NL2026155B1

NL2026155B1 - Heat staking optical assembly

Info

Publication number: NL2026155B1
Application number: NL2026155A
Authority: NL
Inventors: Smets Paul; Vyvey Morgan
Original assignee: Schreder Sa
Priority date: 2020-07-28
Filing date: 2020-07-28
Publication date: 2022-03-29

Abstract

An optical assembly, said assembly comprising : a frame With at least one opening, preferably a plurality of openings; a plurality of optical modules, Wherein at least one optical module of the plurality of optical modules is provided per opening of the at least one opening; a support means provided to each of the plurality of optical modules and/or to each of the at least one opening, said support means being configured for supporting the optical module at least partially Within the opening of the frame; a plurality of pins comprising a portion configured for being plastically reshaped under an application of heat and/or pressure to assemble the plurality of optical modules to the frame such that the plurality of optical modules are locked between the support means and the reshaped portions of the plurality of pins.

Description

HEAT STAKING OPTICAL ASSEMBLY

FIELD OF INVENTION The field of the invention relates to optical assemblies for a luminaire, preferably for outdoor lighting or industrial lighting. Particalar embodiments relate to an optical assembly which can be assembled using the application of heat and/or pressure.

BACKGROUND In existing luminaire systems it is common to design a specific printed circuit board (PCB) serving as a support for a plurality of light sources together with a specific optical plate with a plurality of optical elements (typically lens elements) for each luminaire application, e.g. a pedestrian road, a highway, etc. The design of the PCB and the optical plate depend notably on the desired light distribution on the surface to be illuminated, i.e. the desired shape of the light onto the illuminated surface. Such approach is costly, time consuming and requires extensive stock keeping. It would therefore be advantageous to be able to design a luminaire system with a more adaptive approach for which the photometry can be tailored at the factory, depending on the desired application and the desired intensity distribution. In prior art solutions, to address the above mentioned problems, optical elements may be provided which are adjustable on an individual basis or within relatively restricted boundaries. Also, it is known to provide a luminaire system in which the position of the optical elements can be adjusted relative to the printed circuit board. However, the existing solutions are still limited in terms of flexibility, especially when it is desirable to be able to build many different large and small luminaire systems. WO2020/136197 Al in the name of the applicant describes a laminaire system comprising a support structure, a plurality of light sources arranged on the support structure, and an optical structure provided with a plurality of optical elements. The plurality of optical elements may be interconnected in various ways, e.g. interlocked through dove-tail connections. Such an approach has the advantage of providing a modular system.

SUMMARY

The object of embodiments of the invention is to provide an optical assembly with a securely assembled optical plate, while maintaining a high flexibility in the choice of optical elements composing the optical plate to adapt to various illumination schemes and an easy assembly.

According to a first aspect of the invention, there is provided an optical assembly. The optical assembly comprises: a frame with at least one opening; a plurality of optical modules; a support means; and a plorality of pins. At least one optical module of the plurality of optical modules is provided per opening of the at least one opening. The support means is provided to each of the plurality of optical modules and/or to each of the at least one opening, said support means being configured for supporting the optical module at least partially within the opening of the frame. The plurality of pins comprises each a portion configured for being plastically reshaped under an application of heat and/or pressure to assemble the plurality of optical modules to the frame preferably such that the plurality of optical modules are locked between the support means and the reshaped portions of the plurality of pins.

By providing the support means for supporting the optical module at least partially within the opening, on the one hand, and by providing and deforming pins, on the other hand, the optical module can be positioned and locked with respect to the frame. Indeed, the plastic reshaping may then fix in place the optical module with respect to the frame. Thus, a secure assembly of the optical modules in regards to the frame may be obtained.

The plastic reshaping typically allows reshaping a protruding portion of a pin of the plurality of pins such that said protruding portion extends over and overlaps with the optical module and/or the frame, fixing the position of one with respect to the other and complementing the support means to set the optical modale three-dimensional positioning along one axis by preventing motions along the main axis of the pin. In an embodiment, one pin may be used to assemble a plurality of optical modules by overlapping, when reshaped, over at least two optical modules and/or the frame. In another embodiment, one pin may be used per optical module to assemble it to the frame. In yet another embodiment, there may be a plurality of pins, preferably two pins, used per optical module to assemble it to the frame.

In an automatized assembly performing the optical assembly, more than one pin at a time may be reshaped under the application of heat and/or pressure. Additionally, a reshaping head of the tool applying heat and/or pressure may be designed to reshape the reshapable portion of the pin following a preset form. Indeed, under the application of heat and/or pressure, the reshapable portion will complement the shape of the reshaping head applied to it. In an embodiment, the reshaping head may comprise a semi-spherical cavity and the reshapable portion will be reshaped as a semi-sphere. In another embodiment, the reshaping head may comprise an elongated cavity and the reshapable portion will be reshaped accordingly. There may be one or more optical module per opening of the frame. For example, an opening may be dimensioned to receive two optical modules one next to the other. Optionally, at least two optical modules may be assembled together using interlocking mechanical means, glue, and/or by magnetic force. Also, there may be a plurality of openings in the frame. So, the optical modules may be picked individually to custom design the optical properties of the optical assembly. Therefore, a high flexibility of the optical assembly is reached in terms of light patterning.

The plurality of optical modules may be the same or different. The plurality of optical modules may be picked from a storage comprising many different optical modules, and this picking may be based on the desired light distribution of the luminaire in which the resulting optical assembly is to be included. Thus, a highly modular optical assembly can be manufactured in a fast and accurate manner. Further, by deforming pins, the connection can be robust and permanent.

In a preferred embodiment, the plurality of pins are oriented substantially perpendicular to a plane of the at least one opening. This will facilitate the manufacturing process.

According to an exemplary embodiment, for each opening and optical module paired, at least one recess is provided to the optical module and/or to a surface adjacent to the opening, said at least one recess being configured for receiving a portion of the pin.

In this manner, the optical modules may be supported by another structure, i.e. the frame, and the plurality of pins may be provided to the at least one recess for assembling the gathered parts of the optical assembly. The recesses may be designed such that the plurality of pins are located at an interface between the optical module and the frame in order to provide a secure assembly having a low impact on the optical properties of the optical assembly.

Preferably, there are two recesses provided for each opening and optical module paired, said two recessed being located in diametrical opposition of one with respect to the other. According to a preferred embodiment, each optical module of the plurality of optical modules may correspond to an opening of the at least one opening.

In other words, there may be at least one optical module provided to each opening of the frame.

In this way, fewer constraints are imposed to the choices of the plurality of optical modules, and high optical assembly modularity can be obtained.

According to a preferred embodiment, the plurality of optical modules comprises a plurality of lens modules, each lens module comprising at least one lens element, preferably a single lens element.

The plurality of lens modules may form secondary lenses while corresponding light sources may already be provided with primary lenses.

Preferably, each optical module of the plurality of optical modules has a flat bottom surface.

Such flat bottom surface may be deposited on a support carrying the light sources or may be positioned at a distance of the support carrying the light sources, preferably parallel to the support carrying the light sources.

An optical module may comprise a single optical element or multiple optical elements.

If the optical module comprises multiple optical elements, those elements may be the same, e.g. two or more identical lens elements, or different, e.g. a lens element and a backlight element or two different lens elements.

More generally the plurality of optical modules may comprise any one of the following: a lens module, a reflector module, a backlight module, a prism module, a collimator module, a diffusor module, a light shielding structure, and the like.

