Cluster Linear Cup Optics

Abstract

Illumination modules and illumination systems incorporating such modules are provided. The illumination system includes a housing body that secures one or more arrays of illumination modules, each array of illumination modules including one or more individual illumination modules. Specifically, each illumination module includes a retaining cup having a first end, a second end, and a sidewall extending from the first end to the second end, the second end of the retaining cup defining an exit opening of the illumination module, a light source disposed on a portion of a first surface of a light source substrate, the portion of the first surface of the light source substrate covering the first end of the retaining cup, and a total internal reflection (TIR) ​​optical device having an optical film, the TIR optical device disposed within the retaining cup and abutting the light source.

Description

[Technical field]

[0001] The present disclosure relates generally to illumination systems, and more particularly to illumination systems having configurable beam arrangements. [Background technology]

[0002] Despite advances in LED lighting, many consumers continue to find visible LED lenses to be bright, glaring, or objectionable. Current approaches to solving such problems typically involve the use of multiple very small total internal reflection (TIR) ​​lenses, which result in an intense and unpleasant visible light beam that casts shadows on the work surface, or the use of a single optical device that is expensive, large, and round in shape. Summary of the Invention [Problem to be solved by the invention]

[0003] It is therefore desirable to provide lighting systems and lighting modules with a large light emitting surface and a very low unified glare rating (UGR) for visual comfort while maintaining optical precision for many light beam patterns. [Means for solving the problem]

[0004] According to a first embodiment of the present disclosure, an illumination module is described. The illumination module may include a retaining cup having a first end, a second end, and a sidewall extending from the first end to the second end, the second end of the retaining cup defining an exit aperture of the illumination module, a light source disposed on a portion of a light source board, the portion of the light source board covering the first end of the retaining cup, and a total internal reflection (TIR) ​​optical device having an optical film, the TIR optical device disposed within the retaining cup and abutting the light source.

[0005] In one embodiment, the light source of the lighting module may include a light emitting diode (LED).

[0006] In one embodiment, the light source of the lighting module may include two or more LEDs.

[0007] In one embodiment, the TIR optical device of the lighting module may include a TIR lens.

[0008] In one embodiment, the TIR optical device of the lighting module may include an arrangement of at least two TIR lenses.

[0009] In one embodiment, the optical film of the TIR optical device may be disposed directly on the TIR optical device.

[0010] In one embodiment, the optical film of the TIR optical device may be disposed directly on an array of at least two TIR lenses.

[0011] In one aspect, a TIR optical device of the lighting module may be configured to receive a light beam from a light source, and an optical film of the TIR optical device may be configured to create one or more beam patterns from the light beam, including a glaze pattern, a narrow pattern, a medium pattern, a stack pattern, a batwing pattern, and an asymmetric pattern.

[0012] According to a second embodiment of the present disclosure, an illumination system is described. The illumination system includes a housing body that secures one or more arrays of illumination modules, each array of illumination modules may include one or more illumination modules. Each illumination module of the array of illumination modules may include a retaining cup having a first end, a second end, and a sidewall extending from the first end to the second end, the second end of the retaining cup defining an exit opening of the illumination module, a light source disposed on a portion of a first surface of a light source substrate, the portion of the first surface of the light source substrate covering the first end of the retaining cup, and a total internal reflection (TIR) ​​optical device having an optical film, the TIR optical device disposed within the retaining cup and abutting the light source.

[0013] In one embodiment, the lighting system may further include a light board bracket secured to a second surface of the light source board, a housing cover disposed on a second end of one or more retaining cups of one or more arrays of lighting modules, and one or more side cover panels attached to an end of the housing body.

[0014] In one embodiment, each array of lighting modules may include between 2 and 6 lighting modules.

[0015] In one embodiment, the one or more arrays of lighting modules may include between two and six arrays of lighting modules.

[0016] In one embodiment, the light source of each lighting module may include a light emitting diode (LED).

[0017] In one embodiment, the light source of each lighting module may include two or more LEDs.

[0018] In one embodiment, the optical film of each lighting module may be disposed directly over the TIR optical device.

