CN105051451A - Light unit with light output pattern synthesized from multiple light sources and modular refractors - Google Patents

Abstract

The present disclosure provides an LED based light unit that produces an output lighting pattern that meets desired lighting characteristics using a reduced number of LED elements. The present disclosure provides a number of point sources that are directed into a desired direction such that, when combined with other point sources, a synthesized light output is provided that minimizes the LED headcount.. Modular refractors are provided having optic components that may be coupled with lighting modules. The modular refractors may provide environmental protection to lighting components housed within the refractor, and a separate external protective lens may not be required. One or more lenses of one or more of the modular refractors may include materials of at least two different refractive indices that are co-molded together.

Description

There is the lighting unit of the light output pattern synthesized by multiple light source and modularization refractor

Technical field

The present invention relates to a kind of LED-based lighting unit, and more specifically, relate to the LED-based lighting unit with synthesis output pattern using the LED element of fewer number of and less Optical devices.

Background technology

Illuminator uses various dissimilar lighting device usually, generally comprises incandescent lamp, fluorescent lamp and the lamp based on light emitting diode (LED).In order to the needs of specific lamp or illuminator, LED-based lamp generally relies on multiple diode element to produce enough light.Meaningfully reduce a kind of approach of the generation of greenhouse gases as the continuous growth being used for offsetting energy prices, LED illumination provides great potential in this respect.Because effect is close to every watt of 150 lumens, and the life-span was more than 50000 hours, may march the illumination market of house and business, indoor and outdoors application based on the LED of LED technology and illuminating product potentially.

Compared with such as incandescent source, LED-based lamp has significant advantage in efficiency with in the life-span, and produces less used heat.For example, if desirable solid state illumination device will be manufactured, can be only the brightness that 1/20 of energy required for equivalent incandescent lighting source realizes phase same level by using.Compare with compact fluorescent lamp with other light sources many such as incandescent lamp, LED has the higher life-span, and does not comprise any environmentally harmful mercury be present in fluorescent lamp.LED-based lamp also has the advantage of instantaneity, and not deteriorated because repeating on-off circulation.

As mentioned above, LED-based lamp generally relies on multiple LED element to produce light.As known in the art, LED element is a little region light source, normal with shaping radiation pattern and the optics of the reflection of assisting LED to export be associated.LED through being often used as the bezel on electronic equipment, and more and more for more high-power application, as flashlight and area illumination.The color of the light launched depends on composition and the state of the semi-conducting material tied for the formation of LED, and can be infrared ray, visible ray or ultraviolet.

In the visible spectrum, LED can be manufactured into the color needed for generation.To be used in the application scenario in area illumination for LED, the output of white light is normally desirable.Production high strength white light LED has two kinds of common methods.One first produces the independent LED launching three primary colors (red, green, blue), then mixes all colors to produce white light.This series products is commonly called polychromatic white light LED, and sometimes referred to as RGBLED.The Electron optics design of multi-colored led usual needs complexity like this, to control the mixed of different colours and diffusion, and current this method is seldom used to produce White LED in a large number in the industry.In principle, this mechanism has relatively high quantum efficiency on generation white light.

Producing the second method that White LED exports is manufacture to have a kind of LED of color, and such as, with the blue led that InGaN makes, and the phosphor coating applying different colours on LED is to produce white light.Producing a kind of commonsense method that is this and LED-based light-emitting component is epoxy inner InGaN blue led being encapsulated in phosphor-coating.Common yellow phosphor material is the yttrium-aluminium-garnet (Ce3+:YAG) of cerium dopping.According to the color of original LED, the phosphor of different colours also can be used.The LED of this technology manufacture is used to be commonly referred to as White LED based on phosphor.Although manufacture lower than multi-colored led cost, the LED based on phosphor has lower quantum efficiency relative to multi-colored led.LED based on phosphor also has the degenerate problem that phosphor is relevant, and wherein, the output of described LED will be degenerated in time.Although relatively more easily manufacture based on the White LED of phosphor, such LED is by the impact of Stokes energy loss, lose when the photon (such as, blue photons) of shorter wavelength is converted to photon (such as the white photon) of longer wavelength.Therefore, usually expect the amount reducing the phosphor used in such applications, thus reduce this energy loss.Consequently, when being watched by observer, use the LED-based white lamps with the LED element of this minimizing phosphor usually in blue.

The solid-state lighting elements of other type various also can be used in various illumination application.Such as, quantum dot is the semiconductor nanocrystal with unique optical properties.The glow color of quantum dot can be tuning based on the visible ray of whole infrared spectrum.This makes quantum dot LED produce nearly all output color.Organic Light Emitting Diode (OLED) comprises the emitting layer material for organic compound.In order to be used as semiconductor, luminous organic material must have conjugatedπbond.Described luminescent material can be organic molecule or the polymer of crystalline phase.Polymeric material can be flexible; Such LED is called as PLED or FLED.

Summary of the invention

The invention provides a kind of LED-based lighting unit, it uses the LED element of lesser amt to produce the output lighting pattern reaching required illumination feature.The invention provides many spot lights being oriented to desired direction, make when its with other spot light in conjunction with time, the light output of synthesis is provided, thus minimizes LED sum, and do not need extra light beam to turn to optics.

Various aspects of the present invention describe several novel SSL light fixture, by reducing the number of the lens face that light has to pass through thus having more large effect, also provide necessary protection to environment simultaneously.Which not only provides larger effect, also make the production of SSL light fixture more cost-effective.

Therefore, be reduce the quantity on the surface that the light that produces must pass through for increasing a kind of scheme of effect in given illumination.Various aspects of the present invention provide by diverging lens and outer protection lens being combined in single device modularization refractor to reduce system, the method and apparatus of the number of faces that light must pass through.The realization of effect additional gain can collimate by using compound parabolic reflector the light produced by LED, instead of by TIR type lens, thus not only make the quantity of light composition surface minimize, and the volume minimization of the lens material making it pass.