Also, an optical module may be combining multiple optical functions, e.g. a lens and a reflector function, or a collimator and a reflector function.

The plurality of optical modules may be the same or different.

This will allow combining different optical functions in the same frame in a modular manner.

For example, a first subset of light sources of a luminaire may be provided with a first set of optical modules of a first type, and a second subset of light sources may be provided. with a second set of optical modules of a second type.

This allows choosing suitable optical modules in function of the position of the light sources in the laminaire system.

For example, light sources near the periphery of the support structure may be provided with a different optical module compared to light sources provided in the centre of the support structure, and/or light sources near the luminaire pole may be provided with a different optical module compared to light sources provided near a front end of a luminaire head of the luminaire system.

The optical modules may also comprise one or more light shielding structures complying with a certain glare classification, e.g. the G classification defined according to the CIE115:2010 standard and the G* classification defined according to the EN13201-2 standard.

The light shielding structures may be configured for reducing a solid angle of light beams of the plumity of Hight sources by cutting off or reflecting light rays having a large incident angle, thereby reducing the light intensities at large angles and improving the G/G* classification of the luminaire system. Exemplary embodiments of shielding structures are disclosed in patent application 5 PCT/EP2020/066221 in the name of the applicant which is included herein by reference. Other exemplary embodiments of shielding structures are disclosed in patent applications PCT/EP2019/074894, and NL2025168 in the name of the applicant which are included herein by reference.

Also, in order to reduce glare, a spacer element could be provided between the frame to which the optical modules are welded and a support, such as a PCB, carrying the light sources. An example of a suitable spacer is disclosed in NL2025166.

In the context of the invention, a lens element of the optical module may include any transmissive optical element that focuses or disperses light by means of refraction. It may also include any one of the following: a reflective portion, a backlight portion, a prismatic portion, a collimator portion, a diffusor portion. For example, the lens element may have a lens portion with a concave or convex surface for facing a light source, or more generally a lens portion with a flat or curved surface facing the light source, and optionally a collimator portion integrally formed with said lens portion, said collimator portion being configured for collimating light transmitted through said lens portion. Also, a lens element may be provided with a reflective portion or surface, referred to as a backlight clement in the context of the invention, or with a diffusive portion.

A lens element may comprise a lens portion having an outer surface and an inner surface intended to face an associated light source. The outer surface may be a convex surface and the inner surface may be a concave or planar surface. Also, the lens element may comprise multiple lens portions adjoined in a discontinuous manner, wherein each lens portion may have a convex outer surface and a concave inner surface.

Preferably, the entire optical module, e.g. the entire lens module is made of a transparent or translucent material.

According to an exemplary embodiment, the pin is integrally formed with the frame or with the optical module, preferably integrally formed with the frame.

In this manner, the structural integrity of the optical module or of the frame with the plurality of pins is improved and the overall assembly strength of the optical assembly is increased.

In an embodiment, the reshapable portion of the pin is protruding from a surrounding surface of the optical module or of the frame. The protruding portion of the pin may be sized in height and width such that there is an amount of material sufficient to ensure a safe fixation after reshaping. In another embodiment, the pin is separately formed from the frame and from the optical module paired.

Preferably, the pin may be integrally formed with the frame which makes it easier to assemble the optical module to the frame, said optical module being provided from an upward direction, and which makes it easier to reshape the pin from the upward direction as well. According to a preferred embodiment, the support means is integrally formed with the frame and/or with the optical module, preferably integrally formed with the frame.

In this manner, the structural integrity of the optical module or of the frame with the support means is improved and the overall assembly strength of the optical assembly is increased.

Generally, the support means comprises a supporting portion on one of the frame or the optical module, and a bearing portion on the other one of the frame or the optical module. The supporting portion and the bearing portion may be overlapping as seen in a direction perpendicular toa plane of the opening.

Preferably, the support means comprises at least one tab extending substantially parallel to a plane of the openings of the frame. Even more preferably, the at least on tab extends inwardly inside the openings. Additionally, the at least one tab may be configured for being provided to at least one complementary indent formed in the optical module. More preferably, the at least one tab may be a plurality of tabs located oppositely with respect to each other. In another example, the at least one tab may be one tab extending along the entire periphery of the opening.

Preferably, the support means is integrally formed with the frame to ease the logistics from the viewpoint of optical modules stock-keeping. Indeed, when designing the optical assembly, the task may be made easier if the optical modules have predefined footprints and only the frame has to be custom-designed with the support means provided at given points of the frame.

According to an exemplary embodiment, the frame is made of a translucent or transparent material. In this way, the optical properties of the optical assembly may be less affected by having a heterogencous structure.

According to a preferred embodiment, the pin is made of a material chosen among polybutylene terephthalate (PBT), acrylonitrile butadiene styrene (ABS), poly-methyl methacrylate (PMMA), polycarbonate (PC), or a combination thereof; and the frame is made of a material chosen among PBT, ABS. PMMA, PC, or a combination thereof. In a preferred embodiment the frame may be made of polybutylene terephthalate (PBT) or a mixture of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS). According to an exemplary embodiment, the at least one opening describes an array of openings with a plurality of rows and a plurality of columns.

Typically, for a laminaire, a plurality of LEDs is provided to a PCB in an array. To have a correspondence between the optical modules and the plurality of LEDs, it is preferable to also provide the at least one opening of the frame in an array. Also, doing so may allow a more accurate prediction of the optical properties of the optical assembly when making a custom design optical assembly than when having the at least one opening located randomly.

In a possible embodiment, the plurality of optical modules comprises four adjacent optical modules provided to four adjacent openings of the at least one opening, wherein a portion of the frame surrounded by the four adjacent openings is provided with a hole or a recess or a protrusion. A hole may be intended for receiving a fixation means such as a bolt or a screw, e.g. for fixing the frame to the luminaire. A protrusion and/or recess and/or hole may also be used for other purposes, e.g. for alignment or indication purposes or for allowing another component to be fitted on the frame. More in particular, each opening may have substantially the shape of a rectangle with cut- off corners. In that manner additional space is provided for arranging a hole or a recess or a protrusion as required. This is based on the insight that many optical modules do not need functional part in the corners of the optical module.

According to a preferred embodiment, the pin, when the optical module is assembled to the frame, is located at substantially 90° with respect to the support means as seen in the plane of the opening.

In this manner, the plurality of pins and the support means provide a substantially balanced maintaining action of the optical module respective to the frame. In an embodiment, there may be two pins per optical module and two tabs per optical module. The two pins may be located in diametrical opposition, the two tabs may be located in diametrical opposition, and the two pins may be located at substantially 90° respective to the two tabs.

In an alternative embodiment, the plurality of pins may be located oppositely with respect to each other and the support means comprises a peripheral tab per opening. In yet another embodiment, the support means may comprise more than two tabs.

According to an exemplary embodiment, the reshapable portion of the pin is protruding outwardly, e.g. in an upward direction when the frame is on its bottom surface intended to face the light sources, when the optical module is provided to the opening.

By upward direction, it is meant a direction opposite to a plurality of light sources when the optical module is assembled to the frame. Additionally, when providing the optical module to the opening, the optical module may be preferably coming from the upward direction. In this way, no unneeded protrusion is present on a side of the optical assembly facing the light sources which could perturb light rays travel, or which could obstruct a fixation of the optical assembly on a support of the light sources.

