Linear light emitting diode luminaires
11162652 · 2021-11-02
Assignee
Inventors
- John N. Magno (St. James, NY, US)
- Eric W. Teather (Elkton, MD, US)
- Christopher C. Rich (Rancho Palos Verdes, CA, US)
Cpc classification
F21Y2103/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V3/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21S4/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21Y2115/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F21S4/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F21V3/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A minimally complex, low cost/economical luminaire that distributes point source light for general lighting applications, the luminaire having a substrate with a linear array of discrete light sources positioned to emit light into an air-filled cavity and a light redirecting assembly on the other side the air-filled cavity, the assembly comprising a clear, light transmissive rigid cover and a clear, light transmissive semi-rigid flexible film positioned between the cover and the substrate, wherein the film is non-adhesively secured within the luminaire and flexed to generally conform to the shape of the cover and wherein the surface of the film facing into the air-filled cavity comprises an array of optical relief structures extending into the air-filled cavity.
Claims
1. A light redirecting assembly, comprising: a light transmissive cover that forms an inner surface and an outer surface; and a flexible sheet of a light transmissive material, the flexible sheet forming a first surface and an opposite second surface, wherein: the first surface of the flexible sheet comprises an array of optical relief structures selected from the group consisting of: V-groove, isosceles triangular groove, right triangular groove, acute triangular groove, pyramid, square pyramid, square right pyramid, rectangular pyramid, rectangular right pyramid, rhombic pyramid, and polygonal pyramid, at least a portion of the optical relief structures form respective bases adjoining the first surface, and the second surface of the flexible sheet is affixed to the inner surface of the light transmissive cover.
2. The light redirecting assembly of claim 1, wherein: at least a subset of the optical relief structures form at least first and second sides opposite one another, and for each optical relief structure of the subset of the optical relief structures: an angle between the first side and the base is a first base angle; an angle between the second side and the base is a second base angle; and the first base angle and the second base angle are different from one another.
3. The light redirecting assembly of claim 1, wherein heights of the optical relief structures are between 5 and 200 microns.
4. The light redirecting assembly of claim 1, wherein: each of the portion of the optical relief structures forms at least first and second faces that extend upwardly from the respective bases, and the first and second faces of adjacent ones of the optical relief structures are opposite one another.
5. The light redirecting assembly of claim 4, wherein, for each optical relief structure of the portion of the optical relief structures: an angle between the first face and the base is a first base angle; an angle between the second face and the base is a second base angle; and the first base angle and the second base angle are different from one another.
6. The light redirecting assembly of claim 1, wherein the flexible sheet is adhered to the inner surface of the light transmissive cover.
7. The light redirecting assembly of claim 1, wherein: the light transmissive cover includes a curved sheet of a clear, rigid optical material; the outer surface of the light transmissive cover is convex; and the inner surface of the light transmissive cover is concave.
8. The light redirecting assembly of claim 1, wherein: each of the portion of the optical relief structures forms at least two opposite faces that extend upwardly from the respective bases; and angles between the two opposite faces, and the respective bases of the portion of the optical relief structures, vary from structure to structure over at least a portion of the first surface.
9. The light redirecting assembly of claim 1, wherein each of the optical relief structures forms a respective rectangular base, and dimensions of sides of the respective rectangular bases vary from structure to structure over at least a portion of the first surface.
10. The light redirecting assembly of claim 1, wherein: heights of the optical relief structures are between 5 and 200 microns; each of the optical relief structures forms a respective rectangular base; and sides of the respective rectangular bases are between 5 and 200 microns in length.
11. A luminaire, comprising: a linear array of discrete light sources, disposed along an axial direction and configured to emit light; and a light redirecting assembly that is disposed adjacent to the linear array of discrete light sources, and is oriented so that when the light is emitted by the light sources, the light is received through a first surface of a light redirecting film and emitted through an outer surface of a light transmissive cover; wherein: the light transmissive cover includes a curved sheet of a clear, rigid optical material that is curved transverse to the axial direction; the outer surface of the light transmissive cover is convex; an opposing inner surface of the light transmissive cover is concave; the light redirecting film is a flexible sheet of a light transmissive material, the flexible sheet forming a first surface and an opposite second surface; the first surface of the flexible sheet comprises an array of optical relief structures selected from the group consisting of: V-groove, isosceles triangular groove, right triangular groove, acute triangular groove, pyramid, square pyramid, square right pyramid, rectangular pyramid, rectangular right pyramid, rhombic pyramid, and polygonal pyramid; at least a portion of the optical relief structures form respective bases adjoining the first surface; and the second surface of the flexible sheet is affixed to the inner surface of the light transmissive cover.
