WO2015118378A1 - Glare free yet efficient led-based typologies for extra-wide light distribution - Google Patents

Glare free yet efficient led-based typologies for extra-wide light distribution Download PDF

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Publication number
WO2015118378A1
WO2015118378A1 PCT/IB2014/058799 IB2014058799W WO2015118378A1 WO 2015118378 A1 WO2015118378 A1 WO 2015118378A1 IB 2014058799 W IB2014058799 W IB 2014058799W WO 2015118378 A1 WO2015118378 A1 WO 2015118378A1
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WIPO (PCT)
Prior art keywords
light
reflector
heatsink
light source
canopy
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Application number
PCT/IB2014/058799
Other languages
French (fr)
Inventor
Stefan Kreidler
Original Assignee
Stefan Kreidler
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Publication date
Application filed by Stefan Kreidler filed Critical Stefan Kreidler
Priority to PCT/IB2014/058799 priority Critical patent/WO2015118378A1/en
Publication of WO2015118378A1 publication Critical patent/WO2015118378A1/en

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V3/00Globes; Bowls; Cover glasses
    • F21V3/02Globes; Bowls; Cover glasses characterised by the shape
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00Reflectors for light sources
    • F21V7/0008Reflectors for light sources providing for indirect lighting
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21VFUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V7/00Reflectors for light sources
    • F21V7/0025Combination of two or more reflectors for a single light source
    • F21V7/0033Combination of two or more reflectors for a single light source with successive reflections from one reflector to the next or following
    • F21V7/0041Combination of two or more reflectors for a single light source with successive reflections from one reflector to the next or following for avoiding direct view of the light source or to prevent dazzling
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21LIGHTING
    • F21YINDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00Light-generating elements of semiconductor light sources
    • F21Y2115/10Light-emitting diodes [LED]

Definitions

  • LED luminaires have become increasingly popular. The advantages of the use of LEDs are widely accepted. Regulation and cost reasons are causing the LED-technology to penetrate all fields of the lighting market very quickly. Many problematic topics of the LED-technology have been overcome in the recent years but some issues are still causing problems to producers and users of LED light. The following topics shall be considered: a) Glare: LED light sources are typically very small and they have extremely high luminance. In comparison with the quite efficient "traditional" light source of sodium-vapor lamps that emits about 5-10 6 cd/m 2 powerful LEDs emit about 10 times more light-intensity (50-10 6 cd/m 2 ). When emitting this light directly from the LED it can have disturbing or even damaging effects. Therefore glare-effect is regulated for many applications as for instance for illumination of workplaces and in traffic (e.g. Headlight or Streetlight applications).
  • Glare A typical canopy fully cuts off the source of the light beam and increases the surface of the perceived light to a multiple while the luminance decreases proportionally. The canopy (and no longer the LED) must now be considered as the light source. The canopy and the original light source inside constitute a system with specific lighting characteristics. The light emitted by the canopy can be shaped and conditioned with secondary optical elements to the need and purpose of the illuminating apparatus. The directly visible luminance can be reduced to levels that are a fraction the ones of LEDs/LED-Packages emitting directly.
  • b) Lambertian typology of Light While in some applications a lambertian light distribution can be wanted and helpful, such distribution is not easy to manage for applications with wide light distribution. Since with the use of a canopy the light can get transformed to different "diffuse" pattern, a canopy can also help to transform the light pattern to be redirected to precisely controlled, guided and wide beam angles - even when using a single light source. Different typologies of arrangements to achieve optimized results will be specified with this invention and make constitutional part of the same. By the use of a canopy, LED light sources no longer follow the characteristics of a lambertian distribution. This effect is intended and controlled to comply with the requirements of the apparatus ' typology for illumination.
  • the Canopy also helps to summarize the light beam of possibly multiple LEDs or light sources under it, to be considered as a single light source with specific characteristics.
  • This single (canopy-) light source is not to be considered a point light source since its surface is the emitting body of the light.
  • the geometry and make of the canopy can greatly influence its light distribution. Due to possibly small dimensions - also in relation to the (eventually) adjunctive secondary optical elements - the geometry of the entire apparatus in relation to every single point of the canopy's surface is relevant for the light distribution result.
  • Efficient light control One part of the invention is based on reflectors with high efficiency.
  • reflectors do not absorb or mask out any light (except for efficiency-loss on the reflector's surface).
  • Effective Light control The use of primary (collective) and secondary (distributive) reflectors according to arrangements specified in this invention enables a precise control of the light beam and its intensity to the targeted surface. Losses by masking or diffusion to non targeted areas are minimized.
  • Uneven light distribution and multiple shadows Thanks to the increased surface and the diffusion inside the canopy the conditions in respect to uneven distribution or the formation of hard shadows are improved. Yet the proportions and geometry of the apparatus can be designed in a way to optimize the light distribution to a desired pattern.
  • This invention has a broad scope of application ranging from possible streetlight applications, to billboards or any kind of area of substantial dimension and need for light. In smaller scale applications it may be used for retrofit lamps or for shop displays, ceiling or wall fixtures, suspended table lamps etc.
  • Wide light distribution in the scope of this invention is defined as the "opposite" of focused "spot light”. Wide light distribution does not primarily define a beam angle but it shall be defined as the target to spread the light over a "substantial" surface - in a pattern as equal as possible if required. A "substantial” surface is further defined as a surface with dimensions typically at least lO'OOO times bigger than the original primary light source (LED-Chip - see definition further down).
  • Glare free The effect of glare shall be referenced and avoided according to DIN/EN norms and other Traffic/Street-Lighting regulation according to the field of application.
  • Canopy or remote Phosphor Any kind of cover or diffuser applied to one or multiple light sources. Ideally the canopy collects and rearranges 100% of the light emitted by the primary light source(s).
  • a Canopy can consist of any kinds of suitable material and it can be transparent, semi-transparent, mirrored or partially mirrored (partially in transmission or in terms of surface covered), it can have coatings to change its characteristics or it can also contain chemical, optical or mechanical substances to change its behavior.
  • a typical typology of Canopy used in the illustrations of this invention are Polycarbonate Cones containing Phosphor to modify blue LED-Light to white.
  • Light source Light emitting body with the purpose of illumingtion or providing desired chgmcteristics to the light mgngged by the gppgrgtus.
  • the primgry light source is typicglly gn LED-Chip with [gmbertign chgmcteristics (similgr to the entire LED-Pgckgge). As such it hgs g typicgl extension of 0.25 ... 1 mm 2 gnd it is providing extremely high luminosity (typicglly 50x10 6 cd/m 2 ).
  • the term "light source” is specified gs the entire surfgce of the cgnopy in use - unless differently specified (normglly ngmed LED- or primgry Light-Source).
  • the cgnopy does normglly not correspond to [gmbertign chgmcteristics but it is gctive with its entire surfgce.
  • Cgnopy Light source of the opticgl grmngement - normglly coinciding with the definition of light source gs gbove (exceptions mgy gpply).
  • Lgmbertign Light Source Light source with [gmbertign typology (typicglly LED-Pgckgge).
  • Light Begm Simulgtive illustmtion of single light begm pgth in the specific gppgrgtus.
  • Source Begm Illustmtion of directly visible light begm emitted from light source (Cgnopy) without gny reflection or other opticgl control.
  • Distributive Reflector Reflector used to relegse the light to the specified direction or surfgce gnd in the desired mgnner / distribution pgttern (intensity).
  • Auxiligry Deflector Unit used for the guidgnce or control of light or potentigl glgre.
  • Support Structure to keep g light source or gn opticgl element (Reflector) in g specified position.
  • Hegt sink Structure to gbduct gnd dissipgte thermgl energy from the gppgrgtus contgining the primgry light source.
  • Cgp Unit used to gttgch illumingting gppgrgtus to g socket.
  • figure 1 shows typicgl exgmples, gn outline dmwing of Cgnopies (Remote Phosphor Devices) gnd two different typologies of LED-Light-Sources
  • Figure 2 shows typicgl luminous intensity diggmmsfor the cgnopies shown in Figure 1
  • Figure 3 shows grmngements of Cgnopies to be used in lumingires with visible light source gnd two types of Ggs-Lgntern gppgrgtus for streetlight! ng
  • Figure 5 shows g schemgtic illustmtion of possible Mgteriglizgtion + grmngement of Hegtsink
  • Figure 6. shows g stgck of Cgnopies with Reflectors gnd hegtsink
  • Figure 7 shows gn grmngement with [gmbertign light source in g glgre free gppgrgtus b: shows g bifocgl collector (Collective Reflector)
  • Figure 8. shows g glgre free grmngement with g Cgnopy light source on top
  • Figure 9. shows g glgre free grmngement with g Cgnopy light source on the bottom
  • Figure 10 shows g glgre free grmngement with g Cgnopy light source on the right side
  • Figure 11 shows g glgre-free grmngement with lgmbertign Light source in guxiligry reflector with figt cgnopy gnd gnti-glgre-def lector
  • Figure 12 shows Two glgre-free grmngements "bgck-to-bgck" with cover for Protection
  • Figure 13 shows grmngements to control the light output on the y-gxes of the gppgrgtus
  • FIG. 14 shows grmngements of multiple gnd mixed grmngements to mgtch multiple lighting requirements Detailed description of the invention - Part 4:
  • Figure 1 shows typical examples, an outline drawing of Canopies (Remote Phosphor Devices) and two different arrangement-typologies of primary LED-Light-Sources. Typically these Canopies are arranged for operation with blue (and red) LEDs to obtain white Light in a desired distribution pattern ( Figure 2). These examples are representing a selection of typologies only Flat units and any other shape of Canopy may be applicable according to the purpose of the illuminator in target.
  • the examples in this invention are normally based on Canopies of the type shown in Figure 1.
  • the invention includes however all possible pattern and layouts of Canopies with the aim to modify and/or shape the Light on its beam from the primary light source to the targeted surfaces. To obtain optimal results a big portion (possibly 100%) of the primary light shall be captured and transferred through the canopy.
  • the canopy shall be optimized for efficiency in its targeted functions that are: a) Transforming the Light to the required color and light quality (CRI)
  • the light sources may be arranged in different quantity or manner inside / below the canopy.
  • the primary (lambertian) light source(s) is/are placed in the middle upright below the canopy on its (rotation) axes.
  • a blue power LED is used to activate the phosphor of the Canopy.
  • LED-Packages with multiple LED-Chips or LED-Arrays, COBs or other types can be used. Even different colors of LED can be added to obtain different characteristics of the emitted light. Often red LEDs are used to push up the CRI of an arrangement. Further arrangements are explicitly mentioned as follows: “Corn"-LED- Assemblies may be placed inside the canopy to eradiate directly towards the cone.
  • “Strips" or other PCB-Based LED-Assemblies may be placed radially on the contour of a carrying Element inside a canopy to inhabit a contour shaped canopy.
