1. Field of the Invention
The invention relates to troffer-style lighting fixtures and, more particularly, to troffer-style fixtures that are well-suited for use with solid state lighting sources, such as light emitting diodes (LEDs).
2. Description of the Related Art
Troffer fixtures are ubiquitous in commercial office and industrial spaces throughout the world. In many instances these troffers house elongated fluorescent light bulbs that span the length of the troffer. Troffers may be mounted to or suspended from ceilings or walls. Often the troffer may be recessed into the ceiling, with the back side of the troffer protruding into the plenum area above the ceiling. Typically, elements of the troffer on the back side dissipate heat generated by the light source into the plenum where air can be circulated to facilitate the cooling mechanism. U.S. Pat. No. 5,823,663 to Bell, et al. and U.S. Pat. No. 6,210,025 to Schmidt, et al. are examples of typical troffer-style fixtures.
More recently, with the advent of the efficient solid state lighting sources, these troffers have been used with LEDs, for example. LEDs are solid state devices that convert electric energy to light and generally comprise one or more active regions of semiconductor material interposed between oppositely doped semiconductor layers. When a bias is applied across the doped layers, holes and electrons are injected into the active region where they recombine to generate light. Light is produced in the active region and emitted from surfaces of the LED.
LEDs have certain characteristics that make them desirable for many lighting applications that were previously the realm of incandescent or fluorescent lights. Incandescent lights are very energy-inefficient light sources with approximately ninety percent of the electricity they consume being released as heat rather than light. Fluorescent light bulbs are more energy efficient than incandescent light bulbs by a factor of about 10, but are still relatively inefficient. LEDs by contrast, can emit the same luminous flux as incandescent and fluorescent lights using a fraction of the energy.
In addition, LEDs can have a significantly longer operational lifetime. Incandescent light bulbs have relatively short lifetimes, with some having a lifetime in the range of about 750-1000 hours. Fluorescent bulbs can also have lifetimes longer than incandescent bulbs such as in the range of approximately 10,000-20,000 hours, but provide less desirable color reproduction. In comparison, LEDs can have lifetimes between 50,000 and 70,000 hours. The increased efficiency and extended lifetime of LEDs is attractive to many lighting suppliers and has resulted in their LED lights being used in place of conventional lighting in many different applications. It is predicted that further improvements will result in their general acceptance in more and more lighting applications. An increase in the adoption of LEDs in place of incandescent or fluorescent lighting would result in increased lighting efficiency and significant energy saving.
Other LED components or lamps have been developed that comprise an array of multiple LED packages mounted to a (PCB), substrate or submount. The array of LED packages can comprise groups of LED packages emitting different colors, and specular reflector systems to reflect light emitted by the LED chips. Some of these LED components are arranged to produce a white light combination of the light emitted by the different LED chips.
In order to generate a desired output color, it is sometimes necessary to mix colors of light which are more easily produced using common semiconductor systems. Of particular interest is the generation of white light for use in everyday lighting applications. Conventional LEDs cannot generate white light from their active layers; it must be produced from a combination of other colors. For example, blue emitting LEDs have been used to generate white light by surrounding the blue LED with a yellow phosphor, polymer or dye, with a typical phosphor being cerium-doped yttrium aluminum garnet (Ce:YAG). The surrounding phosphor material “downconverts” some of the blue light, changing it to yellow light. Some of the blue light passes through the phosphor without being changed while a substantial portion of the light is downconverted to yellow. The LED emits both blue and yellow light, which combine to yield white light.
In another known approach, light from a violet or ultraviolet emitting LED has been converted to white light by surrounding the LED with multicolor phosphors or dyes. Indeed, many other color combinations have been used to generate white light.
Some recent designs have incorporated an indirect lighting scheme in which the LEDs or other sources are arranged in a direction other than the intended emission direction. This may be done to encourage the light to interact with internal elements, such as diffusers, for example. One example of an indirect fixture can be found in U.S. Pat. No. 7,722,220 to Van de Ven which is commonly assigned with the present application.
