Luminaire with seamless ring-shaped lens

Abstract

A lighting device includes an outer frame having an outer frame wall and an outer frame ledge. The outer frame ledge extends around the outer frame wall at an inner side of the outer frame wall. The lighting device further includes an inner frame having an inner frame wall and an inner frame ledge, wherein the inner frame ledge extends around the inner frame wall at an outer side of the inner frame wall, wherein the outer frame is positioned around the inner frame, wherein the inner frame and the outer frame are fixedly spaced from each other. The lighting device further also includes a lens having a ring shape, wherein the lens is seamless and wherein the lens is positioned on the outer frame ledge and the inner frame ledge.

Description

[0001] LUMINAIRE WITH SEAMLESS RING-SHAPED LENS

[0002] FIELD OF THE INVENTION

[0003] The present disclosure relates generally to lighting solutions, and in particular to luminaires with a seamless ring-shaped lens.

[0004] BACKGROUND OF THE INVENTION

[0005] A ring-shaped luminaire typically includes a light source that emits a downlight. For example, ring-shaped luminaires may be installed as suspended luminaires such as a pendant or a chandelier. A typical ring-shaped luminaire includes a lens that is attached to the housing of the luminaire. One of the challenges of making a ring-shaped luminaire is related to unwanted light leakage between the lens and the housing of the luminaire. For example, the width of the lens may be made relatively narrow for ease of attachment to the housing, which can result in unwanted light leakage, for example, between an edge of the lens and the housing. In some cases, to avoid light leakage by using a lens with a relatively wider width, lens segments are individually attached to the luminaire housing and are abutted against each other to make up the seamed lens of the luminaire. The seams of the lens can lower the quality of light provided by the luminaire or may generally be undesirable. Thus, a solution that provides a luminaire with a seamless ring-shaped lens is desirable.

[0006] SUMMARY OF THE INVENTION

[0007] The present disclosure relates generally to lighting solutions, and in particular to luminaires with a seamless ring-shaped lens. In an example embodiment, a lighting device includes an outer frame having an outer frame wall and an outer frame ledge. The outer frame ledge extends around the outer frame wall at an inner side of the outer frame wall. The lighting device further includes an inner frame having an inner frame wall and an inner frame ledge, wherein the inner frame ledge extends around the inner frame wall at an outer side of the inner frame wall, wherein the outer frame is positioned around the inner frame, wherein the inner frame and the outer frame are fixedly spaced from each other. The lighting device further also includes a lens having a ring shape, wherein the lens is seamless and wherein the lens is positioned on the outer frame ledge and the inner frame ledge. In another example embodiment, a method (1900) of assembling a lighting device includes placing an outer frame around an inner frame. The outer frame is spaced from the inner frame. The outer frame includes an outer frame wall and an outer frame ledge. The outer frame ledge extends around the outer frame wall at an inner side of the outer frame wall. The inner frame comprises an inner frame wall and an inner frame ledge. The inner frame ledge extends around the inner frame wall at an outer side of the inner frame wall. The method further includes attaching a brace to the outer frame and the inner frame such that the outer frame ledge is aligned with the inner frame ledge. The method also includes placing a lens on the outer frame ledge and the inner frame ledge through a gap between the outer frame ledge and the inner frame ledge, wherein the lens is ring-shaped and seamless.

[0008] These and other aspects, objects, features, and embodiments will be apparent from the following description and the appended claims.

[0009] BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0011] FIGS. 1 A and IB illustrate a lighting device having a seamless ring-shaped lens according to an example embodiment;

[0012] FIGS. 2A and 2B illustrate an outer frame of the lighting device of FIGS. 1 A and IB according to an example embodiment;

[0013] FIGS. 3A-3C illustrate an inner frame of the lighting device of FIGS. 1 A and IB according to an example embodiment;

[0014] FIG. 4 illustrates an assembly of the outer frame and the inner frame of the lighting device of FIGS. 1A and IB according to an example embodiment;

[0015] FIGS. 5A and 5B illustrate the A-A cross-section of the assembly of the outer frame and the inner frame shown in FIG. 4 according to an example embodiment;

[0016] FIG. 6 illustrates a brace attached to the outer frame and the inner frame shown in FIG. 4 according to an example embodiment;

[0017] FIG. 7 illustrates the B-B cross-section of an assembly of the brace, the outer frame, and the inner frame shown in FIG. 6 according to an example embodiment;

[0018] FIG. 8 illustrates a light source module attached to the brace shown in FIG. 6 according to an example embodiment;

[0019] FIG. 9 illustrates a bottom view of the seamless ring-shaped lens of the lighting device of FIGS. 1A and IB according to an example embodiment; FIGS. 10 A- 10C illustrate the seamless ring-shaped lens of FIG. 9 during attachment to the outer frame and the inner frame shown in FIG. 8 according to an example embodiment;

[0020] FIG. 11 illustrates a partial cross-section view corresponding to FIG. 10C and to the C-C cross-section shown in FIG. 8 according to an example embodiment;

[0021] FIG. 12 illustrates a bottom view of the seamless ring-shaped lens of FIG. 9 during attachment to the outer frame and the inner frame shown in FIG. 8 according to an example embodiment;

[0022] FIG. 13 illustrates the seamless ring-shaped lens fully attached to the outer frame and the inner frame shown in FIG. 11 according to an example embodiment;

[0023] FIG. 14 illustrates a D-D cross-section of the seamless ring-shaped lens, the outer frame, and the inner frame shown in FIG. 13 according to an example embodiment;

[0024] FIG. 15 illustrates the D-D cross-section of the seamless ring-shaped lens, the outer frame, and the inner frame shown in FIG. 13 with the seamless ring-shaped lens in a different position than shown in FIG. 14 according to an example embodiment;

[0025] FIG. 16 illustrates a top perspective view of a light source module positioned to provide an uplight of the lighting device of FIGS. 1A and IB according to an example embodiment;

[0026] FIG. 17 illustrates a top perspective view of the lighting device of FIGS. 1 A and IB according to an example embodiment;

[0027] FIGS. 18A and 18B illustrate an E-E cross-section of the lighting device shown in FIG. 17 according to an example embodiment; and

[0028] FIG. 19 illustrates a method of assembling the lighting device of FIGS. 1A and IB according to an example embodiment.