In one aspect, a solid-state lighting device is provided.This device generally comprises the housing with multiple different mounting surface, the multiple optical modules be coupled with described each mounting surface, and multiple modularization refractor, each modularization refractor optical module corresponding to is coupled, and comprise one or more lens, these lens are configured to the diffusion controlling the light produced with one or more light emitting diode (LED) illumination component that the optical module be associated is coupled.Each modularization refractor can provide isolates with the environment of at least some parts of the optical module be associated.In some embodiments, multiple mounting surface can have the multiple different setting angle relative to the surface will irradiated by this device.In some further embodiments, this device does not comprise independent outer protection lens, can reduce the number on the surface that light has to pass through like this and improve effect of device.

In some embodiments, at least one subset in optical module comprises two or more LED, PCB of being coupled with printed circuit board (PCB) (PCB) and is arranged in relevant mounting surface.In some embodiments, one or more mounting surface can comprise the radiator of the heat being configured to shift auto-correlation LED.

In some instances, modularization refractor can comprise one or more total internal reflection (TIR) lens or compound parabolic reflector.One or more lens can also comprise the diverging lens being incorporated to external lens surface or being coupled with external lens surface, as the secondary element of lens.According to some embodiments, one or more lens of each modularization refractor are integrated with a modularization refractor housing, and are formed in arbitrary inner surface or the outer surface of described housing.In further embodiment, one or more lens of some or all modularization refractors comprise by the co-molded material with at least two kinds of different refractivities together.In further embodiment, one or more lens of one or more modularization refractor can comprise graded index (GRIN) lens being molded into modularization refractor.

Rather broadly outline the characteristic sum technical advantage according to the embodiment of the present invention above, detailed description subsequently can be understood better.Other feature and advantage will be described below.Disclosed concept can easily with making an amendment or designing other structure to perform the basis of the identical object of the present invention with specific embodiment.This type of equivalent constructions does not depart from the spirit and scope of claims.Be considered to the feature of concept characteristic disclosed herein, no matter be as its structure or method of operating, be better understood from description below by reference to the accompanying drawings together with the advantage be associated.Each accompanying drawing is provided to for example and describes object, and not as the definition of limitations on claims.

Accompanying drawing explanation

Fig. 1 illustrates that the lamp of LED and gas-discharge lamp exports the relation schematic diagram with lamp cost;

The lamp that Fig. 2 shows LED and gas-discharge lamp exports the relation with lamp cost, comprises total life cycle cost;

Fig. 3 shows the schematic diagram of relative luminous intensity relative to the propagation angle limited from LED peak strength of LED;

Fig. 4 is the cross-sectional view of the LED element array of embodiment of the present disclosure;

Fig. 5 is the perspective view of the LED element array of embodiment of the present disclosure;

Fig. 6 is the exploded view of the collimating optic of embodiment of the present disclosure;

Fig. 7 is the schematic diagram of the angle intensity of the output of light-emitting component;

Fig. 8 is the schematic diagram of the two-dimensional surface of an embodiment, has spot light on a surface, to provide light output in the direction perpendicular to the surface;

Fig. 9 has spot light thereon, to provide the schematic diagram of the two-dimensional surface of another embodiment of the light output with different light intensity degree and different collimation;

Figure 10 is the schematic diagram that the light beam of another embodiment of the present disclosure turns to optics;

Figure 11 is the schematic diagram of the road using the light fixture with asymmetric output pattern to illuminate in an embodiment;

Figure 12 is the schematic diagram of the output area on the road surface of an embodiment;

The schematic diagram of the skew output area of Figure 13 on the road surface of another embodiment;

Figure 14 is the top plan view of the lamp assembly of an embodiment of the present disclosure;

Figure 15 is the side view of the lamp assembly of Figure 14;

Figure 16 is the perspective view of the lamp assembly of Figure 14;

Figure 17 is the bottom perspective view of the lamp assembly of another embodiment of the present disclosure;

Figure 18 is the side view of the lamp assembly of Figure 17;

Figure 19 is the profile of the lamp assembly at Figure 17;

Figure 20 is the bottom plan view of the lamp assembly of Figure 17 of sections fit;

Figure 21 is mounted in the front perspective view of an embodiment of the modularization refractor assembly in framework;

Figure 22 is the rear view of the modularization refractor assembly of Figure 21;

Figure 23 is the bottom view of the modularization refractor assembly of Figure 21;

Figure 24 is front view and the side view of the modularization refractor assembly of Figure 21;

Figure 25 is the detailed view in the cross section shown in Figure 24;

Figure 26 is the front perspective view of the internal part of the modularization refractor assembly of Figure 21;

Figure 27 is the front view of the internal part of the modularization refractor assembly of Figure 21;

Figure 28 is the front perspective view of the frameless modularization refractor assembly of Figure 21;

Figure 29 is the front perspective view of the frameless modularization refractor assembly of another embodiment;

Figure 30 is front view and the side view of the modularization refractor assembly of Figure 29;

Figure 31 is the front perspective view of an embodiment of the lamp assembly of the modularization refractor assembly combining multiple Figure 29;

Figure 32 is 1/4th bottom perspective view of an embodiment of the lamp assembly of the modularization refractor assembly combining multiple Figure 29;

Figure 33 is the front perspective view of an embodiment of the combined type protect-ing frame structure of the lamp assembly being merged in Figure 32 and 33;

Figure 34 is 1/4th bottom perspective view of an embodiment of the combined type protect-ing frame structure of the lamp assembly being merged in Figure 32 and 33.

Detailed description of the invention

The present invention recognizes that LED-based Lighting Design is gratifying to create the LED comprising the low cost of LED array.The present invention also recognizes to be needed to produce uniform lighting pattern, or, when the specific non-uniform lighting pattern of needs, need the lighting pattern that expectation is provided.In addition, the present invention recognizes, in order to reduce costs further, requires that the LED quantity of collimation also should minimize.The invention provides the lighting unit meeting these standards, and produce this method strengthening design.In the application using this lamp, as illumination or the residential lighting in road lighting, office or other places, there is the requirement of basic output pattern.The requirement of this output pattern can comprise the minimal illumination of footcandle, and depends on the field of illumination scope of the spacing between the height of lamp and lamp.First, when required pattern width is enough to allow it, the uncollimated LED of sufficient amount is used to create central illumination peak.After this, narrow LED light Shu Zhixiang " filling " output pattern meets the even output pattern of output pattern requirement to create.Therefore, the invention provides the lamp with desired output pattern, and reduce lamp cost by the quantity reducing illumination component with the optics reduced needed for lamp.