12. The luminaire of claim 11, wherein: at least a subset of the optical relief structures form at least first and second sides opposite one another, and for each optical relief structure of the subset of the optical relief structures: an angle between the first side and the base is a first base angle; an angle between the second side and the base is a second base angle; and the first base angle and the second base angle are different from one another.
13. The luminaire of claim 11, wherein: each of the portion of the optical relief structures forms at least first and second faces that extend upwardly from the respective bases; the first and second faces of adjacent ones of the optical relief structures are opposite one another; and, for each optical relief structure of the portion of the optical relief structures: an angle between the first face and the base is a first base angle; an angle between the second face and the base is a second base angle; and the first base angle and the second base angle are different from one another.
14. The luminaire of claim 11, wherein the flexible sheet is adhered to the inner surface of the light transmissive cover.
15. The luminaire of claim 11, wherein: each of the portion of the optical relief structures forms at least two opposite faces that extend upwardly from the respective bases; and angles between the faces, and the respective bases of the portion of the optical relief structures, vary from structure to structure over at least a portion of the first surface.
16. The luminaire of claim 11, wherein each of the optical relief structures forms a respective rectangular base, and dimensions of sides of the respective rectangular bases vary from structure to structure over at least a portion of the first surface.
17. The luminaire of claim 11, wherein: heights of the optical relief structures are between 5 and 200 microns; each of the optical relief structures forms a respective rectangular base; and sides of the respective rectangular bases are between 5 and 200 microns in length.
18. A method of manufacturing a light redirecting assembly, comprising: providing a clear, light transmissive cover comprising an inner surface and an outer surface; providing a clear, flexible light redirecting film comprising a first surface and an opposite second surface, wherein: the first surface of the light redirecting film comprises an array of optical relief structures selected from the group consisting of: V-groove, isosceles triangular groove, right triangular groove, acute triangular groove, pyramid, square pyramid, square right pyramid, rectangular pyramid, rectangular right pyramid, rhombic pyramid, and polygonal pyramid, at least a portion of the optical relief structures form respective bases adjoining the first surface; and affixing the second surface of the clear, flexible light redirecting film to the inner surface of the clear, light transmissive cover, to form the light redirecting assembly.
19. The method of claim 18, wherein affixing the second surface of the clear, flexible light redirecting film to the inner surface of the clear, light transmissive cover comprises adhering the second surface of the clear, flexible light redirecting film to the inner surface of the clear, light transmissive cover.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The novel features of the aspects described herein are set forth with particularity in the appended claims. The aspects, however, both as to organization and methods of operation may be further understood by reference to the following description, taken in conjunction with the accompanying drawings.
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
DETAILED DESCRIPTION
(14) We have now devised simple and relatively inexpensive luminaire designs that redistribute the light from a row of LEDs into a continuous bar of light of relatively uniform luminance and then disperses that light in a desirable distribution with a high energy efficiency.
(15) The device 100 depicted in
(16) The exemplary sawtooth topology 116 is but one example or means to describe the geometric structures intended to influence the reflection and transmission of light to achieve a preferred light distribution pattern. These geometric structures are sometimes referred to as optical relief structures or optics and are generally deployed in an array across the entire surface of the polymeric material. Or, as disclosed in U.S. Pat. No. 7,878,690, the array may be characterized as a microlens or prism lens array. Suitable optical relief structures may include V groove-, isosceles triangular groove-, right triangular groove-, acute triangular groove-, pyramid-, square pyramid-, square right pyramid, rectangular pyramid-, rectangular right pyramid-, rhombic pyramid-, or polygonal pyramid-like structures.
