WO2019040966A1

WO2019040966A1 - A modular led troffer system

Info

Publication number: WO2019040966A1
Application number: PCT/AU2018/000154
Authority: WO
Inventors: Mark Ziegler
Original assignee: Gerard Lighting Pty Ltd
Priority date: 2017-08-30
Filing date: 2018-08-29
Publication date: 2019-03-07
Also published as: AU2018322692A1; GB2588836B; GB2588836A; CN111386424A; GB202003132D0

Abstract

A modular LED troffer system (100) comprising: a number of LED modules (108) electrically coupled to each other to form a LED assembly (102), each LED module (108) having predetermined dimensions, a first electrical contact (110), and a second electrical contact (112), the first electrical contact (110) and the second electrical contact (112) are configured to electrically couple to a respective second electrical contact (112) and/or a respective first electrical contact (110) of adjacent LED modules (108) in the LED assembly (102); a frame (104) having a longitudinal axis (10) and a number of apertures (120) extending along the longitudinal axis (10), each LED module (108) being positioned with respect to the frame (104) such that LEDs of each LED module (108) are substantially aligned with a respective one of the apertures (120); wherein a predetermined length of the frame (104) determines the number of LED modules (108) based on the predetermined dimensions of the LED modules (108).

Description

A MODULAR LED TROFFER SYSTEM

Field

[0001] The present invention relates to a modular LED troffer system. Background

[0002] Troffer lighting fixtures are known. These known troffer lighting fixtures are typically used with modular dropped ceiling grids and consist of a frame, or mount box, to suspend the troffer lighting fixture from the ceiling grid. These fixtures are typically "off the shelf products and the dimensions of the fixtures are generally dictated by the lighting source utilised (e.g. fluorescent, LED, etc. ). Accordingly, a user will have to design around the dimensions of the fixtures, which may potentially reduce the aesthetics of the lighting system.

Object of the Invention

[0003] It is an object of the present invention to overcome or at least ameliorate one or more disadvantages of known systems.

Summary of Invention

[0004] In a first aspect, the present invention provides a modular LED troffer system

comprising:

a number of LED modules electrically coupled to each other to form a LED assembly, each LED module having predetermined dimensions, a first electrical contact, and a second electrical contact, the first electrical contact and the second electrical contact are configured to electrically couple to a respective second electrical contact and/or a respective first electrical contact of adjacent LED modules in the LED assembly;

a frame having a longitudinal axis and a number of apertures extending along the longitudinal axis, each LED module being positioned with respect to the frame such that LEDs of each LED module are substantially aligned with a respective one of the apertures;

wherein a predetermined length of the frame determines the number of LED modules based on the predetermined dimensions of the LED modules. [0005] In a preferred form, each LED module comprises a housing.

[0006] In a preferred form, each LED module further comprises a male connector and a female connector, the male connector configured to couple to a female connector of an adjacent LED module in the LED assembly and the female connector configured to couple to a male connector of another adjacent LED module in the LED assembly, thereby coupling each LED module to an adjacent LED module in the LED assembly.

[0007] In a preferred form, the male connector of each LED module comprises the first electrical contact and the female connector of each LED module comprises the second electrical contact.

[0008] In a preferred form, the housing of each LED module defines the male connector and the female connector.

[0009] In a preferred form, each LED module abuts an adjacent LED module in the LED assembly.

[0010] In a preferred form, the number of apertures are disposed centrally along the longitudinal axis of the frame.

[0011] In a preferred form, the LED module at an end of the LED assembly is configured to be coupled to a power supply.

[0012] In a preferred form, the LED module at the end of the LED assembly is configured to couple to the power supply through a junction box.

[0013] In a preferred form, the system further comprises:

two elongate openings extending along the longitudinal axis of the frame, one of the elongate openings located on one side of the number of apertures and the other of the elongate openings located on the other side of the number of apertures; and

a LED side panel disposed with respect to each elongate opening, each LED side panel configured to emit light through a respective one of the elongate openings. [0014] In a preferred form, each LED side panel is configured to couple to the power supply through the junction box.

[0015] In a preferred form, the length of each elongate opening and of each LED side panel is substantially equal to the predetermined length of the frame.

[0016] In a preferred form, the number of apertures is equal to the number of LED modules, and each LED module is disposed with respect to the frame such that LEDs from each LED module are aligned with a respective one of the number of apertures.

[0017] In a preferred form, the number of apertures is twice the number of LED modules, and each LED module is disposed with respect to the frame such that LEDs from each LED module are aligned with two respective apertures

[0018] In a preferred form, the system further comprises a number of guides coupled to the frame, each guide configured to receive a respective one of the LED modules to align and couple the respective LED module to the frame.

[0019] In a preferred form, one or more of the LED modules comprises a louver cell, each louver cell configured to provide optical cut off of light produced by a respective LED module to reduce the level of glare.

[0020] In a preferred form, the number of apertures and the LED assembly of LED modules extend along a majority of the predetermined length of the frame.

[0021 ] In a second aspect, the present invention provides a method of customizing a modular LED troffer system as described with respect to the first aspect, the method comprising the step of selecting a length of the frame of the modular LED troffer system, the length of the frame determining the number of LED modules in the LED assembly and the number of apertures in the frame.

