Putting the light only where it's needed A Primer on LED Optics

Future-Lumileds Engineering Meeting November 2007

Designing with LEDs September 2011

Outline
Understanding Light How We See and Measure Light How Are Optics Tested What Can We Do With Light Standard Optics New Developments in LED Optics Custom Optics

Optics 101

Understanding Light
(lite)

The Electromagnetic Spectrum

The speed of light

How fast does light travel? 300 000 000 meters per second in vacuum

Inside a material it travels slower!

In ordinary glass the velocity is about two-thirds of the velocity in free space. The ratio of the velocity in vacuum to the velocity in a medium is called the index of refraction of that medium, denoted by the letter n.

Index of refraction n =

Velocity in vacuum Velocity in medium

Light propagation
LED = Point Source Emitter
We are used to visualising waves from point sources on 2D surfaces. Light waves radiating from a point source take a spherical form Radius of curvature of the wave front = distance from the point source.

Path of a point on the wave front is a light ray. In a medium a light ray is a straight line.

Lambertian Emission
What is a perfect emitter? A perfectly matt surface or an ideal emitter looks the same brightness regardless of what angle it is viewed from. This type of emitter is called a Lambertian emitter and to be equally bright at all viewing angles its emission with angle must vary as the cosine of the angle. WHITE LED chips are nearly perfect Lambertian emitters. However the packaging will often modify the output by refracting, clipping or reflecting the light leaving the device.

Inverse Square Law

The intensity of light changes as it travels outwards from a perfect point source. Light waves radiating outwards cover an increasingly large area the further they travel. The area that the light covers increases as the square of the distance. The power per area falls as the inverse of the distance squared. This can be written as:

Lagrangian Invariant - Etendue

Smaller Areas (optics) = Wider Angular Spread (Beam Angles) Wider Areas (optics) = Narrow Angular Spread (Beam Angles)

Refraction
The speed of light is lower inside a material than when travelling through air. The wave front has to change direction when it enters a material.

The new direction that the light travels in is given by Snells Law

n1 x sin(I1) = n2 x sin(I2)
Were n is the refractive index

Total Internal Reflection

Amazing things can happen when light leaves a material!
As the angle of the wave front increases, the refracted light angle increases until the refracted light virtually travels along the surface!

At incidence angles > this critical angle Light is reflected back into the material! This is Total Internal Reflection (TIR).
No loss of optical power in TIR. Total Internal Reflection

The most efficient means of reflecting light!

more efficient than any metal mirror

Simple lenses and prisms

What happens as light travels through a prism?

What happens inside a lens? Wave front diagrams of light passing through a lens are complex. A simpler way is to use a ray diagram. The rays shown are straight lines whose direction is normal to the wave front.

Dispersion
The speed of light in a vacuum is the same for all wavelengths. This is isnt true when travelling through a material. The refractive index of a material is a function of the wavelength of light. For White Light: The various wavelengths dont bend by the same amount. Thus we see Rainbow Effects.

The technical term for this effect is dispersion.

Optics 101

How we see and measure Light

The Human Eye

An Incredible Device!
Adapts to a light intensity that ranges from 100,000 lux Bright sunlight 0.00005 lux Starlight The eye can see even 1 photon! Brain suppresses as noise 2 or 3 photons over a small area will produce an impression. The eye is an excellent edge detector.

How the eye responds to light

Photodiodes vs. the Human Eye

Photodiodes are the most widely used device for detecting visible light.
Sensitivity of a photodiode to light of different wavelengths is not like that of the eye. Maximum sensitivity is in the near infra-red region.

To replicate the sensitivity of the eye Filters are needed to cut-off the near infra-red and reduce sensitivity in the red.

Measuring Light
Radiometry The absolute measurement of light (regardless of wavelength) Photometry The science of measuring light as the human eye sees it. For every radiometric measurement there is a photometric equivalent.

Optical Measurement Matrix

Quantities of brightness

LUMENS
Luminous Flux The total amount of visible light emitted. This is measured by collecting all the light emitted by the source into a full sphere. Use this to compare sources or to determine how efficient your source is.

