The invention relates to lighting systems, and more particularly to ducted lighting systems that employ a light engine in which components are arranged in a single file.
The long-distance transport of visible light can be facilitated by mirror-lined light ducts and is employed in architectural lighting to deliver light throughout the interior parts of buildings. Mirror-lined ducts also provide advantages of large cross-sectional area and large numerical aperture (enabling larger fluxes with less concentration), a robust and clear propagation medium (that is, air) that leads to both lower attenuation and longer lifetimes, and a potentially lower weight per unit of light flux transported. Mirror-lined light ducts can be uniquely enabled by the use of 3M optical films, including mirror films such as enhanced specular reflector (ESR) films that have greater than 98% specular reflectivity across the visible spectrum of light.
Concurrently, LEDs are increasingly deployed as an energy saving replacement for traditional tungsten or fluorescent lighting systems. Lamps installed with LEDs typically have LEDs mounted on a plate, which is in turn affixed on a wall or ceiling, and the LEDs are arranged directly behind the light output surface of the lamp. LED lighting systems that use LED strips for a large room may consequently require installation of a plurality of LED strips throughout the room, along with sizeable driver circuit units for powering the LEDs. Heat generated by individual LED units on the strip requires effective dissipation to avoid overheating which could affect the lifespan of the LED units, but limited space exists in lighting systems, such as mirror-lined light ducts, to implement effective heat dissipation devices.
Given the myriad of competing factors such as those described above influencing the design of lighting systems and the ever increasing stringency end users place on both cost and performance, the need continues to exist for innovative approaches in developing new solutions.
In one aspect, the present disclosure provides a lighting system that comprises a light engine, a duct connected to the light engine defining a light transport passage for transporting light emitted from the light engine along a propagation direction through the duct, and one or more light output surfaces on the duct through which light is emitted. The light engine comprises, arranged sequentially in a single file, a light collimator having an output end arranged to face the conduit, a LED light source arranged to direct light into an input end of the light collimator, and a heat sink thermally coupled to the LED light source, respectively.
This and other aspects of the invention are described in the detailed description below. In no event should the above summary be construed as a limitation on the claimed subject matter which is defined solely by the claims as set forth herein.
Throughout the specification, reference is made to the appended drawings, where like reference numerals designate like elements, wherein:
The figures are not necessarily drawn to scale. However, it will be understood that the use of a numeral to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number
The present disclosure describes a lighting system in which a light duct is coupled to a light engine having components assembled sequentially in a single file, namely, the light collimator, LED light source and, heat sink, and in certain embodiments, the driver circuit, are sequentially arranged. By arranging the components of the light engine in this manner, the distribution of heat was optimized while enabling the light engine to adopt an appearance visually similar to the light duct. It was found that the light engine was able to operate for long periods of time without damaging the collimator or the LED driver circuitry in this manner.
The present specification is not limited to the specific examples or data set forth herein. The embodiments disclosed herein are capable of being made, practiced, used, carried out and/or formed in various ways expected of a skilled person in the field once an understanding of the invention is acquired. Numerical indicators, such as first, second, and third, as used in the description and the claims to refer to various structures or method steps, are not meant to be construed to indicate any specific structures or steps, or any particular order or configuration to such structures or steps. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “for example”) provided herein, is intended merely to better illustrate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification, and no structures shown in the drawings, should be construed as indicating that any non-claimed element is essential to the practice of the invention. The use herein of the terms “including” “comprising” or “having” and permutations thereof, is meant to encompass the features defined thereafter and equivalents thereof, as well as additional items.
Recitation of ranges of values herein are intended to refer individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. For example, if a compositional range is stated as 1% to 50%, it is intended that values such as 2% to 40%, 10% to 30%, or 1% to 3%, etc., are expressly enumerated in this specification. These are only examples of what is specifically intended, and all possible combinations of numerical values between and including the lowest value and the highest value enumerated are to be considered to be expressly stated in this disclosure. Use of the word “about” to describe a particular recited amount or range of amounts is meant to indicate that values very near to the recited amount are included in that amount, such as values that could or naturally would be accounted for due to manufacturing tolerances, instrument and human error in forming measurements, and the like.
Unless otherwise stated, reference to any document herein does not constitute an admission that any of these documents forms part of the common general knowledge in the art.
Referring to
The duct 140 defines a light transport passage 141. The duct 140 may be made up of 1, 2, 3, 4, 5 or more duct sections. Each duct section may be attached onto the ceiling or wall via nails or adhesive, or via fastening clips, and are coupled to each other via fastening clips or alternatively, each duct section may comprise mating end portions so that one duct section can be telescopically fitted to another duct section. Any other means of coupling duct sections together can also be used, where preferably the adjoining surfaces are well-fitting and do not suffer from light leaks.
Light exits the duct 140 via light output surfaces 150 located on the duct's surface. In one embodiment, each light output surface is arranged in a plane parallel to the longitudinal axis of the duct. Light therefore exits the duct in a direction, as represented by arrow 188, that is transverse to its propagation direction 179. Optical right angle films, such as 3M Transmissive Right Angle Films II (TRAF) may be used for this purpose. Advantageously, a single LED light source may be used to illuminate a duct ranging from several meters long to several tens of meters long, or preferably about ten duct sections of 1.2 meters each, i.e. total of 12 meters. Light rays 176 arriving at the end of the duct 140 are reflected off surface 165 and are recycled.
