Light emitting diode reflector

[0002] This application claims the benefit of U.S. Provisional patent application No. 60/361,140 filed Mar. 1, 2002, hereby incorporated by reference in the entirety.

[0003] 1. Field of the Invention

[0004] The present invention relates to a reflector for collecting and redirecting light from a light source. Specifically, the invention relates to a reflector usable with, for example, a standard light emitting diode (LED) package utilizing an epoxy housing with a top facing lens.

[0005] 2. Description of the Related Art

[0006] The ability to maximize light output from a light source increases energy efficiency and reduces manufacturing cost. By minimizing light losses, i.e. light rays not directed into the desired light pattern, all the light generated by a signal may be used. Maximizing a signals light output in the desired light pattern minimizes the number of and power level required for light emitting devices that would otherwise be needed to overcome light losses previously accepted as a design loss.

[0007] As shown in FIG. 1, standard light emitting diodes utilize an epoxy housing wherein a LED die 1 is located. When current is applied, the die activates and emits light. The light is reflected upward by one of the leads 15 which is in the form of a cup 20. The majority of the light is directed out of the top of the housing 10 through a lens 5 which directs it in a conical distribution pattern with an angle, in a standard LED, of approximately 20 to 30 degrees. FIG. 2 shows a typical light distribution emitted by a light emitting diode. The majority of light is projected forward in the desired direction but a large percentage (40-50%) is directed in other directions and is therefore treated as a design loss in most applications.

[0008] The light distribution shown in FIG. 2, may be categorized into three components. As shown in FIG. 3, the main component of the LED light is directed vertically through the lens 5. However, a second component is not directed into the lens 5 but instead escapes out of the side of the housing 10 at an increased spreading angle to the vertical axis of the housing 10 as shown in FIG. 4. A third component of the light is subject to total internal reflection within the housing from which it exits at an increased angle as shown in FIG. 5.

[0009] Previous reflectors used with LEDs attempted to collect and redirect sideways emitted light but did not account for the light subject to total internal reflection, effectively wasting this component of the LED light output. It is an object of the present invention to provide an energy efficiency maximizing LED reflector which, in addition to redirecting sideways emitted LED light, also redirects the light rays subject to total internal reflection, thereby maximizing light output for an individual or cluster of LEDs.

[0010] The present invention provides a reflector for individual or groups of light emitting devices, for example LEDs. Redirecting light normally escaping through the side of an LED package, the reflector also redirects light that reflects under total internal reflection conditions within the LED housing. A second reflection surface of the reflector is aligned with the increased exit angle of the total internal reflection light component. Because the angle is higher than that of light escaping sideways from the LED housing, the second reflector surface appears as a step back in the first reflection surface and does not degrade the first surface's ability to redirect the sideways escaping light component. Pairing light emitting devices in a shared reflector configuration with a light deflecting pattern on non-reflector surface areas of the reflector creates an oval light pattern with reduced sun phantom properties useful for creating traffic signals according to Institute of Traffic Engineers (ITE) specifications.

[0011] FIG. 1 is a cutaway side view of a typical LED package.

[0012] FIG. 2 is a light ray diagram showing the light emission pattern of a typical LED.

[0013] FIG. 3 is a light ray diagram showing the light component of FIG. 2 that is forward projected via the LED lens.

[0014] FIG. 4 is a light ray diagram showing the light component of FIG. 2 that is escaping via the side of the LED housing.

[0015] FIG. 5 is a light ray diagram showing the light component of FIG. 2 that is subject to total internal reflection.

[0016] FIG. 6 is a cutaway side view of a light emitting diode with a reflector according to one embodiment of the invention.

[0017] FIG. 7 is a light diagram showing the effect of the reflector of FIG. 6 upon the side emitted light component of an LED.

[0018] FIG. 8 is a light diagram showing the effect of the reflector of FIG. 6 upon the total internal reflection component of an LED.

[0019] FIG. 9 is a cutaway side view of a multiple LED reflector embodiment according to the present invention.

