EP4689490A1

EP4689490A1 - Gap filler device for a luminaire assembly

Info

Publication number: EP4689490A1
Application number: EP24712506.5A
Authority: EP
Inventors: Bryan DUMLER; Benjamin Noble TAZIRI
Original assignee: Signify Holding BV
Current assignee: Signify Holding BV
Priority date: 2023-03-30
Filing date: 2024-03-22
Publication date: 2026-02-11
Also published as: CN120917270A; WO2024200245A1

Abstract

A gap filler device for a luminaire assembly is provided. The gap filler device includes a lens filler portion and a spring member. The lens filler portion extends across a gap between an end cap and a lens of the luminaire assembly. The lens filler portion has a profile configured to substantially align with an edge surface of the lens. The spring member extends from the lens filler portion to meet a stopping face within a recess of the end cap. The spring member biases the lens filler portion against the edge surface of the lens during expansion or contraction of the lens. The spring member may include a pair of curved arms such that each of the pair of curved arms curves away from the lens filler portion.

Description

GAP FILLER DEVICE FOR A LUMINAIRE ASSEMBLY

FIELD OF THE DISCLOSURE

The present disclosure is generally directed to a luminaire assembly, and more specifically, to a gap filler device configured to enable a seamless lighting aesthetic despite expansion and contraction of a lens of the luminaire assembly.

BACKGROUND

Thermal expansion of plastic lenses in luminaire assemblies can cause a variety of problems, such as deformed housings, or even lenses falling out of housings. This thermal expansion is primarily caused by heat generated by light sources (such as lightemitting diodes) of the luminaire assembly during operation. Other components of the luminaire assembly, such as driver circuits, may also contribute to the heat causing the thermal expansion. These problems may be exacerbated in luminaire assemblies incorporating a continuous run of two or more lenses in a housing. Some luminaire assembly designs account for this thermal expansion by arranging the lens at a slight recess from the outside of the housing and incorporating room in an end cap for the lens to expand without interference. However, in other luminaire assembly designs, the lens cannot be recessed into the housing and/or the end cap, requiring the lens to be cut short to allow for expansion. Cutting the lens short introduces additional unknowns into the assembly design, such as the lens temperature when cutting as compared to the final, steady state, lens temperature during operation. Due to the need to accommodate for worst-case expansion scenarios based on these unknowns, luminaire assemblies are often left with a gap between the lens and the end cap. This gap may allow light to escape the luminaire assembly without being refracted by the lens, and may even expose light sources, (such as light emitting diodes) to the external environment, creating undesirable aesthetic effects. According, there is a need in the art for a luminaire assembly to enable a seamless lighting aesthetic despite expansion and contraction of a lens of the luminaire assembly. SUMMARY OF THE DISCLOSURE

The present disclosure is generally directed to a luminaire assembly with a gap filler device configured to interact with a lens and an end cap of the luminaire assembly to enable a seamless lighting aesthetic despite expansion and contraction of the lens. The gap filler device will be of particular use in configurations where the lens is not recessed within the end cap, but is rather cut short, creating a gap between the lens and the end cap at certain temperatures.

Generally, the luminaire assembly includes at least the lens, the end cap, the gap filler device, and a housing. The lens is arranged within the housing, and the housing couples the lens to the end cap, forming a gap between the lens and the end cap. The gap filler device includes a lens filler portion and a spring member. The lens filler portion is configured to extend from the recess of the end cap across the gap between the lens and the end cap. The lens filler portion also has a profile to substantially align with an edge surface of the lens. For example, the lens filler portion and the lens could be each similarly curved. The gap filler portion also includes a spring member extending from the lens filler portion. The spring member is configured to meet a stopping face of the end cap such that the spring member biases the lens filler portion against the edge surface of the lens. Thus, as the lens expands or contracts, the spring member flexes against the stopping face of the end cap to bias the lens filler portion against the lens, eliminating the appearance of the gap to provide the seamless lighting aesthetic in all states of lens expansion or contraction.

To secure the gap filler device in place, the gap filler device may also include alignment tabs. The alignment tabs are configured to be received by an alignment notch of the end cap. The alignment tabs may extend from any aspect of the gap filler device, including the lens filler portion or the spring member.

