CN117178140A - Systems and methods for providing illumination using modular heat sink structures and lenses - Google Patents

Abstract

A luminaire (50), comprising: an electronic device housing (51); first and second heat sink structures (52, 54, 56, 58, 60, 62) coupled to the electronic device housing, wherein each of the first and second heat sink structures is at least partially defined by a heat sink outer arc (64) having first and second end points (72, 74), and wherein each heat sink structure is further at least partially defined by two heat sink radii (66, 68) extending from the first and second end points, respectively, to a center point (P) of the luminaire; a first light source and a second light source (53); at least two lenses (106, 108, 110, 112, 114, 116) comprising a first lens attached to the first heat sink structure and covering the first light source and a second lens attached to the second heat sink structure and covering the second light source, wherein each of the first and second lenses is at least partially defined by a lens outer arc (120) having a first end point and a second end point (128, 130), wherein each lens is further at least partially defined by two lens radii (122, 124) extending from the first and second end points, respectively, to a point (P1) different from a center point of the luminaire, and wherein each lens is further at least partially defined by an inner arc (126) extending between the two lens radii (122, 124); and a ventilation channel (76, 78, 80, 82, 84, 86) arranged between the first and second radiator structures.

Description

Systems and methods for providing illumination using modular heat sink structures and lenses

Technical Field

The present disclosure relates generally to systems and methods for providing high output illumination using modular thermal management structures and lenses.

Background

Some overhead lights (highbay light fixture) include modular heat sink structures that create gaps between the optical lenses. The gaps or channels create the necessary ventilation paths that allow heat generated by the light source to flow upward away from the heat sink structure. The optical lenses within these fixtures are typically arranged concentrically with respect to the center of the fixture to provide 360 degree coverage. Such high-top fixtures, which include an array of arcuate Light Emitting Diodes (LEDs), each having an optical lens, are configured to provide uniform task plane illumination. Unfortunately, the gaps created by the modular heat sink structure of high-top fixtures can separate colors and cast shadows on task plane lighting. This is especially true when the luminaire comprises one or more arc-shaped LED arrays and at least one annular optical lens shared by at least two LEDs.

There is a need in the art for improved systems and methods for providing uniform illumination for high output lighting fixtures featuring modular heat sink structures and lenses.

Disclosure of Invention

The present disclosure relates generally to lenses or optical elements for high-output lighting fixtures and high-output lighting fixtures including improved lenses or optical elements. An exemplary high-output luminaire includes a modular heat sink structure separated by a ventilation channel. In general, embodiments of the present disclosure relate to improved lenses or optical elements for such high output light fixtures, wherein the improved lenses or optical elements are non-concentrically arranged within the light fixture. Applicant has recognized and appreciated that high-top luminaires that include modular heat sink structures with ventilation channels can separate colors and create shadows on task plane lighting. Advantageously, the systems and methods described herein produce task plane illumination without color separation or shading, without reducing the number of LEDs and without increasing cost.

Generally, in one aspect, a luminaire is provided. The luminaire includes an electronic device housing and first and second heat sink structures coupled to the electronic device housing, wherein each of the first and second heat sink structures is defined at least in part by a heat sink outer arc having first and second endpoints, and wherein each of the heat sink structures is defined at least in part by two heat sink radii extending from the first and second endpoints, respectively, to a center point of the luminaire. The luminaire further comprises a first light source and a second light source and at least two lenses having a first lens attached to the first heat sink structure and covering the first light source and a second lens attached to the second heat sink structure and covering the second light source. Each of the first and second lenses is defined at least in part by a lens outer arc having first and second endpoints and two lens radii extending from the first and second endpoints, respectively, to a point different from a center point of the luminaire. The luminaire further comprises a ventilation channel arranged between the first and second heat sink structures.

In an embodiment, each of the at least two lenses is further defined at least in part by an inner arc extending between the two lens radii.

In an embodiment, the point different from the center point of the luminaire is arranged along an imaginary line connecting the center point of the luminaire to the midpoint of the inner arc.

In an embodiment, the first lens is not concentric with the first heat sink structure.

In an embodiment, the second lens is not concentric with the second heat sink structure.

In an embodiment, the first lens or the second lens is not concentric with the luminaire.

