Abstract
A lighting system for providing uniform bright lighting of products within in a glass door refrigerated cabinet. The lighting system has a frame member with an angled wing extending therefrom that wraps around a side edge of a light-transmitting optical shield, and a LED lighting strip positioned between the frame member and the optical shield. The LED lighting strip has a plurality of spaced-apart LED lights mounted therealong with a coined reflective facet optic mounted around each LED light. The angled wing(s) reflects light emitted laterally outwards from the at least one LED lighting strip such that the light can be re-directed to evenly illuminate products in a refrigerated cabinet. The angled wing(s) also protects a user's fingers from cracking the plastic optical shield which can become brittle in the cool or cold temperatures of the refrigerated cabinet.
Claims
1. A lighting system, comprising: a frame member having a base with at least one angled wing extending away from the base; a light-transmitting optical shield mounted onto the frame member, the light-transmitting optical shield having an outwardly projecting side edge; and at least one LED lighting strip positioned between the frame member and the optical shield, wherein the LED lighting strip has a plurality of spaced-apart LED lights mounted therealong and a coined reflective facet optic mounted around each LED light, and wherein the at least one angled wing extends outwardly beyond the outwardly projecting side edge of the light-transmitting optical shield and reflects light emitted from the at least one LED lighting strip, and wherein the at least one angled wing wraps around and is in supporting contact with the outwardly projecting side edge of the light-transmitting optical shield.
2. The lighting system of claim 1, wherein the angled wing reflects light emitted in a lateral direction from the at least one LED lighting strip.
3. The lighting system of claim 2, wherein the light-transmitting optical shield has at least one side portion and a top portion, and wherein the at least one angled wing reflects light emitted in the lateral direction through the at least one side portion.
4. The lighting system of claim 3, wherein the at least one angled wing has a height generally equal to the height of the side portion of the light-transmitting optical shield.
5. The lighting system of claim 1, wherein the at least one angled wing extends away from the base of the frame member at an angle of between 20 and 60 degrees.
6. The lighting system of claim 1, wherein the at least one angled wing extends away from the base of the frame member at an angle of about 30 degrees.
7. The lighting system of claim 1, wherein the light-transmitting optical shield is made of plastic and the at least one angled wing is made of metal.
8. The lighting system of claim 1, wherein the at least one angled wing and the frame member are formed from the same block of material.
9. The lighting system of claim 1, wherein the outwardly projecting side edge of the optical shield is inserted into the angled wing.
10. The lighting system of claim 1, wherein the angled wing wraps around the outwardly projecting side edge of the optical shield.
11. The lighting system of claim 1, wherein the optical shield extends over and covers open top ends and open lateral side ends of each of the coined reflective facet optics.
12. The lighting system of claim 1, further comprising: a microwave proximity sensor mounted onto the frame member.
13. The lighting system of claim 1, further comprising: front and back end caps covering ends of the optical shield and the at least one angled wing.
14. The lighting system of claim 1, wherein: the at least one angled wing is a pair of angled wings extending from opposite sides of the base of the frame member, and the at least one LED lighting strip is a pair of lighting strips positioned back-to-back perpendicular to the base of the frame member.
15. The lighting system of claim 14, wherein there is no intervening support wall between the pair of LED strips.
16. The lighting system of claim 14, wherein the light-transmitting optical shield extends continuously across the top and both sides of the lighting system between the pair of angled wings.
17. The lighting system of claim 1, further comprising: a side wall extending perpendicular to the base of the frame, wherein the side wall extends from a first side of the base and the at least one angled wing comprises a single angled wing that extends from an opposite side of the base.
18. The lighting system of claim 17, wherein the at least one LED lighting strip is a single LED lighting strip positioned adjacent to the side wall.
19. The lighting system of claim 17, wherein the light-transmitting optical shield extends continuously across the top and one side of the lighting system.
20. The lighting system of claim 1, wherein the lighting system is positioned within an enclosure for illuminating the enclosure.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) FIG. 1 is a perspective view of a first embodiment of the present LED lighting system, having a pair of angled wings for reflecting light and protecting a user's hands.