  • Figure 2 shows typical luminous intensity diagrams for the canopies shown in Figure 1. These diagrams are a limited selection of a vast variety of possible distribution pattern that can be achieved by designing particular Canopies. It is substantial for many aspects of this invention that the light gets transformed in both ways described above. However: It is also possible to achieve glare-free arrangements with lambertian light emitted from a standard LED with incorporated phosphor (see Figure 7 and figure 11).
  • a canopy provides essential advantages to the benefit of the quality of the light and to its distribution. Since the radiation from a canopy is no longer lambertian but follows it's specified characteristics the design of luminaires is to be changed essentially - while amazing new possibilities are disclosed. But the biggest advantage of the canopy is that the luminosity of the light source (canopy) is a fraction of the luminosity of the underlying LED. This allows the design of luminaires with high lumen output (e.g. Streetlight) with visible light sources (Canopies).
  • Figure 3 shows arrangements of Canopies to be used in luminaires with visible light source and two types of Ggs-Lgntern gppgrgtus for streetlighting.
  • Thgnks to the "cgnopy-shielding" of the primgry light source (LED) gnd the big surfgce of the Cone-Shgped Cgnopies the light of such lumingire will not be glgring - even if the emission of one single cone cgn regch over lOOOlm (with g surfgce of gbout 23.5cm 2 ).
  • the gpplicgtion rgnge is open for more or less powerful grrgngements.
  • FIG 3 show two possible layouts of many more. Gas lanterns are used with various numbers and layouts of Gas-Socks.
  • the embodiment of the existing gas lantern can be emulated in identical manner by the use of remote phosphor cone canopies.
  • the proposed technology is - due to its comfortable light - not restricted to the emulation of gas lanterns. It has a vast range of possible applications both - with the canopy visible or enclosed (cutoff).
  • the use of this technology is very promising also for the modernization or substitution of "mushroom-lanterns" that are/were very popular for illuminating urban areas and pathways. By adding simple reflectors to these canopies the performance of such canopy-systems can be further improved.
  • a number of Canopy-Modules (l...n) can be equipped with a cap to connect to existing fixtures. Electronics to "drive” the lighting modules can be built into the assembly or they can be added externally similar to a "ballast". In some cases even the simple exchange of existing lighting bulbs (incandescent, discharge or fluorescent) with a LED-Replacement of the following typologies (see Figures 4a, b + c and 6) can bring big savings and a better quality of light.
  • Figure 4a, b +c show open stack and opposite plate-stack arrangements of Canopies with heatsink.
  • the technology and arrangements proposed in this invention are suitable for illuminators with considerable light output within yet a compact body shape.
  • the power-requirements - imposing expansive and heavy heat sink arrangements in traditional LED-luminaires - can be reduced to a minimum.
  • the heat-sink- modules (9. to be illustrated in Figure 5.) the heat gets dissipated in best way while the weight and dimensions of the assembly remain at limited extent.
  • Figure 4a (sectional concept drawing in x-axes-direction) shows a Stack of Canopy Modules assembled to a Retrofit-Lamp with a cap for connection to a luminaire.
  • the assembly consists of the following functional components: 1. Canopy Light Source mounted to a Heatsink arrangement (9.). Distributive reflectors (6.) are used to increase the light output of the apparatus. These reflectors can be of parabolic, free form, multi-facet or other geometry. Reflectors can be adapted to the luminaires requirements in any position of it.
  • the drawing does not show an eventually needed power supply unit (PSU). This PSU can be inside or outside of the arrangement.
  • the number of Canopy- Modules can vary (l..n) according to the requirements of luminous output of the apparatus.
  • Figure 4b (sectional concept drawing in x-axes-direction) shows a Stack of Multiple Canopy Modules assembled to a Retrofit-Lamp with a cap for connection to a luminaire.
  • the assembly consists of similar components as the arrangement in Figure 4a but it has multiple (in this case 2) light sources per Module.
  • Two modules are mounted opposite to each other to constitute a Module-Package. Within this package an additional reflector (6.) can be added to optimize the light distribution and output.
  • the oppositely positioned modules can be rotated to an "offset" of 90° between each light-source in the package to achieve an optimized light-distribution. Multiple such packages can be stacked to increase the luminous output of the apparatus.
  • Figure 5 shows a schematic illustration of possible Materialization + arrangement of Heatsink.
  • the majority of energy supplied to the LED-Light-Source is to being abducted to the underlying structure bearing the same. Since typically 90% of the energy is transformed to heat the design and management of heatsink is highly relevant for the quality of LED- Lighting.
  • 4.5W of it have to be thermally abducted by the heatsink structure.
  • the invention is not limited to the data or pattern provided but it extends to all possible applications bearing the use of claims contained in this invention.
  • the present invention includes a new approach for heatsink design of LED-Modules (indifferent for lambertian light sources or canopy-emitters, indifferent of the power to be dissipated and also indifferent to the shape provided to the heatsink element(s)).
  • LED-Modules indifferent for lambertian light sources or canopy-emitters, indifferent of the power to be dissipated and also indifferent to the shape provided to the heatsink element(s)
  • heatsink-modules are made of metal (Copper or Aluminum, not excluding other materials or combinations of them).
  • the background of the invention in this heatsink is the need to maximize the actively dissipating surface.
  • the exchange of heat to the ambient air shall be provided by passive (intended) or active air convection (Ventilators can be added if required).
  • Heat pipes may be used to transfer heat as well. It is the aim of this invention to enable "passive" heatsink for the arrangements of illuminators. Active elements (Ventilators and heat pipes) shall only be used if the system requires them.
  • the arrangements and production method for the heatsink modules (9.) in this invention can be specified as follows:
  • the basic material is thin Aluminum-Sheet metal. This metal is punched with holes and shaped according to the requirements of the heatsink module. The shape can be given by crimping ("ondulation" as for corrugated paper) or by punching cones or other shapes to the surface in a (tight) pattern. The holes in the metal-sheet will allow air to pass and to remove the heat.
  • This "corrugated” metal unit (one or more) must be connected well to the outer shell of the heatsink module (method(s) below) to ensure the heat transmission and dissipation.
  • metal-sheet metal-wool can be shaped and fixed to the requirements of the heatsink module (as a stuffing inside the shells). A balance between heat conduct and surface maximization must be found by doing so. Also the connection of the wool to the outer shell of the heatsink module must be guaranteed to entire the heat transfer to the wools "fibers". The dimensioning of the "fibers" is essential for the emission of heat. Therefore the "roughness" of the wool will have to be specified according to the technical characteristics of the targeted apparatus.
  • a shell is contouring the heatsink core(s).
  • the shell is typically made from thin aluminum sheet-metal. It can be corrugated, punched with cones, shaped to the shape of a reflector or to any other suitable shape.
  • the heatsink-shell can contain mechanical elements to attach apparatus' components to each other.
  • the Shell can coincide with a reflector or it can contain links to heat-pipes or auxiliary structures such as deflectors (7.). If possible also the surface of the shell is pinched with holes to ensure free or forced airflow.
  • shell and / or core can be treated in their surface to increase the heatsink capacity (e.g. by matte black coating). This coating shall not hinder the distribution and flow of light.
  • heatsink modules are not limited to the aluminum sheet-metal or wool as specified above but it extends to all kind of materials (incl. heat sink "plastics") or "honeycomb-structures". Also the SMD-Soldering-process can be replaced by welding (also by induction) or by other methods (eg. Filling fluid metals to drain the excess). Also thermal or chemical glues or silicone can be used for making the heatsink. When weight is no issue, such heatsink module could be even cast or punched at full.
  • a surface-coated foam or plastic "shell” could be used to make the heatsink modules.
  • the present invention explicitly includes the integration of functional parts such as heatsink and reflectors. As a consequence a next level of invention is introduced - the glare free "cut-off” and control of the light source ( Figures 6.).
  • Figure 6 shows two examples of Canopy- Stacks with Reflectors and integrated heatsink.
  • the number of stacks, light sources and the shape or proportions of the optical elements are of purely indicative character.
  • FIG. 6 a new concept is being introduced to allow the control of big quantities (portion) of the light emitted by the light source (s).
  • the objective of capturing and controlling the light is achieved by combining two reflectors - a Collective Reflector (5.) and a Distributive Reflector (6.). If required and in order to further control or cut out the visibility of the light source additional Distributive Reflectors (Deflectors) (7.) can be added to the assembly.
  • the two illustrations in Figure 6 show two arrangements for lighting apparatus equipped with a cap for direct connection to the power. Both solutions will emit the light in a wide beam angle with a similar pattern. Such arrangements are useful for ceiling and pole-fixtures but also for many other applications that require a large distribution.
  • the reflectors and the heatsink are forming an integral functional part.
  • Reflectors for such apparatus can be symmetric on the axis of rotation but this is not given.
  • an asymmetric and even a rectangular distribution can be desired.
  • This concept will allow to efficiently retrofit basically obsolete styles of street lanterns (Mushroom, suspended "Helmets” or Ball-Pole-Lamps, etc.)
  • the reflectors of such illuminator have typically a "parabolic" shape on the collective unit. Since the canopy-light-source does not have a single focal point to refer to the parabolic curve is to be adjusted to achieve an optimal result. Further the reflector can be shaped as a "multi-facet-mirror" to optimize the making and the light distribution.
  • the Distributive reflector is often a combination by additional "parabolic" surface to capture the remaining light of the light source. At least one part of the secondary reflector is dedicated to direct the majority of emitted light to surface for illumination. Even i more than the collective reflector the distributive reflector can be of free form according to the requirements of light distribution. It can be convex, concave, parabolic, multi facet, flat or any other shape that may be required to obtain the targeted light distribution pattern.
  • Auxiliary deflectors can be freely defined according to the illuminators requirement.
  • All reflectors, deflectors and components of the apparatus can also be used for structural or other purposes.
  • an Auxiliary Deflector can be used to assemble the different lighting modules in a Stack of Canopies with Reflectors.
  • An Auxiliary deflector can also bear an (essential) part of the Heatsink-Function of an illuminating apparatus (see Figure 7.).
  • Figure 7 a shows an arrangement with lambertian light source in a glare free apparatus (sectional concept drawing in x-axes-direction).
  • This new type of arrangement for LED illuminators is capturing 100% of the emitted light.
  • the "double semi-parabolic" collective reflector (6.) transfers the light to the distributive reflector on the "opposite" side.
  • the light beam (3.) exiting the collective reflector can be directed to at least two different zones on the distributive reflector.
  • the benefit of this invention becomes clear: 100% of the light is captured and controlled and can be directed to the required pattern of distribution.
  • a sector of over 90° can be totally controlled and evenly distributed.
  • the apparatus is totally free of glare. This is due to two factors:
  • the light source is totally "cut-off" (not visible for the user).
  • the high intensity of the light source is fractional due to the multiple expansion of the light beam by the reflectors.
  • the example shown in Figure 7 is intending to illustrate a sectional view of an aluminum profile to illuminate a shop display cabinet with glass walls.
  • the auxiliary deflector 7. can be used to control the light distribution on the y-axes (see figure 12 for details).
  • the deflector (7.) performs as support for the light source attached to its front-end.
  • the angle of attach (A) - relative to the collectors direction for projection - and the collector design - can be defined according to the requirements of the light distribution of the apparatus.
