Note: Descriptions are shown in the official language in which they were submitted.
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PATENT APPLICATION
Attorney Docket No. 2012PF00309
Optical System for LEDs for Controlling Light Utilizing Reflectors
Technical Field
[0001] The present invention is directed generally to an optical system for
control of light
output from the LEDs. More particularly, various inventive methods and
apparatus disclosed
herein relate to an optical system having optical pieces and reflectors
utilized to control light
output from a plurality of LEDs.
Background
[0002] Digital lighting technologies, i.e. illumination based on
semiconductor light sources,
such as light-emitting diodes (LEDs), offer a viable alternative to
traditional fluorescent, high
intensity discharge (HID), and incandescent lamps. Functional advantages and
benefits of LEDs
include high energy conversion and optical efficiency, durability, lower
operating costs, and
many others. Recent advances in LED technology have provided efficient and
robust full-
spectrum lighting sources that enable a variety of lighting effects in many
applications. Some of
the fixtures embodying these sources feature a lighting module, including one
or more LEDs
capable of producing different colors, e.g. red, green, and blue, as well as a
processor for
independently controlling the output of the LEDs in order to generate a
variety of colors and
color-changing lighting effects, for example, as discussed in detail in U.S.
Patent Nos. 6,016,038
and 6,211,626, incorporated herein by reference.
[0003] In certain lighting fixtures implementing LEDs there is motivation
to limit or eliminate
the amount of light from the LEDs that is directed from the lighting fixture
to areas that are not
intended to be illuminated. Motivations to limit such stray light from LEDs
may include the
desire to achieve compliance with one or more standards. For example,
obtaining credit for
Leadership in Energy and Environmental Design (LEED) certifications requires
conforming to
specified spill light levels in lighting layouts. Current designs directed at
limiting the amount of
stray light from LEDs may significantly reduce the efficiency of light
directed at the intended
illumination area by blocking, and thereby wasting, light not directed in the
desired illumination
direction. Current designs may additionally or alternatively fail to limit
stray light to the degree
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necessary to achieve compliance with one or more standards such as the
requirements
specified by LEED.
[0004] Thus, there is a need in the art to provide an optical system
for LEDs for control of
light output from the LEDs that optionally overcomes one or more drawbacks of
some current
designs.
Summary
[0005] The present disclosure is directed to inventive methods and
apparatus for an optical
system for LEDs for control of light output from the LEDs. For example, a
plurality of optical
_ pieces may be provided, each being over one or more LEDs and configured
to direct a majority
of light output from such one or more LEDs toward a desired illumination
direction. A reflector
- array may be placed over the optical pieces.The reflector array may
include a plurality of
openings each sized to at least partially receive one of the optical pieces
and may also include a
plurality of reflectors each extending upward from one of the openings. Each
reflector
redirects light rays from one or more respective LEDs towards the desired
illumination
direction.
[0006] Generally, in one aspect, an LED optical system placeable over
top of LEDs is provided
and includes a plurality of optical pieces. Each of the optical pieces
includes a free form LED
cavity on a first side thereof and a free form protrusion on a second side
thereof over the LED
cavity. Each LED cavity is sized to receive at least a portion of at least one
of the LEDs. Each of
the optical pieces is configured to direct a first light portion of a light
output received from at
least one of the LEDs in a desired illumination range toward a desired
illumination direction and
to direct a second light portion of the light output in a stray illumination
range away from the
desired illumination direction. The first light portion is a majority of the
light output. The LED
optical system also includes a reflector array placed over the optical pieces.
The reflector array
includes a plurality of openings each sized to receive at least one of the
optical pieces and a
plurality of reflectors each extending upward from and provided partially over
one of the
openings. Each of the reflectors includes a reflective interior surface
generally facing the
desired illumination direction. Each reflective interior surface is provided
partially over one of
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the openings opposite the desired illumination direction and reflects a
majority of the second
light portion of the light output transmitted from one or more corresponding
optical pieces.
The second light portion of the light output that is reflected by the
reflective interior surface is
reflected generally toward the desired illumination direction.
[0007] In some embodiments each of the reflectors is provided partially
over a respective at
least one of the optical pieces.
[0008] In some embodiments the reflector array is a cohesive reflector
array that includes
an intermediary outward facing surface extending between the plurality of
openings. In some
versions of those embodiments the intermediary outward facing surface of the
cohesive
reflector array is low reflectance and substantially black in color.
[0009] In some embodiments each of the optical pieces is configured to
redirect a majority
- of the light output generated from a single of the LEDs received within a
respective of the LED
cavities in an iso-illuminance distribution pattern. In some versions of those
embodiments the
iso-illuminance distribution pattern includes at least one IES distribution
pattern.
[0010] In some embodiments each reflective interior surface is
substantially planar.