According to a preferred embodiment, when the optical module is assembled to the frame, a first bottom surface of the optical module is substantially at a same level as a second bottom surface of the frame, said first bottom surfaces and second bottom surface being adapted for facing a support, such as a PCB, carrying a plurality of light sources.

In this manner, one can obtain an optical assembly with a flush bottom side which allows for an accurate placement of the optical assembly over light sources. Indeed, the first bottom surface and the second bottom surface may be adapted for being arranged on a support, such as a PCB. By aligning both bottom surfaces, the assembly can be mounted in a similar manner as the lens plates of the prior art on a support carrying the light sources. However, it is noted that in other embodiments it may be interesting to arrange the optical modules such that the first bottom surfaces of the optical modules are recessed within the frame or protrade out of the frame. For example, when the optical modules are slightly recessed within the frame, the frame could function as a spacer element to reduce glare, e.g. in a similar manner as the spacer described in NL2025166. Also, it could be envisaged to use a frame which allows the optical modules to be present in different positions closer or further away from the bottom surface of the frame so that the optical element can be positioned closer or further away from a support such as a PCB carrying the light sources.

According to an exemplary embodiment, a peripheral surface of the at least one recess is configured as the support means for supporting the corresponding optical module at least partially within the opening of the frame. In this way, the material forming the at least one recess may have a double usage as a part of the support means as well. According to a preferred embodiment, the at least one recess is provided to a side surface of the optical module. In an alternative embodiment, the at least one recess may be provided to a side surface delimiting the opening. When the recess is provided to a side surface delimiting the opening, the pin corresponding to the at least one recess may be integrally formed with the optical module and may be provided to a side of the optical module, preferably along its thickness. Alternatively, when the recess is provided to a side surface of the optical module, the pin corresponding to the at least one recess may be integrally formed with the frame and may be provided to a side surface delimiting the opening. By this approach, the at least one recess may be formed as a U-shaped indent along the thickness of the opening, instead of a through-hole for example. No extra material is wasted to form the at least one recess. According to an exemplary embodiment, a diameter of the pin is larger than | mm and smaller than 7 mm before the application of heat and/or pressure.

In this way, the pin comprises a sufficient amount of material to be reshaped such that, after reshaping, the pin can maintain the optical module fixed to the frame. The advantages and features of the embodiments of the above described optical assembly apply mutatis mutandis for embodiments of the below presented lighting system. According to a second aspect of the invention, there is provided a lighting system. The lighting system comprises: a plurality of light sources, preferably a plurality of LED light sources, provided to a substrate; an optical plate comprising a plurality of optical elements, each optical element of the plurality of optical elements corresponding to a light source of the plurality of light sources.

The optical plate is formed with an optical assembly according to any one of the embodiments described above.

The plurality of light sources may comprise a plurality of LEDs. Further, each light source of the plurality of light sources may comprise a plurality of LEDs, more particularly a multi-chip of LEDs; said light sources may be similar or may have different colours or different colour temperatures. Further, each light source may be associated with one or more optical elements (e.g. a lens and/or a reflector), or a number of light sources may share one or more optical elements (e.g. one reflector and/or one lens and/or one diffusor for multiple light sources).

The plurality of optical elements may comprise one or more lens elements as defined IO above.

The optical plate may comprise a frame with at least one opening as defined above. There may be one or more optical modules per opening of the frame, and each optical module may comprise one or more optical elements.

Preferably, the lighting system is an outdoor or industrial lighting system. By outdoor or industrial lighting system, it is meant lighting systems which are installed on roads, tunnels, industrial plants, stadiums, airports, harbors, rail stations, campuses. parks, cycle paths, pedestrian paths or in pedestrian zones, for example, and which can be used notably for the lighting of an outdoor area or large indoor area, such as roads and residential areas in the public domain, private parking areas and access roads to private building infrastructures, warehouses, industry halls, etc.

According to an exemplary embodiment, the lighting system further comprises a moving means. The optical plate is movable with respect to the substrate, and the moving means is configured to move the optical plate relative to the substrate, preferably in a movement plane substantially parallel to the substrate.

Examples of luminaire with such moving means are disclosed in patent applications WO 2019/134875 Al, WO 2920/136202 Al, WO 2020/136200 Al, WO 2020/136205 Al, WO 2020/136203 Al, WO 2020136204 Al, WO 2020/136197 Al, and WO 2020/136196 Al in the name of the applicant, which are included herein by reference.

For example, the substrate provided with the plurality of light sources may be fixed in the luminaire system, and the optical plate comprising the plurality of optical elements moves relative to the substrate. This arrangement allows heat dissipation of the substrate via thermal contact with a heat dissipative surface part of the luminaire system.

The movement of the optical plate relative to the substrate in the movement plane may be a translational movement along one translational axis in a plane parallel to the surface of the substrate or may be a more complex movement, e.g. zig-zag, S-shaped, curved, along an acute angle, simultaneously with a rotational movement.

In another exemplary embodiment, there may be a first and a second moving means configured for movements as described above, said first moving means being configured to move the optical plate relative to the substrate along a first trajectory in the movement plane substantially parallel to the substrate, and said second moving means being configured to move, independently from the first moving means, the optical plate relative to the substrate along a second trajectory in the movement plane substantially parallel to the substrate.

In yet another exemplary embodiment, in addition to the moving means, the luminaire system may comprise an elevating means configured to change the elevation of the optical plate relative to the substrate. A plurality of spring elements may be arranged between the substrate and the optical plate to maintain the optical plate substantially parallel to the substrate.

Exemplary embodiments of the obtained frame with assembled optical modules may be included in a cover module as described in WO 2020074229 Al, or may be an integral part of a cover module as described in WO 2020/074229 Al, which is included herein by reference. Indeed, because the optical modules may be assembled in a tight manner in the frame, the frame can be part of a cover module which is intended to cooperate in a sealing manner with a mounting substrate. Exemplary embodiments of the obtained frame with assembled optical modules may have one or more optical modules with a deformable part, ¢.g. a deformable lens element as described in PCT application WO 2020/025427 Al in the name of the applicant, which is included herein by reference. The frame may then be provided with a retaining and adjustment means configured to change the shape of the deformable portion whilst an edge portion of the optical module is retained in a fixed position with respect to the support carrying the one or more light sources. By changing the shape of the deformable portion, the light beam emitted through the optical modules can be changed.

Exemplary embodiments of the obtained frame with assembled optical modules may be used in a lighting apparatus as disclosed in WO 2019/020366 Al in the name of the applicant, which is included herein by reference. More in particular, the driving apparatus may be provided with a drive and control means configured to drive selectively a plurality of groups of LEDs wherein LEDs of the same group are driven simultaneously. LEDs of a same group may be associated with one or more optical modules.

Exemplary embodiments of the obtained frame with assembled optical modules may be used in a luminaire assembly comprising a support carrying the light source, a protector for protecting the light source from external environmental influences, the protector having a peripheral wall comprising a transparent or translucent portion, wherein the protector is provided with a light absorbing surface arranged inside of the protector and facing the light source, such that in use part of the light emitted from the light source is absorbed by the light absorbing surface to reduce upward light pollution. An example of such a luminaire assembly is disclosed in patent application NL2024425 in the name of the applicant, which is included herein by reference.

