The present invention relates generally to automotive light modules having near field lenses collecting and directing light from sources such as light emitting diodes.
Light emitting diodes (LED's) are fast becoming the preferable light source for automotive lighting applications, as they consume less power but provide light output which is acceptable for such applications. Near field lenses (NFL's) are used to collect as well as to collimate the light from a LED source, and generally provide high light collection efficiency (typically 70-90%), but the output beam size for a given source depends on the size of the lens. The larger the lens size (i.e. the larger the starting focal length of the lens), the smaller of the output beam size and the higher the peak intensity. However, manufacturing larger lenses poses complex molding issues and takes higher molding cycle time, thus requiring expensive molding tools and processes.
Accordingly, there exists a need to provide a lighting assembly having a lens that provides the output beam size and peak intensity for automotive applications, while reducing the size of the NFL.
One embodiment of the present invention provides a near field lens which reduces the size of the near field lens. Generally, the near field lens includes a main body of light transmitting material and a pocket formed in the main body for receiving light from the light source. The main body defines an outer longitudinally facing surface and an outer laterally facing surface. The outer longitudinally facing surface is structured to redirect light along the lateral axis towards the outer laterally facing surface. The pocket is defined by an inner longitudinally facing surface and an inner laterally facing surface. The inner longitudinally facing surface is curved towards the pocket.
According to more detailed aspects, the lens collimates light longitudinally relative to the longitudinal axis. The lens also collimates light vertically relative to a vertical axis (the longitudinal, lateral and vertical axes being mutually perpendicular). The inner longitudinally facing surface is structured to refract light towards the outer longitudinally facing surface. The inner longitudinally facing surface is curved between an upstream point and a downstream point, a tangent of the curve at the downstream point being generally parallel to the lateral axis. The inner longitudinally facing surface preferably follows a circular arc. The inner laterally facing surface is also curved towards the pocket and is preferably structured as a lens to longitudinally collimate light from the pocket. The outer laterally facing surface is generally parallel to the longitudinal axis. In one embodiment, the main body includes a central hub which permits some light to pass longitudinally therethrough.
In another embodiment of a NFL constructed in accordance with the teachings of the present invention, the main body includes a first body portion and a second body portion which each direct light along the lateral axis but in opposite directions. The first and second body portions are preferably mirrored about the longitudinal axis. Thus, the first and second body portions each define inner longitudinally facing surface portions which in combination form the inner longitudinally facing surface, and likewise each define inner laterally facing surface portions which in combination form the inner laterally facing surface. As such, the inner longitudinally facing surface has a compound curvature and the inner laterally facing surface has a compound curvature.
In yet another embodiment of a NFL constructed in accordance with the teachings of the present invention, the main body is disc shaped and represents a revolution of the cross-sectional shape about the longitudinal axis. Here, the main body defines a vertical axis mutually perpendicular to the longitudinal and lateral axes, in the main body emits light in both the lateral and vertical directions. That is, light is emitted over 360 degrees relative to the longitudinal axis, and the outer laterally facing surface is annular.
The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings:
Turning now to the figures,
The inner radially facing surface 32 is curved to refract light towards the outer laterally facing surface 24. Specifically, the inner radially facing surface 32 is curved in a manner that permits reduction in the thickness of the NFL 20. The surface 32 is curved between an upstream point 36 and a downstream point 38, and in the depicted embodiment is curved over its entire surface. A tangent 15 to the curvature of the inner radially facing surface 32, taken at the downstream point 38, runs generally parallel to the longitudinal axis 14. By the term generally, it is meant that the tangent 15 and axis 14 are parallel within 1 degree of each other. The inner radially facing surface 32 is preferably curved to follow a circular arc. Further details of the NFL 20 may be found in U.S. patent application Ser. No. 11/252,008 as noted above.
Turning now to
As best seen in
Generally, light from light source 10 enters the pocket 50. A portion of light is refracted by inner laterally facing surfaces 52, 54, and hence longitudinally collimated and vertically collimated and directed laterally downstream through outer laterally facing surfaces 46, 48. The remainder of the light is refracted by inner longitudinally facing surface portions 56, 58 towards the outer longitudinally facing surface portion 62, 64, which in turn collimates and redirects the light laterally along the lateral axis through outer laterally facing surfaces 46, 48.
Accordingly, it will be recognized that the near field lens 40 has a reduced lateral thickness (measured along the lateral axis 16) due to the construction of the inner longitudinally facing surface portions 56, 58, which are preferably constructed in accordance with the teachings of the inner laterally facing surface 32 described above with reference to
Turning now to
Another embodiment of a near field lens 240 constructed in accordance with the teachings of the present invention has been depicted in
Accordingly, it will be recognized by those skilled in the art that the NFL 240 emits light along both the lateral axis 16 as well as the vertical axis 18, and specifically emits light over 360 degrees relative to the longitudinal axis 14. As with the prior embodiment, the NFL 240 permits a reduction in the lateral thickness of the NFL 240, while maintaining a small longitudinal height and providing light distribution and collection well suited for special lighting applications such as automotive functions.
Turning now to
It will be recognized by those skilled in the art that through the unique construction of the near field lens as described above, the size of the NFL can be significantly reduced in the lateral direction without increasing the longitudinal height of the NFL. At the same time, a beam pattern having the size and intensity desired and required for automotive applications is provided. By way of this structure, numerous benefits in cost, weight and manufacturing are achieved.
The foregoing description of various embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Numerous modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
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