[0022] In a preferred form, the method further comprises the step of customizing colours and dimensions of the frame.

[0023] In a preferred form, the method is performed through an online internet interface. [0024] In a preferred form, the method further comprises the step of presenting a rendering representing the visual appearance of the LED troffer system after features of the LED troffer system have been customized.

[0025] In a preferred form, the method further comprises the step of generating manufacturing drawings and CAD files representing the modular LED troffer system after a user has completed customizing the modular LED troffer system.

[0026] In a preferred form, the method further comprises the step of manufacturing the modular LED troffer system utilizing the manufacturing drawings and/or CAD files.

Brief Description of Drawings

[0027] Figure 1 shows a top view of a modular LED troffer system according to a first embodiment of the present invention;

[0028] Figure 2 shows a bottom perspective view of the modular LED troffer system of Figure i ;

[0029] Figure 3 shows a perspective exploded parts view of the modular LED troffer system of Figure 1 ;

[0030] Figure 4 shows a bottom perspective view of one LED module of the modular LED troffer system of Figure 1;

[0031] Figure 5 shows a top perspective view of the LED module of Figure 4; [0032] Figure 6 shows a bottom view of the LED module of Figure 4; [0033] Figure 7 shows a left side view of the LED module of Figure 4; [0034] Figure 8 shows a right side view of the LED module of Figure 4; [0035] Figure 9 shows a front view of the LED module of Figure 4;

[0036] Figure 10 shows a perspective exploded parts view of the LED module of Figure 4; [0037] Figure 11 shows a perspective view of one LED side panel of the modular LED troffer system of Figure 1 ;

[0038] Figure 12 shows a perspective exploded parts view of the LED side panel of Figure 11 ;

[0039] Figure 13 shows a top view of a modular LED troffer system according to a second embodiment of the present invention;

[0040] Figure 14 shows a bottom perspective view of the modular LED troffer system of Figure 13;

[0041] Figure 15 shows a perspective exploded parts view of the modular LED troffer system of Figure 13;

[0042] Figure 16 shows a bottom perspective view of one LED module of the modular LED troffer system of Figure 13;

[0043] Figure 17 shows a bottom view of the LED module of Figure 16;

[0044] Figure 18 shows a perspective exploded parts view of the LED module of Figure 16;

[0045] Figure 19 shows a perspective view of a printed circuit board assembly including LEDs used with the LED module of Figures 4 and 16;

[0046] Figure 20 shows a bottom view of the printed circuit board assembly of Figure 19;

[0047] Figure 21 shows a bottom view of the printed circuit board assembly of Figure 19 installed in the LED module of Figure 16;

[0048] Figure 22 shows a perspective exploded parts view of a modular LED troffer system according to a third embodiment of the present invention;

[0049] Figure 23 shows a top perspective view of one LED module of the modular LED troffer system of Figure 22;

[0050] Figure 24 shows a side view of the LED module of Figure 23; [0051] Figure 25 shows a perspective exploded parts view of the LED module of Figure 23; and

[0052] Figure 26 shows an embodiment of how a user may customise/configure a modular LED troffer system over the internet using a configurator accessed via a web browser of a computer, mobile device, etc.

Description of Embodiments

[0053] Figures 1 and 2 show a modular LED troffer system 100 according to a first embodiment of the present invention. The system 100 comprises a LED assembly 102, a frame 104 and two LED side panels 106.

[0054] The LED assembly 102 comprises a number of LED modules 108 (only one is labelled for clarity of illustration) manufactured having predetermined/fixed dimensions (i.e. length, width, and height). Each LED module 108 comprises a first electrical contact 1 10 (see for example Figure 6) and a second electrical contact 112 (see for example Figure 5). The first electrical contact 110 of each LED module 108 is configured to electrically couple to the second electrical contact 112 of an adjacent LED module 108 in the LED assembly 102. The second electrical contact 1 12 of each LED module 108 is configured to electrically couple to the first electrical contact 110 of an adjacent LED module 108 in the LED assembly 102, except for the second electrical contact 112 of the last LED module 108a in the LED assembly 102. The second electrical contact 112 of the LED module 108a is configured to electrically couple to a junction box 1 14. The junction box 1 14 electrically couples the LED assembly 102 to a power supply (not shown), such as, for example, an LED driver. As can be seen from the figures, the first electrical contact 110 and the second electrical contact 112 form a pin and socket connection, however, other electrical connections known in the art may otherwise be used.

[0055] The frame 104 has a longitudinal axis 10, a first side 1 16, a second side 1 18, and a number of apertures 120 aligned centrally along the longitudinal axis 10. On either side of the apertures 120 is an elongate opening 122 extending along the longitudinal axis 10. As can be seen from Figure 2, the apertures 120 and the openings 122 extend along a majority of the predetermined length of the frame 104. The frame 104 further comprises mountings 124 for mounting the system 100 to a ceiling grid or the like (not shown). [0056] Referring to Figures 1 and 2, the number of LED modules 108 is equal to the number of apertures 120. Referring to Figure 3, each LED module 108 is coupled to the second side 1 18 of the frame 104 and aligned with one of the apertures 120, such that LEDs from each LED module 108 are aligned with a respective one of the apertures 120. It will be appreciated therefore that light emitted from LEDs of each LED module 108 will pass through a respective one of the apertures 120 through to the first side 1 16 of the frame 104.

