Note: Descriptions are shown in the official language in which they were submitted.
EXTREME CUTOFF BEAM CONTROL OPTICS
CROSS REFERENCE TO RELATED APPLICATIONS
100011 The present application is a continuation-in-part of U.S. Patent
Application No.
17/686,799, filed on March 4, 2022, and claims the benefit of U.S. Patent
Application No.
63/356,130, filed on June 28, 2022, the subject matter of each of which is
incorporated herein by
reference in its entirety.
FIELD OF DISCLOSURE
100021 This disclosure relates generally to an optical assembly that can be
used in luminaires
and other light elements, and more particularly to reflectors around light
emitting diodes (LED)
to direct light beams from LEDs in a desired direction while cutting off the
light beams from
travelling in an undesired direction.
BACKGROUND
100031 Light emitting diodes (LED) are typically used in luminaires for street
lighting, porch
lighting, back yard lighting, in house lighting, decorative lighting, or other
lighting purpose. LED
lights used in roadway luminaires typically include a series of LEDs arranged
in rows, with the
LEDs being covered by an optic designed to provide a particular light
distribution profile. In
outdoor lighting applications, it may be desirable to direct light toward a
desired direction (such
as toward a street, parking lot, or other area), while preventing light from
being directed toward
an undesired direction to leave other areas, such as unpaved areas, buildings,
yards, and the like,
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unlit. However, traditional lighting systems may not provide the ability to
carefully cutoff off
light such that predominately all light emitted from the lighting system is
emitted in a desired
direction. Therefore, improvements in light cutoff capabilities of lighting
systems are desired.
BRIEF SUMMARY
100041 One aspect of the present disclosure relates to an optical assembly
configured to direct
light in a desired direction. The optical assembly includes a base, a
plurality of lenses disposed
on the base and spaced from each other in a row. Each lens may have a dome
shape with a
central or optical axis perpendicular to a plane of the base. The optical
assembly can include a
plurality of light emitting diodes (LED). Each LED can be disposed between the
base and a
respective lens of the plurality of lenses. Each LED can have a central axis
perpendicular to a
plane of the LED. The central axis of an LED may be offset from the central
axis of the
respective lens of the plurality of lenses. At least one reflector having a
curved surface (e.g.,
concave shape, parabolic shape, etc.) may be disposed adjacent to at least one
of the plurality of
LEDs such that the at least one of the plurality of LEDs are at a first side
of the at least one
.. reflector. The curved surface may extend from the base and curve over the
at least one of the
plurality of LEDs and beyond the central axis of each of the at least one of
the plurality of LEDs.
The curved surface can be configured to direct light emitted by the at least
one of the plurality of
LEDs toward the first side and prevent the light from leaking toward a second
side of the at least
one reflector that is opposite the first side.
.. 100051 In some embodiments, each lens of the plurality of lenses defines a
cavity, and each LED
of the plurality of LEDs may be disposed in a respective one of the cavities
such that the central
axis of the LED is offset relative to a central axis of the respective lens in
a direction of the
curved surface of the at least one reflector.
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10006] In some embodiments, the curved surface of the reflector may have a
free form shape
characterized by multiple curvatures between end points of the curved surface,
a first end point
being at the base and a second end point being positioned above at least some
of the plurality of
lenses. For example, a first curvature may be between the first end point at
the base and an
intermediate point between the first end point and the second end point, and a
second curvature
may be between the intermediate point and the second end point of the curved
surface.
100071 In some embodiments, the curved surface of the reflector may be
characterized by a first
angle between a plane of the base and a first line (e.g., joining a distal end
of a lens furthest from
the curved surface and a distal end of the curved surface located over the
lens). For example, the
first angle is in a range between 600 and 90 . In some embodiments, the curved
surface of the
reflector may be characterized by a second angle between the plane of the base
and a second line
(e.g., a line joining a point on the lens located at the central axis of the
LED and the distal end of
the curved surface located over the lens). For example, the second angle is in
a range between
70 and 130 .
10008] Further, one aspect of the present disclosure relates to a luminaire.
The luminaire
includes a base, a plurality of lenses disposed on the base and spaced from
each other, a plurality
of light emitting diodes (LED) disposed between the base and a respective lens
of the plurality of
lenses, at least one reflector having a curved surface and disposed proximate
to at least one of the
plurality of LEDs, and a frame supporting the base and the at least one
reflector.
100091 In some embodiments, each lens may have a dome shape having a central
axis
perpendicular to a plane of the base.
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100101 In some embodiments, each LED may have a central axis perpendicular to
a plane of the
LED, and the central axis of an LED may be offset from the central axis of a
respective lens of
the plurality of lenses.
100111 In some embodiments, the curved surface of the reflector may extend
from a surface of
the base and curve over the at least one of the plurality of LEDs and beyond
the central axis of
the at least one of the plurality of LEDs. The curved surface may be
configured to direct light
emitted by the at least one of the plurality of LEDs toward the first side and
prevent the light
from leaking toward a second side of the at least one reflector that is
opposite the first side.
100121 In some embodiments, the frame may be oriented such that the curved
surface of the at
least one reflector curves toward the street to direct the light from the at
least one of the plurality
of LEDs toward a street side and prevent light from leaking in a direction
that is away from the
street.
100131 The forgoing general description of the illustrative implementations
and the following
detailed description thereof are merely exemplary aspects of the teachings of
this disclosure, and
are not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
100141 The accompanying drawings, which are incorporated in and constitute a
part of the
specification, illustrate one or more embodiments and, together with the
description, explain
.. these embodiments. The accompanying drawings have not necessarily been
drawn to scale. Any
values dimensions illustrated in the accompanying graphs and figures are for
illustration
purposes only and can or cannot represent actual or preferred values or
dimensions. Where
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applicable, some or all features cannot be illustrated to assist in the
description of underlying
features. In the drawings:
100151 Figure 1 illustrates backlight leakage associated with a prior art
street light.
100161 Figure 2 illustrates a street light with improved backlight control,
according to one
embodiment.
100171 Figure 3 is a perspective view of an optical assembly including a
reflector with a curved
surface, according to one embodiment.
100181 Figure 4A is a top perspective view of a lens or optic arranged on a
base surface,
according to one embodiment.
100191 Figure 4B is a bottom perspective view of the base surface showing
access to a cavity
of the lens for mounting a light source, according to one embodiment.
100201 Figure 4C is a cross-section view of a lens disposed on the base
showing the light
source exploded from the cavity of the lens, according to one embodiment.
100211 Figure 5 is a perspective view of a lens or optic co-molded to a base,
according to one
embodiment.
100221 Figure 6 illustrates a cross-section of an optical assembly, (a)
showing a perspective
view of an optical assembly and a cross-section, and (b) showing a front view
of the cross-
section illustrating a cross-section of reflectors, lenses, and light sources,
according to one
embodiment.
100231 Figure 7A is a perspective cross-section view of the reflector, lens
and a light source
arranged in an optical assembly, according to one embodiment.
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100241 Figure 7B is a perspective view of an optical assembly with a central
axis of the light
source pointing downward and reflector directing the light from the light
source toward the front,
according to one embodiment.
100251 Figure 8A is a perspective cross-section view of the reflector, lens
and a light source
.. arranged in an optical assembly, according to one embodiment.
100261 Figure 8B is a cross-section view of the lens and the light source
viewed from a side
(e.g., house side) illustrating a symmetric configuration of the lens with
respect to the light
source, according to one embodiment.
100271 Figure 8C is a cross-section view of the lens and the light source
viewed from a front
with a house side on the left and a street side on the right illustrating
asymmetry of the lens with
respect to the light source, according to one embodiment.
100281 Figure 9A illustrates a first angle associated with the reflector
characterizing a curved
surface, according to one embodiment.
100291 Figure 9B illustrates a second angle associated with the reflector
characterizing a
curved surface, according to one embodiment.
100301 Figure 9C illustrates a traditional reflector with straight surface,
according to one
embodiment.
100311 Figure 10 is a perspective view of a corner reflector assembled on a
base with a light
source disposed in the lens, according to one embodiment.
100321 Figure 11 is a perspective view of an optical assembly with a plurality
of corner
reflectors assembled on a base with a plurality of light sources disposed in
corresponding lenses,
according to one embodiment.
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100331 Figure 12 is a luminaire employing an optical assembly according to an
embodiment
disclosed herein.
100341 Figure 13 is a perspective view of an optical assembly, according to
another
embodiment.
100351 Figure 14 is a top perspective view of a base and lens assembly of the
optical assembly
of Figure 13.
100361 Figure 15 is a bottom perspective view of the base and lens assembly of
Figure 14.
100371 Figure 16 illustrates photometric views of light emitted by the optical
assembly of
Figure 13 and a number of competitor products.
100381 Figure 17 illustrates photometric views of light emitted over an area
by a number of the
optical assemblies of Figure 13 and a number of competitor products.
