U.S. patent application number 15/315074 was filed with the patent office on 2017-04-27 for hybrid optical systems including flexible optical systems and light control films.
This patent application is currently assigned to OSRAM SYLVANIA Inc.. The applicant listed for this patent is OSRAM SYLVANIA Inc.. Invention is credited to Douglas Harriott, Bruce Radl, Zhuo Wang.
Application Number | 20170114983 15/315074 |
Document ID | / |
Family ID | 53442979 |
Filed Date | 2017-04-27 |
United States Patent
Application |
20170114983 |
Kind Code |
A1 |
Wang; Zhuo ; et al. |
April 27, 2017 |
HYBRID OPTICAL SYSTEMS INCLUDING FLEXIBLE OPTICAL SYSTEMS AND LIGHT
CONTROL FILMS
Abstract
A hybrid optical system, and lighting devices including the
same, are provided. The hybrid optical system includes a cellular
optical element a light control film. The cellular optical element
includes a first opening, a second opening, and a space defined
therebetween. The light control film includes a single layer of
light transparent material having a first side and a second side,
and a plurality of first microstructures formed on the first side.
The light control film is located within the space of the cellular
optical element. The light control film may include a plurality of
second microstructures formed on the second side to reduce glare.
The hybrid optical system may include a plurality of interconnected
cellular optical elements.
Inventors: |
Wang; Zhuo; (Middleton,
MA) ; Radl; Bruce; (Stow, MA) ; Harriott;
Douglas; (Melrose, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
OSRAM SYLVANIA Inc. |
Wilmington |
MA |
US |
|
|
Assignee: |
OSRAM SYLVANIA Inc.
Wilmington
MA
|
Family ID: |
53442979 |
Appl. No.: |
15/315074 |
Filed: |
June 1, 2015 |
PCT Filed: |
June 1, 2015 |
PCT NO: |
PCT/US2015/033605 |
371 Date: |
November 30, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62005963 |
May 30, 2014 |
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|
62005946 |
May 30, 2014 |
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62142779 |
Apr 3, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F21S 8/026 20130101;
G02B 5/0278 20130101; F21V 7/0083 20130101; G02B 5/0231 20130101;
F21V 13/04 20130101; G02B 6/0038 20130101; G02B 6/0036 20130101;
F21Y 2115/00 20160801; F21Y 2105/16 20160801; G02B 6/0045 20130101;
F21V 5/002 20130101 |
International
Class: |
F21V 13/04 20060101
F21V013/04; F21V 5/00 20060101 F21V005/00; F21V 7/00 20060101
F21V007/00; F21S 8/02 20060101 F21S008/02 |
Claims
1. A hybrid optical system, comprising: a cellular optical element,
comprising a first opening, a second opening, and a space defined
therebetween; and a light control film, comprising a single layer
of light transparent material comprising a first side and a second
side, and a plurality of first microstructures formed on the first
side; wherein the light control film is located within the space of
the cellular optical element.
2. The hybrid optical system of claim 1, wherein the cellular
optical element comprises one of a pyramid shape, a volcano-like
shape, a frustum shape, and a stepped pyramid shape.
3. (canceled)
4. (canceled)
5. (canceled)
6. The hybrid optical system of claim 2, wherein the cellular
optical element comprises the stepped pyramid shape, and wherein
the stepped pyramid shaped cellular optical element comprises a
base including the first opening and a plurality of steps from the
base to the second opening.
7. The hybrid optical system of claim 6, wherein the light control
film is placed across a step in the plurality of steps of the
stepped pyramid shaped cellular optical element.
8. The hybrid optical system of claim 7, wherein a second light
control film is placed across a second step in the plurality of
steps of the stepped pyramid shaped cellular optical element.
9. (canceled)
10. The hybrid optical system of claim 7, wherein the cellular
optical element further comprises an insert placed on the light
control film, wherein the insert has a stepped pyramid shape,
corresponding to the stepped pyramid shape of the cellular optical
element and comprising a set of steps that extends from the light
control film to the second opening.
11. The hybrid optical system of claim 10, wherein the insert is
coupled to the cellular optical element so as to hold the light
control film on the step within the cellular optical element.
12. The hybrid optical system of claim 6, wherein the cellular
optical element comprises a lower section including the base and
configured to receive an insert, and an insert including the second
opening.
13. The hybrid optical system of claim 12, wherein the lower
section includes a first set of steps, and wherein the insert
includes a second set of steps.
14. The hybrid optical system of claim 13, wherein the light
control film is placed in the lower section across a first step in
the first set of the plurality of steps that is immediately above
the base, such that the first set of steps of the lower section is
equal to the second set of steps of the insert.
15. The hybrid optical system of claim 14, wherein the light
control film is placed in the lower section at a number of steps
above the first step, and the second set of steps of the insert is
equal to the first set of steps less the number of steps.
16. The hybrid optical system of claim 2, wherein the cellular
optical element comprises the stepped pyramid shape, wherein the
stepped pyramid shape includes a single step, and wherein the light
control film is placed across the single step of the stepped
pyramid shape.
17. (canceled)
18. The hybrid optical system of claim 1, wherein the cellular
optical element comprises a receiving portion and a corresponding
insert, wherein the light control film is placed within the
receiving portion and is held in place by the corresponding
insert.
19. The hybrid optical system of claim 2, wherein the cellular
optical element comprises the stepped pyramid shape, wherein the
cellular optical element comprises a lower section comprising a
base including the first opening, wherein the lower section is
configured to receive an insert, and an insert including the second
opening.
20. The hybrid optical system of claim 19, wherein the lower
section and the insert together comprise a plurality of steps,
wherein at least one step of the lower section overlaps with at
least one step of the insert.
21. The hybrid optical system of claim 19, wherein the insert is
correspondingly shaped to the lower section.
