Optical cells for modular luminaires

Abstract

An optical cell (10) for forming a luminaire, the optical cell (10) comprising: (i) a light collector element (14), (ii) a cover element (15) attached to the light collector element (14), and (iii) a transmission element (16) mounted between the light collector element (14) and the cover element (15); wherein: (iv) the light collector element (14) comprises a body including: an input, e.g. an input opening, for receiving and collecting light from at least one light source, e.g. one or more LEDs (32) pre-mounted on a circuit- or wiring board (30); an output, e.g. an output opening, for propagating collected light towards the transmission element (16); at least one wall (52) defining one or more portions of the body, such as an internal chamber (53) therewithin, between its input and output, and configured for collecting light entering the body/chamber (53) via its input and conveying or directing said light towards its output; and attachment means (55, 65) for mechanically attaching the light collector element (14) to the cover element (15) and securing the transmission element (16) therebetween; (v) the cover element (15) comprises: an input opening facing towards the transmission element (16) and for receiving light transmitted thereby; an output opening via which light is outputted from the optical cell (10); and at least one internal surface (62) defining a cavity (63) within the cover element (15) between its input and output openings, the cavity's internal surface(s) (62) being configured for allowing or effecting passage of light, or a portion of the light, through the cavity (63) from the cover element's input opening towards its output opening; and (vi) the transmission element (16) comprises: one or more planar optical elements, wherein the or each optical element includes a first surface facing towards the output of the light collector element (14) and a second surface facing towards the input opening of the cover element (15), and the or each optical element exhibits a predetermined optical activity or function in its transmission of light incident thereon which has exited the output of the light collector element (14) and is transmitted by the transmission element (16) towards the input opening of the cover element (15).

Claims

1. An optical cell for forming a luminaire, the optical cell comprising: (i) a light collector element, (ii) a cover element attached to the light collector element, and (iii) a transmission element mounted between the light collector element and the cover element; wherein: (iv) the light collector element comprises a body including: an input for receiving and collecting light from at least one light source, an output for propagating collected light towards the transmission element, at least one wall defining one or more portions of the body between its input and output and configured for collecting light entering the body via its input and conveying or directing said light towards its output, and attachment means for mechanically attaching the body of the light collector element to the cover element and securing the transmission element between the light collector element and the cover element; (v) the cover element comprises: an input opening facing towards the transmission element and for receiving light transmitted by the transmission element, an output opening via which light is outputted from the optical cell, and at least one internal surface defining a cavity within the cover element between its input and output openings, the cavity's internal surface(s) being configured for allowing or effecting passage of light, or a portion of the light, through the cavity from the cover element's input opening towards its output opening; (vi) the transmission element comprises: one or more planar optical elements, wherein the or each optical element includes a first surface facing towards the output of the light collector element and a second surface facing towards the input opening of the cover element, and the or each optical element exhibits a predetermined optical activity or function in its transmission of light incident thereon which has exited the output of the light collector element and is transmitted by the transmission element towards the input opening of the cover element; and wherein: (vii) the transmission element comprises at least one optically active transmission optical element in the form of a generally flat or planar foil, film, sheet, web, plate, layer or other thin body of optical material exhibiting a desired optical function which effects or facilitates a desired distribution and/or one or more output characteristics of light emanating from the optical cell, by modifying or modulating one or more optical properties of the light emitted by the light source(s) as determined by the optical function of the optically active transmission element of the optical cell, wherein the transmission element comprises a said first surface, which is a first major face thereof, and a said second surface, which is a second major face thereof, and at least one of said first and second surfaces, or each of said first and second surfaces, comprises or is formed with optical functional nano-relief or micro-relief which displays either diffractive or refractive behaviour or a combination of diffractive and refractive behaviour.

2. An optical cell according to claim 1, wherein the light collector element actually has the said at least one light source mounted or positioned in or on or adjacent the input thereof.

3. An optical cell according to claim 1, wherein the optical cell further comprises at least one circuit board or wiring board, or a portion of a circuit board or wiring board, having the said at least one light source mounted, or pre-mounted, thereon.

4. An optical cell according to claim 1, wherein: either (i) the or each optical cell comprises, or has mounted or positioned therein or thereon or thereadjacent, or is for having mounted or positioned therein or thereon or thereadjacent, a single LED or other light emitting device as the said at least one light source; or (ii) the or each optical cell comprises, or has mounted or positioned therein or thereon or thereadjacent, or is for having mounted or positioned therein or thereon or thereadjacent, an array, cluster, series or group of a plurality of LEDs or other light emitting devices as the said at least one light source.

5. An optical cell according to claim 1, wherein one of the following (i) or (ii) is present or satisfied: (i) the said at least one light source which is/are used to form the luminaire is/are mounted or arranged on at least one circuit board or wiring board, or at least one portion of a circuit board or wiring board, in substantially a single common plane, by virtue of being mounted on a single common planar circuit board or wiring board, or a single common planar portion of either thereof, or a plurality of individual circuit board or wiring board elements each lying in a common plane; or (ii) the said at least one light source which is/are used to form the luminaire is/are mounted or arranged either: (ii)(a) on a single common circuit board or wiring board, or a single common portion of either thereof, which is shaped or configured in a substantially non-planar, or arcuate or otherwise curved in three dimensions, shape or configuration, or (ii)(b) on a plurality of individual circuit board or wiring board elements which are collectively arranged or configured relative to each other so as to form a substantially non-planar, or arcuate or otherwise curved in three dimensions, shaped or configured circuit board/wiring board arrangement.

6. An optical cell according to claim 1, wherein the light collector element of the or each optical cell takes the form of a hollow body, the hollow body comprising: an input opening for receiving and collecting light from the at least one light source, an output opening for propagating collected light towards the transmission element, at least one internal wall defining a chamber within the light collector element between its input and output openings, the chamber wall(s) being configured for collecting light entering the chamber via the light collector element's input opening and conveying or directing or redirecting said light, or a portion of said light, towards its output opening, and attachment means for mechanically attaching the light collector element to the cover element and securing the transmission element between the light collector element and the cover element; wherein the light collector element comprises a hollow body, housing, casing or container which comprises one or more internal walls defining and enclosing the said internal chamber therewithin, wherein the chamber is configured for containing, or having protruding thereinto, or for having mounted adjacent a lower opening or mouth thereof, the respective light source(s) when the components of the final luminaire are fully assembled.