100391 Figure 18 illustrates photometric views of simulated light emitted by a
corner optical
assembly of in accordance with the present invention and a number of
competitor products.
DETAILED DESCRIPTION
100401 The description set forth below in connection with the appended
drawings is intended
as a description of various embodiments of the disclosed subject matter and is
not necessarily
intended to represent the only embodiment(s). In certain instances, the
description includes
specific details for the purpose of providing an understanding of the
disclosed embodiment(s).
However, it will be apparent to those skilled in the art that the disclosed
embodiment(s) can be
practiced without those specific details. In some instances, well-known
structures and
components can be shown in block diagram form in order to avoid obscuring the
concepts of the
disclosed subject matter.
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100411 Reference throughout the specification to "one embodiment" or "an
embodiment"
means that a particular feature, structure, or characteristic described in
connection with an
embodiment is included in at least one embodiment of the subject matter
disclosed. Thus, the
appearance of the phrases "in one embodiment" or "in an embodiment" in various
places
throughout the specification is not necessarily referring to the same
embodiment. Further, the
particular features, structures or characteristics can be combined in any
suitable manner in one or
more embodiments. Further, it is intended that embodiments of the disclosed
subject matter
cover modifications and variations thereof.
100421 It is to be understood that terms such as "top," "bottom," "front,"
"side," "length,"
"lower," "interior," "inner," "outer," and the like that can be used herein
merely describe points
of reference and do not necessarily limit embodiments of the present
disclosure to any particular
orientation or configuration. Furthermore, terms such as "first," "second,"
"third," etc., merely
identify one of a number of portions, components, steps, operations,
functions, and/or points of
reference as disclosed herein, and likewise do not necessarily limit
embodiments of the present
disclosure to any particular configuration or orientation.
100431 Conventional lighting applications may attempt to control an amount of
back light or
corner light to meet visibility/non-visibility, intensity or other
specifications. However, existing
back light control and corner control optics have several limitations. For
example, conventional
optics may not be able to produce a light distribution having a sharp and
precise backlight cutoff,
which may result in a backlight cutoff line which is spaced apart from a
fixture installation line
and may enable unwanted light to spill in an undesired direction, such as
toward neighboring
properties (e.g., see Figure 1). Existing optics may also be unable to meet
specification related to
a LEED program such as LEED v4 program and earning additional points.
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100441 The present disclosure provides an optical assembly that overcomes
several limitations
above. In some embodiments, the optical assembly herein comprises a reflector
frame that offers
extreme light cut off while also reflecting a greater portion of light in the
desired direction to
improve light coverage. In some embodiments, the extreme light cut off may be
characterized by
mounting height to back light distance ratio. For example, if the optical
assembly is mounted at a
height of 20 feet, the back light cutoff will be less than 5 feet rearward of
the pole. Some
embodiments, ratios of back light cutoff to mounting height that are less than
0.5, less than 0.4.
less than 0.3, less than 0.25, less than 0.2, less than 0.15, less than 0.1,
or less may be achieved.
For example, comparing a first cut off line 15 (in Figure 1) and another cut
off line 25 (in Figure
2) shows that the cut off line 25 is much closer to the street than the house
side, thereby
achieving much sharper cut off using the optical assembly of the present
disclosure.
100451 Additionally, an asymmetric lens design is provided that can reduce the
reflector size
while offering more precise and/or sharp light cutoff. The structure of the
lens can take various
forms. In some non-limiting examples, the lens may include a clear optic that
is co-molded into a
base (e.g., a black or other colored base), a clear optic that is glued and/or
otherwise secured to a
base (e.g., a black or other colored base), and/or may include an integrally
formed base and
optic, with a surface of the base being painted or otherwise colored (e.g.,
black or another color).
In some embodiments, the lens and/or base may include a silicone material, as
silicone can offer
desirable photometric and thermal performance.
100461 Regardless of the lens material, it may be desirable for as much of the
surface of the
base 100 that is exposed to the emitted light (e.g., first surface 100f in
Figure 4A) to incorporate
a light absorbing mechanism (e.g., one that absorbs at least 90% of the light
that impinges upon
it). As explained above, the exposed surface (e.g., first surface 100f) of the
base 100 may be
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painted a dark color (e.g., black). If the lenses are formed from PMMA or
another paintable
material, the portion of the lenses that couple to the base 100 (e.g., that
flat portion of strips 110
in FIG. 4A) can be similarly painted a dark color (e.g., black). Lenses formed
of a silicone
material cannot be painted. Thus, a dark (e.g., black) material (e.g., felt,
paper, etc.) may be
provided on the upper or lower surface of the portion of the lenses that
couple to the base for
light absorption. Alternatively, the clear portion of the lenses (the dome-
shaped portions) can be
co-molded with and/or adhered to a darker material that forms the portion of
the lenses that
couple to the base 100.
100471 In some embodiments, the optical assembly comprises one or more light
sources, a
.. number of lenses (e.g., made of PMMA or silicone material) placed over the
light sources, and
one or more reflectors (e.g., made of pure black plastic and vacuum metalized
reflective surface)
placed proximate the lens. Different components of the optical assembly and
their configuration
are further discussed in detail with respect to Figures 3-15, according to
some embodiments.
100481 Figure 3 is a perspective view of an optical assembly 10, according to
one embodiment.
The optical assembly 10 includes a base 100, a plurality of lenses (e.g.,
lenses 111-115 and
lenses 121-125) disposed on the base 100 and over a plurality of light sources
150 (e.g., shown in
Figure 4C), and one or more reflectors 201-204 that each have a reflector
surface 201c-203c
disposed adjacent to one or more of the plurality of light sources 150 and/or
the plurality of
lenses (e.g., lenses 111-115 and lenses 121-125). Each of reflector surfaces
201c-203c can be a
.. reflective surface configured to reflect light from the LEDs, as such can
be alternatively referred
as the reflective surfaces 201c-203c. Reflector surface 201c may project over
at least a portion of
one or more of the light sources 150. In some embodiments, the reflector
surface 201c-203c may
be formed from one or more angled and/or curved sections so as to project
upward from the base
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100 and over at least of portion of one or more of the light sources 150. For
example, the
reflector surface 201c may include a single planar surface that is angled
relative to the base 100
to extend over at least of portion of one or more of the light sources 150,
while in other
embodiments the reflector surface 201c may be formed from multiple planar
portions that are at
different angles relative to one another. In yet other embodiments, all or
part of the reflector
surface 201c may be curved, and may include a constant or varying degree of
curvature. In some
embodiments, the light sources 150 can be light emitting diodes (LED) 150. The
reflector surface
201c in combination with the lenses 111-115 and LEDs 150 allows the light to
be directed in a
desired direction. The reflector surface 201c is also configured to cutoff
light from traveling in
undesired directions. For example, as will be discussed in greater detail
below, the reflectors 201
may be positioned relative to the LEDs 150 and lenses 111-115 such that light
emitted from each
lens 111-115 in undesired directions may contact one of the surfaces 201c,
which then reflects
such light in a desired direction and/or otherwise away from the undesired
direction. The base
100 can also prevent the light from the LEDs from traveling in other
directions than the desired
direction. For example, in some embodiments, the base 100 may be formed from
and/or coated
with a black (or other dark color) material. For example, the base 100 may
absorb at least 90%,
at least 91%, at least 92%, at least 93%, at least 94%, at least 95%, at least
96%, at least 97%, at
least 98%, at least 99%, or more of light. This may enable the base 100 to
absorb light directed
toward the base 100 to prevent and/or reduce the amount of light reflected by
the base 100, some
of which may otherwise be reflected in an undesired direction. Light emitted
from the LEDs 150
and/or lenses 111-115 in a downward direction and/or light reflected in a
downward direction
using the reflectors 201 may be absorbed by the base 100, which may prevent
such light from
being directed in an undesired direction (e.g., a house side direction). In
some embodiments, the
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optical assembly 10 can be a luminaire used to light a street. In this
example, the optical
assembly is configured to project light in a desired direction (in this case,
a street side), while
limiting or preventing the projection of light in an undesired direction (in
this case, a house side
such as a front yard or a back yard or any other area that should not be
illuminated/does not
allow light trespass). The components of the optical assembly including the
lenses, the LEDs and
reflectors are further discussed in detail below.
100491 A light source emits light that can be received and further distributed
by the lens, as
discussed herein. In some embodiments, the light source can be or can comprise
one or more
light emitting diodes, for example. The light source and/or the emitted light
can have an
associated optical axis. The light source can be deployed in applications
where it is desirable to
bias illumination laterally relative to the optical axis. For example, as
shown in Figures 2 and 7B,
in a street luminaire where the optical axis is pointed down towards the
ground, it may be
beneficial to direct light towards a street side of the optical axis, rather
than towards a row of
houses that are beside the street (e.g., see Figure 2). The light source can
be positioned relative to
a lens that receives light propagating on one side or both sides of the
optical axis and redirects
that light toward the reflector and/or sends the light forward toward the
street side. For example,
the lens can receive light that is headed towards the houses and redirect that
light towards the
street via the reflector 201.