Exemplary embodiments of the obtained frame with assembled optical modules may be used in a luminaire system comprising a support carrying a plurality of first light sources and a plurality of second light sources, wherein a first frame with first assembled optical modules is associated with the plurality of first light sources and a second frame with second assembled optical modules is associated with the plurality of second light sources. Alternatively, the first and second optical modules may be assembled in the same frame. The luminaire system may then further comprise a drive and control means configured to drive and control the plurality of first light sources according to a first profile and the plurality of second light sources according to a second profile different from the first profile, wherein the first profile defines a first drive output as a function of time and the second profile defines a second drive output as a function of time. The plurality of first light sources and the first optical modules may be configured to output a first light beam having a first color temperature according to a first intensity distribution within a first solid angle, and the plurality of second light sources and the second optical modules may be configured to output a second light beam having a second color temperature according to a second intensity distribution within a second solid angle, said second intensity distribution being different from the first intensity distribution and/or said first color temperature being different from said second color temperature. Examples of similar luminaire systems are disclosed in patent application NL2024571 in the name of the applicant, which is included herein by reference.

The advantages and features of the embodiments of the above described optical assembly and lighting system apply mutatis mutandis for embodiments of the below presented assembly method, preferably an automatized assembly method.

According to a third aspect of the invention, there is provided an assembly method for assembling optical modules. The method comprises the steps of: - providing a frame with at least one opening;

- providing a plurality of optical modules, wherein at least one optical module of the plurality of optical modules is provided per opening of the at least one opening; - providing a support means to each of the plurality of optical modules and/or to each of the at least one opening, said support means being configured for supporting the optical module at least partially within the opening of the frame; - assembling the plurality of optical modules to the frame by plastically reshaping a plurality of pins, each pin of the plurality of pins comprising a portion configured for being plastically reshaped under an application of heat and/or pressure such that the plurality of optical modules are locked between the support means and the reshaped portions of the plurality of pins.

By using a plurality of pins, there is provided a fast and accurate means for assembling optical modules in the frame. The plurality of optical modules may be the same or different. The plurality of optical modules may be picked from a storage comprising many different optical modules, and this picking may be based on the desired light distribution of the luminaire in which the resulting optical assembly is to be included. Thus, the method for assembling optical modules is highly modular and allows fast and accurate manufacturing of optical assemblies. Further, by using reshaped pins, the connection can be robust and permanent.

According to a preferred embodiment, when assembling the plurality of optical modules to the frame, at least two pins of the plurality of pins are plastically reshaped simultaneously.

According to an exemplary embodiment, when assembling the plurality of optical modules to the frame, a pin of the plurality of pins is plastically reshaped over at least two of the plurality of optical modules.

According to a preferred embodiment, each pin of the plurality of pins is provided at a periphery of an optical module of the plurality of optical modules.

To reshape the plurality of pins, a tool with a heated head may be applied on each reshapable portion. The shape of the heated head may define the reshaped form of the pin. Indeed, under the application of heat and/or pressure, the reshapable portion will complement the shape of the reshaping head applied to it. In an embodiment, the reshaping head may comprise a semi-spherical cavity and the reshapable portion will be reshaped as a semi-sphere. In another embodiment, the reshaping head may comprise an elongated cavity and the reshapable portion will be reshaped accordingly. For example, the elongated reshaped portion may overlap at least two adjacent optical modules; thereby decreasing the number of pins required for the assembly.

Preferably, the reshaped form of the pin extends along and/or across the periphery of the optical module. Also, each of the plurality of pins may be provided to a periphery of the corresponding optical module; thereby decreasing an impact of the pins on the optical properties of the optical modules.

During assembly, the heated head may be configured to apply heat at a temperature above the glass transition temperature of the reshapable portion. More than one reshapable portion may be reshaped at once by the tool to increase assembly speed. For example, the tool may reshape at once two adjacent pins simultaneously. In an embodiment, the tool may be configured for reshaping five pairs of adjacent pins organized in one column at once.

According to an exemplary embodiment, the providing of the plurality of optical modules comprises the steps of: - receiving digital data representative for the optical modules to be included in the frame, and - based on the received digital data, selecting the plurality of optical modules from a storage comprising multiple different optical modules.

In this manner the method may be fully or partially automated, wherein a computer means may control the selecting based on the digital data. For example, the selecting and the placing of the optical modules in the frame may be done using a robotic means controlled by the computer means.

The advantages and features of the embodiments of the above described optical assembly, lighting system, and assembly method apply mutatis mutandis for embodiments of the below presented luminaire.

According to a fourth aspect of the invention, there is provided a luminaire. The luminaire comprises an optical assembly according to any one of the above described optical assembly embodiments.

According to another aspect of the invention there is provided an assembly for use in a luminaire, said assembly comprising : a frame with at least one opening, preferably a plurality of openings; a plurality of modules, wherein at least one module of the plurality of modules is provided per opening of the at least one opening; a support means provided to each of the plurality of modules and/or to each of the at least one opening, said support means being configured for supporting the module at least partially within the opening of the frame; a plurality of pins comprising a portion configured for being plastically reshaped under an application of heat and/or pressure to assemble the plurality of modules to the frame such that the plurality of modules are locked between the support means and the reshaped portions of the plurality of pins.

Thus, instead of using optical modules also other modules may be assembled in a frame to provide an assembly for use in a luminaire. For example, a module may comprise a non-optical element such as a sensor, e.g. a light sensor or an image sensor.

The preferred features disclosed above for optical assemblies may be included generally in IO any assemblies for use in a luminaire, e.g. assemblies comprising non-optical modules. Preferably, the luminaire is an outdoor or industrial luminaire. By outdoor or industrial luminaires, it is meant luminaires which are installed on roads, tunnels, industrial plants, stadiums, airports, harbors, rail stations, campuses, parks, cycle paths, pedestrian paths or in pedestrian zones, for example, and which can be used notably for the lighting of an outdoor area or a large indoor area, such as roads and residential areas in the public domain, private parking areas and access roads to private building infrastructures, warehouses, industry halls, etc.

BRIEF DESCRIPTION OF THE FIGURES This and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing a currently preferred embodiment of the invention. Like numbers refer to like features throughout the drawings. Figures 1A-1B are schematic perspective views from the top side and from the bottom side, respectively, of an exemplary embodiment of an optical assembly; Figure 2 illustrates schematically a perspective view of an exemplary embodiment of a lighting system; Figure 3 is a schematic exploded perspective view of a lighting system with the exemplary embodiment of Figure 2; Figures 4A-4B are partially cut perspective views of the frame of the exemplary embodiment of Figures 2 and 3; Figures 5A-5B are close-up views of the optical module of the exemplary embodiment of Figures 2 and 3; Figure 6 is a partially cut perspective view of the frame according to another exemplary embodiment;

Figure 7 illustrates the selecting of optical modules in accordance with an embodiment of the method; Figure 8 illustrates a flow chart of an exemplary embodiment of a method for assembling optical modules.

DESCRIPTION OF EMBODIMENTS Figures 1A-1B are schematic perspective views from the top side and from the bottom side, respectively, of an exemplary embodiment of an optical assembly according to the present invention.

The optical assembly 100 comprises: a frame 10, a plurality of optical modules 20, a support means 30, and a plurality of pins 40. The optical assembly 100 may be included in a laminaire system.

The luminaire system typically comprises a luminaire head with a luminaire housing and optionally a luminaire pole. The luminaire head may comprise a supporting substrate, e.g. a PCB and at least one optical assembly, e.g. lens plates. The luminaire head may be connected in any manner known to the skilled person to the luminaire pole. Typical examples of such systems are street lights. In other embodiments, a luminaire head may be connected to a wall or a surface, e.g. for illuminating buildings or tunnels. In yet other embodiment, the luminaire head may be connected to catenary cables.

