Customized composite beam light assembly

Abstract

A lighting assembly for a luminaire includes a circuit board and a light source disposed on the circuit board. A heat sink is coupled to the circuit board. A solid integrated optical array is coupled to the circuit board. The solid integrated optical array includes a solid optical lens. Each solid optical lens is disposed over a corresponding one of the light sources. Each solid optical lens includes a light guiding body defining a total internal reflection lens and an external light guiding surface. Each solid optical lens is adapted to pass a light beam in a predefined direction to form a light beam pattern. Each solid optical lens is configured to maintain a base beam size of light therethrough, wherein the base beam size is less than 11 degrees. A bezel is disposed adjacent to the at least one solid integrated optical array and coupled to the heat sink.

Description

Technical Field

[0001] The present disclosure relates generally to a lighting assembly, and more particularly to a lighting assembly for emitting a customized composite light beam and a luminaire including multiple lighting assemblies to provide a customized light output pattern. Background Art

[0002] Lighting systems have been developed for outdoor applications such as sports stadiums. Such systems typically include light fixtures mounted at elevated heights, such as poles or raised stands. The lighting industry has been drawn to the use of mass-producible fixtures to control the light generated and effectively project that light onto the target field. The best efforts have involved running a large number of low-output LEDs for efficiency, but only giving up control of the light because the optics used are too small to adequately control the beam and secondary reflectors are used that absorb a large amount of reflected light. The goal is to illuminate the entire target field evenly to the desired level with the least amount of energy consumed. Attempts to get more light on the field at the expense of smoothness or, more generally, to demonstrate fixture efficiency rather than overall field efficiency (the ability to illuminate the field with less energy consumption while still maintaining a high level of smoothness) have generally failed. Improvements to previous lighting systems are desired. Summary of the Invention

[0003] According to one aspect of the present disclosure, a luminaire for illuminating a target area includes an array of lighting assemblies. Each lighting assembly includes a circuit board, a solid-state light source arranged on a surface of the circuit board, and an optical system. The optical system includes a first solid integrated optical array associated with a first portion of the light source. The first solid integrated optical array includes a fixed optical lens that defines a predefined directional focus and a predefined angular beam so that the light directed therethrough forms a first beam pattern. A second solid integrated optical array is associated with a second portion of the light source. The second solid integrated optical array includes a fixed optical lens that defines a predefined directional focus and a predefined angular beam so that the light directed therethrough forms a second beam pattern. The second beam pattern is different from the first beam pattern and is combined with the first beam pattern to form a composite beam for the target area. The optical system includes a combination of symmetrical and asymmetrical configurations of fixed optical lenses.

[0004] According to another aspect of the present disclosure, a lighting assembly for a lamp includes a circuit board and a light source arranged on a first surface of the circuit board. A heat sink is coupled to the second surface of the circuit board. The second surface is opposite to the first surface. At least one solid integrated optical array is coupled to the first surface of the circuit board. The at least one solid integrated optical array includes a substrate and a solid optical lens fixed to the substrate. Each solid optical lens is positioned above a corresponding one of the light sources. Each solid optical lens includes a light guiding body and an external light guiding surface that define a total internal reflection lens. Each solid optical lens is adapted to pass a light beam in a predefined direction to form a beam pattern. Each solid optical lens is configured to maintain a base beam size of light passing therethrough, wherein the base beam size is less than eleven degrees. A frame is positioned adjacent to the at least one solid integrated optical array and coupled to the heat sink.

[0005] According to yet another aspect of the present disclosure, a method for designing a luminaire includes: determining a light output pattern and light distribution at a target area; selecting solid optical lenses to form an optical array of rows of the solid optical lenses; rotating each solid optical lens about an aiming axis to define a direction of directional light, while redirecting the directional light by molding a light guiding surface to form a beam pattern of the optical array, each solid optical lens being a narrow beam optical lens configured to define a base beam size of less than eleven degrees of the directional light passing therethrough; molding the solid optical lenses into the optical array; selecting a plurality of optical arrays and positioning the plurality of optical arrays above a light source on a circuit board to form an optical assembly that defines a composite light beam; and selecting a plurality of optical assemblies to form the luminaire, the luminaire defining the light output pattern and the light distribution at the target area.

[0006] Those skilled in the art will further understand and appreciate these and other aspects, objects and features of the present disclosure through a study of the following specification, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In the attached figure:

[0008] Figure 1 is a side perspective view of a lighting assembly including an optical system having a plurality of optical arrays according to the present disclosure;

[0009] Figure 2 is an exploded side perspective view of a lighting assembly having an optical system according to the present disclosure;

[0010] Figure 3 is a side perspective view of a lighting assembly including an optical system having multiple optical arrays with a bezel removed according to the present disclosure;

[0011] Figure 4 is a front perspective view of a first optical array having optical lenses according to the present disclosure;

[0012] Figure 5 According to the present disclosure Figure 4 a rear perspective view of the first optical array illustrating the light guiding bodies of the optical lenses;

[0013] Figure 6 It is taken along line VI-VI according to the present disclosure Figure 4 a cross-sectional view of a first optical array;

[0014] Figure 7 is a side perspective view of an optical lens having a light-guiding body and an inclined inverted conical surface according to the present disclosure;

[0015] Figure 8 is a side perspective view of an optical lens having an asymmetric light guiding body according to the present disclosure;

[0016] Figure 9 is a side perspective view of an optical lens having a light guiding body and a flat lens according to the present disclosure;

[0017] Figure 10 is a front perspective view of a second optical array having optical lenses according to the present disclosure;

[0018] Figure 11 According to the present disclosure Figure 10 a rear perspective view of a second optical array illustrating the light guiding bodies of the optical lenses;

[0019] Figure 12 It is taken along line XII-XII according to the present disclosure Figure 10 a cross-sectional view of a second optical array;

[0020] Figure 13 is a front perspective view of a third optical array having optical lenses according to the present disclosure;

[0021] Figure 14 According to the present disclosure Figure 13 a rear perspective view of a third optical array illustrating the light guiding bodies of the optical lenses;

[0022] Figure 15 It is taken along line XV-XV according to the present disclosure Figure 13 a cross-sectional view of a third optical array;

[0023] Figure 16 is a side perspective view of an optical lens having a light guiding body and a Fresnel-type lens according to the present disclosure;

[0024] Figure 17is a front perspective view of a fourth optical array having optical lenses according to the present disclosure;

[0025] Figure 18 According to the present disclosure Figure 17 a rear perspective view of a fourth optical array illustrating the light guiding bodies of the optical lenses;

[0026] Figure 19 It is taken along line XIX-XIX according to the present disclosure Figure 17 a cross-sectional view of a fourth optical array;

[0027] Figure 20 It is taken along the line XX-XX according to the present disclosure Figure 17 a cross-sectional view of a fourth optical array;

[0028] Figure 21 is a front perspective view of a fifth optical array having optical lenses according to the present disclosure;

[0029] Figure 22 According to the present disclosure Figure 21 a rear perspective view of a fifth optical array illustrating the light guiding bodies of the optical lenses;

[0030] Figure 23 It is taken along line XXIII-XXIII according to the present disclosure Figure 21 a cross-sectional view of a fourth optical array;

[0031] Figure 24 It is taken along line XXIV-XXIV according to the present disclosure Figure 21 a cross-sectional view of a fourth optical array;

[0032] Figure 25 It is taken along line XXV-XXV according to the present disclosure Figure 21 a cross-sectional view of a fourth optical array;

[0033] Figure 26 is a side perspective view of an optical lens having a light guiding body and a Fresnel-type lens having primary and secondary ridges and grooves according to the present disclosure;

[0034] Figure 27 is a side perspective view of a bezel positioned over an optical system of a lighting assembly according to the present disclosure;

[0035] Figure 28 It is taken along line XXVIII-XXVIII according to the present disclosure Figure 27 A cross-sectional view of the frame and optical system;

[0036] Figure 29is a rear elevation view of a bezel of a lighting assembly according to the present disclosure;

[0037] Figure 30 is a side perspective view of a luminaire according to the present disclosure comprising a plurality of lighting assemblies, wherein the luminaire produces a light output pattern formed by a composite light beam combination from the lighting assemblies; and

[0038] Figure 31 is a flow chart of a method for designing a lamp according to the present disclosure. DETAILED DESCRIPTION

[0039] As marked in the figures, the same reference numerals may be used herein to refer to the same parameters and components or similar modifications and alternatives thereof. For the purpose of the description herein, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal" and their derivatives shall be used in conjunction with Figure 1 The disclosure herein is oriented in the manner described. However, it should be understood that the disclosure may adopt various alternative orientations, except where expressly specified to the contrary. It should also be understood that the specific devices and processes shown in the drawings and described in the following description are merely exemplary embodiments of the inventive concepts defined in the appended claims. Therefore, unless the claims expressly state otherwise, specific dimensions and other physical characteristics related to the embodiments disclosed herein should not be considered limiting. The drawings cited herein are schematic and the associated views are not necessarily drawn to scale.

[0040] The terms "including," "comprises," "comprising," or any other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. In the absence of more constraints, a sentence preceded by "comprising..." does not exclude the presence of additional identical elements in the process, method, article, or apparatus that comprises the elements.

[0041] refer to Figure 1-31 , reference numeral 10 generally designates a luminaire 10 for illuminating a target area 12, the luminaire including an array 14 of lighting assemblies 16. Each lighting assembly 16 includes a circuit board 18, solid-state light sources 20 disposed on a surface 22 of the circuit board 18, and an optical system 24. The optical system 24 includes a plurality of optical arrays 26, including optical arrays 26a-26e, having optical lenses 28 associated with groupings 30 of light sources 20. The groupings 30 include groups or portions 30a-30d disposed on the circuit board 18. The optical arrays 26 form beam patterns 32 corresponding to the configuration of the respective optical arrays 26a-26e.

[0042] For example, the optical system 24 includes a first solid integrated optical array 26a associated with a first portion 30a of the light source 20. The first solid integrated optical array 26a includes a fixed optical lens 28 that defines a predefined directional focus and a predefined annular beam to form light directed therethrough into a first beam pattern 32. The optical system 24 also includes a second solid integrated optical array 26b associated with a second portion 30b of the light source 20. The second solid integrated optical array 26b includes a fixed optical lens 28 that defines a predefined directional focus and a predefined annular beam to form light directed therethrough into a second beam pattern 32. The second beam pattern 32 is different from the first beam pattern 32 and is combined with the first beam pattern to form a composite beam 34 for the target area 12. The optical system 24 also includes a combination of symmetric and asymmetric configurations of the fixed optical lenses 28.

[0043] The optical system 24 uses multiple "micro-spotlights" to form a beam pattern 32, thereby forming a composite beam 34. Each "micro-spotlight" is formed by a beam emitted by one LED 20 and passing through a corresponding optical device 28. Generally, the beam width is defined by the central beam intensity and a certain number of degrees until the central beam drops to 10% of the maximum value (multiplied by 2). The original beam from each optical device 28 is a beam with a width of less than 11 degrees. This original beam with a width of less than 11 degrees is then bent in different ways to move the beam to form the beam pattern 32. Therefore, the optical device 28 redirects the 11-degree base beam as described herein.