[0011] In some embodiments the LED optical system further includes a
reflective layer
having a reflective surface and including a plurality of openings each sized
to receive at least
one of the LEDs. The optical pieces are placed atop the reflective layer and
the reflective layer
generally faces the optical pieces.
[0012] Generally, in another aspect, an LED optical system placeable over
top of LEDs is
provided and includes a plurality of optical pieces each configured for
placement over at least
one of the LEDs generating an LED light output. The optical pieces include a
first portion
configured to redirect the LED light output incident thereon in a distribution
pattern generally
toward a desired illumination direction, and a second portion configured to
redirect the LED
light output incident thereon in an illumination range away from the desired
illumination
direction. The LED optical system also includes a plurality of reflectors,
each of the reflectors
extending upward from and provided partially over at least one of the optical
pieces. Each of
the reflectors includes a reflective interior surface generally facing a
corresponding optical
piece of the at least one of the optical pieces and positioned opposite the
desired illumination
[
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direction. Each reflective interior surface reflects the LED light output
transmitted in the
illumination range from the corresponding optical piece and redirects the
incident LED light
output generally toward the desired illumination direction.
[0013] In some embodiments each reflective interior surface is vacuum
metalized.
[0014] In some embodiments each of the reflectors is provided
partially over the second
portion of a respective of the at least one of the optical pieces.
[0015] In some embodiments each of the reflectors is not provided over
the second portion.
[0016] In some embodiments the optical pieces form a cohesive optical
array, the cohesive
optical array including an optical array intermediary outward facing surface
extending between
the optical pieces. In some versions of those embodiments the plurality of
reflectors form a
_
cohesive reflector array, the cohesive reflector array including a plurality
of openings each sized
- to receive at least one of the optical pieces and an intermediary
outward facing surface
extending between the plurality of openings.
[0017] In some embodiments the intermediary outward facing surface of
the cohesive
reflector array is low reflectance and substantially black in color.
[0018] Generally, in another aspect, an LED lighting unit is provided
and includes at least one
LED, an optical piece positioned over the LED, and at least one reflector
piece placed over the
optical piece. The optical piece redirects a majority of light output
generated by the LED in an
iso-illuminance distribution pattern generally toward a desired illumination
direction and
redirects a secondary portion of light output generated by the LED generally
away from the
desired illumination direction. The reflector piece includes an opening sized
to receive the
optical piece, an outward facing surface peripheral of the opening, and a
reflector extending
upward from and provided partially over the opening. The reflector includes a
reflective
interior surface generally facing the desired illumination direction. The
reflective interior
surface is provided partially over the opening opposite the desired
illumination direction and
reflects the secondary portion of light output redirected by the optical
piece. The secondary
portion is reflected by the reflective interior surface generally toward the
desired illumination
direction.
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[0019] In some embodiments each reflective interior surface is vacuum
metalized. In some
versions of those embodiments, the outward facing surface is substantially low
reflectance. In
some versions of those embodiments the optical piece is part of a cohesive
optical array
including additional optical pieces.
[0020] In some embodiments the LED lighting unit further includes an
intermediary
reflective layer interposed between the LED and the optical piece. The
intermediary reflective
layer has a reflective surface generally facing the optical piece and includes
an opening sized to
receive the LED.
[0021] As used herein for purposes of the present disclosure, the term
"LED" should be
understood to include any electroluminescent diode or other type of carrier
injection/junction-
based system that is capable of generating radiation in response to an
electric signal. Thus, the
- term LED includes, but is not limited to, various semiconductor-based
structures that emit light
in response to current, light emitting polymers, organic light emitting diodes
(OLEDs),
electroluminescent strips, and the like. In particular, the term LED refers to
light emitting
diodes of all types (including semi-conductor and organic light emitting
diodes) that may be
configured to generate radiation in one or more of the infrared spectrum,
ultraviolet spectrum,
and various portions of the visible spectrum (generally including radiation
wavelengths from
approximately 400 nanometers to approximately 700 nanometers). Some examples
of LEDs
include, but are not limited to, various types of infrared LEDs, ultraviolet
LEDs, red LEDs, blue
LEDs, green LEDs, yellow LEDs, amber LEDs, orange LEDs, and white LEDs
(discussed further
below). It also should be appreciated that LEDs may be configured and/or
controlled to
generate radiation having various bandwidths (e.g., full widths at half
maximum, or FWHM) for
a given spectrum (e.g., narrow bandwidth, broad bandwidth), and a variety of
dominant
wavelengths within a given general color categorization.
[0022] For example, one implementation of an LED configured to generate
essentially white
light (e.g., a white LED) may include a number of dies which respectively emit
different spectra
of electroluminescence that, in combination, mix to form essentially white
light. In another
implementation, a white light LED may be associated with a phosphor material
that converts
electroluminescence having a first spectrum to a different second spectrum. In
one example of
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this implementation, electroluminescence having a relatively short wavelength
and narrow
bandwidth spectrum "pumps" the phosphor material, which in turn radiates
longer wavelength
radiation having a somewhat broader spectrum.