22. The hybrid optical system of claim 1, wherein the first opening
is configured to receive a light source and the second opening is
configured to emit light exiting the hybrid optical system.
23. The hybrid optical system of claim 22, wherein cellular optical
element extends in an outward direction from the first opening to
the second opening.
24. The hybrid optical system of claim 1, wherein the second
opening is configured to receive a light source and the first
opening is configured to emit light exiting the hybrid optical
system.
25. The hybrid optical system of claim 1, wherein the cellular
optical element comprises a plurality of cellular optical elements,
each comprising a first opening, a second opening, and a space
defined therebetween.
26. The hybrid optical system of claim 25, wherein the plurality of
cellular optical elements are interconnected so as to occupy a
plane.
27. The hybrid optical system of claim 1, wherein a vertical
cross-section of the cellular optical element includes a portion of
the first opening, a portion of the second opening, and two walls,
wherein each wall has an acute angle relative to the first
opening.
28. The hybrid optical system of claim 27, wherein the acute angle
of each wall is chosen so as to achieve a particular light
distribution from a light source located at the first opening of
the cellular optical element, independent of any optical effects of
the light control film.
29. The hybrid optical system of claim 1, wherein the cellular
optical element has a lower portion and an upper portion, wherein
the lower portion includes the first opening and the upper portion
includes the second opening.
30. The hybrid optical system of claim 29, wherein the first
opening is configured to receive a light source, and wherein light
emitted by a light source located at the first opening in the lower
portion of the cellular optical element exits the hybrid optical
system by first passing through the light control film and then
passing through the second opening in the upper portion of the
cellular optical element.
31. (canceled)
32. The hybrid optical system of claim 29, wherein the second
opening is configured to receive a light source, and wherein light
emitted by a light source located at the second opening in the
upper portion of the cellular optical element exits the hybrid
optical system by first passing through the light control film and
then passing through the first opening in the lower portion of the
cellular optical element.
33. (canceled)
34. The hybrid optical system of claim 25, wherein each cellular
optical element in the plurality of cellular optical elements has a
lower portion and an upper portion, wherein the lower portions are
joined together to interconnect the plurality of cellular optical
elements.
35. The hybrid optical system of claim 34, wherein the lower
portions are joined together by a material, wherein the material is
a same material used to construct the plurality of cellular optical
elements, and wherein the material has a substantially planar shape
where interconnecting the plurality of cellular optical
elements.
36. (canceled)
37. (canceled)
38. (canceled)
39. The hybrid optical system of claim 25, wherein the plurality of
interconnected cellular optical elements comprise a flexible
optical system, wherein the flexible optical system is capable of
entering a set of states, wherein the set of states comprises a
substantially flat state and a substantially flexed state.
40. (canceled)
41. The hybrid optical system of claim 1, wherein the cellular
optical element reflects light from a light source located at least
partially within the cellular optical element.
42. The hybrid optical system of claim 41, wherein the cellular
optical element reflects light from a light source located at least
partially within the cellular optical element prior to the light
passing through the light control film and after the light passes
through the light control film.
43. The hybrid optical system of claim 1, wherein the light control
film is configured to receive incident light on the first side and
to produce an off-axis light distribution in a light field
downstream of the second side, and wherein the light control film
further comprises a plurality of second microstructures on the
second side, the second microstructures configured to reduce glare
in the off axis light distribution.
44. A lighting device, comprising: one or more solid state light
sources; a hybrid optical system, comprising: a plurality of
interconnected cellular optical elements, each cellular optical
element comprising a first opening, a second opening, and a space
defined therebetween, wherein a corresponding one of the solid
state light sources is located within either the first opening or
the second opening of each cellular optical element; and one or
more light control films, each comprising a single layer of light
transparent material comprising a first side and a second side, and
a plurality of first microstructures formed on the first side;
wherein the one or more light control films are located within the
space of the plurality of interconnected cellular optical elements;
wherein the one or more solid state light sources are coupled to
the hybrid optical system so as to form the lighting device.
45. (canceled)
46. The lighting device of claim 44, wherein the lighting device is
located within a space defined by a ceiling tile.
47. (canceled)
48. The lighting device of claim 44, wherein the one or more light
control films are configured to receive incident light on the first
side and to produce an off-axis light distribution in a light field
downstream of the second side, and wherein the one or more light
control films further comprise a plurality of second
microstructures on the second side, the second microstructures
configured to reduce glare in the off axis light distribution.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is an international application of,
and claims priority to, U.S. Provisional Application No.
62/005,963, entitled "HYBRID OPTICS" and filed May 30, 2014, U.S.
Provisional Application No. 62/005,946, entitled "OPTICAL FILM WITH
MICROSTRUCTURES ON OPPOSING SIDES" and filed May 30, 2014, U.S.
Provisional Application No. 62/142,779, entitled "OPTICAL FILM AND
CHIP PACKAGE WITH ENGINEERED MICROSTRUCTURES" and filed Apr. 3,
2015, and U.S. Provisional Application No. 62/005,972, entitled
"INTEGRATED OPTICS AND INTEGRATED LIGHT ENGINES" and filed May 30,
2014, the entire contents of all of which are hereby incorporated
by reference.
TECHNICAL FIELD
[0002] The present invention relates to lighting, and more
specifically, to optical systems for solid state light sources.
BACKGROUND
[0003] Due to its size and structure, light emitted from a solid
state light source often looks like it comes from a single point. A
group of solid state light sources thus creates the effect of many
points of light that might blend together, but are otherwise at
least partially seen as distinct. This results in dim spots, dark
spots, bright spots, and the like. Due to the typical uniformity of
light created by conventional light sources, and the aesthetically
pleasing qualities of that uniformity, it is desirable to have
uniformity in light emitted by solid state light sources, too.
Typically, this results when a batwing distribution is created,
using known optical devices such as lenses and films.