[0044] The luminaire 10 provides an adjustable and customizable lighting effect 50 or light output pattern 50 for the target area 12. The light output pattern 50 can be adjusted and customized during the manufacture and assembly of the lighting assembly 16 and during the assembly of the luminaire 10. In addition, the light output pattern 50 can be adjusted and customized by adjusting the light intensity while the luminaire 10 is assembled and in operation. The luminaire 10 and its manufacturing process provide a lamp fixture that can achieve a full range of beam patterns 32 by using narrow optics 28.

[0045] refer to Figure 1 and 2 , shows an exemplary light assembly 16 that may be included in the array 14 of lighting assemblies 16. The light assembly 16 includes a heat sink 52, a circuit board 18 with light sources 20 disposed on the heat sink 52, an optical system 24 including four optical arrays 26 disposed on the circuit board 18, and a bezel 54 disposed above the optical arrays 26. The bezel 54 is configured to be secured to the heat sink 52 by fasteners 56, which facilitates coupling the optical system 24 and the circuit board 18 to the heat sink 52. Figure 1 and 2 The four optical arrays 26 shown in FIG are an exemplary configuration of the optical system 24. The optical arrays 26 selected for the lighting assembly 16 are based on the beam patterns 32 produced by the optical arrays 26 and the overall lighting effect 50 produced as described herein.

[0046] The heat sink 52 includes a support surface 58 and fins 60 extending from the support surface 58. The fins 60 extend laterally, generally in a top to bottom direction of the lighting assembly 16 (see FIG. Figure 30 ). Based on the mounting orientation of the lighting assembly 16, this configuration of the heat sink 52 can also be described as having vertical fins 60. This vertical configuration of the fins 60 dissipates heat faster than fins that extend along the longitudinal extent of the heat sink 52 (e.g., from right to left or horizontally).

[0047] In various aspects, the heat sink 52 can be formed by various processes. Typically, the fins 60 define a square shape, but the fins 60 can be formed into other shapes, such as a semicircle, without departing from the teachings herein. In various non-limiting examples, the fins 60 extend approximately three inches from the support surface 58 and have a width that corresponds to the width of the support surface 58 or the front face of the heat sink 52, which is approximately six inches. Heat dissipation increases near the support surface 58 compared to near the distal end of the fins 60. Heat dissipation decreases away from the support surface 58. Thus, a three-inch length of the fins 60 provides heat dissipation along at least a majority or the entire length of the fins 60. Significantly increasing the length of the fins 60 beyond this exemplary length may not significantly increase heat dissipation.

[0048] Still refer to Figure 1 and 2 , a heat transfer layer 68 is disposed on the support surface 58 of the heat sink 52 and between the support surface 58 and the second surface 70 of the circuit board 18. The heat transfer layer 68 is typically a thin layer that conforms to the support surface 58 of the heat sink 52 and the second lower surface 70 of the circuit board 18 when the lighting assembly 16 is assembled. In a non-limiting example, the thickness of the heat transfer layer 68 is approximately 5 / 1000 of an inch. The heat transfer layer 68 typically includes cutouts for the fasteners 56 to extend through. The heat transfer layer 68 includes a high graphite content to allow high heat transfer from the circuit board 18 to the heat sink 52 for heat dissipation.

[0049] A circuit board 18 having solid-state light sources 20 is positioned on the heat transfer layer 68. The circuit board 18 may include one or more circuits and may be configured as a printed circuit board. The solid-state light sources 20 are typically light-emitting diodes 20 (LEDs 20), which are arranged in groups 30 on the surface 22 of the circuit board 18. Each group 30 includes multiple rows 74 of LEDs 20 arranged in a specific pattern. In the illustrated configuration, the LEDs 20 are arranged in four groups 30a-30d, and each group 30 has six rows 74 of LEDs 20, including rows 74a-74f. Generally, the plurality of LEDs 20 alternates from the first or top row 74a to the sixth or bottom row 74f. As illustrated, the odd-numbered rows 74 (first, third, and fifth rows 74a, 74c, 74e) have six LEDs 20, while the even-numbered rows 74 (second, fourth, and sixth rows 74b, 74d, 74f) have five LEDs 20, for a total of 33 LEDs 20 per group 30. Thus, one circuit board 18 supports 132 LEDs 20. This number and arrangement of LEDs 20 provides a composite light beam 34 formed by the lighting assembly 16. Furthermore, this configuration of LEDs 20 allows for increased or maximum customization of the 132 narrow beam "micro-spotlights" (e.g., less than 11 degrees of base beam width) that are rotated and directed (using various optics 28) to form the composite light beam 34.

[0050] Still refer to Figure 1 and 2 , each opposing end of the circuit board 18 (shown as the right and left ends) includes a wire or power terminal 80. Thus, the circuit board 18 can be powered from either end of the circuit board 18. The alternating number of LEDs 20 in the rows 74 results in an asymmetrical arrangement of the LEDs 20 (i.e., in each grouping 30, there are six LEDs 20 at the top and five LEDs 20 at the bottom). Thus, the circuit board 18 has a specific orientation with the first row 74a at the top of the circuit board 18 having six LEDs 20. Therefore, the circuit board 18 cannot generally be rotated 180° independently of the rest of the lighting assembly 16. Having power terminals 80 at each side of the circuit board 18 facilitates an asymmetrical configuration of the LEDs 20. For example, when multiple lighting assemblies 16 are coupled together (see Figure 30 ), the lighting assemblies 16 can be arranged in any order and powered on either end. This provides the luminaire 10 with increased flexibility to create an overall lighting effect 50. The lighting assemblies 16 can be interchanged or moved relative to each other without the power connection hindering such rearrangement.

[0051] A thermal overload circuit 82 is positioned between the power terminals 80 on each end of the circuit board 18. The thermal overload circuit 82 is typically a resistor circuit in which increased heat (based on various sensors and circuitry) increases resistance. It should be understood that once the resistance exceeds a predefined range, the temperature will also rise outside the predefined temperature range. The resistance can be limited so that the LED 20 can be derated and the power reduced to cool the lighting assembly 16 until the resistance returns to the predefined range.

[0052] Still refer to Figure 1 and 2 , a barrier layer 84 is disposed on the surface 22 of the circuit board 18. The barrier layer 84 defines holes for receiving the LEDs 20, the fasteners 56, and the power terminals 80. Therefore, the barrier layer 84 does not extend over the LEDs 20, does not interfere with the power supply to the circuit board 18, and does not interfere with the assembly of the components of the lighting assembly 16. The barrier layer 84 allows the removal of an additional external lens that extends over the circuit board 18, the LEDs 20, and the optical array 26. The external barrier layer 84 can be black to limit the escape of unwanted light (glare) from between the optical devices 28. This barrier layer 28 is sealed to each array 26 and the heat sink 52, eliminating the need for an additional external lens. Such an additional external lens may affect the light emitted by the LEDs 20 and reduce the efficiency of the lighting assembly 16. Therefore, the use of the barrier layer 84 is advantageous for producing the selected lighting effect 50 and controlling glare.

[0053] Still refer to Figure 2 as well as Figure 3 , the lighting assembly 16 includes an optical system 24 for directing the focus of the emitted light beam from the LED 20 and maintaining a predefined light angle of the emitted light beam. The optical system 24 includes a plurality of optical arrays 26, each having a fixed optical lens 28 that is aligned with and corresponds to one of the LEDs 20 on the circuit board 18. In the illustrated configuration, each optical array 26 corresponds to one of the groupings 30 of LEDs 20. Thus, there are four optical arrays 26 arranged above the LEDs 20 on the circuit board 18. Furthermore, since each grouping 30 of LEDs 20 in the illustrated configuration includes 33 LEDs 20, each optical array 26 includes 33 optical lenses 28, which are arranged in six rows 90a-90f, collectively referred to as rows 90, in the same alternating pattern as the LEDs 20.

[0054] There are many optical arrays 26 that can be created by varying various aspects associated with optical lenses 28 (also referred to as optical devices 28). Each optical lens 28 includes a light-guiding body 92, such as a symmetric light-guiding body 92a or an asymmetric light-guiding body 92b, and a light-guiding surface 94, also referred to as an optical face 94 or a light-refractive surface 94. Different optical arrays 26 can be created by at least, but not limited to, the following: the arrangement of optical lenses 28, the rotational orientation of optical face 94, making light-guiding body 92 symmetric or asymmetric relative to at least one plane, the orientation or rotational orientation of one or more asymmetric light-guiding bodies 92b, the configuration of light-guiding surface 94, the orientation of light-guiding surface 94 relative to a surrounding substrate surface 96, and combinations thereof. Five exemplary optical arrays 26a-26e are described in detail herein, each of which includes a different configuration and arrangement of optical lenses 28 to produce a different beam pattern 32, thereby producing a composite beam 34. Other configurations of optical arrays 26 are contemplated without departing from the teachings herein.

[0055] Each optical array 26 includes a base 104 surrounded by an outer rim 106. The base 104 couples each optical lens 28 together. In the illustrated configuration, each optical array 26 has a width (from left to right) of approximately 130 mm to approximately 140 mm, a height (from top to bottom) of approximately 115 mm to approximately 125 mm, and a depth (from the bottom of the rim 106 to the top of the rim 106) of approximately 5 mm to approximately 15 mm. The outer rim 106 extends from the circuit board 18 and toward the base 104, defining a generally "L" shape. A groove 108 extends along the perimeter of the base surface 96 between the base surface 96 and the outer rim 106. The distance between the outer edge of the rim 106 and the base surface 96 is approximately 3 mm to approximately 8 mm. In various aspects, the base surface 96 is offset from the surface of the outer rim 106. Thus, the base surface 96 is positioned farther from the circuit board 18 than the surface of the outer edge 106 , by a distance of about 0.5 mm to about 1 mm.

[0056] The outer edge 106 is configured to be positioned around a single grouping 30 of LEDs 20 on the circuit board 18. The optical lens 28 extends from the circuit board 18, around a corresponding one of the LEDs 20, and to or beyond the substrate surface 96. The substrate 104 is spaced apart from the surface 22 of the circuit board 18 by the outer edge 106 and the optical lens 28.

[0057] 1. Locating feet 110 extend from the outer edge 106 of each optical array 26. In various aspects, the locating feet 110 extend from the bottom of the outer edge 106 by about 0.5 mm to about 2 mm. The locating feet 110 are spaced around the outer edge 106 and are used to position and align the optical arrays 26 relative to the circuit board 18 and the LEDs 20. In the illustrated configuration, each of the optical arrays 26 defines a rectangular or square shape, and the locating feet 110 extend from the corners of the optical arrays 26. In this configuration, the horizontally aligned feet 110 are spaced apart by a distance of about 115 mm to about 130 mm, and the vertically aligned feet 110 are spaced apart by a distance of about 105 mm to about 115 mm.

