Luminaires and optical devices therefor with integrated resilient features and related mounting methods

Abstract

A total internal reflection (TIR) optic having a body, fins, and a resilient member. The body includes a truncated, conical first end having a first circumference and a truncated, conical second end have a second circumference. The first circumference is greater than the second circumference. The fins of the TIR optic extend radially from the first end of the body. The resilient member of the TIR optic extends circumferentially from a fin, the resilient member having a secured end at the fin and a free end opposite the secured end. The free end of the resilient member is configured to be moved between first and second positions that are different. When in the first position, the free end is offset from the first circumference of the first end. A luminaire having the TIR optic and methods of mounting the optic in a luminaire.

Description

[0001] Luminaires and optical devices therefor with integrated resilient features and related mounting methods

[0002] FIELD OF THE INVENTION

[0003] The present disclosure is directed generally to luminaires. More specifically, the present disclosure relates to luminaires having an optical assembly that accurately positions an optical device with respect to a light source and / or a chip on board in the luminaire.

[0004] BACKGROUND OF THE INVENTION

[0005] Conventional recessed lighting assemblies include a light module and a trim that is removably attached to the light module. Typically, the light module includes a light source and optical devices (e.g., reflectors, lenses, diffusers) that are designed to control the way that light emitted by the light source is distributed from the light module. Different optical device configurations may produce different light distributions. In order to ensure that target beam angles are met, it is critical that the light source is properly aligned with the optical devices. Variability in distance between the light source and a TIR optic, for example, can lead to large variations of beam angles in the assembled product. Unfortunately, the spacing between a light source and one or more optical devices can suffer variability due to a combination of individual part tolerances. The spacing between the light source and the one or more optical devices can also suffer from variation when the assemblies undergo field replacement. In compact, small aperture fixtures, field replacement is particularly challenging since space is limited.

[0006] Accordingly, there is a need in the art for improved systems and methods for attaining and maintaining accurate positioning and alignment between the light source and one or more optical devices in lighting assemblies. There is a further need in the art for improved systems and methods for attaining and maintaining accurate positioning and alignment between the light source and one or more optical devices in compact, small aperture fixtures where there is limited space for accommodating an alignment mechanism. SUMMARY OF THE INVENTION

[0007] The present disclosure is directed generally to lighting assemblies or luminaires with improved systems and methods for achieving and maintaining proper positioning and alignment between the light source therein and one or more optical devices. In various embodiments of the present disclosure, an optical device, such as an optical reflector or total internal reflection (TIR) optic, of exemplary lighting assemblies described herein includes integral spring-loaded or resilient members or features that are configured to force the optic against an upper heat sink, luminaire body, or an optic holder. Simultaneously, the integral resilient members are configured to urge the lens downwardly in the assembly. Advantageously, the configurations described herein provide a fixed critical gap or spacing between the optic and the light source without requiring any special manufacturing methods. Additionally, this configurations close gaps that can form due to various part tolerances. The spring forces that cause downward pressure on the lens serves to seal any gaps that can form between the lens and the trim in the lighting assembly. Thus, the configurations described herein can achieve an interface between the lens and the trim that is airtight and wet location compatible. The configurations described herein also enable easy field replacement of the optical device, even when applied to compact, small aperture fixtures.

[0008] Generally, in one aspect, a total internal reflection (TIR) optic is provided. The TIR optic includes a body, a plurality of fins, and at least one resilient member. The body includes a first end that is truncated and conical, the first end having a first circumference. The body further includes a second end that is truncated and conical, the second end having a second circumference. The first circumference is greater than the second circumference. The plurality of fins extend radially from the first end of the body. The at least one resilient member extends circumferentially from at least one fin of the plurality of fins. The at least one resilient member includes a secured end at the at least one fin and a free end opposite the secured end.

[0009] The free end of the at least one resilient member is configured to be moved between first and second positions that are different. In the first position, the free end is offset from the first circumference of the first end.

[0010] According to an example, the plurality of fins are equidistantly positioned along the first circumference.