  • the deflector also has the function to carry the light source (or its carrying structure) (8.) and the power-cable to supply the light source. It even has a third integral function. By making use of its (metallic) structure it will dissipate the heat of the light source. By using the principles and features described above the heatsink-capacity can get adjusted to the light sources requirements.
  • the Figure 7 b is illustrating that an essential part if this invention may be the use of two differently focused and / or directed collective mirrors (CI / C2).
  • This arrangement allows re-directing the collected light to different areas on the distributive mirror (in the illustration 7 b shown for a canopy light source).
  • One and the same light source can therefore be used to generate two (or more) independently controllable light beams.
  • the proportioning of the amount of light directed to "beam 1 or beam 2" can be adjusted by positioning the light source relatively to the collectors.
  • Theoretically an unlimited number of collectors can be specified around the light source in order to fraction the light in the corresponding amount of light beams.
  • Proposed solution if doing so is by dividing the collective reflector to different parabolic sectors around the center (in x-axes) of the light source. Since these light beams can be directed freely in the segment of over 90° this feature allows very particular designs of glare-free luminaires.
  • This new feature - single, double or multiple collectors with different focal points and beam directions - makes part if this invention.
  • the possible subdivision and shaping of the distributive reflector can additionally be used to shape and direct the light beam as required.
  • Convex, concave, flat, free form, multi-facet - the range of freedom is barely limited.
  • Figure 7 a shows that the most upper light beam - leaving the collector in parallel to the others - meets the distributive reflector in a different point above and radiates differently as a consequence of this.
  • a lambertian light source may set limits to the design of powerful non glaring luminaires.
  • a canopy light source can bring improvements and ease for the design of luminaires in response to complex lighting demands.
  • the further analysis of this invention is therefore (unless mentioned differently) based on canopy-based light sources with their specific light distribution- pattern as shown in Figure 2.
  • Figure 8 shows a glare free arrangement with a Canopy light source on top of the apparatus (sectional concept drawing in x-axes-direction).
  • the positioning of the light source on top-front of the luminaire is influencing the optical characteristics of the luminaire as follows:
  • the light source (1.) may be partly visible for the user - see source beam (4.).
  • a long shield used as extended distributive reflector can prevent the direct visibility at some extent but there may remain some viewing angles that still allow direct radiation.
  • the light emitted by the canopy may not be controlled completely. Depending on the length of the distributive reflector a portion of light radiates directly through the gap between collector and distributor. If the distributor is long enough to capture all the light emitted by the canopy source, half of it is controlled only by the distributing reflector.
  • Figure 9 shows a glare free arrangement with a Canopy light source on the bottom of the apparatus (sectional concept drawing in x-axes-direction).
  • the positioning of the light source on the bottom- front of the luminaire is influencing the optical characteristics of the luminaire as follows:
  • the light source may be partly visible for the user - see source beam.
  • a long shield used as extended distributive reflector can prevent the direct visibility at some extent but there may remain some viewing angles that still allow direct radiation.
  • Figure 10 shows a glare free arrangement with a Canopy light source on the right side (sectional concept drawing in x-axes-direction).
  • the light source is on the right side of the collective reflector pointing to it in axes with the main targeted direction of the same. Modifications to the axes of the light source and its relative position to the (parabolic) collector will change the arrangements behavior.
  • the positioning of the light source and the shaping of reflectors is to be elaborated with detailed studies in relation to the canopies emission diagram, in order to achieve the illumination targets.
  • the positioning of the light source opposite to the collective reflector(s) is influencing the optical characteristics of the luminaire as follows:
  • the light source is barely visible directly and even in an angle with low luminosity of the same.
  • the heatsink (9.) of the light source can be allocated (at least partly) in its "shadow” directly behind the emitting surface.
  • the support structure of the light source may serve as heat-pipe (e.g. made from copper or aluminum) and it can be extended in surface (as a deflector (7.) to the y-axes). Also it shall carry the power-supply-duct for the light source.
  • the positioning of the support-structure (8.) can be optimized to the benefit of the apparatus.
  • a proposed solution is to the top of the luminaire (see proposal in lower section of Figure 10) to abduct the heat optimally (9.) to eventual heat-dissipation structure allocated nearby (if required).
  • a support to the bottom may be useful.
  • the distributive reflector can be made in many different ways. Adjustable (e.g. by rotation or by universal joint support) reflector elements (E) can be added to the arrangement.
  • One more possibility for the management of the alternative distribution patterns is to provide modular reflector-kits as distributive mirrors. Such kits will for instance reduce the number of types of fixtures for streetlight apparatus responding to different typologies. Modifications to the distribution pattern by the use of modular or adjustable elements could possibly be done even on site. This arrangement can represent the "perfect" apparatus to build streetlight fixtures with excellent characteristics.
  • Figure 11 shows a glare-free (cut-off) arrangement with lambertian Light source in auxiliary reflector with flat canopy and anti-glare-deflector.
  • a lambertian light source is placed directly opposite to the distributive reflector.
  • the "collector” can be optimized to capture a big proportion of light.
  • the lambertian light source (eventually behind the phosphor shield - but also possible “directly” with "standard-LEDs) - only a part of the emitted light gets in control of the primary reflector. A part of the light will radiate in different angles from the canopy. Since the light source may be directly visible to the eye an additional deflector can be added (7).
  • the secondary (distributive) reflector can be enhanced with (eventually adjustable (E.)) optical characteristics.
  • This arrangement may be applicable to apparatus using remote phosphor or direct light source.
  • the use of a diffuser / canopy over the light beam may be even hindering the required capturing and control of a possibly big portion of emitted light.
  • the use of an optical lens (collector), auxiliary reflector or refractor placed in front of the canopy can help to ease the "diffusion- and control-issue" but it will be in trade off with the efficiency and glare of this solution.
  • a canopy (cone) light-source can be installed inside the collective reflector with its "front” directly pointing to the distributive reflector (arrangement similar to Figure 11 but with cone canopy instead of the flat canopy. Direct emission to the distributing of a big part of the emitted light without any reflection on a collective mirror may increase the efficiency. On the other hand it is more difficult to control the "unstructured direct light on the distributing reflector.
  • Figure 12 shows two glare-free arrangements "back-to-back" with cover for Protection.
  • the illuminator will be attached "back-to-back".
  • the side with the distributive reflector will be in the center of the apparatus.
  • the distributive Reflector can be made big in its dimensions to reduce glare effects to a minimum. Also it can be equipped with adjustable or modular devices as specified above.
  • a cover added to the fixture shall not hinder the light on its path more than necessary. If needed however, the cover can be equipped with additional refractors, reflectors or filters.
  • Figure 12 looks like an arrangement for streetlamps the invention is clearly not limited to such application.
  • the proposed arrangements can be perfectly used for general lighting (indoors and outdoors) such as for floodlight, for wall washing, for high bay lighting, for small or large scale illuminated billboards, for automotive or other mobility use and for any other application that will make benefit of these inventions.
  • Figure 13 shows arrangements to control the light output on the y-axes of the apparatus. While Figures 7 to 12 were sections along the x-z-axes Figure 13 is dedicated to possible sections along the y-z-axes. The illustrations 1-4 in Figure 13 show a selection of arrangements to control the light output on the y-axes too while the x-axes is controlled by the collecting and distributing reflectors illustrated above.
  • Double parabolic reflectors with round or oval (or any form) sections will direct the light to one main desired direction. Since 100% of the emission of a light source can be captured by a collector the result can be optimal. The engineering and manufacture of such reflector can be complex and costly however.
  • FIG. 13-2 shows a "double-semi-parabolic" as manufactured e.g. as a profile or shaped sheet metal.
  • the axes of the parabolic reflector is leading in parallel of the y-axes.
  • no lateral deflectors or reflectors are applied - upright or similar to the y-axes - the light will expand along the y-axes with up to 180° under the illuminator in a quite uncontrolled manner. In many applications a controlled beam will be required.
  • Figure 13-3 shows the effect of adding an additional parabolic reflector "over the x-axes" of the apparatus - along with the axes of the light source.
  • an arrangement as illustrated in Figure 13-4 can help.
  • the upper part of the deflector is collecting the light in an optimized manner while the lower - rather rectangular part - is providing a broad but glare free distribution. Due to an increased number of reflections in this arrangement the efficiency can be affected. Since the aspects of glare, wide beam angle and efficiency are linked to the "mechanics" of this arrangement, the optical layout of it is matter of optimization. More distance from one side to the other (extension on the y-axes) will increase the efficiency but reduce the control over the light.
  • Narrowly positioned side reflectors reduce the glare (in case the light source would be directly visible from below) and increase the beam angle but as mentioned the efficiency will suffer from a high number of reflections in a relatively "small optical compartment".
  • Figure 14 shows arrangements of multiple and mixed arrangements to match multiple lighting requirements.
  • Figure 14 illustrates an apparatus for a streetlighting fixture with added features.
  • the "original" streetlight luminaire for extra wide beam angle can be enhanced with an additional illuminator with a second purpose. Since this (one or more) is allocated in the center of the apparatus (more could be added to the sides too) it is 90° turned against the x-axes, so it radiates to the y-axes primarily.
  • the invention can be used for small lighting applications e.g. inside of an aluminum profile but also it can be used for Mercury- or Sodium-Bulb-Retrofitting, as powerful accident site-illumination or even as floodlights for sports fields.

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  • General Engineering & Computer Science (AREA)
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Abstract

The present invention (Glare free yet efficient LED-Based Typologies for extra-wide light distribution) relates to light emitting device methods and optical arrangements for single or multiple lighting modules with the scope of efficient collection and efficient yet glare free, shaped distribution of light for illumination. The present invention contemplates the use of LED light sources in combination with remote phosphor or other canopy technology permeated or pervaded by the direct or indirect light beam of a primary light source. The emitting device including the canopy may be in combination with secondary or multiple optical elements like reflectors, collimators or refractors. It is the aim of this invention to grant glare-free light shaping and guidance while maintaining best efficiency of Devices, Modules, Light Engines, lighting Elements or any kind of Apparatus with deriving benefit from wide light distribution. The invention may be considered to be used for LED light sources in combination with a remote phosphor canopy but is not limited thereto. The invention may be considered for newly designed or modernized lighting apparatus such as for retrofit applications.

