Patent Application
20110199767
The present invention relates to light-emitting diode (“LED”) luminaires, and in particular LED luminaires adaptable for use in refrigerated display cases.
Display cases, including refrigerated display cases, historically have used fluorescent sources to light the interior of the case. However, the fluorescent bulbs used in such applications have limited life and must be replaced often. The electrodes in fluorescent bulbs are easily burnt out or broken, requiring that the entire bulb be replaced. Moreover, the glass bulbs themselves are susceptible to breakage.
The fluorescent bulbs have been positioned in various locations within the cases, including at the top and along the underside of shelves within the case. A lamp provided at the top of the unit illuminates the products positioned near the top of the case, but fails to adequately illuminate those products positioned lower within the case. This is particularly true if all of the shelves have the same depth. The use of a lamp positioned along the underside of shelf within the case helps illuminate the products located on a shelf below the lamp. Yet, the use of multiple lamps increases the energy and thus cost needed to adequately illuminate the case. There is a need to illuminate products with a display case more efficiently and effectively.
LED strip luminaires have been used to replace fluorescent lamps for illuminating merchandise in display cases. Typically, lenses, diffusers, and/or covers are positioned in close proximity to the LEDs to direct the light emitted from the LEDs directly on the products being displayed. In this way, such LEDs provide non-uniform, direct illumination of merchandise.
In one embodiment, a lighting luminaire includes an LED mounting portion comprising a plurality of LEDs mounted thereon, a reflector, and a lens. The LED mounting portion and reflector are sized and arranged to form a reflective cavity for diffusing and directing light from the plurality of LEDs through the lens and out of the luminaire.
In an embodiment, the LED mounting portion and reflector are attached to each other as separate components or are integrally formed. In another embodiment, if the LED mounting portion and reflector are separate components the LED mounting portion can include a slot for receiving the reflector and attaching the reflector thereto.
In yet other embodiments, the lens is held in place in the luminaire between the LED mounting portion and the reflector or is mounted directly on the LED mounting portion over the plurality of LEDs. In a further embodiment, the lens is clear or is refractive with a symmetrical, asymmetrical or non-symmetrical light output.
In some embodiments, the LED mounting portion and/or reflector have a reflective surface for reflecting light from the plurality of LEDs. In some embodiments the reflective surface is a reflective paint or a reflective liner
In further embodiments the LED mounting portion and reflector are attached to each other via engagement of a ball or socket on the LED mounting portion with a corresponding socket or ball on the reflector. In certain embodiments, the reflector is repositionable within the luminaire so as to allow the direction of light exiting the luminaire to be adjusted.
In other embodiments the luminaire can further include one or more fins for dissipating heat generated by the plurality of LEDs away from the luminaire. In yet other embodiments the LED mounting portion can further include at least one void or offset to further promote dissipation of heat generated by the LEDs.
In some embodiments the luminaire is mounted on a shelf, such as a shelf of a refrigerated display case. A thermal insulation pad may be located between the luminaire and the shelf to minimize heat transfer from the luminaire to the shelf. In certain high-humidity environments, the luminaire can include one or more water shedding surfaces for directing condensation away from the LEDs and off the luminaire.
In a further embodiment, an existing luminaire in a refrigerated display is retrofitted with an LED luminaire.
Embodiments of the present invention overcome traditional spotty illumination and striations by occluding the direct point-source lighting with an integral, highly-reflective diffuse optical reflector that provides uniform illumination and color temperature to products positioned within the display. More specifically, embodiments of the present invention use LEDs positioned to emit light into a reflective cavity. In one embodiment, the LEDs are positioned on the surface of an LED mounting portion so as to direct emitted light into a reflective cavity.
The reflector 130 is preferably treated so as to render its inner surface 136 highly diffusely reflective, preferably, but not necessarily, between 96%-99.5%, inclusive and more preferably 98.5-99% reflective. To achieve the desired reflectivity, in one embodiment the inner surface 136 of the reflector 130 is coated with a highly reflective material, including, but not limited to, paints sold under the tradenames GL-22, GL-80 and GL-30, all available from DuPont. Other embodiments may utilize textured or colored paints or impart a baffled shape to the reflector surface to obtain a desired reflection. Alternatively, a reflective liner (not illustrated), such as Optilon™ available from DuPont, may be positioned within the reflector 130. In some embodiments, portions of the LED mounting portion 100 may also be rendered reflective by these same methods.