[0029] The drawings illustrate only example embodiments and are therefore not to be considered limiting in scope. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Additionally, certain dimensions or placements may be exaggerated to help visually convey such principles. In the figures, the same reference numerals used in different figures may designate like or corresponding and not necessarily identical elements. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0030] In the following paragraphs, particular embodiments will be described in further detail by way of example with reference to the figures. In the description, well known components, methods, and / or processing techniques are omitted or briefly described. Furthermore, reference to various feature(s) of the embodiments is not to suggest that all embodiments must include the referenced feature(s).

[0031] Turning now to the drawings, example embodiments are described. FIGS. 1 A and IB illustrate a lighting device 100 having a seamless ring-shaped lens 106 according to an example embodiment. In some example embodiments, the lighting device 100 may be a ring-shaped luminaire. For example, the lighting device 100 may be a ring-shaped suspended luminaire. The lighting device 100 may be suspended, for example, from a ceiling structure using suspension cables 108.

[0032] In some example embodiments, the lighting device 100 may include a housing that includes an outer frame 102 and an inner frame 104. The lens 106 may be positioned between the outer frame 102 and the inner frame 104 proximal to bottom edges of the outer frame 102 and the inner frame 104. For example, the lens 106 may be positioned on ledges of the outer frame 102 and the inner frame 104 and between the outer frame 102 and the inner frame 104. The lens 106 may be positioned such that a light provided by a light source of the lighting device 100 may exit the lighting device 100 through the lens 106.

[0033] In some example embodiments, the lighting device 100 may include uplight lenses 110, 112, 114. For example, the uplight lenses 110, 112, 114 may be separated from each other by suspension brackets of the lighting device 100 that are used to suspend the lighting device 100 using the suspension cables 108. The uplight lens 110, 112, 114 may be attached to the outer frame 102 and the inner frame 104 such that an uplight provided by the lighting device 100 exits through the uplight lenses 110, 112, 114, for example, to illuminate an area above the lighting device 100.

[0034] FIGS. 2A and 2B illustrate the outer frame 102 of the lighting device 100 of FIGS. 1 A and IB according to an example embodiment. Referring to FIGS. 1 A-2B, in some example embodiments, the outer frame 102 may have a hollow cylindrical shape or a ring shape. The outer frame 102 may include an outer frame wall 202 and an outer frame lens groove 204 that is formed in the outer frame wall 202. For example, the outer frame lens groove 204 may be formed proximal to a bottom perimeter edge 212 of the outer frame 102. The lens 106 of the lighting device 100 may be positioned in the outer frame lens groove 204 after attachment to the outer frame 102 as shown in FIG. 1 A. The outer frame 102 may also include a brace attachment groove 206 and a bracket attachment groove 208. The bracket attachment groove 208 may be located proximal to a top perimeter edge 210 of the outer frame 102, and the brace attachment groove 206 may be between the outer frame lens groove 204 and the brace attachment groove 208. The outer frame lens groove 204, the brace attachment groove 206, and the bracket attachment groove 208 may be on an inner side 214 of the outer frame 102. The outer side 216 of the outer frame 102 may have a smooth surface.

[0035] In some example embodiments, the outer frame 102 may be extruded with the outer frame lens groove 204, the brace attachment groove 206, and the bracket attachment groove 208 formed by the extrusion process. For example, the outer frame 102 may be made from aluminum and / or another material (e.g., another metal such as steel). To illustrate, after extrusion, the extruded flat sheet that includes the outer frame lens groove 204, the brace attachment groove 206, and the bracket attachment groove 208 may be rolled into a rolled sheet using a metal rolling machine, and the ends of the rolled sheet may be, for example, welded together to form the outer frame 102 having the ring shape. In some alternative embodiments, the outer frame lens groove 204, the brace attachment groove 206, and the bracket attachment groove 208 may be milled out from the outer frame wall 202. In some alternative embodiments, the outer frame 102 may be made using other methods such as die casting.

[0036] In some example embodiments, the outer frame 102 may be painted. For example, the outer frame 102 may be painted after some of the components of the lighting device 100 have been attached to the outer frame 102. The outer frame 102 may be painted after a brace has been welded to the outer frame 102 as explained below with respect to FIG. 6.

[0037] In some alternative embodiments, the outer frame 102 may have a different exterior shape than shown without departing from the scope of this disclosure. In some alternative embodiments, other lighting device components may be positioned on the outside of the outer frame 102 without departing from the scope of this disclosure. In some alternative embodiments, the outer frame lens groove 204 may be farther from the bottom perimeter edge 212 than shown without departing from the scope of this disclosure. In some alternative embodiments, the bracket attachment groove 208 may be farther from the top perimeter edge 210 than shown without departing from the scope of this disclosure. In some alternative embodiments, the brace attachment groove 206 and / or the bracket attachment groove 208 may be omitted without departing from the scope of this disclosure. In some alternative embodiments, the outer frame lens groove 204 may be omitted, and the outer frame 102 may include a ledge or a lip upon which the lens 106 is positioned without departing from the scope of this disclosure.

[0038] FIGS. 3A-3C illustrate the inner frame 104 of the lighting device 100 of FIGS. 1 A and IB according to an example embodiment. Referring to FIGS. 1 A, IB, and 3A-3C, in some example embodiments, the inner frame 104 may have a hollow cylindrical shape or a ring shape. The inner frame 104 may include an inner frame wall 302 and an inner frame lens groove 304 that is formed in the inner frame wall 302. For example, the inner frame lens groove 304 may be formed proximal to a bottom perimeter edge 312 of the inner frame 104. The lens 106 of the lighting device 100 may be positioned in the inner frame lens groove 304 after attachment to the inner frame 104 as shown in FIG. 1 A. The inner frame 104 may also include a brace attachment groove 306 and a bracket attachment groove 308. The bracket attachment groove 308 may be located proximal to a top perimeter edge 310 of the inner frame 104, and the brace attachment groove 306 may be between the inner frame lens groove 304 and the brace attachment groove 308. The inner frame lens groove 304, the brace attachment groove 306, and the bracket attachment groove 308 may be on an outer side 314 of the inner frame 104. The inner side 316 of the inner frame 104 may have a smooth surface.