Quantities of brightness

LUX
Illuminance The amount of visible light per unit area. Use this in the Near Field to define how dense you want the light to be. Specifying lighting levels on surfaces. Lighting levels in buildings.

Quantities of brightness

CANDELA
Luminous Flux
The amount of visible light per unit solid angle. Use this in the Far Field to define how intense you want the light to be. Specifying light intensity into free space. The brightness of beacons or traffic signals.

Quantities of brightness

NITS
(Candela per m2)

Luminance The amount of visible light per unit area per unit solid angle . Use this to define the brightness of a display. Combination of Near Field and Far Field Used to measure the brightness of a surface emitting in to free space.

Summary On Light Measurement

Lumens are for the total amount of visible light Lux are for light incident on surfaces
.think area Candela are for light emitted in to free space .think solid angle

Nits are for light emitted from a large area in to free space
.think area into solid angle

57

Candela to Lux Conversion

REMEMBER THIS ONE IMPORTANT FACT !! At a distance of 1 meter, the values of Candela and Lux are the same. Then use the inverse square law to get from one to the other

To convert from Candela to Lux: Divide by the distance squared.

To convert from Lux to Candela : Multiply by the distance squared.

Optics 101

Testing LED Optics at Carclo

Optical Testing Key Parameters

LED luminous flux in Lumens Optic coupling efficiency
% LED package output

Luminous intensity FWHM

Full Width beam angle in degrees at Half Maximum intensity

Peak intensity / LED lumens output

Candelas/Lumen

Measured at 350mA

Labsphere Integrating Sphere (9 Diameter)

LED luminous flux (in lumens) Optic coupling efficiency (%) E% = 100 x [Lumens (LED+Optic) / Lumens (LED)
9 Labsphere Integrating Sphere
LED optic under test

Prometric Imaging Photometry

Luminous intensity FWHM (Full Width in degrees at Half Maximum intensity) Peak intensity / LED lumens output ( i.e.Cd / lumen)

FWHM - Specifying Beam Width

Beam widths are usually Full Width Half Maximum (FWHM) OR Half Width Half Maximum (HWHM) FWHM or HWHM is just a single figure. It doesnt give the whole picture.

Graphs and Contour Maps

If you want to know
how far the light will spread how it changes across the beam you need Intensity Distribution Graphs Contour Maps
Graph of Candela per lumen

Contour map of Lux per lumen at 2.5m

Data For Optical Designers

ProSource Files
Models LED output Generates ray data for optical ray tracing programs. Used to design and simulate the effect of additional optics

Ray Files
Information on the large number of light rays leaving an LED Optical ray tracing programs will follow the paths of these rays through the optical component being designed Used to calculate the beam intensity

Software For Optical Designers Zemax ASAP Photopia Lightools AGi32 Optical Design Software Photometric Software

Data For Lighting Designers

Excel Spreadsheets
Lab Data Calculate Intensity and Illuminance profiles

Specified LED output (in lumens) Specified distance

2-D Graphs 3-D Models IES Type C Files

Import into photometric applications Light level/Beam contour simulations

Carclo Spreadsheet Data

Click 'Illuminance' tab to change Target Distance or LED Output Flux. Illuminance & Intensity Distributions are recalculated. Display graphs are automatically updated.

Illuminance Graphical Output

Luminous Intensity Graphical Output

Illuminance in XY Plane

Luminous Intensity in XY Plane

IES Type C Files

Elliptical Optic with Rebel White LED. Text file for import into photometric applications.

Optics 101

BASIC OPTICAL SYSTEMS

What Can You Do With Light?

Reflect
From metallized surfaces Using Total Internal Reflection (TIR) From white diffuse surfaces

Refract
Bend it using prisms. Focus it using lenses. Spread it using diffusers.

Absorb
Using black surfaces Using structured surfaces

No Optics
Main Uses Area Illumination Advantages What could be simpler! Even Wide Output Pattern Disadvantages Low intensity Uncomfortably Bright

Tip Make sure you have enough Lumens available. Shade areas where you dont want light.

Simple Lenses
Either (Conventional or Fresnel) Main Uses Spot Lights Advantages Low cost Can be fabricated as large arrays Disadvantages Poor Efficiency ~50%

Tip Dont try too produce a very tight spot of light. This will produce an image of the LED chip. Either deliberately defocus or use a diffuser.