7. An optical cell according to claim 6, wherein the internal wall(s) defining the chamber within the light collector element are configured such that the chamber has a three-dimensional shape which is: (i) generally substantially conical, part-conical or frusto-conical, or (ii) generally substantially cylindrical, or (iii) generally substantially inverted-pyramidal, with any number of sides from 3 upwards, and in each case (i), (ii) or (iii) with the chamber's diameter/width increasing passing from the light collector element's input opening to its output opening.

8. An optical cell according to claim 1, wherein the light collector element of the optical cell takes the form of a substantially solid body of light-permeable or light-transparent or light-transmissible material, the body comprising: an input surface for receiving and collecting light from the at least one light source, an output surface for propagating collected light towards the transmission element, at least one wall defining one or more portions of the body of the light collector element between its input and output surfaces, the at least one wall being configured for collecting light entering the body via the light collector element's input surface and redirecting and/or guiding said light, or a portion of said light, towards its output surface at least in part by means of TIR (total internal reflection) phenomena, and attachment means for mechanically attaching the light collector element to the cover element and securing the transmission element between the light collector element and the cover element.

9. An optical cell according to claim 1, wherein the light collector element includes support means for supporting the transmission element in the finally assembled optical cell, in order to assist in effecting a secure and stable supported mounting of the transmission element, relative to the light collector element and the cover element, in the finally assembled optical cell.

10. An optical cell according to claim 1, wherein the light collector element includes mounting means for mounting and/or aligning the light collector element on a circuit board or wiring board carrying the said at least one light source; wherein one or more of the following (i), (ii) and (iii) is present or satisfied: (i) the mounting means comprises one or more, or one or more pairs of, pins, spigots, ribs, protrusions, detents, clips, hooks, retaining members/elements, friction-fit or snap-fit elements, or solderable components, or other (inter-)engagement elements, provided on one of the light collector element and a portion of the circuit-or wiring board, and a corresponding or appropriate number of one or more holes, apertures, recesses, grooves, channels, or corresponding clip, hook, retainer, friction-fit, snap-fit elements, or solderable components, or other (inter-)engagement elements (for inter-engagement with the preceding defined (inter-)engagement element(s)) provided on the other of the light collector element and the portion of the circuit-or wiring board, whereby the light collector element can be united with the circuit-or wiring board; (ii) the mounting means comprises a suitably sized, shaped and positioned land, seating element or portion, or mounting surface on at least one of, or both of, the light collector element and a portion of the circuit-or wiring board, via which the light collector element can be adhered to the circuit-or wiring board by use of an adhesive; (iii) the mounting means comprises one or more sockets provided on one of the light collector element and a portion of the circuit-or wiring board into which can be plugged a corresponding pin, spigot, protrusion, or other pluggable securement element provided on the other of the light collector element and a portion of the circuit-or wiring board.

11. An optical cell according to claim 1, wherein the light collector element includes first attachment means, or a component of first attachment means, for mechanically and securely attaching the light collector element to the cover element of the optical cell, with the transmission element secured therebetween; wherein the first attachment means comprise one or more, or one or more pairs of, snap-fit connection elements provided on the light collector element which is/are inter-engageable in a snap-fit manner with one or more corresponding snap-fit connection elements, or pairs of snap-fit connection elements, provided on the cover element.

12. An optical cell according to claim 1, wherein, in the cover element, for the purpose of the cover element's cavity's internal surface(s) being configured for allowing or effecting passage of light, or a portion of the light, through the cavity from the cover element's input opening towards its output opening, any one or more of the following optical effects (i), (ii), (iii) or (iv) is/are present: (i) one or more internal surfaces, or one or more portions of one or more internal surfaces, of the cavity is/are configured for allowing passage or propagation of light, or any portion of the light, through the cavity from the cover element's input opening towards its output opening substantially unhindered, substantially without any interaction with or impingement or incidence on the or the respective cavity internal surface(s) or surface portion(s); (ii) one or more internal surfaces, or one or more portions of one or more internal surfaces, of the cavity is/are configured so as to reflect or redirect or scatter light, or any portion of the light, that interacts therewith or impinges or is incident thereon, as it is conveyed or passes or travels through the cavity from the cover element's input opening towards its output opening; (iii) one or more internal surfaces, or one or more portions of one or more internal surfaces, of the cavity is/are configured so as to substantially block or prevent or absorb the passage or travel of light, or any portion of the light, through the cavity from the cover element's input opening towards its output opening, where the said light is light (or a portion of it) that is so passing or travelling through the cavity at angles (relative to a central axis of the cover element) greater than or beyond one or more predetermined boundary angle(s); (iv) any one or more of the effects (i), (ii) and/or (iii) above is/are present simultaneously, as or when effected by different or discrete portions of the one or more internal surfaces of the cavity or a part thereof.

13. An optical cell according to claim 1, wherein the cover element comprises a frame, casing, surround or body which comprises one or more internal surfaces which define and enclose the said internal cavity therewithin, wherein the said internal cavity is defined by the said internal surface(s) thereof which at least partially unite with or which are at least partially contiguous with or which are at least partially continuations of the wall(s) of the body, or at least an upper portion or upper peripheral region of the body, of the light collector element.

14. An optical cell according to claim 1, wherein the cover element includes one or more anti-glare features, wherein the or each anti-glare feature is constituted by one or more internal walls of the cover element having an extended height or upward length and being configured so as to have one or more internal walls or surfaces which are oriented at an angle, relative to a central or optical axis of the optical cell, of 20, and in the range of from about 0 or 5 or 10 or 15 or 20 or 30 up to about 50 or 60 or 70 or 80, whereby light rays emanating from the light source in that optical cell and being conveyed or directed by the light collector element through the transmission element and into the cavity within the cover element and towards the cover element's output opening, at an exit angle beyond a certain maximum angle value (as dependent on the actual aforementioned wall orientation angle and/or in conjunction with the height of the cover element's wall(s)) are blocked, cut out or at least partially absorbed by the cover element's wall material and thereby prevented from exiting the optical cell and causing unwanted glare.

15. An optical cell according to claim 1, wherein the light collector element of the or each optical cell takes the form of a hollow body, the hollow body comprising: an input opening for receiving and collecting light from the at least one light source, an output opening for propagating collected light towards the transmission element, at least one internal wall defining a chamber within the light collector element between its input and output openings, the chamber wall(s) being configured for collecting light entering the chamber via the light collector element's input opening and conveying or directing or redirecting said light, or a portion of said light, towards its output opening, and attachment means for mechanically attaching the light collector element to the cover element and securing the transmission element between the light collector element and the cover element; wherein the light collector element comprises a hollow body, housing, casing or container which comprises one or more internal walls defining and enclosing the said internal chamber therewithin, wherein the chamber is configured for containing, or having protruding thereinto, or for having mounted adjacent a lower opening or mouth thereof, the respective light source(s) when the components of the final luminaire are fully assembled; and wherein the internal surface(s) defining the cavity within the cover element are configured such that the cavity has a three-dimensional shape which is: (i) generally substantially part-conical or frusto-conical, or (ii) generally substantially cylindrical, or (iii) generally substantially inverted-pyramidal, with any number of sides from 3 upwards, and in each case (i), (ii) or (iii) with the cavity's diameter/width increasing passing from the cover element's input opening to its output opening.

16. An optical cell according to claim 1, wherein the transmission element is cut or shaped to include a suitable number of peripheral indents, notches, recesses, channels, or cut-outs, for the purpose of accommodating and allowing to extend therepast any elements or components of snap-fit-type attachment means that extend between the cover element and the light collector element for the purpose of attaching those two elements together, with the transmission element securely and stably trapped or clamped therebetween.

17. A luminaire comprising: one or more optical cells according to claim 1; a body or frame in which is/are contained the said one or more optical cells; and one or more light sources, the or each said light source being contained in a respective light collector element of a respective optical cell; further comprising at least one circuit board or wiring board on which is/are mounted the said one or more light sources; and further comprising a configuring element for accommodating the one or more optical cells in a predefined relative configuration or pattern in the luminaire, wherein the configuring element comprises a sheet or plate or film of material having one or more apertures therein in the said predefined relative configuration or pattern, each aperture being for receiving therein a respective one of the said optical cells.

18. An assembly for forming into a luminaire, which assembly is any one of the following (i), (ii) or (iii): (i) an assembly comprising: one or more optical cells according to claim 1; and a body or frame in which is/are contained the said one or more optical cells; wherein each respective light collector element of a respective optical cell is for containing or having mounted therein or thereon or thereadjacent a respective one of the said at least one light source; (ii) an assembly comprising: one or more optical cells according to claim 1; and at least one light source, the or each said light source being mounted or positioned in or on or adjacent a respective light collector element of a respective optical cell, wherein the or each light source is mounted or pre-mounted on at least one circuit board or wiring board, or a portion of a circuit board or wiring board; (iii) an assembly comprising: a body or frame; and at least one light source mounted or positioned in the body or frame, the or each said light source being mounted or pre-mounted on at least one circuit board or wiring board or a portion of a circuit board or wiring board, wherein the or each light source is arranged and/or positioned and/or configured for having mounted or positioned thereon or thereover or thereadjacent a respective light collector element of a respective optical cell according to claim 1, once the or the respective optical cell has been mounted or positioned in the body or frame; wherein any one of the said assemblies further comprises a configuring element for accommodating the one or more optical cells in a predefined relative configuration or pattern in the luminaire, wherein the configuring element comprises a sheet or plate or film of material having one or more apertures therein in the said predefined relative configuration or pattern, each aperture being for receiving therein a respective one of the said optical cells.

19. A method of production of a luminaire, the method comprising: (i) forming one or more optical cells according to claim 1 by, for each optical cell: (i)(a) providing a light collector element, a cover element for attachment to the light collector element, and a transmission element for mounting between the light collector element and the cover element; wherein: the light collector element comprises a body including: an input for receiving and collecting light from at least one light source, an output for propagating collected light towards the transmission element, at least one wall defining one or more portions of the body between its input and output and configured for collecting light entering the body via its input and conveying or redirecting said light towards its output, and attachment means for mechanically attaching the light collector element to the cover element and securing the transmission element between the light collector element and the cover element; the cover element comprises: an input opening facing towards the transmission element and for receiving light transmitted by the transmission element, an output opening via which light is outputted from the optical cell, and at least one internal surface defining a cavity within the cover element between its input and output openings, the cavity's internal surface(s) being configured for allowing or effecting passage of light, or a portion of the light, through the cavity from the cover element's input opening towards its output opening; and the transmission element comprises: one or more planar optical elements, wherein the or each optical element includes a first surface facing towards the output of the light collector element and a second surface facing towards the input opening of the cover element, and the or each optical element exhibits a predetermined optical activity or function in its transmission of light incident thereon which has exited the output of the light collector element and is transmitted by the transmission element towards the input opening of the cover element, and wherein the transmission element comprises at least one optically active transmission optical element in the form of a generally flat or planar foil, film, sheet, web, plate, layer or other thin body of optical material exhibiting a desired optical function which effects or facilitates a desired distribution and/or one or more output characteristics of light emanating from the optical cell, by modifying or modulating one or more optical properties of the light emitted by the light source(s) as determined by the optical function of the optically active transmission element of the optical cell, wherein the transmission element comprises a said first surface, which is a first major face thereof, and a said second surface, which is a second major face thereof, and at least one of said first and second surfaces, or each of said first and second surfaces, comprises or is formed with optical functional nano-relief or micro-relief which displays either diffractive or refractive behaviour or a combination of diffractive and refractive behaviour; and (i)(b) attaching the cover element to the light collector element, with the transmission element mounted therebetween; (ii) mounting or positioning at least one light source in or on or adjacent respective light collector element(s) of the respective optical cell(s); and, either before or after this step (ii), (iii) mounting or positioning the one or more optical cells in a body or frame of the luminaire; wherein the step (ii) of mounting or positioning the at least one light source in or on or adjacent respective light collector element(s) of the respective optical cell(s) comprises either: mounting or positioning in or on or adjacent respective light collector element(s) of the respective optical cell(s) a or a respective one of at least one circuit board or wiring board, or a portion of a circuit board or wiring board, on which has/have already been pre-mounted the said at least one light source; or mounting or positioning respective light collector element(s) of the respective optical cell(s) on or over or adjacent respective one(s) of the said at least one light source, or on or over or adjacent respective one(s) of the said at least one light source which has/have already been pre-mounted on the said circuit board or wiring board or portion of a circuit board or wiring board; and further wherein the step (i) of forming the one or more cells additionally comprises, for each cell, additional steps (i)(c) and (i)(d), subsequent to step (i)(b), which comprise: (i)(c) providing a configuring element for accommodating the one or more optical cells in a predefined relative configuration or pattern in the luminaire, wherein the configuring element comprises a sheet or plate or film of material having one or more apertures therein in a predefined relative configuration or pattern, each aperture being for receiving therein a respective one of the said optical cells; and (i)(d) inserting the respective optical cell into a respective aperture in the configuring element.

20. A luminaire according to claim 17, wherein the said at least one circuit board or wiring board and the said configuring element are present in the luminaire, and the luminaire further includes means for forming or creating one or more air gaps or spaces, or series of air gaps or spaces, between the components of any one or more of the following pairs of components of the luminaire: (i) an input side of the or each optical cell and the configuring element; or (ii) an input side of the or each optical cell and the circuit board or wiring board carrying the respective light source associated with that respective optical cell; or (iii) an input side of the or each optical cell and the respective light source associated with that respective optical cell; or (iv) one or more side walls of the or each optical cell and the respective light source associated with that respective optical cell; or (v) the configuring element and the circuit board or wiring board carrying the respective light source associated with that respective optical cell.

21. An optical cell according to claim 6, wherein the light collector element comprises at least one reflecting and/or collimating element or feature for reflecting and/or collimating light entering the chamber therewithin from the light source associated with that optical cell and directing or redirecting that light towards the chamber's output opening and thus towards the transmission element, and optionally further onwards towards the cover element of that optical cell, wherein the at least one reflecting and/or collimating element or feature comprise(s) one or more internal light-reflecting walls or surfaces, and/or one or more internal walls or surfaces that function to collimate light passing through the light collector element.

22. A kit of parts for use in forming one or more optical cells for use in forming a luminaire, the kit comprising: (i) at least one light collector element, (ii) at least one cover element for attachment to the or a respective light collector element, and (iii) at least one transmission element for mounting between the or the respective light collector element and cover element; wherein: (iv) the or each respective light collector element comprises a body including: an input for receiving and collecting light from at least one light source, an output for propagating collected light towards the or the respective transmission element, at least one wall defining one or more portions of the body between its input and output and configured for collecting light entering the body via its input and conveying or directing said light towards its output, and attachment means for mechanically attaching the or the respective light collector element to the or the respective cover element and securing the or the respective transmission element between the or the respective light collector element and cover element; (v) the or each respective cover element comprises: an input opening facing towards the or the respective transmission element and for receiving light transmitted by the or the respective transmission element, an output opening via which light is outputted from the optical cell, and at least one internal surface defining a cavity within the cover element between its input and output openings, the cavity's internal surface(s) being configured for allowing or effecting passage of light, or a portion of the light, through the cavity from the cover element's input opening towards its output opening; and (vi) the or each respective transmission element comprises: one or more planar optical elements, wherein the or each optical element includes a first surface facing towards the output of the or the respective light collector element and a second surface facing towards the input opening of the or the respective cover element, and the or each optical element exhibits a predetermined optical activity or function in its transmission of light incident thereon which has exited the output of the or the respective light collector element and is transmitted by the transmission element towards the input opening of the or the respective cover element, and wherein the transmission element comprises at least one optically active transmission optical element in the form of a generally flat or planar foil, film, sheet, web, plate, layer or other thin body of optical material exhibiting a desired optical function which effects or facilitates a desired distribution and/or one or more output characteristics of light emanating from the optical cell, by modifying or modulating one or more optical properties of the light emitted by the light source(s) as determined by the optical function of the optically active transmission element of the optical cell, wherein the transmission element comprises a said first surface, which is a first major face thereof, and a said second surface, which is a second major face thereof, and at least one of said first and second surfaces, or each of said first and second surfaces, comprises or is formed with optical functional nano-relief or micro-relief which displays either diffractive or refractive behaviour or a combination of diffractive and refractive behaviour.

23. A kit of parts for use in forming a luminaire, the kit comprising: one or more, or any plurality of, optical cells each including: (i) at least one light collector element, (ii) at least one cover element for attachment to the or a respective light collector element, and (iii) at least one transmission element for mounting between the or the respective light collector element and cover element; wherein: (iv) the or each respective light collector element comprises: an input for receiving and collecting light from at least one light source, an output for propagating collected light towards the or the respective transmission element, at least one wall defining one or more portions of the body between its input and output and configured for collecting light entering the body via its input and conveying or directing said light towards its output, and attachment means for mechanically attaching the light collector element to the or the respective cover element and securing the or the respective transmission element between the or the respective light collector element and cover element; (v) the or each respective cover element comprises: an input opening facing towards the or the respective transmission element and for receiving light transmitted by the or the respective transmission element, an output opening via which light is outputted from the optical cell, and at least one internal surface defining a cavity within the cover element between its input and output openings, the cavity's internal surface(s) being configured for allowing or effecting passage of light, or a portion of the light, through the cavity from the cover element's input opening towards its output opening; and (vi) the or each respective transmission element comprises: one or more planar optical elements, wherein the or each optical element includes a first surface facing towards the output of the or the respective light collector element and a second surface facing towards the input opening of the or the respective cover element, and the or each optical element exhibits a predetermined optical activity or function in its transmission of light incident thereon which has exited the output of the or the respective light collector element and is transmitted by the transmission element towards the input opening of the or the respective cover element, and wherein the transmission element comprises at least one optically active transmission optical element in the form of a generally flat or planar foil, film, sheet, web, plate, layer or other thin body of optical material exhibiting a desired optical function which effects or facilitates a desired distribution and/or one or more output characteristics of light emanating from the optical cell, by modifying or modulating one or more optical properties of the light emitted by the light source(s) as determined by the optical function of the optically active transmission element of the optical cell, wherein the transmission element comprises a said first surface, which is a first major face thereof, and a said second surface, which is a second major face thereof, and at least one of said first and second surfaces, or each of said first and second surfaces, comprises or is formed with optical functional nano-relief or micro-relief which displays either diffractive or refractive behaviour or a combination of diffractive and refractive behaviour; optionally together with one or more of the following: a body or frame for containing the said optical cell(s) and any other components of the luminaire; or at least one, or a plurality of, said light source(s) for mounting or positioning in or on or adjacent the or each respective said light collector element of the or each respective optical cell; or a configuring element for accommodating the one or more optical cells in a predefined relative configuration or pattern in the luminaire, wherein the configuring element comprises a sheet or plate or film of material having one or more apertures therein in the said predefined relative configuration or pattern, each aperture being for receiving therein a respective one of the said optical cells.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Various embodiments of the present invention in its various aspects will now be described in detail, by way of example only, with reference to the accompanying drawings, in which:

(2) FIG. 1 is a plan view of an arrangement for forming into a luminaire, comprising an array of a plurality of optical cells each according to an embodiment of the invention, in which arrangement a hexagonal configuring element (as just one example of a possible polygonal shape thereof) is employed for accommodating the various optical cells of the array, in order to enhance the modular nature of the luminaire-building system;

(3) FIG. 2 is a perspective view of the arrangement of FIG. 1, in which the optical cells of the array are in the process of being inserted into the respective apertures in the configuring element;

(4) FIG. 3(a) is an enlarged side-on sectional view of part of the arrangement shown in FIGS. 1 & 2, showing the manner in which each optical cell is mounted in its respective aperture in the configuring element, and how a circuit board on which are pre-mounted the various LEDs is then brought together with the optical cells+configuring element arrangement in the formation of the complete luminaire;

(5) FIG. 3(b) is an enlarged side-on sectional view of the arrangement of FIG. 3, showing more clearly the manner in which the light collector element of each optical cell is mounted in its respective aperture in the configuring element;

(6) FIGS. 4(a), (b) & (c) are, respectively, upper-perspective, side-perspective and lower-perspective views of one complete optical cell according to an embodiment of the invention, which is used in FIGS. 1 to 3 to build up the array of optical cells for forming into the luminaire;

(7) FIG. 5 is an exploded side-perspective view of the optical cell of FIG. 4, showing its constituent components;

(8) FIGS. 6(a) & (b) are, respectively, side-perspective and lower-perspective views of the light collector element alone of the optical cell of FIGS. 4 and 5;

(9) FIGS. 7(a) and 7(b) are, respectively, side-perspective & side views and cross-sectional views of an alternative form of light collector element alone, of the nature of a TIR solid body, which may be used in some alternative embodiments in place of the hollow-body form of light collector element shown in FIGS. 4 to 8 and 12 to 15;

(10) FIGS. 7(c) & 7(d) are, respectively, upper perspective and lower perspective view of an alternative design of a light collector element alone of the nature of a TIR solid body, more akin in general shape and configuration to the hollow-body version thereof shown in FIGS. 4 to 8 and 12 to 15 and usable in some alternative embodiments as a replacement therefor;

(11) FIGS. 8(a), (b) & (c) are side views of three different techniques by which the light collector element of FIGS. 6(a) & (b) may be mounted on a LED-carrying circuit board or wiring board;

(12) FIG. 9(a) is a side-perspective view of the transmission element alone of the optical cell of FIGS. 4 and 5, and FIGS. 9(b) & (c) are, respectively, side-perspective and side elevational cut-away views showing in clearer detail the positioning of the transmission element in the overall optical cell assembly;

(13) FIG. 10(a) is a side-perspective view of the cover element alone of the optical cell of FIGS. 4 and 5, and FIG. 10(b) is a side-elevational cut-away view showing in clearer detail the positioning of the cover element relative to the other components of the overall optical cell assembly;

(14) FIG. 11 is a side-perspective view of an alternative form of cover element, for use in another embodiment of the invention;

(15) FIGS. 12(a) & (b) are, respectively, side-perspective and exploded views of a further alternative embodiment of optical cell, in which the constructions of certain parts of the light collector element and the cover element have been modified, and the configuration of the transmission element has been modified, whereby the components of the optical cell are securable together in a modified way, in comparison with those of the cell of FIGS. 4-10;

(16) FIG. 13(a) is an upper-perspective view of a yet further alternative embodiment of optical cell in accordance with the invention, in which the general basic shape (in plan) of the optical cell is circular;

(17) FIGS. 13(b), (c) & (d) are upper-perspective and lower-perspective views of, respectively, the light collector element, the transmission element, and the cover element of the modified embodiment optical cell of FIG. 13(a);

(18) FIG. 14(a) is an upper-perspective view of a yet further alternative embodiment of optical cell in accordance with the invention, in which the general basic shape (in plan) of the optical cell is square;

(19) FIGS. 14(b), (c) & (d) are upper-perspective and lower-perspective views of, respectively, the light collector element, the transmission element, and the cover element of the modified embodiment optical cell of FIG. 14(a);

(20) FIG. 15(a) is an upper-perspective view of a yet further alternative embodiment of optical cell in accordance with the invention, in which the general basic shape (in plan) of the optical cell is hexagonal;

(21) FIGS. 15(b), (c) & (d) are upper-perspective and lower-perspective views of, respectively, the light collector element, the transmission element, and the cover element of the modified embodiment optical cell of FIG. 15(a); and

(22) FIGS. 16(a), (b), (c) & (d) are perspective views of four different types of LED chips, which may be used as any of the light sources in any of the illustrated, or even other, embodiments of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

(23) Embodiments of the present invention provide a modular system of optical cells and optical cell components for use in constructing luminaires, and are based on the use of a modular set of optical cell components which are constructionally simple and cheap to mass-produce and deploy, and versatile in being able to form optical cells or optical modules that can be combined in any desired numbers and array configurations or layouts to form, together with appropriate LEDs-carrying circuit- or wiring board(s), luminaires of a wide range of sizes, shapes and designs.

(24) Each optical cell or optical module may have associated with itby virtue of having mounted or positioned therein or thereon or thereadjacentone or more LEDs, and each optical cell's assemblage of optical components can represent or be assembled into individual optical cells each being designed and configured to redistribute light from each light source (LED), and from the light sources (LEDs) collectively, into a desired final output light distribution of the finished luminaire. Within luminaires according to embodiments of the invention, therefore, the optical cells can be spatially distributed according to the luminaire's design. They can form any type of regular or irregular arrangement, such as linear, rectangular, hexagonal, radial, randomized etc.

(25) FIG. 1 shows an example embodiment arrangement 1 for forming into a luminaire, in which a hexagonal configuring element 20, e.g. die-cut from a flat sheet or plate (such as of a thickness tsee FIG. 3(b)of around 1-2 mm) of a suitably strong and rigid plastics material, containing an array of optical cell-locating apertures 22 is employed for accommodating a symmetrical array of a large number of compact optical cells 10. Each optical cell 10 is an optical cell in accordance with any of various embodiments of the present invention. FIG. 2 shows those optical cells 10 in the process of being inserted into the respective apertures 22 in the configuring element 20, and fixed therein by appropriate means such as a simple friction fit, or gluing, or a click-in or snap-fit docking mechanism.

(26) FIGS. 3(a) & 3(b) show more clearly and in greater detail the manner in which each optical cell 10 is mounted in its respective aperture 22 in the configuring element 20, and how a circuit board 30 on which are pre-mounted the various LEDs 32 is then brought together with the optical cells 10+configuring element 20 arrangement in the formation of the complete luminaire.

(27) As shown in FIGS. 3(a) & 3(b), but shown more clearly in FIGS. 4(a), 4(b) & 4(c) and FIG. 5 (the latter in exploded form), each optical cell 10 comprises a lower light collector element 14, an upper click-on cover element 15, and, mounted in a stable clamped manner therebetween, an optical transmission element 16.

(28) The light collector element 14 is shown more clearly alone in FIGS. 6(a) & (b). The light collector element 14 is in the form of an injection-moulded hollow body or container of e.g. a polycarbonate (or other suitably strong and rigid polymeric material), and its internal walls 52 define a circular-transverse-sectioned frusto-conical void or chamber 53 therewithin which is accessible from beneath via a lower hole or aperture 59 through which can protrude a respective LED 32 provided pre-mounted on a circuit board or wiring board 30. A lower portion of the light collector element 14 includes a generally cylindrical outer surface portion 54 for enabling the light collector element 14's friction-fit into the respective aperture 22 in the configuring element 20 used to form the luminaire. It also includes at least one suitably sized, shaped and positioned contact land, seating element or portion, or mounting surface 57 via which the light collector element 14 can be adhered to the circuit- or wiring board 30, e.g. by use of a suitable adhesive (examples of which are well-known in the art and widely commercially available). The top planar wall portions 51 (FIG. 6(a)) of the light collector element 14 serve as support means for stably and securely supporting the transmission element 16 in the finally assembled optical cell 10.

(29) The internal walls 52 of the frusto-conical chamber 53 within the hollow-body light collector element 14 are formed with a light-reflecting and/or light-collimating coating of vacuum-deposited aluminium (or other suitable light-reflective material), for collecting and redirectingby reflecting and/or collimatingthe light emitted from the respective LED 32 contained in that optical cell 10 and directing or redirecting it towards the optical cell's transmission element 16, and from there onwards towards the optical cell's light output (i.e. which in practice is the upper output opening or mouth of the optical cell's cover element 15).

(30) Although the hollow light collector element 14 of this embodiment is shown here as being circular in transverse cross-section, with its internal chamber 53 being frusto-conical, like the alternative light collector element 314 shown in FIG. 13(b), other alternative cross-sectional and/or three-dimensional shapes of the internal chamber 53 within the light collector element 14 are possible in other embodiments: for example an inverted-pyramidal chamber that in cross-section is square, as shown for the alternative light collector element 414 in FIG. 14(b); or hexagonal, as shown for the alternative light collector element 514 in FIG. 15(b).

(31) In addition to the one or more mounting surface(s) 57 (via which the light collector element 14 can be adhered to the circuit- or wiring board 30), the light collector element 14 further includes additional mechanical attachment means in the form of two pairs of mounting pins or spigots 58, which not only provide a more secure means of mounting the light collector element 14 on the circuit- or wiring board 30, but also serve to align it into its correct position and orientation upon it being mounted on the circuit- or wiring board 30. The mounting pins or spigots 58 also inherently act as spacers for defining and setting a predetermined spacing distance between the circuit- or wiring board 30 and the light collector element 14 once the latter has been mounted thereon.

(32) The light collector element 14 further includes an appropriate number of locating holes or apertures 55 formed in an upper wall or attachment portion thereof, into which are locatable in an inter-engageable snap-fit or click-in fashion a corresponding number and spatial arrangement of elongate legs 65 extending from a lower wall or attachment portion of the cover element 15 (as shown more clearly in FIG. 10). Each of the legs 65 includes a respective lower locking or engagement detent, step, notch, hook or catch element 65L, and each of the holes/apertures 55 in the light collector element 14 includes a respective locking seating, recess, edge, abutment surface or catch feature 55L, for forming the respective inter-engagement snap-fit/click-in attachment feature of the light collector and cover elements 14, 15.

(33) The light collector element 14 shown in the drawings so far is of the hollow-body species, with sidewalls that form an internal chamber therewithin for collecting and conveying light therethrough. However, as an alternative to such a hollow-body species type of light collector element, a solid-body species type may be used insteadone example of which is shown in FIGS. 7(a) and (b). Such an alternative form of light collector element 14 relies on TIR (total internal reflection) phenomena at one or more of its external surfaces to perform the necessary task of directing or redirecting light (or a portion of the light) passing through the solid body from its input surface or side to its output surface or side.

(34) The body of the light collector element 14 comprises a suitably shaped and configured substantially solid body of light-permeable or light-transparent or light-transmissible material, e.g. various plastics materials, such as polycarbonate (PC), polymethylmethacrylate (PMMA), polyethylene terephthalate (PET), or a glass. The body's external walls are shaped or configured in any suitable or appropriate manner (or combination of manners in different portions thereof) which effects the desired TIR (total internal reflection) phenomena which at least in part serve to redirect and/or guide light, or a portion of the light, that has entered the body towards the body's output surface/side. Suitable such exterior shapes of any one or more of, or one or more portions of, the TIR solid body side wall(s) may include, for example: conical, part-conical or frusto-conical, paraboloidal, hyperboloidal, cylindrical, pyramidal (especially inverted pyramidal) with any number of sides from 3 upwards (e.g. a pyramid with from 3 to 6 or 7 or 8 sides), or circular or elliptical or polygonal in horizontal or transverse cross-section, or with side wall(s) or one or more portions of one or more side walls being either substantially planar or alternatively curved or arcuate in shape moving from the body's input surface to its output surface with a curve function defined by any suitable/appropriate geometric curve function, especially a curve function that provides the TIR capability. As with the hollow-body version of light collector element 14 shown in the other FIGS., the alternative TIR-based solid body light collector element 14 shown here likewise includes, inter alia, locating holes or apertures 55 formed in an upper wall or attachment portion thereof, into which are locatable in an inter-engageable manner corresponding snap-fit or click-in locking or attachment legs from the relevant cover element of the respective optical cell.

(35) The form and optical behavior of the solid-body TIR-based light collector element 14 are illustrated by way of self-explanatory example in FIG. 7(b).

(36) FIGS. 7(c) & 7(d) show an alternative design of a TIR-based solid body light collector element 14 alone, which is more akin in general shape and configuration to the hollow-body version thereof shown in FIGS. 4 to 8 and 12 to 15 and usable in some alternative embodiments as a replacement therefor.

(37) FIGS. 8(a), 8(b) & 8(c) show three different techniques by which the light collector element 14 of FIGS. 6(a) & (b) of each given optical cell 10 may be mounted on the LED-carrying circuit- or wiring board 30. For example: As shown in the technique of FIG. 8(a), the pins/spigots 58 fit snugly into corresponding holes, apertures or recesses 58A in the upper surface of the circuit- or wiring board 30, and they may optionally be glued therein, and they thereby act primarily as alignment features to ensure the correct positioning and alignment of the light collector element 14 at its mounting site on the board 30; As shown in the technique of FIG. 8(b), here the apertures or recesses 58A in the upper surface of the board 30 are omitted, and instead the pins/spigots 58 are glued directly to the upper surface of the board 30, and they thereby act primarily as spacers to define the correct spacing between the light collector element 14 and the board 30 once they have been mounted together; As shown in the technique of FIG. 8(c), here the pins/spigots 58 have been chopped or cut off, so are omitted altogether, and instead the light collector element 14 is glued onto the upper surface of the board 30 via its remnant back mounting surface(s) 57.

(38) FIG. 8(b) also illustrates by way of example one way in which the arrangement may be designed so as to include an air gap AG (e.g. of up to about 0.5 or 1 or 2 or 3 mm in depth) formed or created between the lower (i.e. input) side of each optical cell 10 and the circuit- or wiring board 30 on which the respective LED 32 is mounted. In this particular illustrated case, the air gap AG is formed by virtue of the one or more pairs of spacer members 58, which are provided on the lower face of the optical cell's light collector element 14, in the form of legs, pins, legs, or spigots 58, which simultaneously also act as mounting means of type (i) defined hereinabove which act as spacer means for defining and setting a predetermined spacing distance between the circuit- or wiring board 30 and the light collector element 14 of the respective optical cell 10. The provision of this air gap AG helps promote air flow around the components of the arrangement, thereby helping to dissipate heat generated from the respective LED 32 by convective air flow or even by forced air flow (e.g. using a fan included within the overall luminaire apparatus), and thus to help prevent or ameliorate a risk of overheating of the respective LED 32 and/or the neighbouring/adjacent/surrounding components of the optical cell or assembly or luminaire. The provision of the air gap AG also helps to prevent the respective LED 32 from being enclosed in a substantially air-tight space which could itself lead to overheating of same and/or the neighbouring/adjacent/surrounding components.

(39) FIGS. 9(a), 9(b) & 9(c) show more clearly the transmission element 16 and its positioning, relative to the light collector element 14 and cover element 16, in the complete assembled optical cell 10. The transmission element 16 comprises a light-transmissible flat, planar foil, film, sheet, web, plate, layer or other thin planar body of optical material exhibiting a desired optical function. It may be formed, e.g. die-cut, for example from a foil or film substrate of polycarbonate (or other suitable polymer, or perhaps even a metal or metal alloy), e.g. of a thickness of around 250 m. The optical function of the transmission element 16 may be any optical function which effects or facilitates a desired distribution and/or one or more output characteristics of light emanating from the respective optical cell 10, such as by modifying or modulating one or more optical properties (especially directional optical properties) of the light emitted by the respective LED 32 as determined by the optical function of the transmission element 16 of that optical cell 10.

(40) Typically at least one major surface or face, optionally both major surfaces or faces, of the transmission element 16 is/are formed with optical functional relief, especially optical functional relief of a nanometer(s) order of size, and more especially nano-relief which displays either diffractive or refractive behaviour, or a combination of diffractive and refractive behavior. Suitable sizes of the surface relief features may for example be in the range of from about 0.5 or 1 up to about 500 nm, e.g. from about 1 or 2 or 3 up to about 10 or 20 or 50 or 100 or 250 nm.

(41) Specific examples of surface nano-scale optical functional relief, and techniques for how to create or apply it to a variety of optical substrate materialssuch as various embossing processesare all widely known in the art of optics and holographics, and will be within the general skill and knowledge of the skilled person.

(42) If desired or appropriate, the transmission element 16 may be cut or shaped to include any suitable number of peripheral indents, notches, recesses, channels, or cut-outs 16C (as illustrated in FIG. 9), for the purpose of accommodating and allowing to extend therepast the snap-fit attachment legs 65 of the cover element 15. Although the transmission element 16 of this embodiment is shown here in FIG. 9 as having one configuration of such peripheral indents, notches or cut-outs 16C as also appears in the alternative optical cell's transmission element 316 shown in FIG. 13(c), other alternative configurations of such peripheral indents, notches or cut-outs 16C are possible in other embodiments: for example those differently positioned and shaped peripheral indents, notches or cut-outs 416C as shown for the alternative transmission element 416 in FIG. 14(c) or the further alternatively shaped peripheral indents, notches or cut-outs 516C as shown for the further alternative transmission element 516 in FIG. 15(c).

(43) FIGS. 10(a) & 10(b) show more clearly the cover element 15 and its positioning, relative to the light collector element 14, in the complete assembled cell 10. The cover element 15 comprises an injection-moulded casing, surround or body 15, e.g. of a polycarbonate, with internal surfaces 62 that define a circular-transverse-sectioned frusto-conical interior cavity 63 therewithin. The cavity's defining internal surfaces 62 are contiguous with, i.e. are a continuation of, the interior walls 52 of the upper region of the internal chamber 53 within the light collector element 14. As already mentioned, extending from the lower wall portion of the cover element 15 are snap-fit or click-in attachment legs 65, which are used to unite the cover element 15 with the light collector element 14.

(44) The cover element 15 also includes an anti-glare feature, which is formed by its internal surfaces 62 having an extended height or upward lengthe.g. a height at least that of the height of the light collector element 14 or of the distance between the respective LED 32 of that optical cell and a base of the cover element 15 when the optical cell 10 is fully assembled (or a height up to about 1.5 or 2 or 2.5 or even as much as 3 times the height of the light collector element 14 or of the distance between the respective LED 32 of that optical cell and a base of the cover element 15 when the optical cell 10 is fully assembled)and being configured so as to be sloped or inclined at an angle, relative to a central axis A (FIG. 10(b)) of the optical cell 10 (i.e. an axis A perpendicular or normal to a plane of the circuit- or wiring board 30 upon which the optical cell 10 is to be mounted) of >0, especially in the region of around 20 to 30. As a result of this inclined or sloping configuring of the heightened internal surfaces 62 of the cover element 15, light rays emanating from the LED 32 in that optical cell and being directed towards the optical cell's output opening at an exit angle beyond a certain minimum angle valuewhich in this illustrated example is a minimum exit angle of around 60can be blocked, cut out or (at least partially) absorbed by the cover element 15's wall material and thereby prevented from exiting the optical cell 10 and causing unwanted glare.

(45) It may be possible, in some alternative embodiment implementations of kits according to the invention, to provide a plurality of differently configured cover elements 15 for selective use singly with a single given light collector element 14 and transmission element 16 of a given optical cell 10, wherein each differently configured cover element 15 has a different angle of slope or inclination of its internal surfaces 62 and thus a different degree of anti-glare properties in terms of the light ray exit angle beyond which the exiting light rays are blocked. Such plural cover elements 15, per single given light collector and transmission elements 14, 16, may thus enhance the modular versatility of some embodiment kits within the scope of this aspect of the invention.

(46) Although the interior cavity 63 within the cover element 15 of this embodiment is shown here in FIG. 10 as being circular in transverse cross-section and thus generally frusto-conical in three-dimensional shape, like the alternative cover element 315 shown in FIG. 13(d), other alternative cross-sectional and/or three-dimensional shapes of the internal cavity 63 within the cover element 15 are possible in other embodiments: for example an inverted-pyramidal cavity that in cross-section is square, as shown for the alternative cover element 415 in FIG. 14(d); or hexagonal, as shown for the alternative cover element 515 in FIG. 15(d).

(47) FIG. 11 shows an alternative form of cover element 115, for use in an alternative embodiment optical cell of the invention, which alternative cover element 115 is of a more basic construction and has the anti-glare sloped/inclined walls feature omitted.

(48) FIGS. 12(a) & 12(b) show a further alternative embodiment of optical cell 210 (where corresponding reference numerals are used to identify corresponding features already discussed in relation to preceding embodiments based on the same basic reference numeral but incremented by 100). Here, the peripheral positioning and orientation of the various snap-fit or click-in legs 265 on the cover element 216 have been modified, as shown in these FIGS., and the corresponding locating holes/apertures 255 with which they inter-engage to attach and fasten the light collector element 214 and cover element 215 together are now in the form of peripheral recesses, channels or cut-outs 255, as also shown in these FIGS.

(49) FIGS. 16(a), (b), (c) & (d) are perspective views of four different types of LED chips, which may be used as any of the light sources 32 in any embodiments of the invention. By way of example, the two LED chips 32a & 32b shown in FIGS. 16(a) & (b) may be, respectively, the 3030 and 2835 LED packages from OSRAM, and the two LED chips 32c & 32d shown in FIGS. 16(c) & (d) may be any of the LED chips LM101A, LM101B, LH181B, LH231B from SAMSUNG.

(50) Especially in the case of embodiment modular arrangements of optical cells 10 according to embodiments of the present invention which are formed into luminaires such as in the manner of the arrangement shown in FIGS. 1 & 2which include a plurality of LEDs 32 finally mounted into a plurality of optical cells 10 which are themselves mounted in respective mounting apertures 22 in a configuring element 20, such modular systems may have an advantage in that they may be readily designed so as to have a plurality of different optical cells or groups of optical cells combined into a single given array or arrangement, with each optical cell or optical cell group thereof performing a different optical function, such as collimation (i.e. operating as a spot light) or formation of a wide light cone (i.e. operating as a flood light), and these different functions may be switchable by turning on and off certain groups of LEDs on the board. Additionally, the overall outer shapes and sizes of the optical cells may be the same, despite individual optical cells having different optical functionalities. This is just one simple example of a multifunctional luminaire. This is just one simple example of a multifunctional luminaire. Other examples could perform other differing optical functions as between different optical cells or groups of optical cells, for example colour mixing functions or sequential or cycling operations. Thus, with appropriate design of the modular system luminaires may be designed and created with a wide range of optical functions and overall optical characteristics, thereby giving luminaire designers a wide range of options for how to configure many different luminaire products, which may for example be customized according to specific needs of an end customer.

(51) Throughout the description and claims of this specification, the words comprise and contain and linguistic variations of those words, for example comprising and comprises, mean including but not limited to, and are not intended to (and do not) exclude other moieties, additives, components, elements, integers or steps.

(52) Throughout the description and claims of this specification, the singular encompasses the plural unless expressly stated otherwise or the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless expressly stated otherwise or the context requires otherwise.

(53) Throughout the description and claims of this specification, features, components, elements, integers, characteristics, properties, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith or expressly stated otherwise.