In a preferred embodiment, the gap filler device (including both the lens filler portion and the spring member) are formed from the same material as the lens, such as acrylic, polycarbonate, or another type of plastic or polymer material. The material may be substantially transparent or substantially translucent. By using the same material for the gap filler device and the lens, light transmitted through the lens and the lens filler portion will appear the same for a seamless lighting aesthetic. Further, the gap filler device may be a monolithic structure formed by injection molding, additive manufacturing, or other appropriate manufacturing processes.

The aforementioned luminaire assembly may be assembled by first inserting the gap filler device into the recess of the end cap such that the spring member meets the stopping face of the recess. The gap filler device may be oriented such that any alignment tabs of the gap filler device are positioned within the alignment notch of the end cap. The lens is then arranged within the housing, and the housing is coupled to the end cap. In coupling the housing to the end cap, the lens filler portion of the gap filler device extends across the gap formed between the end cap and the lens, a profile of the lens filler portion is substantially aligned with the edge surface of the lens, and the spring member biases the lens filler portion against the edge surface of the lens. In some examples, the gap filler device may be inserted into the end cap after the end cap is coupled to the housing.

Generally, in one aspect, a gap filler device for a luminaire assembly is provided. The gap filler device includes a lens filler portion. The lens filler portion is configured to extend across a gap between an end cap and a lens of the luminaire assembly. The lens filler portion has a profile configured to substantially align with an edge surface of the lens. The profile of the lens filler portion may be curved. The lens filler portion may extend at least partially into the recess of the end cap.

The gap filler device further includes a spring member. The spring member extends from the lens filler portion. The spring member is configured to meet a stopping face within a recess of the end cap. The spring member is further configured to bias the lens filler portion against the edge surface of the lens. The spring member may be configured to maintain the bias of the lens filler portion against the edge surface of the lens during expansion or contraction of the lens. The spring member may include a pair of curved arms such that each of the pair of curved arms curves away from the lens filler portion.

According to an example, the lens filler portion and the spring member are formed of the same material as the lens of the luminaire assembly.

According to an example, the lens filler portion and the spring member are acrylic or polycarbonate.

According to an example, the lens filler portion and the spring member are a monolithic structure formed by injection molding.

According to an example, the gap filler device further includes one or more alignment tabs. The one or more alignment tabs extend from the lens filler portion or the spring member. The one or more alignment tabs are configured to be received by an alignment notch of the end cap.

Generally, in another aspect, a luminaire assembly is provided. The luminaire assembly includes an end cap. The end cap includes a recess. The recess includes a stopping face. The luminaire assembly includes a lens. The lens is arranged within a housing. The housing is configured to mechanically couple the lens to the end cap.

The luminaire assembly further includes a gap filler device. The gap filler device includes a lens filler portion. The lens filler portion is configured to extend across a gap between the end cap and the lens of the luminaire assembly. The lens filler portion has a profile configured to substantially align with an edge surface of the lens. The lens filler portion may extend at least partially into the recess of the end cap.

The gap filler device further includes a spring member. The spring member extends from the lens filler portion. The spring member is configured to meet the stopping face within the recess of the end cap. The spring member is further configured to bias the lens filler portion against the edge surface of the lens.

According to an example, the gap filler device and the lens are substantially translucent or substantially transparent.

According to an example, the gap filler device further includes one or more alignment tabs extending from the lens filler portion or the spring member. The end cap may further include an alignment notch configured to receive at least one of the one or more alignment tabs.

Generally, in another example, a method for manufacturing a luminaire assembly is provided. The method includes inserting a gap filler device into a recess of an end cap such that a spring member of the gap filler device meets a stopping face within the recess.

The method further includes arranging a lens within a housing.

The method further includes coupling the housing to the end cap such that a lens filler portion of the gap filler device extends across a gap between the end cap and the lens. The lens filler portion has a profile configured to substantially align with an edge surface of the lens. The spring member is configured to bias the lens filler portion against the edge surface of the lens.

It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided 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. It should also be appreciated that terminology explicitly employed herein that also may appear in any disclosure incorporated by reference should be accorded a meaning most consistent with the particular concepts disclosed herein.

These and other aspects of the various embodiments will be apparent from and elucidated with reference to the embodiment s) described hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the various embodiments.

Fig. 1 is an isometric view of a luminaire assembly having a gap between a lens and an end cap configured to receive a gap filler device in the gap, according to aspects of the present disclosure.

Fig. 2 is an isometric view of a luminaire assembly having a gap filler device inserted between a lens and an end cap, according to aspects of the present disclosure.