In an embodiment, the first lens is attached to a first base of the first heat sink structure on a first surface facing away from the electronic device housing, and the second lens is attached to a second base of the second heat sink structure on a second surface facing away from the electronic device housing.

In an embodiment, the point is radially outside the center point of the luminaire.

In general, in another aspect, a method for manufacturing a luminaire is provided. The method includes providing an electronic device housing and coupling a first heat sink structure and a second heat sink structure to the electronic device housing, wherein each of the first heat sink structure and the second heat sink structure is defined at least in part by a heat sink outer arc having a first end point and a second end point, wherein each heat sink structure is further defined at least in part by two heat sink radii extending from the first end point and the second end point, respectively, to a center point of the luminaire. The method further includes providing a first light source and a second light source, attaching a first lens to the first heat sink structure and covering the first light source, and attaching a second lens to the second heat sink structure and covering the second light source. Each of the first and second lenses is defined at least in part by a lens outer arc having a first end point and a second end point, and wherein each lens is further defined at least in part by two lens radii extending from the first end point and the second end point, respectively, to points different from a center point of the luminaire. The method further includes providing a ventilation channel between the first and second heat sink structures.

In an embodiment, the first lens or the second lens is further defined at least in part by an inner arc extending between the two lens radii.

In an embodiment, the point different from the center point of the luminaire is arranged along an imaginary line connecting the center point of the luminaire to the midpoint of the inner arc.

In an embodiment, the first lens is not concentric with the first heat sink structure and the second lens is not concentric with the second heat sink structure.

In an embodiment, the first lens or the second lens is not concentric with the luminaire.

In an embodiment, the first lens is attached to a first base of the first heat sink structure on a first surface facing away from the electronic device housing, and the second lens is attached to a second base of the second heat sink structure on a second surface facing away from the electronic device housing.

In an embodiment, the point different from the center point of the luminaire is radially outside the center point of the luminaire.

It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in more detail below (where such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein.

Drawings

In the drawings, like reference numerals generally refer to the same parts throughout the different views. Moreover, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the disclosure.

FIG. 1 illustrates an example bottom view of a high output luminaire including at least two modular heat sink structures and at least two optical lenses, one optical lens for each modular heat sink structure, in accordance with aspects of the present disclosure;

FIG. 2 illustrates an example bottom view of a modular heat sink structure of the high-output luminaire of FIG. 1, in accordance with aspects of the present disclosure;

FIG. 3 illustrates an example light source for one of the modular heat sink structures of FIG. 2 in accordance with aspects of the present disclosure;

FIG. 4 illustrates an example top view of a lens for the example light source of FIG. 3, in accordance with aspects of the present disclosure;

FIG. 5 is an example bottom view of the high-output luminaire of FIG. 1, according to aspects of the present disclosure;

FIG. 6 is an example bottom perspective view of a high output light fixture according to aspects of the present disclosure;

FIG. 7 illustrates an example cross-sectional view of a high-output luminaire taken generally along line 7-7 in FIG. 6, in accordance with aspects of the present disclosure;

FIG. 8A shows an example bottom perspective view of the lens of FIG. 4;

FIG. 8B illustrates an example cross-sectional view of the lens of FIG. 8A taken generally along the frame 8B in FIG. 8A; and

fig. 9 illustrates an example process for manufacturing a high output luminaire with a modular heat sink structure and lens in accordance with aspects of the present disclosure.

Detailed Description

The present disclosure describes various embodiments of improved systems and methods for providing high-output luminaires with modular heat sink structures for task plane illumination. While some high-output luminaires with modular heatsink structures include an array of LEDs and an optical lens for each LED, these luminaires provide shadow-free task plane illumination, regardless of whether they are configured to generate a narrow beam or a wide beam. Applicants have recognized and appreciated that a high-output luminaire having a modular heat sink structure, an array of LEDs, and concentric annular lenses shared by multiple LEDs can generate task plane illumination with shadows cast by gaps between the lenses. Applicants have also recognized and appreciated that it would be beneficial to modify the annular lens structure relative to other components of the luminaire to generate task plane illumination without shadows.