First with reference to Fig. 1, the curve map of the relative cost representing dissimilar lamp is discussed.As observed from Fig. 1, the increase that the cost that the every lumen of a typical gas-discharge lamp exports exports along with lumen and declining.But, in order to the lumen improving LED exports, need to add more LED element, make the cost of LED linear with output.In other words, for the output increased, the cost that every lumen of LED exports is constant substantially.According to design now, this is by establishment scene, and wherein at least under three situations, LED-based lighting apparatus has cost competitiveness relative to gas-discharge lamp.First is when lower lumen output level, and as usually seen in low power illumination market such as automotive lighting and flashlight, wherein LED-based illumination has obtained the significant market share.Second is when the cost of decorative lamp accounts for high percentage in general ambient light equipment cost, as in architectural lighting.3rd is when the cost (being commonly called life cycle cost or proprietorial totle drilling cost) changing light source is high, such as aloft, is difficult to close to illumination application.

Along with the continuous progress of technology, LED exports in increase, and cost is in decline, and this has the effect reducing the LED slope of a curve shown in Fig. 1, makes higher-power applications more attractive.Because the LED lamp for general lighting application generally needs the array of LED lamp (being placed on as whole region to be lighted provides multiple lamps of the position of sufficient light), between the quantity of the lamp needed for effect of LED lamp and application, there is a kind of accurate transaction (aquasi-trade).This transaction is used for balancing the savings of expection life cycle and loses with the initial cost born.

With reference now to Fig. 2, the curve map of the relative life cycle cost that dissimilar lamp is shown is discussed.The curve of Fig. 2 illustrates the cost curve of two LED and the cost curve of a gas-discharge lamp.The curve of the LED 1 of mark shows the life cycle cost of the LED of the LED element with a greater number that the lower operating current of use runs.The curve of the LED 2 of mark shows the life cycle cost having and use compared with the LED of the LED element of the lesser amt of high workload electric current operation for LED 1.The gas-discharge lamp curve of mark shows the life cycle cost of gas-discharge lamp, and the several discontinuous place corresponding in curve and again change lamp cost is shown.In the situation of the LED of two shown in Fig. 2, LED 1 has higher effect, and initial cost is also higher.LED 1 has the life cycle savings higher than LED 2, and initial cost loss is also higher.For application-specific, preferably which lamp will depend on various economic factor.From the angle of total cost of ownership, because cost entirety reduces, LED 1 is preferred.But secondary cause is as the time value (saving after time to run) of money and may produce LED 2 situation that even gas-discharge lamp is more attractive relative to the psychology of the cost of time.Ideally will provide the LED with the LED element reducing number, use relatively low operating current to run, thus reduce operating cost, and extend the life-span of lamp.

As discussed above, from the angle of light output, single led is the equipment of relatively low light level, about 100 lumens usually.In order to obtain the output of a normal incandescent lamp or compact fluorescent bulb, technology is now used to need 10 to 20 LED emitter.This causes relative to traditional lighting device, and light fixture has relatively high initial installation cost to use.The present invention is minimized by the LED quantity that provides LED lamp and make to use in design, thus provides the LED-based illuminating product compared with current production with cost competitiveness.The quantity of the LED element used in lamp is called as LED sum.

LED sum is by the impact of multiple factor.First, light is logical to be maintained, and refers to the age of LED and discharges the mode of electric power along with passage of time.Traditional method is that design lamp makes the light of the unnecessary generation when the life-span of lamp starts identical with the minimizing of light output at the end of the appointment in life-span.Such as, the life-span due to typical LED is defined as when its power drops to relative to its initial value 30%, the LED sum that LED-based illuminating product will comprise higher than 30%, maintains to realize this lumen.Another factor of LED sum is the quantity of the LED element required for beam pattern producing the expectation sent from described lamp.Another factor of LED sum is the total output needed for lamp, and the lamp needing higher lumen to export needs higher LED sum.

Because LED-based lighting apparatus uses multiple single LED emitter, the lighting pattern of gained is the incoherent summation of the pattern of each LED.Such as, the pattern usually creating lighting pattern use is the summation of the multiple LED patterns on all same directions.In this case, the output pattern of all LED follows the pattern of each independent LED closely.Other design can use the optics having and be associated to provide the LED element group of beam shape, when the output of itself and other LED element is combined, provides the lamp meeting specified value to export.Therefore, the overlapping bundles of rays from discrete LED element is used to the rough approximation value creating required lighting pattern.Usually, in order to outer peripheral for lighting pattern luminous intensity is increased to minimum desirable strength, such design provides the center peak of lighting pattern than required height.But, this generates the design that LED sum is significantly less than optimum value.By lighting pattern being cut out further the actual requirement to meeting lighting device, the present invention achieves huge advance.

With reference now to Fig. 3, show the curve map of the basic output of uncollimated White LED and uncollimated color LED.Can observe, relative luminous intensity is essentially Cos (θ) form, and wherein θ is the angle of the propagation limited based on LED peak strength.Such radiation pattern is often called as lambert's pattern (Lambertianpattern).The width defining light beam with a critical consideration of LED light bundle work.For the IESNA/ANSI/NEMA definition of Type B distribution, " beam angle " is defined as 50% of maximum.And " angle of visual field " is maximum 10%.These angles typically refer to half-angle.In the curve of Fig. 3, the beam angle of uncollimated LED will be about 50 degree, and the angle of visual field will be about 20 degree.By propagating the protuberance in above-mentioned angular distribution to required surface, obtain the luminous intensity in the plane away from light source certain distance.