Preferably, the luminaire is an outdoor or industrial luminaire. By outdoor or industrial luminaires, it is meant luminaires which are installed on roads, tunnels, industrial plants, stadiums, airports, harbors, rail stations, campuses, parks, cycle paths, pedestrian paths or in pedestrian zones, for example, and which can be used notably for the lighting of an outdoor area or a large indoor area, such as roads and residential areas in the public domain, private parking areas and access roads to private building infrastructures, warehouses, industry halls, etc.

As can be seen in Figures 2 and 3, a support structure may comprise the supporting substrate 50, e.g. a PCB, and a heat sink (not shown) onto which the supporting substrate 50 may be mounted, said heat sink being made of a thermally conductive material, e.g. aluminium. Alternatively, the PCB may be mounted directly on the luminaire housing functioning as heat sink. A plurality of light sources 55 may be provided to the supporting substrate 50. The plurality of light sources 55 may comprise a plurality of LEDs. Further, each light source 55 may comprise a plurality of LEDs, more particularly a multi-chip of LEDs. The plurality of light sources 55 may be arranged without a determined pattern or in an array with at least two rows of light sources 55 and at least two columns of light sources 55, typically an array of more than two rows and more than two columns,

an array of five rows by four columns in the embodiments of Figures 2 and 3. The surface onto which the plurality of light sources 55 is mounted can be made reflective or white to improve the light emission. The plurality of light sources 55 could also be light sources other than LEDs, e.g. halogen, incandescent, or fluorescent lamps.

Further, the light sources 55 may be similar or may have different colours or different colour temperatures. Additionally, each light source 55 may be associated with one or more optical elements (e.g. a lens and/or a reflector), or a number of light sources 55 may share one or more optical elements (c.g. one reflector and/or one lens and/or one diffusor for multiple light sources) In Figures 1A-1B, each optical module 10 may comprise one or more optical elements, typically lens elements 21, associated with the plurality of light sources. Indeed, lens elements may be typically encountered in outdoor or industrial luminaire systems, although other types of optical clements may be additionally or alternatively present in such luminaires, such as reflectors, backlights, prisms, collimators, diffusors, and the like. The plurality of optical elements may be {5 mounted such that each of the plurality of light sources is arranged opposite an optical element. In the exemplary embodiment shown in Figures 1A-1B, the optical elements are lens elements 21 which are similar in size and shape and there is one lens element 21 planned for each light source. Each lens element 21 comprises a concave surface configured for facing a corresponding light source, and a convex surface opposite the concave surface. The lens element 21 may be a secondary lens element while the corresponding light source may be provided with a primary lens element.

In another exemplary embodiment, some or all of the optical elements may be different from each other. In a further exemplary embodiment, there may be more optical elements than light sources, and the frame provided with the optical modules 10 may be movable such that a light source can be moved from a position opposite a first optical element to a position opposite a second optical element. In other embodiments, there may be provided a plurality of LEDs opposite some or all of the optical elements. The lens elements 21 may be in a transparent or translucent material. They may be in optical grade silicone, glass, poly(methyl methacrylate) (PMMA), polycarbonate (PC), or polyethylene terephthalate (PET), ABS, or PBT, preferably PMMA.

The optical elements may each be surrounded by a mounting portion 22. The mounting portion 22 may be configured for mounting the optical module 20 within a corresponding opening 11 of the frame. The mounting portion 22 and the optical element may be integrally formed. The mounting portion 22 in Figures 1A-1B comprises a plate surrounding the lens element 21 of the optical module with an upper flat surface 22a and a bottom flat surface 22b opposite the upper flat surface 224, said bottom flat surface 22b facing a light source in a mounted state of the optical assembly 100.

The frame 10 comprises at least one opening 11, a plurality of openings 11 in the embodiments of Figures 1A-1B. At least one optical module 20 of the plurality of optical modules is provided per opening 11 of the plurality of openings. In the embodiment of Figures 1A-1B, there is one optical module 20 provided per opening 11. In another embodiment, there may be a plurality of optical modules provided per opening such that the plurality of optical modules fills the corresponding opening. More generally, the optical modules 20 may be the same or different and/or the openings 11 may be the same or different. Preferably, the openings 11 are the same and the optical modules 20 are the same or different but all fit in the same openings 11. Preferably, the plurality of openings 11 describes an array with a plurality of rows and a plurality of columns.

The frame 10 may be in an opaque, transparent, or translucent material, preferably in a transparent material. It may be in ABS, PBT, PMMA, PC, or a combination thereof. In a preferred embodiment the frame may be made of polybutylene terephthalate (PBT) or a mixture of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS).

The plurality of openings 20 may be arranged in an array, an array of two lines by two columns in the embodiment of Figures 1A-1B. The support means 30 is provided to each of the plurality of optical modules 20 and/or to each of the plurality of openings 11. The support means 30 is configured for supporting the optical module 20 at least partially within the opening 11 of the frame. In an embodiment, the optical module 20 may be supported at least partially within the opening 11 using glue. In another embodiment, the optical module 20 may be supported at least partially within the opening 11 using magnetic forces. Preferably, the support means 30 is a mechanical support means. In the embodiment of Figure 1A-1B, the support means 30 comprises elements 31, 34 integrally formed with the optical module 20 and elements 32, 33 integrally formed with the frame 10.

The support means 30 may be configured such that, when the optical module 20 is assembled to the frame 10, the bottom surface 22b of the optical module is substantially at a same level as a bottom surface 12b of the frame, said bottom surface 22b of the optical module and bottom surface 12b of the frame being adapted for facing a plurality of light sources. One can thus obtain an optical assembly 100 with a flush bottom side which allows for an accurate placement of the optical assembly 100 over light sources against the supporting substrate.

The support means 30 may comprise at least one tab 33 extending substantially parallel to a plane of the opening 11 of the frame. In the embodiment of Figures 1 A-1B, the support means 30 comprises a plurality of tabs 33 which extends inwardly inside the opening 11. There may be two tabs 33 in diametrical opposition of one another. In another embodiment, there may be only one tab, a peripheral tab to the opening 11 for example. In yet another embodiment, there may be more than two tabs. By extending inwardly, the plurality of tabs 33 may prevent the optical module 20 to fall through the corresponding opening 11. Indeed a distance between extremities of the tabs 33 is tess than a corresponding longitudinal distance of the bottom surface 22b of the optical module. In the embodiment of Figures 1A-1B, the plurality of tabs 33 may be configured for being provided to a plurality of complementary indents 34 formed in the optical module 20. More particularly, the tabs 33 may extend in prolongation of the bottom surface 12b of the frame, and the complementary indents 34 may be formed in the bottom surface 22b of the optical module such that, when the optical module 20 is arranged at least partially withm the opening, the bottom surface 12b of the frame and the bottom surface 22b of the optical module are flush with each other.

In the embodiment of Figures 1A, 1B, the upper surface 12a of the mounting portion is provided with a plarality of tongues 31. The plurality of tongues 31 may extend substantially parallel to the plane of the opening 11 of the frame. The plurality of tongues 31 may extend in prolongation of the upper surface 22a of the optical module. In the embodiment of Figures 1A-1B, there may be two tongues 31 in diametrical opposition of one another. In another embodiment, there may be only one tongue. In yet another embodiment, there may be more than two tongues. By extending outwardly, the plurality of tongues 31 may prevent the optical module 20 to fall through the corresponding opening 11. Indeed a distance between extremities of the tongues 31 is more than a corresponding lateral distance of the upper surface 12a of the optical module.