SUMMARY
[0004] Conventional techniques for creating a batwing distribution
add cost and create their own issues, such as increased glare
and/or sensitivity to the position of the solid state light source.
In some applications and/or devices, adding a lens or a film is not
practical, and thus specialized solid state light sources which
include optics themselves must be used, potentially significantly
increasing cost. Embodiments are designed to create a uniform
distribution of light from solid state light sources, in two
dimensions, while also reducing glare and cost.
[0005] Embodiments provide flexible optical systems, as well as
combinations of such systems with various films including patterned
microstructures, referred to through as hybrid optical systems. The
design of these flexible optical systems and hybrid optical systems
redirects incident light emitted from one or more solid state light
sources located within cellular optical elements of each, cut off
at particular angles by the cellular optical elements, so as to
create a certain light distribution. In embodiments of the hybrid
optical systems, one or more films are added to the cellular
optical elements to further change the light distribution. In some
embodiments, the hybrid optical systems use one or more lenses
instead of one or more films. In some embodiments, a plurality of
films are placed within the optical cellular elements. Films
including patterned microstructures, in some embodiments, are on a
flat film material, and in some embodiments, are on a flexible film
material. Some embodiments include such microstructures on both
sides of the film, in order to reduce and/or better control glare.
The resultant light distribution is uniform and/or substantially
uniform across a wide field.
[0006] In an embodiment, there is provided a hybrid optical system.
The hybrid optical system includes: a cellular optical element,
comprising a first opening, a second opening, and a space defined
therebetween; and a light control film, comprising a single layer
of light transparent material comprising a first side and a second
side, and a plurality of first microstructures formed on the first
side; wherein the light control film is located within the space of
the cellular optical element.
[0007] In a related embodiment, the cellular optical element may
include a pyramid shape. In another related embodiment, the
cellular optical element may include a volcano-like shape. In still
another related embodiment, the cellular optical element may
include a frustum shape.
[0008] In yet another related embodiment, the cellular optical
element may include a stepped pyramid shape. In a further related
embodiment, the stepped pyramid shaped cellular optical element may
include a base including the first opening and a plurality of steps
from the base to the second opening. In a further related
embodiment, the light control film may be placed across a step in
the plurality of steps of the stepped pyramid shaped cellular
optical element. In a further related embodiment, a second light
control film may be placed across a second step in the plurality of
steps of the stepped pyramid shaped cellular optical element. In
another further related embodiment, the light control film may be
coupled to the step. In yet another further related embodiment, the
cellular optical element further may include an insert placed on
the light control film, the insert may have a stepped pyramid
shape, corresponding to the stepped pyramid shape of the cellular
optical element and including a set of steps that extends from the
light control film to the second opening. In a further related
embodiment, the insert may be coupled to the cellular optical
element so as to hold the light control film on the step within the
cellular optical element.
[0009] In still another further related embodiment, the cellular
optical element may include a lower section including the base and
configured to receive an insert, and an insert including the second
opening. In a further related embodiment, the lower section may
include a first set of steps, and the insert may include a second
set of steps. In a further related embodiment, the light control
film may be placed in the lower section across a first step in the
first set of the plurality of steps that is immediately above the
base, such that the first set of steps of the lower section is
equal to the second set of steps of the insert. In a further
related embodiment, the light control film may be placed in the
lower section at a number of steps above the first step, and the
second set of steps of the insert is equal to the first set of
steps less the number of steps.
[0010] In yet another further related embodiment, the stepped
pyramid shape may include a single step. In a further related
embodiment, the light control film may be placed across the single
step of the stepped pyramid shape.
[0011] In still yet another related embodiment, the cellular
optical element may include a receiving portion and a corresponding
insert, the light control film may be placed within the receiving
portion and may be held in place by the corresponding insert. In a
further related embodiment, the cellular optical element may
include a lower section including a base including the first
opening, the lower section may be configured to receive an insert,
and an insert including the second opening. In a further related
embodiment, the lower section and the insert together may include a
plurality of steps, wherein at least one step of the lower section
may overlap with at least one step of the insert. In another
further related embodiment, the insert may be correspondingly
shaped to the lower section.
[0012] In yet still another related embodiment, wherein the first
opening may be configured to receive a light source and the second
opening may be configured to emit light exiting the hybrid optical
system. In a further related embodiment, the cellular optical
element may extend in an outward direction from the first opening
to the second opening.
[0013] In still yet another related embodiment, the second opening
may be configured to receive a light source and the first opening
may be configured to emit light exiting the hybrid optical system.
In yet still another related embodiment, the cellular optical
element may include a plurality of cellular optical elements, each
including a first opening, a second opening, and a space defined
therebetween. In a further related embodiment, the plurality of
cellular optical elements may be interconnected so as to occupy a
plane.
[0014] In yet another related embodiment, a vertical cross-section
of the cellular optical element may include a portion of the first
opening, a portion of the second opening, and two walls, each wall
may have an acute angle relative to the first opening. In a further
related embodiment, the acute angle of each wall may be chosen so
as to achieve a particular light distribution from a light source
located at the first opening of the cellular optical element,
independent of any optical effects of the light control film.
[0015] In still another related embodiment, the cellular optical
element may have a lower portion and an upper portion, the lower
portion may include the first opening and the upper portion may
include the second opening. In a further related embodiment, the
first opening may be configured to receive a light source. In a
further related embodiment, light emitted by a light source located
at the first opening in the lower portion of the cellular optical
element may exit the hybrid optical system by first passing through
the light control film and then passing through the second opening
in the upper portion of the cellular optical element. In another
further related embodiment, the second opening may be configured to
receive a light source. In a further related embodiment, light
emitted by a light source located at the second opening in the
upper portion of the cellular optical element may exit the hybrid
optical system by first passing through the light control film and
then passing through the first opening in the lower portion of the
cellular optical element.