[0023] It should also be understood that the term LED does not limit the
physical and/or
electrical package type of an LED. For example, as discussed above, an LED may
refer to a
single light emitting device having multiple dies that are configured to
respectively emit
different spectra of radiation (e.g., that may or may not be individually
controllable). Also, an
LED may be associated with a phosphor that is considered as an integral part
of the LED (e.g.,
some types of white LEDs). In general, the term LED may refer to packaged
LEDs, non-packaged
- LEDs, surface mount LEDs, chip-on-board LEDs, T-package mount LEDs,
radial package LEDs,
power package LEDs, LEDs including some type of encasement and/or optical
element (e.g., a
diffusing lens), etc.
[0024] The term "light source" should be understood to refer to any one or
more of a
variety of radiation sources, including, but not limited to, LED-based sources
(including one or
more LEDs as defined above), incandescent sources (e.g., filament lamps,
halogen lamps),
fluorescent sources, phosphorescent sources, high-intensity discharge sources
(e.g., sodium
vapor, mercury vapor, and metal halide lamps), lasers, other types of
electroluminescent
sources, pyro-luminescent sources (e.g., flames), candle-luminescent sources
(e.g., gas mantles,
carbon arc radiation sources), photo-luminescent sources (e.g., gaseous
discharge sources),
cathode luminescent sources using electronic satiation, galvano-luminescent
sources, crystallo-
luminescent sources, kine-luminescent sources, thermo-luminescent sources,
triboluminescent
sources, sonoluminescent sources, radioluminescent sources, and luminescent
polymers.
[0025] A given light source may be configured to generate electromagnetic
radiation within
the visible spectrum, outside the visible spectrum, or a combination of both.
Hence, the terms
"light" and "radiation" are used interchangeably herein. Additionally, a light
source may
include as an integral component one or more filters (e.g., color filters),
lenses, or other optical
components. Also, it should be understood that light sources may be configured
for a variety of
applications, including, but not limited to, indication, display, and/or
illumination. An
"illumination source" is a light source that is particularly configured to
generate radiation
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having a sufficient intensity to effectively illuminate an interior or
exterior space. In this
context, "sufficient intensity" refers to sufficient radiant power in the
visible spectrum
generated in the space or environment (the unit "lumens" often is employed to
represent the
total light output from a light source in all directions, in terms of radiant
power or "luminous
flux") to provide ambient illumination (i.e., light that may be perceived
indirectly and that may
be, for example, reflected off of one or more of a variety of intervening
surfaces before being
perceived in whole or in part).
[0026] The term "lighting fixture" is used herein to refer to an
implementation or
arrangement of one or more lighting units in a particular form factor,
assembly, or package.
- The term "lighting unit" is used herein to refer to an apparatus
including one or more light
sources of same or different types. A given lighting unit may have any one of
a variety of
,
mounting arrangements for the light source(s), enclosure/housing arrangements
and shapes,
and/or electrical and mechanical connection configurations. Additionally, a
given lighting unit
optionally may be associated with (e.g., include, be coupled to and/or
packaged together with)
various other components (e.g., control circuitry) relating to the operation
of the light
source(s). An "LED-based lighting unit" refers to a lighting unit that
includes one or more LED-
based light sources as discussed above, alone or in combination with other non
LED-based light
sources.
[0027] It should be appreciated that all combinations of the foregoing
concepts and
additional concepts discussed in greater detail below (provided such concepts
are not mutually
inconsistent) are contemplated as being part of the inventive subject matter
disclosed herein.
In particular, all combinations of claimed subject matter appearing at the end
of this disclosure
are contemplated as being part of the inventive subject matter disclosed
herein. It should also
be appreciated that terminology explicitly employed herein that also may
appear in any
disclosure incorporated by reference should be accorded a meaning most
consistent with the
particular concepts disclosed herein.
Brief Description of the Drawings
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[0028] In the drawings, like reference characters generally refer to the
same parts
throughout the different views. Also, the drawings are not necessarily to
scale, emphasis
instead generally being placed upon illustrating the principles of the
invention.
[0029] FIG. 1 illustrates a lower perspective view of an embodiment of an
LED lighting unit
with a single piece reflector array of the LED lighting unit exploded away
from a single piece
array of optical pieces of the LED lighting unit.
[0030] FIG. 2 illustrates a close-up lower perspective view of a portion
of the embodiment of
the LED lighting unit.
[0031] FIG. 3 illustrates a section view of a portion of the embodiment
of the LED lighting
unit taken along the section line 3-3 of FIG. 2.