Lens 150, having a first edge 152 and a second edge 154, is positioned adjacent the LED mounting portion 100 and the reflector 130. The LED mounting portion 100 includes a first slot 120 that receives the first edge 132 of the reflector 130 and a second slot 160 that receives the second edge 154 of the lens 150. The second edge 134 of the reflector 130 has a shelf 170 formed thereon and is snap-fitted over the first edge 152 of the lens 150. In this way, the LED mounting portion 100, the reflector 130, and the lens 150 are connected together to define a cavity 135, rendered reflective by virtue of the reflective inner surface 136 of the reflector 130. Other methods for connecting the LED mounting portion 100, reflector and/or lens 150 to each other are known and can be used in place of or in combination with the slots 120, 160 and shelf 170 described herein.
A plurality of LEDs 110 are mounted on the LED mounting portion 100 with screws 140 or other fastening mechanism. The LEDs 110 are mounted on a surface of the LED mounting portion 100 (usually, but not necessarily, via a printed circuit board) so as to direct emitted light into the reflective cavity 135. For ease of discussion, the light sources are referred to generally as LEDs 110. However, the LEDs referenced herein can be single-die or multi-die light emitting diodes, DC or AC, or can be an organic light emitting diodes (O-LEDs). While not required, strips of uniformly-spaced LEDs are particularly suitable for use in embodiments of the present invention.
The light from the LEDs 110 is directed toward the reflective inner surface 136 and mixed within the reflective cavity 135 and exits the cavity 135 through lens 150. In one embodiment, the lens 150 is clear and provided with no optical enhancements such that the light exiting the reflective cavity 135 passes directly through the lens 150. In other embodiments, the lens 150 can be refractive with symmetrical, asymmetrical, or non-symmetrical light output, include a diffractive optical element, or otherwise be tailored to produce the desired light output. The lens 150 could be made out of glass, acrylic, polycarbonate, or any other optically clear material. The lens may be contoured as desired for a particular application or straight.
End caps 400 may be positioned on each side of the luminaire 10 to enclose the reflective cavity 135 and impart a polished appearance to the luminaire 10. The end caps 400 may be formed of any suitable material, including but not limited to polymeric and metallic materials. In some embodiments, particularly those in which the displays are not refrigerated displays, it may be desirable to include apertures 600 in the end caps 400 through which heat generated by the LEDs 110 can escape, and/or through which electrical cables for powering the LEDs 110 can pass.
The luminaire can be attached to the display case shelves 800 in a variety of ways. In one embodiment, a ledge 105 is provided on the luminaire 10 (it can be, but does not have to be, formed integrally with the luminaire 10 as shown in
LEDs 210 according to exemplary embodiments described above are mounted on the LED mounting portion 200 with screws or other fastening mechanism as described above. The LEDs 210 are mounted on a surface of the LED mounting portion 200 so as to direct emitted light into the reflective cavity 220. The light from the LEDs 210 is mixed within the reflective cavity 220 and exits the cavity through lens 300. The lens 300 can be clear or be provided with optical enhancements as described above.
As described above, end caps 500 may be positioned on each end of the luminaire 20 to enclose the reflective cavity 220 and impart a polished appearance to the luminaire 20. The end caps 500 may be formed of any suitable material, including but not limited to polymeric and metallic materials.
In some embodiments, it may be desirable to provide fins 230 on the luminaire 10, to facilitate heat dissipation. See
While
As illustrated in more detail in
The luminaires described herein may be retro-fitted into existing refrigerated displays illuminated by fluorescent bulbs or may be installed in new units during assembly. While embodiments of the present invention are discussed for use with refrigerated display cases, such as open, multi-deck display cases, they are by no means so limited but rather may be used to illuminate products stored in any type of display case.
