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WO2011143015A1 - Dispositifs de mise en forme de faisceau optique utilisant des microfacettes - Google Patents

Dispositifs de mise en forme de faisceau optique utilisant des microfacettes Download PDF

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Publication number
WO2011143015A1
WO2011143015A1 PCT/US2011/035095 US2011035095W WO2011143015A1 WO 2011143015 A1 WO2011143015 A1 WO 2011143015A1 US 2011035095 W US2011035095 W US 2011035095W WO 2011143015 A1 WO2011143015 A1 WO 2011143015A1
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Prior art keywords
facets
microfacets
optic
lens
light
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Ceased
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PCT/US2011/035095
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English (en)
Inventor
Ken G. Purchase
Thomas A. Rinehart
Robert L. Wood
Robert. M. Soule, Iii
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BrightView Technologies Inc
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BrightView Technologies Inc
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Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G02B3/02—Simple or compound lenses with non-spherical faces
    • G02B3/08—Simple or compound lenses with non-spherical faces with discontinuous faces, e.g. Fresnel lens

Definitions

  • Fresnel Zones Each Fresnel zone consists of a segment with a prismatic shape defined by generally planar faces. The prism bends incident light in a specific direction according to Snell's law. The width of individual segments is generally small compared with the aperture of the optical device, thereby allowing an array of many flat segments to approximate a curved surface.
  • Segments may be curved along their path and arranged in concentric rings to form conventional circular positive (converging) or negative (diverging) spherical and aspherical lenses.
  • Straight segments may be arrayed side by side to form similar cylindrical lenses.
  • the prismatic shape of each segment generally varies in a prescriptive way from segment to segment so that the array of segments produces the desired overall beam shaping effect.
  • a spherical lens is emulated by using Fresnel zones that are steeper near the edge of the lens and gradually get shallower toward the center.
  • each circular zone is tilted away from the center, while a spherical negative lens has zones tilted toward the center.
  • Fresnel lenses have been very successful in providing beam shaping solutions in applications as diverse as lighthouse optics, projection television screens, and solar concentrators, they may impose limitations in some applications.
  • circular optics such as a conventional lens
  • it is practical to produce Fresnel optics using a "turning" process wherein a mandrel or tool is formed by inscribing a set of concentric grooves whose geometry corresponds to the Fresnel zone prism shapes.
  • a block of soft metal such as brass may be rotated on a turntable while being inscribed with a diamond-tipped tool having the appropriate geometry. The tool may be rotated or changed with each succeeding ring in the course of the machining process.
  • This method can be extended to linear optics such as cylindrical lenses by traversing the machined part linearly, rather than rotationally.
  • This type of machining process imposes limits on the degree of variation possible along the machining direction.
  • the cross-sectional shape along the longitudinal path of a Fresnel zone on a Fresnel optic will generally be invariant.
  • the unidirectional shape limitation imposed by conventional Fresnel optics generally reduces or prevents the ability to create new types of optics which may be a superposition of two or more optical elements. For example, creating a convergent spherical Fresnel lens that also steers light to the left or right is very difficult to manufacture since it requires that each Fresnel zone have a constantly varying cross sectional shape.
  • some illumination applications require a combination of light collimation and diffusion. PAR lamps make use of such an approach to provide a concentrated beam output to the illuminated surface, but with a smoothly distributed light distribution in the illumination pattern. Multiple optical elements may be combined to achieve this effect, such as a metalized parabolic reflector combined with a light-scattering diffuser. Achieving the collimation and diffusion in a single element using a Fresnel approach may not be practical because it generally requires the ability to alter the Fresnel zone cross section in the machining direction.
  • micro-lens diffuser Another technology, generally referred to as a micro-lens diffuser, is created wherein each lens of a collection of micro-lenses, by its curvature and shape, creates an ensemble of output rays with a given far-field distribution.
  • the collection of lenses which may be identical or randomized, creates a far- field distribution which is the sum of all input distribution.
  • speckle or interference effects such as rings (through processes well-known to those in the art), often the average distribution is acceptable, and in the case of broadband (white) light, the amount of speckle or interference may approach zero.
  • diffmctive optical elements are created in which a surface with a given refractive index and defined surface shape is created which redirects through diffraction input light into a desired output light distribution.
  • a pseudo-random surface diffuser is created, such as through speckle lithography, holographic lithography, or by direct writing by a focused laser beam, and the pseudorandom surface redirects light into a desired output distribution.