Description

Glare free yet efficient LED-Based Typologies for extra-wide light distribution Background of the invention (Description - Part 1):
LED luminaires have become increasingly popular. The advantages of the use of LEDs are widely accepted. Regulation and cost reasons are causing the LED-technology to penetrate all fields of the lighting market very quickly. Many problematic topics of the LED-technology have been overcome in the recent years but some issues are still causing problems to producers and users of LED light. The following topics shall be considered: a) Glare: LED light sources are typically very small and they have extremely high luminance. In comparison with the quite efficient "traditional" light source of sodium-vapor lamps that emits about 5-106 cd/m2 powerful LEDs emit about 10 times more light-intensity (50-106 cd/m2). When emitting this light directly from the LED it can have disturbing or even damaging effects. Therefore glare-effect is regulated for many applications as for instance for illumination of workplaces and in traffic (e.g. Headlight or Streetlight applications).
b) Lambertian typology of light: Many LEDs, LED-Arrays , light Engines or COB-Packages (etc.) are allocated to planar geometries. They radiate the light in a lambertian pattern often requiring additional guidance (optics, collimators, refractors, reflectors, etc.). Two problems arise: 1. Optical systems are often very inefficient in particular if they shall "cut off" or blur the direct light beam. 2. In many cases the "cut off" is not sufficiently granted what may cause glare due to direct eradiation of the (collimated) LEDs light beam on a very small surface. c) Efficient light control: In many cases optical systems of LEDs are extremely inefficient.
d) Effective Light control: Often the precise projection of light beams is claimed for LED- luminaires but in many cases the real effect does not comply with promise or expectation. e) Uneven light distribution and multiple shadows: The small dimension of the light source(s) along with high efficient and sharply defining optical systems may cause uneven light distribution. Also the formation of multiple shadows (created by LED-Arrays) can be an issue for the perception and for the safety in work or traffic processes.
f) Light Color and Color Rendering in relation to Efficiency: Actually the typical setup of an LED for lighting is using a blue LED with phosphor directly applied to it (many different principles). Higher color rendering and warmer color of light are thereby in "trade-off" with significant efficiency loss.
This present invention will help to overcome these issues in a very effective and efficient manner. By the use of a canopy - for instance and preferably constituted of remote phosphor - and by applying new optical arrangements the issues listed above can be resolved or ease off. a) Glare: A typical canopy fully cuts off the source of the light beam and increases the surface of the perceived light to a multiple while the luminance decreases proportionally. The canopy (and no longer the LED) must now be considered as the light source. The canopy and the original light source inside constitute a system with specific lighting characteristics. The light emitted by the canopy can be shaped and conditioned with secondary optical elements to the need and purpose of the illuminating apparatus. The directly visible luminance can be reduced to levels that are a fraction the ones of LEDs/LED-Packages emitting directly.
b) Lambertian typology of Light: While in some applications a lambertian light distribution can be wanted and helpful, such distribution is not easy to manage for applications with wide light distribution. Since with the use of a canopy the light can get transformed to different "diffuse" pattern, a canopy can also help to transform the light pattern to be redirected to precisely controlled, guided and wide beam angles - even when using a single light source. Different typologies of arrangements to achieve optimized results will be specified with this invention and make constitutional part of the same. By the use of a canopy, LED light sources no longer follow the characteristics of a lambertian distribution. This effect is intended and controlled to comply with the requirements of the apparatus' typology for illumination. The Canopy also helps to summarize the light beam of possibly multiple LEDs or light sources under it, to be considered as a single light source with specific characteristics. This single (canopy-) light source is not to be considered a point light source since its surface is the emitting body of the light. The geometry and make of the canopy can greatly influence its light distribution. Due to possibly small dimensions - also in relation to the (eventually) adjunctive secondary optical elements - the geometry of the entire apparatus in relation to every single point of the canopy's surface is relevant for the light distribution result.
c) Efficient light control: One part of the invention is based on reflectors with high efficiency.
Other than the typically used collimators, PC- or Glass-Lenses, "milky" or "frosted" diff users and refractors, reflectors do not absorb or mask out any light (except for efficiency-loss on the reflector's surface).
d) Effective Light control: The use of primary (collective) and secondary (distributive) reflectors according to arrangements specified in this invention enables a precise control of the light beam and its intensity to the targeted surface. Losses by masking or diffusion to non targeted areas are minimized.
e) Uneven light distribution and multiple shadows: Thanks to the increased surface and the diffusion inside the canopy the conditions in respect to uneven distribution or the formation of hard shadows are improved. Yet the proportions and geometry of the apparatus can be designed in a way to optimize the light distribution to a desired pattern.
f) Light Color and Color Rendering in relation to Efficiency: The fact that the canopy is integrating the function of transforming blue LED-light to white with the function of a targeted "diffusion" of the light, can help to increase the efficiency of LED-illumination. By using high performance-low-CRI Phosphorus in combination with high efficient red LEDs the efficiency can be further increased, while excellent light, color and color rendering values can be achieved. The positive effect may be applicable also by adding other LEDs/Colors than blue and red if required.
This invention has a broad scope of application ranging from possible streetlight applications, to billboards or any kind of area of substantial dimension and need for light. In smaller scale applications it may be used for retrofit lamps or for shop displays, ceiling or wall fixtures, suspended table lamps etc.
Definitions (Description - Part 2):
Wide light distribution: Wide light distribution in the scope of this invention is defined as the "opposite" of focused "spot light". Wide light distribution does not primarily define a beam angle but it shall be defined as the target to spread the light over a "substantial" surface - in a pattern as equal as possible if required. A "substantial" surface is further defined as a surface with dimensions typically at least lO'OOO times bigger than the original primary light source (LED-Chip - see definition further down).
Glare free: The effect of glare shall be referenced and avoided according to DIN/EN norms and other Traffic/Street-Lighting regulation according to the field of application.
Canopy or remote Phosphor: Any kind of cover or diffuser applied to one or multiple light sources. Ideally the canopy collects and rearranges 100% of the light emitted by the primary light source(s). A Canopy can consist of any kinds of suitable material and it can be transparent, semi-transparent, mirrored or partially mirrored (partially in transmission or in terms of surface covered), it can have coatings to change its characteristics or it can also contain chemical, optical or mechanical substances to change its behavior. A typical typology of Canopy used in the illustrations of this invention are Polycarbonate Cones containing Phosphor to modify blue LED-Light to white. Light source: Light emitting body with the purpose of illumingtion or providing desired chgmcteristics to the light mgngged by the gppgrgtus. Actuglly the primgry light source is typicglly gn LED-Chip with [gmbertign chgmcteristics (similgr to the entire LED-Pgckgge). As such it hgs g typicgl extension of 0.25 ... 1 mm2 gnd it is providing extremely high luminosity (typicglly 50x106 cd/m2). To fgcilitgte the considergtions of this invention the term "light source" is specified gs the entire surfgce of the cgnopy in use - unless differently specified (normglly ngmed LED- or primgry Light-Source). The cgnopy does normglly not correspond to [gmbertign chgmcteristics but it is gctive with its entire surfgce.
Definition of Elements used in illustrations with their reference-numbers:
1. Cgnopy: Light source of the opticgl grmngement - normglly coinciding with the definition of light source gs gbove (exceptions mgy gpply).
2. Lgmbertign Light Source: Light source with [gmbertign typology (typicglly LED-Pgckgge).
3. Light Begm: Simulgtive illustmtion of single light begm pgth in the specific gppgrgtus.
4. Source Begm: Illustmtion of directly visible light begm emitted from light source (Cgnopy) without gny reflection or other opticgl control.
5. Collective Reflector: Reflector used to cgpture the light of the light source in distinct mgnner.
6. Distributive Reflector: Reflector used to relegse the light to the specified direction or surfgce gnd in the desired mgnner / distribution pgttern (intensity).
7. Auxiligry Deflector: Unit used for the guidgnce or control of light or potentigl glgre.
8. Support: Structure to keep g light source or gn opticgl element (Reflector) in g specified position.
9. Hegt sink: Structure to gbduct gnd dissipgte thermgl energy from the gppgrgtus contgining the primgry light source.
10. Cgp: Unit used to gttgch illumingting gppgrgtus to g socket.
Description - Part 3:
Listing and brief description of the illustrations & drawings: figure 1. shows typicgl exgmples, gn outline dmwing of Cgnopies (Remote Phosphor Devices) gnd two different typologies of LED-Light-Sources
Figure 2. shows typicgl luminous intensity diggmmsfor the cgnopies shown in Figure 1
Figure 3. shows grmngements of Cgnopies to be used in lumingires with visible light source gnd two types of Ggs-Lgntern gppgrgtus for streetlight! ng
Figure 4. g, b + c: Show Open stgck gnd opposite plgte-stgck grmngements of Cgnopies with hegtsink
Figure 5. shows g schemgtic illustmtion of possible Mgteriglizgtion + grmngement of Hegtsink
Figure 6. shows g stgck of Cgnopies with Reflectors gnd hegtsink
Figure 7. g: shows gn grmngement with [gmbertign light source in g glgre free gppgrgtus b: shows g bifocgl collector (Collective Reflector)
Figure 8. shows g glgre free grmngement with g Cgnopy light source on top
Figure 9. shows g glgre free grmngement with g Cgnopy light source on the bottom
Figure 10. shows g glgre free grmngement with g Cgnopy light source on the right side
Figure 11. shows g glgre-free grmngement with lgmbertign Light source in guxiligry reflector with figt cgnopy gnd gnti-glgre-def lector
Figure 12. shows Two glgre-free grmngements "bgck-to-bgck" with cover for Protection
Figure 13. shows grmngements to control the light output on the y-gxes of the gppgrgtus
Figure 14. shows grmngements of multiple gnd mixed grmngements to mgtch multiple lighting requirements Detailed description of the invention - Part 4:
Figure 1 shows typical examples, an outline drawing of Canopies (Remote Phosphor Devices) and two different arrangement-typologies of primary LED-Light-Sources. Typically these Canopies are arranged for operation with blue (and red) LEDs to obtain white Light in a desired distribution pattern (Figure 2). These examples are representing a selection of typologies only Flat units and any other shape of Canopy may be applicable according to the purpose of the illuminator in target. The examples in this invention are normally based on Canopies of the type shown in Figure 1. The invention includes however all possible pattern and layouts of Canopies with the aim to modify and/or shape the Light on its beam from the primary light source to the targeted surfaces. To obtain optimal results a big portion (possibly 100%) of the primary light shall be captured and transferred through the canopy. The canopy shall be optimized for efficiency in its targeted functions that are: a) Transforming the Light to the required color and light quality (CRI)
b) Redirect the Light to a desired pattern of distribution and diffusion
The light sources may be arranged in different quantity or manner inside / below the canopy. Typically the primary (lambertian) light source(s) is/are placed in the middle upright below the canopy on its (rotation) axes. Often a blue power LED is used to activate the phosphor of the Canopy. LED-Packages with multiple LED-Chips or LED-Arrays, COBs or other types can be used. Even different colors of LED can be added to obtain different characteristics of the emitted light. Often red LEDs are used to push up the CRI of an arrangement. Further arrangements are explicitly mentioned as follows: "Corn"-LED- Assemblies may be placed inside the canopy to eradiate directly towards the cone. "Strips" or other PCB-Based LED-Assemblies may be placed radially on the contour of a carrying Element inside a canopy to inhabit a contour shaped canopy.
Figure 2 shows typical luminous intensity diagrams for the canopies shown in Figure 1. These diagrams are a limited selection of a vast variety of possible distribution pattern that can be achieved by designing particular Canopies. It is substantial for many aspects of this invention that the light gets transformed in both ways described above. However: It is also possible to achieve glare-free arrangements with lambertian light emitted from a standard LED with incorporated phosphor (see Figure 7 and figure 11).