With reference now to Fig. 4, show the array for 5 LED of an embodiment and the cross-sectional view of collimating optic that is associated.In the present embodiment, array 100 comprises the independent LED104 of 5 of being installed on substrate 108.Substrate 108 comprises and connects the interconnector of each LED104 to the power supply (not shown) be associated.Substrate 108 can also comprise a hot transfer device, and as radiator, it is used for the heat that produced by LED104 of dissipating.Collimating optic 112 to be arranged on substrate 108 and to be positioned at above each LED104 be associated, and to provide output light pattern from each LED104, it is collimated relative to the light beam produced without the need to collimating optic 112.The cross section of Fig. 4 shows a kind of hybrid design, and the described central ray wherein from each LED104 experiences collimation via refracting element 116, and extraneous light experiences collimation via reflection part 120.Such optics is known technology, and refracting element can comprise for the optical lens by the pattern desired by anaclasis one-tenth, and reflection part, light reflexes in desired pattern to create mirror surface by its reflecting material that can comprise deposition.In one embodiment, the beam angle of the collimation generation of LED104 is in 5% scope.In another embodiment, LED104 produces the beam angle of about 2%.In the diagram of Fig. 4, it should also be noted that 5 optics all point to same direction, and will have spacing distribution, its intensity distribution is identical with the intensity distribution of each light beam.As described with reference to fig. 3, the LED without any secondary optics can give off Cos (θ) or lambert's pattern usually.Add the optics of positive and numerical aperture with suitable focal length and will be used for collimated telescope pattern, to create the light beam having and disperse pattern, this pattern is narrower than the pattern produced by the LED without any optics.

In order to understand the effect after far field intensity collimation, first it is noted that the uncollimated LED with lambertian radiation pattern has following intensity distribution:

Io＝PT/2[cos(θ)]

Wherein PT is for always to send power.Collimation LED has following distribution:

Io＝nPT/2[cos(nθ)]

Standard lambert pattern has halfwidth (FWHM) angle of 120 °, and the FWHM of 5 ° collimation pattern will have n=24.Therefore, in the fig. 4 embodiment, the LED that each LED in array is collimation provides the intensity defined in equation.

With reference now to Fig. 5, discuss the perspective view of the array 150 for the LED element of an embodiment.In the present embodiment, the array of 5 LED154 is installed on substrate 158.As described above with reference to Figure 4 same, substrate 158 comprises the interconnector each LED154 being connected to associated power (not shown).Substrate 158 can also comprise hot transfer device, and as radiator, it is used for the heat that produced by LED154 of dissipating.Collimating optic 162 is arranged on substrate 158 and above each LED154 be associated, to provide output light pattern from each LED154, it is collimated relative to the light beam produced without the need to collimating optic 162.In this embodiment, the additional shaping exported to provide described LED154, fresnel-type lens 166 can be attached to collimating optic 162, and to be shaped further, collimated light exports.These dismountable camera lens 166 types can create wider and ellipse pattern.Therefore, the output of LED150 array can be selected to gathering is provided or synthesis, the pattern with desired characteristic.

Fig. 6 is the schematic diagram of collimating optic 162.Collimating optic 162 comprises the lens component 170 being suitable for holding LED illumination element 154.In this embodiment, lens 170 are installed in substrate by adhesive pad 174.As mentioned above, fresnel-type lens can be attached to lens 170, with the light output that is shaped further.As described in detail in addition below, that can reduce the LED quantity needed for given illumination has the low cost lamp evenly exported, can by using appropriately combined being implemented of non-aligned, narrow collimation, wide-angle and/or ellipse projection LED light bundle pattern.

As above with reference to figure 3 discuss, nearly all LED emitter has a center lobe, and the luminous intensity of launching in this place is peak value, and when angle function declines away from described intensity during center line.This is also the situation for collimation and indivedual LED emitter that is shaped.This center lobe can be considered to a vector, and its direction coordinate in XYZ space describes the direction of propagation of center lobe, and the size of this vector is the peak strength of light.When uncollimated LED, the vector of this center lobe will at zero degree, and size equals Pt/2.As mentioned above, the LED of collimation will have similar direction and the size of nPT/2, and wherein n is collimation.

When manufacture has the lamp of Uniform Illumination pattern, the angle intensity of illumination component also must be considered.With reference to figure 7, the lamp at height h place illuminates a surface.For given angle (θ), walk more from illuminated normal to a surface, the illuminated surface of this angle will increase.For Uniform Illumination, angle intensity must follow following relation:

h[tan(θ+δ/2)-tan(θ-δ/2)]

In typical lighting environment, the spacing of lamp is defined by the height of lamp; That is, if the spacing between lamp is nh, the maximum angle considered so is needed to be tan (θ max)=n/2.The establishment of Uniform Illumination pattern will corresponding to a kind of situation, and the LED light wherein propagating into angle delta θ must be increased by relation shown above, to provide the luminous intensity of expectation.

In one embodiment, LED element is selected to be placed in lamp assembly, to provide desired output pattern.In the present embodiment, described lamp assembly itself comprises the LED be installed on different surfaces, to provide light output at different directions from LED.By the direction of the light of selection, in conjunction with the pattern without collimating optic, narrow collimation, wide-angle and ellipse projection LED light bundle, the lamp can developing a kind of synthesis exports, and it provides uniform lighting pattern by the LED element of minimum number.This lamp is in providing from the teeth outwards or higher than the illumination of required illumination level, and there is the cost of reduction, based on little, if have the extra LED element exceeding and provide the minimal amount of specifying required for brightness of illumination at whole desired lighting field, then based on little extra LED element.

In one embodiment, the layout by designing LED element realizes such LED lamp component to produce required output light pattern.For LED illumination, the luminous intensity from single led element is linearly increased by incoherent increase.When designing LED layout, assuming that work as the half intensity Point matching of every bar light beam, then the intensity between two light beams is almost equal.In such embodiments, as mentioned above, output center lobe can be considered to a vector, and its direction coordinate in XYZ space describes the direction of propagation of central lobe, and the large young pathbreaker of this vector corresponds to the peak strength of light.In one embodiment, lighting pattern can be synthesized by creating a surface, making LED center lobe vector normal in this surface.Such as, Fig. 8 and 9 shows the two-dimensional surface with LED element thereon, to illuminate the zones of different on field of illumination.In the example of fig. 8, surface 200 comprises five LED element, A to E.In the present embodiment, each LED element A-E comprises collimating optic, and it collimates the output beam from each LED, to provide 5 ° of beam angles.The part of field of illumination is shown as region A1 to E1, is illuminated by corresponding LED element A to E.Fig. 9 shows an embodiment, and wherein different optics is arranged in the different LED on surface 250.In this embodiment, being illustrated as a LED of " A ", is the uncollimated LED with 20 ° of beam angles, thus provides illumination for the part A1 of field of illumination.Be illustrated as the 2nd LED of " B ", comprise collimating optic and think that LED provides the beam angle of 5 °, thus provide illumination for the described part B1 of field of illumination.Similarly, the 3rd LED, is illustrated as " C ", comprises collimating optic and thinks that LED provides the beam angle of 5 °, thus provides illumination to the described part C1 of field of illumination.All the other LED being installed to surface 250 can be uncollimated, or can comprise collimating optic and/or diverging lens, to provide the light of desired intensity to field of illumination, make whole field of illumination have consistent uniformity.