' [0032] FIG. 4 illustrates a lower perspective view of another
embodiment of an LED lighting
unit with a single piece reflector array, a cohesive array of optical pieces,
an intermediary
reflective array, and an LED array exploded away from one another.
[0033] FIG. 5 illustrates a side view of the single piece reflector array
of the embodiment of
the LED lighting unit.
[0034] FIG. 6 illustrates another side view of the single piece reflector
array of the
embodiment of the LED lighting unit.
[0035] FIG. 7 illustrates a lower perspective view of a portion of an
embodiment of an LED
optical system.
[0036] FIG. 8 illustrates a lower perspective view of the embodiment of
the LED optical
system with a reflector of the LED lighting unit exploded away from an optical
piece of the LED
optical system.
[0037] FIG. 9 illustrates a side view of the embodiment of theLED optical
system with a
single reflector of the LED optical system and a single optical piece.
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Detailed Description
[0038] In certain lighting fixtures implementing LEDs there is motivation
to limit or eliminate
stray light from the LEDs that is directed from the lighting fixture to areas
that are not intended
to be illuminated. Current designs directed at limiting the amount of stray
light from LEDs may
significantly reduce the efficiency of light directed at the intended
illumination area. Thus,
Applicant has recognized a need in the art to provide an optical system for
LEDs for control of
light output from the LEDs that limits illumination in unwanted areas and
redirects light that is
initially directed in an unwanted direction towards the intended illumination
direction.
[0039] More generally, Applicants have recognized and appreciated that it
would be
- beneficial to provide methods and apparatus related to an optical system
having optical pieces
and reflectors utilized to control light output from a plurality of LEDs.
[0040] In view of the foregoing, various embodiments and implementations
of the present
invention are directed to an optical system for LEDs for control of light
output from the LEDs.
[0041] In the following detailed description, for purposes of explanation
and not limitation,
representative embodiments disclosing specific details are set forth in order
to provide a
thorough understanding of the claimed invention. However, it will be apparent
to one having
ordinary skill in the art having had the benefit of the present disclosure
that other
embodiments according to the present teachings that depart from the specific
details disclosed
herein remain within the scope of the appended claims. Moreover, descriptions
of well-known
apparatus and methods may be omitted so as to not obscure the description of
the
representative embodiments. Such methods and apparatus are clearly within the
scope of the
claimed invention. For example, aspects of the methods and apparatus disclosed
herein are
described in conjunction with particular distributions of LEDs on an LED
board. However, one
or more aspects of the methods and apparatus described herein may optionally
be
implemented in combination with other LED configurations (e.g., one or more
LEDs in an
alternative distribution mounted directly to a heatsink) and implementation of
the one or more
aspects of an optical system described herein in combination with
alternatively configured LED
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configurations is contemplated without deviating from the scope or spirit of
the claimed
invention.
[0042] Referring to FIGS. 1 through 3, an embodiment of an LED lighting
unit is illustrated.
The LED lighting unit includes an array of LEDs 102 mounted on an LED circuit
board 104 (FIG.
3). An optical system of the illustrated LED lighting unit includes a cohesive
single piece
reflector array 100 and a cohesive array of optical pieces 101. The optical
array101 includes a
plurality of individual optical pieces 115 that are cohesively formed with one
another so that
each optical piece 115 may be positioned and aligned over a single of the LEDs
102. In some
embodiments one or more of the optical pieces 115 may be separate from and not
cohesively
- formed with other of the optical pieces.ln the illustrated embodiment the
optical pieces 115
each include a first portion 116 and a second portion 117 and each share a
substantially
common configuration. In other embodiments one or more of the optical pieces
may have a
configuration different than that illustrated and/or may have a configuration
that is unique
from other optical pieces. Each of the optical pieces 115 is also commonly
oriented relative to a
respective of the LEDs it is provided over so that the first portion 116 of
each of the optical
pieces directs light output from an LED 102 it is provided over generally in
the desired
illumination direction.
[0043] The individual optical pieces 115 may be designed and populated in
combination
with the LEDs 102 to produce any desired distribution pattern. For example,
the individual
optical pieces 115 may be designed to produce asymmetric full cut-off
Illumination Engineering
Society (IES) patterns such as IES Type II, 111, and/or IV full cut-off
patterns. As an example, in
some embodiments each of the opticalpieces 115 may produce an IES Type II
pattern. Each of
the optical pieces 115 includes an LED cavity 106 (FIG. 3) on an inner facing
side thereof. The
LED cavities 106 are each positioned and sized to surround at least a portion
of a single of a
respective LED 102 (e.g., at least the light emitting die and/or light
emitting epoxy casing) and
direct light output therefrom through a respective individual optical piece
115 provided
thereover. The LED cavities 106 may optionally receive at least a portion of a
respective LED
102 therein. The illustrated LED cavities 106 have a generally arcuate profile
on a side (e.g., as
illustrated in FIG. 3). The portion of the arcuate profile of the LED cavities
106 underlying the
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first portion 116is configured to refract a majority of light output from LED
102 generally
directed thereto generally in the desired illumination direction. The portion
of the arcuate
profile of the LED cavities 106 underlying the second portion 117 is
configured to refract the
majority of the remaining light input from LED 102 opposite the desired
illumination direction.
