Köhler integrating lenslet arrays can provide collimated, uniform, and color mixed beams from an array of sources of arbitrary color. The integration can be achieved with two lenslet arrays after collimation, with lenslet arrays embedded into certain collimators or close to the sources before collimation with a double sided lenslet shell. The degree of color mixing of the different approaches can be less than ideal. We have investigated the main mixing degradation mechanisms both in the near and in the far field and quantified them for certain source and architecture combinations. From this analysis we can derive simple design rules for successful color mixing.
Optical design requires accurate characterization of light sources for computer aided design (CAD) software. Various methods have been used to model sources, from accurate physical models to measurement of light output. It has become common practice for designers to include measured source data for design simulations. Typically, a measured source will contain rays which sample the output distribution of the source. The ray data must then be exported to various formats suitable for import into optical analysis or design software. Source manufacturers are also making measurements of their products and supplying CAD models along with ray data sets for designers. The increasing availability of data has been beneficial to the design community but has caused a large expansion in storage needs for the source manufacturers since each software program uses a unique format to describe the source distribution. In 2012, the Illuminating Engineering Society (IES) formed a working group to understand the data requirements for ray data and recommend a standard file format. The working group included representatives from software companies supplying the analysis and design tools, source measurement companies providing metrology, source manufacturers creating the data and users from the design community. Within one year the working group proposed a file format which was recently approved by the IES for publication as TM-25. This paper will discuss the process used to define the proposed format, highlight some of the significant decisions leading to the format and list the data to be included in the first version of the standard.
Collimators for spot LED lamps have to meet stringent requirements like high efficiency and on axis intensity, good
beam control, color and position mixing, low cost, and a low aspect ratio to enable compact devices with sufficient space
for drive electronics and cooling. To meet such requirements only very few optical architectures are routinely used,
namely Fresnel lenses, parabolic or aspheric reflectors, and TIR lenses, often called Photon funnels.
Collimators make use of five different deflection mechanisms, namely refraction, total internal reflection, metallic or
metallic like reflection, scattering, and diffraction. Light, when travelling through a given collimator type undergoes a
characteristic sequence of deflections but many collimators exhibit different paths where portions of the light undergo
different deflection sequences.
In this paper we illustrate the design space for collimators for a single Lambertian LED or LED array source located on
the optical axis under the boundary conditions of low aspect ratio, rotational symmetry and minimum Etendue dilution.
All possible optical architectures with up to 4 deflections are mapped out in terms of paths of distinct deflection
sequences. The important characteristics of deflection sequences are investigated. For a given collimator, the deflection
paths involved allows predicting efficiency, on axis intensity, and compactness. Additionally the beam shape as well as
position and color mixing capabilities can be estimated from the influence of the deflection sequence on pinhole image
rotation and distortion. Such results are compared to raytrace results for some designed collimators of standard and
uncommon architectures.
High flux and high CRI may be achieved by combining different chips and/or phosphors. This, however, results in
inhomogeneous sources that, when combined with collimating optics, typically produce patterns with undesired artifacts.
These may be a combination of spatial, angular or color non-uniformities. In order to avoid these effects, there is a need
to mix the light source, both spatially and angularly. Diffusers can achieve this effect, but they also increase the etendue
(and reduce the brightness) of the resulting source, leading to optical systems of increased size and wider emission
angles.
The shell mixer is an optic comprised of many lenses on a shell covering the source. These lenses perform Kohler
integration to mix the emitted light, both spatially and angularly. Placing it on top of a multi-chip Lambertian light
source, the result is a highly homogeneous virtual source (i.e, spatially and angularly mixed), also Lambertian, which is
located in the same position with essentially the same size (so the average brightness is not increased). This virtual light
source can then be collimated using another optic, resulting in a homogeneous pattern without color separation.
Experimental measurements have shown optical efficiency of the shell of 94%, and highly homogeneous angular
intensity distribution of collimated beams, in good agreement with the ray-tracing simulations.
In SSL general illumination, there is a clear trend to high flux packages with higher efficiency and higher CRI addressed with the use of multiple color chips and phosphors. However, such light sources require the optics provide color mixing, both in the near-field and far-field. This design problem is specially challenging for collimated luminaries, in which diffusers (which dramatically reduce the brightness) cannot be applied without enlarging the exit aperture too much. In this work we present first injection molded prototypes of a novel primary shell-shaped optics that have microlenses on both sides to provide Köhler integration. This shell is design so when it is placed on top of an inhomogeneous multichip Lambertian LED, creates a highly homogeneous virtual source (i.e, spatially and angularly mixed), also Lambertian, which is located in the same position with only small increment of the size (about 10-20%, so the average brightness is similar to the brightness of the source). This shell-mixer device is very versatile and permits now to use a lens or a reflector secondary optics to collimate the light as desired, without color separation effects. Experimental measurements have shown optical efficiency of the shell of 95%, and highly homogeneous angular intensity distribution of collimated beams, in good agreement with the ray-tracing simulations.