Fig. 3 is an isometric view of a gap filler device, according to aspects of the present disclosure.

Fig. 4 is a front view of a gap filler device, according to aspects of the present disclosure.

Fig. 5 is an isometric view of an end cap, according to aspects of the present disclosure.

Fig. 6 is an isometric view of a gap filler device inserted into an end cap, according to aspects of the present disclosure.

Fig. 7 is an isometric view of a lens, according to aspects of the present disclosure.

Fig. 8 is an isometric view of a gap filler device aligned with a lens, according to aspects of the present disclosure.

Fig. 9 is a flowchart of a method for manufacturing a luminaire assembly, according to aspects of the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

The present disclosure is generally directed to a luminaire assembly with a gap filler device configured to interact with a lens and an end cap of the luminaire assembly to enable a seamless lighting aesthetic despite expansion and contraction of the lens. The luminaire assembly includes at least the lens, the end cap, the gap filler device, and a housing. The lens is arranged within the housing, and the housing couples the lens to the end cap, forming a gap between the lens and the end cap. The gap filler device includes a lens filler portion and a spring member. The lens filler portion is configured to extend from the recess of the end cap across the gap between the lens and end cap. The lens filler portion also has a profile to substantially align an edge surface of the lens. The gap filler portion also includes a spring member extending from the lens filler portion. The spring member is configured to meet a stopping face of the end cap such that the spring member biases the lens filler portion against the edge surface of the lens. Thus, as the lens expands or contracts, the spring member flexes against the stopping face of the end cap to bias the lens filler portion against the lens, eliminating the appearance of the gap to provide the seamless lighting aesthetic in all states of lens expansion or contraction.

FIG. 1 is an isometric view of a luminaire assembly 10 having a gap 500 between a lens 300 and an end cap 200. In the non-limiting example of FIG. 1, the gap 500 is formed when the lens 300 is arranged within a housing 400. A portion of the housing 400 is then inserted into and secured within the end cap 200, thus mechanically coupling the end cap 200, the lens 300, and the housing 400. The end cap 200 is configured to receive a gap filler device 100 (FIG. 2) as shown in more detail in FIG. 5, while the lens is shown in more detail in FIG. 7.

The lens 300 may be a substantially transparent or substantially translucent material or composite material, such as acrylic, polycarbonate, or any other type of appropriate plastic or polymer. As light sources (not shown), such as light-emitting diodes (LEDs) within the luminaire assembly 10 generate light, heat is also generated, causing the lens 300 to expand and contract relative to the generated heat. Other aspects of the luminaire assembly 10, such as driver circuitry, may also generate heat. Lens 300 may also expand and contract based on environmental temperature changes. As will be shown in subsequent figures, the end cap 200 lacks an appropriate recess to receive an expanding lens 300. Accordingly, without the gap 500 between the lens 300 and the end cap 200, the expanding lens 300 could damage the end cap 200, threatening the integrity of the mechanical coupling of the end cap 200, the lens 300, and the housing 400. In extreme cases, this damage could cause the lens 300 to fall out of the housing 400, creating a safety hazard for individuals underneath the luminaire assembly 10.

Accordingly, the gap 500 between the lens 300 and the end cap 200 is used to prevent the expanding lens 300 from damaging the end cap 200. The gap 500 allows the lens 300 to safely expand along the longitudinal axis of the luminaire assembly 10 without exerting pressure (or reducing any pressure exerted) on the end cap 200. However, this gap 500 may allow light to escape the luminaire assembly 100 without being refracted by the lens 300, and may even expose the light sources to the external environment.

FIG. 2 illustrates a solution to the aesthetic and safety issues presented with respect to the luminaire assembly 10 in FIG. 1 by arranging the gap filler device 100 in between the end cap 200 and the lens 300. The gap filler device 100 is shown in greater detail in FIGS. 3, 4, and 6. Preferably, the gap filler device 100 is composed of the same material (such as acrylic, polycarbonate, or any other type of appropriate plastic or polymer) as the lens 300, resulting in a seamless appearance of light being emitted from the lens 300 and the gap filler device 100.