[0057] Referring to Figure 3, the LED side panels 106 are slightly longer and wider than the elongate openings 122 such that the LED side panels 106 cover a respective one of the elongate openings 122. Each LED side panel 106 is coupled to the second side 118 of the frame 104 and covers a respective one of the elongate openings 122, such that light emitted from LEDs of each LED side panel 106 passes through a respective one of the openings 122 through to the first side 116 of the frame 104. The LED side panels 106 are electrically coupled to the power source via the junction box 114.

[0058] The length of the frame 104 is chosen (i.e. predetermined) by a user to meet certain design criteria (e.g. grid ceiling dimensions, lighting levels, etc.). The user may select from a number of predetermined frame lengths. Each of the predetermined frame lengths are determined based on the lengths of the LED modules 108, which are predetermined/fixed. Accordingly, the length of the frame 104 chosen by the user will determine the number of LED modules 108 in the LED assembly 102 based on the predetermined/fixed dimensions of the LED modules 108. It will be appreciated that more LED modules 108 will form the LED assembly 102 for longer frame lengths compared to shorter frame lengths. It will also be appreciated that the length of the LED side panels 106 will be determined by the length of the frame 104 selected.

[0059] Figures 4 to 9 show an LED module 108 according to a first embodiment of the present invention. In these figures, the LED module 108 is removably coupled to a guide 126.

Referring to Figure 1, each guide 126 is coupled to the second side 118 of the frame 104 and surrounds one of the apertures 120. One LED module 108 is removably received within each guide 126, thereby coupling the LED module 108 to the second side 1 18 of the frame 104. Each guide 126 comprises a skirt 128 configured to couple the guide 126 to the second side 1 18 of the frame 104. [0060] Each LED module 108 comprises a housing 130. Referring to Figure 10, the housing 130 comprises a top portion 132 removably coupled to a louver cell 146. The top portion 132 comprises a male connector 134 and a female connector 136.

[0061] Referring to Figures 5, 6, and 9, the male connector 134 comprises the first electrical contact 110 and is formed as a downwardly facing projection. Referring to Figure 6, the first electrical contact 1 10 is in the form of a socket facing downwardly. It is also envisaged that the first electrical contact 1 10 may be of other suitable forms that are known in the art.

[0062] Referring to Figure 1, the male connector 134 and the female connector 136 have complimentary profiles such that the male connector 134 is removably receivable within the female connector 136. The male connector 134 and the female connector 136 of each LED module 108 are configured to couple to a respective female connector 136 and a respective male connector 134 of adjacent LED modules 108 in the LED assembly 102, thereby coupling each LED module 108 to an adjacent LED module 108 in the LED assembly 102.

[0063] Referring to Figures 5 and 8, the female connector 136 comprises the second electrical contact 1 12 and is formed as a cut out in the top portion 132. Referring to Figure 8, the second electrical contact 112 is in the form of pins facing upwardly. It is also envisaged that the second electrical contact 112 may be of other suitable forms that are known in the art. Accordingly, it will be appreciated that inserting the male connector 134 of one LED module 108 into the female connector 136 of an adjacent module 108 in the LED assembly 102 results in the first electrical contact 110 of the male connector 134 contacting the second electrical contact 1 12 of the female connector 136, thereby electrically coupling the two LED modules 108.

[0064] Referring to Figure 10, each LED module 108 further comprises a printed circuit board assembly (PCBA) 138, a mixing chamber 140 and a diffuser 144. Referring to Figures 19 and 20, the PCBA 138 is electrically coupled to the first electrical contact 1 10 and the second electrical contact 112. The PCBA 138 comprises two sets of LEDs 152a and 152b.

[0065] Referring to Figure 10, the PCBA 138 is coupled to the mixing chamber 140 such that both sets of LEDs 152a and 152b align with a hole 142 of the mixing chamber 142. The mixing chamber 140 is configured to reflect, scatter and redirect light emitted from the two sets of LEDs 152a and 152b toward an opening 143 of the mixing chamber 140. [0066] Disposed at the opening 143 of the mixing chamber 140 is the diffuser 144. Light passing from the mixing chamber 140 through the diffuser 144 is further scattered by the diffuser 144, thereby reducing the appearance of the individual LEDs in each of the two sets of LEDs 152a and 152b to provide a more even lighting. The diffuser 144 is a flat opal coloured diffuser, however, other diffusers of other colours and suitable materials may be used.

[0067] The louver cell 146 comprises an orifice 148 and surfaces 150. The mixing chamber 140 is removably coupled to the louver cell 146 such that the diffuser 144 covers the orifice 148. The surfaces 150 flare outwardly toward the lower edge of the louver cell 146 to define a border 151. Referring to Figures 4 and 6, the border 151 has approximately the same dimensions as one of the apertures 120. The surfaces 150 are configured to direct light passing through the diffuser 144 downwardly. The louver cell 146 provides optical cut-off of the light produced by the LED module 108. Optical cut-off is measured by a cut-off angle. The cut-off angle is the angle, measured from below the troffer system 100, where the louver cell 146 begins to shield light emitted from the LEDs of the LED modules 108 and where no direct light from the LED modules 108 is visible.

[0068] Each LED module 108 is removably coupled to the second side 118 of the frame 104 by removably inserting and coupling the louver cell 146 of the LED modules 108 to a respective guide 126 such that the guide 126 surrounds the louver cell 146.

[0069] Figure 1 1 shows an LED side panel 106. Referring to Figure 12, the LED side panel 106 comprises a reflector 154, a printed circuit board assembly strip (PCBA strip) 156 having a number of LEDs, a first layer of double sided tape 158, a diffuser 160, a second layer of double sided tape 162, and two end caps 164a and 164b.

[0070] The reflector 154 is made of powder coated sheet metal and defines an internal reflection surface 166 as well as serving as a structural housing for the PCBA strip 156. The PCBA strip 156 is disposed within a folded channel 168 on one side of the reflector 154 and held in place with double sided tape 169. It is envisaged that the reflector may be made from any other suitable material known in the art. The end caps 164a, 164b are coupled to respective ends of the reflector 154 to provide a level of protection against the ingress of foreign matter inside the LED side panel 106 as well as minimise light leakage at the ends of the LED side panel 106. The diffuser 160 is then coupled to the reflector 154 via the first layer of double sided tape 158. The second layer of double sided tape 162 is disposed on the second side 118 of the frame 104 around one of the elongate openings 122. The diffuser 160 is coupled to the second layer of double sided tape 162, thereby coupling the LED side panel 106 to the second side 118 of the frame 103 such that the LED side panel 106 covers a respective one of the elongate openings 122.

[0071 ] The internal reflection surface of the reflector 154 is configured to reflect, scatter and direct light emitted from LEDs of the PCBA strip 156 toward the diffuser 160. Light passing through the diffuser 160 is further scattered, thereby reducing the appearance of the individual LEDs in PCBA strip 156 to provide a more even lighting. The diffuser 160 is a flat opal coloured diffuser, however, other diffusers of other colours and suitable materials may be used.

[0072] Figures 13 and 14 show a modular LED troffer system 200 according to a second embodiment of the present invention. The system 200 is similar to that of the system 100, but does not include the apertures 122 or the LED side panels 106 of the system 100. Further, the LED modules 208 of the system 200 are similar to that of the LED modules 108 of the system 100, except that the LED modules 208 have a different mixing chamber 240, a different louver cell 246, and have two diffusers 244a and 244b (discussed below). Accordingly, features of the system 200 that are identical or equivalent to those of the system 100 are provided with reference numerals that are equivalent to those of the system 100 but incremented by 100. For features that are identical between the system 100 and the system 200, it will be appreciated that the above description of these features in relation to the system 100 is also applicable to the corresponding identical/equivalent features found in the system 200.

[0073] The frame 204 of the system 200 has a longitudinal axis 20 with a number of apertures 220 aligned centrally along the longitudinal axis 20. As can be seen from Figure 14, the apertures 220 extend along a majority of the predetermined length of the frame 204. As can also be seen from the Figure 14, each of the apertures 220 are narrower compared to the apertures 120 of the system 100.

[0074] Similar to the frame 104 of system 100, the length of the frame 204 is chosen (i.e.

predetermined) by a user to meet certain design criteria (e.g. grid ceiling dimensions, lighting levels, etc.). The user may select from a number of predetermined frame lengths. Each of the predetermined frame lengths are determined based on the lengths of the LED modules 208, which are predetermined/fixed. Accordingly, the length of the frame 204 chosen by the user will determine the number of LED modules 208 in the LED assembly 202 based on the predetermined/fixed dimensions of the LED modules 208. It will be appreciated that more LED modules 208 will form the LED assembly 202 for longer frame lengths compared to shorter frame lengths.

[0075] Referring to Figure 18, the mixing chamber 240 has two holes 242a and 242b, and each hole 242a, 242b has a respective opening 243a and 243b. As best seen in Figure 21 , the PCBA 138 is coupled to the mixing chamber 240 such that the set of LEDs 152a align with the hole 242a and the set of LEDs 152b align with the hole 242b. The mixing chamber 240 is configured to reflect, scatter and redirect light emitted from the two sets of LEDs 152a and 152b towards the openings 243a and 243b, respectively.

[0076] Disposed at each opening 243a and 243b of the mixing chamber 240 is a diffuser 244a and a diffuser 244b, respectively. Light passing from the mixing chamber 240 through the diffusers 244a and 244b is further scattered by the diffusers 244a and 244b, thereby reducing the appearance of the individual LEDs in each of the two LED sets 152a and 152b. The diffusers 244a and 244b are flat opal coloured diffusers, however, other diffusers of other colours and suitable materials may be used.

[0077] Referring to Figures 16 to 18, the louver cell 246 has two orifices 248a and 248b, and each orifice 248a, 248b has a surface 250a and 250b, respectively. The mixing chamber 240 is removably coupled to the louver cell 246 such that the diffuser 244a covers the orifice 248a and the diffuser 244b covers the orifice 248b. The surface 205a and 250b flare outwardly toward the lower edge of the louver cell 246 to define borders 251a and 251b, respectively. Referring to Figures 16 and 17, each of the borders 251 a and 251 b have approximately the same dimensions as one of the apertures 220. The surfaces 250a and 250b are configured to direct light passing through a respective diffuser 244a, 244b downwardly. The louver cell 246 provides optical cutoff of the light passing through the LED module 208. Optical cut-off is measured by a cut-off angle. The cut-off angle is the angle, measured from below the troffer system 200, where the louver cell 246 begins to shield light emitted from the LEDs of the LED modules 208 and where no direct light from the LED modules 208 is visible. [0078] Referring to Figures 13 and 14, the number of apertures 220 is twice the number of LED modules 208. Referring to Figure 15, each LED module 208 is coupled to the second side 218 of the frame 204 and aligned with two of the apertures 220, such that each set of LEDs 152a and 152b align with a respective one of the apertures 220. It will be appreciated therefore that light emitted from each set of LEDs 152a and 152b of each LED module 208 will pass through a respective one of the apertures 220 through to the first side 216 of the frame 204.

[0079] Each LED module 208 is removably coupled to the second side 218 of the frame 204 by removably inserting and coupling the louver cell 246 of the LED modules 208 to a respective guide 126 such that the guide 126 surrounds the louver cell 246.

[0080] Although the system 200 has been described without LED side panels 106, it will be appreciated that the system 200 may also be manufactured to include LED side panels 106 in a similar manner to that described above with respect to the system 100.

[0081] Figure 22 shows a modular LED troffer system 300 according to a third embodiment of the present invention. The system 300 is similar to that of the system 100. In particular, the LED modules 308 of the system 300 are similar to that of the LED modules 108 of the system 100, except that the LED modules 308 have a different mixing chamber 340, a different louver cell 346, and have a gasket 370 and a reflector 372 (discussed below) as shown in Figures 23 to 25. Further, the LED side panels 306 of the system 300 are similar to that of the LED side panels 106 of the system 100, except that the LED side panels 306 have a different overall shape, that is, the LED side panels 306 have a generally semi-circular transverse cross-section. The LED side panels 306 are configured to electrically couple to the LED modules 308 via the junction box 314a. Accordingly, features of the system 300 that are identical or equivalent to those of the system 100 are provided with reference numerals that are equivalent to those of the system 100 but incremented by 200. For features that are identical between the system 100 and the system 300, it will be appreciated that the above description of these features in relation to the system 100 is also applicable to the corresponding identical/equivalent features found in the system 300.

[0082] Referring to Figure 22, the frame 304 has a longitudinal axis 30, a first side 316, a second side 318, and a number of apertures 320 aligned centrally along the longitudinal axis 30. On either side of the apertures 320 is an elongate opening 322 extending along the longitudinal axis 30. As can be seen from Figure 22, the apertures 320 and the openings 322 extend along a majority of the predetermined length of the frame 304. The frame 304 further comprises mountings 324 for mounting the system 300 to a ceiling grid or the like (not shown).

[0083] Similar to the frame 104 of system 100, the length of the frame 304 is chosen (i.e.

predetermined) by a user to meet certain design criteria (e.g. grid ceiling dimensions, lighting levels, etc.). The user may select from a number of predetermined frame lengths. Each of the predetermined frame lengths are determined based on the lengths of the LED modules 308, which are predetermined/fixed. Accordingly, the length of the frame 304 chosen by the user will determine the number of LED modules 308 in the LED assembly 302 based on the predetermined/fixed dimensions of the LED modules 308. It will be appreciated that more LED modules 308 will form the LED assembly 302 for longer frame lengths compared to shorter frame lengths.

[0084] Referring to Figure 25, the PCBA 338 of each of the LED modules 308 is coupled to the mixing chamber 340 such that the sets of LEDs (not shown) of the PCBA 338 align with the hole 342 of the mixing chamber 340, similar to the arrangement of the PCBA 138 with the mixing chamber 140 of the system 100. Differently, however, the mixing chamber 340 further includes the gasket 370 inserted between the PCBA 338 and the mixing chamber 340 and positioned around the hole 342 to provide a level of protection against the ingress of foreign matter inside the mixing chamber 340. The gasket 370 is typically comprised of urethane foam or similar.

[0085] The mixing chamber 340 also includes the reflector 372 nestable within the mixing chamber 340 via the opening 343 and detachable from the mixing chamber 340. The reflector 372 is made of sheet aluminum with a mirror finish and defines an internal reflection surface 371. The internal reflection surface 371 of the reflector 372 is configured to reflect, scatter and direct light emitted from the LEDs toward the opening 343 of the mixing chamber 340.

[0086] Disposed at the opening 343 of the mixing chamber 340 is the diffuser 344. Light passing from the mixing chamber 340 through the diffuser 344 is further scattered by the diffuser 344, thereby reducing the appearance of the individual LEDs to provide a more even lighting. The diffuser 344 is a flat opal coloured diffuser, however, other diffusers of other colours and suitable materials may be used. [0087] Like the louver cell 146, the louver cell 346 comprises the orifice 348 and the surfaces 350. Differently, however, the orifice 348 is narrower than the orifice 148 thereby providing a different optical cut-off of the light passing through the diffuser 344. Further, the mixing chamber 340 is removably coupled to the louver cell 346 such that the diffuser 344 covers and overlaps the orifice 348. A particular advantage of this arrangement is that it allows different louver cells to be utilised with the LED module. For example, the louver cell can be

manufactured in various colours (e.g. white, black, etc.), finishes, textures and coatings (e.g. metallisation).

[0088] Another point of difference between the louver cell 146 and the louver cell 346 is that the louver cell 346 lacks bounding walls extending upwardly from the border 351. Instead, the louver cell 346 is bounded by the walls which provide the surfaces 350 thereby simplifying the overall structure of the louver cell 346.

[0089] A further point of difference between the louver cell 146 and the louver cell 346 is that the louver cell 346 includes cable retaining means in the form of hooks 347 disposed on either side of the louver cell 346 along opposite edges (see Figures 23 and 24). The hooks 347 are preferably configured for retaining any cabling from either the LED side panels 306 or any other accessory or module as detailed in [0091] below.

[0090] Each LED module 308 is removably coupled to the second side 318 of the frame 304 by removably inserting and coupling the louver cell 346 of the LED modules 308 to a respective guide 326 such that the guide 326 at least partially surrounds the louver cell 346.

[0091] The systems 100, 200, 300 may also include further modules to provide control, emergency, audio, and surveillance configurations to the systems 100, 200, 300. The systems 100, 200, 300 may include light level, movement/presence, and temperature sensors. The systems 100, 200, 300 may further include emergency modules that enable the systems 100, 200, 300 to be configured as emergency luminaires. Speaker modules may also be provided with the systems 100, 200, 300 for EVAC, public addressing and audio. Camera modules may be also be provided to the systems 100, 200, 300 for surveillance reasons.

[0092] Although the systems 100, 200, 300 have been described with respect to the number of apertures 120, 220, 320 being aligned centrally along the longitudinal axis 10, 20, 30 it will be appreciated that other configurations of the number of apertures 120, 220, 320 and therefore the LED modules 108, 208, 308 may be utilised.

[0093] Assembly of the system 100 will now be described. The frame 104 is manufactured from flat sheet steel that is punched to size, formed to shape and then powder coated. The number of apertures 120 and the two elongate openings 120 are formed during the punching step. It is envisaged that the frame 104 may be manufactured from other suitable materials known in the art and may be formed using any suitable methods in known in the art. It is also envisaged that the frame 104 may coated in other materials such as, for example, resins, paints, varnishes, etc.

[0094] Referring to Figure 3, double sided tape 270 (see Figure 15) is attached on the second side 1 18 of the frame 104 along either side of the number of apertures 120 and extends along the longitudinal axis 10. The double sided tape 270 extends along a majority, if not entirely along, the length of the number of apertures 120. The skirt 128 of each guide 126 is then attached to the double sided tape 270 such that each guide 126 surrounds one of the apertures 120, thereby coupling the guides 126 to the second side 1 18 of the frame 104. One guide 126 is attached to the second side 118 of the frame 104 for each aperture 120. During use, the skirt 128 of each guide 126 also serves to act as an optical barrier, blocking spill light produced via light bleeding through the louver cell 146. This reduces the level of light bleed observed at the second side 1 18 and ends of the system 100. Light bleed at the second side 1 18 and the ends of the system 100 can be undesirable in some installations. It is envisaged that each of the guides 126 may be attached to the second side 118 of the frame 104 using other means such as, for example, adhesives, mechanical means, etc.

[0095] LED modules 108 are then inserted into and coupled to a respective one of the guides 126, thereby coupling each of the LED modules 108 to the second side 1 18 of the frame 104. Each LED module 108 is coupled to a respective guide 126 such that the female connector 136 receives the male connector 134 of an adjacent LED module 108 in the LED assembly 102 therein, thereby mechanically and electrically coupling each LED module 108 to an adjacent LED module 108 in the LED assembly 102. The junction box 1 14 is inserted into the female connector 136 of the LED module 108a and electrically contacts the second electrical contact 112 of the LED module 108a. Referring to Figure 1, each of the LED modules 108 abuts an adjacent LED module 108 in the LED assembly 102. It is also envisaged that the LED modules 108 may be coupled to a respective one of the guides 126 before each of the guides 126 are coupled to the second side 1 18 of the frame 104.

[0096] Referring to Figure 3, double sided tape 162 (see Figure 12) is attached to the second side 118 of the frame 104 around the periphery of each of the elongate openings 122. The LED side panels 106 are then attached to the double sided tape 162 that is attached around a respective one of the elongate openings 122 such that the diffuser 160 of each LED side panel 106 faces the second side 1 18 of the frame 104, thereby coupling the LED side panels to the second side 118 of the frame 104. The LED side panels 106 are then electrically coupled to the junction box 114. It will be appreciated that assembly of the system 300 occurs in a similar manner to the assembly of the system 100 described above.

[0097] Assembly of the system 200 will now be described. The frame 204 is manufactured from flat sheet steel that is punched to size, formed to shape and then powder coated. The number of apertures 220 are formed during the punching step. It is envisaged that the frame 204 may be manufactured from other suitable materials known in the art and may be formed using any suitable methods in known in the art. It is also envisaged that the frame 204 may coated in other materials such as, for example, resins, paints, varnishes, etc.

[0098] Referring to Figure 15, double sided tape 270 is attached on the second side 218 of the frame 204 along either side of the number of apertures 220 and extends along the longitudinal axis 20. The double sided tape 270 extends along a majority, if not entirely along, the length of the number of apertures 220. The skirt 228 of each guide 226 is then attached to the double sided tape 270 such that each guide 226 surrounds two of the apertures 220, thereby coupling the guides 226 to the second side 218 of the frame 204. One guide 226 is attached to the second side 218 of the frame 204 for every two apertures 220. During use, the skirt 228 of each guide 226 also serves to act as an optical barrier, blocking spill light produced via light bleeding through the louver cell 246. This reduces the level of light bleed observed at the second side 218 and ends of the system 200. Light bleed at the second side 218 and the ends of the system 200 can be undesirable in some installations. It is envisaged that each of the guides 226 may be attached to the second side 218 of the frame 204 using other means such as, for example, adhesives, mechanical means, etc. [0099] LED modules 208 are then inserted into and coupled to a respective one of the guides 226, thereby coupling each of the LED modules 208 to the second side 218 of the frame 204. Each LED module 208 is coupled to a respective guide 226 such that the female connector 236 receives the male connector 234 of an adjacent LED module 208 in the LED assembly 202 therein, thereby mechanically and electrically coupling each LED module 208 to an adjacent LED module 208 in the LED assembly 202. The junction box 214 is inserted into the female connector 236 of the LED module 208a and electrically contacts the second electrical contact 212 of the LED module 208a. Referring to Figure 13, each of the LED modules 208 abuts an adjacent LED module 208 in the LED assembly 202. It is also envisaged that the LED modules 208 may be coupled to a respective on of the guides 226 before each of the guides 226 are coupled to the second side 218 of the frame 204.

[0100] As discussed above, it will be appreciated that the system 200 may also be

manufactured/assembled to include LED side panels 106 in a similar manner to that described above with respect to the system 100.

[0101] Customising/configuring the system 100, the system 200 and the system 300 will now be described. A user will select a length of the frame 104, 204, 304 from a number of

predetermined lengths. As discussed above, each of the predetermined lengths is based on the predetermined/fixed dimensions of the LED modules 108, 208, 308. The predetermined lengths of the frames 104, 204, 304 determine the number of LED modules 108, 208, 308 in the LED assembly 102, 202, 302 of the system 100, 200, 300. The user may also select the width of the frame 104, 204, 304 and the colour of the frame 104, 204, 304.

[0102] The user selects whether they would like to use LED modules 108, LED modules 208, LED modules 308, or a combination thereof in the system 100, 200, 300. The choice of LED modules 108, 208, 308 along with the predetermined length of the frame 104, 204, 304 chosen by the user, will determine the number of apertures 120, 220, 320 in the system 100, 200, 300. Further, the user can decide to have the louver cells 146, 246, 346 manufactured in various colours (e.g. white, black, chrome, etc.), finishes, textures and coatings (e.g. metallisation).

[0103] The user also selects whether they would like to have LED side panels 106, 306 in the system 100, 200, 300. The user is also given the option to include the control, emergency, audio, and/or surveillance modules (see paragraph [0091]). Accordingly, it will be appreciated that the user may customise/configure a modular LED troffer system according to the system 100, the system 200, the system 300 or combinations thereof.

[0104] The modular LED troffer systems disclosed herein may be customised/configured by a configurator (i.e. interface) accessible through an internet browser. The configurator contains functions to interactively guide the user through the configuration process, thereby enabling the user to customise/configure a modular LED troffer system to meet certain design criteria. The configurator allows the user to customise/configure each of the components of the modular LED troffer system as discussed in paragraph [0101] - [103]. The configurator provides a dropdown menu, a list, or the like which the user uses to customise/configure the components discussed in the paragraphs [101 ] - [0103]. The configurator also presents a rendering of the modular LED troffer system after each feature of the modular LED troffer system is customised/configured.

[0105] After the user has completed customising/configuring the modular LED troffer system, the configurator generates a bill of materials (BOM). The configurator will calculate the quantity of components required (e.g. number of LED modules 108, 208, 308, inserts 126, 226, 326 etc.) as well as the components that have been customised (e.g. the length and/or width of the frame 104, 204, 304, colours of the frame 104, 204, 304 and the louver cells 146, 246, 346 etc.), and these calculations will be included in the BOM.

[0106] The configurator will generate manufacturing drawings and computer aided drawing (CAD) files in accordance with the customised/configured modular LED troffer system and the BOM. The manufacturing drawings and the CAD files are then used to manufacture and assemble the customised/configured modular LED troffer system.

[0107] Figure 26 shows how a user may configure/customise a modular LED troffer system using the configurator accessed through the internet. The configurator is hosted by a server 472 and is accessed by a user over the internet using a web browser of a computer, mobile device, etc. 474. After the user has completed customising/configuring the modular LED troffer system, the configurator will calculate the quantity of components required (e.g. number of LED modules 108, 208, 308, inserts 126, 226, 326, etc.) as well as the components that have been customised (e.g. the length and/or width of the frame 104, 204, 304, colours of the frame 104, 204, 304 and the louver cells 146, 246, 346 etc.), and these will calculations will be included in a BOM. The calculations may be made by backend configurator software using calculation tables along with predefined rules. Rules can be based on:

• a mathematical formula;

• a conditional or logical statement;

• the stringing together of a series of text; and/or

• looking up a value in a table of data.

[0108] The configurator will then generate manufacturing drawings and CAD files according to the BOM and send (e.g. over the internet, file sharing systems, etc.) the manufacturing drawings and CAD files to a manufacturing process/plant 476, where the customised/configured modular LED troffer system is manufactured and assembled.

[0109] Utilising LED modules having predetermined/fixed dimensions allows a user to easily customise/configure modular LED troffer systems having various lengths. A user can design the modular LED troffer system to meet certain design criteria (e.g. aesthetics, lighting levels, ceiling grid dimensions, etc.), instead of designing around the dimensions of troffer systems known and currently available to the user. Accordingly, the modular LED troffer systems disclosed herein allow a user to customise/configure multiple modular LED troffer systems capable of meeting different/varying design criteria.

[0110] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims

1. A modular LED troffer system comprising:

wherein a predetermined length of the frame determines the number of LED modules based on the predetermined dimensions of the LED modules.

2. The system of claim 1, wherein each LED module comprises a housing.

3. The system of claim 2, wherein each LED module further comprises a male connector and a female connector, the male connector configured to couple to a female connector of an adjacent LED module in the LED assembly and the female connector configured to couple to a male connector of another adjacent LED module in the LED assembly, thereby coupling each LED module to an adjacent LED module in the LED assembly.

4. The system of claim 3, wherein the male connector of each LED module comprises the first electrical contact and the female connector of each LED module comprises the second electrical contact.

5. The system of claim 3 or 4, wherein the housing of each LED module defines the male connector and the female connector.

6. The system of any one of the preceding claims, wherein each LED module abuts an adjacent LED module in the LED assembly.

7. The system of any one of the preceding claims, wherein the number of apertures are disposed centrally along the longitudinal axis of the frame.

8. The system of any one of the preceding claims, wherein the LED module at an end of the LED assembly is configured to be coupled to a power supply.

9. The system of claim 8, wherein the LED module at the end of the LED assembly is configured to couple to the power supply through a junction box.

10. The system of any one of the preceding claims, further comprising:

a LED side panel disposed with respect to each elongate opening, each LED side panel configured to emit light through a respective one of the elongate openings.

1 1 . The system of claim 10, when dependent on claim 9, wherein each LED side panel is configured to couple to the power supply through the junction box.

12. The system of claim 10 or 11, wherein the length of each elongate opening and of each LED side panel is substantially equal to the predetermined length of the frame.

13. The system of any one of the preceding claims, wherein the number of apertures is equal to the number of LED modules, and each LED module is disposed with respect to the frame such that LEDs from each LED module are aligned with a respective one of the number of apertures.

14. The system of any one of claims 1 to 13, wherein the number of apertures is twice the number of LED modules, and each LED module is disposed with respect to the frame such that LEDs from each LED module are aligned with two respective apertures.

15. The system of any one of the preceding claims, further comprising a number of guides coupled to the frame, each guide configured to receive a respective one of the LED modules to align and couple the respective LED module to the frame.

16. The system of any one of the preceding claims, wherein one or more of the LED modules comprises a louver cell, each louver cell configured to provide optical cut off of light produced by a respective LED module to reduce the level of glare.

17. The system of any one of the preceding claims, wherein the number of apertures and the LED assembly of LED modules extend along a majority of the predetermined length of the frame.

18. A method of customizing a modular LED troffer system as defined in claim 1, the method comprising the step of selecting a length of the frame of the modular LED troffer system, the length of the frame determining the number of LED modules in the LED assembly and the number of apertures in the frame.

19. The method of claim 18, further comprising the step of customizing colours and dimensions of the frame.

20. The method of claim 18 or 19, wherein the method is performed through an online internet interface.

21. The method of claim 20, further comprising the step of presenting a rendering representing the visual appearance of the LED troffer system after features of the LED troffer system have been customized.

22. The method of any one of claims 18 to 21 , further comprising the step of generating manufacturing drawings and CAD files representing the modular LED troffer system after a user has completed customizing the modular LED troffer system.

23. The method of claim 22, further comprising the step of manufacturing the modular LED troffer system utilizing the manufacturing drawings and/or CAD files.