# US 12,222,494 B2 · Extreme cutoff beam control optics

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- Number: US 12,222,494 B2
- Document ID: US12222494B2
- Status: Granted
- Kind: B2
- Application number: 18/394,324
- Filed: 2023-12-22
- Published: 2024-04-18
- Granted: 2025-02-11
- Earliest claimed: 2022-03-04
- Assignees: ABL IP Holding LLC
- Applicants: ABL IP Holding LLC
- Inventors: Qi Ai; Jie Chen; Craig Eugene Marquardt
- Web page: https://patentgrep.com/patent/US12222494B2

## CPC

- G02B 27/0012: {Optical design, e.g. procedures, algorithms, optimisation routines}
- F21S 8/086: {with lighting device attached sideways of the standard, e.g. for roads and highways}
- F21V 5/007: {Array of lenses or refractors for a cluster of light sources, e.g. for arrangement of multiple light sources in one plane (combination of two or more refractors F21V5/008)}
- F21V 7/0083: {Array of reflectors for a cluster of light sources, e.g. arrangement of multiple light sources in one plane (combination of two or more reflectors F21V7/0025)}
- F21V 7/04: Optical design
- F21V 13/04: the elements being reflectors and refractors {(for vehicle rear lights F21S43/40)}
- G02B 3/0037: {characterized by the distribution or form of lenses}
- G02B 5/003: {Light absorbing elements}
- G02B 7/003: {Alignment of optical elements (G02B7/001, G02B7/002 take precedence; for mirrors G02B7/1822)}
- G02B 19/0028: {refractive and reflective surfaces, e.g. non-imaging catadioptric systems}
- G02B 19/0061: {the light source comprising a LED}
- G02B 19/0066: {in the form of an LED array}
- F21V 5/048: {the lens being a simple lens adapted to cooperate with a point-like source for emitting mainly in one direction and having an axis coincident with the main light transmission direction, e.g. convergent or divergent lenses, plano-concave or plano-convex lenses}
- F21W 2131/103: of streets or roads
- F21Y 2105/14: characterised by the overall shape of the two-dimensional [2D] array
- F21Y 2115/10: Light-emitting diodes [LED]
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- F21S: NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21V: FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21W: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
- F21Y: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED

## Abstract

An optical assembly and a luminaire with extreme cutoff beam control optics. The optical assembly includes a base, at least one lens, at least one light emitting diode (LED) positioned to emit light into the lens, and a curved reflector disposed adjacent to the LED. The reflector can be characterized by a first angle between a plane of the base and a first line joining a distal end of the lens furthest laterally from a first end of the reflector and a second end of the reflector located over the lens, and a second angle between the plane of the base and a second line joining a point on the lens located at the optical axis of the LED and the second end of the reflector. The first angle can be between 60° and 90°, and the second angle can be between 70° and 130°.

## Claims

### Claim 1

An optical assembly comprising:
a base comprising a first surface, a second surface opposite the first surface, and at least one aperture extending through the base from the first surface to the second surface;
at least one lens coupled to the base, the at least one lens having a lens central axis perpendicular to a plane of the base, wherein the at least one lens is attached to the second surface of the base and extends at least partially through the at least one aperture so as to be at least partially exposed on the first surface of the base;
at least one light emitting diode (LED) positioned to emit light into the at least one lens, the at least one LED having an optical axis; and
at least one curved reflector disposed adjacent to the at least one LED such that the at least one LED is at a first side of the at least one curved reflector,
wherein:
the at least one curved reflector comprises a first end proximate the base, a second end opposite the first end, and a reflective surface extending at least partially between the first end and the second end, the at least one curved reflector extending from the base over the at least one of the LEDs such that the second end of the at least one curved reflector extends beyond the optical axis of the at least one LED; and
the at least one curved reflector characterized by at least one of:
a first angle between a first line and a plane of the base, the first line joining a distal end of the at least one lens furthest laterally from the first end of the at least one curved reflector and the second end of the at least one curved reflector located over the lens; and
a second angle between a second line and the plane of the base, the second line joining a point on the at least one lens located at the optical axis of the LED and the second end of the at least one curved reflector located over the lens,
wherein the first angle is in a range between 60° and 90°, and the second angle is in a range between 70° and 130°.

### Claim 2 (depends on 1)

The optical assembly of claim 1, wherein the at least one lens defines a cavity, and the at least one LED seat within the cavity.

### Claim 3 (depends on 1)

The optical assembly of claim 1, wherein the first surface of the base is configured to absorb at least 90% of emitted light incident on the first surface, wherein the first surface of the base comprises a light absorbing material or coating.

### Claim 4 (depends on 1)

The optical assembly of claim 1, wherein the at least one curved reflector comprises a light absorbing material or coating on a side of the at least one curved reflector opposite the reflective surface.

### Claim 5 (depends on 1)

The optical assembly of claim 1, wherein the reflective surface is defined by connected line segments.

### Claim 6 (depends on 1)

The optical assembly of claim 1, wherein the at least one lens is coupled to the base with adhesive, and wherein the second surface of the base defines channels for the adhesive.

### Claim 7 (depends on 1)

The optical assembly of claim 1, wherein:
the at least one lens comprises a dome that extends through the at least one aperture; and
the dome is asymmetric along at least one axis that is parallel to the base.

### Claim 8 (depends on 1)

The optical assembly of claim 1, wherein the second surface of the base defines at least one recess and wherein the at least one lens is seated within the at least one recess.

### Claim 9 (depends on 8)

The optical assembly of claim 8, wherein:
the at least one recess comprises a first recess and a second recess that extend parallel to each other;
the at least one lens comprises a first row of lenses and a second row of lenses;
the first row of lenses is disposed within the first recess; and
the second row of lenses is disposed within the second recess.

### Claim 10 (depends on 1)

The optical assembly of claim 1, wherein:
the at least one LED is provided on a substrate; and
the at least one lens is sandwiched between the substrate and the base.

### Claim 11 (depends on 1)

The optical assembly of claim 1, wherein the at least one lens is made of silicone or acrylic.

### Claim 12 (depends on 1)

The optical assembly of claim 1, further comprising side reflectors projecting from the reflective surface of the at least one curved reflector toward the first side, wherein the side reflectors are adapted to redirect and reflect toward the first side light emitted by the at least one LED in a direction that is aligned with or substantially aligned with a length of the at least one curved reflector.

### Claim 13

An optical assembly comprising:
at least one lens having a lens central axis;
at least one light emitting diode (LED) oriented to emit light into the at least one lens, the at least one LED having an optical axis; and
at least one curved reflector disposed adjacent to the at least one LED such that the at least one LED is at a first side of the at least one curved reflector, wherein the at least one curved reflector has a reflective surface extending over the at least one LED and beyond the optical axis,
wherein the at least one LED is configured to emit light from the optical assembly and wherein the optical assembly is configured to direct at least 95% of the emitted light in a first direction relative to a light cutoff plane (1) that extends through the optical axis of the at least one LED located within the optical assembly at a location most distal from the first direction and (2) that extends parallel to the optical axis and perpendicular to the first direction.

### Claim 14

An optical assembly comprising:
a base having a surface and defining at least one aperture;
at least one lens having a dome shape portion and a lens central axis, wherein the at least one lens is coupled to the base and extends through the at least one aperture so as to be visible on the surface;
at least one light emitting diodes (LED) oriented to emit light into the at least one lens and the at least one LED having an optical axis; and
at least one curved reflector disposed adjacent to the at least one LED such that the at least one LED is at a first side of the at least one curved reflector, wherein the at least one curved reflector has a reflective surface extending over the at least one LED and beyond the optical axis of the at least one LED and
wherein the dome shape portion of the at least one lens extends from the surface and wherein the surface is configured to absorb at least 90% of light incident on the surface.

### Claim 15 (depends on 14)

The optical assembly of claim 14, wherein the surface comprises a light absorbing material or coating.

### Claim 16 (depends on 14)

The optical assembly of claim 14, wherein the at least one LED is provided on a substrate.

### Claim 17 (depends on 14)

The optical assembly of claim 14, further comprising side reflectors projecting from the reflective surface of the at least one curved reflector toward the first side, wherein the side reflectors are adapted to redirect and reflect toward the first side light emitted by the at least one LED in a direction that is aligned with or substantially aligned with a length of the at least one curved reflector.

### Claim 18

An optical assembly comprising:
a base comprising a first surface, a second surface opposite the first surface, and at least one aperture extending through the base from the first surface to the second surface;
at least one lens coupled to the base, the at least one lens having a lens central axis perpendicular to a plane of the base, wherein the at least one lens is attached to the second surface of the base and extends at least partially through the at least one aperture so as to be at least partially exposed on the first surface of the base;
at least one light emitting diode (LED) positioned to emit light into the at least one lens, the at least one LED having an optical axis; and
at least one curved reflector disposed adjacent to the at least one LED such that the at least one LED is at a first side of the at least one curved reflector, wherein the at least one curved reflector comprises a curved surface defined at least partially by connected line segments such that the at least one curved reflector curves over the at least one lens and extends beyond the optical axis of that the at least one LED,
wherein the line segments comprise a linear segment extending perpendicularly to the base.

### Claim 19 (depends on 18)

The optical assembly of claim 18, wherein the connected line segments comprise connected curved line segments.

### Claim 20 (depends on 18)

The optical assembly of claim 18, further comprising side reflectors projecting from the curved surface of the at least one curved reflector toward the first side, wherein the side reflectors are adapted to redirect and reflect toward the first side light emitted by the at least one LED in a direction that is aligned with or substantially aligned with a length of the at least one curved reflector.