In the non-limiting example of FIG. 2, the end cap 200 is substantially circular, though in other examples, the end cap 200 may be any other appropriate shape. Similarly, the portion of the lens 300 exposed by the housing 400 is substantially curved. Accordingly, the exposed portion of the gap filler device 100 (the lens filler portion 102 shown in more detail in FIGS. 3, 4, and 6) is also substantially curved to correspond to the shape and aesthetics of the lens 300. In other examples, the exposed portions of the lens 300 and the gap filler device 100 may be substantially square or another appropriate shape.

As shown in the non-limiting example of FIG. 2, the circular end cap 200, the lens filler portion 102 of the gap filler device 100, and the curved portion of the lens 300 are substantially concentric. Further, the radius of the lens filler portion 102 of the gap filler device 100 is slightly less than the radius of the curved portion of the lens 300, exposing a portion of an edge surface 302 of the lens 300. In other examples, the radius of the lens filler portion 102 of the gap filler device 100 may be equal to or greater than the radius of the curved portion of the lens 300.

Although the end cap 200 is shown on a single end of the housing 400 of the luminaire assembly 10, in some examples, the luminaire assembly 10 may incorporate the end cap 200 on each end of the housing 400. In these examples, the gap filler device 100 may be used with each end cap 200 of the luminaire assembly 10.

FIG. 3 is an isometric view of the gap filler device 100 shown in FIG. 2. While the gap filler device 100 may be a monolithic structure formed via injection molding or additive manufacturing, the gap filler device 100 conceptually includes two aspects, the lens filler portion 102 (as also shown in FIG. 2) and a spring member 104. As illustrated in FIG. 2, the lens filler portion 102 is configured to extend across the gap 500 formed between the end cap 200 and the lens 300 to meet an edge surface 302 of the lens 300. Further, the lens filler portion 102 may partially extend into a recess 202 (see FIG. 5) of the end cap 200.

The non-limiting example of the spring member 104 of FIG. 3 is illustrated as a pair of curved arms 110a, 110b curving away from the lens filler portion 102. The pair of curved arms 110a, b is configured to meet a stopping face 204 (see FIG. 5) of the end cap 200. As the lens 300 heats up and expands during operation, the edge surface 302 of the lens 300 applies a longitudinal force against the lens filler portion 102 of the gap filler device 100, thereby pressing the curved arms 110a, b against the stopping face 204 of the end cap 200. Pressed against the stopping face 204, the curved arms 110a, b generate an opposing force against the longitudinal force from the lens 300. This opposing force biases the lens filler portion 102 against the edge surface 302 of the lens 300, eliminating the gap 500 between the end cap 200 and the lens 300 while preserving the mechanical integrity of the end cap 200.

The gap filler device 100 of FIG. 3 also includes a pair of alignment tabs 108a, b. In the example of FIG. 3, the alignment tabs 108a, b effectively couple the lens filler portion 102 of the gap filler device 100 to the spring member 104. The pair of alignment tabs 108a,b are configured to be received by one or more alignment notches 206 (see FIGS. 5 and 6) of the end cap 200 to secure the gap filler device 100 in place and prevent rotation of the gap filler device 100 about the longitudinal axis of the end cap 200.

While the example of FIG. 3 illustrates two alignment tabs 108a,b substantially centered relative to the lens filler portion 102, any practical number of alignment tabs 108 may be used. Further, the alignment tabs 108 may be arranged in other portions of the gap filler device 100. For example, the alignment tabs 108 may extend from only the lens filler portion 102 or the spring member 104. The example of FIG. 3 also includes a pair of additional tabs 112a,b extending from the lens filler portion 102. These additional tabs 112a, b may also be used to secure the position of the gap filler device 100 within the end cap 200.

FIG. 4 illustrates a front view of the gap filler device 100 of FIG. 3. As more clearly shown in FIG. 4, the lens filler portion 102 has a curved profile 106. This curved profile 106 enables the lens filler portion 102 to substantially align with the edge surface 302 of the lens 300. In other examples, the profile 106 may be rectangular or any other practical shape to align with the edge surface 302 of the lens 300.

While the examples of FIG. 3 and 4 illustrate the spring member 104 including a pair of curved arms 110a, b, any other practical configuration of a spring configured to meet the stopping face 204 of the end cap 200 and bias the lens filler portion 102 against the edge surface 302 of the lens 300 may be used for the spring member 104.