[0020] FIG. 10 is a ray diagram showing the effect of the reflector of FIG. 9 on the light emission pattern of an LED.

[0021] FIG. 11 is a top view of a paired LED reflector embodiment, showing a sun phantom deflection surface on non-reflector surface area between paired LEDs.

[0022] FIG. 12 is a top view of a reflector for a matrix of LEDs.

[0023] FIG. 13 is an exploded isometric view of a traffic signal embodiment of the invention.

[0024] FIG. 14 is a cutaway side view of the traffic signal embodiment of FIG. 13.

[0025] A reflector 40 as shown in FIGS. 6, 9 and 11 fits over the LED housing(s) 10. The reflector 40 has a reflective coating on its inner surface. The reflector 40 may be plastic, for example, with a chrome coating and/or be formed using aluminum or other metallic material with a reflective coating or polished reflective surface.

[0026] When aluminum or other heat conducting metal/material is used as the reflector material, the reflector itself may also function as a heat sink. To further increase heat dissipation away from the PCB or specific heat generating electrical components mounted on the PCB and the LED's themselves, holes may be formed in areas between the reflective surfaces of different LEDs, as shown in FIG. 12. Holes may also be formed to accommodate electrical components that are oversize and would otherwise interfere with mounting of the reflector with respect to the LEDs.

[0027] The reflector 40 has a first surface 50aconfigured to reflect light emitted sideways through the LED housing. A second surface 60 reflects light subject to total internal reflection within the LED housing 10. A third surface 50bis configured to also reflect light escaping on the side of the LED housing. As the angle of the second surface 60 is higher than that of either 50aor 50bthe step back that it creates does not cause any loss with respect to the sideways emitted LED light component.

[0028] As shown in FIGS. 7 and 8, the reflector 40 intercepts and redirects the light rays into a forward direction. The angles of the reflector surfaces 50a, 60, and 50bwith respect to a vertical axis of the LED are selected to create a generally collimated or generally spreading light pattern as desired for the intended application. By modifying the mounting height of the reflector 40 with respect to the LED housing 10, a range of light patterns ranging from generally collimated to varying degrees of opened or closed light spread may be obtained from a single reflector embodiment.

[0029] When the reflector is configured with pairs of LEDs associated with each other as shown in FIG. 9 an oval light pattern is created. Traffic signals according to ITE specifications benefit from an initial oval light pattern created by the reflector, requiring less optical shaping of the light pattern in further optics of the signal.

[0030] Traffic signals are also required to minimize sun phantom effect. Large reflector matrixes 41 for traffic signals, for example as shown in FIG. 12 create a large reflective surface upon which undesirable reflections may occur. Previously, non reflector surfaces of reflectors have been masked or coated to reduce these reflections. By forming a deflector pattern 70, for example as shown in FIG. 11, on the non-reflector surfaces of each reflector and any areas between reflectors any extraneous light entering the traffic signal will be deflected away from the light pattern rather than reflected into it, creating undesired sun phantom effects. The deflector pattern 70 redirects the light, via for example 45 degree corrugations. By forming the deflector pattern 70 integral with the reflector, the extra step and cost of masking or coating the reflector may be avoided and the entire front facing reflector surface given a single reflective coating/finish.

[0031] A traffic signal embodiment of the invention is shown in FIGS. 13 and 14. A housing 100 contains a PCB 110 with a matrix of LEDs and a power supply circuit thereon. The reflector matrix 41 fits around the LEDs and has holes 80 for oversize electrical components and/or heat dissipation. An optical element 120 may be used along with optical features in the distribution cover 130 to create the desired light pattern.

[0032] The reflector may be mounted to the PCB via screws, posts or one or more support legs. The support legs allowing a snap connection to the printed circuit board (PCB) or heat sink that the LED(s) are mounted on.

[0033] The invention has been described with respect to LEDs. However, the invention is usable with any form of light emitting device, especially those with integrated housings that may create extraneous light emission patterns causing a design loss that may be corrected and utilized via the invention. The invention is entitled to a range of equivalents and is to be limited only by the scope of the following claims.