The use of a canopy provides essential advantages to the benefit of the quality of the light and to its distribution. Since the radiation from a canopy is no longer lambertian but follows it's specified characteristics the design of luminaires is to be changed essentially - while amazing new possibilities are disclosed. But the biggest advantage of the canopy is that the luminosity of the light source (canopy) is a fraction of the luminosity of the underlying LED. This allows the design of luminaires with high lumen output (e.g. Streetlight) with visible light sources (Canopies).
Figure 3 shows arrangements of Canopies to be used in luminaires with visible light source and two types of Ggs-Lgntern gppgrgtus for streetlighting. Thgnks to the "cgnopy-shielding" of the primgry light source (LED) gnd the big surfgce of the Cone-Shgped Cgnopies the light of such lumingire will not be glgring - even if the emission of one single cone cgn regch over lOOOlm (with g surfgce of gbout 23.5cm2). The gpplicgtion rgnge is open for more or less powerful grrgngements. Normglly cones gre used for illumingtion with high lumen output (3001m or more). But glso for smgller gpplicgtions g cone cgn glwgys egse the issue of glgre. According to the gpplicgtion rgnge in lumingires the expected lumen output per cone (of the dimensions gs gbove) is likely to extend from 400 to 12001m. Higher luminous output is possible gnd desired in some gpplicgtions. In order to keep the luminosity under control the size of the cone / cgnopy would be likely to be incregsed in proportion to the luminous output of the grrgngement.
The proposed grrgngements gs on figure 3 will be perfectly suitgble to replgce Ggs Lgntern Lumingires thgt provide gbout 4501m per Fig me (Ggs-Sock). Since g Ggs-Sock hgs g very similgr gppegrgnce gnd light distribution pattern as specific canopies, this cone-canopy technology will comply also to requirements of the protection of historic buildings and monuments. Using suitable LEDs and Phosphor even the light color and CRI of the Gas-Light can be emulated - while using 98.8% less Energy.
The arrangements in Figure 3 show two possible layouts of many more. Gas lanterns are used with various numbers and layouts of Gas-Socks. The embodiment of the existing gas lantern can be emulated in identical manner by the use of remote phosphor cone canopies.
The proposed technology is - due to its comfortable light - not restricted to the emulation of gas lanterns. It has a vast range of possible applications both - with the canopy visible or enclosed (cutoff). The use of this technology is very promising also for the modernization or substitution of "mushroom-lanterns" that are/were very popular for illuminating urban areas and pathways. By adding simple reflectors to these canopies the performance of such canopy-systems can be further improved. Also a number of Canopy-Modules (l...n) can be equipped with a cap to connect to existing fixtures. Electronics to "drive" the lighting modules can be built into the assembly or they can be added externally similar to a "ballast". In some cases even the simple exchange of existing lighting bulbs (incandescent, discharge or fluorescent) with a LED-Replacement of the following typologies (see Figures 4a, b + c and 6) can bring big savings and a better quality of light.
Figure 4a, b +c show open stack and opposite plate-stack arrangements of Canopies with heatsink. The technology and arrangements proposed in this invention are suitable for illuminators with considerable light output within yet a compact body shape. By the use of high efficient LEDs and canopy the power-requirements - imposing expansive and heavy heat sink arrangements in traditional LED-luminaires - can be reduced to a minimum. By the use of particular heat-sink- modules (9. to be illustrated in Figure 5.) the heat gets dissipated in best way while the weight and dimensions of the assembly remain at limited extent. By the arrangements used in this invention all critical aspects of proportions in LED-luminaires reach a totally new level of balancing light output, total power used (efficiency + inducted heat), weight and dimension of heatsink and optical characteristics. By using the inventions potential even powerful HQL and HQI-Bulbs are becoming targets to be replaced with LED-Retrofit apparatus.
Figure 4a (sectional concept drawing in x-axes-direction) shows a Stack of Canopy Modules assembled to a Retrofit-Lamp with a cap for connection to a luminaire. For the ease of understanding the conceptual approach, all mechanical construction-elements are not illustrated. The assembly consists of the following functional components: 1. Canopy Light Source mounted to a Heatsink arrangement (9.). Distributive reflectors (6.) are used to increase the light output of the apparatus. These reflectors can be of parabolic, free form, multi-facet or other geometry. Reflectors can be adapted to the luminaires requirements in any position of it. The drawing does not show an eventually needed power supply unit (PSU). This PSU can be inside or outside of the arrangement. The number of Canopy- Modules can vary (l..n) according to the requirements of luminous output of the apparatus.
Figure 4b (sectional concept drawing in x-axes-direction) shows a Stack of Multiple Canopy Modules assembled to a Retrofit-Lamp with a cap for connection to a luminaire. The assembly consists of similar components as the arrangement in Figure 4a but it has multiple (in this case 2) light sources per Module. Two modules are mounted opposite to each other to constitute a Module-Package. Within this package an additional reflector (6.) can be added to optimize the light distribution and output. When using two modules of two Light-Sources, the oppositely positioned modules can be rotated to an "offset" of 90° between each light-source in the package to achieve an optimized light-distribution. Multiple such packages can be stacked to increase the luminous output of the apparatus.
How much luminous output can be expected? For an apparatus using 3 Module-Packages (Figure 4a.) operating at 5W each, the following output can be achieved: System-Efficiency 140lm/W => 3x5x140 => 21001m with only 15W electric power. This level is sufficient to replace a 50W (60W effective power) HQL-Lamp with 20001m. With an expected luminous Efficiency of LEDs of 200lm/W future solutions can replace a 50W HQL with only WW (3x 3W). With only 3W per Module the heatsink of all elements will be an "easy" issue and even smaller designs will be possible. A 90W HQL-System (80W net. HQL) with 40001m output commonly used for streetlighting can actually be replaced with a 30W (in the future with a 20W) arrangement consisting of 3 Modules with 2 light sources per module (Figure 4c shows a possible arrangement of such apparatus).
The number of variants and arrangements of such canopy-based lighting-modules is numerous. The selection of three reference-types to illustrate this inventions potential does not exclude the protection of all other variants that make use of claims of this invention.
Figure 5 shows a schematic illustration of possible Materialization + arrangement of Heatsink. As with every LED-Light apparatus the majority of energy supplied to the LED-Light-Source is to being abducted to the underlying structure bearing the same. Since typically 90% of the energy is transformed to heat the design and management of heatsink is highly relevant for the quality of LED- Lighting. In case of supplying 5W to each canopy-light-source 4.5W of it have to be thermally abducted by the heatsink structure. As for all other examples made in this document the invention is not limited to the data or pattern provided but it extends to all possible applications bearing the use of claims contained in this invention.
The present invention includes a new approach for heatsink design of LED-Modules (indifferent for lambertian light sources or canopy-emitters, indifferent of the power to be dissipated and also indifferent to the shape provided to the heatsink element(s)). The objectives of this particular heatsink are the following:
- abduct the heat reliably to maximize endurance of the lighting modules
- save space to allow compact arrangements of lighting devices
- save weight to keep the entire apparatus weight within required limits
- ease of make at low cost
Typically heatsink-modules are made of metal (Copper or Aluminum, not excluding other materials or combinations of them). The background of the invention in this heatsink is the need to maximize the actively dissipating surface. The exchange of heat to the ambient air shall be provided by passive (intended) or active air convection (Ventilators can be added if required). Heat pipes may be used to transfer heat as well. It is the aim of this invention to enable "passive" heatsink for the arrangements of illuminators. Active elements (Ventilators and heat pipes) shall only be used if the system requires them. The arrangements and production method for the heatsink modules (9.) in this invention can be specified as follows:
- Heatsink Core: The basic material is thin Aluminum-Sheet metal. This metal is punched with holes and shaped according to the requirements of the heatsink module. The shape can be given by crimping ("ondulation" as for corrugated paper) or by punching cones or other shapes to the surface in a (tight) pattern. The holes in the metal-sheet will allow air to pass and to remove the heat. This "corrugated" metal unit (one or more) must be connected well to the outer shell of the heatsink module (method(s) below) to ensure the heat transmission and dissipation.
Alternatively to metal-sheet metal-wool can be shaped and fixed to the requirements of the heatsink module (as a stuffing inside the shells). A balance between heat conduct and surface maximization must be found by doing so. Also the connection of the wool to the outer shell of the heatsink module must be guaranteed to entire the heat transfer to the wools "fibers". The dimensioning of the "fibers" is essential for the emission of heat. Therefore the "roughness" of the wool will have to be specified according to the technical characteristics of the targeted apparatus.
- Heatsink-Shell: A shell is contouring the heatsink core(s). As the core also the shell is typically made from thin aluminum sheet-metal. It can be corrugated, punched with cones, shaped to the shape of a reflector or to any other suitable shape. The heatsink-shell can contain mechanical elements to attach apparatus' components to each other. Also the Shell can coincide with a reflector or it can contain links to heat-pipes or auxiliary structures such as deflectors (7.). If possible also the surface of the shell is pinched with holes to ensure free or forced airflow.
- If useful and possible shell and / or core can be treated in their surface to increase the heatsink capacity (e.g. by matte black coating). This coating shall not hinder the distribution and flow of light.
- The making of the heatsinks sandwich-arrangement is proposed by using a baking-process similar to SMD-Soldering. By "moistening" the "tips" (outstanding parts) of the corrugated or punched core (equivalently applicable for the outer "fibers" of a woolen core) with SMD-solder-paste, then adding and pressing the shells around the moistened cores to finally bake the heatsink-module in an SMD-oven (while keeping the assembly under pressure). After cooling down a very lightweight but yet stiff and efficient heatsink module will be available.
The making of such heatsink modules is not limited to the aluminum sheet-metal or wool as specified above but it extends to all kind of materials (incl. heat sink "plastics") or "honeycomb-structures". Also the SMD-Soldering-process can be replaced by welding (also by induction) or by other methods (eg. Filling fluid metals to drain the excess). Also thermal or chemical glues or silicone can be used for making the heatsink. When weight is no issue, such heatsink module could be even cast or punched at full.
When accepting a reduced lifetime of the apparatus' electronic components or in case of small power to dissipate also a surface-coated foam or plastic "shell" could be used to make the heatsink modules. In general the present invention explicitly includes the integration of functional parts such as heatsink and reflectors. As a consequence a next level of invention is introduced - the glare free "cut-off" and control of the light source (Figures 6.).
Figure 6 shows two examples of Canopy- Stacks with Reflectors and integrated heatsink. As for all the other elements in this invention the number of stacks, light sources and the shape or proportions of the optical elements are of purely indicative character. The inventor claims all aspects to the benefit of any illuminator making use of elements of this invention.