[0016] In another further related embodiment, each cellular optical
element in the plurality of cellular optical elements may have a
lower portion and an upper portion, the lower portions may be
joined together to interconnect the plurality of cellular optical
elements. In a further related embodiment, the lower portions may
be joined together by a material, the material may be a same
material used to construct the plurality of cellular optical
elements, and the material may have a substantially planar shape
where interconnecting the plurality of cellular optical
elements.
[0017] In yet still another related embodiment, the hybrid optical
system may further include a lens located within the space of the
cellular optical element. In still another related embodiment, the
light control film may be angled within the space of the cellular
optical element.
[0018] In another further related embodiment, the light control
film may be angled within the space so as to rest on at least two
different steps of the stepped pyramid shape. In yet another
further related embodiment, the plurality of interconnected
cellular optical elements may include a flexible optical system,
the flexible optical system may be capable of entering a set of
states, the set of states may include a substantially flat state
and a substantially flexed state.
[0019] In still yet another related embodiment, the light control
film may include a lens. In yet another related embodiment, the
cellular optical element may reflect light from a light source
located at least partially within the cellular optical element. In
a further related embodiment, the cellular optical element may
reflect light from a light source located at least partially within
the cellular optical element prior to the light passing through the
light control film and after the light passes through the light
control film.
[0020] In yet another related embodiment, the light control film
may be configured to receive incident light on the first side and
to produce an off-axis light distribution in a light field
downstream of the second side, and the light control film may
further include a plurality of second microstructures on the second
side, the second microstructures configured to reduce glare in the
off axis light distribution.
[0021] In another embodiment, there is provided a hybrid optical
system. The hybrid optical system includes: a plurality of
interconnected cellular optical elements, each comprising a first
opening, a second opening, and a space defined therebetween; and a
plurality of lenses, wherein each lens in the plurality of lens is
located within the space of a corresponding cellular optical
element in the plurality of interconnected cellular optical
elements.
[0022] In another embodiment, there is provided a hybrid optical
system. The hybrid optical system includes: a plurality of
interconnected cellular optical elements, each including a first
opening, a second opening, and a space defined therebetween; and a
plurality of lenses, wherein each lens in the plurality of lens is
located within the space of a corresponding cellular optical
element in the plurality of interconnected cellular optical
elements.
[0023] In yet another embodiment, there is provided a lighting
device. The lighting device includes one or more solid state light
sources; a hybrid optical system, including: a plurality of
interconnected cellular optical elements, each cellular optical
element comprising a first opening, a second opening, and a space
defined therebetween, wherein a corresponding one of the solid
state light sources is located within either the first opening or
the second opening of each cellular optical element; and one or
more light control films, each including a single layer of light
transparent material comprising a first side and a second side, and
a plurality of first microstructures formed on the first side;
wherein the one or more light control films are located within the
space of the plurality of interconnected cellular optical elements;
wherein the one or more solid state light sources are coupled to
the hybrid optical system so as to form the lighting device.
[0024] In a related embodiment, the lighting device may include a
luminaire. In another related embodiment, the lighting device may
be located within a space. In a further related embodiment, the
space may be defined by a ceiling tile. In still another related
embodiment,
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The foregoing and other objects, features and advantages
disclosed herein will be apparent from the following description of
particular embodiments disclosed herein, as illustrated in the
accompanying drawings in which like reference characters refer to
the same parts throughout the different views. The drawings are not
necessarily to scale, emphasis instead being placed upon
illustrating the principles disclosed herein.
[0026] FIG. 1 shows a hybrid optical system, including a cut away
of a portion of the hybrid optical system, including cellular
optical elements and light control films, according to embodiments
disclosed herein.
[0027] FIG. 2 shows a light distribution for a hybrid optical
system, according to embodiments disclosed herein.
[0028] FIGS. 3A-3B show a hybrid optical system having conical
volcano-like shapes, according to embodiments disclosed herein.
[0029] FIG. 3C shows a close-up of a portion of the hybrid optical
system of FIGS. 3A-3B.
[0030] FIGS. 4A-4C show respective examples of individual cellular
optical elements for use in hybrid optical systems, according to
embodiments disclosed herein.
[0031] FIG. 5 shows a hybrid optical system having stepped pyramid
shapes, according to embodiments disclosed herein.
[0032] FIG. 6 shows a hybrid optical system having linear pyramid
shapes, according to embodiments disclosed herein.
[0033] FIGS. 7A-7D show hybrid optical systems with various linear
shapes, according to embodiments disclosed herein.
[0034] FIGS. 8A-8B show hybrid optical systems including inserts,
according to embodiments disclosed herein.
[0035] FIGS. 9A-9D show vertical cross sections of the hybrid
optical system of FIG. 5 according to embodiments disclosed
herein.
[0036] FIGS. 10A-10C show vertical cross sections of hybrid optical
systems including a lens, according to embodiments disclosed
herein.
[0037] FIG. 11 shows a vertical cross section of a hybrid optical
system including two or more optical elements, according to
embodiments disclosed herein.
[0038] FIG. 12 shows various distributions for an LED, a LED with a
light control film, an LED with a flexible optical system, and an
LED with a hybrid optical system, according to embodiments
disclosed herein.
[0039] FIGS. 13A-13B show a luminaire and a ceiling tile,
respectively, including a hybrid optical system, according to
embodiments disclosed herein.
DETAILED DESCRIPTION
[0040] Embodiments provide thermal formed sheets of polymer, such
as but not limited to PET, which are able to achieve desired
cut-off angles by being shaped into one or more cellular optical
elements. When one or more cellular optical elements are combined
with one or more microstructures-based light control films, such as
but not limited to a plurality of pyramid-shaped microstructures, a
hybrid optical system is created.