The term "luminaire" as used herein refers to one or more lighting units implemented or arranged in a particular form factor, component or package. A lighting unit refers to a device comprising one or more light sources of the same or different types, and other components (e.g. thermal management structures, light directing structures, etc.), if applicable. A given luminaire may have any of a variety of mounting arrangements for the light source(s), housing/case arrangements and shapes, and/or electrical and mechanical connection configurations. Additionally, a given luminaire may optionally be associated with (e.g., include, be coupled to, and/or be packaged with) various other components (e.g., control circuitry) related to the operation of the light source(s).

Referring to fig. 1, an example bottom view of a high-output luminaire 50 is shown. High output fixtures (i.e., high top fixtures) generally refer to those fixtures that hang at heights above twelve feet and those fixtures that produce at least about 10000 lumens of light. Although not visible in fig. 1, the high-output luminaire 50 includes an electronics housing containing electrical components such as LED drivers, power supply units, communication modules, and the like. The electronic device housing 51 is shown in fig. 6 and 7. As described herein, the high-output luminaire 50 includes at least two modular heat sink structures and at least two optical lenses, one optical lens for each modular heat sink structure. Each of the at least two modular heat sink structures may be fixedly secured to the electronic device housing. Each of the at least two optical lenses is secured to the modular heat sink structure. In the exemplary high-output luminaire 50 shown in fig. 1, six heat sink structures 52, 54, 56, 58, 60, and 62 are depicted. Although six heat sink structures are shown, it should be appreciated that the exemplary high-output luminaire may also include four heat sink structures, three heat sink structures, or even two heat sink structures. An exemplary high-output luminaire may also include more than six heat sink structures. Any suitable number of modular heat sink structures are contemplated.

Also depicted in fig. 2 are heat sink structures 52, 54, 56, 58, 60, and 62. The base of each modular radiator structure is defined by a radiator outer arc, a radiator radius, and a radiator inner arc or segment. Thus, the base of the radiator structure 52 is defined by a radiator outer arc 64, a first radiator radius 66, a second radiator radius 68, and an inner arc or segment 70. The heat sink outer arc 64 includes end points 72 and 74 and an arc length L1 between the end points 72 and 74. The first heat sink radius 66 extends from an end point 72 toward the center point P of the luminaire 50. The second heat sink radius 68 extends from the end point 74 toward the center point P of the luminaire 50. The base of each heat sink structure includes an outer arc to match the shape of the entire luminaire 50. Thus, it should be appreciated that the base of each heat sink structure may be modified to form any suitable perimeter to match any suitable shape of the entire luminaire. In an embodiment, the heat sink structures 52, 54, 56, 58, 60, and 62 are made of aluminum sheet metal using a method such as stamping. However, any suitable alternative materials and methods are contemplated.

As shown in fig. 1, 5, 6 and 7, each heat sink structure includes a surface on which the light source and the lens are mounted. The surface supporting the light source and the lens is facing away from the electronic device housing. Each heat sink structure also includes an upwardly facing surface opposite the surface supporting the light source and the lens. The base of each heat sink structure may further include one or more sidewalls extending upwardly from an edge of the base toward the electronic device housing. In fig. 1, such sidewalls would extend into the page; thus, they are not visible. Such side walls are visible in fig. 6 and 7. In an embodiment, the side wall or a portion of the side wall extends upwardly from the inner arc or section 70 to be secured to the electronics housing. In the embodiment depicted in fig. 6 and 7, the side walls of the heat sink structure 52 that contact the electronic device housing 51 are higher than the other side walls that extend upward from the base of the heat sink structure 52. As shown in fig. 7, the base of each modular heat sink structure is spaced apart from the electronics housing 51. The distance between the base of each of the at least two modular heat sink structures and the electronics housing 51 is dependent on the height of the one or more connection sidewalls and the angle at which the one or more connection sidewalls are disposed between the base and the electronics housing 51. This distance allows air to pass between the heat sink structure and the electronic device housing to reduce the temperature of the heat sink structure when in use. In the embodiment, the electronic device case 51 is made of aluminum using a method such as die casting. However, any suitable alternative material(s) and method(s) are contemplated.