[0011] According to an example, the at least one resilient member is configured to be moved from the first position to the second position in response to an axial force applied to the free end towards the second end. According to an example, the at least one resilient member is configured to return to the first position in response to the axial force being released.

[0012] According to an example, the at least one resilient member is part of a number of resilient members and the plurality of fins comprises a number of fins and the number of resilient members equals the number of fins.

[0013] According to an example, the body further comprises a first aperture defined by the first circumference and a second aperture defined by the second circumference. The second aperture is configured to be in light communication with a light source.

[0014] Generally, in another aspect, a luminaire is provided. The luminaire includes a heat sink assembly, a light source positioned within the heat sink assembly, a lens, a trim, and a TIR optic positioned between the lens and the heat sink assembly. The TIR optic of the luminaire includes a body, a plurality of fins, and at least one resilient member. The body includes a first end that is truncated and conical, the first end having a first circumference. The body further includes a second end that is truncated and conical, the second end having a second circumference. The first circumference is greater than the second circumference. The plurality of fins extend radially from the first end of the body. The at least one resilient member extends circumferentially from at least one fin of the plurality of fins. The at least one resilient member includes a secured end at the at least one fin and a free end opposite the secured end.

[0015] The free end of the at least one resilient member is configured to be moved between first and second positions that are different. In the first position, the free end is offset from the first circumference of the first end.

[0016] According to an example, the at least one resilient member is configured to be moved from the first position to the second position in response to an axial force (AF) applied by the lens to the free end towards the second end.

[0017] According to an example, the at least one resilient member is configured to return to the first position in response to the axial force being released.

[0018] According to an example, the luminaire further includes a holder that is removably securable to the TIR optic. The holder includes a first annular member arranged to contact the plurality of fins, and a second annular member arranged proximate the second end. The first and second annular members are connected. According to an example, the luminaire further includes a fastening ring configured to removably secure the TIR optic within the holder. The fastening ring includes at least one annular segment configured to contact the free ends of the TIR optic. The fastening ring further comprises at least one tab. According to an example, the first annular member of the holder further includes at least one recess configured to receive the at least one tab of the fastening ring.

[0019] According to an example, the fastening ring is removably securable to the holder by a twist and lock mechanism.

[0020] According to an example, the twist and lock mechanism of the fastening ring includes at least one radially extending snap that is configured to rotate circumferentially relative to the holder.

[0021] According to an example, the luminaire is a downlight.

[0022] Generally, in another aspect, a method of mounting an optic in a luminaire is provided. The method involves the steps of mounting a holder of a holder assembly in a luminaire, providing an optic within the holder, and securing the optic in the holder.

[0023] The step of mounting the holder of a holder assembly in a luminaire involves achieving a predetermined fixed distance between a light source of the luminaire and an opening defined by an annular member of the holder.

[0024] The step of providing the optic in the holder involves providing an optic. The optic includes a body comprising a first end, the first end comprising a first circumference. The optic further comprises a second end for the body, the second end comprising a second circumference, where the first circumference is greater than the second circumference. The optic further includes a plurality of fins extending radially from the first end of the body and at least one resilient member extending circumferentially from at least one fin of the plurality of fins. The at least one resilient member includes a secured end at the at least one fin and a free end opposite the secured end. The free end of the at least one resilient member is configured to be moved between first and second different positions in the provided optic.

[0025] The step of securing the optic in the holder involves pushing the optic into the holder and locking a fastening ring to the holder with the optic therebetween. This securing step involves the holder assembly causing the free end of the at least one resilient member to be moved from the first position to the second position and holding the optic closely against the holder. When the optic is secured within the holder, the optic is held in close alignment with the light source of the luminaire.

[0026] Generally, in another aspect, a method of mounting an optic in a luminaire is provided. The method involves the steps of providing an optic and installing the optic between a lens and a heat sink assembly in a luminaire.

[0027] The step of providing the optic involves providing a body comprising a first end, the first end comprising a first circumference. The step of providing the optic further involves providing a second end for the body, the second end comprising a second circumference, where the first circumference is greater than the second circumference. The step of providing the optic further involves providing a plurality of fins extending radially from the first end of the body and at least one resilient member extending circumferentially from at least one fin of the plurality of fins. The at least one resilient member comprises a secured end at the at least one fin and a free end opposite the secured end. The free end of the at least one resilient member is configured to be moved between first and second different positions in the provided optic.

