, the laser light is reflected back to the rear of the illumination system where it does not exit the lamp system. Because the laser light does not exit the assembly 902, this is an intrinsic safety feature of this arrangement and in sharp contrast to the prior known approaches, the intrinsically safe arrangements of the present application do not require any sensors, detectors, ECUs nor power interrupt systems to contain the laser beams.

(33) FIG. 10 depicts in another example 1000 the intrinsically safe illumination system of FIG. 7 with a failed phosphor coating failure. Depicted in FIG. 10 is an intrinsically safe laser illumination system 1002 such as 702 from FIG. 7. In FIG. 10, the numerical assignments of FIG. 7 are retained, only in the 1000 series. Assembly 1002 includes the laser light source 1010, the dichroic mirror 1012, the condensing lens set 1014, dispersing element 1018, collimating lens set 1016, the second dichroic mirror 1022 and the final light output 1050. In this example used to illustrate an intrinsically safe feature, the yellow phosphor element 1018 has become dislodged, having moved from its original location 1018a to the example position 1018. Laser light 1030 retains its collimated composition since the phosphor element is no longer in place. The collimated laser light 1030 is considered dangerous and it should not exit the illumination system. In this failure example, the symmetric aperture nature of the reflective area on the second dichroic mirror 1022, simply reflects the laser light back into the lens sets 1016 and then 1014 where it passes thru dichroic mirror 1012 where it is contained within the illumination system 1002. The laser light does not exit the assembly 1002. This is an intrinsic safety feature of the arrangements of the present application, and unlike the prior known approaches, does not require any detectors, ECUs nor power interrupt systems to contain the laser beams. Thus the use of the novel arrangements of the present application provide an intrinsically safe laser illumination system.

(34) FIG. 11 is a flow diagram illustrating an example method of creating an intrinsically safe illumination system. In FIG. 11, there are seven sequential steps illustrated in blocks 1101, 1105, 1107, 1109, 1111a or 1111b, 1113, and 1115. Step 1101 begins the method 1100 by arranging a plurality of laser sources in a pattern providing a symmetric laser light source, typically sourced from blue laser diodes, that produces laser light beams. At step 1105, a dichroic mirror is provided with an aperture that corresponds to the pattern of the laser sources. At step 1107, a phosphor element is provided positioned to receive laser beams from the laser sources through the aperture in the dichroic mirror. At step 1107, light is outputted from the phosphor including fluorescent light and dispersed laser light to form combined light. At step 1111a, in example arrangements such as illustrated in FIG. 2, the combined light is reflected from the dichroic mirror, but in some arrangements that have the output in line with the phosphor, such as shown in FIG. 7, step 1111b shows that the light will pass through a second dichroic mirror. In step 1113, the illumination light is output from the system.

(35) The arrangements described herein can be incorporated into a laser source illumination headlight or headlamp. These headlights or headlamps can be used with a variety of vehicles including automotive and truck applications, marine applications, recreational applications such as snowmobiles, motocross, ATVs and the like, airplane and aerospace applications. The bright light provided by the use of the laser illumination sources is not limited to vehicular applications and can also be applied to outdoor lighting, portable lighting, spotlights, flashlights, and a variety of other lighting environments. Additional applications for lighting are also contemplated as benefitting from the use of the novel features of the arrangements.

(36) Various modifications can also be made in the order of steps and in the number of steps to form additional novel arrangements that incorporate aspects of the present application, and these modifications will form additional alternative arrangements that are contemplated by the inventors as part of the present application and which fall within the scope of the appended claims.

(37) Although the example illustrative arrangements have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the present application as defined by the appended claims.

(38) Moreover, the scope of the present application is not intended to be limited to the particular illustrative example arrangement of the process, machine, manufacture, and composition of matter means, methods and steps described in this specification. As one of ordinary skill in the art will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding example arrangements described herein may be utilized according to the illustrative arrangements presented and alternative arrangements described, suggested or disclosed. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.