[0039] In some example embodiments, the inner frame 104 may be extruded with the inner frame lens groove 304, the brace attachment groove 306, and the bracket attachment groove 308 formed by the extrusion process. For example, the inner frame 104 may be made from aluminum and / or another material (e.g., another metal such as steel). To illustrate, after extrusion, the extruded flat sheet that includes the inner frame lens groove 304, the brace attachment groove 306, and the bracket attachment groove 308 may be rolled into a rolled sheet using a metal rolling machine, and the ends of the rolled sheet may be, for example, welded together to form the inner frame 104 having the ring shape. In some alternative embodiments, the inner frame lens groove 304, the brace attachment groove 306, and the bracket attachment groove 308 may be milled out from the inner frame wall 302. In some alternative embodiments, the inner frame 104 may be made using other methods such as die casting.

[0040] In some example embodiments, the inner frame 104 may be painted. For example, the inner frame 104 may be painted after some of the components of the lighting device 100 have been attached to the inner frame 104. The inner frame 104 may be painted after a brace has been welded to the inner frame 104 as explained below with respect to FIG. In some alternative embodiments, the inner frame 104 may have a different exterior shape than shown without departing from the scope of this disclosure. In some alternative embodiments, other lighting device components may be positioned on the inner side 316 of the inner frame 104 without departing from the scope of this disclosure. In some alternative embodiments, the inner frame lens groove 304 may be farther from the bottom perimeter edge 312 than shown without departing from the scope of this disclosure. In some alternative embodiments, the bracket attachment groove 308 may be farther from the top perimeter edge 310 than shown without departing from the scope of this disclosure. In some alternative embodiments, the brace attachment groove 306 and / or the bracket attachment groove 308 may be omitted without departing from the scope of this disclosure. In some alternative embodiments, the inner frame lens groove 304 may be omitted, and the inner frame 104 may include a ledge or a lip upon which the lens 106 is positioned without departing from the scope of this disclosure.

[0041] FIG. 4 illustrates an assembly 400 of the outer frame and the inner frame of the lighting device of FIGS. 1 A and IB according to an example embodiment. Referring to FIGS. 1 A-4, in some example embodiments, during the assembling of the lighting device 100, the outer frame 102 is positioned around the inner frame 104. For example, the inner frame 104 may be centrally positioned within the space surrounded by the outer frame 102.

[0042] FIGS. 5A and 5B illustrate the A-A cross-section of the assembly 400 of the outer frame 102 and the inner frame 104 shown in FIG. 4 according to an example embodiment. Referring to FIGS. 1-5B, in some example embodiments, the outer frame 102 includes the outer frame lens groove 204, the brace attachment groove 206, and the bracket attachment groove 208 that are formed in the outer frame wall 202 of the outer frame 102. As described above with respect to FIGS. 2 A and 2B, the outer frame lens groove 204, the brace attachment groove 206, and the bracket attachment groove 208 are at the inner side 214 of the outer frame 102 facing the inner frame 104.

[0043] In some example embodiments, the outer frame 102 may include an outer frame ledge 502 that serves as a sidewall of the outer frame lens groove 204. The outer frame lens groove 204 may also have a backwall 504 and another sidewall 506. The outer frame ledge 502, the backwall 504, and the sidewall 506 may together define the outer frame lens groove 204 that faces the inner frame 104. The outer frame ledge 502 may have a surface 508, and the lens 106 shown in FIG. 1 A may be positioned on the outer frame ledge 502 in contact with the surface 508. In some example embodiments, the inner frame 104 includes the inner frame lens groove 304, the brace attachment groove 306, and the bracket attachment groove 308 that are formed in the inner frame wall 302 of the inner frame 104. As described above with respect to FIGS. 3A-3C, the inner frame lens groove 304, the brace attachment groove 306, and the bracket attachment groove 308 are at the outer side 314 of the inner frame 104 facing the outer frame 102.

[0044] In some example embodiments, the inner frame 104 may include an inner frame ledge 512 that serves as a sidewall of the inner frame lens groove 304. The inner frame lens groove 304 may also have a backwall 514 and another sidewall 516. The inner frame ledge 512, the backwall 514, and the sidewall 516 may together define inner frame lens groove 304 that faces the outer frame 102. The inner frame ledge 512 may have a surface 518, and the lens 106 shown in FIG. 1A may be positioned on the inner frame ledge 512 in contact with the surface 518.

[0045] In some example embodiments, the outer frame 102 and the inner frame 104 may be positioned with respect to each other such that the outer frame lens groove 204 is horizontally aligned with the inner frame lens groove 304 of the inner frame 104. The outer frame lens groove 204 and the inner frame lens groove 304 may be held in alignment with each other by a brace that gets positioned in the brace attachment groove 206 of the outer frame 102 and in the brace attachment groove 306 of the inner frame 104. The brace may be positioned in a space 510 that is between the outer frame 102 and the inner frame 104. The outer frame 102 and the inner frame 104 may be attached to the brace such that the outer frame ledge 502 and the inner frame ledge 512 are spaced from each other by a gap 520. For example, the distance between the outer frame ledge 502 and the inner frame ledge 512 (i.e., the width of the gap 520) is shown in FIG. 5B as D-ledges.