In such mode, the LED-based lamp of the illumination optical pattern providing required can be produced.Lamp as vectorial combination is exported and carries out modeling and can allow various technology, as created the density of pointing vector and intensity to produce the intensity pattern of expectation; The density assembling vector is selected to create the intensity of expectation; And select the density of parallel vectors with the splicing providing LED to export (tiling).Certainly, the combination of vector can be used to the Strength Changes creating density and splicing.In addition, the shaping type change of LED array also can be modeled.Ideal pattern causes the optimum combination of the vector changed based on direction vector change, vector density change and vector length (intensity).

With reference now to Figure 10, another embodiment is described.Except arranging LED at the tube face with multiple direction vector, the light beam being combined with LED element turns to optics also to can be used to produce the lighting pattern expected.In the example of Figure 10, surface 300 comprises two LED element 304,308.Each LED element has a light beam be associated respectively and turns to optics 312,316.Therefore, the light beam produced from LED304 turns to optics 312 directed in the direction expected by light beam.Equally, the light beam produced from LED308 turns to optics 316 directed in the direction expected by light beam.Multiple LED element can be included on a surface, with different LED, or LED group, turn to optics to be associated with particular beam, to produce the synthesis lighting pattern meeting application-specific needs.In addition, in other embodiments, can be combined there is multiple direction vector lamp surface and light beam turn to optics to produce the lighting pattern of expectation.

In one embodiment, based on output pattern needed for light fixture, pattern synthesis is used to determine the structure of light fixture.This method schematically describes in fig. 11.In the present embodiment, the observability of the object strengthened in the road is expected.Object due to road lighting is not only to see road clearly, is also may on the way any object in order to see.As in road lighting field understand, be usually used in the two-way light fixture do not had on the street of median and two-way traffic, create little target visibility (STV) by positive and negative contrast.At pitch period, twice contrast inversion occurs usually, namely on the line of first time below light fixture, and second time is at about 1/3rd places of the spacing of light fixture.By alternate arrangement, the number of contrast inversion can increase.It is contemplated that reduce the number of times and minimizing inversion region that reverse between positive and negative contrast.In positive contrast region, this target front should become clear as far as possible and with seem that contrary road surface should be quite dark.In negative contrasted zones, the fact should be contrary.Therefore, expect to realize to have from close to the average road surface brightness needed for changing to MIN brightness uniformity to greatest extent.Correct illumination profile and the selection of spacing are very crucial to realizing high level STV.

Referring again to Figure 11, show the setting height(from bottom) with high h and spacing is the light fixture 320 of d and the relation relative to the direction be traveling on road 324.The substantial scope of the lighting pattern before lamp is illustrated as x, and the substantial scope of lighting pattern after lamp is illustrated as y, and the overlap between lamp is regarded as z.Angle from lamp to the ground away from lamppost is defined as θ, θ=0, lamppost place.Desired lighting pattern will have the substantial scope of lighting pattern before lamp, and make distance x correspond to an angle, this angle is less than the visible angle of oncoming driver.This will reduce the dazzle experience of the driver advanced at the direct of travel of road surface 320.Lamp substantial scope y is below by such as excessively invading and limiting the problem that the driver of opposite lane produces dazzle.In addition, the visibility of target is overlapping region z by minimizing between lamp and is enhanced.This point can be accomplished by the fall area carefully controlling light.Uniform lighting pattern will have the angle intensity being described as tan in essence.In one embodiment, relatively narrow light beam is used to provide this to stop, from the transition of tan (θ) angle intensity line, to the transition gone to zero as early as possible.This transition wire should follow the beam pattern of the outermost beam component of light.Synthesized the use of the light beam processing the height collimation limited by pattern, can be used to create the pattern termination characteristic brightness of light curtain and dazzle being minimized and improves needed for the visibility of target.The top plan view with the exemplary road 324 of lamp 320 and region x, y and z is shown in Figure 12.

The diagram of Figure 12 is well suited for be had in the application of single direct of travel for one or more tracks of road 324.This application can comprise highway and the half-duplex channel of division.Have been found that best angle light being pointed to road (along direct of travel) is downwards between 60 degree to 76 degree, and be more preferably between about 72 degree to 76 degree.Have been found that the best angle of (inciding direct of travel) upstream light is for being between zero to about 50 degree.Relative wagon flow, with the eyes of the more possible direct irradiation driver of the light of more high angle transmitting, causes potential safety hazard.In the embodiment in figure 11, LED module is configured in at the light output providing about 72 degree along the direction of direct of travel in each lamp, and provides about 45 degree of light output in the direction entering direct of travel.

The track two (or multiple) with relative direct of travel is all present in the application in road, all lamps 320 as shown in figure 12 are not too applicable to, because the traffic in a direction will have more dazzle, thus decrease the visibility to Small object.In another embodiment, as shown in figure 13, each lamp exports lighting pattern, and wherein the field of illumination of road surface 350 is direct of travel based on track specific in road 350 and is offset.In the present embodiment, light fixture 354 exports light along the direction that the first lane of road 350 is advanced with the angle of about 72 degree, and this field of illumination is designated region " a " in fig. 13.Light fixture 354 exports light with about miter angle deviating from the direction that first lane advances, and this field of illumination is designated region " b " in fig. 13.Similarly, light fixture 354 is deviating from direction that second lane advances along exporting light with miter angle and deviating from direction that second lane advances with about 72 degree angles output light, and these regions are designated region " c " and " d " in fig. 13 respectively.