100501 In some embodiments, as shown in Figures 3, 4A and 5, the plurality of
lenses 111-115
are disposed on the base 100 and spaced from each other in a row 110.
Similarly, another
plurality of lenses 121-125 are disposed in another row 120. In one
embodiment, as shown in
Figures 3 and 4A, the lenses 111-115 may be provided as individual components,
as sheets
containing multiple rows of lenses, as strips 110s containing a single row of
lenses, and/or other
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forms. Providing the lenses in one or more sheets or strips 110s may
facilitate coupling multiple
lenses to a corresponding array of LEDs and/or to the base 100. For example,
the lens strips 110s
and 120s are coupled to a first surface 100f (e.g., a front, upper, or exposed
surface in Figure 4A)
of the base 100. An inner surface of each lens 111-115 may define a cavity 140
(as shown in
Figure 4C) or other volume that may receive light from a respective one of the
LEDs 150. The
base 100 can include a plurality of apertures or openings (e.g., 131-135). The
openings 131-135
can be accessed from an opposite second surface 100b of the base 100 (e.g., a
back, lower, or
rear surface in Figure 4B) of the base 100. The array of LEDs can be disposed
through the
openings 131-135 from the second surface 100b. In such an embodiment, the
printed circuit
board ("PCB") supporting such an array of LEDs would typically be located
under the base 100.
Accordingly, an optical assembly or an illumination system can comprise a two-
dimensional
array of LEDs. The resulting two-dimensional array of LEDs can comprise a
light module or
light bar, one or more of which can be disposed in a luminaire or other
lighting apparatus, for
example.
100511 In some example embodiments, the lenses (e.g., lenses 111-115 and
lenses 121-125) can
be formed of optical grade silicone and can be pliable and/or elastic. In some
example
embodiments, the lenses can be formed of an optical plastic such as poly-
methyl-methacrylate
(PMMA), polycarbonate, silicone, or an appropriate acrylic, to mention a few
representative
material options without limitation. The base 100 may be configured to absorb
light and/or
redirect light in a desired direction. For example, in some embodiments, the
base 100 may be
colored such that the base 100 has desired reflectance and/or absorption
properties. For example,
the base 100 may be a colored black, or any dark color that absorbs a high
percentage of light
(e.g., greater than 90%). In embodiments, the base 100 may include a host
material and a
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colorant in the base material. The colorant may be a pigment, a dye, etc. that
colors the host
material, thereby adjusting its absorption/reflection properties. For example,
in some
embodiments, the material of the base 100 may be selected to absorb at least
90%, at least 91%,
at least 92%, at least 93%, at least 94%, at least 95%, at least 96%, at least
97%, at least 98%, at
least 99%, or more of light. Non-limiting examples of suitable host materials
include PMMA,
silicone, and/or other polymeric materials. In embodiments, the base 100 may
include a host
material having a first surface and a second surface opposite the first
surface. The first surface
may be an upward facing surface. A colored layer may be disposed on the first
surface. The
colored layer may be a layer of paint, dye, etc.
100521 By providing the base 100 with a black or otherwise dark outer surface,
any light incident
on the first surface 100f can be absorbed and not reflected thereby preventing
light leakage
toward an undesired direction (e.g., the house side).
100531 Referring to Figure 5, the plurality of lenses 111-115 and 121-125 can
be individually
coupled to the base 100. In some embodiments, the plurality of lenses 111-115
and 121-125 can
be glued or co-molded with the base 100. For example, the plurality of lenses
111-115 and 121-
125 can be attached to the base 100 by an adhesive. In other embodiments, the
lenses 111-115
may be snapped, fastened, and/or otherwise mechanically secured with the base
100.
100541 As shown in Figures 4C and 5, the lenses 111-115 can have a dome-shaped
outer surface
1110 with a central axis perpendicular to a plane of the base 100. For
example, the lenses 111
and 121 have central axes 111a and 121a, respectively, as shown in Figure 4C.
The central axis
111a or 121a can be an axis passing through a center of the lens 111 or 121.
In some
embodiments, the central axis of a lens lies within a plane (perpendicular to
plane 311 in Figure
8A) (1) that extends through the lens in a direction that is parallel to the
house side to street side
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direction (i.e., the x direction in Figure 8A) and/or extends perpendicular to
the length of the
reflector (i.e., they direction in Figure 8A) and (2) that extends through the
optical cavity 140.
With reference to that plane (see FIG. 8C), the central axis of the lens
extends along the height of
the lens (i.e., along the z direction) and bisects the midpoint of the linear
distance between the
end points 901, 904 of the outer surface 1110 (i.e., where the outer surface
intersects the plane of
the base 100).
100551 In some embodiments, as shown in Figures 8C and 9A-9B, the LED 150 of
the plurality
of LEDs is disposed in a cavity 140 of lens 111 of the plurality of the lens
111-115 such that the
central or optical axis 150a of the LED is offset from the central axis 111a
of the lens 111 in a
direction toward the reflector surface 201c of the reflector 201. In
embodiments, the plurality of
lenses 111-115 have a corresponding plurality of LEDs 150 disposed therein
such that the central
axes of the lenses are offset toward and/or close to the reflector 201.
100561 In some embodiment, as shown in Figures 4C and 6(b), each of the
plurality of light
emitting diodes (LED) 150 are placed in a corresponding lens of the plurality
of lenses 111-115.
.. The LED 150 has an optical axis 150a perpendicular to a plane of the LED or
perpendicular to
the base 100. In embodiments, as shown in Figures 4C and 8A-8C, the optical
axis 150a of an
LED 150 is offset from the central axis 111a of an outer surface of the lens
111 of the plurality of
lenses 111-115. In embodiments, the optical axis 150a of the LED 150 and a
central axis 111a of
the outer surface 1110 of the lens 111 are aligned or not offset from each
other. In some
embodiments, each LED 150 may be provided on a printed circuit board (PCB) 160
and/or other
substrate. The PCB 160 can be attached to the second surface 100b of the base
100 such that the
LEDs reside within and/or emits light into the cavities 140 of the lenses. In
some embodiments,
the PCB 160 and/or other substrate may be configured to absorb at least 90% of
light incident
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thereon, such as by including a light-absorbing material (e.g., a material
containing a pigment
that absorbs at least 90%, at least 91%, at least 92%, at least 93%, at least
94%, at least 95%, at
least 96%, at least 97%, at least 98%, at least 99%, or more of light).
100571 Figures 7A and 8A illustrate a cross-section view showing structure of
an exemplary lens
111, according to one embodiment. As shown, the lens 111 has a dome shape with
an inner
surface 111i facing the LED 150 and an outer surface 1110 facing away from the
LED 150,
opposite the inner surface 111i. The inner surface 111i can include a
refractive surface that
receives light headed away from the optical axis of the LED 150, for example
away from the
street to be lighted. The inner surface 111i can be a concave lens surface
facing toward the LED
150, with the inner surface 111i being spaced apart from an outer surface of
the LED 150. The
inner surface 111i can receive the incident light from the LED 150 and create
a refracted beam
that exits the lens 111 through the outer surface 111o, which causes the beam
to diverge. The
outer surface 1110 can be a convex lens surface, for example. In some
embodiments, the inner
surface 111i may have a shape that differs from a shape of the outer surface
111o. For example,
the inner surface 111i may have a concave shape that is different from the
convex shape of the
outer surface 111o. In embodiments, the concave shape of the inner surface
111i is offset from
the outer surface 111o.
100581 As noted above, each lens 111-115 can comprise a cavity 140 (see Figure
4C and 7A)
that has a concave shape. The walls of the lens may be asymmetric in some
embodiments. For
example, a rear wall (e.g., closest to the reflector 201) may be thinner than
a front wall (e.g.,
further from the reflector 201), which may enable the LED 150 to be positioned
closer to the
reflector 201 to provide a sharper light cut off angle. The cavity 140 can be
filled with air
between the inner surface 111i and the LED 150. The cavity 140 receives light
from the LED
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150. In some embodiments, the lens 111 comprises a receptacle in which the LED
150 can be
seated or is otherwise disposed. The receptacle can be irregularly shaped to
receive a circuit
board to which one or more light emitting diodes is mounted, for example.
100591 Referring to Figures 8A-8B, a lens (e.g., lens 111) is symmetric in a
reference plane 311
extending through the optical axis 150a of the LED 150 along the y direction
(in FIG. 8A) and
when viewed in the x direction (in FIG. 8A). Additionally, referring to
Figures 8A and 8C, the
lens is asymmetric about the reference plane 311 when viewed in the y
direction (in FIG. 8A) in
that the central axis 111a of the lens is offset from the reference plane 311.
As shown in Figure
8C, the reference plane 311 separates the lens into a street-side portion and
a house-side portion.
The street-side portion is larger in size than the house-side portion in order
to reduce the size of
the optical system while providing better cut-off. The street-side portion
controls a main beam
emitted from the LED 150 and directs the beam toward a desired direction
(e.g., between 55 -
75 relative to nadir). The house-side portion acts as the light transmission
layer which sends the
light to the reflector 201. Such lens construction advantageously sends more
light towards a
desired direction through the lens. For example, a reduced size of a lens
portion (e.g., the house-
side lens portion) provides better light beam cutoff by the reflector as well
as enables lowering a
height of the reflector 201 thereby making an optical assembly compact. For
example, by
offsetting the cavity 140 and/or LED 150 from the central axis 111a of the
lens 111 in a direction
toward the reflector 201 (i.e., the optical axis 150a of the LED 150 is closer
to the reflector base
than the central axis 111a of the lens 111), the optical axis 150a of the LED
150 may be
positioned closer to the reflector 201, which may enable a height of the
reflector 201 to be
reduced while still providing a desired cutoff angle for light.
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100011 Referring to Figures 3, 6, 7, 8A, 9A and 9B, each reflector 201 may
protrude from the
base 100 at a first end 905 and terminate at a second end 903 and may have a
reflective surface
201c that extends between the first end 905 (proximate the base) and the
second end 903 (see
FIGS. 9A, 9B). For example, each reflector 201 may include a first side that
includes the
reflective surface 201c (e.g., street side) and an opposite second side 20 lb
(e.g., a house-side or a
side behind the reflective surface 201c). In one embodiment, the reflector 201
is an elongated
member having a reflective material or coating on the reflective surface 201c,
while the second
side may be painted black (or other dark color) to prevent light from a
different row of LEDs
from reflecting toward the house side. Each reflector 201 is disposed adjacent
to the plurality of
lenses 111-115 having corresponding plurality of LEDs 150 therein such that
the plurality of
LEDs 150 or lenses 111-115 are at the first side (e.g., street side). As
illustrated, the reflective
surface 201c extends in a direction perpendicular to the plane of the base
100, however in other
embodiments the reflective surface 201c may extend from the base 100 at other
angles. The
reflective surface 201c curves over the plurality of LEDs 150 located in the
corresponding
plurality of lenses 111-115. The reflective surface 201c (i.e., the second end
903) further extends
beyond the optical axis 150a of the LED 150. Accordingly, the reflective
surface 201c is
configured to direct light emitted by the plurality of LEDs 150 toward the
first side (e.g., the
street side) and prevent the light from leaking toward the second side (e.g.,
the house side) of the
reflector 201.
100601 Referring to Figure 3, the optical assembly 10 can include a plurality
of reflectors 201,
202, 203 and 204 and corresponding rows of lenses and LEDs. In one embodiment,
each
reflector 201-204 has the same construction and is positioned in a similar
manner with respect to
the corresponding plurality of LEDs. For example, the reflector 202 is
positioned adjacent to the
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second plurality of lenses 121-125 covering a corresponding plurality of LEDs
150 such that the
reflective surface 202c extends over and beyond a central axis of the LEDs
150. While shown
with a single reflector extending along a length of each row of LEDs 150, it
will be appreciated
that in some embodiments multiple reflectors may be provided for each row of
LEDs 150. For
example, each LED 150 and lens pair (or a number of pairs within each row) may
include a
dedicated reflector.
100611 In Figure 3, the plurality of lenses, the plurality of LEDs, and
reflectors are disposed in a
number of rows. For example, as shown in Figure 3, the first plurality of
lenses 111-115 are
arranged in a first row and a first plurality of LEDs (e.g., see 111 in Figure
4C) disposed in
corresponding lens of the first plurality of lenses 111-115. The first
reflector 201 is disposed
adjacent to the first plurality of lenses 111-115 such that the reflective
surface 201c of the first
reflector 201 extends over the first plurality of lenses 111-115.
100621 The second plurality of lenses 121-125 are arranged in a second row
spaced from the first
row and a second plurality of LEDs (e.g., see LED 150 in lens 121 in Figure
4C) disposed in the
corresponding second plurality of lenses 121-125. The second reflector 202 is
disposed between
the first plurality of lenses 111-115 and the second plurality of lenses 121-
125 such that a
reflective surface 202c of the second reflector 202 extends over the second
plurality of lenses
121-125. In other words, with respect to the reflector 202, the second
plurality of LEDs in the
lenses 121-125 are located at the first side of reflector 202 (e.g., street
side), and the first
plurality of lenses 111-115 are located at the second side of reflector 202
(e.g., house side). In
some embodiments, the second side of the reflectors 201-204 can be coated or
formed from a
black (or other dark color) material to absorb light emitted by LEDs on the
second side or
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partially reflective to reflect light emitted by LEDs on the second side
without interfering with
the light emitted by LEDs on the first side.
100631 While illustrated with the LEDs 150 and lenses 111-115, 121-125
arranged in two
parallel rows, it will be appreciated that other arrangements are possible in
embodiments. For
example, the LEDs and lenses may be arranged in any number of rows, columns,
and/or other
patterns. The LEDs and lenses may be arranged at regular and/or irregular
intervals in one or
more directions. Additionally, a total number of LEDs and lenses and/or a
number of LEDs and
lenses in a given row, column, or other array may vary across embodiments to
meet the needs of
a particular lighting application.
100641 In some embodiments, as shown in Figure 3, the reflector 201 (and 202-
204) can include
side reflectors between each lens to redirect and reflect the light traveling
in a direction that is
aligned with or substantially aligned with a length of reflector 201 in a
desired direction (e.g.,
street side) thereby improving the illumination profile at the street side.
The side reflectors may
also prevent light interference between adjacent LEDs thereby improving
efficiency of light
utilization. For example, the reflector 201 includes side reflectors 211, 212,
213 and 214
projecting from the reflective surface 201c toward the first side (e.g.,
street side). In some
embodiments, the side reflectors 211-214 may be curved or transition from the
surface of the
reflector 201. In some embodiments, the side reflectors 211-214 may be angled
(e.g., up to 5 )
with respect to a perpendicular to the base 100. The side reflector 211 has a
reflecting surface
211r facing the LED in the lens 111. The side reflector 212 located between
the lenses 111 and
112 has two reflecting surfaces 212r, one surface 212r faces the lens 111 and
another surface
212r faces the lens 112. Similarly, each of the side reflectors 213 and 214
has reflecting surfaces
213r and 214r facing the lenses between which each is interposed.
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100651 Accordingly, the optical assembly 10 can be configured to direct light
from each row of
LEDs via a corresponding reflector toward the street without light
interference between LEDs or
light interference between adjacent rows of LEDs. Thus, light emitted from
each LED or rows of
LEDs can be better directed to a desired direction (e.g., street side) to
improve light utilization,
while cutting off or otherwise preventing light emitted by the optical
assembly 10 from being
directed toward undesired directions (e.g., house side).
100661 In some embodiments, as shown in Figures 7A, 8A and 9A-9B, the
reflective surface
201c of the reflector 201 can have a partially concave shape. However, the
present disclosure is
not limited to a concave shape. In some embodiments, different linear and/or
curved surfaces can
be created to direct light in a desired direction. For example, the reflective
surface 201c of the
reflector 201 can have a parabolic shape extending from the base 100 toward
and beyond the
central axis of the plurality of LEDs. As another example, the reflective
surface 201c of the
reflector 201 can have a free form shape characterized by multiple curvatures
between end points
of the reflective surface 201c, with a first end point being at the junction
of the reflective surface
201c and the base 100 and a second end point being a distal end of the
reflective surface 201c
that extends over the plurality of lenses 111-115. For example, the free form
shape comprises a
first curvature between the first end point at the base 100 and an
intermediate point between the
first end point and the second end point; and a second curvature between the
intermediate point
and the second end point of the curved surface. The free form may be generally
characterized by
the curved portion elongating in a direction of the selected area (e.g., a
street-side direction).
100671 In some embodiments, the reflector 201 has a reflective surface 201c
with a linear
segment or base extending approximately perpendicularly from the base 100 up
to a height
corresponding to a top of the outer surface 1110 of the lens 111. Extending
from the linear
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segment, the reflective surface 201c can extend further with a curve toward
the central axis of
the LED. For example, the curve can be characterized by a plurality of points
connected by
curved line segments. The series of curved segments each comprise a reflective
surface and a
curvature having a profile of an arc segment of an ellipse, a parabolic
curvature, a hyperbolic
curve, or other second or higher degree curve portions.
100681 Referring to Figures 9A and 9B, the reflective surface 201c of the
reflector 201 can be
characterized by a first angle a, a second angle 13, or both. The first angle
a is formed between
the base 100 and a line 902 that extends between a distal end 901 (e.g.,
street side) of the lens
111 furthest from the reflective surface 201c and a distal end 903 of the
reflective surface 201c
located over the lens 111. The second angle (3 is formed between the base 100
and a line 912 that
extends from a position 911 on the outer surface 1110 of the lens 111 that is
aligned with the
optical axis 150a of the LED 150 and the distal end 903 of the reflective
surface 201c located
over the lens 111.