[0046] In some example embodiments, the distance D-ledges may be smaller than the width of the lens 106 such that the lens 106 can rest on both the outer frame ledge 502 and the inner frame ledge 512. For example, the lens 106 can rest on both the outer frame ledge 502 and the inner frame ledge 512 all around the outer frame lens groove 204 and the inner frame lens groove 304 or at least along arc sections of both the outer frame ledge 502 and the inner frame ledge 512. In general, the distance D-ledges may be as small or large as desired (e.g., less than an inch, an inch, more than an inch) to accommodate lighting needs. For example, the distance D-ledges may be 1.61 inch, and the width of the lens may be 1.665 inch. The backwall 504 of the outer frame ledge 502 and the backwall 514 of the inner frame ledge 512 may be spaced from each other by a distance D-grooves. In general, the distance D-grooves may be as small or large as desired (e.g., less than an inch, an inch, more than an inch). For example, the distance D- grooves may be 1.86 inch, and the width of the lens may be 1.665 inch. In general, the height of the backwall 504 is large enough to accommodate the slanting of the lens 106 during the insertion of the lens 106 into the lens grooves 204, 304 as explained below in more detail. For example, the height of each one of the backwall 504 and the backwall 514 may be, for example, 0.25 inch, and the width of the lens may be 1.665 inch.

[0047] In some example embodiments, the bracket attachment groove 208 of the outer frame 102 and the bracket attachment groove 308 of the inner frame 104 may be used to attach suspension brackets to the outer frame 102 and the inner frame 104. For example, the bracket attachment groove 208 and the bracket attachment groove 308 may be aligned with each other. The suspension brackets may be inserted into the bracket attachment groove 208 and into the bracket attachment groove 308. The suspension brackets may be attached to the suspension cables 108 shown in FIG. IB and may be used to install the lighting device 100 suspended from, for example, a ceiling using the suspension cables 108.

[0048] In some example embodiments, the outer frame 102 and the inner frame 104 may be positioned with respect to each other such that the bottom perimeter edge 212 of the outer frame 102 and the bottom perimeter edge 212 of the inner frame 104 are horizontally aligned with each other. The outer frame 102 and the inner frame 104 may also be positioned with respect to each other such that the top perimeter edge 210 of the outer frame 102 and the top perimeter edge 310 of the inner frame 104 are horizontally aligned with each other. Alternatively, the top perimeter edge 210 and the top perimeter edge 310 may be horizontally misaligned with each other without departing from the scope of this disclosure. For example, the outer frame 102 and the inner frame 104 may have different heights, where the bottom perimeter edge 212 and the bottom perimeter edge 312 are horizontally aligned with each other while the top perimeter edge 210 and the top perimeter edge 310 are horizontally misaligned.

[0049] In some alternative embodiments, the lens grooves 204, 304 may each have a different shape than shown without departing from the scope of this disclosure. In some alternative embodiments, the brace attachment grooves 206, 306 may each have a different shape or may be omitted without departing from the scope of this disclosure. In some alternative embodiments, the bracket attachment grooves 208, 308 may each have a different shape or may be omitted without departing from the scope of this disclosure. In some alternative embodiments, the outer frame lens groove 204 may be omitted, and the outer frame 102 may include the outer frame ledge 502 upon which the lens 106 is positioned without departing from the scope of this disclosure. In some alternative embodiments, the inner frame lens groove 304 may be omitted, and the inner frame 104 may include the inner frame ledge 512 upon which the lens 106 is positioned without departing from the scope of this disclosure.

[0050] FIG. 6 illustrates a brace 602 attached to the outer frame 102 and the inner frame 104 shown in FIG. 4 according to an example embodiment, and FIG. 7 illustrates the B-B cross-section of an assembly of the brace 602, the outer frame 102, and the inner frame 104 shown in FIG. 6 according to an example embodiment. Referring to FIGS. 1 A-7, in some example embodiments, the brace 602 may be positioned in the space 510 that is between the outer frame 102 and the inner frame 104. To illustrate, the brace 602 may be positioned in the brace attachment groove 206 of the outer frame 102 and the brace attachment groove 306 of the inner frame 104. The brace 602 may include multiple brace segments that may be individually inserted into the brace attachment groove 206 and the brace attachment groove 306. The brace segments may then be attached to each other to form a ring-shaped of the brace 602 that extends around the inner frame 104.

[0051] In some example embodiments, the brace 602 may be made from sheet metal (e.g., aluminum or steel) using methods such as cutting, stamping, and / or other methods and may be welded to the outer frame 102 and the inner frame 104. The brace 602 may be welded to the outer frame 102 and the inner frame 104 such that the outer frame 102 and the inner frame 104 are fixedly spaced from each other. The brace 602 may be welded to the outer frame 102 and the inner frame 104 such that the outer frame lens groove 204 and the inner frame lens groove 304 are maintained aligned to each other. The brace 602 may be welded to the outer frame 102 and the inner frame 104 such that the width of the gap 520 (i.e., the distance D-ledges shown in FIG. 5B) between the outer frame ledge 502 and the inner frame ledge 512 is maintained constant or substantially constant. In addition to firmly holding the outer frame 102 and the inner frame 104 in a desired relative position, the brace 602 may also provide a platform for electronic components (e.g., a light emitting diode (LED) driver) of the lighting device 100 that may, for example, provide power to the light source(s) of the lighting device 100. In general, to avoid damaging the lens 106 of the lighting device 100, the lens 106 is attached to the outer frame 102 and the inner frame 104 after the brace 602 is welded to the outer frame 102 and the inner frame 104.

[0052] In some example embodiments, suspension brackets 604, 606, 608 may be attached to the outer frame 102 and the inner frame 104. The suspension brackets 604, 606, 608 may each be positioned in the bracket attachment groove 208 of the outer frame 102 and the bracket attachment groove 308 of the inner frame 104. The suspension brackets 604, 606, 608 may be located generally equidistant from each other. The suspension brackets 604, 606, 608 may each have dimensions such that, after between placed between the bracket attachment groove 208 and the bracket attachment groove 308, the suspension brackets 604, 606, 608 may each be rotated to be inserted into the bracket attachment groove 208 and the bracket attachment groove 308. The suspension brackets 604, 606, 608 may be welded to the outer frame 102 and the inner frame 104 or may be left unwelded. The suspension brackets 604, 606, 608 may be attached to the suspension cables 108 shown in FIG. IB and may be used to install the lighting device 100 suspended from, for example, a ceiling using the suspension cables 108.