[0028] The step of installing the optic involves the heat sink assembly causing the free end of the at least one resilient member to be moved between the different positions and the at least one resilient member forcing the optic to be held closely against the heat sink assembly. Such installing step involves achieving a predetermined fixed distance between the installed optic and a light source of the luminaire.

[0029] It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein. It should also be appreciated that terminology explicitly employed herein that also may appear in any disclosure incorporated by reference should be accorded a meaning most consistent with the particular concepts disclosed herein.

[0030] These and other aspects of the various embodiments will be apparent from and elucidated with reference to the embodiment(s) described hereinafter.

[0031] BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the various embodiments.

[0033] FIG. 1A is a perspective elevational view of an example TIR optic, according to aspects of the present disclosure.

[0034] FIG. IB is atop down view of the example TIR optic of FIG. 1A, according to aspects of the present disclosure.

[0035] FIG. 1C is a side elevational view of the example TIR optic of FIGS. 1A and IB, according to aspects of the present disclosure. FIG. 2 is an example cross-sectional elevational view of a luminaire incorporating the TIR optic of FIGS. 1A, IB, and 1C, according to aspects of the present disclosure.

[0036] FIG. 3 is an exploded elevational view of the luminaire of FIG. 2, according to aspects of the present disclosure.

[0037] FIG. 4A is a perspective exploded elevational view of an example TIR optic with a holder and a fastening ring, according to aspects of the present disclosure.

[0038] FIG. 4B is a perspective elevational view of the example TIR optic with a holder and a fastening ring in FIG. 4A, according to aspects of the present disclosure.

[0039] FIG. 5 is an example cross-sectional elevational view of a luminaire incorporating the optic holder assembly of FIG. 4B, according to aspects of the present disclosure.

[0040] FIG. 6 is a flowchart depicting a method of mounting an optic in a luminaire, according to aspects of the present disclosure.

[0041] FIG. 7 is a flowchart depicting another method of mounting an optic in a luminaire, according to aspects of the present disclosure.

[0042] DETAILED DESCRIPTION OF EMBODIMENTS

[0043] The present disclosure is directed generally to lighting assemblies or luminaires with improved systems and methods for achieving and maintaining proper positioning and alignment between the light source and one or more optical devices. Applicant has recognized and appreciated that it would be beneficial to provide resilient features integral to the one or more optical devices to allow the one or more optical devices to be positioned accurately with respect to the light source. The resilient features can be configured to provide a desired retaining force, as well as close a desired range of gaps that can occur in the assembly due to tolerance stackup. The resilient features also advantageously allow the one or more optical devices to be repeatedly positioned in the same way even when replaced in field, and even when replaced in compact, small aperture fixtures. An exemplary optical device, such as an optical reflector or total internal reflection (TIR) optic can include resilient members at the light emitting end of the optic that deform when installed in a lighting assembly.

[0044] A particular goal of utilization of the embodiments and implementations described herein is to provide an alignment mechanism for compact, small aperture fixtures. While the alignment mechanism can be effectively deployed with a PORTFOLIO brand recessed LED architectural downlighting solutions available from Cooper Lighting Solutions, the components of the alignment mechanism are envisioned to be compatible with many other lighting assemblies. This disclosure shall not be limited by the embodiments depicted and described.

[0045] Referring now to the Figures, FIG. 1 A is a perspective elevational view of a TIR optic, according to some embodiments of the present disclosure. FIG. IB is a top down view of the example TIR optic of FIG. 1A. FIG. 1C is a side elevational view of the example TIR optic of FIGS. 1A and IB. The following should be understood in view of FIGS . 1A, IB, and 1C. The total internal reflection (TIR) optic 100 broadly includes a body 102, at least one or a plurality of fins 104, and at least one or a plurality of resilient members 106. The body 102 includes a first end 108 that is truncated and conical. The first end 108 has a first circumference CL The first circumference Cl defines a first aperture 109 of the body. The second end 110 is truncated, conical, and has a second circumference C2. The second circumference C2 defines a second aperture 111 of the body 102. In embodiments, the first circumference Cl is greater than the second circumference C2; however, it should be appreciated that in alternate embodiments, the first circumference can be equal to or smaller than the second circumference. The second aperture 111 is configured to be in optical communication with a light source of a luminaire.