Concentration Photovoltaics (CPV) is one of the most promising areas for competitive solar electricity production. This
promise relies upon the use of high-efficiency triple-junction solar cells (which already have proven efficiencies over
41%) and upon advanced optics designs, which allow for high concentration concurrent with high manufacturing
tolerances, both key elements for low cost mass production.
In this paper we will present the progress in the development of the most advanced CPV optical designs at present. These
are based on free-form optics using Köhler homogenization. The degree of freedom of using free-forms allows the
introduction of multiple functionalities in a few optical elements, which provide the required concentration with high
tolerance and excellent light homogenization.
Different families are presented. The first group uses a Fresnel lens as a primary optic (called the FK concentrator and
the F-RXI concentrator) and a second group using mirrors as primaries (the XR and the XXR). How they compare
among them and also with classical designs will be discussed. The FK is in the process of being brought to market and
has already experimentally proven module electrical (DC) efficiencies over 30% (equivalent to over 32% with correction
to Tcell=25ºC) with no AR coatings at a concentration of 625x with high tolerance angle (over ±1.2º).
The Boeing Company Phantom Works has
developed three different prototype photovoltaic
concentrator arrays since March 2007. Identified as
Prototype A, B and C, the experimentally proven technical
characteristics of each design are presented. The
concentrator designs utilize a 1 cm2 multi-junction solar
cell assembly in conjunction with SMS non-imaging optical
designs [1, 2] manufactured with low-cost mass-producible
technologies. Prototype A is an on-axis XR optical
concentrator with a 733x geometrical concentration
demonstrating a ± 1.73° acceptance angle and 23.7%
conversion efficiency. Prototype B is an off-axis free-form
XR optical concentrator with a 810x geometrical
concentration demonstrating a ± 1.32° acceptance angle
and 25.3% conversion efficiency. Prototype C is the most
recent off-axis free-form XR optical concentrator with a
801x geometrical concentration and a theoretical ±1.80°
acceptance angle demonstrating a conversion efficiency
greater than 27.0%. Prototype C is also the basis for the
Boeing Proof of Design (POD) module, demonstrating an
acceptance angle of ±1.48° and a conversion efficiency of
29.4% (as of May 8, 2009). Manufacturability has been
paramount during the design process, resulting in high
performance concentrating photovoltaic modules using
production quality components.
The Köhler illumination concept was originally invented to achieve uniform illumination in microscopy1. Köhler
integrators can also be formed by arrays of lenticulations that can be any combination of reflective and/or refractive
surfaces, organized in corresponding pairs. Arrays of integrating facets can be arranged not only on flat surfaces but on
rotationally symmetric and even freeform surfaces6. Currently flat lenslet arrays are widely applied as homogenizing
optics2 for lithography, machine vision illumination, and projection.
Adding Köhler facets onto already designed surfaces can improve the optical system performance, while respecting its
original function. In general, the optics output can be made somewhat independent of the source characteristics, although
at the expense of a slight ètendue dilution or efficiency losses.
This work revises the Köhler concept and its application to different kind of optics, ranging from photovoltaic
concentrators to automotive LED headlights. In the former, irradiance peaks on the solar cell can be avoided, while
preserving high aiming tolerance (acceptance) of the solar concentrator. In the latter, LEDs drawbacks like large source
image sizes, source misalignments, ill defined source edges, and low source radiance can be compensated.
The performance of the XR solar concentrator, using a high efficiency multi-junction solar cell developed
recently by Spectrolab, is presented. The XR concentrator is an ultra-compact Nonimaging optical design
composed of a primary mirror and a secondary lens, which can perform close to the thermodynamic limit
of concentration (maximum acceptance angle for a given geometrical concentration). The expected
acceptance angle of the concentrator is about ±2 deg for a geometrical concentration of 800x (a Fresnel
lens and secondary system typically has ±0.6 deg of acceptance for 300x of geometrical concentration).
This concentrator is optimized to improve the irradiance distribution on the solar cell keeping it under the
maximum values the cell can accept.
The XR concentrator has high manufacturing tolerance to errors and can be produced using low cost
manufacturing techniques. The XR is designed with the Simultaneous Multiple Surface (SMS) design
method of Nonimaging Optics. Its application to high-concentration photovoltaics is now being
developed in a consortium led by The Boeing Company, which has recently been awarded a project by
the US DOE in the framework of the Solar America Initiative.