Modern lighting applications often demand high power LEDs for increased brightness. High power LEDs can draw large currents, generating significant amounts of heat that must be managed. Many systems utilize heat sinks which must be in good thermal contact with the heat-generating light sources. Troffer-style fixtures generally dissipate heat from the back side of the fixture that which often extends into the plenum. This can present challenges as plenum space decreases in modern structures. Furthermore, the temperature in the plenum area is often several degrees warmer than the room environment below the ceiling, making it more difficult for the heat to escape into the plenum ambient.
An embodiment of a light fixture comprises the following elements. At least one light source emits light that is incident on a back reflector. A first exit lens is arranged to receive at least some light redirected from the back reflector at least a portion of said back reflector. The light fixture provides an asymmetric light distribution.
An embodiment of a light fixture comprises the following elements. A back reflector is at least partially surrounded by a housing. A heat sink comprises a mount surface. A plurality of light sources are on the mount surface, the light sources arranged to emit light such that at least a portion of light from the light sources is initially incident on the back reflector. The back reflector is asymmetric relative to the primary emission direction.
An embodiment of a light fixture comprises the following elements. A back reflector is at least partially surrounded by a housing. A mount surface is proximate to the back reflector. An exit lens extending between the back reflector and the mount surface. At least one light source is on the mount surface and arranged to emit light such that a first portion of the light initially impinges on the back reflector and a second portion of the light initially impinges on the exit window.
An embodiment of an elongated light fixture comprises the following elements. The fixture includes a lighting subassembly and an electronics assembly. The lighting assembly comprises: a lens plate; an asymmetric back reflector; a heat sink comprising a mount surface; at least one light source on the mount surface and arranged to emit toward the back reflector, the back reflector arranged to redirect at least a portion of impinging light toward the lens plate; and end caps on both ends of the lens plate, the back reflector, and the heat sink, the end caps holding the lens plate, the back reflector, and the heat sink in position relative to one another. The electronics subassembly comprises the following elements: an elongated housing at least partially defines an internal cavity. Driver electronics are mounted to the housing within the cavity. The lighting subassembly attaches to the electronics subassembly such that the back reflector and the at least one light source are disposed within the internal cavity.
Embodiments of the present invention provide an indirect troffer-style fixture that is particularly well-suited for use with solid state light sources, such as LEDs. The fixture comprises an elongated back reflector that runs along the longitudinal direction of the fixture. At least one light source is arranged to emit toward the back reflector. In some embodiments multiple light sources are mounted to a mount surface on a heat sink structure arranged so that at least a portion of the light emitted from the source(s) is initially incident on the back reflector which redirects at least a portion of the light toward an exit lens. The exit lens interacts with the light as it is emitted from the fixture. Both the shape of the individual fixture elements (e.g., the back reflector and the exit lens) and the arrangement of these elements provide an asymmetrical light output distribution. Structural elements, such as a housing and end caps, may be used to hold the fixture elements in position relative to each other. Various mount mechanisms may be used to attach the fixture to a surface such as a ceiling or a wall.
With reference to
With reference to
In this particular embodiment, the back reflector 124 has a curved shape approximated by a spline curve. The shape has an asymmetric transverse cross-section. The back reflector 124 extends farther in the transverse direction on one side of the light source 122 than on the other side. The light source 122 is disposed off-center relative to a central longitudinal axis running through the center of the housing 102. Additionally, the light source 122 is arranged to emit in a primary direction at an angle that is off-center with respect to the back reflector 124. The positioning of the light source 122 and the asymmetric shape and placement of the back reflector 124 result in an asymmetric light distribution. Such an output is useful for lighting areas where more light is required in a given direction, such as stairwell, for example. In a stairwell it is important to light stairs that descend and/or ascend from a given level; thus, an asymmetric output distribution may be used to direct more of the light into these specific areas, reducing the total amount of light that is necessary to light such as an area.
The back reflector 124 can be constructed from many different materials. In one embodiment, the back reflector 124 comprises a material which allows it to be extruded for efficient, cost-effective production. Some acceptable materials include polycarbonates, such as Makrolon 6265X or FR6901 (commercially available from Bayer) or BFL4000 or BFL2000 (commercially available from Sabic). Many other materials may also be used to construct the back reflector 124. Using an extrusion process for fabrication, the back reflector 124 is easily scalable to accommodate lighting assemblies of varying length.