Further, the gap filler device 100 illustrated in FIGS. 3 and 4 may be particularly useful in a luminaire assembly 10 comprising a run of two or more lenses 300 arranged consecutively within the housing 400. As each lens 300 will expand and contract individually, the overall degree of expansion and contraction may be significantly more than a single lens 300, requiring the gap filler device 100 to absorb the expansion of the lens 300 and cover the gap 500 between the lens 300 and the end cap 200.

FIG. 5 illustrates an isometric view of a non-limiting example of the end cap 200 depicted in FIGS. 1 and 2. As shown in FIG. 5, the end cap 200 includes an outer rim 208 and an inner disk 210. The outer rim 208 and the inner disk 210 are separated by a cap channel 212.

Further, a recess 202 is formed in the end cap 200 by removing portions of the outer rim 208 and the inner disk 210. The recess 202 is sized to receive the spring member 104 of the gap filler device 100 as depicted in FIGS. 3 and 4. The recess 202 includes two stopping faces 204a, b. The first stopping face 204a is formed within the inner disk 210, while the second stopping face 204b is formed within the outer rim 204b. Other examples may include one stopping face 204 or more than two stopping faces 204 depending on the configuration of the spring member 104 and/or the end cap 300.

The non-limiting example of the end cap 200 of FIG. 5 also includes an alignment notch 206. The alignment notch 206 is formed within the inner disk 210 adjacent to the first stopping face 204b. The alignment notch 206 is shaped to receive one or more alignment tabs 108 of a gap filler device 100, such as the first and second alignment tabs 108a,b shown in FIGS. 3 and 4.

FIG. 6 illustrates the gap filler device 100 shown in FIGS. 3 and 4 inserted into the end cap 200. As can be seen in FIG. 6, the spring member 104 meets both the first and second stopping faces 204a, b. The alignment tabs 108a, b of the gap filler device 100 are positioned within the alignment notch 206 of the end cap 200. A section of the lens filler portion 102 sits within the recess 200, while the remainder of the lens filler portion 102 hangs over the edge of the outer rim 208.

During operation of the luminaire assembly 10, the expansion of lens 300 applies a longitudinal force against lens filler portion 102. Accordingly, this force also presses the spring member 104 (embodied as the pair of curved arms 110a, b) into the first and second stopping faces 204a, b. In turn, the spring member 104 generates an opposing, resistive force to bias the lens filler portion 102 against the lens 300. The arrangement of the alignment tabs 108a,b within the alignment notch 206 secures the gap filler device 100 in place by preventing it from rotating about the longitudinal axis of the end cap 200. Additional tabs 112a, b extending from the lens filler portion 102 may also provide additional security against potential rotation of the gap filler device 100.

Notably, while the end cap 200 of FIGS. 5 and 6 is configured with the recess 202 to accommodate the spring member 104 of the gap filler device 100, the recess 202 is not configured to receive the lens 300 during expansion or contraction.

FIG. 7 illustrates the lens 300 of the luminaire assembly 10 of FIGS. 1 and 2, while FIG. 8 illustrates an edge surface 302 of the lens 300 substantially aligned with lens filler portion 102 of the gap filler device 100 of FIG. 3 and 4. As shown in FIG. 7, the edge surface 302 is defined along the curved surface of the lens 300. As shown in FIGS. 1 and 2, this curved surface is exposed when the lens 300 is installed in the housing 400 of the luminaire assembly 10. As previously described, the edge surface 302 of the lens 300 applies a longitudinal force against lens filler portion 102 when the lens 300 heats up during operation. Spring member 104 counters this force by pressing against the stopping faces 204a, b of the end cap 200, as illustrated in FIG. 6, thus biasing the lens filler portion 102 against the edge surface 302 of the lens 300 to eliminate any gap 500 (as shown in FIG. 1) between the end cap 200 and the lens 300.

FIG. 9 is a flowchart of a method 900 for manufacturing a luminaire assembly, such as the luminaire assembly 10 shown in FIG. 2 by way of example. Referring to FIGS. 1- 9, the method 900 includes, in step 902, inserting the gap filler device 100 into recess 202 of the end cap 200 such that the spring member 104 of the gap filler device 100 meets the stopping faces 204a, b within the recess 202. The method 900 further includes, in step 904, arranging the lens 300 within the housing 400. The method 900 further includes, in step 906, coupling the housing 400 to the end cap 200 such that the lens filler portion 102 of the gap filler device 100 extends across the gap 500 between the end cap 200 and the lens 300. The lens filler portion 102 has profile 106 configured to substantially align with edge surface 302 of the lens 300. The spring member 104 is configured to bias the lens filler portion 102 against the edge surface 302 of the lens 300.

In further examples, the method 900 could include additional steps, such as forming the gap filler device 100 (or individual aspects thereof) via injection molding or additive manufacturing, or aligning one or more alignment tabs of the gap filler device 100 with an alignment notch of the end cap 200. 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 the defined terms.

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

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 conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements can optionally be present other than the elements specifically identified by the “and/or” clause, 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” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of’ or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.”

As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements can optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.

It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include 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.

In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of’ and “consisting essentially of’ shall be closed or semi-closed transitional phrases, respectively.

The above-described examples of the described subject matter can be implemented in any of numerous ways. For example, some aspects can be implemented using hardware, software, or a combination thereof. When any aspect is implemented at least in part in software, the software code can be executed on any suitable processor or collection of processors, whether provided in a single device or computer or distributed among multiple devices/computers.

The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various examples of the present disclosure. In this regard, each block in the flowchart or block diagrams can represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the blocks can occur out of the order noted in the Figures. For example, two blocks shown in succession can, in fact, be executed substantially concurrently, or the blocks can sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.

Other implementations are within the scope of the following claims and other claims to which the applicant can be entitled.

While various examples have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function 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 examples 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 is/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 examples described herein. It is, therefore, to be understood that the foregoing examples are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, examples can be practiced otherwise than as specifically described and claimed. Examples of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.

Claims

CLAIMS:

1. A luminaire assembly (10), comprising: an end cap (200) comprising a recess (202), wherein the recess (202) comprises a stopping face (204); a lens (300) arranged within a housing (400), wherein the housing (400) is configured to mechanically couple the lens (300) to the end cap (200); and a gap filler device (100) comprising: a lens filler portion (102) configured to extend across a gap (500) between the end cap (200) and the lens (300), the lens filler portion (102) having a profile (106) configured to substantially align with an edge surface (302) of the lens (300), and a spring member (104) extending from the lens filler portion (102), wherein the spring member (104) is configured to meet the stopping face (204) within the recess (202) of the end cap (200) and to bias the lens filler portion (102) against the edge surface (302) of the lens (300).

2. The luminaire assembly (10)of claim 1, wherein the lens filler portion (102) and the spring member (104) are formed of the same material as the lens (300) of the luminaire assembly (10).

3. The luminaire assembly (10)of claim 1, wherein the lens filler portion (102) and the spring member (104) are acrylic or polycarbonate.

4. The luminaire assembly (10)of claim 1, wherein the lens filler portion (102) and the spring member (104) are a monolithic structure formed by injection molding.

5. The luminaire assembly (10)of claim 1, wherein the profile (106) of the lens filler portion (102) is curved.

6. The luminaire assembly (10)of claim 1, wherein the lens filler portion (102) extends at least partially into the recess (202) of the end cap (200).

7. The luminaire assembly (10)of claim 1, wherein the spring member (104) is configured to maintain the bias of the lens filler portion (102) against the edge surface (302) of the lens (300) during expansion or contraction of the lens (300).

8. The luminaire assembly (10)of claim 1, wherein the spring member (104) comprises a pair of curved arms (110) such that each of the pair of curved arms (110) curves away from the lens filler portion (102).

9. The luminaire assembly (10) of claim 1, wherein the gap filler device (100) and the lens (300) are substantially translucent or substantially transparent.

10. The luminaire assembly (10) of claim 1, wherein the gap filler device (100) further comprises one or more alignment tabs (108) extending from the lens filler portion (102) or the spring member (104).

11. The luminaire assembly (10) of claim 10, wherein the end cap (200) further comprises an alignment notch (206) configured to receive at least one of the one or more alignment tabs (108).

12. A method (900) for assembling a luminaire assembly, comprising: inserting (902) a gap filler device into a recess of an end cap such that a spring member of the gap filler device meets a stopping face within the recess; arranging (904) a lens within a housing; and coupling (906) the housing to the end cap such that a lens filler portion of the gap filler device extends across a gap between the end cap and the lens, wherein the lens filler portion has a profile configured to substantially align with an edge surface of the lens, wherein the spring member is configured to bias the lens filler portion against the edge surface of the lens, and wherein the spring member comprises a pair of curved arms such that each of the pair of curved arms curves away from the lens filler portion.