[0058] The circuit board 18 defines a receiving hole 112 configured to receive the locating foot 110. The width or diameter of the locating foot 110 is in the range of about 0.1 mm to about 0.5 mm, and the receiving hole 112 has a corresponding shape and size to receive the locating foot 110. The engagement between the locating foot 110 and the receiving hole 112 maintains the alignment between the optical lens 28 and the LED 20.

[0059] The optical arrays 26 of the optical system 24 are arranged in a linear side-by-side arrangement along the circuit board 18. Typically, the optical arrays 26 extend from the top edge of the circuit board 18 to the bottom edge of the circuit board 18. The optical arrays 26 are arranged adjacent to each other and may be spaced apart, such as Figure 3 The optical array 26 is positioned between power terminals 80 on each end, which are accessible when the optical array 26 is positioned on the circuit board 18 .

[0060] refer to Figure 3-26, the optical system 24 of each lighting assembly 16 is constructed from four optical arrays 26 per circuit board 18. In various examples, the lighting assembly 16 is a single fixture that includes one heat sink 52, one circuit board 18, and four optical arrays 26. This configuration may be a 2-foot lighting assembly 16. In additional or alternative examples, the lighting assembly 16 is a double fixture that includes two heat sinks 52, two circuit boards 18, and eight optical arrays 26. The double fixture may be two single fixtures coupled together. This configuration may be a 4-foot lighting assembly 16. The set of optical arrays 26 used to form the optical system 24 may be selected from one or more configurations of optical arrays 26 disclosed herein. Thus, the optical arrays 26 positioned above one circuit board 18 may all be of the same configuration, some may be of the same configuration, or may all be of different configurations. The selected optical array 26 and the positioning of the optical array 26 on the circuit board 18 (e.g., which grouping 30 of LEDs 20 to align with) may be selected based on the beam pattern 32 produced by the optical array 26 and the desired or selected composite beam 34 and lighting effect 50 to be generated for the target area 12.

[0061] The optical lens 28 is configured to direct, guide, and / or move the light beam emitted by the LED 20. Depending on the configuration of the optical lens 28, the light beam may be directed along an aiming axis 120 ( 122 ) of the LED 20 that is generally perpendicular to the surface 22 of the circuit board 18. Figure 28 ) or can be moved or angled relative to aiming axis 120. When the light beam is not moving relative to aiming axis 120, aiming axis 120 can coincide with the center intensity of the light beam. This direction or movement relative to aiming axis 120 can be referred to as the focus of the emitted light. Thus, optical lens 28 defines the focus of the emitted light corresponding to LED 20.

[0062] In addition, optical lens 28 is configured to define a predefined width or size of the light beams emitted therethrough. The predefined base beam width of each light beam is less than 11 degrees. The predefined width is determined by the ratio between the size of LED 20 and the size of the corresponding optical lens 28. Thus, optical system 24 utilizes multiple narrow beams or "spotlights" to form beam pattern 32 and composite light beam 34.

[0063] Still refer to Figure 3-26, each optical lens 28 includes a light guiding body 92 and an outer light guiding surface 94. Light guiding body 92 extends from circuit board 18 toward base 104 of optical array 26. Light guiding body 92 may terminate at base 104 or may extend beyond base surface 96. Between circuit board 18 and base 104, light guiding body 92 includes an inner side surface and outside base 104, light guiding body 92 includes an outer side surface of optical lens 28. Light guiding body 92 generally forms a substantially solid conical or frustoconical shape. Optical lens 28 increases in outer width or diameter from approximately 5 mm at circuit board 18 to approximately 17 mm at optical face 94.

[0064] Additionally, the light guide body 92 can be symmetrical or asymmetrical along at least one plane. In a symmetrical example, the thickness of the light guide body 92 remains consistent about the aiming axis 120, which is generally aligned with the central axis of the optical lens 28. The thickness near the interface between the optical lens 28 and the circuit board 18 is between about 0.3 mm and about 0.5 mm.

[0065] In asymmetric instances, such as Figure 8 As shown, one or more portions of the light guide body 92 have increased thickness to be asymmetric along at least one plane. The increased thickness generally does not form an arcuate shape that follows the overall frustoconical shape of the light guide body 92, resulting in the asymmetric nature. The increased thickness of this portion is between about 0.5 mm and about 2.5 mm. Thus, the thickness of the optical lens 28 near the interface between the optical lens 28 and the circuit board 18 is between about 0.3 mm and about 0.5 mm, with the optical lens 28 being thinner and at most between about 0.8 mm and about 3 mm (where the optical lens 28 is the thickest).

[0066] In some aspects, about one-quarter to about one-half of light guiding body 92 can have an increased thickness to form an asymmetric configuration. In such examples, the majority of light guiding body 92 has a reduced thickness. In alternative, non-limiting aspects, about one-half to about three-quarters of light guiding body 92 can have an increased thickness. In such examples, the majority of light guiding body 92 has a greater thickness. Asymmetric light guiding body 92b can utilize central beam intensity and less material in optical face 94 to influence the direction or focus of emitted light. The change in direction or focus can be caused by the additional or less material that light passes through before reaching optical face 94, without requiring a thicker optical face 94 to define light guiding features.

[0067] The light guiding bodies 92 define a total internal reflection (TIR) ​​lens 122 that is integrally defined or molded within the solid optical lens 28 for collimating and guiding the emitted light. Thus, each light guiding body 92 defines a cavity positioned above a corresponding LED 20 (see Figure 28 ). The width or diameter of the cavity is in the range of about 4 mm to about 5 mm. The emitted light is directed toward the inner surface and passes through the light guide body 92 to the side surface. The light is redirected by the side surface to pass through the light guide surface 94 or optical face 94. For any configuration of the optical lens 28 disclosed herein, the emitted light is configured to reach the side surface at an angle of less than 45°. This allows the light to be redirected by the light guide body 92 rather than emitted through the side surface, thereby reducing light loss and reducing glare.

[0068] Each optical lens 28 also includes an integral or molded light-directing surface 94 for redirecting light to at least partially define the direction or focus of the emitted light. The light-directing surface 94 is configured to define a predefined focus or direction of the emitted light relative to the aiming axis 120. The specific configuration of the light-directing surface 94 depends on the composite light beam 34 and the overall lighting effect 50 to be produced. Different light-directing surfaces 94 are used based on how the surface 94 adjusts the focus of the light, including shifting the light beam to disperse multiple "spotlights" (while maintaining a narrow "spotlight") to form the composite light beam 34. For example, certain optical lenses 28 may allow light to pass through without significantly shifting the light relative to the aiming axis 120. In another non-limiting example, the light-directing surface 94 may direct or shift the emitted light so that it is focused at a certain angle relative to the aiming axis 120. In such examples, the emitted light from certain LEDs 20 may be shifted left, right, up, down, etc. In a specific example, the emission of selected LEDs 20 can be shifted approximately 5° to the left or approximately 5° to the right relative to the aiming axis 120 to form a wider or larger beam pattern 32 in only one direction. In other words, the underlying beam from each LED 20 is bent or rotated in a single direction to fill a specific point or location within the designed beam pattern 32.

[0069] Still refer to Figure 3-26 To shift the light beams to form beam pattern 32 and subsequently composite light beam 34, various optical lenses 28 having predefined configurations of optical faces 94 and light guiding bodies 92 are selected for inclusion in optical array 26, positioned in predefined orientations, and one or both of optical faces 94 and light guiding bodies 92 are rotated to shift the light in a selected direction to a selected number of degrees. Rotation may be used to position asymmetric light guiding bodies 92b and / or light guiding surfaces 94.

[0070] According to various aspects, each light-guiding body 92 and the optical surface 94 of the optical lens 28 can be rotated between a 0° orientation and approximately + / - 180°. In various examples, the optical lens 28 can be rotated about 45°, about 90°, about -45°, or about -90° relative to the aiming axis 120. For example, a particular light-guiding surface 94 may cause the emitted light to move 5° relative to the aiming axis 120. When the optical lens 28 is rotated 90°, the light is directed to the right, and when the optical lens 28 is rotated -90°, the light is directed to the left. In this way, the same optical lens 28 can be utilized at different rotational orientations to generate different focal points or directions of the emitted light. In addition to defining the focal point or direction of the emitted light, the optical lens 28 is configured to define and maintain the angle of the emitted light beam. As described herein, each optical lens 28 defines and maintains a narrow base beam width of light of less than 11 degrees.

[0071] The light guiding surface 94 can have various relationships with the substrate 104, depending on the configuration. In various aspects, the light guiding surface 94 can be coplanar with the substrate surface 96. In another non-limiting example, a portion of the light guiding surface 94 can be aligned with the substrate surface 96, while another portion can be offset from the substrate surface 96, thereby forming an inclined and / or sloped configuration. In yet another non-limiting example, the entire light guiding surface 94 can be offset from the substrate surface 96. Generally, when offset from the substrate surface 96, the optical lens 28 protrudes relative to the substrate surface 96.

[0072] Various types of light directing surfaces 94 may be used with the optical lens 28. These light directing surfaces 94 may include a flat or planar lens 130, a Fresnel lens 132 (e.g., Fresnel lenses 132a-132d), an elevated conical lens 134, an optical device having a rotated inverted conical surface 136, or a rotated configuration thereof. Figure 9 As shown, the applanation lens 130 has a generally smooth and flat light directing surface 94. The applanation lens 130 can be coplanar with the substrate surface 96. This lens 130 may not significantly shift the emitted light beam relative to the aiming axis 120 and, therefore, can be more commonly used with narrower composite light beams 34. In other words, the applanation lens 130 can be used for a more direct light beam with minimal loss of efficiency. The applanation lens 130 can also be offset from the substrate surface 96, remaining parallel to the substrate surface 96 but with the optical lens 28 protruding from the substrate surface. In addition, the applanation lens 130 can also be tilted, with a portion offset from the substrate surface 96. Tilting the applanation lens 130 can shift the light beam more, which can be achieved by using a center beam intensity and additional material for the light to be emitted through.

[0073] like Figure 16 and 26As shown, Fresnel lens 132 can be used to shift a light beam more than other disclosed configurations. Fresnel lens 132 generally refracts or shifts a light beam based on an alternating pattern of ridges 140 and grooves 142 (e.g., steps) disposed at predefined angles relative to boresight axis 120. Ridges 140 and grooves 142 can be any feasible repeating regular or irregular pattern, extending partially or completely across optical surface 94. In various examples, Fresnel lens 132 can define an alternating pattern of grooves 142 and ridges 140, each pattern forming a generally triangular or wedge-shaped shape. In another non-limiting example, each ridge 140 can define secondary grooves 144 between secondary ridges 146, wherein secondary grooves 144 are smaller than primary grooves 142. Because Fresnel lens 132 shifts a light beam to a greater extent, Fresnel lens 132 is more commonly used with wider or larger composite light beams 34.