The back reflector 124 is an example of one shape that may be used in the fixture 100. The back reflector 124 may be designed to have several different shapes to perform particular optical functions, such as color mixing and beam shaping, for example. The back reflector 124 may be rigid, or it may be flexible in which case it may be held to a particular shape by compression against other surfaces. Emitted light may be bounced off of one or more surfaces. This has the effect of disassociating the emitted light from its initial emission angle. Output color uniformity typically improves with an increasing number of bounces, but each bounce has an associated optical loss. In some embodiments an intermediate diffusion mechanism (e.g., formed diffusers and textured lenses) may be used to mix the various colors of light.
The back reflector 124 should be highly reflective in the wavelength ranges emitted by the source(s) 122. In some embodiments, the reflector may be 93% reflective or higher. In other embodiments it may be at least 95% reflective or at least 97% reflective.
The back reflector 124 may comprise many different materials. For many indoor lighting applications, it is desirable to present a uniform, soft light source without unpleasant glare, color striping, or hot spots. Thus, the back reflector 124 may comprise a diffuse white reflector such as a microcellular polyethylene terephthalate (MCPET) material or a Dupont/WhiteOptics material, for example. Other white diffuse reflective materials can also be used.
Diffuse reflective coatings may be used on a surface of the back reflector to mix light from solid state light sources having different spectra (i.e., different colors). These coatings are particularly well-suited for multi-source designs where two different spectra are mixed to produce a desired output color point. For example, LEDs emitting blue light may be used in combination with other sources of light, e.g., yellow light to yield a white light output. A diffuse reflective coating may eliminate the need for additional spatial color-mixing schemes that can introduce lossy elements into the system; although, in some embodiments it may be desirable to use a diffuse surface in combination with other diffusive elements. In some embodiments, the surface may be coated with a phosphor material that converts the wavelength of at least some of the light from the light emitting diodes to achieve a light output of the desired color point.
By using a diffuse white reflective material for the back reflector 124 and by positioning the light sources to emit light first toward the back reflector 124 several design goals are achieved. For example, the back reflector 124 performs a color-mixing function, effectively doubling the mixing distance and greatly increasing the surface area of the source. Additionally, the surface luminance is modified from bright, uncomfortable point sources to a much larger, softer diffuse reflection. A diffuse white material also provides a uniform luminous appearance in the output. Harsh surface luminance gradients (max/min ratios of 10:1 or greater) that would typically require significant effort and heavy diffusers to ameliorate in a traditional direct view optic can be managed with much less aggressive (and lower light loss) diffusers achieving max/min ratios of 5:1, 3:1, or even 2:1.
The back reflector 124 can comprise materials other than diffuse reflectors. In other embodiments, the back reflector 124 can comprise a specular reflective material or a material that is partially diffuse reflective and partially specular reflective. In some embodiments, it may be desirable to use a specular material in one area and a diffuse material in another area. For example, a semi-specular material may be used on the center region with a diffuse material used in the side regions to give a more directional reflection to the sides. Many combinations are possible.
In this embodiment, the heat sink 118 is mounted to an internal surface of the housing 102 that is bent back toward the back reflector 124. The heat sink 500 can be constructed using many different thermally conductive materials. For example, the heat sink 500 may comprise an aluminum body. Similarly as the back reflector 124, the heat sink 500 can be extruded for efficient, cost-effective production and convenient scalability. In other embodiments, the heat sink 118 can be integrated with a printed circuit board (PCB), for example. Indeed the PCB itself may function as the heat sink, so long as the PCB is capable of handling thermal transmission of the heat load. Many other heat sink structures are possible.
The heat sink 118 can be mounted to the housing 102 using various methods such as, screws, pins, or adhesive, for example. In this particular embodiment, the heat sink 118 comprises an elongated thin rectangular body with a substantially flat area on which one or more light sources can be mounted. The flat area provides for good thermal communication between the heat sink 118 and the light sources 122 mounted thereon. In some embodiments, the light sources will be pre-mounted on light strips.