[0053] In some example embodiments, support brackets 610, 612, 614 may be attached to the brace 602 in the space 510 between the outer frame 102 and the inner frame 104. For example, the support brackets 610, 612, 614 may be located equidistant from each other. The support brackets 610, 612, 614 may each be inserted in respective attachment slots in the brace 602 such that the support brackets 610, 612, 614 are firmly attached to the brace 602. Alternatively or in addition, the support brackets 610, 612, 614 may be attached to the brace 602 using fasteners such as screws or may alternatively be welded to the brace 602. The support brackets 610, 612, 614 may provide a platform for an uplight light source module and / or other component(s) of the lighting device 100 that can be positioned on the support brackets 610, 612, 614 within the space 510.

[0054] In some alternative embodiments, the brace 602 may include brace segments that are attached to the outer frame 102 and the inner frame 104 but not to each other without departing from the scope of this disclosure. In some alternative embodiments, the brace 602 may be attached to the outer frame 102 and the inner frame 104 at locations other than at the brace attachment groove 206 and the brace attachment groove 306 without departing from the scope of this disclosure. In some alternative embodiments, the brace 602 may be welded or otherwise firmly attached to the outer frame 102 and the inner frame 104 without being inserted into the brace attachment groove 206 and the brace attachment groove 306. For example, the brace attachment groove 206 and the brace attachment groove 306 may be omitted without departing from the scope of this disclosure. In some alternative embodiments, the brace 602 may have a different shape and may be attached to the outer frame 102 and the inner frame 104 in a different manner than described herein without departing from the scope of this disclosure. In some alternative embodiments, more or fewer than three suspension brackets may be attached to the outer frame 102 and the inner frame 104 without departing from the scope of this disclosure. In some alternative embodiments, the support brackets 610, 612, 614 may be at different locations than shown without departing from the scope of this disclosure.

[0055] FIG. 8 illustrates a light source module 802 attached to the brace shown in FIG. 6 according to an example embodiment. Referring to FIGS. 1 A-8, in some example embodiments, the lighting device 100 may include the light source module 802 (e.g., an LED light source module that may include LEDs attached to one or more circuit boards). To illustrate, after the brace 602 is attached (e.g., welded) to the outer frame 102 and the inner frame 104, the light source module 802 may be attached to the brace 602 to emit through the gap 520 between the outer frame ledge 502 and the inner frame ledge 512. When the lens 106 is positioned in the outer frame lens groove 204 and the inner frame lens groove 304, the light source module 802 may emit a light that exits the space 510 between the outer frame 102 and the inner frame 104 through the lens 106. The light source module 802 may include multiple light source segments (e.g., multiple circuit boards) or may include a single light source segment. A power supply (e.g., an LED driver) may be positioned in the space 510, for example, on an opposite side of the brace 602 from the light source module 802 to provide power to the light source module 802 and / or other electrical components.

[0056] In some example embodiments, the outer frame 102 and the inner frame 104 may be painted after the brace 602 is attached to the outer frame 102 and the inner frame 104. The brace 602 may also be painted along with the outer frame 102 and the inner frame 104. For example, the outer frame 102 and the inner frame 104 may be painted before the light source module 802 is attached to the brace 602. The outer frame 102 may be painted a light reflective color on the inner side 214 of the outer frame 102, and the inner frame 104 may be painted a light reflective color on the outer side 314 of the inner frame 104. The portions of the outer frame 102 and the inner frame 104 that are exposed to occupants after the lighting device 100 is installed may be painted colors that are aesthetically desired.

[0057] FIG. 9 illustrates a bottom view of the seamless ring-shaped lens 106 of the lighting device of FIGS. 1 A and IB according to an example embodiment. Referring to FIGS. 1A-9, in some example embodiments, the lens 106 may have a ring shape and may be seamlessly formed. The lens 106 may be made from a polycarbonate material and / or another material such as acrylic or glass. For example, the lens 106 may be machined or cut out of a rigid polycarbonate sheet. The lens 106 may be sized such that the lens 106 is rigid. In some example embodiments, the lens 106 may have an outer perimeter edge 902 and an inner perimeter edge 904. The outer perimeter edge 902 has an outer diameter D- outer. For example, the outer diameter D-outer may be two feet or may be shorter or longer than two feet. The inner perimeter edge 904 has an inner diameter D-inner. The difference between the outer diameter D-outer and the inner diameter D-inner defines the width W of the lens 106. The lens 106 may be sized such that the width W of the lens 106 is greater than the distance D-ledges (i.e., the width of the gap 520) between the outer frame ledge 502 and the inner frame ledge 512.

[0058] FIGS. 10 A- 10C illustrate the seamless ring-shaped lens 106 of FIG. 9 during attachment to the outer frame 102 and the inner frame 104 shown in FIG. 8 according to an example embodiment. Referring to FIGS. 1 A-10C, in some example embodiments, after the light source module 802 is attached to the brace 602 as shown in FIG. 8, the lens 106 may be attached to the outer frame 102 and the inner frame 104, for example, from below the outer frame 102 and the inner frame 104. In general, to avoid damaging the lens 106 of the lighting device 100, the lens 106 is attached to the outer frame 102 and the inner frame 104 after the brace 602 is welded to the outer frame 102 and the inner frame 104. As shown in FIG. 10A, a person may hold the lens 106 in a hand 1002 and move the lens 106 closer to the bottom perimeter edge 212 of the outer frame 102 and generally closer to the outer frame 102 and the inner frame 104. As shown in FIG. 10B, the person may slant the lens 106 such that a portion 1006 of the lens 106 is closer to the bottom perimeter edge 212 of the outer frame 102 than a portion 1008 of the lens 106 that is diametrically opposite from the portion 1006. For example, the person may hold the lens 106 with the hand 1002 and may push the portion 1006 closer to the outer frame 102 and the inner frame 104, for example, shown in FIG. 8. The portion 1006 of the lens 106 may be a relatively small arc segment of the lens 106.