100691 In some embodiments, the first angle a can be in a range between 60
and 90 (e.g.,
between 60 -70 , 70 -80 , 80 -90 or other narrow ranges). In some
embodiments, greater
angles may further enable the height of the reflector to be decreased and/or
may provide sharper
backlight cutoff.
100701 In some embodiments, the second angle (3 can be in a range between 70
and 130 . In
some embodiments, the reflector 201 that satisfies the first angle a, the
second angle 13, or both
facilitates a compact design, while providing a desired cutoff of the
backlight (e.g., light directed
toward the house side). For example, the reflective surface 201c of the
reflector that satisfies the
first angle and the second angle conditions facilitates reducing a height of
the reflector 201
required to cut toff the backlight and also allows positioning of the LEDs 150
proximate to the
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reflective surface 201c so that the light from the LEDs can be directed in a
desired direction
(e.g., street side). In other words, the first angle a and the second angle f3
bring the distal end 903
of the reflective surface 201c closer to the LEDs while facilitating cutoff of
the backlight (e.g.,
light directed toward the house side).
100711 In some embodiments, referring to Figures 9A-9C, the reflective surface
201c of the
reflector 201 facilitates compact design compared to a straight edge reflector
250 (see Figure
9C). For example, the reflective surface 201c extends over the optical axis
150a of the LED 150
which allows the beam emitting from the LED and transmitted by the lens 111 to
be cutoff close
to the lens 111 before the beam can spread. The height of the reflective
surface 201c can be Hl.
On the other hand, if the straight edge reflector 250 is used, a height H2 of
the straight edge
reflector 250 from the base 100 is needed to intercept a beam 922 transmitted
at the distal end
901 of the lens 111. Comparing Figures 9A and 9C shows that the beam 922 in
FIG. 9A is
intercepted at the reflective surface 201c within a short distance. On the
other hand, the beam
922 in FIG. 9C needs to travels much further before being intercepted by the
straight edge
reflector 250. Thus, the height H1 of the reflector 201 can be substantially
smaller than the
height H2 of the straight edge reflector 250 while still providing the desired
backlight cutoff
ability. For example, the Hl/H2 ratio may be between 1/3 to 1/2. As such,
using reflector 201 a
more compact illumination system (e.g., a luminaire) can be designed.
100721 In some embodiments, a reflector can have an angular shape to light a
corner space. In
some embodiments, as shown in Figures 10 and 11, a reflector 400 can be
angular in shape
comprising a first surface portion 401, a second surface portion 403 disposed
at an angle with the
first surface portion 401, and a corner surface portion 402 connecting the
first surface portion
401 and the second surface portion 401. The first surface portion 401 and the
second surface
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portion 403 have surfaces 401c and 403c, respectively. The surfaces 401c and
403c can have
similar structure as the reflective surface 201c of the reflector 201
discussed herein. The corner
surface portion 402 also has a surface 402c to direct the light emitted
towards a corner back to a
desired direction (e.g., street side). In one embodiment, the surface portion
402 curves along
multiple axes to connect the first surface portion 401 and the second surface
portion 403.
Likewise, the surface 402c of the surface portion 402 also curves along
multiple axes (e.g., x and
y axis in the plane defined by the base 100) connecting the surfaces 401c and
403c and also
further curves along another axis (e.g., z axis perpendicular to the base 100)
and extends over the
lens to at least partially cover the lens.
100731 Figure 11 illustrates an exemplary corner optical assembly 40
comprising a plurality of
corner reflectors such as reflectors 400 and 410. At the corners of each
reflector 400 and 410, an
LED 150 is located in each of the lenses 111 and 112, respectively. The
surfaces 401c, 402c and
403c of the reflector 400 face the LED 150 in the lens 111. Similarly, the
surfaces 411c, 412c
and 413c of the reflector 410 face the LED 150 in the lens 112. The optical
assembly 40 includes
additional similar corner reflectors, and lenses, although not numbered. As
discussed herein, the
reflectors 400 and 410, and lenses 111 and 112 of the optical assembly 40 can
be installed on the
base 100. The base 100 along with the reflectors, lens, and LEDs can be
further supported by a
frame 450. The frame 450 can provide a support structure for the base and
reflectors. The frame
450 can be further adapted to be installed in a casing of a luminaire.
100741 Figure 12 illustrates an example luminaire 20 implementing an optical
assembly 10. The
optical assembly 10 can be installed in a casing 50 coupled to a pole 60. The
pole 60 can be
installed at the housing side and the casing 50 can extend toward the street
or a corner desired to
be illuminated. While not illustrated, the optical assembly 40 may be
incorporated into a
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luminaire, e.g., by replacing the optical assembly 10 of the luminaire 20 with
the optical
assembly 40.
100751 The optical assemblies discussed herein can be configured for various
applications. For
example, the optical assembly can be used to illuminate a selected area (e.g.,
a street) while
cutting off and/or otherwise preventing leakage of the light away from the
selected area (e.g.,
towards a house). For this purpose, the reflector can be curved as discussed
herein. The optical
assembly can be oriented downwardly towards ground such that the optical axes
150a of the
LEDs 150 are oriented in a general downward direction (e.g., see Figures 2 and
7B), and the
curved surface of the reflector directs the light toward a selected area
(e.g., the street, a pathway,
or other indoor or outdoor areas). The reflector can be configured as a corner
reflector (e.g., see
Figures 10-11) to direct light to a particular corner. In some embodiments,
the optical assembly
can include a combination of curved reflectors (e.g., reflector 201) and
corner reflectors (e.g.,
400). In some embodiments, the optical axis 150a of the LEDs 150 can be
oriented upward and
reflectors can be positioned to direct light to a particular wall, porch, or
an object of interest for
decorative purposes. It can be understood that the present application uses a
selected area as a
street to illustrate the concepts. However, the present disclosure is not
limited to a particular
application and the optical assembly may be configured to direct light to any
selected area or
region that is indoor (e.g., a wall inside a house) or outdoor (e.g., a
street, a walkway, a porch,
etc.).
100761 Figure 13 illustrates an optical assembly 500, according to another
embodiment. The
optical assembly 500 may be similar to optical assembly 10 and may include any
of the features
described in relation to optical assembly 10. Optical assembly 500 may include
a base 502, a
plurality of lenses 504 disposed on or coupled with the base 502 so as to
extend from and/or
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above the exposed surface of the base, a plurality of light sources (not
shown) disposed in or
behind the plurality of lenses 504, and one or more reflectors 506 that each
have a reflective
surface 508 (which may be similar to the reflective surface 201) disposed
adjacent to one or
more of the plurality of light sources and/or the plurality of lenses 504. In
some embodiments,
the lenses 504 and/or light sources may be arranged in one or more rows that
are spaced apart
from one another. Each row of lenses 504 and/or light sources may include one
or more of the
reflectors 506, with the reflective surface 508 of each reflector 506
extending from the base 502
and extending over at least a portion of one or more of the lenses 504 and/or
light sources such
as described previously with respect to reflectors 201.
100771 Figures 14 and 15 illustrate top and bottom perspective views of the
base 502 and
lenses 504. As illustrated, the base 502 may be configured to prevent the
light from the LEDs
from traveling in other directions than the desired direction. For example, in
some embodiments,
the base 502 may be configured to absorb at least 90%, or greater of light
incident thereon. In
some embodiments, the base 502 may be formed from and/or coated with a light-
absorbing
material, such as a material that contains a dark pigment that absorbs
substantially all light (e.g.,
absorbs at least 90). This may enable the base 502 to absorb light directed
toward the base 502 to
prevent and/or reduce the amount of light reflected by the base 502, some of
which may
otherwise be reflected in an undesired direction.
100781 The base 502 may define a number of apertures 510, with each of the
apertures 510
receiving a respective one of the lenses 504 and/or light sources. For
example, each lens 504 may
include a dome that extends from a backside of the base 502 and extends at
least partially
through a respective one of the apertures 510. As described in relation to
lenses 111-115, the
dome may be asymmetric along at least one axis that is parallel to the base
502. For example, in
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some embodiments, each lens 504 may have an elliptical shape having a major
axis and a minor
axis that extend in a direction parallel to the base 502. The dome of each
lens 504 may protrude
away from the base 502 and may be asymmetric along the major axis (or other
axis that extends
through the lens 504 and the corresponding reflector 506). For example, a
slope of the dome may
be greater on a reflector-side of the dome than on an opposite surface along
the major axis. The
light sources may be disposed closer to the reflector-side of the dome in some
embodiments,
which may enable the corresponding reflector 506 to be positioned closer to
the light source to
provide a sharper light cut off angle.