[0044] The specific curvature of the outer surface for each of the
individual optical pieces
115 may be selected based on a number of parameters such as the light output
characteristics
of LEDs 102, the spacing of LEDs 102, height constraints, the configuration of
LED cavities 106,
and/or desired IES distribution. The surface profile of the outer surface for
each of the
individual optical pieces 115 and/or of the inner surface (LED cavities 106)
of the individual
- optical pieces 115 may optionally be designed in a ray tracing program
and modified with
weighting factors and multiple iterations to create the final free form shape
of the optical piece
115.
[0045] The illustrated embodiment of the optical pieces 115 includes a
first portion 116 and
a second portion 117. Each first portion 116 directs a majority of the light
from a respective of
the LEDs 102 that is incident thereon generally toward the desired
illumination direction. Each
second portion 117 redirects a majority of light from a respective of the LEDs
102 that is
incident thereon away from the illumination direction and generally toward a
respective
reflective interior surface 120 of the reflector 125. The first portion 116
and second portion
117 may both have a substantially arcuate outer profile with a substantially
planar adjoining
section that joins the first portion 116 and the second portion 117. Each
second portion 117 is
placed on the backside of a corresponding first portion 116 away from the
illumination
direction.The illustrated embodiment includes a slight recess in the outer
surface of the first
portion 116. The recess may be positioned to receive the most intense portion
of light from a
respective LED 102 and may provide for wider dispersion of the light incident
therein.
[0046] Each LED 102 is positioned within the respective LED cavity 106 so
that the LED 102 is
primarily positioned under the first portion 116 and, optionally primarily
positioned under the
recess of the first portion 116. In other words, a majority of each LED 102 is
positioned under a
respective first portion 116 and a majority of the light output from the LED
102 may be directed
into the first portion 116. The LED cavity 106 and the outer surface of the
first portion 116 of
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the optical piece 115are configured to cooperatively work together to direct a
substantial
majority of light output generated by an LED 102 generally in the desired
illumination
directionas illustrated by example light ray 301. The LED cavity 106 and the
outer surface of the
second portion 117 are configured to cooperatively work together to
substantially direct other
light output generated by LED 102 generally toward the reflective interior
surface 120 of the
respective reflector 125 as illustrated by example light ray 300 in FIG. 3.
Each interior reflective
surface 120 reflects light rays that have been directed thereto by the second
portion 117
toward the desired illumination direction (e.g., light ray 300 in FIG. 3). The
illustrated light rays
in FIG. 3 are provided as an example to illustrate an example interaction
between light output
of an LED 102 and corresponding optical piece 115 and reflector 125 provided
over the LED
102. One of ordinary skill in the art, having had the benefit of the present
disclosure, will
* recognize and appreciate that many additional light rays will be provided
and may interact with
the optical piece 115 and/or the reflector 125 in a manner that is different
than that illustrated
by light rays 300 and 301. Moreover, one of ordinary skill in the art will
recognize and
appreciate that alternative interactions of light rays with the optical piece
115 and/or reflector
125 may occur.
[0047] In some implementations the LED lighting unit may be installed
along the perimeter
of a parking lot such that the optical pieces are oriented to direct
illumination toward the
parking lot while minimizing any light directed peripherally of the parking
lot perimeter. Each
of the first portions 116 may be positioned on a side of the LED lighting unit
that is more
proximal the desired illumination area than a corresponding second portion
117. Other
potential implementations of lighting unit include, for example, utilization
in pedestrian
pathway applications to limit house side light and installation along the
perimeter of a parking
garage to provide substantially zero line of sight from outside the garage of
light emitting from
the lighting unit.
[0048] In some embodiments individual optical pieces and/or optical array
101 may be
manufactured as a single piece of acrylic, optionally utilizing standard
injection molding
procedures. In some embodiments the optical pieces may be placed in fixed
relation to one of
the LEDs 102 utilizing an adhesive to attach the optical piece 115 to a
surface surrounding the
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LED 102. In some embodiments where the optical array 101 is formed as a single
acrylic piece
the optical pieces 115 may be connected by an outward facing surface 105. In
some
embodiments the outward facing surface 105 may be translucent and, optionally
manufactured
from acrylic. In some embodiments the underside of the outward facing surface
105may be in
contact with the circuit board 104.