With Figure 6 a new concept is being introduced to allow the control of big quantities (portion) of the light emitted by the light source (s). The objective of capturing and controlling the light is achieved by combining two reflectors - a Collective Reflector (5.) and a Distributive Reflector (6.). If required and in order to further control or cut out the visibility of the light source additional Distributive Reflectors (Deflectors) (7.) can be added to the assembly. The two illustrations in Figure 6 show two arrangements for lighting apparatus equipped with a cap for direct connection to the power. Both solutions will emit the light in a wide beam angle with a similar pattern. Such arrangements are useful for ceiling and pole-fixtures but also for many other applications that require a large distribution. In the arrangements as shown in Figure 6 the reflectors and the heatsink are forming an integral functional part.
Reflectors for such apparatus can be symmetric on the axis of rotation but this is not given. For many applications (such as streetlight lanterns) an asymmetric and even a rectangular distribution can be desired. By shaping the reflectors accordingly or by adding suitable deflectors (according to concepts in Figure 13) such apparatus can be conditioned to the requested light distribution. This concept will allow to efficiently retrofit basically obsolete styles of street lanterns (Mushroom, suspended "Helmets" or Ball-Pole-Lamps, etc.)
The reflectors of such illuminator have typically a "parabolic" shape on the collective unit. Since the canopy-light-source does not have a single focal point to refer to the parabolic curve is to be adjusted to achieve an optimal result. Further the reflector can be shaped as a "multi-facet-mirror" to optimize the making and the light distribution. The Distributive reflector is often a combination by additional "parabolic" surface to capture the remaining light of the light source. At least one part of the secondary reflector is dedicated to direct the majority of emitted light to surface for illumination. Even i more than the collective reflector the distributive reflector can be of free form according to the requirements of light distribution. It can be convex, concave, parabolic, multi facet, flat or any other shape that may be required to obtain the targeted light distribution pattern.
As Collective and distributive reflectors also Auxiliary deflectors can be freely defined according to the illuminators requirement.
All reflectors, deflectors and components of the apparatus can also be used for structural or other purposes. Typically an Auxiliary Deflector can be used to assemble the different lighting modules in a Stack of Canopies with Reflectors. An Auxiliary deflector can also bear an (essential) part of the Heatsink-Function of an illuminating apparatus (see Figure 7.).
Figure 7 a shows an arrangement with lambertian light source in a glare free apparatus (sectional concept drawing in x-axes-direction). This new type of arrangement for LED illuminators is capturing 100% of the emitted light. The "double semi-parabolic" collective reflector (6.) transfers the light to the distributive reflector on the "opposite" side. By selecting focus, direction, size and offset of the two semi-parabolic "collectors" the light beam (3.) exiting the collective reflector can be directed to at least two different zones on the distributive reflector. The benefit of this invention becomes clear: 100% of the light is captured and controlled and can be directed to the required pattern of distribution. With this kind of innovative arrangement a sector of over 90° (relative to the x-axes) can be totally controlled and evenly distributed. As an additional advantage of the invention, the apparatus is totally free of glare. This is due to two factors:
- The light source is totally "cut-off" (not visible for the user). No light beam (3.) cam meet the user's eye as a direct emission of the light source.
- The high intensity of the light source is fractional due to the multiple expansion of the light beam by the reflectors.
Since there is no diffuser at all in this arrangement the efficiency if the apparatus is likely to be very high, relative to the efficiency of the reflector's (5. & 6.) surface.
The example shown in Figure 7 is intending to illustrate a sectional view of an aluminum profile to illuminate a shop display cabinet with glass walls. By the use / in spite of a lambertian light source the apparatus is totally glare-free. The auxiliary deflector 7. can be used to control the light distribution on the y-axes (see figure 12 for details). In the same the deflector (7.) performs as support for the light source attached to its front-end. The angle of attach (A) - relative to the collectors direction for projection - and the collector design - can be defined according to the requirements of the light distribution of the apparatus. But the deflector also has the function to carry the light source (or its carrying structure) (8.) and the power-cable to supply the light source. It even has a third integral function. By making use of its (metallic) structure it will dissipate the heat of the light source. By using the principles and features described above the heatsink-capacity can get adjusted to the light sources requirements.
The Figure 7 b is illustrating that an essential part if this invention may be the use of two differently focused and / or directed collective mirrors (CI / C2). This arrangement allows re-directing the collected light to different areas on the distributive mirror (in the illustration 7 b shown for a canopy light source). One and the same light source can therefore be used to generate two (or more) independently controllable light beams. The proportioning of the amount of light directed to "beam 1 or beam 2" can be adjusted by positioning the light source relatively to the collectors. Theoretically an unlimited number of collectors can be specified around the light source in order to fraction the light in the corresponding amount of light beams. Proposed solution if doing so is by dividing the collective reflector to different parabolic sectors around the center (in x-axes) of the light source. Since these light beams can be directed freely in the segment of over 90° this feature allows very particular designs of glare-free luminaires. This new feature - single, double or multiple collectors with different focal points and beam directions - makes part if this invention.
The possible subdivision and shaping of the distributive reflector can additionally be used to shape and direct the light beam as required. Convex, concave, flat, free form, multi-facet - the range of freedom is barely limited. Figure 7 a shows that the most upper light beam - leaving the collector in parallel to the others - meets the distributive reflector in a different point above and radiates differently as a consequence of this. The most upper beam in the analysis before, it is under passing all the other beams to descend to the projection area in a different angle (3.).
A lambertian light source may set limits to the design of powerful non glaring luminaires. In many situations a canopy light source can bring improvements and ease for the design of luminaires in response to complex lighting demands. The further analysis of this invention is therefore (unless mentioned differently) based on canopy-based light sources with their specific light distribution- pattern as shown in Figure 2.
Figure 8 shows a glare free arrangement with a Canopy light source on top of the apparatus (sectional concept drawing in x-axes-direction). The positioning of the light source on top-front of the luminaire is influencing the optical characteristics of the luminaire as follows:
- The light source (1.) may be partly visible for the user - see source beam (4.).
- A long shield used as extended distributive reflector can prevent the direct visibility at some extent but there may remain some viewing angles that still allow direct radiation.
- The light emitted by the canopy may not be controlled completely. Depending on the length of the distributive reflector a portion of light radiates directly through the gap between collector and distributor. If the distributor is long enough to capture all the light emitted by the canopy source, half of it is controlled only by the distributing reflector.
- This may be an advantage for efficiency, since about 50% of the light does not have an additional loss from a first reflection. With a good design of the secondary reflector the distribution of the light can be perfectly organized according to the requirements of the apparatus.
Figure 9 shows a glare free arrangement with a Canopy light source on the bottom of the apparatus (sectional concept drawing in x-axes-direction). The positioning of the light source on the bottom- front of the luminaire is influencing the optical characteristics of the luminaire as follows:
- The light source may be partly visible for the user - see source beam.
- A long shield used as extended distributive reflector can prevent the direct visibility at some extent but there may remain some viewing angles that still allow direct radiation.
- Due to the limitation in geometry between the lower edge of the collecting reflector and the visibility and control of the light source some issues may incur.
- This arrangement can be useful if the lower part of the housing of the luminaire shall be used as heatsink.
Figure 10 shows a glare free arrangement with a Canopy light source on the right side (sectional concept drawing in x-axes-direction). The light source is on the right side of the collective reflector pointing to it in axes with the main targeted direction of the same. Modifications to the axes of the light source and its relative position to the (parabolic) collector will change the arrangements behavior. The positioning of the light source and the shaping of reflectors is to be elaborated with detailed studies in relation to the canopies emission diagram, in order to achieve the illumination targets. The positioning of the light source opposite to the collective reflector(s) is influencing the optical characteristics of the luminaire as follows:
- Depending on the distribution pattern a majority of light hits the (parabolic) collector in perfect manner.
- 100% of the light is captured and controlled.
- The light source is barely visible directly and even in an angle with low luminosity of the same.
- To avoid self-shading of reflected light a small "dome" shall capture the light emitted from the center of the canopy - and lead it to the "out taking" side of the collector (needs 2 reflections in the collector)
- This setup 'promises' big degrees of freedom for the design of collectors, distributors and the eventual need of deflectors and structural parts.
- The heatsink (9.) of the light source can be allocated (at least partly) in its "shadow" directly behind the emitting surface.
- The support structure of the light source may serve as heat-pipe (e.g. made from copper or aluminum) and it can be extended in surface (as a deflector (7.) to the y-axes). Also it shall carry the power-supply-duct for the light source.
- The positioning of the support-structure (8.) can be optimized to the benefit of the apparatus. A proposed solution is to the top of the luminaire (see proposal in lower section of Figure 10) to abduct the heat optimally (9.) to eventual heat-dissipation structure allocated nearby (if required). Depending on the selected luminaire topology and requirements for light beam control on the y-axes a support to the bottom may be useful.
- The arrangements in Figure 10 pose a minimum of restrictions to the use for side-deflectors to control the radiation on the y-axes of the apparatus.
The degrees of freedom of this arrangement seem to be the optimal alternative and make it the preferred selection. Also this arrangement allows the easy adjustment of the canopy and its angle (see Figure 7 a letter A) opposite to the collecting reflector. All light comes clean and precisely directed from the primary reflector. The distributive (secondary) reflector neither has [imitations from this arrangement.
In fact the distributive reflector can be made in many different ways. Adjustable (e.g. by rotation or by universal joint support) reflector elements (E) can be added to the arrangement. One more possibility for the management of the alternative distribution patterns is to provide modular reflector-kits as distributive mirrors. Such kits will for instance reduce the number of types of fixtures for streetlight apparatus responding to different typologies. Modifications to the distribution pattern by the use of modular or adjustable elements could possibly be done even on site. This arrangement can represent the "perfect" apparatus to build streetlight fixtures with excellent characteristics.
Figure 11 shows a glare-free (cut-off) arrangement with lambertian Light source in auxiliary reflector with flat canopy and anti-glare-deflector. In this typology of apparatus a lambertian light source is placed directly opposite to the distributive reflector. In order to capture the emitted (lambertian) light beams in optimal way, the "collector" can be optimized to capture a big proportion of light. In this construction however - depending on the distribution of the lambertian light source (eventually behind the phosphor shield - but also possible "directly" with "standard-LEDs) - only a part of the emitted light gets in control of the primary reflector. A part of the light will radiate in different angles from the canopy. Since the light source may be directly visible to the eye an additional deflector can be added (7). In order to capture and distribute the light according to required pattern, the secondary (distributive) reflector can be enhanced with (eventually adjustable (E.)) optical characteristics.
This arrangement may be applicable to apparatus using remote phosphor or direct light source. The use of a diffuser / canopy over the light beam may be even hindering the required capturing and control of a possibly big portion of emitted light. The use of an optical lens (collector), auxiliary reflector or refractor placed in front of the canopy can help to ease the "diffusion- and control-issue" but it will be in trade off with the efficiency and glare of this solution.
If the direct visibility of the light source is not critical for an arrangement a canopy (cone) light-source can be installed inside the collective reflector with its "front" directly pointing to the distributive reflector (arrangement similar to Figure 11 but with cone canopy instead of the flat canopy. Direct emission to the distributing of a big part of the emitted light without any reflection on a collective mirror may increase the efficiency. On the other hand it is more difficult to control the "unstructured direct light on the distributing reflector.