[0041] FIG. 1 shows a hybrid optical system 100 that combines, as
shown more clearly in the cut out, one or more cellular optical
elements 102 with one or more light control films 104. The one or
more cellular optical elements 102, which in some embodiments are a
flexible optical system, include a first opening 105, a second
opening 106, and a space 108 defined therebetween. In some
embodiments, as shown in FIG. 1, the one or more cellular optical
elements 102 are a plurality of shapes made from thermally formed
polymer, such as but not limited to PET, which sit on top of a
substrate (not shown in FIG. 1 due to being obscured by the one or
more cellular optical elements 102) including a plurality of solid
state light sources 110. In some embodiments, such as shown in FIG.
1, the cellular optical elements 102 have a pyramid shape, though
of course other shapes are possible and are used in some
embodiments, as described in greater detail below (for example, see
FIGS. 3A-3C). In some embodiments, each cellular optical element
102 in the plurality of cellular optical elements 102 has a single
solid state light source 110 within. In some embodiments, each
cellular optical element 102 in the plurality of cellular optical
elements 102 has more than one solid state light source within that
reflector. In some embodiments, the number of solid state light
sources within a single cellular optical element 102 varies. In
some embodiments, there is at least one cellular optical element
that does not include a solid state light source (see, for example,
FIG. 7A). In some embodiments, as shown in FIG. 1, the second
opening 106 is configured to receive the light source 110 and the
first opening 105 is configured to emit light exiting the hybrid
optical system 100. As described in greater detail below, in some
embodiments, the cellular optical elements 102 are interconnected
so as to occupy a plane 150.
[0042] The one or more light control films 104 are made of, for
example but not limited to, a single layer of light transparent
material including a first side 104A and a second side 104B, and a
plurality of microstructures 104C formed on the first side 104A
(and not easily visible in the figures due to their small size).
The light control film 104 is located within the space 108 of the
cellular optical element 102, as shown in FIG. 1. More
specifically, in some embodiments, a larger light control film is
cut into small pieces, and at least one piece is placed over the
one or more solid state light sources 110 within each cellular
optical element 102. In some embodiments, each individual solid
state light source 110 receives its own distinct piece of light
control film 104; in some embodiments, where there are more than
one solid state light source 110 within a cellular optical element
102, the solid state light sources 110 may share a piece of light
control film 104. The film may be mounted in any known way, as
described in greater detail herein.
[0043] In some embodiments, the plurality of microstructures 104C
are any known shapes, including combinations thereof. Thus, in some
embodiments, the light control film 104 includes one or more
pyramid-shaped microstructures, which include but are not limited
to different shapes of pyramid (e.g. a four sided pyramid, five
sided pyramid, six sided pyramid, seven sided pyramid, eight sided
pyramid, and so on). In some embodiments, the plurality of
microstructures 104C are different shapes altogether (for example
but not limited to cone shape), any and all of different sizes.
When the microstructures 104C face toward the light sources 110, a
particular light distribution, such as but not limited to a batwing
distribution, results. When the microstructures 104C face away from
the light sources 110, the light distribution changes (e.g., the
light focuses). In some embodiments, the light control film
includes a plurality of second microstructures 104D (and not
visible in the figures due to their small size) on the second side
104B of the light control film 104. In some embodiments, the light
control film 104 is configured to receive incident light on the
first side 104A and to produce an off-axis light distribution in a
light field downstream of the second side 104B. In some
embodiments, the second microstructures 104D are configured to
create a different distribution or effect than the first
microstructures 104C, such as but not limited to reducing glare,
reducing glare in an off axis light distribution, and so on.
Depending on the application, any type of light control film may be
used, such as but not limited to a diffuser film, which may or may
not include microstructures. Such light control films are described
in greater detail in co-pending application entitled "LIGHT CONTROL
FILMS AND LIGHTING DEVICES INCLUDING SAME" and filed on the same
day as the current application.
[0044] FIG. 2 shows a vertical cross-section of an embodiment of
the hybrid optical system 100 of FIG. 1 overlaid on a light
distribution 200 thereof. In FIG. 2, the light control film 104 is
placed above the light source 110 within a thermal formed
polymer-based cellular optical element 102. The cellular optical
element 102 reflects light emitted by the light source 110 at a
higher angle above, for example, fifty degrees, and in combination
with the light control film 104, also reduces the glare from the
light source 110. In some embodiments, the cellular optical element
102 is Lambertion (e.g., white), and in some embodiments, the
cellular optical element 102 is specular, and in some embodiments
the cellular optical element 102 is a combination of both. As a
result, the hybrid optical system 100 shows a mild batwing
distribution 200 with a cut-off angle at fifty degrees, as seen in
FIG. 2.
[0045] As seen in FIG. 2, the cross-section of the cellular optical
element 102 includes a portion of a first opening 105A and a
portion of a second opening 106A. The cellular optical element 102
also includes two walls 102A, 102B. Each wall 102A, 102B has an
acute angle relative to the portion of the first opening 105A. This
angle, in some embodiments, is measured with respect to the second
opening 106A. The acute angle of each wall 102A, 102B is chosen so
as to achieve a particular light distribution from the light source
110 located within the cellular optical element 102, independent of
any optical effects of the light control film 104 also located
within the cellular optical element 102. In the cross section shown
in FIG. 2, the second opening 106A is configured to receive the
light source 110, and thus when the light source 110 emits light,
this light exits the hybrid optical system 100 by first passing
through the light control film 104 and then passing through the
first opening 105A. In some embodiments, as also shown in FIG. 2,
the cellular optical element 102 reflects light from the light
source 110, located at least partially within the cellular optical
element 102, prior to the light passing through the light control
film 104, and after the light passes through the light control film
104.