The performance of the XR solar concentrator, using a high efficiency multi-junction solar cell developed
recently by Spectrolab, is presented. The XR concentrator is an ultra-compact Nonimaging optical design
composed of a primary mirror and a secondary lens, which can perform close to the thermodynamic limit
of concentration (maximum acceptance angle for a given geometrical concentration). The expected
acceptance angle of the concentrator is about ±2 deg for a geometrical concentration of 800x (a Fresnel
lens and secondary system typically has ±0.6 deg of acceptance for 300x of geometrical concentration).
This concentrator is optimized to improve the irradiance distribution on the solar cell keeping it under the
maximum values the cell can accept.
The XR concentrator has high manufacturing tolerance to errors and can be produced using low cost
manufacturing techniques. The XR is designed with the Simultaneous Multiple Surface (SMS) design
method of Nonimaging Optics. Its application to high-concentration photovoltaics is now being
developed in a consortium led by The Boeing Company, which has recently been awarded a project by
the US DOE in the framework of the Solar America Initiative.
In LED projection displays, total lumen-output equals the source-luminance multiplied by the etendue of the spatial light modulator, the latter being a bottleneck that cannot be overcome. In addition, the luminance of existing LED sources is still too low for many projection-display applications. This has spurred research into finding ways to increase their brightness without a significant loss in efficacy. Current techniques to increase LED source-luminance include: (a) a photonic lattice atop the LED, which partially collimates the exiting light though lowering the efficacy (by Luminus), (b) recycling the LED light through the chip via TIR on a flat cover rather than a dome (several LED suppliers), and (c) a light-confining box with an exit aperture smaller than the chip (GoldenEye). All the above mentioned existing approaches achieve an increase in luminance for the LEDs at the expense of a considerable drop in efficacy. In this paper we present four novel and different ways (patent pending) to considerably enhance LED luminance and offering the possibility of having relatively high efficacy.
Light from several LEDs or other light sources may be combined using light guides shaped as manifolds. These manifolds are composed of smaller elements such as CPCs, angle transformers, angle rotators, light shifters, light guides or others. Although some components, such as CPCs or angle transformers, have all-optical surfaces, other devices may be designed with non-optical surfaces. These may be used to place the injection gate in the case of injection-molded optics, to attach handles or holders and other non-optical components to the manifold without affecting the optical performance. Also, in some of these devices, the geometry can be changed by simple changes in the position of the curves that compose the optic profile. These optics may be applied in efficiently combining light from several LEDs into one single large source, changing the aspect ratio of a light source or in distributing light from one (or more) sources onto several targets.
Brightness enhancement of backlighting for displays is typically achieved via crossed micro prismatic films that are introduced between a backlight unit and a transmissive (LCD) display. Prismatic films let pass light only into a restricted angular range, while, in conjunction with other reflective elements below the backlight, all other light is recycled within the backlight unit, thereby increasing the backlight luminance. This design offers no free parameters to influence the resulting light distribution and suffers from insufficient stray light control. A novel strategy of light recycling is introduced, using a microlens array in conjunction with a hole array in a reflective surface, that can provide higher luminance, superior stray light control, and can be designed to meet almost any desired emission pattern. Similar strategies can be applied to mix light from different colored LEDs being mounted upside down to shine into a backlight unit.
A novel LED light extraction and mixing optic and two free form SMS surfaces are employed in a high efficiency projection optic. By combining the light of several high brightness LEDs with a single optical element, an ultrabright light source can be formed, whose shape and emission characteristics can be adapted to almost many kinds of illumination problems. A LED combiner forms a virtual source that is tailored for application. The illuminance distribution of this virtual source facilitates the generation of the desired intensity pattern by projecting it into the far field. The projection is accomplished by one refractive and one reflective freeform surface calculated by the 3D SMS method. The method is demonstrated for an LED automotive headlamp. A high quality intensity pattern shape and a very sharp cutoff are created tolerant to LED to optics misalignment and illuminance variations across the LED surface. A low and high beam design with more than 75% total optical efficiency have been achieved.
A new design method of free-form Kohler integrator array optics is presented. Only few solutions to the integrator design problem are known, which apply for specific and simple source and targets (for instance, flat integrator lenslet arrays when the source and target are squares located at infinity). The method presented here find more general solutions and the resulting optics is formed by two arrays of free-form optical surfaces (which can be either reflective of refractive). The contour curves of the array units are also obtained from the design.
Two types of Kholer integrators will be defined, depending if they integrate only along one direction across the source (one-directional integrators) or in the two directions (two-directional integrators).
This design method has been applied for an ultra-compact high efficiency LED low beam head lamp producing a legal pattern independently of the chip luminance variation and permitting LED position tolerances of ±200 microns. The ray tracing proves that the high gradient (0.32) and its vertical position in the pattern remain invariable when chip is moved.