(2) FIG. 2 is a side elevation view corresponding to FIG. 1, but with the end cap removed, showing the geometry of the angled wing wrapping around the opposite sides of the optical shield.
(3) FIG. 3 is a perspective view of a lighting strip showing the LEDs and their associated coined reflective facet optics.
(4) FIG. 4 is a top plan view of the embodiment of FIGS. 1 and 2.
(5) FIG. 5 is a perspective view of a second embodiment of the present LED lighting system, having a single angled wing for reflecting light and protecting a user's hands.
(6) FIG. 6 is a side elevation view corresponding to FIG. 5, but with the end cap removed, showing the geometry of the angled wing wrapping around one side of the optical shield.
(7) FIG. 7 is a front perspective view of a refrigerated cabinet with the present illumination system mounted therein.
(8) FIG. 8 is a top sectional view corresponding to FIG. 7.
(9) FIG. 9 is a perspective view of the present illumination system showing the positioning of an optional microwave proximity sensor.
(10) FIG. 10 is a perspective view illustrating successive steps in the stamping of the coined reflective facet optics.
DETAILED DESCRIPTION OF THE DRAWINGS
(11) The present illumination system will be described herein in an exemplary use inside a refrigerated cabinet (for example, the refrigerated cabinets having glass front doors that are typically found in grocery and convenience stores for placing milk, dairy products, sodas, frozen dinners, etc. into). It is to be understood, however, that the present lighting system could be used in other contexts and arrangements and that the claims below are not limited solely to uses in refrigerated cabinets.
(12) In preferred aspects, the present lighting system includes a “two-wing” embodiment that can be mounted vertically onto a central beam at the front of a refrigerated cabinet to cast light towards both the left and right sides of the cabinet. The present lighting system also includes a “one-wing” embodiment that can be mounted vertically onto a side beam at the of the refrigerated cabinet to cast light either only to the left side or to the right side of the beam. Merely by mounting this “one-wing” embodiment right-side-up or upside-down, the illumination can be directed either to the left side or to the right side.
(13) It is also to be understood, however, that the various embodiments of the present system can alternatively be mounted horizontally (for example at the top and bottom of the cabinet), thereby providing illumination upwardly or downwardly.
(14) FIGS. 1, 2, and 4 represent a first (“two-wing”) embodiment of the present illumination system in which light is emitted from both sides of the illumination system. FIGS. 5 and 6 represent a second (“one-wing”) embodiment of the present illumination system in which light is emitted only from one side of the illumination system. FIG. 3 shows an LED lighting strip with associated coined reflective facet optics for insertion into either embodiment of the present lighting system.
(15) FIGS. 7, 8 and 9 show the present system in use in a refrigerated cabinet.
(16) Lastly, FIG. 10 shows steps in the manufacture of the LED lighting strips.
(17) Referring first to the “two-wing” embodiment of FIGS. 1, 2, 4 and 5, a lighting system 10 is provided. Lighting system 10 comprises: a frame member 20 having a base 21 with a pair of angled wings 22 extending away from base 21; a light-transmitting optical shield 30 mounted onto frame member 20; and a pair of LED lighting strips 40 positioned between frame member 20 and optical shield 30.
(18) As best seen in FIG. 2, the angled wings 22 extend outwardly beyond the side edges of the light-transmitting optical shield 30. As such, angled wings 22 prevent a user's fingers from coming into contact with optical shield 30. This provides a safety feature since optical shield 30 is preferably made of a transparent or translucent plastic which can become fragile (and prone to chipping or breaking) in the cold temperatures of the refrigerated cabinet. As such, the present angled wings protect the fingers of both a customer accessing products within the refrigerated cabinet, and a store person initially stocking the cabinet with product.
(19) FIG. 2 also shows the ease of assembly of the present lighting system. Preferably, light-transmitting optical shield 30 is made of plastic and the angled wings 22 are made of metal. The metal may optionally be aluminum, but the present system is not so limited as other metals and materials may be used instead. As can be seen, the angled wings 22 and the frame member 20 itself can preferably be formed from the same block of material (for example as a metal extrusion, or simply by bending a planar sheet of material into this preferred shape). During assembly, the optical shield 30 is simply slid into frame member 20 with the angled wings 22 wrapping around the side edges 31 (shown in dotted lines) of optical shield 30.