[0046] As shown throughout the figures, the cellular optical
elements of hybrid optical systems according to embodiments may
take many shapes, including but not limited to conical shapes,
volcano-like shapes, pyramid shapes, flat top pyramid shapes, apex
pyramid shapes, stepped pyramid shapes, frustum shapes,
multiple-sided (i.e., three side, four sided, five sided, six
sided, seven sided, eight sided and so forth) pyramid shapes,
hemispherical shapes, dome shapes, spheroid shapes, and so on.
Singular examples of some of these shapes 400, 409, 410 are shown
in FIGS. 4A, 4B, and 4C, respectively.
[0047] FIGS. 3A-3C show embodiments of a hybrid optical system
where the cellular optical elements are volcano-like shapes. FIG.
3A shows a hybrid optical system 100A including a plurality of
interconnected cellular optical elements 102A, each including a
light control film 104A (not visible in FIG. 3A but shown in FIG.
3B). As stated above, the cellular optical elements 102A are in the
shape of volcanos, with an open top and a conical interior that
decreases from the top to the bottom of the volcano, where a light
source 110A (not visible in FIG. 3A but shown in FIG. 3B) is
located. Thus, each cellular optical element 102A includes a first
opening 305A and a second opening 306A. The first opening 305A is
configured to receive the light source 110A and the second opening
306A is configured to emit light exiting the hybrid optical system
100A. As shown in FIG. 3A, the cellular optical elements 102A
extend in an outward direction from the first opening 305A to the
second opening 306A.
[0048] As shown more easily in FIG. 3C, a cellular optical element
300A has a lower portion 310 and an upper portion 320. The lower
portion 310 includes the first opening 305A and the upper portion
320 includes the second opening 306A. Light emitted by the light
source 110 located at the first opening 305A in the lower portion
310 of the cellular optical element 102A exits the hybrid optical
system 100A by first passing through the light control film 104,
which sits immediately over the light source 110, and then passing
through the second opening 306A in the upper portion 320 of the
cellular optical element 102A.
[0049] As shown in FIGS. 3A-3C, the cellular optical elements 102A
are joined together so as to form a sheet of cellular optical
elements 102A, which in some embodiments is a flexible optical
system. In some embodiments, it is the lower portions 310 of the
cellular optical elements 102A that are joined together, and thus
interconnect the cellular optical elements 102A. In some
embodiments, as shown in FIG. 1, it is the upper portions of the
cellular optical elements 102 that are joined together so as to
interconnect the cellular optical elements 102. Returning to FIGS.
3A-3C, the lower portions 310 are joined together by a material
311, wherein the material 311 is the same material used to
construct the cellular optical elements 102A. As shown most clearly
in FIGS. 3B and 3C, the material 311 has a substantially planar
shape where interconnecting the cellular optical elements 102A. In
embodiments where the material 311 is flexible, the cellular
optical elements 102A are a flexible optical system 103A, which is
capable of entering a set of states, including but not limited to a
substantially flat state, as shown in FIGS. 3B and 3C, and a
substantially flexed state, as shown in FIG. 3A.
[0050] Of course, in some embodiments, all of the cellular optical
elements 102A are the same within a given hybrid optical system
100A, as shown in FIGS. 3A-3C, and in some embodiments, the shapes
of the cellular optical elements vary within the same hybrid
optical system.
[0051] FIG. 6 shows a hybrid optical system 100C, where each
cellular optical element 102C includes more than one light source
110C, but a single light control film 104C. As shown in FIG. 6, the
cellular optical elements 102C are in the shape of linear pyramids,
or linear trays, or open troughs, interconnected. FIGS. 7A-7D show
various embodiments of hybrid optical systems 100D, 100E, 100F, and
100G that are also linear in shape. In FIG. 7A, the hybrid optical
system 100D includes a plurality of cellular optical elements 102D
that are partial cubes with an open top and an opening in a bottom
(top and bottom being used to denote relational direction and not
requiring that the `top` face upward or that the `bottom` face
downward) to receive light sources 110D. In some embodiments, the
partial cubes 102D are formed by placing walls across a linear
cellular optical element. FIGS. 7C and 7D show the hybrid optical
systems 100F and 100G, respectively, which are similar in shape to
a single cellular optical element 102C of FIG. 6, but which are
divided into smaller cellular optical elements 102F and 102G,
respectively, but a plurality of walls 700. IN FIG. 7C, the
cellular optical elements 102F of the hybrid optical system 100F
each include two light sources 110F, while in FIG. 7D, the cellular
optical elements 102G of the hybrid optical system 100G each
include three light sources 110G. Of course, the cellular optical
elements may include any number of light sources. FIG. 7B shows the
hybrid optical system 100E, which is similar in overall shape to
the hybrid optical systems 100F and 100G of FIGS. 7C and 7D, but is
instead divided into small cellular optical elements 102E by a
plurality of angled dividers 700E. Such cellular optical elements
as shown in FIGS. 6-7D may be, and in some embodiments are, used
with linear light engines (not shown in FIGS. 6-7D).
[0052] FIGS. 8A and 8B shows embodiments of a hybrid optical system
where one or more inserts are used to hold the light control
film(s) in place within the cellular optical elements. In FIG. 8A,
one or more cellular optical elements 102H include a receiving
portion 102H-1 and a corresponding insert 102H-2, a portion of
which is not yet inserted. The light control film 104 is placed
within the receiving portion 102H-1 and is held in place by the
corresponding insert 102H-2. The fully inserted insert 102H-2 is
shown in FIG. 8B. In some embodiments, the receiving portion 102H-1
includes a base including a first opening 105H and the insert
102H-2 includes a second opening 106H. In some embodiments, as
shown in FIG. 8A, the receiving portion 102H-1 and the insert
102H-2 together include a plurality of steps 800, wherein at least
one step 801 of the receiving portion 102H-1 overlaps with at least
one step 802 of the insert 102H-2. In some embodiments, the insert
102H-2 is correspondingly shaped to the receiving portion 102H-1,
such that the combined cellular optical element 102H looks the same
as such a cellular optical element that is not formed from a
receiving portion 102H-1 and an insert 102H-2 (see, for example, a
cellular optical element 102B shown in FIG. 5).