[0049] In some embodiments each optical piece 115 and/or the optical array
101 may be
adhered to the circuit board 104. In some embodiments the optical array 101
may be coupled
to an intermediary surface between the circuit board 104 and the optical
pieces. In some
embodiments the intermediary surface may be a reflective layer such as
reflective layer 410
= shown in FIG. 4. The LEDs 102 may be attached to a circuit board 104 in
some embodiments
and/or may be attached to another surface in some embodiments. For example, in
some
embodiments the LEDs 102 may be directly attached to a heatsink and/or an
additional circuit
board.
[0050] The single piece reflector array 100 is placeable over the optical
array 101 and
includes a plurality of openings 135. The openings 135 are each aligned with
and each receive
and surround one of the free form optical pieces 115. In the illustrated
embodiment the optical
pieces 115 extend through the openings 135. Alignment protrusions 150 on
outward facing
surface 105 align with respective alignment receptacles151 on reflector array
surface 130 and
may optionally be utilized to achieve accurate alignment of the reflector
array layer 100 and the
optical array101. The openings 135 may optionally be larger than the
peripheries of the optical
pieces 115 in some embodiments. In some embodiments the openings 135 may be
smaller
than the peripheries of the optical pieces 115 and the single piece reflector
array 100 may
optionally rest atop the optical pieces. In some embodiments a single interior
reflective surface
120 may be utilized by two or more optical pieces 115. For example, a single
reflective surface
120 may be provided partially over two optical pieces 115, may intersect stray
light rays
emitted by such optical pieces 115, and reflect the intersected stray light
rays in a desired
illumination direction. An intermediary outward facing surface 130 extends
between and
surrounds the openings 135. In some of those embodiments the reflector array
outer surface
130 may be painted with and/or molded out of a flat black material to minimize
any light
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reflection off the reflector array surface 130. Minimization of light
reflection off the reflector
array surface 130 may minimize the amount of light from LEDs 102 that is
incident thereon and
directed in a stray direction away from the desired illumination direction.
[0051] A plurality of reflectors 125 is provided. Each of the
corresponding reflectors 125
extends upward from and is provided partially over one of the openings 135 and
partially over
one of the optical pieces 115. Each of the reflectors 125 has a reflective
interior surface 120
that is positioned and shaped to reflect a majority ofthe refracted light out
of second portion
117in the direction of desired illumination. In addition, any stray light
incident on the
reflective interior surface 120 is reflected toward the desired illumination
direction. The
- reflective interior surface 120 of each reflector 125 is also positioned
and shaped so as to
minimize interference with light emitted from the surrounding optical pieces
and directed in
the desired illumination direction. The interior surface 120 of each reflector
125 may be
constructed of a single surface or multiple facets. In some embodiments the
reflective interior
surface 120 may extend at least partially over the second portion 117 (as in
FIG. 3). In some
embodiments the reflective interior surface 120 may optionally extend
partially over the first
portion 116. In some embodiments the interior reflective surface 120 may be
vacuum
metalized and/or painted to achieve a reflective surface. In some embodiments
the reflective
interior surface may be formed of a reflective material such as aluminum.
[0052] Referring to FIGS. 4 through 6, another embodiment of an LED
lighting unit is
illustrated. The LED lightingunit includes a single piece reflector array 400,
a cohesive optical
array 401, an intermediary reflecting layer 410, and a PCB board 404. The PCB
board 404
supports an array of LEDs 402. The optical array 401 may share one or more
common aspects
with the previous described optical array 101. The optical array 401 may be a
cohesive array as
shown in FIG. 4 or multiple pieces (e.g., each optical piece 415 may be a
separate piece). The
intermediary layer 410 may optionally be reflective on at least the upward
facing surface
(surface facing away from 404). The intermediary reflective layer 410 may
contain an array of
openings 440 corresponding to the placement of the LEDs 402 on PCB board 404
to receive one
or more of the LEDs 402. The intermediary reflective layer 410 may be a highly
reflective
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laminate and may adhere to the PCB board 404 and to the optical array 401
using translucent
double-sided adhesive.
[0053] The plurality of optical pieces 415 may share one or more
characteristics with optical
pieces 115 of the previously described embodiment. The optical pieces 415 may
include a first
portion and a second portion similar to the first portion 116 and second
portion 117 of
theembodiment illustrated in FIGS. 1 through 3. The first portionmay be
configured similarly to
the first portion in the previously described embodiment and direct light as
generally shown by
example light ray 301 in FIG. 3. The optical pieces 415 may include a second
portion that
directs light as generally shown by example light ray 300 in FIG. 3. Each of
the individual optical
- pieces 415 may include an LED cavity similar to LED cavity 106 of the
previously described
embodiment on an inner facing side thereof and be positioned and sized to
surround at least a
portion of a single of a respective LED 402.