100791 In such embodiments, the light sources may include a number of LEDs
that are
provided on a printed circuit board and/or other substrate. The lenses 504 may
be inserted
through the apertures 510 of the base 502 from a rear side of the base 502
such that the lenses
504 are sandwiched between the printed circuit board and the base 502. By
positioning the lenses
504 within apertures 510 formed within the base 502, a surface area of the
base 502 that is
exposed on the optical assembly 500 may be increased. When the base 502 is
configured to
absorb substantially all light incident thereon, the increased surface area
may enable greater
levels of light directed toward the base 502 to be absorbed, and may thereby
help prevent light
from being directed in an undesired direction. Such embodiments may enable the
optical
assembly 500 to direct at least or about 95%, at least or about 96%, at least
or about 97%, at least
or about 98%, at least or about 99%, at least or about 99.5%, at least or
about 99.7%, or more of
the light in a desired direction (e.g., a street side), with less than about
5%, less than about 4%,
less than about 3%, less than about 2%, less than about 1%, less than about
0.5%, less than 0.3%,
or less of the light being directed toward an undesired (e.g., opposite)
direction (e.g., a house
side). A cut off plane of the light (i.e., a reference plane that separates
the desired direction from
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the undesired direction) may be in vertical alignment with a rearmost (e.g.,
closest to the
undesired direction) light source and/or reflector of the optical assembly. In
other words, the
light cutoff plane (1) may extend through the optical axis of one or more of
the plurality of LEDs
located within the optical assembly at a location most distal from the desired
direction and (2)
may extend parallel to the optical axis of those one or more LEDs and
perpendicular to the
desired direction.
100801 In some embodiments, the base 502 may include a front surface 512 and a
rear surface
514 that is opposite the front surface 512. The reflectors 506 may be disposed
on the front
surface 512. The rear surface 514 may define one or more recesses 516 that may
receive the
lenses 504. For example, the lenses 504 may be provided as one or more strips
and/or sheets of
optical material that may each include one or more rows of lenses 504. The
strips of material
may be inserted within the recesses 516 to seat the lenses 504 within the
apertures 510 defined
within the base 502. In some embodiments, a thickness of the strips of
material may be
substantially the same as a depth of the recesses 516 such that a rear surface
of each strip of
material is substantially flush with the rear surface 514 of the base 502. In
the illustrated
embodiment, the base 502 defines two recesses 516 that are parallel to one
another. A strip of
material containing a first row of lenses 504 is inserted within a first of
the recesses 516 and a
second strip of material containing a second row of lenses 504 is inserted
within a second of the
recesses 516. It will be appreciated that other arrangements are possible in
various embodiments.
For example, each lens 504 may be a separate component, each sheet and/or
strip of material
may include multiple rows of lenses 504, the lenses 504 may be arranged in non-
row arrays,
and/or other variations are possible. Additionally, some embodiments may
include multiple
bases positioned side-by-side with one another.
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100811 In some embodiments, the rear surface 514 of the base 502 may include
one or more
adhesive channels 520 for receiving adhesive to attach the lenses and/or PCB
(e.g., 160 in FIG.
4C) to the rear surface 514 of the base 502. The adhesive channels 520 can
contain the adhesive
within the channels so that the adhesive cannot enter apertures/openings
(e.g., openings 131-135
in FIG. 4B) in the base 502 so as to detrimentally impact operation of the
lenses 504 and/or
LEDs. The adhesive channels 520 can extend along any length of the rear
surface 514. The
adhesive channels 520 can also extend along a width of the rear surface 514
towards the
apertures through which the lenses 504 can be disposed.
100821 Testing was performed on a fixture with the optical assemblies
described in accordance
with Figures 13-15 to determine the backlight cut off properties of the
fixture with optical
assembly 500. The testing was performed in accordance with the IES LM-79
standard dated
2019. Based on tested distribution, the lumen output of the assembly was
scaled to 20,000
lumen, and the application layout was based on a mounting height of 20 feet. A
cutoff plane 602
is a vertical plane that crosses the optical center of the fixture (e.g., the
plane that separates the
street side and house side). The area that is illustrated as being above the
cutoff plane 602 is a
desired direction (e.g., the "street-side" or the forward direction with
regard to the fixture head
and the pole, counting from the optical center per IES LM-63). The area that
is illustrated as
being lower than the cutoff plane 602 is an undesired direction (e.g., the
"house-side" or the
backward direction with regard to the fixture head and the pole, counting from
the optical center
per IES LM-63-02 and LM-63-19). The fixture with optical assembly 500 produced
the lighting
application layout 600a as shown in Figure 16. The optical assembly 500
directed 99.7% of
emitted light toward a desired direction (e.g., a street side) relative to
cutoff plane 602, while
only 0.3% of the emitted light was directed toward an undesired direction
(e.g., a house side) and
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achieved a BO backlight rating up to 65,000 lumen pursuant to the IES LM-79
goniophotometer
test result. Lighting application layouts 600b-600f illustrate the performance
of several
competitor fixtures at the same lumen output and same application layout
condition. The lighting
fixture with optical assembly 500 produced better backlight control than each
of the tested
competitor optical assemblies, the best of which directed 2% of emitted light
in the undesired
direction. The lighting fixture with optical assembly 500 also produced better
illuminance
uniformity and coverage area compared to the competitor light fixtures. As
illustrated in Figure
16, the optical assembly provided more uniform rectangular illuminance pattern
on the target
area that extended along both length (e.g., orthogonal to plane 602) and width
(e.g., along the
602) axes. For example, as a lighting application layout illustrated in Figure
17, lighting fixture
with optical assembly 500 delivered 1 foot-candle ("fc") of light to an area
approximately 50 feet
wide and 60 feet long, 0.5 fc of light to an area approximately 60 feet wide
and 68 feet long, and
0.1 fc of light to an area approximately 95 feet wide and 95 feet long. When
positioned about an
area to be illuminated (such as, but not limited to, a parking lot), multiple
fixtures including
optical assemblies 500 may provide better coverage (and better backlight
control) than the
competitor optical assemblies, as illustrated in Figure 17. The light coverage
achieved by the
fixtures with optical assemblies 500 is shown in lighting application layout
700a, while the
competitor fixture coverage is illustrated in lighting application layouts
700b-700f. The fixtures
for testing were spaced apart by 146 feet laterally (e.g., along the cutoff
plane 602) and 151 feet
lengthwise (e.g., for fixtures on opposite sides of the area).
100831 Simulations were performed on fixtures including corner optical
assemblies (such as
those described in relation to Figures 10 and 11) that include bases and
lenses similar to base 502
and lenses 504 described herein. The simulations showed greater corner light
control using such
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fixtures as compared to competitor corner control fixtures as illustrated in
the lighting
application layouts shown in Figure 18. Lighting application layout 800a
illustrates the corner
control provided by the fixture including the corner optical assembly of the
present invention,
while lighting application layouts 800b-800d illustrate the performance of the
competitor optical
assemblies.
Examples
100841 A collection of exemplary embodiments, including at least some
explicitly enumerated as
"Examples" providing additional description of a variety of example types in
accordance with
the concepts described herein are provided below. These examples are not meant
to be mutually
exclusive, exhaustive, or restrictive; and the present disclosure is not
limited to these example
examples but rather encompasses all possible modifications and variations
within the scope of
the issued claims and their equivalents.
100851 Example 1. An optical assembly comprising: a base; a plurality of
lenses disposed on the
base and spaced from each other in a row, each lens having a dome shape having
a central axis
perpendicular to a plane of the base; a plurality of light emitting diodes
(LED), each LED being
disposed between the base and a respective lens of the plurality of lenses,
each LED having a
central axis perpendicular to a plane of the LED, the central axis of an LED
being offset from the
central axis of the respective lens of the plurality of lenses; and at least
one reflector having a
curved surface the at least one reflector being disposed adjacent to at least
one of the plurality of
LEDs such that the at least one of the plurality of LEDs are at a first side
of the at least one
reflector, the curved surface extending from the base and curving over the at
least one of the
plurality of LEDs and beyond the central axis of each of the at least one of
the plurality of LEDs,
the curved surface being configured to direct light emitted by the at least
one of the plurality of
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LEDs toward the first side and prevent the light from leaking toward a second
side of the at least
one reflector that is opposite the first side.
100861 Example 2. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein each lens of the plurality of lenses defines
a cavity, and each
LED of the plurality of LEDs is disposed in a respective one of the cavities
such that the central
axis of the LED is offset relative to a central axis of the respective lens in
a direction of the
curved surface of the at least one reflector.
100871 Example 3. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the curved surface of the reflector has a
concave shape.
100881 Example 4. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the curved surface of the reflector has a
parabolic shape
extending from the base toward and beyond the central axis of the plurality of
LEDs.
100891 Example 5. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the curved surface of the reflector has a
free form shape
.. characterized by multiple curvatures between end points of the curved
surface, a first end point
being at the base and a second end point being positioned above at least some
of the plurality of
lenses.
100901 Example 6. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the free form shape comprises: a first
curvature between the
first end point at the base and an intermediate point between the first end
point and the second
end point; and a second curvature between the intermediate point and the
second end point of the
curved surface.
