SYSTEM AND METHOD FOR PROVIDING A UNIFORM BACKLIGHT

Abstract

An illumination system includes an illumination source such as an array of LED's over which is provided a diffuser. The illumination source provides light which, because of light refraction, radiates generally uniformly from edge to edge of the diffuser. The diffuser may be a planar flat piece of may include a hollow, cup like structure formed by a frame with a cover. The illumination system may be scaled up to provide multiple such illumination devices side by side to provide a greater area or strength of illumination. Multiple systems may utilize multiple diffusers or a single diffuser covering multiple illumination sources. The illumination source may be mounted to a backplate or heatsink which is larger than the illumination source to facilitate the addition of further electronic circuitry and or mounting capabilities.

Description

TECHNICAL FIELD

The present invention relates to illumination and lighting and more particularly, relates to a system and method for providing a illumination modules which can be scaled up in size and which provide uniform edge to edge illumination.

BACKGROUND INFORMATION

There are many uses for illumination systems. For example, it is necessary to use a source of illumination to provide automated product inspection. In such inspection systems, the inspection camera and software may be the same while the customer may want to change the product to be inspected. In one application, the product may be smaller than in another and accordingly, a smaller illumination source may work well for the smaller product while a larger illumination source will be required for the larger product.

In the past, a new illumination system had to be designed for each product to be inspected thus making it difficult for a customer to scale up or down in illumination system to work with an existing inspection system. Accordingly, there is a need for an illumination system which can be scaled up or down and which provides uniform and consistent illumination from edge to edge of the illumination system.

SUMMARY

The present invention features an illumination system providing generally uniform illumination from edge to edge. The illumination system comprises at least one illumination device including a source of illumination and a diffuser, disposed proximate the source of illumination and between the source of illumination and an object to be illuminated. The diffuser is made of a light transmissive material and includes a generally planar surface and is disposed a spaced distance from the source of illumination. The diffuser is configured for radiating light from the source of illumination through generally at least the entire planar surface of the diffuser by means of internal light refraction.

The source of illumination may be a single illumination element or multiple illumination element. The illumination elements may include LED elements. The LED elements are typically mounted together on one module or circuit board like structure.

In the preferred embodiment, the diffuser comprises a frame including a left side, right side, top side and bottom side, the frame having a height. The diffuser includes a generally planar cover extending between all the sides and having a length and a width. The cover disposed a spaced distance away from the source of illumination corresponding to the height of the frame. The sides and cover of the diffuser form a hollow cup like structure for radiating light from the source of illumination through generally at least the entire planar surface of the cover. The diffuser is typically the same size as the source of illumination.

The illumination system may include a plurality of the illumination devices mounted edge to edge to create a single larger illumination system of generally uniform illumination.

The source of illumination may include a back plate to which the source of illumination is mounted. The backplate has a width and a length which is generally the same as a length and width as the source of illumination. The backplate is typically larger than the source of illumination along at least one of the length and width of the backplate.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will be better understood by reading the following detailed description, taken together with the drawings wherein:

FIG. 1 is a schematic view of an illumination device in accordance with the present invention;

FIG. 2 is an exploded view of the illumination device of FIG. 1 in accordance with the present invention;

FIG. 3 is a schematic view of a diffuser in accordance with the teachings of the present invention without the cover in place;

FIG. 4 is a partially assembled in view of an illumination system having multiple nation devices in accordance with the teachings of the present invention;

FIG. 5 is a schematic front view of the fully assembled illumination system of FIG. 4 having multiple illumination devices;

FIG. 6 is an exploded view of an illumination system having multiple illumination devices with one diffuser;

FIG. 7 is an assembled view of the illumination device of FIG. 6;

FIG. 8 is an exploded view of an illumination system having an illumination source mounted on a backing plate which is larger than the diffuser;

FIG. 9 is an assembled view of the illumination device of FIG. 8;

FIG. 10 is an exploded view of an illumination system having multiple illumination sources mounted on a backing plate which is larger than the size of multiple diffusers;

FIG. 11 is an assembled view of the illumination device of FIG. 10;

FIG. 12 is an exploded view of an illumination system having multiple illumination sources mounted on a backing plate which is larger than the size of a single diffuser; and

FIG. 13 is an assembled view of the illumination device of FIG. 12.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An illumination system 10, FIG. 1, in accordance with the present invention, includes an illumination source 12, figure to mounted to a mounting plate or heatsink 14 and over which is mounted a diffuser 16. In the preferred embodiment, the illumination source 12 includes a plurality of LED's mounted on a printed circuit board. The LEDs may be of any color, combination of colors and/or strength required to illuminate an object of interest. The mounting plate or heatsink 14 serves to provide a generally rigid mounting area for the light source 12 and also provides for heat dissipation from the light source.