  • facets are discrete refractive elements on the surface of a transmissive or semitransmissive substrate.
  • Such facets may be considered to be "microfacets” if the individual facets within an array of facets are generally below the range of normal human visual acuity.
  • an optical element is subdivided up into areas (such as uniformly- spaced squares or random polygons, for example) when viewed from above, and the surface above a given square has a given height above the substrate.
  • the surface has a shape (such as flat or curved) and is tilted in a given direction.
  • Figure 1 is a perspective view of a microfaceted device.
  • Figures 2 and 3 are cross-sections of microfaceted devices.
  • Figures 4-14 are perspective views of other microfaceted devices.
  • facets are discrete refractive elements on the surface of a transmissive or semitransmissive substrate.
  • Such facets may be considered to be "microfacets” if the individual facets within an array of facets are generally below the range of normal human visual acuity.
  • an optical element is subdivided up into areas (such as uniformly- spaced squares or random polygons, for example) when viewed from above, and the surface above a given square has a given height above the substrate.
  • the surface has a shape (such as flat or curved) and is tilted in a given direction.
  • Figure 1 shows an example of such a surface, which in this case contains a grid of equally spaced squares, each tilted about a random angle relative to the substrate.
  • a cross-section of this type of faceted optic is shown in Figure 2.
  • This optic of figures 1 and 2 is mentioned in references (E R Mendez, 2004, "Design of two-dimensional random surfaces with specified scattering properties," Opt. Lett. 2917-2919 and E R Mendez, 2001, "Photo fabrication of random achromatic optical diffusers for uniform
  • the input beam may be substantially collimated white light and the desired far-field light distribution may be a disc.
  • every facet in the ensemble of facets directs the input light entering that facet in substantially to one part of that disc, and when all facets are considered together, light is delivered to all parts of that disc.
  • the desired far-field distribution may be a ring of desired radial diameter and thickness.
  • the desired far-field distribution may be a square.
  • a collimated or near-collimated input beam is used and the far-field distribution is centered on the axis of the incoming beam, that is, on average the output beam is going the same direction as the input beam.
  • Facets can have a non-zero average tilt, such that the input beam and output beam are not necessarily co-linear.
  • Various embodiments described herein can provide an array of microfacets that can overcome some of the disadvantages of the approaches outlined above.
  • Some embodiments described herein employ large arrays of microfacets, generally laid out in a planar Cartesian coordinate system to create a beam forming device.
  • the individual microfacets are combined in large ensembles to produce optical devices that may have utility in a number of beam forming applications.
  • the beam forming pattern may be determined through the cooperative refraction of the microfacets within the array.
  • macroscopic optical devices such as circular lenses, cylindrical lenses, prisms, beamsplitters, diffusers, and the like may be emulated using arrays of the appropriate microfacets.
  • Microfacets according to various embodiments described herein may have one or more dimensions between about ⁇ and about 500 ⁇ and, in some embodiments, about 30 ⁇ .
  • the overall size of the arrays of microfacets may be between an inch and several feet, for example an array of 4 feet x 7 feet, and may contain billions of microfacets.
  • a spherical lens may be combined in a single array with a prism to provide a combined focusing and beam steering function.
  • a spherical collimating lens may be combined with an optical diffuser pattern to create a collimating/diffusing device.
  • Some embodiments may combine the respect two or more functions into a single unitary layer.
  • Other embodiments may distribute two or more optical functions over two layers, where each layer may stacked one upon another, or separated by a transmissive or partially transmissive layer or layers in between.
  • inventions described herein can provide illumination devices having greater efficiency than conventional devices.
  • the use of superimposed beam forming optics discussed above can permit the creation of unitary secondary optics for illumination devices such as luminaires, backlights, spotlights, and the like.
  • Such unitary optics may reduce the number of air/optics interfaces required to achieve the desired beam shape, thereby reducing the amount of light lost due to reflection.
  • microfaceted devices described herein may include an optically transparent sheet having faceted optical microstractures replicated on a surface.
  • the microstractures may be produced by replicating a master.
  • an optical diffuser film can be made by replication of a master containing the desired shapes as described in U.S. Patent No. 7,190,387 to Rinehart et al., entitled Systems And Methods for Fabricating Optical Microstructures Using a Cylindrical Platform and a Rastered Radiation Beam; U.S. Patent Application Publication No.
  • Example 1 Beamsplitter Device.