Figure 12 shows two glare-free arrangements "back-to-back" with cover for Protection. In order to arrange a setup for a non-glare, wide range apparatus to emit the light to both directions along the x- axes the inventor proposes to join two arrangements as shown in the Figures 8-10. The illuminator will be attached "back-to-back". The side with the distributive reflector will be in the center of the apparatus. The distributive Reflector can be made big in its dimensions to reduce glare effects to a minimum. Also it can be equipped with adjustable or modular devices as specified above.
A cover added to the fixture shall not hinder the light on its path more than necessary. If needed however, the cover can be equipped with additional refractors, reflectors or filters.
Even if Figure 12 looks like an arrangement for streetlamps the invention is clearly not limited to such application. The proposed arrangements can be perfectly used for general lighting (indoors and outdoors) such as for floodlight, for wall washing, for high bay lighting, for small or large scale illuminated billboards, for automotive or other mobility use and for any other application that will make benefit of these inventions.
The specifications were so far mostly done for non directed light or for the light emitted on the x-axes of an illuminator. Many applications - also streetlight! ng - will require control over the x-axes too.
Figure 13 shows arrangements to control the light output on the y-axes of the apparatus. While Figures 7 to 12 were sections along the x-z-axes Figure 13 is dedicated to possible sections along the y-z-axes. The illustrations 1-4 in Figure 13 show a selection of arrangements to control the light output on the y-axes too while the x-axes is controlled by the collecting and distributing reflectors illustrated above.
Double parabolic reflectors with round or oval (or any form) sections (as shown in Figure 13-1) will direct the light to one main desired direction. Since 100% of the emission of a light source can be captured by a collector the result can be optimal. The engineering and manufacture of such reflector can be complex and costly however.
The situation illustrated in Figure 13-2 shows a "double-semi-parabolic" as manufactured e.g. as a profile or shaped sheet metal. The axes of the parabolic reflector is leading in parallel of the y-axes. In case no lateral deflectors or reflectors are applied - upright or similar to the y-axes - the light will expand along the y-axes with up to 180° under the illuminator in a quite uncontrolled manner. In many applications a controlled beam will be required.
Figure 13-3 shows the effect of adding an additional parabolic reflector "over the x-axes" of the apparatus - along with the axes of the light source. As a result a majority of light will be controlled to the direction given by the deflecting mirror. By the use of a parabolic mirror the captured light will radiate to mainly one direction. Only the "non-controlled" portion radiates according the original direction of the emission.
Aiming for a wide but controlled distribution an arrangement as illustrated in Figure 13-4 can help. The upper part of the deflector is collecting the light in an optimized manner while the lower - rather rectangular part - is providing a broad but glare free distribution. Due to an increased number of reflections in this arrangement the efficiency can be affected. Since the aspects of glare, wide beam angle and efficiency are linked to the "mechanics" of this arrangement, the optical layout of it is matter of optimization. More distance from one side to the other (extension on the y-axes) will increase the efficiency but reduce the control over the light. Narrowly positioned side reflectors (short distance on the y-axes) reduce the glare (in case the light source would be directly visible from below) and increase the beam angle but as mentioned the efficiency will suffer from a high number of reflections in a relatively "small optical compartment".
Figure 14 shows arrangements of multiple and mixed arrangements to match multiple lighting requirements. As only one of an uncountable number of variants and alternative of arrangements Figure 14 illustrates an apparatus for a streetlighting fixture with added features. By adding a lighting module of similar arrangement as shown above the "original" streetlight luminaire for extra wide beam angle can be enhanced with an additional illuminator with a second purpose. Since this (one or more) is allocated in the center of the apparatus (more could be added to the sides too) it is 90° turned against the x-axes, so it radiates to the y-axes primarily. By applying different light pattern for this auxiliary or additional "projector" the following purposes can be fulfilled:
- additional lighting for a pedestrian crossing
- lighting of a road or square exiting to another road
- lighting of a parking space or emergency bay next to a road
- lighting of a junction to "all" (3 or 4) directions
- lighting of a "roundabout traffic"
- lighting of squares
- lighting of a monument next to a road
- lighting of traffic or road signs on a non-illuminated pole
Since the number of modules, their arrangements and optical characteristics, their output power and many other aspects can be managed to perfection by using the inventions claimed herewith, the range of possible embodiments is extremely large when using the proposed methods. As illustrated in examples throughout this document the invention can be used for small lighting applications e.g. inside of an aluminum profile but also it can be used for Mercury- or Sodium-Bulb-Retrofitting, as powerful accident site-illumination or even as floodlights for sports fields.

Claims

Claims of the invention:
1. New typologies for glare free illuminators making use of Canopies (Figures 1 + 3), in an arrangement to ensure the light distribution to large surfaces or to reflectors (Figures 4 + 6.).
2. New typologies for glare free illuminators making use of Canopies (Figure 1), two (2 or more / 2...n) oppositely positioned and precisely shaped reflectors (Figures 6, 7. et. ff.), in an arrangement to ensure the glare free light distribution to large surfaces (Figure 14 et. ai).
3. New typologies for glare free illuminators making use of Lambertian or point light sources (Figure 7 + 11), two (2 or more) precisely shaped reflectors (Figure 7. et. Ai), in an arrangement to ensure the glare free light distribution to large surfaces (Figure 14 et. ai).
4. The invention is characterized in that different typologies of illuminators making use of one or more claims may be combined to modular assemblies of illuminators with multiple purposes.
The following Claims are referring to one or more claims above. For the ease of reading and understanding not all logical references are explicitly formulated and repeated in each single claim.
5. Illuminating arrangements of Claim 1 + 2 typically make use of Canopies as shown in Figure 1 (Dome, Cone or similar).
6. Illuminating arrangements of Claim 1 + 2 typically make use of Power LEDs mounted to the open bottom of the Canopies of Claim 5.
7. Illuminating arrangements of Claim 1 + 2 typically make use of blue LEDs to illuminate a Canopy made with incorporated Phosphor to emit white light.
8. Illuminating arrangements of Claim 1 + 2 can be enhanced by the use of red LEDs or differently colored LEDs to increase the quality and color of the emitted light.
9. Illuminating arrangements of Claim 1 + 2 are typically capturing and transferring 100% of the light emitted by the primary light sources.
10. Illuminating arrangements of Claim 1 + 2 are making use of the fact that the light emitted by the primary light source is modified in its qualitative aspects e.g. color and CRI such as in its intensity distribution and diffusion.
11. Illuminating arrangements of Claim 1 + 2 can make use of Power LED, LED Arrays, Light Engines, COBs, corn-Lamps and PCB-Based LED-Assemblies as primary light source.
12. Illuminators according to claim 1 + 2 are characterized in that the (secondary) Canopy light source element (1.) is neither emitting according to lambertian, nor to a point light sources intensity distribution.
13. Illuminators according to claim 1 + 2 are characterized in that the luminosity of the Canopy light source is reduced to a fraction in proportion to the primary LED and the surface of the Canopy.
14. Illuminating arrangements of Claim 1 + 2 can make use of different pattern of luminous intensity provided by the Canopy light source.
15. Illuminating arrangements of Claim 1, 2 + 3 (for 3 see Figures 7a + 11) can make use of planar or any other useful shape for their Canopy.
16. Illuminating arrangements of Claim 1 make use of one or more (l...n) Canopies with visible Canopy light source. (Figure 3)
17. Illuminating arrangements of Claim 1 are particularly suitable to serve as substitute of Gas- Lanterns or any kind of Gas-Lighting using flame-socks.
18. Illuminating arrangements of claim 1 can comply with the requirements for the protection of historic environments.
19. Illuminating arrangements of claim 1 can be used perfectly to emulate the light and appearance of historic gas-luminaires.
20. Illuminating arrangements of claim 1 consider the applicable norms in the field of glare to calculate the minimal surface of a canopy in relation to its luminous output power.
21. The performance of Illuminating arrangements of claim 1 can be enhanced by adding reflectors or other optical elements. Reflectors can be convex, concave, parabolic, free form, multi-facet or any other geometry.
22. Illuminating arrangements of claim 1, 2 + 3 can be equipped with standard or particular heatsink (Figure 5 + Claims 28ff).
23. Heatsink and reflectors according to Claim 22 can be unified.
24. Illuminating arrangements of claim 1, 2 + 3 can be unified with a heatsink-reflector-unit (according to Claim 23) to form a canopy-module with one or more canopy light sources (l...n).
25. A canopy-module according to claim 24 can be equipped with a cap to connect to an apparatus.
26. A number (2...n) of canopy-modules according to claim 24 can be joined to form a stack or any other unified pattern.
27. The power supply of illuminating arrangements according to Claims 24 + 26 can be built into the assembly or it can be placed externally.
28. The particular Heatsink according to claim 22 is of very light weight.
29. Active or passive cooling and heat-pipes may be used to dissipate the heat from the core and surface of the heatsink.
30. The heatsink according to claim 22 is made of core material (l...n cores) and a mantling shell in a Sandwich-Assembly.
31. The core of the heatsink according to claim 22 can be made of flat, punched or corrugated aluminum sheet metal. It can be punched with holes too to enable the air convection. The Corrugated or Dome-Punched surface of the aluminum sheet is maximizing its surface. Alternatively to aluminum sheet metal aluminum wool can be used to form the core. The "alu- wool's fibers will maximize the surface where heat can be abducted to the circulating ambient air. The "roughness" of the wool is to be optimized to maximize surface in relation to air passing, heat-conduct and transmission from the shells.
32. The heatsink-shell according to claim 22 is made of flat, punched or corrugated aluminum sheet metal. It can be punched with holes too to enable the air convection.
33. The heatsink shell according to claim 22 contouring the core of the heatsink (Claim 31) can be shaped according to a reflectors requirements. The surface of the heatsink shell and a reflector may coincide in double function.
34. Both heatsink Shell (Claim 32 + 33) and Heatsink Core (Claim 31) may contain mechanical elements to attach other elements or assemblies of the apparatus, to attach heat-pipes or any kind of mechanical, electrical or optical element.
35. Shell and Core of a heatsink according to claim 22 (30 etc.) can be equipped with surface treatment (e.g. matte-black coating) to increase their heatsink capacity.
36. For making of the heatsinks according to claim 22 (30 etc.) a sandwich-arrangement is applied by making use of a baking-process similar to SMD-Soldering. "Moistening" the "tips" (outstanding parts) of the corrugated or punched core (equivalently applicable for the outer "fibers" of a aluminum-woolen core) with SMD-solder-paste, then adding and pressing the shells around the moistened cores to finally bake and cool the heatsink-module in an SMD-oven (while keeping the assembly under pressure). The structures and procedures of claims 30-36 provide a very lightweight yet stiff and efficient heatsink module.
Alternative to the baking, heatsink-glue or -silicone can be used to assemble shell and cores.
37. With LEDs bearing more heat or getting more efficient and requiring less heatsink, such heatsink according to Claims 22 and 30-36 can be simplified.
38. Aluminum-Honeycomb-Structures can be applied for heatsink assemblies (Claim 22).
39. In reference to claims 22 + 23 and 38 Aluminum-Honeycomb structures can be shaped to serve as reflectors with heatsink capacity.