Many industrial, commercial, and residential applications call for white light sources. The light fixture 100 may comprise one or more emitters producing the same color of light or different colors of light. In one embodiment, a multicolor source is used to produce white light. Several colored light combinations will yield white light. For example, it is known in the art to combine light from a blue LED with wavelength-converted yellow (blue-shifted-yellow or “BSY”) light to yield white light with correlated color temperature (CCT) in the range between 5000K to 7000K (often designated as “cool white”). Both blue and BSY light can be generated with a blue emitter by surrounding the emitter with phosphors that are optically responsive to the blue light. When excited, the phosphors emit yellow light which then combines with the blue light to make white. In this scheme, because the blue light is emitted in a narrow spectral range it is called saturated light. The BSY light is emitted in a much broader spectral range and, thus, is called unsaturated light.
Another example of generating white light with a multicolor source is combining the light from green and red LEDs. RGB schemes may also be used to generate various colors of light. In some applications, an amber emitter is added for an RGBA combination. The previous combinations are exemplary; it is understood that many different color combinations may be used in embodiments of the present invention. Several of these possible color combinations are discussed in detail in U.S. Pat. No. 7,213,940 to Van de Ven et al.
The lighting strips 400, 420, 440 each represent possible LED combinations that result in an output spectrum that can be mixed to generate white light. Each lighting strip can include the electronics and interconnections necessary to power the LEDs. In some embodiments the lighting strip comprises a printed circuit board with the LEDs mounted and interconnected thereon. The lighting strip 400 includes clusters 402 of discrete LEDs, with each LED within the cluster 402 spaced a distance from the next LED, and each cluster 402 spaced a distance from the next cluster 402. If the LEDs within a cluster are spaced at too great distance from one another, the colors of the individual sources may become visible, causing unwanted color-striping. The clusters on the light strips can be compact. In some embodiments, an acceptable range of distances for separating consecutive LEDs within a cluster is not more than approximately 8 mm.
The scheme shown in
The lighting strip 420 includes clusters 422 of discrete LEDs. The scheme shown in
The lighting strip 440 includes clusters 442 of discrete LEDs. The scheme shown in
The lighting schemes shown in
In this embodiment, very little, if any, of the light emitted from the sources 122 is directly incident on the exit lens 104. Instead, most of the light is first redirected off of the back reflector 124. This first bounce off the back reflector 124 mixes the light and reduces imaging of any of the discrete light sources 122. However, additional mixing or other kinds of optical treatment may still be necessary to achieve the desired output profile. Thus, the exit lens 104 may be designed to perform these functions as the light passes through it. This particular embodiment of the fixture 100 comprises the exit lens 104 which faces at least a portion of the back reflector 124 and extends across an opening in the housing 102 from a point adjacent to the edge of the heat sink 118 to a point where the back reflector attaches to the housing 102. The exit lens 104 can comprise many different elements and materials.
In one embodiment, the exit lens 104 comprises a diffusive element. A diffusive exit lens functions in several ways. For example, it can prevent direct visibility of the sources and provide additional mixing of the outgoing light to achieve a visually pleasing uniform source. However, a diffusive exit lens can introduce additional optical loss into the system. Thus, in embodiments where the light is sufficiently mixed by the back reflector 124 or by other elements, a diffusive exit lens may be unnecessary. In such embodiments, a transparent glass exit lens may be used, or the exit lens may be removed entirely. In still other embodiments, scattering particles may be included in the exit lens 104. Some embodiments may include a specular or partially specular back reflector. In such embodiments, it may be desirable to use a diffuse exit lens.
Diffusive elements in the exit lens 104 can be achieved with several different structures. A diffusive film inlay can be applied to the top- or bottom-side surface of the exit lens 104. It is also possible to manufacture the exit lens 104 to include an integral diffusive layer, such as by coextruding the two materials or by insert molding the diffuser onto the exterior or interior surface. A clear lens may include a diffractive or repeated geometric pattern rolled into an extrusion or molded into the surface at the time of manufacture. In another embodiment, the exit lens material itself may comprise a volumetric diffuser, such as an added colorant or particles having a different index of refraction, for example.
In other embodiments, the exit lens 104 may be used to optically shape the outgoing beam with the use of microlens structures, for example. Microlens structures are discussed in detail in U.S. patent application Ser. No. 13/442,311 to Lu, et al., which is commonly assigned with the present application to CREE, INC. and incorporated by reference herein.