Simple Reflectors
Main Uses Area Illumination, spots, wall wash Advantages Produce a sharp cut-off. Even output. Disadvantages Cant produce narrow angle beams Need secondary windows

Tip Dont put the LED at the focus of a parabolic reflector. Produces a bright spot in the center of the output beam.

TIR Optics
(A Total Internal Reflector Combined With A Lens) Main Uses Almost everything! Advantages Very efficient ~85% Compact Robust Can be used as window Disadvantages Cant produce very narrow beams Fixed focus Tip Make sure the optic is properly centered. Otherwise, dark holes can appear in the image. Buy from Carclo!

ANATOMY OF A TIR OPTIC

Planar output face can be replaced with a ripple insert or a frosted insert to generate wider intensity distributions

Light rays collimated in this example Rays over a narrower angle range are refracted by inner lens

Total Internal Reflection (TIR) of high angle light rays at outer optic faceoptic face

Optic holder holds LED optic at correct height above LED

Light rays from LED are output over a wide angular range (typically 120 deg)

Ripple Lenses
Main Uses Widening and shaping beams Advantages Can be incorporated into optics and windows Can create a wide range of beam shapes Disadvantages Used on exterior surfaces they are difficult to clean Cant spread light out by more than 40 degrees

Side Emitting Optics

Main Uses Beacons Backlighting for signage/displays Landscape/Architectural Lighting Advantages Compact. Narrow 5x360 beam. Disadvantages Needs a window. Output divergence varies slightly around the axis. Tip Alignment with the horizontal plane is critical.

Side-Emitter Raytrace

Side Emitting Optics

with light guide
Main Uses Backlights Advantages Efficient coupling. Very little forward illumination.

Disadvantages Needs a reflective edge to the light guide. Output divergence varies around the axis. Tip Works best with light guides between 8 - 12mm thick.

Side Emitting Optics

With Reflector
Main Uses Spot lights Automotive rear lights Advantages Retrofit to existing reflectors possible. Produces Narrow beams. Disadvantages Needs a window. Sensitive to mirror misalignment.

Tip Unless you are retrofitting an LED in to an existing product there may be other ways to produce a narrow beam.

Catadioptric Reflectors
Main Uses Very narrow spot lights or lines when combined with linear spreaders Advantages Compact Produce very tight beams. Disadvantages Expensive Tip When used with secondary linear ripple windows they can produce very narrow lines.

Light Boxes
Main Uses Back Illumination of floors, walls and ceilings Advantages Large area illumination. Even illumination. Disadvantages Inefficient. Requires lots of LEDs.

Tip Small changes in reflectivity of the internal surfaces make a big difference to the total efficiency.

Diffusers
Main Uses Smoothing and widening light output Advantages Simple. Effective. Disadvantages Reduces efficiency. Additional component that increases cost/complexity. Tip Use the minimum diffusion to avoid wasting light. Usually they have a rough and a smooth side. Make sure you orient correctly.

Summary of selecting optics

No Optics - too bright to look at and too dim to use Simple Lenses - simple but inefficient Reflectors - great for wide beams but not narrow ones TIR Optics - great all rounders, not for special requirements Double Reflectors expensive, but best for narrow beams Side emitters - often overlooked but do things others cant Light Boxes - good for large areas or for uniform illumination

Before You Start Selecting Optics

Always do a light budget before you start any new job. Be realistic about the amount of Lumens you will get from your LEDs. Dont forget to specify where you dont want illumination. Tip You can increase the concentration of light within a system using optics - but you cant create light!