A kind of method for designing utilizing pattern synthesis to design the lighting realizing desired output pattern comprises several key element.In one embodiment, provide luminosity file, this luminosity file is provided for the model of the light output of LED.Such file can be provided by LED manufacturer or be produced by optical laboratory.This LED light degree file is used to form lamp model.Then, the luminosity file of the LED for being combined with any secondary optics is produced.If do not comprise necessary secondary optic, then can use modeled surface or solid modeling software, as Rhino and Solidworks, design.Then, predict the illumination application software of the illumination in the level and/or vertical surface of illuminator, such as AGI32, be used to aim at each LED or LED module.Once LED has been located and aimed at, this illumination application software has just started the performance of computing system.This step several times iteration may be necessary, to finely tune described aiming.In this, surperficial software can be used to make so-called dish or module.As mentioned in this article, dish or module are the gatherings of LED, are combined into and are molded as single source.Then, surperficial software is used to the chart dial sights according to being generated by illumination application software.Then, solid modeling software, as Solidworks, is used to simulate light fixture, namely housing, lens and other parts.Then the photometric characteristic of new lamp is emulated.Then light fixture model can be used in illumination application software, as AGI32, to calculate the light fixture performance in various illumination application.

With reference now to Figure 14 to 16, describe the LED-based lamp assembly of an embodiment.In the present embodiment, lamp assembly 400 comprises a surface 404, and it has the mounting surface 406 of multiple different angles, and surface 406 is provided with LED component 408.Lamp assembly 400 provides the light output on main shaft 410 direction.In the present embodiment, LED component 408 is similar to LED array 100 and 150 as previously described in Figure 4 and 5.In the present embodiment, LED component 408 comprises the array of five LED element, and can comprise the collimation or other beam-shaping optical device that are associated with LED.The lamp assembly 400 of the present embodiment, the one being designed to tradition 150 watts of metal halide type building street lamps substitutes.This LED component 408 comprises the standard LED of a type, and LED runs with the electric current of about 500 to 600 milliamperes and provides the White LED of the output flow of about 170 to 250 lumens in one embodiment.

In one embodiment, LED component 408 comprises the collimation of three types, i.e. 5 degree of arrow beam of lights, 20 degree of light beams (uncollimated), and one 20 degree are taken advantage of the oval-shaped beam of 5 degree.As mentioned above, the LED component of the present embodiment comprises five LED, and the splicing providing LED to export.This assembly by allowing the array of five elements to be installed to surface 404, thus simplifies manufacture.But, easily recognize that independent LED can be mounted on a surface, or the LED array on array with different number LED can be adopted.In another embodiment, LED component 408, respectively comprises the collimater that output optical alignment is become 2 degree of arrow beam of lights by, and then diffuse optical device can be placed in LED/ collimater and propagate output light to different expectations diffusion.In one suchembodiment, each lamp assembly has the setting height(from bottom) of 30 feet, and the distance between lamp is 6 times of setting height(from bottom)s (180 feet), and each lamp illuminates road up and down less times greater than the region of +/-3 times of setting height(from bottom)s from lamp position.In the present embodiment, point to and not to be coupled any diverging lens from the light emitting diode in the region of center line 3 times of setting height(from bottom)s of lamp and larger (90+ foot).The LED pointing to the region of setting height(from bottom) (75 to 90 feet) between the center line 2.5 to 3 times of lamp with there are 5 degree of diverging lens spread be coupled.The LED pointing to the region of setting height(from bottom) (60 to 75 feet) between the center line 2 to 2.5 times of lamp with there are 15 degree of diverging lens spread be coupled.The LED pointing to the region of setting height(from bottom) (30 to 60 feet) between the center line 1 to 2 times of lamp with there are 25 degree of diverging lens spread be coupled.Finally, the LED pointing to the region of setting height(from bottom) (0 to 30 foot) between the center line zero to 1 times of lamp with there are 50 degree of diverging lens spread be coupled.

With reference now to Figure 17 to 20, the LED-based lamp assembly 500 of another embodiment is described.In the present embodiment, lamp assembly 500 is " clock " shape assemblies comprising external shell 504 and outer lens 508.Some installation sub-components 512,516,520 are arranged in housing 504, each sub-component 512,516,520 has the mounting surface 524 of multiple different angles, on a surface, LED component 528 is installed in side, and heat abstractor 532 is installed in opposition side.Lamp assembly 500 is provided in the light output in the region that identified by dotted line 510.In this embodiment, LED component 528 is similar to the previously described LED array 100 and 150 of Figure 4 and 5.In the present embodiment, LED component 528 comprises the array of five LED element, is arranged to 3/2 structure, and can comprise the collimating optic or other beam-shaping optical devices that are associated with LED.The lamp assembly 500 of the present embodiment, is designed to provide the one to tradition 150 watts of metal halide type building street lamps to substitute.This LED component 528 comprises the standard LED of a type, and LED runs with the electric current of about 500 to 600 milliamperes and provides the White LED of the output flow of about 170 to 250 lumens in one embodiment.As mentioned above, the LED component of the present embodiment comprises five LED, and the splicing providing LED to export, and simplify manufacture by making five element arrays be installed to surface 524.But, easily recognize that independent LED can be mounted on a surface, or the LED array on array with different number LED can be adopted.

In another embodiment, LED component 528, respectively comprises the collimater that output optical alignment is become 2 degree of arrow beam of lights by, and then diffuse optical device can be placed in LED/ collimater and propagate output light to different expectations diffusion.In one suchembodiment, each lamp assembly has the setting height(from bottom) of 30 feet, and the distance between lamp is 6 times of setting height(from bottom)s (180 feet), and each lamp illuminates road up and down less times greater than the region of +/-3 times of setting height(from bottom)s from lamp position.In the present embodiment, point to and not to be coupled any diverging lens from the light emitting diode in the region of center line 3 times of setting height(from bottom)s of lamp and larger (90+ foot).The LED pointing to the region of setting height(from bottom) (75 to 90 feet) between the center line 2.5 to 3 times of lamp with there are 5 degree of diverging lens spread be coupled.The LED pointing to the region of setting height(from bottom) (60 to 75 feet) between the center line 2 to 2.5 times of lamp with there are 15 degree of diverging lens spread be coupled.The LED pointing to the region of setting height(from bottom) (30 to 60 feet) between the center line 1 to 2 times of lamp with there are 25 degree of diverging lens spread be coupled.Finally, the LED pointing to the region of setting height(from bottom) (0 to 30 foot) between the center line zero to 1 times of lamp with there are 50 degree of diverging lens spread be coupled.