The plurality of tongues 31 may be received in a corresponding plurality of indents 32 formed in the upper surface 12a of the frame. The skilled person will understand that either of the plurality of tongues 31 or the plurality of tabs 33 are sufficient on their own as the support means

30.

In the embodiment of Figures 1A-1B, the plurality of optical modules 20 comprises four adjacent optical modules 20 provided to four adjacent openings 11 of the plurality of openings. A portion of the frame surrounded by the four adjacent openings 11 may be provided with a hole or a recess or a protrusion, a through-hole 13 in the present embodiment. The through-hole 13 may be adapted for a fixation means (not shown) configured for fixing the optical assembly 100 to the support structure. Additionally, each opening 11 may have substantially the shape of a rectangle with cut-off corners. In that manner additional space is provided for arranging a hole or a recess or a protrusion as required. The plurality of tongues 31 and the plurality of tabs 33 may be located on different sides of the rectangular shape of the opening; thereby insuring a stable support of the optical module 20.

The plurality of pins 40 comprises each a portion 41 configured for being plastically reshaped under an application of heat and/or pressure to assemble the plurality of optical modules 20 to the frame 10. The reshapable portion 41 may be located at one or more ends of the pin 40. In an embodiment, the plurality of pins 40 may be arranged at the periphery of optical modules 20 such that, when reshaped, the reshapable portion 41 of the pin overlaps the frame 10 and the optical module 20. In another embodiment the plurality of pins 40 is integrally formed with the optical module 20 and the reshapable portion 41 of each pin overlaps, when reshaped, the frame

10. There may be one or more pins 40 per optical module 20 to achieve the assembly with the frame 10. In an embodiment, one pin may be used to assemble a plurality of optical modules by overlapping, when reshaped, over at least two optical modules and/or the frame. In the embodiment, of Figure 1A-1B, the plurality of pins 40 is integrally formed with the frame 10 and extends through corresponding through-holes in the tongues 31. The reshapable portion 41 of each pin 40 overlaps, when reshaped, the corresponding optical module 20.

When providing the plurality of pins 40 to the plurality of optical modules 20, at least one optical module 20 of the plurality optical modules being at least partially arranged within each opening 11 of the plurality of openings, each of the reshapable portions 41 may protrude from the upper surface 22a of the optical module, the upper surface 12a of the frame, the bottom surface 22b of the optical module, and/or the bottom surface 12b of the frame.

For each opening 11 and optical module 20 paired, at least one recess may be provided to the optical module 20 and/or to a surface adjacent to the opening 11, said at least one recess being configured for receiving a portion of the pin 40. In the embodiment of Figures 1A-1B, one recess is provided to each of the plurality of tongues 31. The recess is a through-hole through a tongue 31. Each pin 40 is extending, upwardly, away from the indent 32 in the upper surface 12a of the frame.

Thus, the plurality of tongues 31 comprises each a peripheral surface of the at least one recess configured as the support means 30 for supporting the corresponding optical module 20 at least partially within the opening 11 of the frame. The reshapable portion 41 of each pin may be protruding out of the recess.

Figure 2 illustrates schematically a perspective view of an exemplary embodiment of a lighting system according to the present invention. Figure 3 illustrates schematically an exploded view of the exemplary embodiment of Figure 2. The lighting system 1000 comprises a support structure 50 and an optical assembly 200. The optical assembly 200 comprises: a frame 210, a plurality of optical modules 220, a support means 231, 232, and a plurality of pins 240. The optical assembly 200 comprises a plurality of optical modules 220 arranged in an array, an array of five rows by four columns in the present embodiment.

In the embodiment of Figure 3, a plurality of light sources 55 is arranged on the support structure 50, each of the plurality of light sources corresponding to one optical module 220 of the plurality of optical modules. The support structure 50 may comprise one or more PCBs. For convenience, the support structure 50 is shown in Figures 2 and 3 as a single plate, but the skilled person understands that the support structure 50 may also be formed with a plurality of PCBs.

The optical modules 220 of Figures 2 and 3 may comprise lens modules comprising each a tens element 221. The plurality of optical modules 220 may all be similar or there may be different optical modules. Further, it should be clear for the skilled person that the plurality of optical modules 220 may additionally or alternatively comprise other elements than lens elements 221, such as reflectors, backlight elements, collimators, diffusors, and the like, backlight elements 222 in the present embodiment. Figures SA-5B are close-up views of the optical module of the exemplary embodiment of Figures 2 and 3. The lens element 221 may be free form in the sense that it is not rotation symmetric. In the embodiments of Figures 2 and 3, the lens elements 221 have a symmetry axis. In another embodiment, the lens elements may have no symmetry plane/axis. Each optical module 220 may be moulded in a transparent or translucent material. The optical modules 220 may be e.g. in optical grade silicone, glass, poly(methyl methacrylate) (PMMA), polycarbonate (PC), or polyethylene terephthalate (PET), ABS, PBT, or a combination thereof, preferably in PMMA. Optionally a reflective coating may be provided on a portion of the optical module 220.

Figures 4A-4B are partially cut perspective views of the frame of the exemplary embodiment of Figures 2 and 3. A portion of the frame surrounded by four adjacent openings 211 may be provided with a hole or a recess or a protrusion, a through-hole 213 in the present embodiment. The through-hole 213 may be adapted for a fixation means (now shown in figure 4A but may be similar to the fixation means 214 in figure 3) configured for fixing the optical assembly 200 to the support stracture 50 or to an element of the support structure 50 below the PCB of the support structure 50. Additionally, each opening 211 may have substantially the shape of a rectangle with cut-off corners. In that manner additional space is provided for arranging a hole or a recess or a protrusion as required.

The support means 231, 232 of Figures 2 and 3 may comprise at least one tab extending substantially parallel to a plane of the opening 211 of the frame. The at least one tab 232 may extend inwardly inside the opening 211 around a periphery of the opening 211. By extending inwardly, the peripheral tab 232 may prevent the optical module 220 to go through the corresponding opening 211. Indeed a distance between opposite extremities of the peripheral tab 232 may be less than a corresponding longitudinal distance of a bottom surface 223b of the optical module 220. The peripheral tab 232 may be configured for being provided to a complementary peripheral indent 231 formed in the optical module 220. More particularly, the peripheral tab 232 may extend in prolongation of the upper surface 212a of the frame 210, and the complementary peripheral indent 231 may be formed in the upper surface 223a of the optical module 220 such that, when the optical module 220 is arranged at least partially within the opening 211, the upper surface 212a of the frame 210 and the upper surface 223a of the optical module 220 are flush with each other. In another embodiment, the support means comprises a plurality of tabs extending inside the opening 211. The plurality of pins 240 comprises each a portion 241 configured for being plastically reshaped under an application of heat and/or pressure to assemble the plurality of optical modules 220 to the frame 210. The reshapable portion 241may be located at one end of the pin 240, at an ends of the pin 240 opposite the peripheral tab 232 in the embodiments of Figures 2 and 3. The plurality of pins 240 may be arranged at the periphery of optical modules 220 such that, when reshaped, the reshapable portions 241 of the pins overlap the frame 210 and the optical module

220. In the embodiments of Figures 2 and 3 the plurality of pins 240 is separately formed from the frame 210, and the reshapable portions 241 of each pin overlap, when reshaped, the optical module 220 and, optionally, the frame 210. In another embodiment, the plurality of pins may be integrally formed with the frame. Additionally or alternatively, the plurality of pins may comprise more than one reshapable portion.

There may be one or more pins 240 per optical module 220 to achieve the assembly with the frame 210, two pins 240 per opening 211 in the embodiments of Figures 2 and 3. When providing the plurality of optical modules 220 to the plurality of openings 211, each of the reshapable portions 241 of the pins may, respectively, protrude from an upper surface 223a of the optical module and an upper surface 212a of the frame, and protrude from a bottom surface 223b of the optical module and a bottom surface 212b of the frame.

For each opening 211 and optical module 220 paired, at least one recess 224 may be provided to the optical module 220 and/or to a surface adjacent to the opening 211, said at least one recess 224 being configured for receiving a portion of the pin 240. In the embodiments of Figures 2 and 3, the at least one recess 224 is provided to a side surface of the optical module 220; more particularly two recesses 224 located in diametrical opposition are provided to each side of the optical module 220.

To reshape the plurality of pins 240, a tool with a heated head may be applied on each reshapable portion 241. The shape of the heated head may define the reshaped form of the pin 240. Indeed, under the application of heat and/or pressure, the reshapable portion 241 will complement the shape of the reshaping head applied to it. In an embodiment, the reshaping head may comprise a semi-spherical cavity and the reshapable portion 241 will be reshaped as a semi-sphere. In another embodiment, the reshaping head may comprise an elongated cavity and the reshapable portion 241 will be reshaped accordingly.

Preferably, the reshaped form of the pin 240 extends along and/or across the periphery of the optical module 220. During assembly, the heated head may be configured to apply heat at a temperature above the glass transition temperature of the reshapable portion 241. More than one reshapable portion 241 may be reshaped at once by the tool. For example, the tool may reshape at once two adjacent pins 240. In the embodiments of Figures 2 and 3, the tool may be configured for reshaping five pairs of adjacent pins 240 organized in one column at once.

Figure 3 is a schematic exploded perspective view of a lighting system similar to the exemplary embodiment of Figure 2 according to the present invention. The lighting system 1000 comprises the supporting substrate 50 and the optical assembly 200. The optical assembly 200 comprises: the frame 210, the plarality of optical modules 220, the support means 231, 232, and the plurality of pins 240. The optical assembly 200 comprises the plurality of optical modules 220 arranged in an array, an array of five rows by four columns in the present embodiment. Each of the plurality of optical modules 220 is similar to the optical modules 220 of Figure 2.

In the embodiment of Figure 3, the plurality of light sources 55 is arranged on the supporting substrate 50, each of the plurality of light sources 55 corresponding to one optical module 220 of the plurality of optical modules. The plurality of light sources 55 may be provided to a PCB and the supporting substrate 50 may comprise a heat sink (not shown) in thermal contact with the PCB.

To assemble the optical assembly 1000, the frame 210 may be provided upside down to an assembly line. An upside face of the frame 210 may correspond to a face in a direction opposite to a plurality of light sources 55 when the optical module 220 is assembled to the frame 210. The plurality of optical modules 220 may then be provided to the frame 210, followed by the plurality of pins 240 through the recesses 224 of each optical module. The plurality of pins 240 may be inserted in the recesses 224 by force. After inserting the plurality of pins 240, both ends of each pin 240 may protrude from, respectively the top face of the frame 210 and the bottom face of the frame

210. In the embodiment of Figure 3, the end of the pin opposite the plurality of light sources 55 is the reshapable portion 241 of the pin. In another embodiment, both ends may be reshapable portions of the pin.

These reshapable portions 241 may be reshaped under the application of heat and/or pressure by a specific tool. Depending on embodiments, a plurality of reshapable portions 241 may be reshaped simultaneously. For example, both reshapable portions of a pin comprising two reshapable ends may be reshaped simultaneously. In another embodiment, a plurality of reshapable portions 241 protruding from one side of the frame 210 is reshaped simultaneously.

After assembly of the optical assembly 1000, the optical assembly 1000 may be provided to the supporting substrate 50, and the optical assembly and the supporting substrate 50 may be fixed together using the fixation means 214 passing through the through-hole 213 of the frame. When providing the optical assembly 1000 to the supporting substrate 50, the frame 210 may be positioned in a preset position using a positioning protrusion 215 as can be seen in Figure 4B configured for cooperating with a corresponding positioning indent 215° of the supporting substrate as can be seen in Figure 3. Figure 6 is a partially cut perspective view of the frame according to another exemplary embodiment of the present invention.

A frame 610 may comprises at least one opening 611, a plurality of openings 611 in the embodiment of Figure 6. A plurality of pins 640 comprises each a portion 641 configured for being plastically reshaped under an application of heat and/or pressure to assemble a plurality of optical modules 620 to the frame 610. The reshapable portion 641may be located at one end of the pin

640. The plurality of pins 640 may be arranged at the periphery of optical modules such that, when reshaped, the reshapable portion 641 of the pin overlaps the optical module and, optionally, the frame 610optical module. In the embodiment of Figure 6 the plurality of pins 640 is integrally formed with the frame 610 and each of the pins 640 is extending upwardly away from the frame

610. There may be one or more pins 640 per optical module to achieve the assembly with the frame 610, two pins 640 per opening 611 in the embodiment of Figure 6. To accommodate the plurality of pins 640, the optical module may comprise at least one corresponding recess 624. The at least one recess 624 may be provided to a side surface of the optical module 620; there are two recesses 624 diametrically located for each optical module 620 of Figure 6.

When providing the plurality of optical modules to the plurality of openings 611, each of the reshapable portions 641 of the pins may protrude from an upper surface 612a of the frame. A support means 630 of Figure 6 may comprise at least one tab, a plurality of tabs 633 in Figure 6, extending substantially parallel to a plane of the opening 611 of the frame. The plurality of tabs 633 may extend inwardly inside the opening 611. Each of the plurality of pins 640, when the optical module 620 is assembled to the frame, may be located at substantially 90° with respect to the support means 630 as seen in the plane of the opening 611. In the embodiment of Figure 6, there may be two tabs 633 in diametrical opposition of one another and two pins 640 in diametrical opposition of one another per opening 611, and the plurality of pins 640 is aligned in a direction at substantially 90° with respect to an alignment of the plurality of tabs 633. By extending inwardly, the plurality of tabs 633 may prevent the optical module 620 to fall through the corresponding opening 611. More particularly, the tabs 633 may extend in prolongation of a bottom surface of the frame 610.

In an embodiment, the plurality of optical modules 620 may comprise at least one indent complementary to the at least one tab 633 of the frame. The complementary indent may be configure such that, when the optical module is assembled to the frame, a first bottom surface of the optical module is substantially at a same level as a second bottom surface of the frame, said first bottom surfaces and second bottom surface being adapted for facing a plurality of light sources.

In another embodiment, the plurality of optical modules 620 may not comprise the at least one complementary indent.

Figures 7 and 8 illustrate schematically an exemplary embodiment of a method for assembling optical modules 220a, 220b, 220c.

As illustrated in Figure 8, the method comprises the following steps.

In a first step S11 digital data representative for the optical modules to be included in the frame is received.

In a second step S12, based on the received digital data in step S11, the plurality of optical modules is selected from a storage 2a, 2b, 2c comprising multiple different optical modules 220a, 220b, 220c, and placed in a frame 210 with a plurality of openings 211, see also Figure 8. This picking and placing may be done automatically using a robotic arm controlled by a computing means based on the received digital data, but could also be done partially manually.

The plurality of optical modules 220a, 220b, 220c is provided to the frame 210 such that each optical module of the plurality of optical modules is provided to a corresponding opening 211 of the plurality of openings 211. In the embodiment of Figure 8, each opening 211 is provided with one optcal module 220, but one could also have an opening 211 with a size which is a multiple of the size of the optical module 220a, 220b, 220c so that multiple optical modules can be arranged in a single opening 211. In a third step S13, the reshaping for locking the plurality optical modules between the support means and the plurality of reshaped pins is performed.

As explained above, the reshaping may be achieved by a tool with a reshaping head.

The reshaping head of the tool may be configured for applying heat and/or pressure and may be designed to reshape the reshapable portion of the pin following a preset form.

Indeed, under the application of heat and/or pressure, the reshapable portion will complement the shape of the reshaping head applied to it. ln an embodiment, the reshaping head may comprise a semi-spherical cavity and the reshapable portion will be reshaped as a semi-sphere.

In another embodiment, the reshaping head may comprise an elongated cavity and the reshapable portion will be reshaped accordingly.

The reshaping may consist in reshaping to lock in place one or more subsets S1, S2 of optical modules 220a, 220b, 220c simultaneously using one or more reshaping heads.

For example a first subset St may be locked thanks to a first reshaping head and a second subset S2 may be locked simultaneously thanks to a second reshaping head.

The subsets S1, S2 are shown to be columns in Figure 8 but can be any group of optical modules, e.g. arrays of 2x2 optical modules or rows of optical modules, or arrays of 2x1 or 2x3 optical modules, etc.

Whilst the principles of the invention have been set out above in connection with specific embodiments, it is to be understood that this description is merely made by way of example and not as a limitation of the scope of protection which is determined by the appended claims.

Claims

CONCLUSIONS

An optical assembly, the assembly comprising: - a frame (10) with at least one opening (11), preferably a plurality of openings (11); - a plurality of optical modules (20), wherein at least one optical module (20) of the plurality of optical modules is provided per opening (11) of the at least one opening; - a support means (30) provided on each of the plurality of optical modules (20) and/or on each of the at least one opening (11), the support means (30) being adapted to be at least partially in the opening (11) supporting the frame of the optical module (20); - a plurality of pins (40) comprising a portion (41) adapted to be plastically reformed upon application of heat and/or pressure to assemble the plurality of optical modules (20) to the frame (10) such that the plurality of optical modules are sandwiched between the support means (30) and the reshaped portions (41) of the plurality of pins.

The optical assembly according to any one of the preceding claims, wherein the pin (40) is integrally formed with the frame (10) or with the optical module (20), preferably integrally formed with the frame (10).

The optical assembly of claim 1 or 2, wherein, for each paired aperture (11) and optical module (20), at least one recess is provided on the optical module (20) and/or on a face adjacent to the aperture (11), wherein the at least one recess is adapted to receive a portion of the pin (40).

The optical assembly of any preceding claim, wherein each optical module of the plurality of optical modules corresponds to an opening of the at least one opening.

The optical assembly of any preceding claim, wherein the plurality of optical modules comprise a plurality of lens modules.

The optical assembly according to any one of the preceding claims, wherein the support means is integrally formed with the frame and/or with the optical module, preferably integrally formed with the frame.

The optical assembly of any preceding claim, wherein the support means comprises at least one tab extending substantially parallel to a plane of the at least one opening of the frame.

The optical assembly of the preceding claim, wherein the at least one tab extends inwardly into the at least one opening.

The optical assembly of any preceding claim, wherein the frame is made of a translucent or transparent material.

The optical assembly of any preceding claim, wherein the pin is made of a material selected from acrylonitrile-butadiene-styrene (ABS), polybutylene terephthalate (PBT), polymethyl methacrylate (PMMA), polycarbonate (PC), or a combination of them; and wherein the frame is made of a material selected from acrylonitrile butadiene styrene (ABS), polybutylene terephthalate (PBT), polymethyl methacrylate (PMMA), polycarbonate (PC), or a combination thereof.

The optical assembly of any preceding claim, wherein the at least one aperture describes a multi-row, multi-column array.

The optical assembly of the preceding claim, wherein the plurality of optical modules comprise four adjacent optical modules provided at four adjacent apertures of the at least one aperture, wherein a portion of the frame surrounded by the four adjacent apertures is provided of a hole or recess or projection.

The optical assembly of any preceding claim, wherein the pin, when the optical module is assembled to the frame, is located at substantially 90° to the support means when viewed in the plane of the aperture.

The optical assembly according to any one of the preceding claims, wherein the reshapeable portion of the pin projects outwardly when the optical module is provided at the opening, preferably in an upward direction when the frame is positioned on a bottom surface intended to face a support that supports light sources to be focused.

The optical assembly of any preceding claim, wherein when the optical module is assembled to the frame, a first bottom surface of the optical module is substantially level with the second bottom surface of the frame wherein the first bottom surface and second bottom surface are arranged to face multiple light sources.

The optical assembly according to claim 3, optionally in combination with any one of claims 4-15, wherein a peripheral surface of the at least one recess is arranged as the support means for supporting at least partially in the opening of the frame the corresponding optical module.

The optical assembly of claim 3, optionally in combination with any one of claims 4-16, wherein the at least one recess is provided on a side face of the optical module.

The optical assembly of any preceding claim, wherein a diameter of the pin is greater than 1mm and less than 7mm prior to the application of heat and/or pressure.

19. A lighting system comprising: - a plurality of light sources, preferably a plurality of LED light sources, provided on a substrate; - an optical plate comprising a plurality of optical elements, each optical element of the plurality of optical elements corresponding to a light source of the plurality of light sources; - wherein the optical plate is formed with an optical assembly according to any one of the preceding claims.

The lighting system of the preceding claim, further comprising moving means; wherein the optical plate is movable relative to the substrate; and wherein the moving means is adapted to move the optical plate relative to the substrate, preferably in a plane of movement substantially parallel to the substrate.

21. An assembly method for assembling optical modules, the method comprising the steps of: - providing a frame with at least one opening, preferably several openings;

- providing a plurality of optical modules, wherein at least one optical module of the plurality of optical modules is provided per opening of the at least one opening; - providing a support means for each of the plurality of optical modules and/or for each of the at least one opening, the support means being adapted to at least partially support the optical module within the opening of the frame; - assembling the plurality of optical modules to the frame by plastically reforming a plurality of pins, each pin of the plurality of pins comprising a portion adapted to be plastically reformed by the application of heat and/or pressure such that the plurality of optical modules are interlocked between the support means and the reshaped portions of the multiple pins.

The assembly method of the preceding claim, wherein when the plurality of optical modules are assembled to the frame, at least two pins of the plurality of pins are plastically reshaped simultaneously.

The assembly method according to claim 21 or 22, wherein, during assembling the plurality of optical modules to the frame, a pin of the plurality of pins is plastically reshaped over at least two of the plurality of optical modules.

The assembly method of any one of claims 21-23, wherein each pin of the plurality of pins is provided peripherally with an optical module of the plurality of optical modules.

The assembly method according to any one of claims 21-24, wherein providing the plurality of optical modules comprises the steps of: - receiving digital data representative of the optical modules to be included in the frame, and - based on the received digital data, selecting the plurality of optical modules from a storage comprising a plurality of optical modules.

A lighting fixture comprising an optical assembly according to any one of claims 1-18.