[0053] Referring to FIG. 5, a plurality of cellular optical
elements 102B in the shape of stepped pyramids are shown. These
cellular optical elements 102B, when combined with one or more
light control films 104B, as shown in FIGS. 9A-9E, form a hybrid
optical system 100B. Each cellular optical element 102B, which are
shown in vertical cross-section in FIG. 9A, includes a base 910,
which has a first opening 105B, and a plurality of steps 920 from
the base 910 to a second opening 106B. The light control film 104B
is placed across a step 920-1 in the plurality of steps 920. In
some embodiments, an optional second light control film 104B-2 is
placed across a second step 920-2 in the plurality of steps 920. In
some embodiments, the light control film 104B is coupled to the
step 920-1 using any known coupling agent or mechanism, such as but
not limited to glue, adhesive, static electricity, or use of an
optional insert 900 that is similarly shaped to the cellular
optical element 102B. That is, the optional insert 900 has a
stepped pyramid shape, corresponding to the stepped pyramid shape
of the cellular optical element 102B and includes a set of steps
930 that extends from the light control film 104B to the second
opening 106B. In some embodiments, the optional insert 900 is
coupled to the cellular optical element 102B so as to hold the
light control film 104 on the step 920-1 within the cellular
optical element 102B.
[0054] In some embodiments, such as shown in FIG. 9A, where the
light control film 104B is placed across the step 920-1, which is
the step immediately above the base 910, and the optional insert
900 is placed within the cellular optical element 102B, the
cellular optical element 102B has the same number of steps as the
optional insert 900. In some embodiments, where the light control
film 104B is placed on a higher step, as shown in FIG. 9B (such as
the second step 920-2 from the base 910), an optional insert 900B
includes a set of steps 930B that is equal to the plurality of
steps 920 of the cellular optical element 102B less the number of
steps the light control film 104B is placed above the first step
920-1 above the base 910. Thus, in the given example shown in FIG.
9B, the cellular optical element 102B includes two steps, and the
optional insert 900B includes one step. In some embodiments, as
shown in FIG. 9E, the stepped pyramid shape of the cellular optical
element 102B includes only a single step 920B, and the light
control film 104B is placed across this single step 920B. In some
embodiments, as shown in FIG. 9C, the light control film 104B is
angled within the cellular optical element 102B. In some
embodiments, as shown in FIG. 9C, this results in the light control
film 104B resting on at least two different steps 920-1, 920-2 of
the cellular optical element 102B having the stepped pyramid shape.
Such embodiments permit the creation of different cut-off angles
and spacing criteria with the same design depending on where the
light control film is placed, how many steps are present, the
angles of the steps (which need not be consistent from one step to
the next up or down the pyramid), and so forth.
[0055] Some embodiments of the hybrid optical system use a
different optical element than a light control film. For example,
embodiments shown in FIGS. 10A-10C use a lens instead of the light
control film. Thus, FIG. 10A shows a hybrid optical system 100I
including a lens 1041 and a cellular optical element 1021. The lens
1041 is located within a space 1081 of the cellular optical element
1021. The lens 1041 may be, and in some embodiments is, any known
type of lens, such as but not limited to a Fresnel lens that
achieves a spotlight distribution with cut-off options. In some
embodiments, the lens 1041 is placed in a location similar to, and
in some embodiments the same/substantially the same as, the light
control film. It is noted that while some light control films are
insensitive to the relative position of the light source 110, some
lenses, such as a Fresnel lens, are location sensitive. The use of
such a location sensitive optic will bring some advantages to the
design at the expense of flexibility, etc. Thus, some embodiments
off-set the lens with respect to the light sources, and the result
is that light emitted to/from the light source 110 may be aimed to
different angles, achieving a greater flexibility in the design.
Instead of moving the lens 1041 or using a different lens, in some
embodiments, as shown in FIG. 10B, the light source 110 itself is
movable within the hybrid optical system 100I, for example but not
limited to through use of a moving mechanism, such as having an
opening 1051 in the cellular optical element 1021 that is larger
than the light source 110. This results in the aesthetics of the
hybrid optical system 100I being maintained using the same
materials and cut-off angles, as is shown in FIG. 10B.
[0056] In some embodiments, the light source 110 is not necessarily
at normal incidence. For example, a stronger batwing distribution
at a higher angle can be achieved, or an asymmetrical beam
distribution can be obtained, if the optical element (i.e., the
light control film and/or the lens) is tilted at an angle, as shown
in FIG. 10C. In some embodiments, such as those described above
with regards to FIG. 10C, the relative position of the light source
to the lens and/or to the film needs to be controlled.
[0057] Further, in some embodiments, such as shown in FIG. 11, a
multi-optical element hybrid optical system 100J is possible,
combining one or more light control films 104J-1, one or more
lenses 104J-2, and/or combinations thereof, all located within a
cellular optical element 102J. A simultaneous specific beam shaping
function results, and again, in some embodiments, the relative
position of the light source(s) 110 to the optical elements 104J
may needs to be controlled, as well as the relative position of the
optical elements 104J with respect to each other.
[0058] FIG. 12 shows candela distributions of a solid state light
source only 1201, a light control film only 1202, a flexible
optical system only 1203, and a hybrid optical system combining the
light control film with the flexible optical system 1204. As shown
in FIG. 12, the light control film only distribution 1202 provides
a large batwing distribution but the glare is worse compared to the
solid state light source only distribution 1201. A cut-off angle of
fifty degrees can be realized for both the flexible optical system
only distribution 1203 and the hybrid optical system distribution
1204, particularly when the flexible optical system comprises a
sheet of a plurality of pyramid shapes, as described above.