(17)
(18) When light is emitted from LEDs 102 in luminaire 100, the light will strike one of the faces of the pyramidal protrusions. For example, as shown in
(19) There is, however, a serious design consideration in the construction of luminaire 100. The three dimensional structure of cover 108 with its array of pyramidal protrusions 116 makes it extremely difficult if not impossible to extrusion mold a polymer into such a part because it may not release from the mold.
(20) A flexible sheet with a surface topology similar to topography 336 of film 328 may optionally be adhered or otherwise affixed to the inner surface of cover 308 in lieu of utilizing some means of capturing film 328. The surface topology similar to 336 would, again, face inward into cavity 301.
(21) A further embodiment of the invention may be explained with reference to
(22) The configurations of the pyramidal structures that may be practically or cost effectively used on cover 108 or film 328 are constrained by the fabrication processes used to produce the cover or film. The angle δ between the faces of adjacent pyramids cannot be made to be too small because of the constraints of the diamond turning process used to fabricate the tooling used in the embossing or molding process. Acute pyramidal structures may be formed on the surface of cover 108 or film 328, but an inner surface with obtuse pyramidal structures cannot be practically produced by the embossing or compression molding techniques.
(23) In embodiments similar to exemplary embodiments 100 and 300, it is often advantageous to vary the configurations of the pyramidal structures on the inner surface 110 of cover 108, or inner surface 330 of film 328, across the cross-sections shown in
(24) In some embodiments of the invention sufficiently improved optical performance may be obtained by utilizing a flexible, but semi-rigid film similar to 328, but in this case the surface topology of the film has a profile that is unchanging along the an axis running the length of the luminaire (that is to say, along an axis analogous to axis A-A′ in
(25) When viewed from the direction of
(26) In embodiments having the grooved surface profiles on the inward facing surface of films similar to 328, it is often advantageous to vary the configurations of the triangular grooves on the inward facing surface (similar to 330) of the films across the cross-sections like those shown in
(27) To fabricate a luminaire similar to embodiment 300 shown in
(28)
(29)
(30) The profile 816 of surface 810 of cover layer 808 in embodiment 800 contains obtuse triangular structures that could not be produced in a film by embossing or compression molding. But, since the surface profile extends along only one axis of cover layer 808, this part may be produced by an extrusion process. Cover layer 848 may be a film with the embossed or compression molded surface topology 856 layered over cover layer 808. In other embodiments cover layers 808 and 848 may exchange places in the structure of a luminaire like luminaire 800. In such a case the outer cover layer (that has a surface topology like 816 in
(31) Embodiments that use two semi-rigid films of clear, transparent material with two orthogonal sets of grooves to replace and function in a similar manner to rigid cover layers 808 and 848 and in which the semi-rigid films are captured by projections from a clear cover similar to 308 in embodiment 300 above are possible so long as the films' surface topologies are capable of being embossed or compression molded. That is to say, films in such embodiments cannot have sawtooth cross-sectional profiles that involve obtuse triangular structures or possibly very steep-sided acute triangular structures.
(32) The embodiments described above are illustrative examples and it should not be construed that the present invention is limited to these particular embodiments. For, although LED devices were used as examples of discrete light sources, other light emitting devices may be used. Further, although the orientation of components in the embodiments were described as being parallel to or running the length of other components, it should be understood that they need not be exactly parallel or running exactly the length, rather in a close range of being normal or substantially normal or in a close range of running the length. Further, various components and aspects described with reference to different embodiments are interchangeable among different embodiments, and are not limited to one particular embodiment. Thus, various changes and modifications may be effected by one skilled in the art without departing from the spirit or scope of the invention as defined in the appended claims.
(33) The drawings illustrating the embodiments of this patent illustrate objects of greatly varying size. The relative sizes and numbers of various objects as portrayed in the drawings have been modified for the sake of clarity and completeness. Therefore, the relative size and number of objects in the drawings should not be taken as accurate in terms of size or extent relative to other objects.
(34) While the present invention has been particularly shown and described with reference to example embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims and equivalents thereof. It is therefore desired that the present embodiments be considered in all respects as illustrative and not restrictive, reference being made to the appended claims and equivalents thereof rather than the foregoing description to indicate the scope of the invention.