[0046] The plurality of fins 104 extend radially from the first end 108 of the body 102. While there are three fins shown in the figures, it should be appreciated that any suitable number of fins is contemplated herein. In embodiments, the fins comprise flanges. As shown in the FIGS., plurality of fins 104 can be equidistantly positioned along the first circumference Cl of first end 108. As shown in FIG. IB, at least one resilient member 106 A of the plurality of resilient members 106 extends circumferentially from fin 104A. The resilient member 106 A includes a secured end 112 at the at least one fin 104A and a free end 114 opposite the secured end. As explained herein, the resilient members are configured to deform during installation in a suitable luminaire. Such deformation allows the TIR optic to be held in place closely against the luminaire body or an optic holder of the assembly. It should be appreciated that such configuration attains an alignment and positioning between the TIR optic and the light source of the luminaire. The free end 114 is configured to be moved between first and second positions Pl, P2 that are different. In the first position Pl (as shown in FIGS. 1A, IB, and 1C), the free end 114 is offset from the first circumference Cl of the first end. As shown, in its undeformed state, free end 114 is arranged in a first position Pl where it is in a circumferential plane that is different from the circumferential plane in which secured end 112 of resilient member 106 A is arranged.

[0047] In some embodiments, each of the resilient members 106 of the TIR optic 100 are substantially similar. In examples, each of the resilient members 106 can be approximately 0.8 in or 0.02032 m in length, 0.1 in or 0.00254 m in depth, and 1.5 cm or 0.0015 m in height. Using these variables, the area moment of inertia of each of the resilient members can be approximately 7.144E-13 m4, the modulus of elasticity can be approximately 2.4 gigapascal, or 2.4E+09 pascal, and the yield strength can be approximately 39 megapascal, or 3.90E+07 pascal. It should be appreciated that the resilient members can be modified or tuned to provide any other suitable desired spring force.

[0048] Each of the resilient members 106 of the TIR optic 100 function as an end- loaded cantilever beam such that when the TIR optic 100 is assembled in a luminaire as further described below, an axial force is applied at the free end 114 and the resilient members 106 are deformed. The deformation that takes place displaces the free ends of the resilient members from the first, default position Pl to a second position P2 where the free ends are closer to the circumferential plane in which the secured ends are arranged (see FIG. 2). In embodiments, there are a number of resilient members, and the number of resilient members is equal to the number of fins. The TIR optic 100 can be an injection molded optic or any suitable alternative.

[0049] FIG. 2 is an example cross-sectional elevational view of a luminaire 200 incorporating the TIR optic 100 of FIGS. 1A, IB, and 1C. Luminaire 200 broadly includes heat sink assembly 202, light source 204, lens 206, trim 208, and TIR optic 100. TIR optic 100 and lens 206 are arranged between heat sink assembly 202 and trim 208. When assembled, optic 100 is held pressed up against the upper heat sink, and therefore maintains a fixed spacing relative to the light source arranged in the heat sink assembly 202. For field replacement, the heat sink assembly 202 can be removed and optic 100 can be swapped out for a new optic. After a new optic 100 is positioned on the lens 206 in the assembly, replacing the heat sink assembly 202 on top of the new optic 100 causes the optic 100 to be compressed so that it is held in proper position and alignment when assembled. During the installation or assembly of the parts, the resilient members of the optic 100 deform as described herein.

[0050] In embodiments, light source 204 is a light emitting diode (LED) array that is integrated with a die cast aluminum luminaire body. The heat sink assembly 202 can also be integrated with the die cast aluminum luminaire body. In embodiments, heat sink assembly 202 is forged aluminum. The integrated design provides quality thermal conductivity of the LED to the luminaire body ensuring optimal thermal management and maximum efficacy in dissipating heat from the LED array. In embodiments, light source 204 comprises a chip on board with a plurality of white LEDs. The combination of the light source 204 and TIR optic 100 produces even light distribution with no pixilation. TIR optic 100 can include a 15° LED optic, 25° LED optic, 40° LED optic, 55° LED optic, a wall wash optic, or any other suitable alternative.