One of the most challenging applications for high brightness LEDs is in automotive headlights. Optical designs for a low or high beam headlights are plagued by the low flux and luminance of LEDs compared to HID or incandescent sources, by mechanical chip placement tolerances and by color and flux variations between different LEDs. Furthermore the creation of a sharp cutoff is very difficult without baffles or other lossy devices.
We present a novel LED headlight design that addresses all of the above problems by mixing the light of several LEDs first in a tailored light guide called LED combiner, thereby reducing color and flux variations between different LEDs and illuminance and color variations across the LED surfaces. The LED combiner forms a virtual source tailored to the application. The illuminance distribution of this virtual source facilitates the generation of the desired intensity pattern by projecting it into the far field. The projection is accomplished by one refractive and one reflective freeform surface calculated by the 3D SMS method. A high quality intensity pattern shape and a very sharp cutoff are created tolerant to LED to optics misalignment and illuminance variations across the LED surface.
A low and high beam design with more than 75% total optical efficiency (without cover lens) and performance as latest HID headlights have been achieved. Furthermore it is shown that the architecture has similar tolerance requirements as conventional mass produced headlights.
A novel backlight concept suitable for LED's has been designed using the flow-line design method, which allows controlling both the illumination uniformity and light extraction without scattering the light. This contrasts with conventional LED backlight optical designs, which are based on the use of a light guide with Lambertian scattering features that break the guidance and extract the light. Since most of Lambertian scattered light is re-guided, the average ray path in conventional backlights is long and multiple bounces are needed, which may lead to low efficiency. On the other hand, the new design presented here is not only efficient but also provide a relatively high collimation of the output beam (an output beam within a 10 degrees half-angle cone, with total theoretical efficiency over 80% including Fresnel and absorption losses). Wider beams can be controlled by design or obtained by adding a holographic diffuser at the exit. The new design offers other very interesting practical features: it can be very thin, can be made transparent (which widens its applications, including front lighting), can mix the colors from several LED's or recover reflected polarization for LCD illumination.
The Simultaneous Multiple Surfaces design method (SMS), proprietary technology of Light Prescription Innovators (LPI), was developed in the early 1990's as a two dimensional method. The first embodiments had either linear or rotational symmetry and found applications in photovoltaic concentrators, illumination optics and optical communications. SMS designed devices perform close to the thermodynamic limit and are compact and simple; features that are especially beneficial in applications with today's high brightness LEDs. The method was extended to 3D "free form" geometries in 1999 that perfectly couple two incoming with two outgoing wavefronts. SMS 3D controls the light emitted by an extended light source much better than single free form surface designs, while reaching very high efficiencies. This has enabled the SMS method to be applied to automotive head lamps, one of the toughest lighting tasks in any application, where high efficiency and small size are required. This article will briefly review the characteristics of both the 2D and 3D methods and will present novel optical solutions that have been developed and manufactured to meet real world problems. These include various ultra compact LED collimators, solar concentrators and highly efficient LED low and high beam headlamp designs.
The simultaneous multiple surface (SMS) method in 3-D geometry is presented. Given two orthotomic input ray bundles and another two orthotomic output ray bundles, the method provides an optical system with two free-form surfaces that deflects the rays of the input bundles into the rays of the corresponding output bundles and vice versa. In nonimaging applications, the method enables controlling the light emitted by an extended light source much better than single free-form-surface designs, and also enables the optics contour to be shaped without efficiency losses. The method is also expected to find applications in imaging optics.
The simultaneous multiple surface (SMS) method is used to design air-gap RXI-type lenses, which efficiently produce a very narrow beam from high-powered LEDs. These designs are compact, with both front surface and reflecting back surface calculated simultaneously from periphery inward, as profiles of circular symmetry, via applying the edge-ray principle to the chip geometry. The light source is a Lambertian-glowing cube 1.2 mm square and 0.15 mm high, as viewed through its clear (n = 1.54) package dome, with emission down to 95 deg from the symmetry axis. A given exit-aperture diameter defines a minimum, étendue-limited collimation angle, = arc sin (chip-width/diameter). At the center of the back surface there is a cavity surrounding the source. The front surface reflects that source flux to the back surface, which reflects it back forward again, accomplishing the optical folding thereby. The back surface is shaped so that the light it reflects forward will be refracted out the front surface to become the collimated output beam.
The Simultaneous Multiple Surface (SMS) method in 3D geometry is presented. Giving two orthotomic input ray bundles and other two orthotomic output ray bundles, the method provides an optical system with two free-form surfaces that deflects the rays of the input bundles into the rays of the corresponding output bundles and vice versa. In nonimaging applications, the method allows controlling the light emitted by an extended light source much better than single free-form surfaces designs, and also enables the optics contour to be shaped without efficiency losses. The method is expected to find also applications in imaging optics
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