[0059] Referring to FIGS. 1 A-10C, in some example embodiments, following the position of the lens shown in FIG. 10B, the person may hold the lens 106 with the hand 1002 and push the portion 1006 of the lens 106 with the hand 1004 through the gap 520 such that the portion 1006 of the lens 106 is positioned in the outer frame lens groove 204. FIG. 11 illustrates a partial cross-section view corresponding to FIG. 10C and to the C-C crosssection shown in FIG. 12 according to an example embodiment. Referring to FIGS. 9-11, in some example embodiments, after the person pushes the portion 1006 of the lens 106 through the gap 520 between the outer frame ledge 502 and the inner frame ledge 512, the lens 106 may be positioned in the outer frame lens groove 204 while the lens 106 remains slanted. As more clearly shown in FIG. 11, the lens 106 may be slanted and abutted against the backwall 504 of the outer frame lens groove 204 such that the outer perimeter edge 902 of the lens 106 at the portion 1006 of the lens 106 is in the outer frame lens groove 204 while the inner perimeter edge 904 of the lens 106 at the portion 1006 of the lens 106 is outside of the inner frame lens groove 304 of the inner frame 104. In general, the lens 106 may be in the position and orientation shown in FIGS. 10C and 11 after the outer perimeter edge 902 of the lens 106 at the portion 1006 of the lens 106 is lifted upward through the gap 520 and shifted into the outer frame lens groove 204 while other portions of the lens 106 including the portion 1008 of the lens 106 are below the outer frame 102 and the inner frame 104. In some alternative embodiments, the lens 106 may be slanted more or less than shown in FIGS. 10B-11 without departing from the scope of this disclosure.

[0060] FIG. 12 illustrates a bottom view of the seamless ring-shaped lens of FIG. 9 during attachment to the outer frame and the inner frame shown in FIG. 8 according to an example embodiment. The position of the lens 106 in FIG. 12 may correspond to the position of the lens 106 shown in FIGS. 10C and 11. For example, in FIG. 12, the portion 1006 of the lens 106 may be positioned in the outer frame lens groove 204 as shown in FIG. 11. Referring to FIGS. 5A-13, in some example embodiments, after the portion 1006 is positioned is positioned in the outer frame lens groove 204, a person may continue to gradually push the lens 106 into the outer frame lens groove 204. For example, the person may use the hand 1004 to gradually push / insert the lens 106 into the outer frame lens groove 204 moving from the portion 1006 of the lens 106 toward the portion 1008 of the lens 106 and back toward the portion 1006 of the lens 106, for example, in clockwise direction as shown by arrows 1202, 1204, 1206, 1208 or in a counterclockwise direction. As more of the lens 106 is positioned in the outer frame lens groove 204, more of the lens 106 is also positioned in the inner frame lens groove 304 of the inner frame 104. In general, the lens 106 may be inserted in the outer frame lens groove 204 and the inner frame lens groove 304 in a manner similar to installing a bicycle tire on a wheel as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure.

[0061] FIG. 13 illustrates the seamless ring-shaped lens 106 fully attached to the outer frame 102 and the inner frame 104 shown in FIG. 8 according to an example embodiment. Following the process of attaching the lens 106 to the outer frame 102 and the inner frame 104 described with respect to FIGS. 10A-12, the lens 106 may be positioned in the outer frame lens groove 204 and the inner frame lens groove 304 of the inner frame 104. To illustrate, in FIG. 13, the lens 106 may be positioned on the outer frame ledge 502 and the inner frame ledge 512.

[0062] FIG. 14 illustrates a D-D cross-section of the seamless ring-shaped lens 106, the outer frame 102, and the inner frame 104 shown in FIG. 13 according to an example embodiment. Some components such as the brace 602 of FIG. 6 are omitted from FIG. 14 for clarity of illustration. Referring to FIGS. 9-14, in some example embodiments, the lens 106 may be positioned in the outer frame lens groove 204 and the inner frame lens groove 304. For example, the outer perimeter edge 902 of the lens 106 along the entire outer perimeter of the lens 106 may be in the outer frame lens groove 204 and on the outer frame ledge 502, and the inner perimeter edge 904 of the lens 106 along the entire inner perimeter of the lens 106 may be in the inner frame lens groove 304 and on the inner frame ledge 512.

[0063] FIG. 15 illustrate the D-D cross-section of the seamless ring-shaped lens 106, the outer frame 102, and the inner frame 104 shown in FIG. 13 with the seamless ring-shaped lens 106 in a different position than shown in FIG. 14 according to an example embodiment. Some components such as the brace 602 of FIG. 6 are omitted from FIG. 15 for clarity of illustration. Referring to FIGS. 9-15, in contrast to the position of the lens 106 shown in FIG. 14, a portion of the lens 106 may be shifted more into the outer frame lens groove 204 and completely out of the inner frame lens groove 304 of the inner frame 104. For example, the outer perimeter edge 902 of the lens 106 at an arc segment of the lens 106 may abut against the backwall 504 of the outer frame lens groove 204. To illustrate, the inner perimeter edge 904 of the lens 106 at the portion 1006 of the lens 106 may be shifted out of the inner frame lens groove 304 and may no longer be on the inner groove ledge 512 of the inner frame 104. The portion 1006 of the lens 106 may not be on the inner groove ledge 512 of the inner frame 104 while other portions of the lens 106, such as the portion 1008, are on the inner groove ledge 512. In general, in some example embodiments, the lens 106 may be positioned on the outer frame ledge 502 such that the inner perimeter edge 904 of the lens 106 is separated from the inner groove ledge 512 by a separation gap 1502.

[0064] In some example embodiments, the separation gap 1502 may be used in the process of removing the lens 106 from the outer frame 102 and the inner frame 104. To illustrate, a person may shift the lens 106 such that the lens 106 is positioned as shown in FIG. 15 at least at an arc segment of the lens 106. To remove the lens 106 from the outer frame 102 and the inner frame 104, a person may insert a relatively rigid item (e.g., a rigid flat card similar to a credit card) into the separation gap 1502 and move the rigid item in clockwise or counterclockwise direction in the separation gap 1502 while applying a downward force on the lens 106 and shifting the lens 106 out of the outer frame lens groove 204. The width of the separation gap 1502 may be, for example, 0.06 inch regardless of the width W of the lens 106.

[0065] FIG. 16 illustrates a top perspective view of a light source module 1602 positioned to provide an uplight of the lighting device 100 of FIGS. 1 A and IB according to an example embodiment. Referring to FIGS. 6-9 and 13-16, in some example embodiments, the light source module 1602 may be positioned in the space 510 between the inner frame 104 and the outer frame 102. The light source module 1602 may include LEDs that may be attached to one or more circuit boards. The light source module 1602 may include light source segments thar are separated from each other by the suspension brackets 604, 606, 608. The light source module 1602 may be attached to the support brackets 610, 612, 614 that are more clearly shown in FIG. 6. For example, the light source module 1602 may be securely attached to the support brackets 610, 612, 614 using fasteners (e.g., screws). The light source module 1602 may be attached to the support brackets 610, 612, 614 before or after the lens 106 is attached to the outer frame 102 and the inner frame 104 as described above.

[0066] FIG. 17 illustrates a top perspective view of the lighting device 100 of FIGS. 1 A and IB after the attachment of the uplight lenses 110, 112, 114 to the inner frame 104 and the outer frame 102 according to an example embodiment. Referring to FIS. 1 A- 17, in some example embodiments, after the light source module 1602 is securely positioned in the space 510 between the inner frame 104 and the outer frame 102, the uplight lenses 110, 112, 114 may be attached to the outer frame 102 and the inner frame 104. The uplight lenses 110, 112, 114 may be attached to the outer frame 102 and the inner frame 104 before or after the lens 106 is attached to the outer frame 102 and the inner frame 104 as described above. The uplight lens 110, 112, 114 may be positioned such that an uplight provided by the light source module 1602 exits through the uplight lenses 110, 112, 114, for example, to illuminate an area above the lighting device 100.

[0067] In some example embodiments, the uplight lenses 110, 112, 114 may be individually positioned in the bracket attachment groove 208 of the outer frame 102 and the bracket attachment groove 308 of the inner frame 104. For example, the uplight lenses 110, 112, 114 may be separated from each other by the suspension brackets 610, 612, 614. The uplight lenses 110, 112, 114 may be flexible enough to be adequately deformed for insertion into the bracket attachment groove 208 and the bracket attachment groove 308 individually. The desired flexibility of the uplight lenses 110, 112, 114 may be achieved, for example, by controlling the thickness of the uplight lenses 110, 112, 114 and / or the material used to make the uplight lenses 110, 112, 114 as can be readily understood by those of ordinary skill in the art with the benefit of this disclosure. For example, the uplight lenses 110, 112, 114 may be made from polycarbonate material or another material such as acrylic.

[0068] In some example embodiments, after the uplight lenses 110, 112, 114 are attached to the outer frame 102 and the inner frame 104 as shown in FIG. 17, the suspension cables 108 may be attached to the suspension brackets 604, 606, 608. In some alternative embodiments, the lighting device 100 may include fewer or more suspension brackets and / or uplight lenses than shown without departing from the scope of this disclosure. In some alternative embodiments, the lighting device 100 may include other components than shown or described herein without departing from the scope of this disclosure. In some alternative embodiments, the one or more components may be attached to the outer frame 102 and / or the inner frame 104 that are visible from the outside of lighting device 100.

[0069] FIGS. 18A and 18B illustrate an E-E cross-section of the lighting device 100 shown in FIG. 17 according to an example embodiment. Referring to FIGS. 4-9 and 13-18B, the lens is attached to the outer frame 102 and the inner frame 104. The light source module 802 may be attached to the brace 602 and oriented to emit a light that passes through the lens 106, for example, to illuminate an area below the lighting device 100. For example, the light source module 802 may be located spaced from the lens 106 by a distance that is at least twice the width W of the lens 106. Alternatively, the light source module 802 may be at a distance from the lens 106 that is closer than twice the width W of the lens 106.

[0070] As described above, the brace 602 may be welded to the outer frame 102 and the inner frame 104, and the light source module 1602 may be positioned above the brace 602 to emit a light that passes through the uplight lenses 110, 112, 114, for example, to illuminate an area above the lighting device 100. As described above, the brace 602 may retain the outer frame 102 and the inner frame 104 at a fixed position with respect to each other. The lighting device 100 may be a ring-shaped luminaire or may be installed as another type of luminaire without departing from the scope of this disclosure.

[0071] By using the lens 106 that is sized to be positioned on the outer frame ledge 502 and the inner frame ledge 512 through the gap 520 between the outer frame ledge 502 and the inner frame ledge 512, the lens 106, that is seamless, can be used in the lighting device 100. Because the lens 106 is seamless, the lighting device 100 may be preferred over other lighting devices that use seamed or otherwise segmented lenses. By sizing the lens such that the separation gap 1502 that exists between the lens 106 and the inner frame ledge 512 is small (e.g., 0.06 inch) when the lens 106 is positioned, for example, as shown in FIG. 15, the lighting device 100 can provide a light through the lens 106 without light leakage or without direct line of sight to the LEDs of the light source module 802.

[0072] In some alternative embodiments, the light source module 1602 may be omitted without departing from the scope of this disclosure. In some alternative embodiments, the uplight lenses 110, 112, 114 may be omitted without departing from the scope of this disclosure.

[0073] FIG. 19 illustrates a method 1900 of assembling the lighting device 100 of FIGS. 1 A and IB according to an example embodiment. Referring to FIGS. 1 A-19, in some example embodiments, the method 1900 includes, at step 1902, placing the outer frame 102 around the inner frame 104. The outer frame 102 is spaced from the inner frame 104, for example, as shown in FIG. 4. The outer frame 102 includes the outer frame wall 202 and the outer frame ledge 502 that extends around the outer frame wall 202. The inner frame 104 includes the inner frame wall 302 and the inner frame ledge 512 that extends around the inner frame wall 302.

[0074] In some example embodiments, at step 1904, the method 1900 includes attaching the brace 602 to the outer frame 102 and the inner frame 104 such that the outer frame ledge 502 is aligned with the inner frame ledge 512. For example, the brace 602 may be welded to the outer frame 102 and the inner frame 104. At step 1906, the method 1900 may include placing a first light source module (e.g., the light source module 802) between the outer frame 102 and the inner frame 104 to emit a first light. For example, the first light may be a downlight provided by the lighting device 100.

[0075] In some example embodiments, at step 1908, the method 1900 includes placing the lens 106 on the outer frame ledge 502 and the inner frame ledge 512 through the gap 520 between the outer frame ledge 502 and the inner frame ledge 512. As described above, the lens 106 is ring-shaped and seamless. Placing the lens 106 on the outer frame ledge 502 and the inner frame ledge 512 through the gap 520 may include slanting the lens 106, for example, as shown in FIG. 10B. After slanting the lens 106, a first portion (e.g., the portion 1006) of the lens 106 may be inserted into the outer frame lens groove 204 through the gap 520 while a second portion (e.g., the portion 1008) of the lens 106 that is diametrically across from the first portion of the lens 106 is outside of the outer frame groove 204. After the first portion (e.g., the portion 1006) of the lens 106 is inserted into the outer frame lens groove 204, the lens 106 may be pushed / inserted gradually into the outer frame lens groove 204 following a clockwise or a counterclockwise direction (like installing a bicycle tire on a wheel) from the first portion of the lens 106 until the lens 106 is positioned on the inner frame ledge 502 and the outer frame ledge 512.

[0076] In some example embodiments, at step 1910, the method 1900 includes placing a second light source module (e.g., the light source module 1602) between the outer frame 102 and the inner frame 104 to emit a second light (e.g., an uplight). At step 1912, the method 1900 may include placing one or more lenses (e.g., the uplight lenses 110, 112, 114) such that the second light passes through the one or more lenses to illuminate an area above the lighting device 100.

[0077] In some alternative embodiments, the method 1900 may include more or fewer steps than described without departing from the scope of this disclosure. In some alternative embodiments, some of the steps of the method 1900 may be performed in a different order than shown in FIG. 19 without departing from the scope of this disclosure.

[0078] Although particular embodiments have been described herein in detail, the descriptions are by way of example. The features of the embodiments described herein are representative and, in alternative embodiments, certain features, elements, and / or steps may be added or omitted. Additionally, modifications to aspects of the embodiments described herein may be made by those skilled in the art without departing from the scope of the following claims, the scope of which are to be accorded the broadest interpretation so as to encompass modifications and equivalent structures.

Claims

CLAIMS1. A lighting device (100), comprising: an outer frame (102) having an outer frame wall (202) and an outer frame ledge (502), wherein the outer frame ledge extends around the outer frame wall at an inner side (214) of the outer frame wall, and wherein the outer frame (102) includes an outer frame lens groove (204) formed within the outer frame wall (202); an inner frame (104) having an inner frame wall (302) and an inner frame ledge (512), wherein the inner frame ledge extends around the inner frame wall at an outer side (314) of the inner frame wall, wherein the inner frame (104) includes an inner frame lens groove (304) formed within the inner frame wall (302), and wherein the outer frame is positioned around the inner frame, wherein the inner frame and the outer frame are fixedly spaced from each other; a lens (106) having a ring shape, wherein the lens is seamless and wherein a width (W) of the lens 106 extending between an inner perimeter edge (904) of the lens and an outer perimeter edge (902) of the lens is larger than a gap (520) between the outer frame ledge (502) and the inner frame ledge (512); and wherein during installation of the lens in between the outer frame and inner frame, a first portion (1006) of an outer perimeter edge (902) of the lens is inserted into the outer frame lens groove (204) through the gap (520) and subsequently other portions of the outer perimeter edge of the lens are inserted into the outer frame lens groove (204) through the gap (520) following a clockwise or a counterclockwise direction starting from the first portion of the lens until all of the lens is located above the inner frame ledge (502) and the outer frame ledge (512) and extending between the outer frame lens groove and the inner frame lens groove.

2. The lighting device of Claim 1, wherein the lens (106) is rigid.

3. The lighting device of Claim 2, wherein the lens (106) is made from one or more materials including a polycarbonate material.

4. The lighting device of Claim 1, further comprising a brace (602) positioned between the outer frame (102) and the inner frame (104) such that the inner frame and the outer frame are fixedly spaced from each other, wherein the brace is attached to the outer frame and the inner frame such that the outer frame ledge (502) is aligned with the inner frame ledge (512).

5. The lighting device of Claim 4, wherein the brace (602) is welded to the outer frame and the inner frame.

6. The lighting device of Claim 1, wherein the outer frame ledge (502) is a sidewall of the outer frame lens groove (204), and wherein the inner frame ledge (512) is a sidewall of the inner frame lens groove (304).

7. The lighting device of Claim 1, further comprising a light source module (802) positioned to emit a light through the lens (106).

8. The lighting device of Claim 7, further comprising a second light source module (1602) positioned to emit an uplight through uplight lenses (110, 112, 114).

9. The lighting device of Claim 7, further comprising suspension brackets (604, 606, 608) attached to the outer frame (102) and the inner frame (104), wherein the suspension brackets are positioned for attachment to luminaire suspension cables (108).

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