In use, the luminaire 10, 20 is attached to the end or underside of an existing display shelf 800. The luminaire may be secured to a shelf by any suitable retention method, including mechanical or chemical means. In one embodiment, the LED mounting portion 100, 200 of the luminaire 10, 20 acts as a mounting means and is adhered to the shelf 800. However, in other embodiments, mechanical fasteners or means for mechanically interlocking the luminaire 10, 20 with the shelf 800 may be used. In situations where the luminaire 10, 20 is not being retro-fitted into an existing display but rather incorporated into a display during manufacture, the luminaire 10, 20 (and particularly the LED mounting portion 100, 200 of the luminaire) may be formed integrally with the display shelves 800.
In use and once positioned as desired on a display shelf 800, the light emitted from the LEDs 110, 210 is directed into and mixed within the reflective cavity 135, 220. The light exiting the reflective cavity 135, 220 via the lens 150, 300 is uniform and directed towards the products being displayed on the display case (typically below) the luminaire 10, 20. In this way, the luminaire 10, 20 uniformly and indirectly illuminates the products.
In yet other embodiments as illustrated in
In other embodiments, the luminaire may include an adjustable reflector 910 that can be adjusted as desired to change the angle of light reflecting off the adjustable reflector 910 and out of the luminaire. In one embodiment, the luminaire may have multiple pairs of grooves 920, 930 into which ends 940 of the adjustable reflector 910 can be attached to allow the adjustable reflector 910 to be easily repositioned. Other methods for enabling the adjustable reflector 910 to be repositioned will be apparent to a person skilled in the art and are within the scope of this disclosure. The adjustable reflector 910 may be formed of a suitable polymeric or metallic material, and may have an inner surface that is rendered diffusely reflective as described above.
In other embodiments, an LED lens 950 can be attached directly to the LED mounting portion 100, 200 over the LEDs 110, 210. By mounting the LED lens directly on the LED mounting portion 100, 200, the lens 300 previously described herein may be eliminated, allowing the reflective cavity 135, 220 to be open, which provides additional heat dissipation capacity for the luminaire 10, 20.
In further embodiments as illustrated in
As illustrated, first section 960 may include the LED mounting portion 200, one or more LEDs 210, and one or more offsets 740. Second section 970 may include the reflector 215 and one or more voids 700, 710. The lens 300 may be affixed between the first section 960 and second section 970 in any manner. In one embodiment, one edge 310 of the lens 300 can be inserted into a groove 218 provided in the second section 970 and the other edge 302 of the lens can be inserted into a groove 304 provided in the first section 960.
When the luminaire 10, 20 is configured for placement in high-humidity environments, such as on a shelf 800 of a refrigerated display, it may be desirable to provide one or more surfaces of the luminaire 10, 20 with a water shedding edge 990 that will direct condensation away from the LEDs 110, 210 and off the luminaire 10, 20.
The luminaires 10, 20 need not use only white LEDs 110, 210. Rather color or multicolor LEDs 110, 210 may be provided. Nor must all of the LEDs 110, 210 within a luminaire 10, 20 or within an LED array be the same color. With colored discrete or multicolor die LEDs, it is possible to select a variety of colors with which to illuminate the display or to program specific colors for each section of the display. In this way, LEDs 110, 210 of different temperatures may be selected and their emitted light blended within the reflective cavity 135, 220 so that the resulting blended light is tailored to improve product color rendering. Thus, the indirect light emitted from the luminaire 10, 20 may be customized depending on the product being illuminated.
To conserve energy and associated costs, the luminaire 10, 20 need not be illuminated at all times or be illuminated the same at all times. Moreover, not all of the LEDs 110, 210 need be illuminated at the same time, but rather one can selectively illuminate some or all of the LEDs as desired. For example, the LEDs 110, 210 could be programmed to turn off at night.
Ultraviolet LEDs 110, 210 may be used to reduce energy costs during non-peak times. During these times, the ultraviolet LEDs would illuminate fluorescent materials on the products or refrigerated unit labels. Such ultraviolet LEDs may be used to create a glowing affect that would make graphics strikingly visible in the dark.
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Further modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of the invention.
This application is a continuation-in-part of U.S. patent application Ser. No. 12/840,704, filed Jul. 21, 2010, which claims the benefit of U.S. Provisional application Ser. No. 61/271,428, filed Jul. 21, 2009, the entire contents of which are incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61271428 | Jul 2009 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12840704 | Jul 2010 | US |
| Child | 13080203 | US |