Channels 76 and 78 are disposed along first and second radiator radii 66 and 68, respectively, such that modular radiator structure 52 is not in direct circumferential contact with modular radiator structure 54 or modular radiator structure 62 about center point P. Channels 76 and 78 provide a path for air to flow upwardly between one or more sidewalls of adjacent modular radiator structures. In the illustrated embodiment of luminaire 50 having six modular heat sink structures, additional channels 80 are provided between modular heat sink structures 54 and 56, additional channels 82 are provided between modular heat sink structures 56 and 58, additional channels 84 are provided between modular heat sink structures 58 and 60, and additional channels 86 are provided between modular heat sink structures 60 and 62. The outer arcs of modular heat sink structures 52, 54, 56, 58, 60, and 62, along with channels 76, 78, 80, 82, 84, and 86, form the entire circumference of light fixture 50. As shown in fig. 1, the distance from the midpoint of the channel 76 along the outer arc 64 to the midpoint of the channel 78 forms one sixth or 60 degrees of the circumference of the luminaire 50. Each of the other modular heat sink structures, when combined with their channels, form other five-sixths or 300 degrees of the circumference of the luminaire 50.

In embodiments having only two modular radiator structures, a first modular radiator structure may be defined by a first radiator radius 66, a second radiator radius 88, an outer arc connecting outermost ends of the first radiator radius 66 and the second radiator radius 88, and an inner arc or segment extending between innermost ends of the first radiator radius 66 and the second radiator radius 88. The heat sink radius 88 is shown in fig. 2. Channels 78 and 80 may be omitted to form a first modular heat sink structure. In other words, the heat sink structures 52, 54, and 56 may be combined to form a first modular heat sink structure. The outer arc of the first modular heat sink structure, along with half of the channels 76 and 82, may form half a circumference of a luminaire comprising only two modular heat sink structures. The second modular heat sink structure of the embodiment having only two modular heat sink structures may have the same structure as the first modular heat sink structure to form a second half of the luminaire with the other half of channels 76 and 82. The second modular heat sink structure will be a mirror image of the first modular heat sink structure. In an embodiment, the luminaire 50 includes a cap 92 and channel covers 94, 96, 98, 100, 102, and 104. In embodiments, the cap 92 and the channel covers 94, 96, 98, 100, 102, and 104 may be made of any suitable plastic or combination of plastics and may be snapped onto the heat sink structures 52, 54, 56, 58, 60, and 62, for example.

The high-output luminaire 50 further comprises at least two light sources attached to the modular heat sink structure. In the embodiment shown in fig. 1 that includes six heat sink structures, at least one light source is provided for modular heat sink structure 52, at least one light source is provided for modular heat sink structure 54, at least one light source is provided for modular heat sink structure 56, at least one light source is provided for modular heat sink structure 58, at least one light source is provided for modular heat sink structure 60, and at least one light source is provided for modular heat sink structure 62. Each light source 53 (shown in fig. 3) may be attached to a respective heat sink structure using a thermal tape or any suitable alternative. As shown in fig. 3, each light source 53 may include a Light Emitting Diode (LED) disposed on a Printed Circuit Board (PCB) 55. The LEDs are configured to be driven by one or more light source drivers to emit light of specific characteristics (i.e. color intensity and color temperature). The LED may be active (i.e., on); inactive (i.e., off); or dimming by a factor d, wherein 0.ltoreq.d.ltoreq.1. The value d=0 means that the LED is off, while d=1 means that the LED is at its maximum illuminance. The LEDs may be embodied as an arc-shaped LED array. For example, the light sources 53 in fig. 3 are arranged along five arcs A1, A2, A3, A4, and A5. However, it should be appreciated that any suitable arrangement is contemplated. In an embodiment comprising four heat sink structures, at least one light source is provided for each of the four heat sink structures. In embodiments comprising only two heat sink structures, a first light source is provided for a first heat sink structure and a second light source is provided for a second heat sink structure. The light source 53 shown in fig. 3 comprising an arc-shaped LED array and a PCB 55 may be attached to the heat sink structure 52.

The high output light fixture 50 also includes at least two lenses attached to the modular heat sink structure and covering the light source. The lens is configured to collimate the light from the LED into a particular controlled beam that will provide a desired light intensity for the area to be covered. In the embodiment shown in fig. 1 and 5 that includes six heat sink structures, at least one lens 106 is provided for modular heat sink structure 52, at least one lens 108 is provided for modular heat sink structure 54, at least one lens 110 is provided for modular heat sink structure 56, at least one lens 112 is provided for modular heat sink structure 58, at least one lens 114 is provided for modular heat sink structure 60, and at least one lens 116 is provided for modular heat sink structure 62. Each of the lenses 106, 108, 110, 112, 114, and 116 may be attached to a respective heat sink structure using fasteners or any suitable alternative. Fig. 4 shows a lens 106, which lens 106 may be attached to the light source 53 and the modular heat sink structure 52 on top of the PCB 55. In an embodiment, the lens 106 is attached to a surface of the base of the modular heat sink structure 52 facing away from the electronic device housing 51. The four openings 107A, 107B, 107C, and 107D in the lens 106 may be configured to receive fasteners that may extend through the openings 109A, 109B, 109C, and 109D in the PCB 55 (in fig. 3). The same fasteners may extend through openings 111A, 111B, 111C, and 111D in the heat sink structure 52. Although the figures illustrate four openings in the lens 106, PCB 55, and heat sink structure 52, it should be appreciated that any number of openings may be included to accommodate any number of fasteners. With the light source 52 positioned between the lens 106 and the heat sink structure 52, attaching the lens 106 to the heat sink structure 52 using fasteners also maintains the light source 53 in contact with the heat sink structure 52. The same applies to the light sources and lenses attached to the heat sink structures 54, 56, 68, 60 and 62. In an embodiment comprising four heat sink structures, at least one lens is provided for each of the four heat sink structures. In embodiments comprising only two heat sink structures, a first lens is provided for a first heat sink structure and a second lens is provided for a second heat sink structure. In an embodiment, each lens is a unitary element made of molded transparent plastic material. In embodiments, each lens is formed of optical grade silicone and may be flexible or elastic. In other embodiments, each lens is formed from an optical grade plastic such as polymethyl methacrylate ("PMMA"), polycarbonate, or any suitable acrylic, or any other suitable material or combination of materials. In an embodiment, each lens includes a prism element to direct light from the LED.

In the embodiments shown in fig. 1, 4 and 5, each lens is defined by a lens outer arc, a lens radius and a lens inner arc. Thus, as shown in fig. 4, lens 106 is defined by lens outer arc 120, first lens radius 122, second lens radius 124, and lens inner arc 126. Outer lens arc 120 includes lens arc length L2 between endpoints 128 and 130. As shown in fig. 5, the first lens radius 122 extends from the endpoint 128 to a point P1. As shown in fig. 5, the second lens radius 124 extends from the end point 130 to a point P1. Importantly, point P1 does not coincide with the center point P of light fixture 50 within cap 92 in FIG. 5. In other words, point P1 is located offset relative to the center point P of luminaire 50.

As shown in fig. 4 and 5, the in-lens arc 126 includes end points 134 and 136, a midpoint 138, and an in-lens arc length L3 extending along a continuous curve from the end point 134 through the midpoint 138 to the end point 136. As shown in fig. 5, point P1 is disposed along an imaginary line 140 connecting the center point P of luminaire 50 and midpoint 138 of inner arc 126.

Lens 106 is not concentric with the modular heat sink structure 52 to which it is attached. In an embodiment, the lens 106 is not concentric with the entire luminaire 50. As shown in fig. 1, 4 and 5, the lens outer arc 120 is not concentric with the heat sink outer arc 64. Similarly, the lens inner arc 126 is not concentric with the heat sink inner arc or segment 70. Lens radii 122 and 124 are also non-concentric with heat sink radii 66 and 68. The same non-concentricity is equally applicable to the other lenses 108, 110, 112, 114 and 116 with respect to the other corresponding modular heat sink structures 54, 56, 58, 60 and 62 and/or the entire luminaire 50.

As described above, the distance from the midpoint of the channel 76 along the outer arc 64 of the heat sink to the midpoint of the channel 78 forms one sixth or 60 degrees of the circumference of the luminaire 50. By providing lenses 106, 108, 110, 112, 114 and 116 such that they are not concentric with the entire luminaire 50, each lens produces 60 degrees of light that covers the circumference of the luminaire 50. In embodiments including four heat sink structures, each lens may be configured to produce 90 degree light rays covering the circumference of the luminaire 50. In embodiments that include only two heat sink structures, each lens may be configured to produce 180 degrees of light that covers the luminaire 50. In an embodiment, each lens may be configured to support beam angles with a narrow distribution. In other embodiments, each lens may be configured to support beam angles with a medium or wide profile. As shown in the embodiment, each lens is shaped as a truncated sector.

A conventional luminaire with a modular heat sink structure includes lenses arranged concentrically with respect to a center point of the luminaire to provide 360 degrees of coverage. Where a lens is provided for each LED, the gap created by the modular heat sink structure (i.e., channel) does not pose a problem. However, where lenses are provided for two or more LEDs for each heatsink structure, the gaps created by the modular heatsink structures (i.e., channels) may cast shadows on task plane illumination. The improved systems and methods disclosed herein provide uniform illumination over a task plane illumination without shadows using a modular heat sink structure and non-concentric lenses that form gaps or channels. Applicants have recognized and appreciated that the gap formed by the modular heat sink structure can be filled by shortening the lens radius of each lens. In so doing, greater light coverage occurs without changing the number of LEDs mounted and without increasing costs. For lenses concentric with the modular heat sink structure and the entire luminaire (i.e., no non-concentric lenses), in embodiments including six heat sink structures, each lens produces 34.91 degrees of light that only covers the circumference of the luminaire 50. Thus, in such an embodiment, all lenses, including concentric lenses, would cover only about 210 degrees of the circumference of the luminaire.

As described above, the light sources 53 in fig. 3 are arranged along five arcs A1, A2, A3, A4, and A5. The same light source arrangement may be provided for each heat sink structure and corresponding lens. As shown in fig. 6 and 7, each of lenses 106, 108, 110, 112, 114, and 116 includes five protruding arcs 150, 152, 154, 156, and 158. In other words, lens 106 includes five protruding arcs, lens 108 includes five protruding arcs, lens 110 includes five protruding arcs, lens 112 includes five protruding arcs, lens 114 includes five protruding arcs, and lens 116 includes five protruding arcs. Although five protruding arcs are shown in the figures, it should be appreciated that any suitable number is contemplated depending on the arrangement of the light sources. Each protruding arc of each lens corresponds to the position of arcs A1, A2, A3, A4, and A5 of the LED shown in fig. 3. Thus, protruding arc 150 of lens 106 is positioned to cover the LEDs arranged along arc A1, protruding arc 152 of lens 106 is positioned to cover the LEDs arranged along arc A2, protruding arc 154 is positioned to cover the LEDs arranged along arc A3, protruding arc 156 is positioned to cover the LEDs arranged along arc A4, and protruding arc 158 is positioned to cover the LEDs arranged along arc A5.

A bottom perspective view of lens 106 is shown in fig. 8A. A cross-sectional view of lens 106 is shown in fig. 8B. In view of fig. 8A and 8B, the following should be appreciated. Protruding arcs 150, 152, 154, 156, and 158 form cavities around the LEDs on arcs A1, A2, A3, A4, and A5. Protruding arcs 150, 152, 154, 156, and 158 have inner surfaces facing the LEDs and outer surfaces facing away from the LEDs. In other words, the inner surfaces of protruding arcs 150, 152, 154, 156, and 158 face upward toward electronic device housing 51 when assembled, and the outer surfaces of protruding arcs 150, 152, 154, 156, and 158 face downward away from electronic device housing 51 when assembled. In an embodiment, each inner surface of protruding arcs 150, 152, 154, 156, and 158 has a first profile 160, and each outer surface of protruding arcs 150, 152, 154, 156, and 158 has a second profile 162, as shown in fig. 8B. In an embodiment, profiles 160 and 162 are not identical, nor are they mirror images of each other. In an embodiment, each contour 160 of the inner surfaces of protruding arcs 150, 152, 154, 156, and 158 is formed by two tapered surfaces 164A and 164B. In an embodiment, each contour 162 of the outer surfaces of protruding arcs 150, 152, 154, 156, and 158 is formed by a single arcuate surface 166. Tapered surfaces 164A and 164B meet along an arc aligned with the midpoint of arcuate surface 166. As shown in fig. 8B, tapered surfaces 164A and 164B are separated from arcuate surface 166 by a distance. Light from the LEDs may pass through contours 162 and 164.