(20) As can also be seen in FIG. 2, the illumination is provided with a pair of lighting strips 40 positioned back-to-back and perpendicular to the base 21 of frame member 20. The advantage of this exemplary arrangement is that there is no intervening support wall required between the pair of LED lighting strips 40.
(21) In preferred embodiments, angled wing 22 extends away from the base of the frame member at an angle θ of from 20 to 60, and more particularly about 30 degrees.
(22) As best seen in FIG. 3, each LED lighting strip 40 has a plurality of spaced-apart LED lights 42 mounted therealong with a coined reflective facet optic 44 mounted around each LED light 42. The facet optics are formed by “coining” (i.e. cold forming) the shapes into a malleable metal surface. As such, these optical facets are formed with high precision and are shaped to direct light into a highly selectable illuminated area. This significantly reduces scattering and resultant glare. The present system of coining the facets into the metal is both highly accurate and inexpensive to produce. In various embodiments of the present system, the metal used for the coined reflective facet optics 44 may be aluminum, copper, or brass.
(23) A second advantage of the coined reflective facet optics 44 are that (being metallic), have high heat conductivity that operates as a heat sink. This is important since the LEDs heat the circuit board that drives them, and this heat needs to be dissipated.
(24) Further details of the applicant's novel coined optic facets and methods for their production are set forth in Applicant's U.S. Pat. No. 8,882,302, incorporated herein by reference in its entirety.
(25) FIG. 4 provides a top view and FIG. 2 provides a sectional view showing light reflection according to the first (i.e.: “two-wing”) embodiment of the invention. Specifically, as best seen in FIG. 2, angled wings 22 intercept and reflect light emitted from lights 42 on LED lighting strip 40. Specifically, each angled wing 22 reflects light L1 that has been emitted in a lateral (i.e.: out to the side) direction from lights 42 on LED lighting strip 40. As also seen, light-transmitting optical shield 30 has a pair of side portions 30A and a top portion 30B.
(26) As can be seen in FIGS. 2 and 3, optical shield 30 covers open top ends 33 and open lateral ends 35 of each of the coined reflective facet optics 44. As can be seen, light-transmitting optical shield 30 extends continuously across the top 30B and both sides 30A of the lighting system between the pair of angled wings 22. As such, optical shield 30 extends continuously across 180 degrees of illumination.
(27) As can also be seen in FIG. 2, each angled wing 22 preferably has a height H generally equal to the height H of a side portion 30A. As a result, the light emitted laterally (i.e.: in direction L1) through side portion 30A will be intercepted and reflected by angled wing 22. Front and back end caps (27 in FIG. 1) can be used to cover the ends of the optical shield and the at least one angled wing 22 (to prevent particles or contaminants from getting into the spaces between frame 20's wing 22 and the side edge of optical shield 30's side portion 30A).
(28) FIGS. 5 and 6 illustrate a second (i.e.: “one-wing”) embodiment of the present illumination system 10, having a side wall 25 extending perpendicular to base 21 of frame 20. As can be seen, side wall 25 extends from a first side of base 10 and the angled wing 22 extends from an opposite side of base 20. In this embodiment, a single LED lighting strip 30 is positioned mounted onto or adjacent to side wall 25. The light-transmitting optical shield 30 extends continuously across the top 30B and one side 30A of the lighting system. As such, the optical shield 30 extends continuously across 90 degrees of illumination. The “one-wing” embodiment of the present lighting system functions similarly to the “two-wing” embodiment of the present lighting system with angled wing 22 reflecting intercepting light emitted laterally outwardly from the side of the illumination system and reflecting the light in direction L1. As will be shown more fully below, the “one-wing” embodiment of FIGS. 5 and 6 can be mounted onto the left side of a cabinet to reflect light to the right, or it can be mounted on the right side of the cabinet to direct light to the left. As that would be required to achieve this would be to mount one lighting fixture upside-down from the other at the other side of the cabinet. Conceivably, a pair of “one-wing” fixtures can even be mounted back to back with their respective wings facing outwardly and be operated similar to the “two-wing” embodiment shown in FIGS. 1, 2 and 4.