As what can observe in the embodiments described, provide the light fixture with some functions, comprise and there is asymmetric Light distribation to provide just contrast (positivecontrast) roadway lighting system with the improvement visuality reducing dazzle.This system meets the requirement of IESNARP-8-2000 and AASHTO Highway Lighting, also meets the setting height(from bottom) ratio for lamppost spacing 5: 1 or higher.The system of embodiments more described herein provides the visuality of improvement, and it has the up light of positive contrast and minimizing, by realizing fully cut-off and reducing the light quantity thus minimizing light pollution that upwards project from luminaire.By having the light beam of the light produced by the several optical elements presenting cross figure, any veiling glare from optical element can also be comprised in lamp housing, thus realize the up light of minimizing.The up light of this minimizing, and reduce by more orientations and the intrusion that provides of output pattern targetedly, greatly reduce light pollution, and contribute to the target of " the dim sky " realizing being present in multiple administrative area.In addition, the illuminator of several embodiment saves the energy by providing the utilization of better lamp and light output with higher vertical angle.

In another embodiment, the invention provides the method for producing desired illumination pattern from LED-based lamp.The method comprises the lighting pattern determining to realize.The requirement that described lighting pattern can be applied based on the illumination of some type is determined, as the minimum constructive height etc. of minimum lighting requirement and lamp.Lighting pattern also can based on one group of self-defined standard for application-specific.Such as, if lamp will be used as street lamp, various specification will be existed for street lighting, comprise minimum lighting requirement.In this case, relevant specification is a factor when determining irradiation pattern.Determine that another factor of lighting pattern is height and the spacing of lamp assembly.Height and the spacing of lamp assembly can be determined based on the specification for application-specific.Such as, street lighting application may have the specification of the minimum constructive height of the maximum spacing related between lamp and the lamp be positioned on road.Alternatively, can in the height determining lamp assembly afterwards of design lamp assembly and the LED element be associated and spacing.Such as, lamp assembly can be designed to provide Uniform Illumination in specific region when being placed on a certain height.Under these circumstances, the spacing of lamp assembly determines based on the uniformity needed for the illumination in illuminated region.

One or more types of the LED element used in lamp are selected, and the illumination provided by selected LED element is determined dissimilar collimation and the different angles for the main shaft relative to lamp assembly.The uniformity of illumination is determined, comprises the minimum magnetic flux level for illuminated region.Then, lamp surface is determined, it comprises the multiple different mounting surface relative to described main shaft with different angles, makes when LED is installed in mounting surface, and this lamp will provide the lighting pattern of the expectation with required uniformity.The luminous intensity exported from LED element and beam angle are selected to provide uniform angle intensity.

In another exemplary embodiment, as shown in figure 21, modularization refractor assembly 601 molded, casting or otherwise form diverging lens region 602 and to provide, necessity of the propagation of produced light is controlled.The function that this embodiment combines the diverging lens 166 shown in Fig. 5 of former application and outer protection lens 508 function described in Figure 17 and 19 of former application.These two kinds of functions are combined by reducing the number of indivedual precision optics in the mode of this novelty, and by removing the outer protection lens that large molded, casting or alternate manner are formed, thus provide cost advantage.Labor cost also can reduce by needing the part number of results of placement in an assembling process.

Described diverging lens region 602 can be the Fresnel lens described in this exemplary embodiment, or they can be conventional lenses, graded index (GRIN) lens maybe can perform the other lenses type of diffusion function.These diverging lens regions 602 can be formed at the outer surface of modularization refractor, inner surface or both because these may be needed to reach required optical property.If optical requirement can be satisfied to the single surface of modularization refractor by forming described lens area 602; preferably this surface be the inner surface of modularization refractor to strengthen the protection of lens area, and provide the longest actual life for described surface.

Although this exemplary embodiment shows these diverging lens regions 602 multiple, also may have other embodiment, wherein the quantity of this diffused component is different from and comprises this exemplary embodiment that a kind of embodiment wherein only exists this class component single.The number in diverging lens region 602 can match with the multiple collimating element such as described in this exemplary embodiment and LED or many LED.Other embodiment can comprise the collimating element without corresponding diverging lens region 602, to keep the narrowest possible field angle.In the embodiment with multiple diverging lens element, described element can be designed to be had identical wave beam diffusion each other or have different beam spread in given modularization refractor.

As shown in figure 22, this installation frame 603 provides first class of protection to external environment condition together with pad 604.The illustrating of installation frame that this place is described is for illustration of object, and can take various shape or size as required in practice, to adapt to the requirement in specific Lighting Design.

Mounting ear in Figure 22 or ledge 605 are parts of modularization refractor 601, and are provided for sealing described packing ring 604 simultaneously for described modularization refractor being positioned at the region on mounting platform.Printed circuit board (PCB) (PCB) 606 provides the installation of multiple LED and connects the circuit of LED.The electric connector 607 being shown in Figure 22 and 23 provides a kind of for the LED of link block inside and the device of external power source.Installing hardware 608 can be any one of multiple securing member well known to those skilled in the art, and in this exemplary embodiment, to be remained on by inner collimating element on PCB606 and PCB606 is fixed to mounting platform.

These LED609 are illustrated as cross-sectional view in fig. 24, and are positioned within the compound parabolic reflector 610 of light collecting and collimate and produced by LED.Then light is diffused to the degree required for requirement of this module meeting given Design of Luminaires by diverging lens region 602.

Modularization refractor 601 is sealingly connected to PCB6 by the inner washer 611 shown in Figure 24 and 25, to provide the protection of the extra level to external environment condition, thus creates a module sealed separately.The geometry of packing ring described herein is one of several possible gasket geometries, and it uses at this to provide the enough sealings to outside ambient inlet.The inside of this module is shown in Figure 26 and 27.Also show in these figures by the internal electrical attachment 612 be directly welded on metal-foil circuits plate, and provide the device for being mounted on the LED on PCB606, this PCB606 powers from described aerial lug 607.The for clarity sake not shown wire that power path between described connector is provided.In the embodiment that other is possible, the another kind of implementation method of aerial lug 607 is that itself directly can be soldered to PCB606.