[0051] FIG. 3 shows an exploded elevational view of the luminaire 200 of FIG. 2. The following should be appreciated in view of FIGS. 2 and 3. At the bottom of the luminaire 200 is trim 208. Lens 206 is configured to be positioned within the sidewall of the trim 208 and on top of shoulder 210. TIR optic 100 is positioned on top of lens 206. A lowermost sidewall portion of heat sink sub-assembly 203 is arranged to nest inside the uppermost sidewall portion of trim 208. The top edge 211 of trim 208 is configured to abut a flange 212 of heat sink sub-assembly 203. At the same time, the bottom edge 214 of the heat sink subassembly 203 is configured to contact the plurality of fins 104 of TIR optic 100. The distance between shoulder 210 of trim 208 and bottom edge 214 of sub-assembly 203 is such that when TIR optic 100 and lens 206 are assembled therebetween, the free ends of the resilient members 106 are deformed to their second positions P2. The chip on board elements and LEDs of light source 204 are mounted centrally within the heat sink sub-assembly 203 above TIR optic 100. A central axis is shown in FIG. 3.

[0052] During assembly, the heat sink sub-assembly 203 twists and locks into slots of the trim 208 (shown in FIG. 3). When locked in place, the plurality of fins 104, the resilient members 106, and the lens 206 are sandwiched between the heat sink 202 and the trim 208. In other words, the fins 104, resilient members 106, and the lens 206 are compressed when assembled. The heat sink sub-assembly 203 applies downward forces to top or upward-facing surfaces of plurality of fins 104 and the free ends of the resilient members 106, i.e., free end 114, are compressed against lens 206. Due to the presence of trim 208, lens 206 imparts an upward axial force AF to the free ends of the resilient members 106. Such compression forces the free ends of resilient members 106 to be moved from position Pl to position P2 as shown in FIG. 2. It should be appreciated that when shown in isolation (as in FIGS. 1A-1C), TIR optic 100 displays its undeformed state and the free ends of the resilient members are in their first positions where the free ends are offset from the secured ends and the first circumference Cl of the first end 108 by a first distance. When assembled (as shown in FIG. 2), TIR optic 100 is in its deformed state and the free ends of the resilient members are in their second positions where the free ends are less offset from the secured ends of the resilient members and the first circumference Cl of the first end 108. In other words, in their second positions, the free ends of the resilient members are more aligned with the secured ends of the resilient members and the first circumference Cl of the first end 108. Or, stated differently, in their second positions, the free ends of the resilient members are offset from the secured ends and the first circumference of the first end 108 by a second distance that is less than the first distance. It should be appreciated that when the heat sink sub-assembly 203 is removed, for example, for field replacement purposes, the axial force is released from the TIR optic 100 and the free ends of the resilient members return to the first position. In other words, when the heat sink is unlocked from the trim, the compression of the fins 104, resilient members 106, and lens 206 is released.

[0053] The resilient members 106 of the optic 100 hold the optic tightly pressed upwards, and close any gaps due to various part tolerances. The resilient members 106 also push lens 206 downwardly so that there are no gaps between the lens 206 and shoulder 210 of trim 208. The spring force from resilient members 106 forms a seal between lens 206 and trim 208 so that the luminaire 200 is airtight and wet location compatible. Due to the configuration of these parts, there is a gap G between the second uppermost end 110 of TIR optic 100 and light source 204 and this gap G is maintained. As discussed previously, this gap G is critical to maintain to ensure that target beam angles are met. In example embodiments, the gap G is approximately 0.07 in or 0.001778 m + / - 0.02 in or 0.000508 m.

[0054] It should be appreciated that the design of the TIR optic can be modified to close a range of gaps per design requirement, and to provide sufficient force for air tightness and IP rating. For example, the length, width, height, number of resilient members, and initial spring deformation can be selected or modified to meet specific application requirements.