Many different kinds of beam shaping optical features can be included integrally with the exit lens 104. Some exemplary lens textures for use in fixture embodiments of the present invention are shown in
For example, in one embodiment one longitudinal half of the exit lens 104 may comprise a textured lens to direct outgoing light in an upward direction while the other longitudinal half comprises a textured lens that directs light in a downward direction. Such an embodiment would be useful in a stairwell, for example, to light ascending and descending stairs with a single fixture.
Again with reference to
The sensor 108 may be adjusted between variable positions. In this embodiment, the sensor body 302 may be rotated about a post 304 across a range of angles (approximately 15 degrees) and locked into one of two selectable positions. Thus, the sensor can be arranged to an area where a person is most likely to be to improve the accuracy of the sensor 108. A pin 306 on the sensor body 302 snap-fits into one of two catch holes 308 on a sensor mount bracket 310 to hold the sensor body 302 into the selected position, although many other adjustment mechanisms may be used. The sensor 108 position is typically set during installation and is adjustable from inside the housing 102 to prevent tampering from the outside.
The lighting subassembly 920 comprises the back reflector 124, the heat sink 118, and the exit lens 104. The end caps 106 hold these elements in place relative to one another.
The electronics subassembly 900 is attached to the lighting subassembly 920 either before or during installation of the fixture 100. In one embodiment, the subassemblies 900, 920 are attached with hinges such that the lighting assembly may be rotatably lifted to expose the internal components as discussed in more detail herein. In another embodiment the two subassemblies 900, 920 may be securely attached such that the parts do not come apart without disassembly.
In this embodiment, exit lenses 1206, 1208 extend from both sides of the heat sink 1204 to the bottom edge of the housing 1202. The back reflector 1212, heat sink 1204, and exit lenses 1206, 1208 at least partially define an interior cavity. In some embodiments, the light sources (not shown) may be mounted to a mount, such as a metal core board, FR4 board, printed circuit board, or a metal strip, such as aluminum, which can then be mounted to a separate heat sink, for example using thermal paste, adhesive and/or screws.
In this embodiment, the heat sink 1204 comprises fin structures on the bottom side (i.e., the room side). Although it is understood that many different heat sink structures may be used. The top side portion of the heat sink 1204 which is in the interior cavity comprises the mount surface 1210. The mount surface 1210 provides a substantially flat area on which light sources such as LEDs, for example, can be mounted. The sources can be mounted to emit in a primary direction orthogonal to the mount surface 1210, to emit in a primary direction toward the center region of the back reflector 1212, or they may be angled to emit in a primary direction toward other portions of the back reflector 1212.
The exposed heat sink 1204 is advantageous for several reasons. For example, air temperature in a typical residential/commercial room is much cooler than the air in the interior cavity, because the room environment must be comfortable for occupants. Additionally, room air is normally circulated, either by occupants moving through the room or by air conditioning. The movement of air throughout the room helps to break the boundary layer, facilitating thermal dissipation from the heat sink 1204.
The exit lenses 1206, 1208 can have the same or different optical properties to produce a desired distribution or effect. For example, the one of the exit lenses 1206, 1208 may be prismatic, diffusive, or one of both. Both exit lenses 1206, 1208 may be prismatic and tilted in the same or different directions. One lens may be more diffusive than the other. The lenses 1206, 1208 may be made of the same or different materials and may have the same or different thicknesses. Many different combinations of optical properties are possible to achieve a desired output.
There are many different housing subassembly and lighting subassembly combinations that can be used to provide various light output distributions. Several such configurations are discussed in U.S. patent application Ser. No. 13/830,698 titled “LINEAR LIGHT FIXTURE WITH INTERCHANGEABLE LIGHT ENGINE UNIT” to Dungan et al., filed on [DATE], which is commonly owned with the present application by Cree, Inc. and incorporated by reference herein.
Fixtures according to embodiments disclosed herein provide an asymmetric light distribution. The back reflector, the exit lens, and the light sources can be arranged in many different configurations to achieve a desired asymmetric output.
The optical assemblies shown in
It is understood that embodiments presented herein are meant to be exemplary. Embodiments of the present invention can comprise any combination of compatible features shown in the various figures, and these embodiments should not be limited to those expressly illustrated and discussed. Many other versions of the configurations disclosed herein are possible. Thus, the spirit and scope of the invention should not be limited to the versions described above.
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