[0019] In one embodiment, the TIR optical device of each lighting module may include a TIR lens.

[0020] In one embodiment, the TIR optical device of each lighting module may include an array of at least two TIR lenses.

[0021] In one embodiment, the optical film of each lighting module may be disposed directly on an array of at least two TIR lenses.

[0022] In one embodiment, the array of at least two TIR lenses may include an array of at least four TIR lenses.

[0023] In one aspect, the TIR optical device of each lighting module may be configured to receive a light beam from a light source, and the optical film of each TIR optical device may be configured to create one or more beam patterns from the light beam: a glaze pattern, a narrow pattern, a medium pattern, a stack pattern, a batwing pattern, and an asymmetric pattern.

[0024] These and other aspects of various embodiments will be apparent from and elucidated with reference to the embodiment(s) described hereinafter. [Brief description of the drawings]

[0025] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of various embodiments. [Figure 1] FIG. 1 is a front perspective exploded view of a lighting system according to the present disclosure. [Diagram 2] FIG. 2 is a first perspective view of a retaining cup of a discrete lighting module according to an embodiment of the present disclosure. [Diagram 3] FIG. 3 is a second perspective view of a retaining cup of a discrete lighting module according to a further embodiment of the present disclosure. [Figure 4] FIG. 4 is a top view of a portion of a light source substrate without a TIR optical device of a lighting system according to the present disclosure. [Diagram 5] FIG. 5 is a top view of a portion of a light source substrate including a TIR optical device of an illumination system according to the present disclosure. [Figure 6] FIG. 6 is a perspective view of a portion of an array of lighting modules according to an embodiment of the present disclosure. [Figure 7] 7A-7F are light beam patterns that may be produced using a lighting module according to the present disclosure. [Figure 8] FIG. 8 is a partial perspective view of a partially assembled lighting system according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] The present disclosure provides lighting modules configured to create one or more light patterns and lighting systems including such modules. The lighting modules described herein are scalable, have a large light emitting surface for visual comfort, and have a very low unified glare rating (UGR), while maintaining precise optical control.

[0027] 1, one embodiment of a lighting system 100 according to the present disclosure is shown in an exploded perspective view. The lighting system 100 includes a housing body 102 that secures one or more arrays 104 of lighting modules 106. In some embodiments, the housing body 102 is an extruded part that includes a lightweight metal or alloy, such as aluminum. In other embodiments, the housing body 102 can be an extruded part that includes a heavier metal or alloy, such as stainless steel.

[0028] The lighting system 100 may further include one or more cover panels 108, one or more housing covers 110, and one or more light source board brackets 112. In a specific embodiment, the one or more cover panels 108 are secured to corresponding ends 114 of the housing body to provide an attractive exterior surface for the lighting system 100 and to prevent movement of the array 104 of lighting modules 106 within the housing body 102. In a further embodiment, the one or more housing covers 110 are disposed below the lighting modules 106 (i.e., along the direction of the generated light pattern) and include a securing feature, such as a flexible clip, that engages with the housing body 102 to provide an attractive bottom surface and to prevent movement of the array 104 of lighting modules 106 within the housing body 102. In yet a further embodiment, the one or more light source board brackets 112 are disposed on the back surface 116 (i.e., the second surface 116) of the light source board 118 of the array 104 of lighting modules 106 and configured to further secure the array of lighting modules 106 within the housing body 102.

[0029] According to certain aspects of the disclosure, each lighting module 106 in the array 104 of lighting modules 106 may include a retaining cup 120, a light source disposed on a portion of a first surface of the light source substrate 118, and a total internal reflection (TIR) ​​optical device 122 having an optical film. As shown in Figures 2 and 3, each retaining cup 120, 220, 320 may include a first end 222, 322, a second end 224, 324, and sidewall(s) 226, 326 extending from the first end 222, 322 to the second end 224, 324, where the second end 224, 324 of the retaining cup 120, 220, 320 defines an exit aperture 328 of the lighting module 106. In certain embodiments, the exit aperture 328 is an opening at the end 224, 324 of the retaining cup 120, 220, 320 through which the light beam pattern generated by the illumination module 106 emanates. In certain embodiments, the sidewall(s) 226, 326 extending from the first end to the second end may be angled such that the second end 224, 324 is wider than the first end 222, 322. While not limited to a particular geometry, the retaining cup 120, 220, 320 shown has a square cross-section with filleted corners that create the appearance of a square inner cup 326.

[0030] Returning to FIG. 1 , each lighting module 106 of the array 104 of lighting modules 106 may include a light source disposed on a portion of a first surface of a light source substrate 118. In certain embodiments, the light source substrate 118 may be shared between one or more arrays 104 of lighting modules 106, and each array 104 of lighting modules 106 may include one or more lighting modules 106. For example, as shown in FIG. 1 , the lighting system 100 includes four arrays 104 of lighting modules 106, with each array 104 including six individual lighting modules 106, shared between two light source substrates 118. Each of the light source substrates 118 is configured to cover a first end 222, 322 of a corresponding retaining cup 120, 220, 320 such that the light source of each lighting module 106 is positioned above the exit aperture 328 of the corresponding lighting module 106.

[0031] 4, a section 401 of a light source substrate 400 is shown in accordance with an embodiment of the present disclosure. As shown, the section 401 includes a portion 402 of a first surface 403 of the light source substrate 400 on which a cluster of light sources 404 is disposed. In accordance with the present disclosure, each portion 402 of the first surface 403 of the light source substrate 400 is configured to cover a first end 222, 322 of a corresponding retaining cup 120, 220, 320 such that the light sources 404 of each lighting module 106 are proximate to the first end 222, 322 of the retaining cup 120, 220, 320.

[0032] According to an embodiment, the light source 404 may include a light emitting diode (LED) disposed within the first portion 402 of the first surface 403 of the light source substrate 400. In a further embodiment, the light source 404 includes a cluster of two or more LEDs disposed within the first portion 402 of the first surface 403 of the light source substrate 400. One or more of the LEDs may be, for example, an ultra-low power LED, a low power LED, a medium power LED, and / or a high power LED.

[0033] 1 , each lighting module 106 in the array of lighting modules 104 may further include a TIR optical device 122. In other words, the array of lighting modules 104 may include multiple TIR optical devices 122, with each TIR optical device 122 corresponding to one light source 404 (or cluster of light sources 404) and one retaining cup 120, 220, 320. The TIR optical device 122, or a portion thereof, may include a polymer, such as polymethylmethacrylate or polycarbonate.

[0034] According to the present disclosure, each of the TIR optical devices 122 can be disposed within a corresponding retaining cup 120, 220, 320 and abutted with a corresponding light source 404. For example, as shown in FIG. 5, the TIR optical device 522 is secured to a portion 502 of the first surface 503 of the light source substrate 500 on which the light source is disposed such that the TIR optical device is proximate to and abuts the light source. The TIR optical device can be secured to a portion 502 of the first surface 503 of the light source substrate 500 such that each TIR optical device 522 sits within a corresponding retaining cup 120, 220, 320. As shown in FIG. 6, a bottom perspective view of two lighting modules 606 is shown, where each lighting module 606 includes a retaining cup 620 and a TIR optical device 622 disposed within the corresponding retaining cup 620.

[0035] According to the present disclosure, each of the TIR optical devices 122, 522, 622 can be configured to receive a light beam from a corresponding light source 404. In certain embodiments, the TIR optical devices 122, 522, 622 can include a TIR lens 630 that collimates the light from the light source 404 toward the exit aperture 328 of the illumination module 106. In further embodiments, the TIR optical devices 122, 522, 622 include an arrangement 534 of at least two TIR lenses 630, integrated or clustered into a single optic, that collimates the light from the light source 404 toward the exit aperture 328 of the illumination module 106. For example, in a particular embodiment, the light source 404 may include four LEDs, and the TIR optical device 122, 522, 622 may include a cluster of four TIR lenses 630 arranged in a 2x2 pattern 534, with each TIR lens 630 of the TIR optical device 122, 522, 622 positioned adjacent to a corresponding LED of the light source 404.

[0036] In yet further embodiments, each of the TIR optical devices 122, 522, 622 of each lighting module 106 may include an optical film, such as MesoOptic® film. The optical film may be utilized to create a controlled light pattern by redirecting light to a desired light distribution. In other words, a light beam from the light source 404 of the lighting module 106 passes through the TIR lens 630 of the TIR optical device 122, 522, 622, which creates a tight / narrow light beam (i.e., a 15°×15° light beam), which may then pass through a corresponding optical film disposed directly on the surface of the TIR optical device 122, 522, 622 to create and precisely control one or more light beam patterns. In certain embodiments, each TIR optical device 122, 522, 622 having an optical film is configured to create from the light beam one or more of the following beam patterns: glaze pattern, narrow pattern, medium pattern, stack pattern, batwing pattern, asymmetric pattern, and combinations thereof, although other light beam patterns are contemplated.

[0037] 7A-7F, each of these beam patterns are shown, including a glaze pattern 701 shown in FIG 7A, a narrow pattern 702 shown in FIG 7B, a medium pattern 703 shown in FIG 7C, a stack pattern 704 shown in FIG 7D, a batwing pattern 705 shown in FIG 7E, and an asymmetric pattern 706 shown in FIG 7F. According to various aspects of the present disclosure, the glaze pattern 701 can have approximate dimensions of 16.6°×55°, the narrow pattern 702 can have approximate dimensions of 23.7°×24.4°, the medium pattern 703 can have approximate dimensions of 42.6°×45.1°, the stack pattern 704 can have approximate dimensions of 60.7°×72.2°, the batwing pattern 705 can have approximate dimensions of 58.1°×36.1°, and the asymmetric pattern can have approximate dimensions of 17.5°.

[0038] 8, a partially assembled lighting system 800 according to various aspects of the present disclosure is shown from a perspective view. As discussed herein, the lighting system 800 includes a housing body 802 that secures one or more arrays of lighting modules 804, each array of lighting modules 804 including one or more lighting modules 804. Each lighting module 804 in the array of lighting modules 804 may include (i) a retaining cup having a first end, a second end, and a sidewall extending from the first end to the second end, where the second end of the retaining cup defines an exit opening 806 of the lighting module 804; (ii) a light source (not visible) disposed on a portion of a first surface of a light source substrate 808, where the portion of the first surface of the light source substrate 808 covers the first end of the retaining cup; and (iii) a total internal reflection (TIR) ​​optical device 810 having an optical film (not visible), where the TIR optical device 810 is disposed on or within the retaining cup and abuts the light source.

[0039] By providing such lighting systems and modules, a large light emitting surface for visual comfort can be achieved while maintaining optical precision for many light beam patterns and having a very low unified glare rating (UGR). Furthermore, different high precision beam patterns can be generated using the disclosed lighting systems and modules without the need to change the shape or size of the retaining cup. Finally, by widely spacing the light sources (e.g., LEDs) rather than clustering them under a single TIR lens, the disclosed lighting systems and modules substantially eliminate shadows due to having discrete points and reduce color-over-angle effects due to certain LED chips.

[0040] As defined and used herein, all definitions should be understood to govern dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0041] The indefinite articles "a" and "an," as used in the specification and claims, unless clearly indicated otherwise, should be understood to mean "at least one."

[0042] The term "and / or," as used in the specification and claims, should be understood to mean "either or both" of the elements so conjoined, i.e., elements that are conjunctive in some cases and disjunctive in other cases. Multiple elements listed with "and / or" should be construed in the same manner, i.e., "one or more" of the elements so conjoined. Other elements than the elements specifically identified by the "and / or" clause may be optionally present, whether related or unrelated to those elements specifically identified.

[0043] As used in the specification and claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" shall be interpreted as inclusive, i.e., including at least one, but also including more than one of an element or list of elements, and optionally additional unlisted items. Only terms such as "only one of" or "exactly one of," or when used in the claims, "consisting of," where the contrary is clearly indicated, refer to the inclusion of exactly one of an element or list of elements. In general, the term "or," as used herein, shall be interpreted as indicating exclusive alternatives (i.e., "one or the other, but not both") only when preceding terms of exclusivity, such as "any of," "one of," "only one of," or "exactly one of."

[0044] As used in this specification and claims, the phrase "at least one" referring to a list of one or more elements should be understood to mean at least one selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each element specifically listed in the list of elements, and not excluding any combinations of elements in the list of elements. This definition also allows for elements other than the elements specifically identified in the list of elements to which the phrase "at least one" refers may optionally be present, whether related or unrelated to those elements specifically identified.

[0045] It should also be understood that, unless expressly indicated to the contrary, in any method claimed herein that includes two or more steps or actions, the order of the method steps or actions is not necessarily limited to the order in which the method steps or actions are recited.

[0046] In the claims and in the above specification, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "holding," "consisting of," and the like, are to be understood to be open-ended, i.e., meaning including but not limited to. Only transitional phrases such as "consisting of" and "consisting essentially of" are closed or semi-closed transitional phrases, respectively.

[0047] While several inventive embodiments have been described and illustrated herein, those skilled in the art will readily envision various other means and / or structures for performing the functions described herein and / or obtaining one or more of the results and / or advantages thereof, and such variations and / or modifications are deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are intended to be exemplary, and that the actual parameters, dimensions, materials, and / or configurations will vary depending on the particular application in which the teachings of the present invention are used. Those skilled in the art will recognize, or be able to ascertain, using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. Thus, the above-described embodiments are presented by way of example only, and it will be understood that, within the scope of the appended claims and their equivalents, inventive embodiments may be practiced other than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and / or method described herein. Furthermore, any combination of two or more such features, systems, articles, materials, kits, and / or methods is within the scope of the present disclosure, provided that such features, systems, articles, materials, kits, and / or methods are not mutually inconsistent.

Claims

1. 1. A lighting module, comprising: a retaining cup having a first end, a second end, and a sidewall extending from the first end to the second end, the second end of the retaining cup defining an exit opening for the lighting module; two or more light sources disposed on a portion of a light source substrate, the portion of the light source substrate covering the first end of the retaining cup; a total internal reflection (TIR) ​​optical device having an optical film, the TIR optical device including two or more integrated TIR lenses, the TIR optical device being disposed within the retaining cup, and each integrated TIR lens of the optical device being aligned with a corresponding light source; a lighting module including:

2. The lighting module of claim 1 , wherein the light source comprises a light emitting diode (LED).

3. The lighting module of claim 2 , wherein the light source comprises two or more LEDs.

4. The lighting module of claim 1 , wherein the optical film is disposed directly on the TIR optical device.

5. The lighting module of claim 1 , wherein the TIR optical device comprises a TIR lens.

6. A lighting module as described in claim 1, wherein the side walls of the retaining cup are angled so that the second end is wider than the first end and present a square cross-section with cut-off corners.

7. The lighting module of claim 1 , wherein the optical film is disposed directly on an arrangement of at least two TIR lenses.

8. 10. The lighting module of claim 1, wherein the TIR optical device is configured to receive light beams from the two or more light sources, and the optical film is configured to create one or more beam patterns from the light beams: a glaze pattern, a narrow pattern, a medium pattern, a stack pattern, a batwing pattern, and an asymmetric pattern.

9. A lighting fixture comprising a housing for securing one or more linear arrays of lighting modules, each lighting module comprising: a retaining cup having a first end, a second end, and a sidewall extending from the first end to the second end, the second end of the retaining cup defining an exit opening for the lighting module; two or more light sources disposed on a portion of a light source substrate, the portion of the light source substrate covering the first end of the retaining cup; a total internal reflection (TIR) ​​optical device having an optical film, the TIR optical device including two or more integrated TIR lenses, the TIR optical device being disposed within the retaining cup, and each integrated TIR lens of the optical device being aligned with a corresponding light source; Including, A lighting fixture in which each lighting module is butted up with one or two other lighting modules.

10. A lighting fixture as described in claim 9, wherein each TIR optical device is configured to receive light beams from the two or more light sources, and the optical film is configured to create one or more beam patterns from the light beams, including a glaze pattern, a narrow pattern, a medium pattern, a stack pattern, a batwing pattern, and an asymmetric pattern.

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