LED light source 114 may comprise an LED array 115 and a driver circuit 118 for powering the LED array. In the embodiment shown in
In order to increase the surface area for heat dissipation, the light engine housing may comprise in an exemplary embodiment a metal casing that is thermally coupled to the heat sink 116, to enable the entire light engine housing to function as a heat sink of sorts. In some embodiments, the light engine housing may be configured as a secondary heat sink, to aid in the cooling of heat sink 116. Optionally, the heat sink 116 may comprise grooves 126 as shown in
In order to provide the light engine 110 with an appearance that is similar to the duct—a desirable goal from an aesthetic perspective—at least one of the length, depth or width of the light engine housing 120, as represented by arrows 191, 193, 195 in
LED array 115 may be a 3×3, 4×4, 5×5, or 6×6 LED array or any other size or configuration, delivering in various instances, a total of 5000, 10000, or 15000 or more lumens of light per LED array. As shown in
The following design rules for the light engine yielded favorable performance in the operation of the lighting system:
Size of the LED array=A×B
Area of output end of light collimator=(3A×3B)
Collimator length=12×B
where A and B represents the dimensions of the edge of a square or rectangular LED array. To achieve a uniform appearance for the light engine and duct, the cross section of the duct may be designed to correspond to the same shape and size of the output end of the light collimator. Accordingly, it has roughly the dimensions of 3A×3B, and may be a square or a rectangle. Notwithstanding the above, a duct with circular or elliptical cross section may also be used if the light collimator has the shape of a conical frustum.
Taking an LED array that is 25 mm×25 mm in size as an example, the above design rule requires the area of the input end of the light collimator to be about 25 mm×25 mm in size. Correspondingly, the output end of the light collimator is designed to be 75 mm×75 mm in size. The length of the light collimator may be designed to be 300 mm. Since each duct is about 1.2 meters in length, in order for the light engine housing 120 to have the same length, the heat sink and driver circuit portion of the light engine may set to about 900 mm in length.
Taking an LED array that is 25 mm×25 mm in size as an example, the above design rule requires the area of the input end of the light collimator to be about 25 mm×25 mm in size. Correspondingly, the output end of the light collimator is designed to be 75 mm×75 mm in size. The length of the light collimator may be designed to be 360 mm. Since each duct is about 1.2 meters in length, in order for the light engine housing 120 to have the same length, the heat sink and driver circuit portion of the light engine may set to about 840 mm in length.
Taking an LED array that is 15 mm×15 mm in size as an example, the above design rule requires the area of the input end of the light collimator to be about 15 mm×15 mm in size. Correspondingly, the output end of the light collimator is designed to be 45 mm×45 mm in size. The length of the light collimator may be designed to be about 180 mm. Since each duct is about 1.2 meters in length, in order for the light engine housing 120 to have the same length, the heat sink and driver circuit portion of the light engine may set to about 102 mm in length.
Further embodiments of the invention with respect to (i) the light output surface (ii) the duct, (iii) modular construction, and (iv) the light collimator, are described in the following paragraphs.
To provide a low cost light output surface with adequate light output performance, it may be preferable to form the light output surface using individual optical film components that are suited to the desired performance. A plurality of light output surfaces may be present on a duct, each light output surface comprising one or more optical films. For example, to achieve good brightness, the light output surface may comprise a brightness enhancement film. A commercially available example is the 3M Vikuiti™ Brightness Enhancement Film (BEF), which is an optical film with prismatic structures microreplicated throughout the film to increase reflection and refraction of light rays. A reflective polarizer film may be used. A commercial example is the 3M Vikuiti™ Dual Brightness Enhancement Film (DBEF). Different layer arrangements of BEF and DBEF may be used: one may deploy an individual layer of BEF for the light output surface, or an individual layer of DBEF, or a plurality of BEF layers, or a plurality of DBEF layers, or a combination of BEF and DBEF layers. Additionally, light diffuser films may be used in conjunction with BEF and DBEF films to diffuse incident light from a light source. Commercially available examples include 3M™ Envision™ Diffuser Films 3735-50 or 3735-60. For structural support, each optical film layer or multi-layer film stack may be affixed on transparent glass or polycarbonate or other equivalent transparent substrate. 3M Optically Clear Adhesive may optionally be used; mechanical fastening of individual optical layers may be done as an alternative; or the margins of the optical film layer contacting the substrate may simply be provided with double sided adhesive tape without interfering with light transmission through the optical layer. An alternative to the use of a transparent substrate is to have the optical film layer stiffened by forming an outer layer of polyethylene terephthalate (PET), or biaxially oriented polypropylene film (BOPP), or cast polypropylene on the optical film.
Alternative to the use of optical films for the light output surface is the use of reflectors, e.g. conventional mirrors. In one embodiment, the duct comprises a plurality of light output surfaces, each light output surface comprising a mirror capable of being actuated to a position in which light transmitted through the duct is incident on the mirror and reflected out of the duct. Mirror may be mounted at each light output surface and may be mechanically actuated to reflect light out of the duct. The mirrors may be tilted at any desired angle to reflect light out of the light duct. Referring to
The duct may comprise a plurality of light output surfaces. In some embodiments, the light output surface is located on either one or a combination of the bottom surface, top surface or lateral surface of the duct relative to its mounted position. Light output surfaces may be located not only at the bottom surface (opposite the surface facing the wall) of the duct, but may also be located on lateral sides of the duct. In some embodiments, sections of the duct may comprise a transparent material e.g. polycarbonate, or a white or colored translucent material, e.g. cast acrylic plexiglass, depending on the aesthetic considerations of the application.
In some embodiments, the light engine, duct and the collimator are made separately as modules, to be assembled during installation. As shown in
Although the present invention has been described with particular reference to preferred embodiments illustrated herein, it will be understood by those skilled in the art that variations and modifications thereof can be effected and will fall within the scope of this invention as defined by the claims thereto now set forth herein below.
Number | Date | Country | Kind |
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10201405166T | Aug 2014 | SG | national |
Filing Document | Filing Date | Country | Kind |
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PCT/US2015/046231 | 8/21/2015 | WO | 00 |