Only a portion of protruding arc 156 is shown in fig. 8B, as this particular arc is divided into two segments, and in the depicted embodiment the cross-section is taken between the two segments. The protruding arc 156 is divided into two sections by an opening 170 in the lens 106 to allow connection to the LED. It should be appreciated that the openings 170 may be arranged in any suitable shape and configuration. For example, although opening 170 is shown as rectangular in shape, any other suitable shape is contemplated. Additionally, for example, in an embodiment including four heat sink structures, each of the four lenses may include three protruding arcs instead of five, and the equivalent opening 170 may be located in the center of the lens 106, dividing the middle protruding arc of the three protruding arcs into two segments.

In fig. 9, an example process for manufacturing a high output luminaire with a modular heat sink structure and lens is provided. At step 902, an electronic device housing (e.g., housing 51) is provided.

At step 904, the first and second heat sink structures (e.g., structures 52, 54, 56, 58, 60, and 62) are coupled to the electronic device housing. Each radiator structure is at least partially defined by a radiator outer arc (e.g., arc 64) having a radiator outer arc length (e.g., length L1). The heat sink outer arc length has a first end point and a second end point (e.g., points 72 and 74). Each heat sink structure is also defined at least in part by two heat sink radii (e.g., radii 66 and 68) extending from the first and second end points, respectively, to a center point (e.g., point P) of the luminaire.

At step 906, a first light source and a second light source (e.g., light source 53) are provided.

At step 908, a first lens (e.g., lens 106) is attached to a first heat sink structure (e.g., heat sink structure 52). The first lens covers the first light source.

At step 910, a second lens (e.g., lens 108) is attached to a second heat sink structure (e.g., heat sink structure 54). The second lens covers the second light source. Each of the first and second lenses is at least partially defined by a lens outer arc (e.g., arc 120) having a lens outer arc length (e.g., length L2). The outer lens arc has a first end point and a second end point (e.g., points 128 and 130). Each of the first and second lenses is also defined at least in part by two lens radii (e.g., radii 122 and 124) extending from the first and second endpoints, respectively, to a point different from a center point of the luminaire (e.g., point P1).

It should also be understood that, in any method claimed herein that includes more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited, unless explicitly indicated to the contrary.

All definitions as defined and used herein should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of defined terms.

The indefinite articles "a" and "an" as used herein in the specification and in the claims should be understood to mean "at least one" unless explicitly indicated to the contrary.

The phrase "and/or" as used herein in the specification and in the claims should be understood to mean "either or both" of the elements so combined, i.e., the elements that are in some cases combined and in other cases separated. The various elements listed with "and/or" should be interpreted in the same manner, i.e. "one or more" of the elements so combined. In addition to the elements specifically identified by the "and/or" clause, other elements may optionally be present, whether related or unrelated to those elements specifically identified.

As used herein in the specification and in the claims, "or" should be understood to have the same meaning as "and/or" defined above. For example, when items in a list are separated, "or" and/or "should be construed as inclusive, i.e., including at least one of a plurality of elements or lists of elements, but also including more than one of a plurality of elements or lists of elements, and optionally additional unlisted items. Only terms explicitly indicated to the contrary, such as only one of "… …" or exactly one of "… …", or when used in a claim, "consisting of … …" will refer to comprising exactly one element of a plurality or list of elements. In general, the term "or" as used herein when preceded by an exclusive term such as "either," "one of … …," "only one of … …," or "exactly one of … …" should be interpreted as indicating an exclusive alternative (i.e., "one or the other, but not both").

As used herein in the specification and in the claims, the phrase "at least one" referring to a list of one or more elements should be understood to mean at least one element selected from any one or more elements in the list of elements, but does not necessarily include at least one of each element specifically listed within the list of elements, and does not exclude any combination of elements in the list of elements. This definition also allows that elements other than those specifically identified within the list of elements to which the phrase "at least one" refers may optionally be present, whether related or unrelated to those elements specifically identified.

In the claims, and in the description above, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "containing," and the like are to be construed as open-ended, i.e., to mean including, but not limited to. Only the transitional phrases "consisting of … …" and "consisting essentially of … …" should be closed or semi-closed transitional phrases, respectively.