In Figure 28, the mounting ear of modularization refractor 601 or ledge 605 are shown as and do not have installing plate.In other embodiments, they can be different from relative size shown in the present example embodiment.The modularization refractor 601 of other embodiment also can be different from the rectangular in form shown in present embodiment.These alternative forms can be square, circular, hexagon, triangle or other shape any needed for requirement meeting given light source design.Suppose that the internal part of modularization refractor will be re-arranged, and revise or otherwise construct, with the alternative form of applicable modularization refractor.

In another exemplary embodiment, the modularization refractor assembly 613 in Figure 29 is shown as and does not comprise mounting ear.Be similar to previously described embodiment, transparent outer protection refractor housing 614 has the diverging lens region 602 that multiple molded, casting or alternate manner are formed.In the present embodiment, the overall outer dimensions that hardware 616 is positioned at refractor instead of the outside mounting ear had as previously shown are installed.Enclosure interior as shown in the cross-sectional view of Figure 30 be collimation lens 617 and for as described in the mounting bracket 618 of lens 617.In the exemplified embodiment, described lens are casting or molded total internal reflection (TIR) kind.

In the exemplary embodiment shown in Figure 31 and 32, modularization refractor assembly 613 is installed to the target platform 620 of directed each module, to realize pattern needed for ground light, and providing a thermally conductive pathways to described housing (not shown) herein, this housing provides structural support, thermal conductivity and thermal diffusivity.Housing can be cast, molding, machining, sintering or be shaped with some other forms, and by the material of necessary mechanical strength and required heat conductivity can be provided to make simultaneously, typically is aluminium.

Region 621 around modularization refractor assembly 613 and is below covered by installation frame 622 and protects; this installation frame can be sub-assembly as shown in the example embodiments; or can be single or multiple independent sheet, this depends on the requirement of given Design of Luminaires.Merely illustrate such framework 622 in the present example embodiment.In figure above, combined type installation frame 622 is conceptually expressed as the installation frame 603 of simplification, and by a pad of the pad 604 be functionally similar to shown in prior figures or multiple pad support.The shape and size of these pads are formed as the external shape meeting modularization refractor assembly 613, to provide the sealing to outer member.

Figure 31 shows the combined type installation frame 622 of the remainder independent of lamp assembly.The shape and size of the opening 623 in framework are formed as suitably holding described modularization refractor assembly, and provide suitable pressure to packing ring.

The not shown connector be arranged on target platform 620 in the present embodiment, it is by the connector 607 on mating die blocking refractor assembly 613, these connectors coordinated will be oriented to allow modularization refractor assembly 613 to be inserted into target platform 614, power to set up the necessary LED that electrically connects as.The connector be arranged on target platform 614 will be routed in together with proper arrangement, to optimize power utilization rate.This wiring extends in the region 621 of modularization refractor assembly 613 behind, and provides environmental protection by installation frame 622.

To be that electric distribution extends through the through hole in PCB606 in a unshowned alternate embodiment, instead of be used in the connector shown in exemplary embodiment above.Needs distribution is directly connected to electrical connection 612 by this, and the space stayed in hole after distribution cabling such as room temperature vulcanization (RTV) silicon compound sealing, be commonly used to resist entering of water, dust and other material.

In these embodiments various securing member is not shown, and in associated component, holds the hole needed for them.Suitable selection for the securing member of given purposes should be apparent to those skilled in the art.

The previous description of the disclosed embodiments is provided to make to enable any those skilled in the art or use the present invention.To will be apparent to those skilled in the art to the various amendments of these embodiments, and General Principle defined herein can be applicable to other embodiment and does not depart from the spirit or scope of the present invention.Therefore, the present invention is not intended to be limited to the embodiment of showing herein, but will meet the widest scope consistent with principle disclosed herein and novel feature.

Claims (10)

1. a lamp set installation, comprising:

Have the housing of multiple mounting surface, described multiple mounting surface comprises the surface relative to the first plane with multiple different angles, and described first plane is arranged essentially parallel to the surface treating to be illuminated by lamp assembly;

At least one solid-state light emitting element, it is installed in each mounting surface, each light-emitting component at least one subset of described multiple light-emitting component provides the light output along respective major axes line separately, described main shaft is crossing with the center line of housing with perpendicular to the second Plane intersects of described first plane, and the output of multiple solid-state light emitting element combines the lighting pattern providing synthesis; And

Multiple modularization refractor, each modularization refractor is coupled with corresponding mounting surface, and comprise one or more lens, described lens is set to the propagation controlling the light produced from least one solid-state light emitting element of being associated, and each modularization refractor provides environment to isolate at least one solid-state light emitting element be associated.

2. device according to claim 1, wherein said device does not comprise independent outer protection lens.

3. device according to claim 1, each of wherein said multiple modularization refractor comprises diverging lens and/or secondary optics assembly.

4. device according to claim 1, also comprises the reflector be associated with one or more solid-state light emitting element, and it is configured to collimate the light from described solid-state light emitting element.

5. device according to claim 1, wherein said modularization refractor comprises the protect-ing frame structure and packing ring that are coupled to relevant mounting surface separately.

6. device according to claim 1, wherein said modularization refractor comprises one or more total internal reflection (TIR) lens or compound parabolic reflector separately.

7. device according to claim 6, wherein said one or more lens comprise further and are merged into diverging lens that is in external lens surface or that be coupled with external lens surface, as the secondary element of lens.

8. device according to claim 1, wherein one or more lens of each modularization refractor are integrated with modularization refractor housing, and on the inner surface being formed on described housing or outer surface.

9. device according to claim 1, one or more lens of wherein one or more modularization refractors comprise by the co-molded material with at least two kinds of different refractivities together.

10. device according to claim 1, one or more lens of wherein one or more modularization refractors comprise graded index (GRIN) lens be molded in modularization refractor.