[0059] Table 1 shows a summary of results. For bare Lambertion
distributed solid state light sources, such as but not limited to
LEDs, the spacing criteria is only 1.3. The spacing criteria is
increased to 1.84 with just a light control film film. However, the
glare is worse as more light will be in the zones of sixty to
eighty degrees and eighty to ninety degrees. The efficiency of the
light control film is eighty-seven percent. If a pyramid-shaped
flexible optical system is placed around the LEDs, the spacing
criteria is dropped to 1.26 and the efficiency is dropped by five
percent compared to the LED only case. A hybrid optical system will
bring the spacing criteria to 1.54 while maintaining the cut-off
angle of fifty degrees. The efficiency is six percent less compared
to the light control film only case. Because the light control film
will redistribute more light to higher angles, the efficiency drops
six percent for the hybrid optical system vs. the light control
film only, compared to five percent for the flexible optical system
only vs. the LED only. Tradeoffs exist between spacing criteria,
glare, and efficiency. Specifically, a design with larger spacing
criteria and less glare will result in a lower optical
efficiency.
TABLE-US-00001 TABLE 1 Comparisons Light Flexible Hybrid LED
Control Optical Optical only Film only System Only System Spacing
criterion (0-180) 1.30 1.84 1.26 1.54 Spacing criterion (0-180)
1.34 1.94 1.28 1.54 Spacing criterion 1.42 2.08 1.36 1.70
(Diagonal) Light in zone 60-80 20.8% 23.7% 7.5% 8.4% Light in zone
80-90 2.9% 3.5% 1.8% 2.1% Flux (lm) 856 744 812 693 Efficiency 100%
87% 95% 81%
[0060] As described above, in some embodiments, to achieve a higher
optical efficiency, it is desired that the substrate on which the
light sources are placed itself has a high reflectivity. This is
achieved, in some embodiments, through the use of, for example but
not limited to, white polymer film, such as but not limited to
white PET film, which may be and in some embodiments is flexible,
though this is not required.
[0061] Further, in some embodiments, the light control film is not
placed within the cellular optical element(s), but rather is placed
on top of the cellular optical elements, such that it is not
located in a spaced defined by the cellular optical element but
rather is outside of the opening through which light passes when
exiting the cellular optical element.
[0062] FIG. 13A shows a lighting device 1000 including a hybrid
optical system 100K, according to embodiments disclosed herein. The
lighting device 1000 includes one or more solid state light source
110K and the hybrid optical system 100K. The hybrid optical system
100K includes a plurality of interconnected cellular optical
elements 102K, each including a first opening 105K, a second
opening 106K, and a space 108K defined therebetween. A
corresponding one of the solid state light sources 110K is located
within either the first opening 105K or the second opening 106K of
each cellular optical element 102K. The hybrid optical system 100K
also includes one or more light control films 104K. The one or more
light control films 104K each include a single layer of light
transparent material, meaning that light is capable of traveling
through the material. The light transparent material includes a
first side 104K-1 and a second side 104K-2, with a plurality of
first microstructures 104K-3 formed on the first side 104K-1. The
one or more light control films 104K are located within the space
108K of the plurality of interconnected cellular optical elements
102K. The one or more solid state light sources 110K are coupled to
the hybrid optical system 100K so as to form the lighting device
1000. As is seen in FIG. 13A, the lighting device 1000 does not
include, or indeed in some embodiments, require a housing or any
portion of a housing, though in some embodiments, the lighting
device 1000 includes a housing (not shown), which in some
embodiments includes locations for one or more power supplies, one
or more control elements, wiring, and so on. In some embodiments,
as shown in FIG. 13A, the lighting device 1000 comprises a
luminaire.
[0063] FIG. 13B shows a lighting device 1000A including a hybrid
optical system 102L and one or more solid state light sources 110L
similar in structure though not size to the lighting device 1000 of
FIG. 13A. In FIG. 13B, the lighting device 1000A is sized so as to
fit within a space, and indeed is located with a space created by
making a hole in a ceiling tile 1001. Thus, the ceiling tile 1001
shown in FIG. 13B holds the lighting device 1000A, such that the
lighting device 1000A functions to illuminate an area in which the
ceiling tile is installed.
[0064] In some embodiments, the one or more light control films
104K/104L of FIGS. 13A-13B are configured to receive incident light
on the first side 104K/104L-1 and to produce an off-axis light
distribution in a light field downstream of the second side
104K-2/104L-2, and include a plurality of second microstructures
104K-4/104L-4 on the second side 104K-2/104L-2, the second
microstructures 104K-4/104L-4 configured to reduce glare in the off
axis light distribution.
[0065] Unless otherwise stated, use of the word "substantially" may
be construed to include a precise relationship, condition,
arrangement, orientation, and/or other characteristic, and
deviations thereof as understood by one of ordinary skill in the
art, to the extent that such deviations do not materially affect
the disclosed methods and systems.
[0066] Throughout the entirety of the present disclosure, use of
the articles "a" and/or "an" and/or "the" to modify a noun may be
understood to be used for convenience and to include one, or more
than one, of the modified noun, unless otherwise specifically
stated. The terms "comprising", "including" and "having" are
intended to be inclusive and mean that there may be additional
elements other than the listed elements.
[0067] Elements, components, modules, and/or parts thereof that are
described and/or otherwise portrayed through the figures to
communicate with, be associated with, and/or be based on, something
else, may be understood to so communicate, be associated with, and
or be based on in a direct and/or indirect manner, unless otherwise
stipulated herein.
[0068] Although the methods and systems have been described
relative to a specific embodiment thereof, they are not so limited.
Obviously many modifications and variations may become apparent in
light of the above teachings. Many additional changes in the
details, materials, and arrangement of parts, herein described and
illustrated, may be made by those skilled in the art.
* * * * *