[0074] The light directing surface 94 can also define an elevated conical lens 134. In such an example, when the optical lens 28 protrudes relative to the base surface 96, the optical face 94 is offset from the base surface 96. The elevated conical lens 134 can be symmetrical, with the apex of its conical shape (generally the lowest point of the cone) being at the center of the optical face 94 and aligned with the aiming axis 120. In another non-limiting example, the elevated conical lens 134 can be asymmetrical, such that the apex of the conical shape is offset from the center of the optical face 94. In such an example, the center of the cone shape is also offset from the corresponding LED 20. The conical lens 134 can define an inverted conical lens 134 or a protruding conical lens 134 (with the apex being the highest point).

[0075] The light guiding surface 94 may be configured as an optical device having a rotationally inverted conical surface 136, such as Figure 7 As shown. Light guiding surface 94 slopes along a radial arc toward the apex of the conical shape. The radial arc can be uniform from one end to the other. Alternatively, the curvature of the radial arc can increase along the length of the radial arc (e.g., an exponential curvature). Furthermore, the rotationally inverted conical surface 136 can be symmetrical, with the apex at the center of the conical surface 136, or asymmetrical, with the apex offset from the center.

[0076] The inverted conical surface 136 can be a specific example of a raised conical lens 134. In such an example, the inverted conical surface 136 is tilted, with a raised portion that deviates from or protrudes from the base surface 96. The optical lens 28 can also have a portion of the optical surface 94 that is generally aligned with the base surface 96. As the inverted conical surface 136 is tilted, the distance between the optical surface 94 and the base surface 96 increases from one side to the opposite side. In such an example, the conical surface 136 generally extends from the base surface 96 at the apex and extends to approximately 3 mm from the base surface 96.

[0077] The tilted inverted conical surface 136 can also have an off-center apex. In the tilted example shown, the apex of the inverted conical shape is located at the outer edge of optical surface 136, affecting the radial arc from the apex to the outer edge along the perimeter or circumference of optical lens 28. This configuration defines different radii from the apex of the conical shape to various locations along the perimeter of optical surface 94. The slopes may have different curvatures and / or different lengths. The radius or slope at locations closer to the outer edge of optical surface 94 is typically different from the radius or slope at locations farther along optical surface 94. For example, if the apex of the conical shape is located at the 12 o'clock position of optical surface 94, then, based on the position of the apex and the tilt configuration, the radius or curve from the 12 o'clock position to the 2 o'clock position is different from the radius or curve from the 12 o'clock position to the 6 o'clock position. This configuration of optical surface 94 is advantageous for maintaining a narrow base beam of light less than 11 degrees and efficiently moving the beam relative to aiming axis 120.

[0078] Still refer to Figure 3-26 Symmetrical light guiding bodies 92a can be used in combination with any configuration of optical faces 94 disclosed herein, and asymmetric light guiding bodies 92b can be used in combination with any optical face 94 disclosed herein. Furthermore, different combinations of rotational orientations of optical faces 94 and different rotational orientations of asymmetric light guiding bodies 92b can be used. Thus, optical array 26 can include one or more combinations of optical faces 94, as well as combinations of symmetric and asymmetric light guiding bodies 92a, 92b. Furthermore, each optical face 94 and each light guiding body 92 can be rotated relative to aiming axis 120.

[0079] Further references Figure 3-26 Each optical array 26 is a solid, integrated feature typically constructed from optical silicone. Thus, the outer rim 106, base 104, and optical lens 28 are constructed from silicone and ultimately fixed or molded together. Silicone can better resist the yellowing effect common in acrylic and polycarbonate optics. Furthermore, by resisting this yellowing, the optical array 26 maintains higher light transmittance and efficiency compared to other conventional materials. Silicone can resist yellowing by over 50% compared to conventional acrylic and polycarbonate. Furthermore, conventional materials tend to be more brittle, making them more susceptible to cracking, chipping, or damage. Optical arrays 26 constructed from silicone have enhanced durability, making them less susceptible to cracking or damage commonly experienced with conventional materials. Silicone can also withstand higher heat levels, withstanding approximately twice the heat of conventional materials. Furthermore, using optical silicone and removing the additional external lens that extends above the optical device 28 improves overall efficiency. Using an additional external lens reduces light transmittance and efficiency, impacting the overall lighting effect 50.

[0080] Each optical array 26 can generally be classified according to the National Electrical Manufacturers Association (NEMA) rating system. Thus, each optical lens 28 disclosed herein can be classified into a NEMA value, where a lower NEMA value is associated with a narrower beam pattern 32 and a higher NEMA value is associated with a wider beam pattern 32.

[0081] Still refer to Figure 4-9 , shows a first optical array 26a. This optical array 26a is generally classified as being similar to NEMA 2, which provides the narrowest beam pattern 32 of the configurations disclosed herein. The first row 90a (i.e., top row 90a) of optical lenses 28 and the outermost optical lenses 28 of the second row 90b include the same or similar optical faces 94 in the same orientation. Each of these optical lenses 28 includes a rotationally inverted conical surface 136 that is partially elevated from a base surface 96. The apex is positioned adjacent the outer edge of the optical face 94 at the top of the optical lens 28 (generally at the 12 o'clock position), which is generally the zero degree rotational orientation of the optical face 94. In addition, each of these optical faces 94 defining the inverted conical surface 136 is inclined, with the apex aligned with the base surface 96 and the bottom edge of the conical surface 136 extending farthest from the base surface 96.

[0082] The remaining optical lenses 28, including the middle three optical lenses 28 in the second row 90b and each of the optical lenses 28 in the third through sixth rows 90c-90f, include an applanation lens 130 configuration of the light directing surface 94. The applanation lens 130 is generally coplanar with the base surface 96.

[0083] In addition to the different optical faces 94, the first optical array 26a also includes a combination of symmetrical and asymmetrical light guiding bodies 92a, 92b. The asymmetrical light guiding body 92b can be asymmetrical with respect to at least one horizontal plane passing through each optical lens 28, having a top or upper portion with increased thickness. Figure 5 As shown, each of the optical lenses 28 in the first through fourth rows 90a-90d and the outermost optical lens 28 in the fifth row 90e define an asymmetric light guiding body 92b. Furthermore, each asymmetric configuration has a thickened top portion of the light guiding body 92b corresponding to a zero-degree rotational orientation of the light guiding body 92b.

[0084] Furthermore, each thickened portion has a substantially similar shape, thickness, and orientation relative to the cavity. The thickened portion has a more rectangular or square shape extending relative to the cavity. The thickened portion may have an outer edge of approximately 10.5 mm and extend an additional distance of up to approximately 0.9 mm from the cavity adjacent to the circuit board 18. The symmetrical light guide body 92a defines a circumference of approximately 17 mm where the optical lens 28 meets the circuit board 18. The additional distance of the thickened portion forms an extension from the outer circumference.

[0085] The orientation of the thicker portion relative to aiming axis 120 affects the focus or direction of light that is shifted using a different central beam intensity than the configuration of optical face 94. In this way, optical lens 28 can minimize the efficiency loss typically associated with a thicker optical cross-section or radius used to bend light on optical face 94. The configuration of asymmetric light guiding body 92b in the illustrated configuration can shift light downward from the central beam intensity.

[0086] The middle four optical lenses 28 in fifth row 74e and all optical lenses 28 in sixth row 74f have symmetrical light guiding bodies 92a. Thus, first optical array 26a includes three configurations of optical lenses 28, including an asymmetrical light guiding body 92b with a rotated inverted conical surface 136, an asymmetrical light guiding body 92b with an applanation lens 130, and a symmetrical light guiding body 92a with an applanation lens 130. In addition, each optical lens 28 defines an internal TIR lens 122.

[0087] refer to Figure 10-12 , shows a second optical array 26b, which is generally classified as similar to NEMA 4. The NEMA 4 optical array 26b produces a wider beam pattern 32 ( Figure 4 ) and generally produces a rectangular or elliptical beam pattern 32. Each optical lens 28 in the second optical array 26b includes a flat lens 130 that is coplanar with the substrate surface 96. Therefore, the outer side of the second optical array 26b appears as a single flat surface within the groove 108.

[0088] Each light-guiding body 92 in the second optical array 26 is asymmetrical. Some light-guiding bodies 92b are asymmetrical relative to at least the horizontal plane (having an increased thickness on the upper or lower side), and some light-guiding bodies 92b are asymmetrical relative to at least the vertical plane (having an increased thickness on the left or right side). In the first row 90a of optical lenses 28, the outer four optical lenses 28 have increased thickness on their outer sides and are rotated + / - 90° relative to the aiming axis 120, which generally directs light inward. The middle two optical lenses 28 are in a zero-degree rotational orientation and have a thickened portion on their top sides to generally direct light downward. The outermost and middle two optical lenses 28 in the first row 90a have thicker portions, approximately 12 mm at the outer edges and extending approximately 1.3 mm, compared to the remaining two optical lenses 28, which have an outer edge of approximately 10.5 mm and extend an additional distance of approximately 0.9 mm.

[0089] Additionally, in the first row 90a, the two outer optical lenses 28 on one side of the array 26b are rotated approximately 90° relative to the aiming axis 120, while the opposing two outer optical lenses 28 are rotated approximately -90° relative to the aiming axis 120. The middle optical lens 28 is positioned at approximately 0° relative to the aiming axis 120. The optical lenses 28 of the third row 90c have a substantially similar configuration.

[0090] In the second row 90b of optical lenses 28, the outermost optical lenses 28 are rotated + / - 90°, resulting in an increased thickness on the outer sides. The top sides of the middle three optical lenses 28 are increased in thickness and positioned at a zero-degree rotation orientation. The thickened portions of the middle three optical lenses 28 are larger than the outer optical lenses 28, with the dimensions being similar to those described in the first row 90a. The difference in thickness of the thickened portions affects the amount of light that can be moved using the center beam intensity. The fourth row 90d of optical lenses 28 has a substantially similar configuration.

[0091] In the fifth row 90e of optical lenses 28, the outer optical lenses 28 have increased thickness at the outer sides, rotated + / - 90 degrees, while the middle four optical lenses 28 have increased thickness at the top sides, in a zero-degree rotation orientation. The top sides of the middle fourth optical lenses 28 have a greater thickness than the outer sides of the outer optical lenses 28. These size differences are similar to the size differences described in the first row 90a. In the sixth row 90f, each optical lens 28 has increased thickness at its top portion, and each increased thickness is substantially similar, i.e., a greater thickness.

[0092] Second optical array 26b includes three configurations of optical lenses 28, including a combination of flat lenses 130 with side thickenings of a first thickness, side thickenings of a second thickness, top thickenings of a first thickness, and top thickenings of a second thickness. Furthermore, optical lenses 28 are positioned at three rotational positions, including approximately 0°, approximately 90°, and approximately −90° relative to aiming axis 120. Thus, second optical array 26b can use light guiding bodies 92 to move light in various directions and at various angles within those directions, thereby forming beam pattern 32.