40. Particularly heat conductive Polymers (plastics) can be used to make Heatsink or Reflector- Heatsink-Units according to Claims 22 + 23.
41. Illuminating arrangements of claim 2 + 3 can be improved by adding two reflectors - positioned in opposition to each other (Figure 6). The first reflector (5.) is collecting a big part or all of the light emitted by the light source. The second reflector (6.) is used to optimize the distribution of the light arriving from the collector (5.) and the Light source (1.) directly.
42. The optimization of illuminating arrangements of claim 2 + 3 can require additional distributive or deflecting mirrors (Deflectors - Figure 6 Element N° 7.).
43. Reflectors for Apparatus according to Claims 25 + 26 (ff.) can be asymmetric, or even rectangular, planar or any other shape delivering the desired light distribution to the arrangement.
44. Reflectors for Apparatus according to Claims 25 + 26 (ff.) can be made adjustable or modular to enhance the arrangement as required.
45. Parabolic, Multi-Facet-Parabolic or similar shape are preferred embodiments for collective reflectors according to Claim 41.
46. With Reference to the illuminating arrangements of Claim 2 + 3 reflectors, deflectors and other components such as heatsink or electric wires can be used for structural or other integrated functions (see Figure 7a Numbers 7. / 8. 9.). In opposite meaning also heatsink or structural elements can be used as reflectors or for shaping the light.
47. The arrangement for lambertian light sources as shown in Figure 7a - according to Illuminating arrangements of Claim 1 - is capturing and controlling 100% of the emitted light by parabolic structures opposite to and fully encapsulating the lambertian light source.
48. The entire light beam captured according the principle of Claim 47 is projected to the distributive reflector. No light is leaving escaping the apparatus without deflection by the collecting reflector.
49. Claims 47 and 48 are applicable also for Canopy light sources referring to claim 5.
50. Illuminating arrangements of Claim 2 + 3 make use of one or more (l...n) collective reflectors that can have individually specific characteristics to re-direct the captured light (see CI + C2 in Figure 7 a + 7 b).
51. With reference to Claim 50 the individual parabolic characteristic may be "dome-shaped" in the x- y-z-axes or it may be of the typology parabolic concave profile along the y- or the z-axes. According to the light source (Lambertian or Canopy) the shape of the "parabolic" reflector has to be adapted to achieve the required results. Therefore the curve does typically not coincide with a mathematically formulated curve for a real parabola. Multi-Facet, and even convex shapes may be required to achieve optimal results.
Further it is very important to assure that in the case of single or multiple parabolic shapes the focal points of the parabolas are specified to optimize the light captured, in particular to avoid light being reflected back to a light source or to a structural element other than targeted reflector or deflector surface.
52. With reference to claim 50 the position of the light source can be modified by its angle (A) against the direction of the collective reflector.
53. With reference to claim 50 the position of the light source can be modified by its room-coordinate along the x-, y, and z-axes of the apparatus.
54. With reference to claim 50 a cone shall be added to the reflector where the rotation axes of the light source meets the collector. This is to avoid inefficiency by possible light being reflected back to its source. This cone - also with parabolic characteristics - shall be optimized and dimensioned in order to avoid "virtual" shadows of the light source and its structure including heatsink and supporting elements.
55. With Reference to the illuminating arrangements of Claim 2 + 3 the distributive reflector can be subdivided in different (deflection) zones according to the possibly different light beams projected from the number of collectors (referring to Claim 50).
56. With Reference to the illuminating arrangements of Claim 2 + 3 the distributive reflector(s) can be extended along the y-z-plane in order to capture nearly 100% of the light transferred from the opposite collector(s).
57. With Reference to the illuminating arrangements of Claim 2 + 3 and 56 the arrangement can be designed to make it impossible to see the light source from any position outside the apparatus (Fully "cut-off" optical arrangement).
58. With Reference to the illuminating arrangements of Claim 2 + 3, 50, 56 (and more) the arrangement grants glare free light due to the primary light beam's luminosity fractured to marginal quantities by an eventual canopy and at least two redirecting and surface-expanding reflectors. The beam's intensity is "leveraged" to very low values, even when looking directly to the light beam coming from the distributive reflector.
59. With Reference to the illuminating arrangements of Claim 1, 2 + 3 optical elements such as reflectors, deflectors and eventual structural elements of the apparatus are used for heatsink to abduct the light-sources heat.
60. With Reference to the illuminating arrangements of Claim 2 + 3 the canopy light source(s) (l...n) can be positioned on top of the collecting reflector, (see Figure 8)
61. With Reference to the illuminating arrangements of Claim 2 + 3 the canopy light source(s) (l...n) can be positioned at the bottom of the collecting reflector, (see Figure 9)
62. With Reference to the illuminating arrangements of Claim 2 + 3 (and others) the canopy light source(s) (l...n) can be positioned at the right side of the collecting reflector pointing to it in x- axes with the main targeted direction of the collectors, (see Figure 10)
63. With reference to Claims 2, 3, 43, 46, 50-59 and 62 the embodiment with light source on the right can provide highest degrees of freedom for the arrangement and design of lighting fixtures. Heatsink in the "shade-area" of the light source. Light-source-support, power-supply, light- shaping on the y-axes with additional heatsink shall be all attached to the top of the arrangement (see Figure 10 - lower).
64. With reference to Claims 2 + 3 the distributive reflector can contain adjustable elements (as shown in Figure 10 - letter E). Such elements can have rotation or universal joint support. They can be convex, concave (both with different focal lengths), flat or any other shape that can be useful to direct and shape the light beam according to requirements.
65. With reference to Claims 2 + 3 the distributive reflector can me made from modular segments to perform according predefined pattern. Modular distributive reflector enables commissioning on site. It can greatly reduce the number of variants on luminaires and SKUs (Stock Keeping Units). A distributing reflector can consist of 1 or more( l...n) modules.
66. With Reference to the illuminating arrangements of Claim 2 + 3 the canopy light source(s) (l...n) can be positioned on the left side of the collecting reflector, (see Figure 11 - arrangement only - no cone illustrated).
67. Referring to Claim 66 the light source can be directly placed in an optimized parabolic reflector to emit a maximum of controlled light in direction of the distributive reflector. Efficiency gain in trade off with light guidance control. A quantity of light will - if not managed by auxiliary deflectors - arrive to the distributing reflector in unstructured manner.
68. With Reference to the illuminating arrangements of Claim 2 + 3 lambertian light source(s) (l...n) can be positioned on the left side of the collecting reflector in the focal point of an auxiliary parabolic reflector, (see Fig*
69. Referring to Claim 68 a planar canopy (or any other suitable shape) can be applied over the opening of the auxiliary parabolic reflector.
70. With Reference to Claims 68 and 69 an additional (second) collective parabolic reflector can capture and redirect eventual light diffusing from the planar (or other) canopy of the arrangement.
71. Referring to claims 66 and 68 additional deflectors (see Figure 11 Element 7.) can be applied to "cut-off" the direct visibility to the light source. Such deflectors shall be optimally positioned in order to avoid masking of light beams but deflecting them in a desired direction.
72. With reference to Claims 2 + 3 the arrangements can be made "bi-directional" by joining two or more (2...n) apparatus in opposite way on the x-axes.
73. Referring to the assembly of 2 or more apparatus according to claim 72 the apparatus shall be joined "back-to-back" on the side of the distributing reflector (see Figure 12). With the availability of a long distributor-reflector in the center of the assembled luminaire any kind of glare can be avoided (if reflectors are made correctly to requirements).
74. Referring to the assembly of 2 or more apparatus according to claim 72 the connection on the side of the collecting reflector is possible for applications arranged with a short distributive reflector and / or beam angles that are relatively big in relation to the x-axes.
75. With reference to Claims 2 + 3 the apparatus can be equipped with arrangements to control the light distribution in the y-axes (lateral control) (see Figure 13).
76. Referring to Claim 75 the lateral light can be captured by the same parabolic apparatus as used for the control of the light in the x-direction (see Figure 13 - 1.).
77. As for the x-direction and with reference to Claims 50, 75 + 76 also the control of the light in y- direction can be controlled by multiple optical geometries / parabolic surfaces or curves.
78. With reference to Claims 50, 51 and 75-77 the light can radiate freely in the direction of the y- axes if no auxiliary deflectors or reflectors are applied (see Figure 13 - 2.). Such embodiment of collecting reflector could be realized as Aluminum profiles or shaped aluminum sheet metal (or other) with single or multiple semi-parabolic surface (only a parabola- section in upright angle to the y-axes).
79. Referring to claims 75-78 an additional parabolic reflector (Figure 13 - 3.) applied "over" the x- axes of the apparatus will straighten the light beam to a minimum.
80. By the use of additional reflectors opposite to the collecting reflector - according to claim 2, 3 and 41-43 - the light beam can be focused to a minimum.
81. According to claim 43 reflectors and deflectors do not need to be symmetric. Therefore an apparatus can have different light distribution pattern also to both sides of the y-axes.
82. According to the claims 77-81 the arrangement of "box-type" reflectors (figure 13 - 4.) will result in a wide beam angle and broad distribution on the y-axes - in particular in combined use with eventual auxiliary distributing reflectors opposite to them.
83. With reference to all claims concerning the lateral distribution (Claims 75-82) the importance of correct proportions and spacing of lateral reflectors is evident to every single light source. Since every single light source can - in case of absence of control - expand its radiation in uncontrolled manner and so "spoil" the targeted light distribution.
84. Referring to Claim 83 the positive aspect of the possibility to control and manage every single unit of the apparatus can be fully controlled and managed.
85. And finally also with reference to all claims above: All types of apparatus and optical arrangements of this invention can be combined in modular or engineered manner in order to obtain illuminators with highly specific characteristics and performances in all dimensions and aspects. See Figure 12 for an example of Lighting modules combined "back-to-back", taking a laterally oriented module "in sandwich" on the y-axes.
PCT/IB2014/058799 2014-02-05 2014-02-05 Glare free yet efficient led-based typologies for extra-wide light distribution WO2015118378A1 (en)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102007054206A1 (en) * 2007-10-15 2009-04-16 Harald Hofmann LED lamp with diffuser
US7988327B1 (en) * 2009-01-30 2011-08-02 Koninklijke Philips Electronics N.V. LED luminaire
US20130063935A1 (en) * 2010-05-24 2013-03-14 John E. Thrailkill Solid state lighting device
WO2013085899A1 (en) * 2011-12-08 2013-06-13 Cree, Inc. Lighting fixture

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102007054206A1 (en) * 2007-10-15 2009-04-16 Harald Hofmann LED lamp with diffuser
US7988327B1 (en) * 2009-01-30 2011-08-02 Koninklijke Philips Electronics N.V. LED luminaire
US20130063935A1 (en) * 2010-05-24 2013-03-14 John E. Thrailkill Solid state lighting device
WO2013085899A1 (en) * 2011-12-08 2013-06-13 Cree, Inc. Lighting fixture

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