In a first embodiment, diffuser 16 includes at least a flat piece of material 18 which is placed in front of the illumination source 12 and serves to defuse or spread the light evenly from each of the individual LEDs or other illumination device which makes up the illumination source 12. In the preferred embodiment, diffuser 16 includes a cover 18 and four sides 20. The sides 20 are arranged to form a frame 22, FIG. 3, defining a hollow central region 24 which fits over the light source 12. Although frame 22 is shown as a square frame, this is not a limitation of the present invention as any shape is contemplated. In the preferred embodiment, the shape of the diffuser frame 22 will generally correspond to the shape and size of the illumination source 12.

Diffuser 16 is made from a light transmissive material such as acrylic. In one embodiment, cover 18 snaps on or is other wise fastened in place over the frame 22 to form a cup like structure which serves to generally uniformly provide illumination through the cover 18 from edge to edge of the diffuser 16 using internal refraction of the light within the diffuser.

Although the illumination system of the present invention may be used as a single stand-alone illumination device, one feature the present invention is the ability to scale up the illumination system by providing a plurality of illumination devices 10, FIG. 4, as one illumination system. As shown, multiple illumination sources 12 and be placed on a backing plate 14 to form a larger and therefore more powerful light source. An additional feature of the present invention is the ability to substitute multiple diffusers 16, FIGS. 4 and 5 with a single larger diffuser 16a, FIGS. 6 and 7 which increases the uniformity of the light by eliminating seams between multiple diffusers.

An additional feature of the present invention is the ability to provide an illumination source 12a and/or mounting plate 14a FIG. 8 with an extended region 26, FIG. 9 which extends beyond the length and width of the diffuser 16. Such an extended length allows for the mounting of additional electronic circuitry or for mounting the illumination system to an additional structure. This feature can also be used with multiple illumination sources and multiple diffusers FIGS. 10 and 11 as well as multiple illumination sources and a single diffuser FIGS. 12 and 13. In addition, as will be apparent to those skilled in the art, the extended region 26 may be provided on one or more sides of the illumination system.

Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the following claims.

Claims

1. An illumination system providing generally uniform illumination from edge to edge, said illumination system comprising: at least one illumination device, said at least one illumination device comprising: a source of illumination; and a diffuser, disposed proximate said source of illumination and between said source of illumination and an object to be illuminated, said diffuser including a generally planar surface and disposed a spaced distance from said source of illumination, said diffuser configured for radiating light from said source of illumination through generally at least said entire planar surface of said diffuser.

2. The illumination system of claim 1, wherein said diffuser comprises a frame including a left side, right side, top side and bottom side, said frame having a height, said diffuser including a generally planar cover extending between all said sides and having a length and a width, said cover disposed a spaced distance away from said source of illumination corresponding to said height of said frame, said sides and cover of said diffuser forming a hollow cup like structure for radiating light from said source of illumination through generally at least said entire planar surface of said cover.

3. The illumination system of claim 1, wherein said illumination system includes a plurality of said illumination devices mounted edge to edge to create a single larger illumination system of generally uniform illumination.

4. The illumination system of claim 1, wherein said diffuser is generally the same size as said source of illumination.

5. Illumination system of claim 1, wherein said source of illumination includes a back plate to which said source of illumination is mounted, and wherein said backplate has a width and a length which is generally the same as a length and width as said source of illumination.

6. The illumination system of claim 5, wherein said backplate is larger than said source of illumination along at least one of said length and width of said backplate.

7. The illumination system of claim 1, wherein said source of illumination is a single illumination element.

8. The illumination system of claim 1, wherein said source of illumination is a multiple illumination element.

9. The illumination system of claim 8, wherein said multiple illumination elements include a plurality of LED elements.

10. The illumination system of claim 9, wherein said plurality of LED elements are mounted together as an LED module.

11. The illumination system of claim 1, wherein said diffuser is made of a light transmissive material.

12. A method of illuminating an object, said method comprising the acts of: determining an amount of illumination required for illuminating an object; and selecting one or more illumination devices for generally uniformly illuminating said object, each of said one or more illumination devices comprising: a source of illumination; and a diffuser, disposed proximate said source of illumination and between said source of illumination and an object to be illuminated, said diffuser including a generally planar surface and disposed a spaced distance from said source of illumination, said diffuser configured for radiating light from said source of illumination through generally at least said entire planar surface of said diffuser.

13. The method of claim 12, wherein each said diffuser comprises a frame including a left side, right side, top side and bottom side, said frame having a height, said diffuser including a generally planar cover extending between all said sides and having a length and a width, said cover disposed a spaced distance away from said source of illumination corresponding to said height of said frame, said sides and cover of said diffuser forming a hollow cup like structure for radiating light from said source of illumination through generally at least said entire planar surface of said cover.

14. The method of claim 12, wherein said act of selecting one or more illumination devices includes selecting a plurality of said illumination devices and further including the act of placing each of said plurality of illumination devices edge to edge, proximate and generally in contact with one another, to provide generally uniform illumination of said object.