Typical Standard Optics

Narrow Optic
Flat fronted Narrow beam Tightly controlled light Ideal for spot lighting & machine lighting

Radial Ripple Optics

Front surface is a radial ripple Output cones of 30deg & 50deg (Medium & Wide) Output is center-weighted Provides very even output when used in large numbers Used on Airbus/Boeing for reading lights Color mixing lights

Elliptical Optic
Gives a linear output of 45deg in one direction and 10-15 deg in the other The output is extremely even along the length of this strip of light Used on obstruction beacons, wall washing

Frosted Optics
Beam Angles
Narrow Medium Wide

Available in 10mm, 20mm and 26.5mm Proprietary Coating Soft Diffused Light
Architectural Commercial Theatrical

Recent New Optics

Small Footprint" Optic

10mm Optic
Designed for: Lumileds Rebel Cree XP-E/XP-G Nichia 119 Osram Oslon

Board with Optics

Small Footprint Optic

Efficiency 90.03% FWHM ~17 Degrees FWHM
Peak intensity / LED lumens output 7.1 Cd/lm

Additional optics in the range

Elliptical (linear) 18x46 degrees Wider Beam Angles
Medium Frosted - 22 Degrees FWHM Wide Frosted 30 Degrees FWHM SuperWide Frosted 42 Degrees FWHM

Optics for Multi-Chip LEDs

New Large Sources Provide High Lumen Output
2K lumens+

Multi-Color
Color Mixing

Require Large Optics

Efficient Collimation Narrow(er) Beams Good Color Mixing Less Overall Efficiency

Optics for Multi-Chip LEDs

20mm

26.5mm

Optics for Multi-Chip LEDs

Seoul Semi P7 30mm Optic New Material
Makrolon LED2643

13.3 FWHM Efficiency = 92.3% Peak Intensity = 13.8 Cd/lm

Bubble Optic
Wide Area Illumination Even Illumination Pattern

Designed for
Luxeon Rebel Seoul Semi P4 Cree XP-E/XP-C/XP-G Nichia 119 Osram Oslon

120/130/180 Degrees Downlight

Bubble Optic Output Pattern

Hemi-Spherical Bubble Optic

Downlight Bubble Optic

Continuous Strip Optic

Single piece optic that can be made in lengths to suit your needs Standard in 4 foot & 1 foot lengths Designed for small footprint LEDs Luxeon Rebel, Cree XP-E/XP-C, Nichia 119, Osram Oslon Diffused front surface means mounting height tolerance less critical

Continuous Strip Optic

An epoxy resin can be used to join or mount the lens Ideal for florescent replacement applications Refrigeration lighting, Cove lighting, Under cupboard lighting, Wall washing Can be used in both single color and RGB mixing. Light is mixed in the long plane - Less need to same color bin LEDs May be mounted to an aluminium extruded housing/heat sink which can be the main basis of the light engine module or fixture

FWHM: 37.91deg Peak INT. = 64.1 Cd Cd/lm: 64.1/46= 1.4 @ 350mA Efficiency: >80%

Custom Optics
Pro
Exactly What You Want Difficult to Duplicate Competitive Advantage

Con
Expensive Time Consuming IP Issues Manufacturability Obsolescence

Custom Optics
Routes to a Custom Optic Do It Yourself Optical Design Firm Full-Service Optics Company

Rapid Prototyping
Direct Machining + Hand Polishing
75% confidence of RP optic matching simulation Cost: ~$500 per part Lead Time: 2-4 weeks

Diamond Turning
95% confidence of RP optic matching simulation Cost: ~$750 per part Lead Time: 4-6 weeks

Rapid Prototyping
Soft Tooling
75% confidence of RP optic matching simulation Cost: ~$5000 for tooling
Lower part cost

Lead Time: 4 weeks

Single Cavity Prototyping Tool

99% confidence of RP optic matching simulation Cost: ~$10K for tooling
Lower part cost

Lead Time: 6-8 weeks Can be used for low volume manufacturing

Almost Finally
Understand LEDs Play to the strengths of LEDs. Be aware of the weaknesses of LEDs. When selecting optics There are many different types of optics that can be used. Dont just think about where you want the light Remember to consider where you dont want it.

Optics that were designed for conventional light sources are unlikely to give good performance.
Designers Tip Always start with the design of the optics with the smallest divergence first. Its much easier to widen the divergence rather than to narrow it.

Contact Information
Jim OConnor Business Development Manager Carclo Technical Plastics USA 600 Depot Street Latrobe PA 15650 724-539-6982 724-244-1976 jim.oconnor@carclo-usa.com

Thank You