Although several inventive embodiments have been described and illustrated herein, one of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure relate to each individual feature, system, article, material, kit, and/or method described herein. Furthermore, if two or more such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, any combination of two or more such features, systems, articles, materials, kits, and/or methods is included within the scope of the present disclosure.

Claims (13)

1. A luminaire (50), comprising:

an electronic device housing (51);

first and second heat sink structures (52, 54, 56, 58, 60, 62) coupled to the electronic device housing, wherein each of the first and second heat sink structures is at least partially defined by a heat sink outer arc (64) having first and second end points (72, 74), and wherein each heat sink structure is further at least partially defined by two heat sink radii (66, 68) extending from the first and second end points, respectively, to a center point (P) of the luminaire;

a first light source and a second light source (53);

at least two lenses (106, 108, 110, 112, 114, 116) comprising a first lens attached to the first heat sink structure and covering the first light source and a second lens attached to the second heat sink structure and covering the second light source, wherein each of the first and second lenses is at least partially defined by a lens outer arc (120) having a first and a second end point (128, 130), wherein each lens is further at least partially defined by two lens radii (122, 124) extending from the first and second end points, respectively, to a point (P1) different from a center point of the luminaire, and wherein each lens is further at least partially defined by an inner arc (126) extending between the two lens radii (122, 124); and

a ventilation channel (76, 78, 80, 82, 84, 86) is arranged between the first and second radiator structures.

2. The luminaire according to claim 1, wherein the point different from the central point of the luminaire is arranged along an imaginary line (140) connecting the central point of the luminaire to a midpoint (138) of the inner arc.

3. The luminaire of claim 1, wherein the first lens is non-concentric with the first heat sink structure.

4. The luminaire of claim 3, wherein the second lens is non-concentric with the second heat sink structure.

5. The luminaire of claim 1, wherein the first lens or the second lens is concentric with the luminaire.

6. The luminaire of claim 1, wherein the first lens is attached to a first base of the first heat sink structure on a first surface facing away from the electronic device housing and the second lens is attached to a second base of the second heat sink structure on a second surface facing away from the electronic device housing.

7. The luminaire of claim 1 wherein the point is radially outward of a center point of the luminaire.

8. A method (900) for manufacturing a luminaire (50), comprising:

providing (902) an electronic device housing (51);

coupling (904) first and second heat sink structures (52, 54, 56, 58, 60, 62) to the electronic device housing, wherein each of the first and second heat sink structures is at least partially defined by a heat sink outer arc (64) having first and second end points (72, 74), wherein each heat sink structure is further at least partially defined by two heat sink radii (66, 68) extending from the first and second end points, respectively, to a center point (P) of the luminaire;

-providing (906) a first light source and a second light source (53);

attaching (908) a first lens (106, 108, 110, 112, 114, 116) to the first heat sink structure and covering the first light source;

attaching (910) a second lens (106, 108, 110, 112, 114, 116) to the second heat sink structure and covering the second light source, wherein each of the first and second lenses is at least partially defined by a lens outer arc (120) having first and second end points (128, 130), wherein each lens is further at least partially defined by two lens radii (122, 124) extending from the first and second end points, respectively, to a point (P1) different from a center point of the luminaire, and wherein the first or second lens is further at least partially defined by an inner arc (126) extending between the two lens radii (122, 124); and

ventilation channels (76, 78, 80, 82, 84, 86) are provided (912) between the first and second radiator structures.

9. The method of claim 8, wherein the point different from the center point of the luminaire is arranged along an imaginary line (140) connecting the center point of the luminaire to a midpoint (138) of the inner arc.

10. The method of claim 8, wherein the first lens is non-concentric with the first heat sink structure and the second lens is non-concentric with the second heat sink structure.

11. The method of claim 8, wherein the first lens or the second lens is concentric with the luminaire.

12. The method of claim 8, wherein the first lens is attached to a first base of the first heat sink structure on a first surface facing away from the electronic device housing and the second lens is attached to a second base of the second heat sink structure on a second surface facing away from the electronic device housing.

13. The method of claim 8, wherein the point different from the center point of the luminaire is radially outward of the center point of the luminaire.