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100911 Example 7. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the reflector is an elongated member having a
reflective
coating on the curved surface.
100921 Example 8. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the curved surface of the reflector is
characterized by at least
one of: a first angle between a first line and a plane of the base, the first
line joining a distal end
of a lens furthest from the curved surface and a distal end of the curved
surface located over the
lens, and a second angle between a second line and the plane of the base, the
second line joining
a point on the lens located at the central axis of the LED and the distal end
of the curved surface
located over the lens.
100931 Example 9. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the first angle is in a range between 600 and
90 .
100941 Example 10. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the second angle is in a range between 70
and 130 .
100951 Example 11. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the base comprises light absorbing material
or coating.
100961 Example 12. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the plurality of lenses are attached to the
base by an adhesive.
100971 Example 13. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the plurality of lenses comprises: a first
plurality of lenses
arranged in a first row; and a second plurality of lenses arranged in a second
row; and the
plurality of LEDs comprises: a first plurality of LEDs disposed in the first
plurality of lenses; and
a second plurality of LEDs disposed in the second plurality of lenses.
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100981 Example 14. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the at least one reflector comprises: a first
reflector disposed
proximate to the first plurality of lenses on an opposite side of the second
plurality of lenses such
that a curved surface of the first reflector extends over the first plurality
of lenses; and a second
reflector disposed between the first plurality of lenses and the second
plurality of lenses such that
a curved surface of the second reflector extends over the second plurality of
lenses.
100991 Example 15. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the at least one reflector extends along a
single lens of the
plurality of lenses.
101001 Example 16. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the at least one reflector has an angular
shape comprising a
first curved surface portion, a second curved surface portion disposed at an
angle with the first
curved surface portion, and a corner portion between the first curved surface
portion and the
second curved surface portion, the corner portion having a curved surface
extending along
multiple axes.
101011 Example 17. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the curved surface of the corner portion of
the at least one
reflector curves between the first curved surface portion and the second
curved surface portion,
and also curves in a plane perpendicular to the base.
101021 Example 18. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein a lens of the plurality of lenses is located
at the corner such
that the curved surface of the corner portion curves at least partially over
the lens.
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101031 Example 19. An luminaire configured to illuminate a selected area, the
luminaire
comprising: a base; a plurality of lenses disposed on the base and spaced from
each other in a
row, each lens having a dome shape having a central axis perpendicular to a
plane of the base; a
plurality of light emitting diodes (LED) disposed between the base and a
respective lens of the
plurality of lenses, each LED having a central axis perpendicular to a plane
of the LED, the
central axis of an LED being offset from the central axis of a respective lens
of the plurality of
lenses; at least one reflector having a curved surface, the at least one
reflector being disposed
proximate to at least one of the plurality of LEDs such that the at least one
of the plurality of
LEDs are at a first side of the at least one reflector, the curved surface
extending from a surface
of the base and curving over the at least one of the plurality of LEDs and
beyond the central axis
of each of the at least one of the plurality of LEDs, the curved surface being
configured to direct
light emitted by the at least one of the plurality of LEDs toward the first
side and prevent the
light from leaking toward a second side of the at least one reflector that is
opposite the first side;
and a frame supporting the base and the at least one reflector, the frame
being oriented such that
the curved surface of the at least one reflector curves toward the selected
area to direct the light
from the at least one of the plurality of LEDs toward a selected area and
prevent light from
leaking in a direction that is away from the selected area.
101041 Example 20. The luminaire of any of the preceding or subsequent
examples or
combination of examples, wherein the curved surface of the reflector has at
least one of: a
concave shape; a parabolic shape extending from the base toward and beyond the
central axis of
the plurality of LEDs; or a free form shape characterized by multiple
curvatures between end
points of the curved surface, a first end point being at the base and a second
end point being
positioned above at least some of the plurality of lenses.
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101051 Example 21. An optical assembly comprising: a base comprising a first
surface, a second
surface opposite the first surface, and a plurality of apertures extending
through the base from the
first surface to the second surface; a plurality of lenses coupled to the
base, each of the lenses
having a lens central axis perpendicular to a plane of the base, wherein each
lens is attached to
the second surface of the base and extends at least partially through a
respective one of the
plurality of apertures so as to be at least partially exposed on the first
surface of the base; a
plurality of light emitting diodes (LEDs), each of the LEDs positioned to emit
light into a
respective one of the plurality of lenses, each of the LEDs having an optical
axis; and at least one
reflector disposed adjacent to at least one of the LEDs such that the at least
one of the LEDs is at
a first side of the at least one reflector, wherein: the at least one
reflector comprises a first end
proximate the base, a second end opposite the first end, and a reflective
surface extending at least
partially between the first end and the second end, the reflector extending
from the base over the
at least one of the LEDs such that the second end of the reflector extends
beyond the optical axis
of that at least one of the LEDs; and the reflective surface is configured to
direct light emitted by
the at least one of the LEDs toward the first side and prevent the emitted
light from leaking
toward a second side of the at least one reflector that is opposite the first
side, wherein the optical
axis of the at least one of the LEDs is laterally offset from the lens central
axis of the respective
one of the lenses in a direction toward the first end of the reflector so as
to be located more
proximate the first end of the reflector than the lens central axis.
101061 Example 22. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: each of the lenses defines a cavity, and
each of the LEDs
seats within a respective one of the cavities.
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101071 Example 23. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the reflective surface of the at least one
reflector has at least
one of a concave shape or a parabolic shape.
101081 Example 24. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: each of the LEDs is aligned with a
respective one of the
plurality of apertures.
101091 Example 25. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the first surface of the base is configured
to absorb at least
90% of emitted light incident on the first surface.
101101 Example 26. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the first surface of the base comprises a
light absorbing
material or coating.
101111 Example 27. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the reflector comprises a light absorbing
material or coating
on a side of the reflector opposite the reflective surface.
101121 Example 28. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the reflective surface is a curved surface
characterized by at
least one of: a first angle between a first line and a plane of the base, the
first line joining a distal
end of a lens furthest laterally from the first end of the reflector and the
second end of the
reflector located over the lens; and a second angle between a second line and
the plane of the
base, the second line joining a point on the lens located at the optical axis
of the LED and the
second end of the reflector located over the lens.
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101131 Example 29. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the first angle is in a range between 600 and
90 .
101141 Example 30. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the second angle is in a range between 70
and 130 .
101151 Example 31. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the reflective surface comprises one or more
linear segments.
101161 Example 32. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the plurality of lenses is coupled to the
base with adhesive,
and wherein the second surface of the base defines channels for the adhesive.
101171 Example 33. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: each of the lenses comprises a dome that
extends through the
respective one of the plurality of apertures; and the dome is asymmetric along
at least one axis
that is parallel to the base.
101181 Example 34. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the second surface of the base defines at
least one recess and
wherein the plurality of lenses are seated within the at least one recess.
101191 Example 35. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the at least one recess comprises a first
recess and a second
recess that extend parallel to each other; the plurality of lenses comprise a
first row of lenses and
a second row of lenses; the first row of lenses is disposed within the first
recess; and the second
row of lenses is disposed within the second recess.
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101201 Example 36. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the plurality of LEDs are provided on a
substrate; and the
plurality of lenses are sandwiched between the substrate and the base.
101211 Example 37. The optical assembly of any of the preceding or subsequent
examples or
.. combination of examples, wherein: each of the lenses comprises a first side
most proximate the
at least one reflector and a second side opposite the first side; and each of
the LEDs is disposed
closer to the first side than the second side of a respective one of the
plurality of lenses.
101221 Example 38. An optical assembly comprising: a plurality of lenses, each
of the lenses
having a lens central axis; a plurality of light emitting diodes (LEDs), each
of the LEDs oriented
to emit light into a respective one of the plurality of lenses, each of the
LEDs having an optical
axis; and at least one reflector disposed adjacent to at least one of the LEDs
such that the at least
one of the LEDs is at a first side of the at least one reflector, wherein: the
at least one reflector
has a reflective surface extending over the at least one of the LEDs and
beyond the optical axis;
and the optical axis of the at least one of the LEDs is laterally offset from
the lens central axis of
the respective one of the lenses in a direction toward the at least one
reflector so as to be located
more proximate the at least one reflector than the lens central axis, wherein
the LEDs are
configured to emit light from the optical assembly and wherein the optical
assembly is
configured to direct at least 95% of the emitted light in a first direction
relative to a light cutoff
plane (1) that extends through the optical axis of one or more of the
plurality of LEDs located
within the optical assembly at a location most distal from the first direction
and (2) that extends
parallel to the optical axis and perpendicular to the first direction.
101231 Example 39. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, further comprising: a base defining a plurality of
apertures, wherein
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each of the lenses extends through a respective one of the plurality of
apertures so as to be visible
on a first surface of the base.
101241 Example 40. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the plurality of LEDs are provided on a
substrate; and the
substrate is configured to absorb at least 90% of light incident on the
substrate.