[0093] refer to Figure 13-16 , shows a third optical array 26c, which is generally classified as similar to NEMA 4 or NEMA 5 and may be referred to herein as NEMA 4W. This optical array 26c forms a beam pattern 32 ( Figure 10-12 ), but the shape of beam pattern 32 is different. The beam pattern 32 generated by third optical array 26 c is generally triangular in shape rather than rectangular in shape. Third optical array 26 c includes six different rows 90 of optical lenses 28. In the first row 90 a, third optical array 26 c includes an asymmetric arrangement of one external optical lens 28 on one side and two external optical lenses 28 on the opposite side, having an inclined inverted conical surface 136 with the apex at the top edge of optical surface 94 (i.e., a zero degree rotation orientation).

[0094] The remaining three optical lenses 28 in the first row 90a comprise Fresnel-style lenses 132, wherein each ridge 140 is defined by a sloped or angled top surface and a bottom surface that is generally perpendicular to the substrate surface 96, which is in a zero-degree rotational orientation. Each groove 142 defines an approximately 60° angle between adjacent ridges 140, with the ridges 140 extending approximately 2 mm from the substrate surface 96, which is typical of the first configuration of Fresnel-style lenses 132a. The ridges 140 and grooves 142 form a uniform pattern from top to bottom across the corresponding optical lens 28. Each optical lens 28 in the first row 90a is in a rotational orientation of approximately 0°. The ridges 140 have a uniform height relative to the substrate surface 96, and the grooves 142 extend to a point that is generally aligned with the substrate surface 96.

[0095] In the second and fourth rows 90b, 90d of optical lenses 28, the outermost optical lenses 28 have tilted inverted conical surfaces 136 at approximately a 0° rotational orientation. The middle three optical lenses 28 have applanation lenses 130. In the third row 90c, each optical lens 28 has a tilted inverted conical surface 136 with its apex at the top of optical face 94 for a zero-degree rotational orientation. In the fifth row 90e, the two outer optical lenses 28 on each side include tilted inverted conical surfaces 136 with their apex at the top of optical face 94, and the middle two optical lenses 28 have applanation lenses 130. In the sixth row 90f, each optical lens 28 has an applanation lens 130.

[0096] The third optical array 26c also includes symmetrical and asymmetrical light guiding bodies 92a, 92b, wherein each asymmetrical light guiding body 92b is in a zero-degree rotation orientation and has a thickened top portion. The thickened portion in this configuration has a greater thickness than the thickened portion in the previous configuration. For example, the outer edge of the thickened portion is approximately 15.4 mm and extends an additional distance of approximately 2.1 mm. The optical lenses 28 having the inclined inverted conical surface 136 each have an asymmetrical light guiding body 92b. The optical lens 28 having the Fresnel lens 132 has a symmetrical light guiding body 92a. The flat lenses 130 in the second and fourth rows 90b, 90d have an asymmetrical light guiding body 92b, while the flat lenses 130 in the fifth and sixth rows 90e, 90f have a symmetrical light guiding body 92a.

[0097] Thus, third optical array 26c includes four configurations of optical lenses 28, including Fresnel lens 132a and symmetrical light guiding body 92a, tilted inverted conical surface 136 and asymmetrical light guiding body 92b, flat lens 130 and symmetrical light guiding body 92a, and flat lens 130 and asymmetrical light guiding body 92b. Different combinations can move light more in certain areas, such as using Fresnel lens 132, and less or no light in other areas, such as using flat lens 130 and symmetrical light guiding body 92a to form a triangular beam pattern 32.

[0098] like Figure 15As shown, one side of the asymmetric light-guiding body 92b of the third optical array 26c is significantly thicker than the other side, which also affects the angle of the side surface of the light-guiding body 92. The increased thickness reduces the angle, or curvature, of the side surface relative to the aiming axis 120 compared to the thinner side of the light-guiding body 92. The angle of the side surface at both the thickened and thinner portions relative to the aiming axis 120 is less than 45°. Thus, the angle of the side surface can range from approximately 0° to approximately 45°. As the angle approaches 45°, the light is more bent within the optical lens 28, while still being directed through the light-guiding surface 94 rather than being scattered through the back side of the optical array 26.

[0099] refer to Figure 17-20 , shows a fourth optical array 26d, which is generally classified as similar to NEMA 5, with a greater degree of flexibility than NEMA 2 ( Figure 4-9 )、NEMA 4( Figure 10-12 ) and NEMA 4W( Figure 13-15 ) wider beam pattern 32. Therefore, the optical lens 28 included in the fourth optical array 26d is configured to direct the light beam into a wider overall beam, moving the "spotlight" to spread the beam pattern 32. The movement of light is typically achieved by using an optical lens 28 having a configuration that moves or bends the light to a greater extent so that the "spotlight" is spread over a larger area.

[0100] In the illustrated configuration, fourth optical array 26d includes optical lenses 28 having Fresnel-type lenses 132 and tilted inverted conical surfaces 136. Furthermore, to diffuse or shift the narrow beam, optical surfaces 94 of Fresnel-type lenses 132 are positioned at different rotational orientations relative to aiming axis 120. In general, upper and side optical lenses 28 include Fresnel-type lenses 132, and lower and center optical lenses 28 include tilted inverted conical surfaces 136.

[0101] The optical lenses 28 of the first row 90a include a first configuration of Fresnel-type lenses 132a. The outermost optical lenses 28 are each rotated, with one rotated approximately -45° and the opposite one rotated approximately 45°, thereby diffusing light outward at an upward angle. The center four optical lenses 28 are positioned at a zero-degree rotational orientation. Each Fresnel-type lens 132a in the first row 90a has an inclined or angled upper face and a lower face on each ridge 140, with the lower face being perpendicular to the circuit board 18 below. The angle defined by each groove 142 is approximately 60°, and each ridge 140 extends approximately 2 mm from the base surface 96.

[0102] In the second row 90b of optical lenses 28, the middle optical lens 28 comprises an inclined inverted conical surface 136 with the apex at the top edge and the highest point at the bottom edge, vertically aligned with the apex (i.e., at a zero-degree orientation). The optical lenses 28 on either side of the middle optical lens 28 comprise a second configuration of Fresnel-type lenses 132b in a zero-degree rotational orientation. The inner Fresnel-type lens 132b has a groove 142 defining an angle of approximately 66°, and a ridge 140 extending approximately 1.5 mm from the substrate surface 96. The outermost optical lens 28 is a third configuration of Fresnel-type lenses 132c, each rotated with one side rotated -90° and the opposite side rotated 90° to diffuse light outward. Rotating 90° clockwise or counterclockwise produces a surface having an outer inclined or angled surface and a ridge 140 that is substantially perpendicular to the inner surface of the circuit board 18. The outer Fresnel lens 132c has grooves 142 defining an angle of approximately 75° and has ridges 140 extending from approximately 0.5 mm to approximately 0.75 mm from the substrate surface 96. The difference in the ridges 140 and grooves 142 changes the focus of the light beam.

[0103] The third and fifth rows 90c and 90e have substantially similar configurations. The outer two optical lenses 28 on each side are Fresnel lenses 132a and 132b, respectively. The Fresnel lenses 132 on the first side are rotated approximately -90° and the opposite side is rotated approximately 90° to diffuse light outward. The outermost Fresnel lens 132a has grooves 142 defining an angle of approximately 60°, and each ridge 140 extends approximately 2 mm from the base surface 96. The inner Fresnel lens 132b has grooves 142 defining an angle of approximately 66° and ridges 140 extending approximately 1.5 mm from the base surface 96. As a result, the narrow "spotlight" of the outer Fresnel lens 132a is displaced further from the aiming axis 120 than that of the inner Fresnel lens 132b. The middle two optical lenses 28 include inclined inverted conical surfaces 136 at a zero-degree rotational orientation. The inverted conical surface 136 extends from being aligned with the base surface 96 (approximately 0 mm) to being approximately 3 mm from the base surface 96 .

[0104] The optical lenses 28 of the fourth row 90d are similar to those of the third and fifth rows 90c and 90e, except that the optical lenses 28 are different. The fourth row 90d includes a central optical lens 28 with the inverted conical surface 136 in a zero-degree rotation orientation. The Fresnel lenses 132a, 132b on the first side are rotated approximately -90°, and the Fresnel lenses 132a, 132b on the opposite side are rotated approximately 90° to diffuse light outward. The outermost Fresnel lens 132a has grooves 142 defining an angle of approximately 60°, and each ridge 140 extends approximately 2 mm from the base surface 96. The inner Fresnel lens 132b has grooves 142 defining an angle of approximately 66°, and the ridges 140 extend approximately 1.5 mm from the base surface 96.

[0105] The sixth row 90 f of optical lenses 28 includes each optical lens 28 having an inclined inverted conical surface 136 at a zero degree rotational orientation. Figure 19 Demonstrates the tilting properties of an inverted cone, and Figure 20 The curvature of inverted conical lens 134 is illustrated relative to Fresnel-type lens 132. Inclined inverted conical surface 136 is not flat or planar, but defines a radius extending between an apex and an outer edge along the perimeter or circumference of optical surface 94. Optical surface 94 curves or slopes inwardly to the center of optical surface 94 and toward the apex, forming an inclined, off-center bowl-like shape.

[0106] Furthermore, the optical lenses 28 in the fourth optical array 26d utilize a combination of symmetrical and asymmetrical light guiding bodies 92a, 92b. The asymmetrical light guiding bodies 92b in this configuration are asymmetrical at least in the corresponding horizontal plane, having a thickened top portion (i.e., at a zero-degree rotational orientation). The thickened portion has an outer edge of approximately 13.6 mm and extends an additional distance of approximately 1.7 mm relative to the thinner side near the interface with the circuit board 18. Furthermore, each of the asymmetrical light guiding bodies 92b is combined with a Fresnel lens 132 for the light guiding surface 94. The symmetrical light guiding bodies 92a are combined with an inclined inverted conical surface 136.

[0107] Thus, six configurations of optical lenses 28 are used within fourth optical array 26d, including a symmetric light guiding body 92a with an inclined inverted conical surface 136, an asymmetric light guiding body 92b with a first Fresnel lens 132a at a zero-degree rotational orientation (e.g., a 60-degree groove 142), an asymmetric light guiding body 92b with a second Fresnel lens 132b at a zero-degree rotational orientation (e.g., a 66-degree groove 142), an asymmetric light guiding body 92b with a first Fresnel lens 132a at a + / -45-degree rotational orientation, an asymmetric light guiding body 92b with a second Fresnel lens 132b at a + / -90-degree rotational orientation, and an asymmetric light guiding body 92b with a second Fresnel lens 132b at a + / -90-degree rotational orientation. Each of these lenses 28 also includes an internal TIR lens 122.

[0108] refer to Figure 21-26 , shows a fifth optical array 26e, which is generally classified as similar to NEMA 6, having the widest beam pattern 32 of the optical arrays 26 described herein. The NEMA 6 optical array 26 produces a generally elliptical or rectangular beam pattern 32 (see Figure 30). Widening of the beam pattern 32 is achieved by directing the individual narrow beams in selected directions and at selected angles relative to the aiming axis 120 to widen the beam pattern 32. The first two rows 90a, 90b of optical lenses 28 include a fourth configuration of Fresnel lenses 132d, each positioned at a zero degree rotational orientation. The Fresnel lenses 132d include primary ridges 140 and grooves 142, and secondary ridges 146 and secondary grooves 144 defined by each primary ridge 140, as shown in FIG. Figure 26 As shown, the primary ridge 140 extends approximately 3 mm from the base surface 96. The upper inclined surface has three sections, wherein the first section extends approximately 1 mm and defines an angle between approximately 55° and approximately 60° with the lower surface of the adjacent primary ridge 140. The upper inclined surface then extends approximately 1.3 mm at an angle between approximately 150° and approximately 155° relative to the first section. The third section of the upper inclined surface then extends approximately 0.8 mm at an angle of approximately 175° relative to the second section. The lower surface of each primary ridge 140 extends substantially perpendicular to the circuit board 18.

[0109] Secondary ridges 146 form two protrusions within each primary ridge 140, separated by a secondary groove 144. The inclined upper surface of the primary ridge 140 forms the upper surface of the first secondary ridge 146. The lower surface of the first secondary ridge 146 is generally perpendicular to the circuit board 18 and extends approximately 1 mm into the primary ridge 140. The lower surface of the second secondary ridge 146 is formed by the lower surface of the primary ridge 140. The upper surface of the second secondary ridge 146 has a first portion, extending approximately 1 mm and defining an angle between approximately 60° and approximately 65° with the lower surface of the first secondary ridge 146, and a second portion, extending approximately 1 mm at an angle of approximately 175° relative to the first portion. Thus, the upper surfaces of the primary and secondary ridges 140, 146 have different angles, which serve to redirect the light beam. Furthermore, the additional angled or inclined surfaces help to shift the light beam to a greater extent than other types of light-guiding surfaces 94. It is also contemplated that the upper surfaces of the primary and secondary ridges 140 , 146 may not have distinct portions, but extend at a single angle without departing from the teachings herein.

[0110] In the third and fifth rows 90c and 90e of optical lenses 28, optical lenses 28 include Fresnel-type lenses 132a and 132b for optical face 94. The outer two optical lenses 28 on each side are each rotated + / - 90° relative to aiming axis 120 to direct light outward. The outermost optical lens 28 is a first configuration of Fresnel-type lens 132a, wherein ridges 140 extend approximately 2 mm from base surface 96 and grooves 142 define an angle of approximately 60°. The optical lens 28 adjacent to the outermost lens 28 is a second configuration of Fresnel-type lens 132b, wherein ridges 140 extend approximately 1.5 mm from base surface 96 and grooves 142 define an angle of approximately 66° between adjacent ridges 140. The middle two optical lenses 28 are each positioned at + / - 45° to direct light outward and upward. Each of these intermediate optical lenses 28 is a first configuration of a Fresnel-type lens 132a in which the ridges 140 extend approximately 2 mm from the substrate surface 96 and the grooves 142 define an angle of approximately 60°.

[0111] The fourth row 90d of optical lenses 28 also includes all Fresnel-type lenses 132 for optical face 94. The outer two optical lenses 28 on each side are each rotated + / - 90° relative to aiming axis 120 to direct light outward. The outermost optical lens 28 is a first configuration of Fresnel-type lenses 132a, with ridges 140 extending approximately 2 mm from base surface 96 and grooves 142 defining an angle of approximately 60°. The optical lens 28 adjacent to the outermost optical lens 28 is a second configuration of Fresnel-type lenses 132b, with ridges 140 extending approximately 1.5 mm from base surface 96 and grooves 142 defining an angle of approximately 66° between adjacent ridges 140. The center optical lens 28 is in a zero-degree rotation orientation and is a third configuration of Fresnel-type lenses 132c, with grooves 142 defining an angle of approximately 75° with adjacent ridges 140 and ridges 140 extending approximately 0.5 mm to approximately 0.75 mm from base surface 96.

[0112] In the sixth row 90 f of optical lenses 28, the outermost optical lens 28 and the center optical lens 28 each have an applanation lens 130 for the optical face 94. The remaining two optical lenses 28 are each a Fresnel lens 132 a at + / - 45°, which directs light upward and outward. These Fresnel lenses 132 a are a first configuration of Fresnel lenses 132 a, in which the ridges 140 extend approximately 2 mm from the base surface 96 and the grooves 142 define an angle of approximately 60°.

[0113] Furthermore, fifth optical array 26e includes a combination of symmetric and asymmetric light guiding bodies 92a, 92b. The outermost two optical lenses 28 in sixth row 90f include asymmetric light guiding bodies 92b with thickened top portions (zero-degree rotation orientation). The outer edge of the thickened portion is approximately 13.2 mm and extends an additional distance of approximately 1.7 mm. The remaining optical lenses 28 have symmetric light guiding bodies 92a. Therefore, the fifth optical array 26e includes seven configurations of optical lenses 28, including a flat lens 130 and an asymmetric light guiding body 92b, a flat lens 130 and a symmetric light guiding body 92a, a first Fresnel lens 132a and a symmetric light guiding body 92a at a + / -45° rotational orientation, a first Fresnel lens 132a and a symmetric light guiding body 92a at a + / -90° rotational orientation, a second Fresnel lens 132b and a symmetric light guiding body 92a at a + / -90° rotational orientation, a third Fresnel lens 132c and a symmetric light guiding body 92a at a + / -90° rotational orientation, and a fourth configuration of the Fresnel lens 132d at a zero degree rotational orientation (for example, with a primary groove 144 and a secondary groove 146).

[0114] Reference again Figure 4-26 Each of the optical arrays 26 herein provides a selected beam pattern 32 based on the selection and orientation (i.e., rotational orientation) of the optical lenses 28 in the particular optical array 26. The optical array 26 can generate a narrower beam pattern 32 (e.g., in a NEMA 2 configuration), a triangular-shaped pattern (e.g., in a NEMA 4W configuration), or a wider beam pattern 32 (e.g., in a NEMA 6 configuration). The narrower beam pattern 32 can focus the beam to form a more intense beam pattern 32, while the wider beam pattern 32 can diffuse or spread the beam to form a larger beam pattern 32.

[0115] Whether the beam pattern 32 is narrow, wide, elliptical, triangular, or the like, each beam pattern 32 herein is a combination of 33 "spotlights" having a base beam width of less than 11 degrees. The spread of the beam pattern 32 does not extend the "spotlights" much beyond the 11-degree range. Therefore, to form a larger beam pattern 32, the light is not spread by the optics 28, but rather tilted or shifted, generally maintaining the width of each optical beam less than 11 degrees. This configuration provides a selected beam pattern 32 with increased efficiency by forming the beam pattern 32 using multiple "spotlights" focused in a predefined direction, rather than spreading the light from the LEDs 20 to encompass the target area 12. The optical lens 28 is used to shift the light relative to the aiming axis 120. The "spotlights" increase the light intensity and contain the light within the beam pattern 32, thereby reducing glare and light scatter. The selection of light guiding body 92 , the location of the thickened portion of asymmetric light guiding body 92 b , the selection of optical face 94 , and the rotational orientation of optical face 94 are all considered and specifically selected to form the selected beam pattern 32 for each array 26 .

[0116] refer to Figure 27 and 28 , each selected optical array 26 is positioned over a grouping 30 of LEDs 20 on a circuit board 18, with each optical lens 28 corresponding to a single LED 20 centered within the TIR lens 122 of the light guide body 92. The lighting assembly 16 includes four optical arrays 26, each having 33 optical lenses 28, corresponding to the 33 LEDs 20 on a single circuit board 18. Thus, each lighting assembly 16 includes 132 LEDs 20 and 132 optical lenses 28, which form 132 "spotlights" per circuit board 18 for generating a composite light beam 34. In this manner, each optical array 26 forms a selected beam pattern 32, which, when combined, form the composite light beam 34 generated by the lighting assembly 16. Based on the selected optical arrays 26 and the optical lenses 28 included in those optical arrays 26, each beam pattern 32 of the optical arrays 26 for the composite light beam 34 can be the same, different, or a combination thereof.

[0117] exist Figure 27 In the example shown, the lighting assembly 16 includes four different optical arrays 26 on one circuit board 18. Each optical array 26 includes a different configuration and arrangement of optical lenses 28 to produce four different beam patterns 32 that combine to form a composite light beam 34 for the lighting assembly 16. As shown, each light guide body 92 is formed in a generally frustoconical shape, and each light guide surface 94 is formed in a circular or rectangular shape.

[0118] The lighting assembly 16 also includes a bezel 54 that is positioned above the optical system 24, as generally described herein. The bezel 54 generally defines a peripheral portion 158 that forms a rectangular shape around the optical system 24 and a separator portion 160 that extends between the optical arrays 26 of the optical system 24. In various configurations, the bezel 54 also extends above the base surface 96, which can be advantageous for reducing glare by minimizing or preventing visibility of any light within the optical system 24 other than light emitted through the light guide surface 94. In various aspects, the bezel 54 is substantially or completely opaque, such as a dark color such as black. This reduces or prevents light from being emitted through the bezel 54, thereby reducing glare from the lighting assembly 16.

[0119] The bezel 54 defines openings 162 that correspond and align with the optical lens 28. Thus, in the illustrated example, the bezel 54 defines 132 circular openings 162 arranged in four groups 164, with each group 164a-164d having six rows 166a-166f (collectively, rows 166) of openings 162 arranged in a pattern that alternates from top to bottom between six openings 162 and five openings 162. This is the same pattern as the optical lens 28 and LED 20.

[0120] For the openings 162 in the second through sixth rows 166b-166f, the frame 54 defines edges 168 that extend along the perimeter of the corresponding openings 162. These edges 168 protrude relative to the surrounding surface of the frame 54 to form raised edges 168 that extend around the perimeter or circumference of the optical surface 94. The edges 168 minimize or prevent light from being emitted through the outer side surfaces of the optical lens 28. For example, where the optical lens 28 protrudes relative to the base surface 96, light emitted from the side surfaces between the base surface 96 and the optical surface 94 may cause glare or light scattering. The edges 168 help block such side-emitted light, facilitating the formation of a movable narrow "spotlight."

[0121] Additionally, for the openings 162 in the first row 166 a, a portion of a rim 168 extends along a lower portion of each opening 162 and a light shield 170 extends along an upper portion of each opening 162. Light shield 170 is integrated with the frame 54 and extends a greater distance from the optical array 26 than rim 168. For example, rim 168 may extend from about 0.5 mm to about 2 mm from the surface of the frame 54 extending above the substrate surface 96, and light shield 170 may extend from about 9 mm to about 20 mm from the surface of the frame 54. Light shield 170 is formed into an arcuate shape that conforms to the corresponding opening 162 and is configured to block light that exceeds a predefined angle relative to the aiming axis 120. In various aspects, light shield 170 blocks light from the LEDs 20 in the first row 74 a that exceeds 12° relative to the aiming axis 120. Additionally, the light shield 170 may also block light from any LEDs 20 in the other rows 74 that are more than 12° relative to the aiming axis 120 of the LEDs 20 in the first row 74a.

[0122] exist Figure 27 In at least three of the illustrated optical arrays 26, the optical lenses 28 in the first or top row 90a include Fresnel-type lenses 132 that direct or bend light at an increased angle relative to the configuration of the other optical lenses 28. The light beams are directed downward to diffuse and increase the size of the beam pattern 32 of the corresponding optical array 26, but "spray" does occur in the transition region of the face 94. A light shield 170 reduces or prevents this upward "spray" of light relative to the aiming axis 120 of the corresponding LED 20. This configuration reduces glare and light scatter generated by the lighting assembly 16.

[0123] Using the visors 170, light remains directed toward the target area 12 and does not spread beyond the target area 12. In a specific example, the target area 12 is a park or field on a residential street, with the park on one side and houses on the opposite side. Light is directed toward the park, and the visors 170 prevent light from scattering from the park behind the lighting assembly 16 and reaching the houses on the opposite side of the street. The visors 170 block light scatter and do not significantly obstruct the direction of light in the remaining beam pattern 32. Adding extended material to the bezel 54 around each optic 28 and the individual visors 170 for each LED 20 reduces glare without requiring a visor over the entire fixture 16. The bezel 54 includes a raised edge 168 and visors 170 around each optic 28, as well as material covering the optical array 28 around the optic 28 and along the outer edge 106 of the optical array 26 to the heat sink 52. Adding additional material to the faces of the bezel 54 and the top row of bezels 170 around the corresponding LEDs 20 (rather than to the entire fixture 16) reduces glare. Using a narrow 11-degree base beam prevents the optical system 24 from generating a wide beam from the optics 28, which would create optical glare that the bezel 54 could not overcome. The lighting assembly 16 generates a narrow beam (without a hot spot in the center), and when the bezel 54 is used, this produces more light on the field or target area 12 while reducing glare (without the need for a full fixture bezel).

[0124] While the lighting assembly 16 and the entire luminaire 10 can be used without a full fixture visor, it is within the scope of the present disclosure to include a full fixture visor with the light assembly 16. In such an example, due to the thin horizontal arrangement of the optic 28, a sharp cutoff (i.e., complete shading) can be achieved at low vertical angles (e.g., approximately 12 degrees above the aiming axis 120). Furthermore, due to the thin horizontal arrangement of the optic 28, a shorter full fixture visor can be used compared to conventional designs.

[0125] Still refer to Figure 28 as well as Figure 29 , the frame 54 is sealed on both the optical array 26 and the heat sink 52 ( Figure 1 ). The sealed joint between the components helps maintain the orientation of the components relative to each other and protects the internal components from environmental conditions. Each optical array 26 includes a groove 108, which is generally defined between the outer rim 106 and the base 104, as described herein. The frame 54 includes a corresponding internal channel 172 that extends around each of the groupings 164 of openings 162. In addition, the frame 54 defines an external channel 174 that extends generally along the perimeter of the frame 54.

[0126] The sealant 176 is configured to be disposed in the interior channel 172 and the exterior channel 174 of the bezel 54. Once the sealant 176 is disposed in the interior and exterior channels 172, 174, the bezel 54 is positioned over the optical system 24 and on the heat sink 52. The sealant 176 is typically silicone having sufficient viscosity to maintain its position as it is dispensed over the bezel 54. The sealant 176 provides an airtight lighting assembly 16.

[0127] refer to Figure 30 , the luminaire 10 includes a plurality of lighting assemblies 16 coupled together. The luminaire 10 is coupled to a support column 180 that extends vertically from the floor area 12 to support the lighting assemblies 16. The luminaire 10 is constructed by selecting and arranging the lighting assemblies 16 having composite light beams 34 to form an overall lighting effect 50. The overall lighting effect 50 is formed by the plurality of combined composite light beams 34. The composite light beams 34 can be the same if the optical arrays 26 on the lighting assemblies 16 are the same; different if the optical arrays 26 are different; or a combination thereof (based on the optical array 26 selected for each lighting assembly 16).

[0128] refer to Figure 31 as well as Figure 1-30 , a method 190 of designing a luminaire 10 for illuminating a target area 12 includes a step 192 of determining an overall lighting effect 50 to be generated by the luminaire 10. The overall lighting effect 50 is a light output pattern 50 and distribution at the target area 12. The light output pattern 50 can be based on the type or location of the target area 12, as well as the height of the luminaire 10 from the ground area 12.

[0129] For example, multiple luminaires 10 may be used to illuminate a sports field. Typically, a similar lighting intensity is desired throughout the field. When the field is divided into a grid, this lighting intensity is typically confined to a predefined range visible within each section of the field. In such instances, multiple luminaires 10 are typically used in the center of the field. These luminaires 10 may have overlapping light output patterns 50. Consequently, the light output patterns 50 from individual luminaires 10 in the center of the field can be larger or more dispersed, with the light intensity formed by the overlapping light output patterns 50 providing a smoother lighting effect. In contrast, fewer luminaires 10 may be positioned at the ends or edges of the field. Fewer luminaires 10 result in less or no overlap in the light output patterns 50. Consequently, individual luminaires 10 at the ends of the field can provide narrower light output patterns 50, resulting in increased light intensity. Narrower light output patterns 50 can provide more intense illumination with fewer luminaires 10. However, using different light output patterns 50, the light intensity at the center and ends of the field is typically within a predefined range.

[0130] In another example, when support column 180 is shorter, meaning that luminaire 10 is closer to the ground, light output pattern 50 may be wider. When support column 180 is taller, light output pattern 50 may be narrower.

[0131] In step 194, optical lenses 28 are selected to form the optical array 26. Each solid optical lens 28 is a narrow beam optical lens 28 configured to limit the beam size of the directed light passing therethrough to less than a base beam width of 11 degrees. Each optical lens 28 generates a narrow beam that is shaped and directed to a specific point, working in conjunction with the other optical lenses 28 of the optical array 26 to form a controlled and shaped beam pattern 32. The optical devices 28 redirect light from the corresponding LEDs 20 with a base beam width of 11 degrees. Thus, 33 optical lenses 28 of the optical array 26 are selected to form the beam pattern 32. The light output pattern 50 to be generated affects the composite light beam 34, the beam pattern 32, and therefore which optical lens 28 is selected. For example, a wider light output pattern 50 can utilize an optical array 26 that produces a wider composite light beam 34.

[0132] In step 196, each solid optical lens 28 is rotated about the aiming axis 120 to move the light in a selected direction, thereby forming the beam pattern 32. Thus, the optical lens 28 is rotated from approximately 0° to up to approximately + / - 90° relative to the aiming axis 120. Other rotational orientations exceeding this 180° range are also contemplated without departing from the teachings herein. Furthermore, each of the optical face 94 and the light guiding body 92 of each optical lens 28 can be rotated independently of one another. The rotational orientation, combined with the redirection of the directed light by the integral or molded TIR lens 122 of the optical lens 28, the light guiding body 92, and the light guiding surface 94, defines the direction or focus of the emitted light.

[0133] Once the optical lens 28 is selected and rotated into an orientation that forms the beam pattern 32, the optical device 28 is molded onto the substrate surface 96 in step 198. Once molded, the optical lens 28 is fixed to the substrate 104 and can no longer be adjusted relative to the substrate 104. This creates a solid optical array 26 with integrated, solid, fixed optical lenses 28.

[0134] In step 200, a plurality of optical arrays 26 are selected for a single light assembly 16 to form a selected composite light beam 34. In this manner, one or more optical arrays 26 of different types can be positioned on the circuit board 18 in an arrangement that provides the selected composite light beam 34 for the lighting assembly 16. This step 200 can include selecting and positioning a plurality of optical arrays 26 having one or more configurations of optical lenses 28, including combinations of symmetric and asymmetric solid optical lenses 28, such as different configurations of optical faces 94 and / or light guiding bodies 92. The optical lenses 28, optical faces 94, and / or light guiding bodies 92 can be symmetric or asymmetric relative to at least one plane. The optical arrays 26 are selected based on the beam pattern 32 and arranged along the circuit board 18 in a manner that combines the beam patterns 32 to form the selected composite light beam 34.

[0135] In step 202, a plurality of lighting assemblies 16 are selected to form a luminaire 10 that generates a light output pattern 50 and distribution for a target area 12. One or more configurations of lighting assemblies 16 may be combined to produce a luminaire 10 having one or more configurations of optical systems 24. For a composite light beam 34, the lighting assemblies 16 may be arranged relative to each other to form an overall light output pattern 50.

[0136] In step 204, the light output pattern 50 can be further adjusted by adjusting the intensity of each of the circuit boards 18 included in the luminaire 10 to adjust the light output pattern 50 and light distribution of the luminaire 10. For example, in the case of using two circuit boards 18 in the luminaire 10, one of the circuit boards 18 can have a set of optical arrays 26 that produces a stronger central beam and a narrow focus, while the second circuit board 18 has a different set of optical arrays 26 that focus light downward or toward the support column 180. Each circuit board 18 is controlled by a different driver or power supply. By varying the power of each of the circuit boards 18, the light output pattern 50 can be changed as a result, as the power control by output percentage can be adjusted remotely and in real time. Therefore, the light output pattern 50 can also be modified after installation without having to adjust the aiming of the luminaire 10 or the optical system 24.

[0137] Steps 192-204 of method 190 may be omitted, repeated, and / or performed simultaneously or sequentially in any order. For example, once the optical array 26 or lighting assembly 16 is formed and selected, the output may be calculated or tested. If the output is not the selected output beam pattern 32, composite beam 34, or overall pattern 50, the optical array 26 or lighting assembly 16 may be modified until the selected output 50 is achieved.

[0138] Each optical lens 28 produces a very narrow beam (typically less than 11 degrees) and is shaped to fill a specific point or location within the selected or designed beam pattern 32 of each optical array 26. Using a very narrow beam increases the light intensity and efficiency of the lighting assembly 16. The movement and shaping of light by the optical lens 28 is achieved through a relatively thin optical face 94 to reduce or eliminate thicker cross-sections that can cause "dip" and distortion. To shift the beam to the greatest extent, a thicker segment or Fresnel lens 132 is used. The Fresnel lens 132 creates a radius in the optical face 94 that scatters light. To reduce this light scattering, a Fresnel lens 132, which directs some light upward, is placed at the top of the optical array 26 in combination with an integrated light shield 170 on the bezel 54. To shift the beam to a lesser extent, optical lenses 28 with thinner optical faces 94 and / or adjustments to the light guiding body 92 (i.e., symmetrical and asymmetrical light guiding bodies 92b) including the TIR lens 122 can be used. The front optics (front optical face 94 ) and the back optics (light guiding body 92 with TIR lens 122 ) may be rotated independently or in combination to achieve light pattern 50 .

[0139] Using the present apparatus and methods can provide a variety of advantages. For example, luminaire 10 can be designed to achieve a full range of beam patterns 32 by using narrow optics 28. Furthermore, each beam emitted from luminaire 10 has a base beam width less than 11 degrees, providing a miniature "spotlight" to maintain the intensity of light emitted by each LED 20. Furthermore, the overall light pattern output 50 can be customized by the selection of optical lenses 28, the orientation of optical lenses 28 within optical array 26, the rotation of optical lenses 28, the selection of optical arrays 26, the orientation of optical arrays 26 on circuit board 18, the selection of lighting assemblies 16 with various optical array 26 configurations, and the arrangement of lighting assemblies 16 relative to one another. Furthermore, each optical array 26 is formed from narrow-beam individual optics 28 to create a composite optical array 26. Furthermore, optical system 24 is constructed of silicone to minimize or prevent yellowing and efficiency loss of the emitted light. Furthermore, each of optical arrays 26 can include a combination of one or more types of optical faces 94 and a combination of symmetric and asymmetric light-guiding bodies 92b to create a composite optical array 26.

[0140] Furthermore, once selected and rotated, the optical lens 28 is fixed to the optical array 26. Thus, after the manufacturing process is complete, the optical lens 28 is not adjustable relative to the LEDs 20. Furthermore, fixing the optical lens 28 to the optical array 26 maximizes the efficiency of the manufacturing process. The luminaire 10 disclosed herein can be mass-produced in a cost-effective manner. Thus, the luminaire 20 provides a customizable pattern 50 by selecting and arranging the optical lens 28 and array 26 that can be efficiently manufactured. Additional benefits or advantages can be realized and / or achieved.

[0141] It will be understood by those of ordinary skill in the art that the construction of the disclosure and other components is not limited to any particular material. Unless otherwise described herein, other exemplary embodiments of the disclosure disclosed herein may be formed from a variety of materials.

[0142] For purposes of this disclosure, the term "couple" (in all its forms, coupling, coupling, coupled, etc.) generally means the joining of two components (electrically or mechanically) directly or indirectly to one another. Such joining may be stationary in nature or removable in nature. Such joining may be achieved using the two (electrical or mechanical) components and any additional intermediate members that are integrally formed as a single unitary body with one another or with the two components. Unless otherwise specified, such joining may be permanent in nature or removable or releasable in nature.

[0143] For the purpose of this disclosure, the term “operably connected” generally means that one component functions with respect to another component even if other components exist between the first and second components, and the term “operable” defines the functional relationship between the components.

[0144] It is also important to note that the construction and arrangement of the elements of the present disclosure as shown in the exemplary embodiments are merely illustrative. Although only a few embodiments of the present invention's innovation have been described in detail in the present disclosure, it will be readily understood by those skilled in the art who consult the present disclosure that, unless otherwise described, without substantially departing from the novel teachings and advantages of the subject matter, there may be many modifications (e.g., changes in the size, dimensions, structure, shape and ratio, parameter values, mounting arrangements, use of materials, colors, orientations, etc. of the various elements). For example, the elements shown as being integrally formed may be constructed from a plurality of parts, or the elements shown as a plurality of parts may be integrally formed, the operation of the interface may be reversed or otherwise changed, the length or width of the structure and / or member or connector or other elements of the system may change, and the nature or quantity of the adjustment orientation provided between the elements may change. It should be noted that the elements and / or assemblies of the system may be constructed from any of a variety of materials providing sufficient strength or durability, with any of a variety of colors, textures, and combinations. Therefore, all such modifications are intended to be included within the scope of the present invention's innovation. Other substitutions, modifications, changes, and omissions may be made in the design, operating orientation, and arrangement of desired and other exemplary embodiments without departing from the spirit of the present innovations.

[0145] It should be understood that any described process or steps within a described process can be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and should not be construed as limiting.

[0146] It should also be understood that changes and modifications may be made to the structures and methods mentioned above without departing from the concepts of the present invention, and it should be further understood that unless the wording of the appended claims expressly states otherwise, such concepts are intended to be covered by these claims.

Claims

1. A lamp for illuminating a target area, the lamp comprising: An array of lighting assemblies, each lighting assembly comprising a circuit board, a solid-state light source disposed on a surface of the circuit board, and an optical system, the optical system comprising: a first solid integrated optical array associated with a first portion of the light source, the first solid integrated optical array comprising a fixed optical lens defining a predefined directional focus and a predefined angular beam to form light directed therethrough into a first beam pattern; as well as a second solid integrated optical array associated with a second portion of the light source, the second solid integrated optical array comprising a fixed optical lens defining a predefined directional focus and a predefined angular beam to form a second beam pattern of light directed therethrough, the second beam pattern being different from the first beam pattern and being combined with the first beam pattern to form a composite beam for the target area, the optical system comprising a combination of a symmetrical configuration and an asymmetrical configuration of the fixed optical lenses.

2. The luminaire of claim 1 , wherein the predefined angular beam of each fixed optical lens in the first solid integrated optical array and the predefined angular beam of each fixed optical lens in the second solid integrated optical array are base beams smaller than eleven degrees.

3. The luminaire according to any one of claims 1 or 2, wherein the array of lighting assemblies comprises: a third solid integrated optical array associated with a third portion of the light source on the circuit board, the third solid integrated optical array including fixed optical lenses to form a third beam pattern of light directed therethrough; as well as a fourth solid integrated optical array associated with a fourth portion of the light source on the circuit board, the fourth solid integrated optical array including fixed optical lenses to form a fourth beam pattern for light directed therethrough, the third beam pattern and the fourth beam pattern being combined with the first beam pattern and the second beam pattern to form the composite beam, wherein each fixed optical lens in the third and fourth solid integrated optical arrays defines a predefined angular beam of light of less than eleven degrees of a base beam for light directed therethrough.

4. The luminaire according to any one of claims 1 to 3, wherein each fixed optical lens in the first solid integrated optical array and the second solid integrated optical array comprises: a light guiding body defining a total internal reflection lens, the combination of the symmetric and asymmetric configurations of the fixed optical lens comprising the symmetric and asymmetric configurations of the light guiding body, the light guiding body being respectively configured to move the light passing therethrough relative to an aiming axis; as well as an external light guiding surface coupled to a respective one of the light guiding bodies, the external light guiding surface being selected from the group consisting of: Fresnel lens; Flat lens; Heightened conical lens; An optical device having a rotationally inverted conical surface; or In its rotational configuration, the fixed optical lenses rotate relative to corresponding aiming axes, the light guide body and the external light guiding surface are configured to maintain the predefined angular beam of less than eleven degrees of base beam when light passes therethrough.

5. The luminaire of claim 4 , wherein the outer light directing surfaces of at least a portion of the fixed optical lenses in the first solid integrated optical array are offset relative to a surface of a substrate of the first solid integrated optical array, the substrate being coupled to each of the fixed optical lenses.

6. The luminaire of any one of claims 1 to 5, wherein the first solid integrated optical array and the second solid integrated optical array are each constructed of optical silicone.

7. The lamp according to any one of claims 1 to 6, further comprising: A frame is disposed above the first solid integrated optical array and the second solid integrated optical array, wherein the frame defines openings that are aligned with the fixed optical lenses in the first solid integrated optical array and the second solid integrated optical array, respectively.

8. The luminaire of claim 7, wherein the bezel includes a light shield for each of a set of the openings to reduce light spread beyond a predefined angle relative to an aiming axis of a corresponding fixed optical lens.

9. A lighting assembly for a lamp, the lighting assembly comprising: circuit boards; a light source, the light source being arranged on the first surface of the circuit board; a heat sink coupled to a second surface of the circuit board, the second surface being opposite to the first surface; at least one solid integrated optical array coupled to the first surface of the circuit board, wherein the at least one solid integrated optical array comprises a substrate and a solid optical lens fixed to the substrate, each solid optical lens being positioned above a corresponding one of the light sources, and wherein each solid optical lens comprises: a light guiding body defining a total internal reflection lens; as well as an external light directing surface, each solid optical lens adapted to pass a light beam therethrough in a predefined direction to form a beam pattern, wherein each solid optical lens is configured to maintain a base beam size of light therethrough that is less than eleven degrees; and A bezel is positioned adjacent to the at least one solid integrated optical array and sealingly coupled to the heat sink.

10. The lighting assembly of claim 9, wherein at least one of the light guiding bodies is asymmetric, having a portion of increased thickness to shift the light beam from a central beam intensity.

11. A lighting assembly according to any one of claims 9 or 10, wherein the at least one solid integrated optical array includes a first solid integrated optical array, the first solid integrated optical array is positioned adjacent to a second solid integrated optical array on the first surface of the circuit board, and the solid optical lens in the first solid integrated optical array is different from the solid optical lens in the second solid integrated optical array.

12. The lighting assembly of any one of claims 9 to 11, wherein the at least one solid integrated optical array having the solid optical lens is constructed of optical silicone.

13. The lighting assembly of any one of claims 9 to 12, wherein the outer light directing surface of each of the solid optical lenses is selected from the group consisting of: Fresnel lens; Flat lens; Heightened conical lens; An optical device having a rotationally inverted conical surface; or In its rotating configuration, the fixed optical lenses rotate relative to the corresponding aiming axes.

14. The lighting assembly of any one of claims 9 to 13, wherein the outer light directing surfaces of at least two of the solid optical lenses are different.

15. The lighting assembly of any one of claims 9 to 14, wherein the bezel defines openings that are respectively aligned with and disposed around the solid optical lenses, and wherein the openings are arranged in rows aligned with the rows of the solid optical lenses.

16. The lighting assembly of claim 15 , wherein the bezel includes an integrated visor adjacent each of the openings in the first row to limit light spread, and wherein the integrated visor in combination with the base beam size of less than eleven degrees is configured to increase light at a target area while reducing glare.

17. A lighting assembly according to any one of claims 15 or 16, wherein the bezel includes a raised edge adjacent to each of the openings in the second row, wherein a group of the solid optical lenses protrude relative to the base surface of the at least one solid integrated optical array to extend through a corresponding one of the openings in the second row, and wherein the raised edge of the bezel extends around the periphery of a corresponding one of the solid optical lenses in the group to reduce light being directed through its side surface.

18. A method for designing a lighting fixture, the method comprising: determining a light output pattern and light distribution at a target area; selecting solid optical lenses to form an optical array of rows of said solid optical lenses; rotating each solid optical lens about an aiming axis to define a direction of a directed light while redirecting the directed light through a molded light directing surface to form a beam pattern of the optical array, each solid optical lens being a narrow beam optical lens configured to define a base beam size of less than eleven degrees for the directed light passing therethrough; molding the solid optical lens into the optical array; selecting a plurality of optical arrays and positioning the plurality of optical arrays over a light source on a circuit board to form a light assembly defining a composite light beam; as well as A plurality of light assemblies are selected to form the luminaire, the luminaire defining the light output pattern and the light distribution at the target area.

19. The method of claim 18, wherein the beam pattern of a first optical array in the plurality of optical arrays is different from the beam pattern of a second optical array in the plurality of optical arrays.

20. The method of any one of claims 18 or 19, wherein the step of selecting and positioning the plurality of optical arrays comprises selecting at least one optical array having a combination of symmetric solid optical lenses and asymmetric solid optical lenses.

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