  • all facets are oriented, for example, 10 degrees from the plane of the optic, and thus form an ensemble of substantially equal prisms, substantially bending the input light by a fixed angle to form the output beam.
  • Half of the microfacets are oriented 10 degrees toward one direction, the other half 10 degrees toward the opposite direction, thus forming an ensemble of prisms that splits a beam of collimated input light into two output beams, each at a fixed but opposite angle from the input beam.
  • the facets are arranged on the substrate in columns, such that all facets in a given column are tilted toward in one direction to the side of that column, and all facets in the adjoining columns are tilted in the opposite direction, such that the collection of facets forms a surface that is corrugated according to a triangle wave.
  • the facets are tilted at substantially 45 degrees, and thus adjacent rows of facets meet at 90 degree angles, the faceted optic forms what is known in the display industry as a "prism film," such as the BEF film made by 3M. See Figure 4.
  • Example 2 Beam diverter with randomization.
  • all facets have, for example, a 10 degree tilt from the plane of the optic in substantially the same direction, plus an additional amount of tilt added according to a desired random distribution.
  • This optic will bend the input light by a fixed angle, and additionally spread that light according to a desired far-field pattern. See Figure 5.
  • Example 3 Beamsplitter with randomization.
  • all facets are oriented, for example, 10 degrees from the plane of the optic, and thus form an ensemble of substantially equal prisms, substantially bending the input light by a fixed angle to form the output beam.
  • Half of the microfacets are oriented 10 degrees toward one direction, the other half 10 degrees toward the opposite direction, thus forming an ensemble of prisms that splits a beam of collimated input light into two output beams, each at a fixed but opposite angle from the input beam.
  • an additional amount of tilt is added to each microfacet according to a desired random distribution.
  • This optic will split input collimated light into two beams, each producing a desired shape in the far-field determined by the distribution of the randomization. See Figure 6.
  • Example 4 Focusing Optical Device.
  • a focusing faceted optic of these embodiments is an optic in which the microfacets approximate a Fresnel lens, in that each microfacet of the lens is designed to refract input light onto substantially the same point in space, which for a collimated input beam will be located along the axis of the input beam, thus focusing the light such as done by a Fresnel lens. See Figure 7.
  • Example 5 Focusing Optical Device.
  • a focusing faceted optic of these embodiments is an optic in which the microfacets approximate a one-dimensional (also known as cylindrical or lenticular) Fresnel lens, in that each microfacet of the lens is designed to ref act input light onto substantially the same line in space, parallel to the plane of the lens, thus focusing the light such as done by a one-dimensional Fresnel lens. See Figure 8.
  • Example 6 Defocusing Optical Device.
  • a defocusing faceted optic of these embodiments is an optic in which the microfacets approximate a Fresnel lens with negative focal length, in that each microfacet of the lens is designed to refract input light away from the normal central axis of the lens, forming a ray which corresponds to a virtual source on the other side of the lens, defocusing the light such as done by a negative focal length Fresnel lens. See Figure 9.
  • Example 7 Focusing with beam tilt.
  • a focusing micro faceted optic wherein the microfacets approximate a Fresnel lens such as in example 3 above, except that each facet has an additional amount of constant tilt added.
  • This lens focuses a collimated input beam substantially onto a single point, which is shifted by the included additional amount of constant tilt to be beside the optical axis of collimated input light. See Figure 10.
  • Example 8 Focusing with beam randomization.
  • a focusing microfaceted optic wherein the microfacets approximate a Fresnel lens such as in example 3 above, except that each facet has an additional amount of tilt added according to a desired random distribution. This lens focuses a collimated input beam onto not a single point, but onto a desired shape centered at a desired point in space. See Figure 11.
  • Example 9 Hybrid focusing optic.
  • two focusing microfaceted optics are combined, such that the desired output distribution is the combination of the two input distributions.
  • the hybrid microfaceted diffuser comprises equally-spaced square microfacets.
  • Microfacets are divided into two groups in alternating microfacets, checkerboard-style. In the first group, the microfacets approximate a first Fresnel lens with a given position of its center, such that an input beam is substantially focused to a first given point in space. In the second group of microfacets, the microfacets approximate a second Fresnel lens with a second given position of its center, such that an input beam is substantially focused to a second given point in space.
  • the input beam is substantially focused into two determined points in space.
  • the same two focusing faceted optics are combined, but in alternating rows, instead of checkerboard-style, with similar result. See Figure 12.
  • Example 10 Hybrid optics with superimposed diffusion patterns.
  • a hybrid faceted optic of these embodiments comprises a faceted optic from any of the above examples wherein a micro-lens diffuser, diffr active optical element and/or a pseudo-random surface diffuser is superimposed by addition and/or multiplication.
  • a focusing faceted diffuser approximates a Fresnel lens, and additionally facets have an added randomized tilt, and in addition, a pseudo-random surface diffuser is superimposed.
  • a collimated input beam is focused toward not a single point in space (as in the Fresnel lens case) but to an area in space that is broadened by the additional randomized tilt applied to the facets, and further broadened by the effect of the superimposed pseudo-random surface diffuser.
  • Example 11 Beam diverter with superimposed diffusion patterns.
  • all facets have, for example, a 20 degree tilt from the plane of the optic in substantially the same direction, and have a pseudo-random surface diffuser is superimposed, shown cross-sectionally in Figure 3.
  • This optic bends a collimated input beam a beam to a new axis at a given angle from the input axis, and additionally diffuses the light into a desired angular distribution around that axis. See Figure 13.
  • Example 12 Optical device with aesthetic patterns.
  • An optic is divided into regions that are large enough to be visible to the unaided eye (for example, 0.5mm to tens or hundreds of mm).
  • the regions are equally-sized equilateral triangles in a close-packed configuration.
  • the microfacets comprise a "Beamsplitter with randomization" according to the above Example 3.
  • Each of these regions has facets oriented at, for example, a 10 degree angle from the optical axis normal to the optical device.
  • Each of these regions has a different azimuthal angle from an arbitrarily-chosen zero-azimuth angle in the plane of the optic.
  • Each region has some degree of additional angle randomization according to a desired distribution.
  • the ensemble of regions with their light distributions is chosen to provide a desired average effect, such that a collimated beam of sufficient size to cover an exemplary group of regions will produce a desired output distribution, such as a disc in the far field.
  • a desired output distribution such as a disc in the far field.
  • first and second are used herein to describe various regions, layers and/or sections, these regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one region, layer or section from another region, layer or section. Thus, a first region, layer or section discussed above could be termed a second region, layer or section, and similarly, a second region, layer or section could be termed a first region, layer or section without departing from the teachings of the present invention. Like numbers refer to like elements throughout.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Optical Elements Other Than Lenses (AREA)

Abstract

Divers modes de réalisation décrits ici se rapportent de façon générale à des dispositifs de mise en forme de faisceau optique constitués de matrices de facettes, autrement dit d'éléments réfractifs discrets sur la surface d'un substrat transmissif ou semi-transmissif. Ces facettes peuvent être considérées comme des microfacettes si les facettes individuelles à l'intérieur d'une matrice de facettes se situent généralement dans une plage inférieure à la plage de l'acuité visuelle humaine normale. Dans un ensemble optique à microfacettes, un élément optique est subdivisé en zones (par exemple des carrés uniformément espacés ou des polygones aléatoires) telles qu'observées par le dessus, la surface au-dessus d'un carré donné ayant une hauteur donnée au-dessus du substrat. La surface a une forme (par exemple plate ou incurvée) et elle est inclinée dans une direction donnée.
PCT/US2011/035095 2010-05-11 2011-05-04 Dispositifs de mise en forme de faisceau optique utilisant des microfacettes Ceased WO2011143015A1 (fr)

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WO2014028652A1 (fr) * 2012-08-14 2014-02-20 Microsoft Corporation Mise en forme d'une lumière d'éclairage pour une caméra de profondeur
WO2014045142A1 (fr) * 2012-09-20 2014-03-27 Koninklijke Philips N.V. Dispositif optique, lentille, dispositif, système et procédé d'éclairage
WO2014045168A1 (fr) * 2012-09-20 2014-03-27 Koninklijke Philips N.V. Dispositif optique, lentille, dispositif d'éclairage, système et procédé associés
WO2014045158A1 (fr) * 2012-09-20 2014-03-27 Koninklijke Philips N.V. Dispositif optique, lentille, et dispositif, système et procédé d'éclairage
EP2898257A1 (fr) * 2012-09-20 2015-07-29 Koninklijke Philips N.V. Dispositif d'éclairage, lentille, système et procédé associés
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JP2019126963A (ja) * 2018-01-24 2019-08-01 凸版印刷株式会社 表示デバイス
WO2020020019A1 (fr) * 2018-07-27 2020-01-30 (Cnbm) Bengbu Design & Research Institute For Glass Industry Co., Ltd Module solaire avec plaque de couverture à motifs et couche d'interférence optique
CN110914721A (zh) * 2017-07-12 2020-03-24 3M创新有限公司 带小面的微结构化表面
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US11808956B2 (en) 2019-07-31 2023-11-07 Lumenco, Llc Diffuser combining a multi-faceted surface and a lens-covered surface to provide specific light distributions
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JP2015531897A (ja) * 2012-09-20 2015-11-05 コーニンクレッカ フィリップス エヌ ヴェＫｏｎｉｎｋｌｉｊｋｅ Ｐｈｉｌｉｐｓ Ｎ．Ｖ． 光学装置、レンズ、照明装置、システム及び方法
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WO2014045158A1 (fr) * 2012-09-20 2014-03-27 Koninklijke Philips N.V. Dispositif optique, lentille, et dispositif, système et procédé d'éclairage
EP2898257A1 (fr) * 2012-09-20 2015-07-29 Koninklijke Philips N.V. Dispositif d'éclairage, lentille, système et procédé associés
JP2015534222A (ja) * 2012-09-20 2015-11-26 コーニンクレッカ フィリップス エヌ ヴェＫｏｎｉｎｋｌｉｊｋｅ Ｐｈｉｌｉｐｓ Ｎ．Ｖ． 照明装置、レンズ、システム及び方法
JP2015535950A (ja) * 2012-09-20 2015-12-17 コーニンクレッカ フィリップス エヌ ヴェＫｏｎｉｎｋｌｉｊｋｅ Ｐｈｉｌｉｐｓ Ｎ．Ｖ． 光学装置、レンズ、照明装置、システム及び方法
WO2014045168A1 (fr) * 2012-09-20 2014-03-27 Koninklijke Philips N.V. Dispositif optique, lentille, dispositif d'éclairage, système et procédé associés
US9719655B2 (en) 2012-09-20 2017-08-01 Philips Lighting Holding B.V. Optical device with micro sized facets, lens, lighting device, system and method having the same
CN104641168B (zh) * 2012-09-20 2018-11-13 飞利浦灯具控股公司 照明设备、透镜、系统和方法
WO2014045142A1 (fr) * 2012-09-20 2014-03-27 Koninklijke Philips N.V. Dispositif optique, lentille, dispositif, système et procédé d'éclairage
CN104641167B (zh) * 2012-09-20 2019-10-18 飞利浦灯具控股公司 光学设备、透镜、照明设备、系统和方法
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JP2019126963A (ja) * 2018-01-24 2019-08-01 凸版印刷株式会社 表示デバイス
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WO2020020019A1 (fr) * 2018-07-27 2020-01-30 (Cnbm) Bengbu Design & Research Institute For Glass Industry Co., Ltd Module solaire avec plaque de couverture à motifs et couche d'interférence optique
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US12334860B2 (en) 2018-07-27 2025-06-17 Cnbm Research Institute For Advanced Glass Materials Group Co., Ltd. Facade elements with patterned cover plate and optical interference layer
US12464853B2 (en) 2018-07-27 2025-11-04 Cnbm Research Institute For Advanced Glass Materials Group Co., Ltd. Solar module with patterned cover plate and optical interference layer
WO2021021411A1 (fr) * 2019-07-31 2021-02-04 Lumenco, Llc Diffuseur à facettes multiples fournissant des répartitions lumineuses spécifiques à partir d'une source de lumière
US10914875B1 (en) 2019-07-31 2021-02-09 Lumenco, Llc Multi-faceted diffuser providing specific light distributions from a light source
CN114286954A (zh) * 2019-07-31 2022-04-05 路曼科有限公司 提供来自光源的特定光分布的多小面漫射器
US11808956B2 (en) 2019-07-31 2023-11-07 Lumenco, Llc Diffuser combining a multi-faceted surface and a lens-covered surface to provide specific light distributions
US11835741B2 (en) 2019-07-31 2023-12-05 Lumenco, Llc Multi-faceted diffuser providing specific light distributions from a light source
EP4004610A4 (fr) * 2019-07-31 2024-02-07 Lumenco, LLC Diffuseur à facettes multiples fournissant des répartitions lumineuses spécifiques à partir d'une source de lumière
US12210172B2 (en) 2019-07-31 2025-01-28 Lumenco, Llc Diffuser combining a multi-faceted surface and a lens-covered surface to provide specific light distributions

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