101251 Example 41. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the reflective surface comprises a curved
surface.
101261 Example 42. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, further comprising: a base, wherein the at least one
reflector is coupled
with the base.
101271 Example 43. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the plurality of lenses are arranged in a
plurality of rows; the
at least one reflector comprises a plurality of reflectors; and at least one
of the plurality of
reflectors extends between adjacent rows of the plurality of rows of lenses.
101281 Example 44. An optical assembly comprising: a plurality of lenses, each
of the lenses
having a dome shape portion and a lens central axis; a plurality of light
emitting diodes (LEDs),
each of the LEDs oriented to emit light into a respective one of the plurality
of lenses and each of
the LEDs having an optical axis; and at least one reflector disposed adjacent
to at least one of the
LEDs such that the at least one of the LEDs is at a first side of the at least
one reflector, wherein
the at least one reflector has a reflective surface extending over the at
least one of the LEDs and
beyond the optical axis of the at least one of the LEDs and wherein the
optical axis of the at least
one of the LEDs is laterally offset from the lens central axis of the
respective one of the lenses in
a direction toward the at least one reflector so as to be located more
proximate the at least one
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reflector than the lens central axis, wherein the optical assembly comprises a
surface from which
the dome shape portions of the plurality of lenses extend and wherein the
surface is configured to
absorb at least 90% of light incident on the surface.
101291 Example 45. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein surface comprises a light absorbing material
or coating.
101301 Example 46. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the plurality of LEDs are provided on a
substrate comprising
the surface.
101311 Example 47. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the plurality of lenses are coupled to a
base and the base
comprises a surface.
101321 Example 48. A luminaire configured to illuminate a selected area, the
luminaire
comprising: an optical assembly comprising: a base comprising a first surface,
a second surface
opposite the first surface, and a plurality of apertures extending through the
base from the first
surface to the second surface; a plurality of lenses coupled to the base, each
of the lenses having
a lens central axis perpendicular to a plane of the base, wherein each lens is
attached to the
second surface of the base and extends at least partially through a respective
one of the plurality
of apertures so as to be at least partially exposed on the first surface of
the base; a plurality of
light emitting diodes (LEDs), each of the LEDs positioned to emit light into a
respective one of
the plurality of lenses, each of the LEDs having an optical axis; and at least
one reflector
disposed adjacent to at least one of the LEDs such that the at least one of
the LEDs is at a first
side of the at least one reflector, wherein: the at least one reflector
comprises a first end
proximate the base, a second end opposite the first end, and a reflective
surface extending at least
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partially between the first end and the second end, the reflector extending
from the base over the
at least one of the LEDs such that the second end of the reflector extends
beyond the optical axis
of that at least one of the LEDs; and the reflective surface is configured to
direct light emitted by
the at least one of the LEDs toward the first side and prevent the emitted
light from leaking
toward a second side of the at least one reflector that is opposite the first
side, wherein the optical
axis of the at least one of the LEDs is laterally offset from the lens central
axis of the respective
one of the lenses in a direction toward the first end of the reflector so as
to be located more
proximate the first end of the reflector than the lens central axis; and a
frame receiving the
optical assembly, the frame being oriented such that the at least one
reflector directs light from
the at least one of the LEDs toward the selected area and prevent light from
leaking in a direction
that is away from the selected area.
101331 Example 49. The luminaire of any of the preceding examples or
combination of
examples, wherein the reflective surface is a curved surface of the reflector,
the curved surface
comprising at least one of: a concave shape; a parabolic shape extending from
the base toward
and beyond the optical axis of the one of the plurality of LEDs; or a free
form shape
characterized by multiple curvatures between end points of the curved surface,
a first end point
being at the base and a second end point being positioned above at least some
of the plurality of
lenses.
101341 Example 50. An optical assembly comprising: a base comprising a first
surface; a plurality
of lenses provided on the first surface of the base, each lens having a dome
shape having a central
axis perpendicular to a plane of the base; a plurality of light emitting
diodes (LED), each LED
positioned to emit light into a respective lens of the plurality of lenses,
each LED having a central
axis perpendicular to a plane of the LED, the central axis of an LED being
offset from the central
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axis of the respective lens of the plurality of lenses; and at least one
reflector extending from the
base and having a curved surface, the at least one reflector being disposed
adjacent to at least one
of the plurality of LEDs such that the at least one of the plurality of LEDs
is at a first side of the
at least one reflector, the curved surface extending from the base and curving
over the at least one
of the plurality of LEDs and beyond the central axis of the at least one of
the plurality of LEDs,
the curved surface being configured to direct light emitted by the at least
one of the plurality of
LEDs toward the first side and prevent the emitted light from leaking toward a
second side of the
at least one reflector that is opposite the first side.
101351 Example 51. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein each lens of the plurality of lenses defines
a cavity, and each
LED of the plurality of LEDs is disposed in the cavity of the respective lens
such that the central
axis of the LED is offset relative to a central axis of the respective lens in
a direction toward the
curved surface of the at least one reflector.
101361 Example 52. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the curved surface of the reflector has at
least one of: a concave
shape; a parabolic shape extending from the base toward and beyond the central
axis of the at least
one of the plurality of LEDs; or a free form shape characterized by multiple
curvatures between
end points of the curved surface, a first end point being at the base and a
second end point being
positioned above at least some of the plurality of lenses.
101371 Example 53. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the free form shape comprises: a first
curvature between the
first end point at the base and an intermediate point between the first end
point and the second end
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point; and a second curvature between the intermediate point and the second
end point of the
curved surface.
101381 Example 54. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the curved surface of the reflector is
characterized by at least
one of: a first angle between a first line and a plane of the base, the first
line joining a distal end of
a lens furthest laterally from the reflector at the base and a distal end of
the reflector located over
the lens, and a second angle between a second line and the plane of the base,
the second line joining
a point on the lens located at the central axis of the LED and the distal end
of the reflector located
over the lens.
101391 Example 55. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the first angle is in a range between 600 and
90 or wherein the
second angle is in a range between 70 and 130 .
101401 Example 56. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the first surface of the base is configured
to absorb at least 90%
of emitted light incident on the first surface.
101411 Example 57. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the first surface of the base comprises a
light absorbing material
or coating.
101421 Example 58. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the base further comprises a second surface
opposite the first
surface and a plurality of apertures extending through the base from the first
surface to the second
surface, wherein each of the plurality of lenses extends at least partially
through a respective one
of the plurality of apertures so as to be provided on the first surface of the
base.
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101431 Example 59. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the plurality of lenses is attached to the
base with an adhesive.
101441 Example 60. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the plurality of lenses comprises a first
plurality of lenses
arranged in a first row and a second plurality of lenses arranged in a second
row; and the plurality
of LEDs comprises a first plurality of LEDs disposed in the first plurality of
lenses and a second
plurality of LEDs disposed in the second plurality of lenses.
101451 Example 61. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the at least one reflector comprises: a first
reflector disposed
proximate to the first plurality of lenses such that a curved surface of the
first reflector extends
over the first plurality of lenses; and a second reflector disposed between
the first plurality of lenses
and the second plurality of lenses such that a curved surface of the second
reflector extends over
the second plurality of lenses.
101461 Example 62. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein the at least one reflector extends along a
single lens of the
plurality of lenses.
101471 Example 63. The optical assembly of any of the preceding or subsequent
examples or
combination of examples, wherein: the at least one reflector has an angular
shape comprising a
first curved surface portion, a second curved surface portion disposed at an
angle with the first
curved surface portion, and a corner portion between the first curved surface
portion and the second
curved surface portion, the corner portion having a curved surface extending
along multiple axes;
the curved surface of the corner portion of the at least one reflector curves
between the first curved
surface portion and the second curved surface portion, and also curves in a
plane perpendicular to
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the base; and a lens of the plurality of lenses is located at the corner such
that the curved surface
of the corner portion curves at least partially over the lens.
101481 Example 64. A luminaire configured to illuminate a selected area and
comprising: the
optical assembly of any preceding claim; and a frame supporting the optical
assembly, the frame
being oriented such that the curved surface of the at least one reflector
curves toward the selected
area to direct the light from the at least one of the plurality of LEDs toward
the selected area and
prevent light from leaking in a direction that is away from the selected area.
101491 Different arrangements of the components depicted in the drawings or
described above,
as well as components and steps not shown or described are possible.
Similarly, some features
and subcombinations are useful and may be employed without reference to other
features and
sub combinations.
101501 While certain embodiments have been described, these embodiments have
been presented
by way of example only, and are not intended to limit the scope of the present
disclosures.
Indeed, the novel methods, apparatuses and systems described herein can be
embodied in a
variety of other forms; furthermore, various omissions, substitutions and
changes in the form of
the methods, apparatuses and systems described herein can be made without
departing from the
spirit of the present disclosures. The accompanying claims and their
equivalents are intended to
cover such forms or modifications as would fall within the scope and spirit of
the present
disclosures.
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