[0055] According to another aspect, the TIR optic 100 described herein can be used with a holder and a fastening ring. The following should be appreciated in view of FIGS. 4A and 4B. FIG. 4A is a perspective exploded elevational view of an example TIR optic with a holder 400 and a fastening ring 450. FIG. 4B is a perspective elevational view of an example TIR optic, such as the one in FIG. 4A, with the holder 400 and the fastening ring 450 removably secured together. As explained further below, when holder 400 and fastening ring 450 are connected with TIR optic 100 secured therebetween, the TIR optic 100 is maintained in its deformed state as described previously. The resilient members 106 of the TIR optic 100 mount the optic to the holder so that the optic is held closely against the holder 400. When the TIR optic 100, holder 400, and fastening ring 450 are connected and assembled within a luminaire, the TIR optic 100 is properly positioned and aligned with respect to the light source of the luminaire. The holder 400 and fastening ring 450 also allow the TIR optic 100 to be easily field replaceable.

[0056] As shown in FIG. 4A, TIR optic 100 is the same as previously described. Holder 400 broadly includes a first annular member 402, a second annular member 404, and at least one connector 406 to connect the first and second annular members 402, 404. In example embodiments, there are at least two connectors to connect the first and second annular members 402, 404 and they are positioned approximately 180 degrees apart from each other. In the depicted example, there are four connectors 406 that connect the first and second annular members 402, 404; however, it should be appreciated that additional or fewer connectors are contemplated. In the depicted design, the four connectors 406 are equidistantly spaced around the holder, i.e., approximately at 90 degree intervals. While the illustrated holder 400 shows the connectors 406 integral with the first and second annular members 402, 404, it should be appreciated that they could be separate components that are coupled thereto.

[0057] Holder 400 also includes at least one recess 408 and protrusion 410 in the first annular member 402. The protrusion 410 is arranged proximate to the at least one recess 408. In FIGS. 4A and 4B, holder 400 has two recesses 408 and two protrusions 410, one protrusion 410 for each recess 408, and the recesses and protrusions are arranged approximately 180 degrees apart around the holder. As further explained below, the at least one recess 408 and protrusion 410 are configured to engage with and lock the fastening ring 450.

[0058] FIG. 4A also shows fastening ring 450 which broadly includes annular segments 452, tabs 454, and radially extending snaps 456. Annular segments 452 are designed to fit under the plurality of fins 104 and resilient members 106 of the TIR optic 100 when assembled. Tabs 454 connect the annular segments 452 of the fastening ring 450 and extend upwardly. While tabs 454 can be integral with the annular segments 452, it should be appreciated that they could be separate components and connected by any suitable means.

[0059] As shown in FIG. 4B, holder 400 can be placed on top of TIR optic 100 and fastening ring 450 can be placed below TIR optic 100. To secure the optic 100 between holder 400 and fastening ring 450, a user presses the annular segments 452 of the fastening ring upwardly while holding the holder 400 and optic 100 together. The radially extending snaps 456 of the tabs 454 of the fastening ring are aligned with the recesses 408 of the holder such that the snaps 456 are received by the recesses 408 of the holder. When the resilient members 106 are sufficiently squeezed between the annular segments 452 of the fastening ring 450 and the first annular member 402 of the holder, the radially extending snaps 456 are positioned above the recesses 408 of the holder and are free to rotate circumferentially in circumferential direction 1 CD1 relative to the holder 400 and optic 100. In case the resilient members 106 are not sufficiently squeezed between the holder 400 and the fastening ring 450, the radially extending snaps 456 would be rotationally limited by the boundaries of the aligned recess 408.

[0060] When the resilient members 106 are sufficiently squeezed, the TIR optic 100 can be locked in the holder 400. To do so, the fastening ring 450 is rotated in circumferential direction CD1 relative to the holder 400 so that the radially extending snaps 456 pass the protrusions 410 of the holder 400. The protrusions 410 help prevent the fastening ring 450 from twisting in the opposite circumferential direction and becoming separated from the holder 400. Additionally, the spring force from the resilient members 106 of the TIR optic 100 urge the fastening ring 450 away from or downwardly from the holder. Due to this spring force from the resilient member 106, the fastening ring 450 is further prevented from accidentally twisting in the opposite circumferential direction and becoming separated from the holder 400. When the holder 400 and fastening ring 450 are locked, the resilient members 106 of the TIR optic 100 are fixed in their second position P2. The fastening ring 450 provides the upward axial force that is provided by the lens 206 in the previous discussion.

[0061] FIG. 5 shows an example cross-sectional elevational view of a luminaire 500 incorporating the optic holder assembly of FIG. 4B. The optic holder assembly of FIG. 4B includes holder 400 and fastening ring 450. Luminaire 500 broadly includes heat sink assembly 502, light source 504, lens 506, trim 508, and TIR optic 100. Optic 100 is secured between holder 400 and fastening ring 450 to form an optic unit. The optic unit and lens 506 are arranged between heat sink assembly 502 and trim 508. When assembled, due to the available spacing between heat sink assembly 502 and trim 508 and the dimensions of the optic unit, optic 100 maintains a fixed spacing relative to the light source 504. Light source 504 is arranged in the heat sink assembly 502. Providing the TIR optic with the holder assembly makes it easy to replace in field over and over again. The holder assembly imparts the proper positioning and alignment for the TIR optic so that it can repeatedly be assembled with the critical light source to optic gap.

[0062] FIG. 6 is a flowchart depicting a method 600 of mounting an optic in a luminaire. At step 610, the holder (i.e., holder 400) of a holder assembly is mounted into a luminaire. In embodiments, holder 400 is secured to the heat sink 502 with one or more screws. This assembling step involves achieving a predetermined fixed distance between the light source of the luminaire and the opening defined by the second annular member 404 of the holder 400. Thus, in this step the holder is held in close alignment with the light source.

[0063] At step 620, the optic is provided onto the holder. The optic, e.g., TIR optic 100, includes a body comprising a first end, the first end comprising a first circumference. The step of providing the optic further involves providing a second end for the body, the second end comprising a second circumference, where the first circumference is greater than the second circumference. The step of providing the optic further involves providing a plurality of fins extending radially from the first end of the body and at least one resilient member extending circumferentially from at least one fin of the plurality of fins. The at least one resilient member comprises a secured end at the at least one fin and a free end opposite the secured end. The free end of the at least one resilient member is configured to be moved between first and second different positions in the provided optic.

[0064] At step 630, the optic is secured to the holder. Securing the optic to the holder 400 involves positioning fastening ring 450 beneath fins 104 and resilient members 106 of optic 100, pushing the optic 100 into the holder 400 with fastening ring 450, and locking the fastening ring 450 to the holder 400 with optic 100 between the two. The securing step involves the holder assembly causing the free ends of the resilient members to be moved from the first position to the second position. The securing step also holds the optic closely against the holder. The at least one resilient member helps hold the optic in place in the holder assembly. Since the holder is held in close alignment with the light source of the luminaire at step 610, when the optic is assembled within the holder at step 630, the optic is also held in close alignment with the light source of the luminaire.

[0065] In embodiments, the locking step involves removably securing fastening ring 450 to holder 400 with a twist and lock mechanism.

[0066] FIG. 7 is a flowchart depicting another method 700 of mounting an optic in a luminaire.

[0067] At step 710, an optic is provided (e.g., TIR optic 100). The optic includes a body comprising a first end, the first end comprising a first circumference. The step of providing the optic further involves providing a second end for the body, the second end comprising a second circumference, where the first circumference is greater than the second circumference. The step of providing the optic further involves providing a plurality of fins extending radially from the first end of the body and at least one resilient member extending circumferentially from at least one fin of the plurality of fins. The at least one resilient member comprises a secured end at the at least one fin and a free end opposite the secured end. The free end of the at least one resilient member is configured to be moved between first and second different positions in the provided optic.

[0068] At step 720, the optic is installed between a lens and a heat sink assembly of the luminaire. The step of installing the optic involves the heat sink assembly causing the free end of the at least one resilient member to be moved from the first position to the second different position and the at least one resilient member forcing the optic to be held closely against the heat sink assembly. In embodiments, the installing step involves securing the heat sink assembly to the trim and sandwiching the optic and lens therebetween. Such installing step involves achieving a predetermined fixed distance between the installed optic and a light source of the luminaire.

[0069] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0070] The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”

[0071] The phrase “and / or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements can optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified.

[0072] As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of’ or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.”

[0073] As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements can optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.

[0074] It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.

[0075] In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of’ and “consisting essentially of’ shall be closed or semi-closed transitional phrases, respectively.

[0076] Other implementations are within the scope of the following claims and other claims to which the applicant can be entitled.

[0077] While various examples have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and / or structures for performing the function and / or obtaining the results and / or one or more of the advantages described herein, and each of such variations and / or modifications is deemed to be within the scope of the examples described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and / or configurations will depend upon the specific application or applications for which the teachings is / are used. Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific examples described herein. It is, therefore, to be understood that the foregoing examples are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, examples can be practiced otherwise than as specifically described and claimed. Examples of the present disclosure are directed to each individual feature, system, article, material, kit, and / or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and / or methods, if such features, systems, articles, materials, kits, and / or methods are not mutually inconsistent, is included within the scope of the present disclosure.

Claims

CLAIMS1. A luminaire (200), comprising: a heat sink assembly (202); a light source (204) positioned within the heat sink assembly; a lens (206); and a TIR optic (100) positioned between the lens and the heat sink assembly, the TIR optic comprising:• a body (102), the body comprising: a first end (108) that is truncated and conical, the first end having a first circumference (Cl); and a second end (110) that is truncated and conical, the second end having a second circumference (C2), wherein the first circumference is greater than the second circumference;and• at least one resilient member (106) extending radially from the first end of the body, the at least one resilient member comprising a secured end (112) and a free end (114) opposite the secured end; wherein the free end of the at least one resilient member is configured to be moved between first and second positions (Pl, P2) that are different, and wherein in the first position the free end is offset from the first circumference of the first end.

2. The luminaire of claim 1, wherein the at least one resilient member is configured to be moved from the first position to the second position in response to an axial force (AF) applied by the lens to the free end towards the second end.

3. The luminaire of claim 2, wherein the at least one resilient member is configured to return to the first position in response to the axial force being released.

4. The luminaire of claim 1, further comprising a holder (400) that is removably securable to the TIR optic, the holder comprising a first annular member (402) arranged tocontact the at least one resilient member, and a second annular member (404) arranged proximate the second end, wherein the first and second annular members are connected.

5. The luminaire of claim 4, further comprising a fastening ring (450) configured to removably secure the TIR optic within the holder, the fastening ring comprising at least one annular segment (452) configured to contact the free end of the TIR optic, the fastening ring further comprising at least one tab (454).

6. The luminaire of claim 5, wherein the first annular member of the holder further comprises at least one recess (408) configured to receive the at least one tab of the fastening ring.

7. The luminaire of claim 6, wherein the fastening ring is removably securable to the holder by a twist and lock mechanism.

8. The luminaire of claim 7, wherein the twist and lock mechanism of the fastening ring comprises at least one radially extending snap (456) that is configured to rotate circumferentially relative to the holder.

9. A method (700) of mounting an optic in a luminaire, comprising the steps of: providing (710) an optic having a body and at least one resilient member, the body of the optic comprises a first end, the first end comprising a first circumference, the body further comprises a second end, the second end comprising a second circumference, the at least one resilient member extending radially from the first end of the body, the at least one resilient member comprising a secured end and a free end opposite the secured end, wherein the free end of the at least one resilient member is configured to be moved between first and second different positions; and installing (720) the optic between a lens and a heat sink assembly of the luminaire, where such installing involves the heat sink assembly causing the free end of the at least one resilient member to be moved between the first and second different positions, and the at least one resilient member forces the optic to be held closely against the heat sink assembly of the luminaire; wherein such installing involves achieving a predetermined fixed distance between the installed optic and a light source of the luminaire.

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