(29) FIGS. 7 and 8 illustrate a preferred use of the present illumination system 10 in a refrigerated cabinet 100 as follows. Cabinet 100 has interior shelves 110 onto which products P are positioned. Cabinet 100 preferably also has a front center beam 120 and left and right side beams 130. A pair of glass doors 140 are also provided, and the doors may be hinged onto opposite left and right side beams 130. Each glass door 140 may have a handle 141. Product P is stacked onto shelfs 110.
(30) As best seen in FIG. 8, the centrally positioned “two-wing” illumination fixture (i.e.: the embodiment of the illumination system of FIGS. 1, 2 and 4) mounted onto beam 120 will illuminate the center of the cabinet with its wings 22 reflecting the light emitted out of the sides of the fixture to the left and right interior sides of the refrigerated cabinet. Similarly, each of the two side-mounted lighting fixtures (i.e.: the embodiment of the illumination system of FIGS. 5 and 6) mounted onto beams 130 provides illumination from the sides of the cabinet, with their respective wings 22 reflecting the light emitted out of the sides of the fixtures.
(31) As can be seen in FIG. 8, the advantage of using the set of three above described illumination systems 10 in the cabinet is that the front facing sides of the products P receive illumination from two directions (i.e.: from one of the side mounted fixtures 10 and the center mounted fixture 10). There are several advantages to this lighting approach. First, having light coming from two directions onto the front of the products provides a bright and even illumination across the fronts of the products P. This makes the product labels clearly easy to read, even when the glass doors 140 are closed. Second, the effect of shadows is minimized since a user's hands will not likely block illumination coming from both directions. Third, as can be seen, angled wings 22 direct the light towards the front faces of the products which are recessed several inches from glass doors 140 to provide uniform lighting.
(32) FIG. 9 illustrates an optional microwave proximity sensor 50 mounted onto the frame member 20 of the centrally mounted “two-wing” embodiment of the illumination fixture 10. As can be seen, microwave proximity sensor 50 is preferably mounted spaced apart (i.e.: several inches behind) the base 21 of frame member 20. In operation, microwave proximity sensor 50 is mounted spaced apart from beam 120 such that beam 120 does not interfere with its signal. As such, the microwave sensor 50's signal has a clear path of transmission through the glass doors 140 of the cabinet. In operation, microwave sensor 50 detects the presence of a customer in the area and the cabinet lighting can then be turned on (or simply increased in intensity) when a customer walks towards the refrigerated cabinet. Ideally, this may be done while the customer is still in a neighboring aisle of the store. As such, the customer would not even notice the activation or change in the lighting as they approach the refrigerated cabinet.
(33) Lastly, FIG. 10 provides further explanation of the successive steps forming the coined reflective facet optics 44 and positioning them around the LED lighting strips 40, as follows. As seen in FIG. 11, a metal strip 200 can be first cut into the generally planar shape illustrated as 200A. Next, this strip can be advanced into a stamping machine (not shown) (where the metal strip is impacted from above and below) to form the shape of coin optic facets 44 illustrated as 200B. Finally, the metal strip can be further advanced into the stamping machine where the metal strip is then broken into two separate portions illustrated as 200C. Finally, as seen back in FIG. 3, the LED lighting strip 40 can then be received down into one of the two separate portions illustrated as 200C. Metal strip 200C can be attached around the top of LED lighting strip 40 with metal projections 201 being bent over the top of LED lighting strip 40, thereby forming the assembly that is inserted into the present illumination systems. As can be seen, the entire assembly of lighting strip 40 (with metal strip 200C wrapped therearound) is simple and easy to manufacture. As previously shown, the insertion of LED lighting strips 40 between frame 20 and optical shield 30 is also a simple and easy to perform operation. Finally, the assembly of optical shield 30 into frame 20 is also easy to perform (i.e.: simply by inserting the side edge of optical shield 30 into wing 22, and then sliding the optical shield 30 into position.
(34) The present illumination system has other features and advantages as disclosed herein.