[0054] Each of a plurality of reflectors 425 extends upward from and is
provided near a
corresponding of the openings 435 on the side of the opening 435 opposite the
primary
illumination direction. In the illustrated embodiment the reflectors 425 are
formed as a
cohesive reflector array 400 and coupled to one another viaa reflector surface
430. In some
embodiments the reflectors 425 may be separate pieces. Each of the reflectors
425 has a
reflective interior surface 420. The reflective interior surface 420 is
positioned and shaped so
as to not interfere with light emitted from the surrounding optical pieces
that are directed in
the desired illumination direction. The illustrated reflective interior
surface 420 is positioned to
intersect light emitted from a corresponding optical piece 415 and reflect the
light towards the
desired illumination direction. The illustrated interior surface 420 is
generally arcuate and
oriented to reflect light incident thereon from a respective optical piece 415
toward the desired
illumination direction. In some implementations the interior surface 420 may
include a single
arcuate face. In some implementations the interior surface 420 may include
plurality of planar
faces adjoining one another. In some embodiments the reflector 425 may extend
at least
partially over a portion of optical piece 415. In some embodiments the
interior reflective
interior surface 420 of the reflector 425 may be vacuum metalized and/or
painted to achieve a
reflective surface. In some embodiments the reflector array surface 430 of
reflector array 400
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may be painted with and/or molded out of a flat black material to minimize any
light reflection
off the outward facing surface. In some embodiments 400 is a single formed
piece made from
reflective aluminum such as Miro and painted flat black on the back side.
[0055] Referring to FIGS. 7 through 9, a third embodiment of the LED
lighting unit is
illustrated. The third embodiment may share one or more characteristics with
the previously
described embodiments. The LED lighting unit includes a single reflector 725
and a single
optical piece 715. The illustrated embodiment includes an outward facing
surface 730 which
may share one or more characteristics with outward facing surface 130 of the
embodiment
illustrated in FIGS. 1 through 3. The optical piece 715 may share one or more
characteristics
- with optical pieces 115 and/or 415 of the previously described
embodiment. In some
embodiments a plurality of optical pieces 715 may be provided with each being
positionable
over one or more LEDs. For example, in some embodiments each optical piece 715
may be
placed over one of a plurality of LEDs on a circuit board,such as LEDs and/or
a circuit board that
share one or more characteristics with the circuit board 104 and/or 404 of the
previously
illustrated embodiments. In some embodiments the optical pieces 715 may be
positioned over
one or more LEDsattached to another surface. For example, in some embodiments
the LEDs
may be directly attached to a heatsink and/or an additional circuit board.
[0056] The illustrated embodiment includes an optical piece surface 705
which may share
one or more characteristics with outward facing surface 105 of the embodiment
illustrated in
FIGS. 1 through 3. The optical piece 715 may include a first portion 716 and a
second portion
717 similar to the first portion 116 and second portion 117 of the previously
illustrated
embodiment in FIG. 3. The first portion may be configured similarly to the
first portion in the
previous embodiments and direct light as generally shown by example light ray
301 in FIG. 3.
The optical piece 715 may include a second portionthat directs light as
generally shown by
example light ray 300 in FIG. 3. The optical piece 715 may include an LED
cavity similar to LED
cavity 106 of the previous embodiments on an inner facing side thereof and be
positioned and
sized to surround at least a portion of a single of a respective LED it is
provided over. Alignment
protrusions 750 on optical piece surface 705 align with respective alignment
receptacles 751 on
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outward facing surface 730 and may optionally be utilized to achieve accurate
alignment of the
reflector 725 and the optical piece 715.
[0057] The reflector 725 extends upward from and is provided near an
opening 735 on the
side of the opening 735 opposite the primary illumination direction. In the
illustrated
embodiment the reflector725 is formed as a single reflector. In some
embodiments the
reflector 725may be part of a cohesive array of reflectors. The reflector 725
has a reflective
interior surface 720 that is positioned and shaped to reflect stray light
emitted from the optical
piece 715 in a direction opposite the desired illumination direction toward
the desired
illumination direction (e.g., as illustrated by example light ray 301 in FIG.
3). The illustrated
= reflective interior surface 720 is positioned to intersect light emitted
from a corresponding
optical piece 715 and reflect the light towards the desired illumination
direction. The
illustrated interior surface 720 is generally arcuate and oriented to reflect
light incident thereon
from a respective optical piece 415 toward the desired illumination direction.
In some
embodiments the interior surface 720 may include a single arcuate face. In
some
implementations the interior surface 720 may include plurality of planar faces
adjoining one
another. In some embodiments the reflector 725 may extend at least partially
over a portion of
optical piece 715. In some embodiments the interior reflective interior
surface 720 of the
reflector 725 may be vacuum metalized and/or painted to achieve a reflective
surface. In some
embodiments the side of the reflector 725 opposite the reflective face 720 may
be painted with
and/or molded out of a flat black material to minimize any light reflection
off the outward
facing surface.
