1. GBU LED Lamps & Systems April 2010 Reflector Design Fortimo Spot Light Module

2. Confidential GBU LED Lamps & Systems, April 2010 Contents Reflectors for Accent Lighting Light mixing for Fortimo SLM Reflector design rules Optical interface Optical modeling using Ray Set files Examples of Reflectors for Fortimo Spot Light Module 2

3. Confidential GBU LED Lamps & Systems, April 2010 3 Accent Lighting luminaires In accent lighting typically 3 beam widths are identified –Spot: 10 degree Full Width at Half Maximum –Medium:24 degree Full Width at Half Maximum –Flood:40 degree Full Width at Half Maximum The light source dimensions determine the limits of the possible beam width – Law of Etendue – for certain max reflector diameters With HID and Halogen smaller beams are possible due to the small source

4. Confidential GBU LED Lamps & Systems, April 2010 4 Reflectors compact high intensity sources Source indoor guide Philips 2008 FWHM (°)12243660 Pictures Graphs Light Output Ratio max. 0.670.650.60 Imax [kcd/klm]15210.75

5. Confidential GBU LED Lamps & Systems, April 2010 5 Reflectors for Fortimo SLM versus DLM Fortimo SLMFortimo DLM Light distributionLambertian Light source uniformity Non uniform (9 or 16 small sources) Uniform Light mixingRequiredNot required Light diffusingRequiredNot required Front glass Required (Transparent or diffuse) Not required

6. Confidential GBU LED Lamps & Systems, April 2010 6 Mixing the light Mixing the light is needed to reduce flux inhomogeneity and color variations between the individual LEDs Options –Segmenting and faceting of reflector wall –3D faceting –Structured reflector surface (ie diffuse) Blurring / mixing widens the source: –Starting 12.8 mm of LED circle –After blurring 14 mm of source diameter

7. Confidential GBU LED Lamps & Systems, April 2010 7 Diffusing the light Diffusing the light is needed to fill the space between LEDs –Eliminates ring features in the beam Highest efficiency is achieved when placed at the top 84%94% Specular reflector without diffuser Specular reflector with diffuser

8. Confidential GBU LED Lamps & Systems, April 2010 8 Rings in the far field A diffusion foil or structured front glass is needed to eliminate rings in the far field projection (if desired). Options: 1.Diffusion foil e.g. 5° diffusing foil of Luminit 2.Structured glass 3.A transparent front glass with shading region at the outer edge 1 and 2 slightly increase the beam width Rings in far field Caused by direct rays BeNeLux - Office BFi OPTiLAS B.V (Chr.Huygensweg 17-2408AJ) P.O. Box 222 2400 AE Alphen aan den Rijn Phone: +31 (0)172-44 60 60 Fax: +31 (0)172-44 34 14 E-mail: info.nl@bfioptilas.com info.nl@bfioptilas.com Anton Schotel http://www.bfioptilas.com/European+offices-3.htm

9. Confidential GBU LED Lamps & Systems, April 2010 Accent factor / punch 9 Large quantity of direct light, large FWHM of direct light The shape of the light distribution determines the punch –Gaussian shape is acceptable for most applications Low height reflectors: more direct light, punch perception is reduced –FWHM ratio direct and reflected light should not be high FWHM ratio direct/reflected light: 2.7 FWHM ratio direct/reflected light: 5.5

10. Confidential GBU LED Lamps & Systems, April 2010 10 Reflector design parameters ParameterBeam angle (FWHM) Perception of punch Peak intensity (CBCP) Source diameterHighMedium Reflector entrance diameterLow Reflector exit diameterHighMediumHigh Reflector heightLowHighLow Reflector wall diffusivityMedium Diffusive front glassMedium

11. Confidential GBU LED Lamps & Systems, April 2010 11 Typical reflector design limits Beam angle (FWHM) for certain reflector diameter is limited by law of Etendue, peak intensity is limited by reflector diameter and average source luminance Using Gaussian beam profile, an acceptable punch perception is achieved for the white shaded area Typical minimal beam width for 1100 lm module is ~15 o FWHM (Source 1100 lm and 14mm)

12. Confidential GBU LED Lamps & Systems, April 2010 12 Typical reflector design limits Beam angle (FWHM) for certain reflector diameter is limited by law of Etendue, peak intensity is limited by reflector diameter and average source luminance Using Gaussian beam profile, an acceptable punch perception is achieved for the white shaded area Typical minimal beam width for 2000 lm module is ~20 o FWHM (Source 2000 lm and 20mm)

13. Confidential GBU LED Lamps & Systems, April 2010 13 Light Output Ratio vs reflector dimensions The reflector Light Output Ratio (LOR) or efficiency decreases for higher reflectors due more reflections at the reflector wall. White shaded area depicts acceptable punch No front glass taken into account 1100 lm2000 lm

14. Confidential GBU LED Lamps & Systems, April 2010 14 Typical reflector designs Table with typical reflector performances –Based on modeling, including mixing/diffusive impact, no front glass, Reflector R = 90%

15. Confidential GBU LED Lamps & Systems, April 2010 15 Reflector technologies Reflector technologies, price points, typical reflectivity Final reflector efficiency (LOR) depends on reflector shape TechnologyRough costTooling cost Spinning / turning, post anodizationMedium Stamping, post anodizationLowMedium Miro folding, pre anodizedMedium, 1.5 EuroLow Plastic molding, post anodizationLow, < 1 EuroHigh Glass, post anodizationMediumHigh Reflective layerReflectivityRough cost Post anodizing chemical75 – 85 %Medium Post anodizing evaporation80 – 90 %High Pre anodized90 – 98%High

16. Confidential GBU LED Lamps & Systems, April 2010 Optical interface 16 Area for reflector mounting Minimal distance of metallic reflector to electrical components is 1.2mm in open air, the cover ensures that this distance is met

17. Confidential GBU LED Lamps & Systems, April 2010 17 Optical interface The surface available for reflector mounting is a ring with width: –1100 lm: 7.3 mm –2000 lm: 4.8 mm Any 2000lm reflector will fit on the 1100lm module as well y x

18. Confidential GBU LED Lamps & Systems, April 2010 18 Optical interface reflector attach Options for reflector attachment: –Mount to housing –Mount to heat sink –Glue to module –Using an additional bayonet on module Option for reflector mounting with additional metal component

19. Confidential GBU LED Lamps & Systems, April 2010 19 Ray Sets 1100/2000 modules for reflector design Available formats for customer use Measurement method –SIG 300, Radiant Imaging, flux measured is relative flux, including color SoftwareNumber of Rayscomments RS7Measurement fileNo color info Light Tools100K, 500K, 10M raysIncludes color info Photopia100K, 500K, 10M raysNo color info Lucid Shape100K, 500K, 10M raysNo color info ASAP100K, 500K, 10M raysNo color info Speos100K, 500K, 10M raysNo color info Trace Pro100K, 500K, 10M raysNo color info Zemax100K, 500K, 10M raysNo color info

20. Confidential GBU LED Lamps & Systems, April 2010 20 Fortimo SLM 1100lm The coordinate system of the ray set is identical to the coordinate system of the CAD-file: Fortimo_LED_SLM_1100_18W-8xx_wk10.stp. If you import both the ray set and the CAD-file to the same location they are aligned. To achieve this the following rotation and translation was performed: –Rotation about Z-axis: -1° –Translation along X-axis: 0.10mm –Translation along Y-axis: 0.01mm –Translation along Z-axis: -0.4mm (determined by defocus-analysis in LightTools) The origin of the coordinate system is now in the center of the module at the height of the LED dies. Part of the light is blocked by the module cover in the measurement. This part is missing in the ray sets (see cross section). The rays start on a cylinder above the LEDs, so no rays start inside the geometry (radius = 9.4mm, 1.491mm < z < 1.5). Alignment Image Cross section of the CAD-model Intensity polar plot 1100 & 200 Lm SLM

21. Confidential GBU LED Lamps & Systems, April 2010 21 Fortimo SLM 2000lm The coordinate system of the ray set is identical to the coordinate system of the CAD-file: Fortimo_LED_SLM_2000_33W-8xx_wk10.stp. If you import both the ray set and the CAD-file to the same location they are aligned. To achieve this the following translation was performed: –Translation along Y-axis: -0.1mm –Translation along Z-axis: -0.6mm (determined by defocus-analysis in LightTools) The origin of the coordinate system is now in the center of the module at the height of the LED dies. Part of the light is blocked by the module cover in the measurement. This part is missing in the ray sets (see cross section). The field of view of the SIG300 is too small for the module. Therefore, part of the indirect light is missing in the ray sets (see alignment image). The rays start on a cylinder above the LEDs, so no rays start inside the geometry (radius = 11.9mm, 1.491mm < z < 1.5). Alignment Image Cross section of the CAD-model Intensity polar plot

22. Confidential GBU LED Lamps & Systems, April 2010 22 Prototype results 1100 lm module + SLS reflector 5° diffuser foil from Luminit TM Lineair scaling Log scaling Δ uv <0.008 for values larger than 5% of peak intensity Uniform spot, no rings Reflector efficiency: 86 – 90% Including POC foil: 82 – 85 %

23. Confidential GBU LED Lamps & Systems, April 2010 23 Prototype results 1100 lm module + SLS reflector 20° diffuser foil from Luminit TM Lineair scaling Log scaling Uniform spot, no rings Δ uv <0.008 for values larger than 5% of peak intensity

24. Confidential GBU LED Lamps & Systems, April 2010 24 Prototype results 2000 lm module + SLS reflector 10° diffuser foil from Luminit TM FWHM 26° Visual appearance (log2 visualisation) Δ uv < 0.006 within 10% of peak intensity Δuv < 0.008 within 5% of peak intensity Reflector efficiency: 86 – 90% Including POC foil: 82 – 84 %

25. Confidential GBU LED Lamps & Systems, April 2010 25 Reflector supplier Jordan Jordan developed three reflector types that fit both 1100 and 2000 lm modules with a click-fit onto the module Example beam profiles 1100 lm, 2 x 12.2 O 2000 lm, 2 x 13.7 O Need diffusing exit window http://www.jordan-reflektoren.de

26. Confidential GBU LED Lamps & Systems, April 2010 26 Reflector supplier Alux-Luxar Alux Luxar is developing a series of reflectors –Both pre-anodized (Miro) and post anodized Example of Miro 8 based reflector for 1100 lm –Efficiency > 90% http://www.alux-luxar.de No diffuser 1 o diffuser 5 o diffuser Efficiency: -3% Reflector in combination with 5 o diffuser gives a Gaussian beam, FWHM < 15°. / 1100 lm

27. Confidential GBU LED Lamps & Systems, April 2010 27 Contact addresses:

28. Confidential GBU LED Lamps & Systems, April 2010 28 Convergent beams - cross over reflector By combining the Fortimo SLM module and a convergent reflector, a system with an aperture can be designed The efficiency of the system is limited by the Law of Etendue Example for an aperture 30 mm and desired FWHM = 2x12 o : –2000 lm module with 20 mm efficiency: 11% –1100 lm module with 14mm efficiency: 20% –With a hypothetical source of 6.5 mm: efficiency: 100% 1100 lm module