[0058] While several inventive embodiments have been described and
illustrated herein,
those of ordinary skill in the art will readily envision a variety of other
means and/or structures
for performing the function and/or obtaining the results and/or one or more of
the advantages
described herein, and each of such variations and/or modifications is deemed
to be within the
scope of the inventive embodiments described herein. More generally, those
skilled in the art
will readily appreciate that all parameters, dimensions, materials, and
configurations described
herein are meant to be exemplary and that the actual parameters, dimensions,
materials,
and/or configurations will depend upon the specific application or
applications for which the
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inventive teachings is/are used. Those skilled in the art will recognize, or
be able to ascertain
using no more than routine experimentation, many equivalents to the specific
inventive
embodiments described herein. It is, therefore, to be understood that the
foregoing
embodiments are presented by way of example only and that, within the scope of
the
appended claims and equivalents thereto, inventive embodiments may be
practiced otherwise
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. In addition, any combination of two or more such features, systems,
articles, materials,
kits, and/or methods, if such features, systems, articles, materials, kits,
and/or methods are not
_ mutually inconsistent, is included within the inventive scope of the
present disclosure.
[0059] All definitions, as defined and used herein, should be understood
to control over
,
dictionary definitions, definitions in documents incorporated by reference,
and/or ordinary
meanings of the defined terms.
[0060] The indefinite articles "a" and "an," as used herein in the
specification and in the
claims, unless clearly indicated to the contrary, should be understood to mean
"at least one."
[0061] The phrase "and/or," as used herein in the specification and in
the claims, should be
understood to mean "either or both" of the elements so conjoined, i.e.,
elements that are
conjunctively present in some cases and disjunctively present in other cases.
Multiple elements
listed with "and/or" should be construed in the same fashion, i.e., "one or
more" of the
elements so conjoined. Other elements may optionally be present other than the
elements
specifically identified by the "and/or" clause, whether related or unrelated
to those elements
specifically identified. Thus, as a non-limiting example, a reference to "A
and/or B", when used
in conjunction with open-ended language such as "comprising" can refer, in one
embodiment,
to A only (optionally including elements other than B); in another embodiment,
to B only
(optionally including elements other than A); in yet another embodiment, to
both A and B
(optionally including other elements); etc.
[0062] As used herein in the specification and in the claims, "or" should
be understood to
have the same meaning as "and/or" as defined above. For example, when
separating items in a
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list, "or" or "and/or" shall be interpreted as being inclusive, i.e., the
inclusion of at least one,
but also including more than one, of a number or list of elements, and,
optionally, additional
unlisted items. Only terms clearly indicated to the contrary, such as "only
one of" or "exactly
one of," or, when used in the claims, "consisting of," will refer to the
inclusion of exactly one
element of a number or list of elements. In general, the term "or" as used
herein shall only be
interpreted as indicating exclusive alternatives (i.e. "one or the other but
not both") when
preceded by terms of exclusivity, such as "either," "one of," "only one of,"
or "exactly one of."
"Consisting essentially of," when used in the claims, shall have its ordinary
meaning as used in
the field of patent law.
- [0063] As used herein in the specification and in the claims, the
phrase "at least one," in
reference to a list of one or more elements, should be understood to mean at
least one
element selected from any one or more of the elements in the list of elements,
but not
necessarily including at least one of each and every element specifically
listed within the list of
elements and not excluding any combinations of elements in the list of
elements. This
definition also allows that elements may optionally be present other than the
elements
specifically identified within the list of elements to which the phrase "at
least one" refers,
whether related or unrelated to those elements specifically identified. Thus,
as a non-limiting
example, "at least one of A and B" (or, equivalently, "at least one of A or
B," or, equivalently "at
least one of A and/or B") can refer, in one embodiment, to at least one,
optionally including
more than one, A, with no B present (and optionally including elements other
than B); in
another embodiment, to at least one, optionally including more than one, B,
with no A present
(and optionally including elements other than A); in yet another embodiment,
to at least one,
optionally including more than one, A, and at least one, optionally including
more than one, B
(and optionally including other elements); etc.
[0064] It should also be understood that, unless clearly indicated to the
contrary, in any
methods claimed herein that include more than one step or act, the order of
the steps or acts
of the method is not necessarily limited to the order in which the steps or
acts of the method
are recited.
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[0065] In the claims, as well as in the specification above, all
transitional phrases such as
"comprising," "including," "carrying," "having," "containing," "involving,"
"holding," "composed
of," and the like are to be understood to be open-ended, i.e., to mean
including but not limited
to. Only the transitional phrases "consisting of" and "consisting essentially
of" shall be closed
or semi-closed transitional phrases, respectively, as set forth in the United
States Patent Office
Manual of Patent Examining Procedures, Section 2111.03.What is claimed is:
