WO2024179824A1

WO2024179824A1 - Flexible circuit boards and other components for luminaires

Info

Publication number: WO2024179824A1
Application number: PCT/EP2024/053573
Authority: WO
Inventors: Philip Winters; Neil Thomas HARDWICK; Kunlin WU; Li Ren CHENG; Kenneth Charles FRATZKE
Original assignee: Signify Holding B.V.
Priority date: 2023-03-02
Filing date: 2024-02-13
Publication date: 2024-09-06

Abstract

A printed circuit board for a luminaire can include a body comprising a connector and main circuitry coupled to the connector. The printed circuit board can also include a plurality of extensions that extend from an outer perimeter along a length of the body, where each extension of the plurality of extensions comprises localized circuitry and a light source receiver coupled to the localized circuitry, where the localized circuitry is further coupled to the main circuitry of the body, where each extension is bendable relative to the body, and where two or more adjacent extensions of the plurality of extensions are separated from each other by a distance at the outer perimeter along the length of the body.

Description

Flexible circuit boards and other components for luminaires

TECHNICAL FIELD

The present disclosure relates generally to luminaires, and more particularly to systems, methods, and devices for flexible circuit boards and other components for luminaires.

BACKGROUND

Linear light fixtures (types of luminaires) are often installed end-to-end to create a single extended linear luminaire. One component of a linear light fixture is an optical device. A linear light fixture can have one or multiple optical devices. An optical device is often made of plastic and is held in place using screws, rivets, and/or other types of fastening devices. These fastening devices can cause stresses on the optical device, causing the optical device to crack or break. When this occurs, the light emitted by the light sources of the linear light fixture have a distorted or otherwise different distribution pattern, causing the optical device to be replaced. Replacement of a cracked or otherwise broken optical device can result in unavailability of the linear light fixture, increased parts and maintenance costs, and inconvenience.

SUMMARY

In general, in one aspect, the disclosure relates to printed circuit board for a luminaire. The printed circuit board can include a body having a connector and main circuitry coupled to the connector. The printed circuit board can also include a plurality of extensions that extend from an outer perimeter along a length of the body, where each extension of the plurality of extensions comprises localized circuitry and a light source receiver coupled to the localized circuitry, where the localized circuitry is further coupled to the main circuitry of the body, where each extension is bendable relative to the body, and where two or more adjacent extensions of the plurality of extensions are separated from each other by a distance at the outer perimeter along the length of the body.

In other aspects, the disclosure relates to a luminaire that includes a housing that forms a cavity with an open side therein. The luminaire can also include a printed circuit board (PCB) disposed within the cavity, where the PCB includes a body and a plurality of extensions that extend from an outer perimeter along a length of the body, where the body includes a connector and main circuitry coupled to the connector, where each extension of the plurality of extensions comprises localized circuitry and a light source receiver coupled to the localized circuitry, where the localized circuitry is further coupled to the main circuitry of the body, where each extension is bent relative to the body, and where two or more adjacent extensions of the plurality of extensions are separated from each other by a distance at the outer perimeter along the length of the body.

These and other aspects, objects, features, and embodiments will be apparent from the following description and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate only example embodiments and are therefore not to be considered limiting in scope, as the example embodiments may admit to other equally effective embodiments. The elements and features shown in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the example embodiments. Additionally, certain dimensions or positions may be exaggerated to help visually convey such principles. In the drawings, reference numerals designate like or corresponding, but not necessarily identical, elements.

Figs. 1 A and IB show various views of a luminaire according to certain example embodiments.

Figs. 2 A through 2D show various views of the printed circuit board of the luminaire of Figs. 1A and IB in a default state according to certain example embodiments.

Figs. 3A and 3B show various views of the printed circuit board of the luminaire of Figs. 1A and IB in a formed state according to certain example embodiments.

Fig. 4 shows a system diagram of a printed circuit board according to certain example embodiments.

Fig. 5 shows a top view of a subassembly of another luminaire according to certain example embodiments.

Fig. 6 shows a top view of a multi-component printed circuit board in a default state according to certain example embodiments.

Fig. 7 shows a top view of a subassembly of yet another luminaire according to certain example embodiments. Figs. 8A through 8C show various views of a PCB assembly that includes another printed circuit board according to certain example embodiments.

DETAILED DESCRIPTION

In general, example embodiments provide systems, methods, and devices for flexible circuit boards and other components for luminaires. Example embodiments can provide a number of benefits. Such benefits can include, but are not limited to, fewer parts to keep in inventory, modularity, ease of installation, increased configurability options, longevity of optical devices, user control, and increased reliability. Example embodiments can be used with new luminaires (e.g., light fixtures) or retrofit with existing luminaires. Example embodiments can be used with any of a number of types of luminaires. Examples of such types of luminaires can include, but are not limited to, linear luminaires, closed-loop luminaires, and curved luminaires. Example embodiments described herein can be used with luminaires having any of a number of lengths (e.g., 6 inches, 12 inches, 24 inches). As used herein, a luminaire is a general term that can include a light fixture, a lighting device, an illumination fixture, and similar devices.

Luminaires with example flexible circuit boards and other components can be located in one or more of any of a number of environments. Examples of such environments can include, but are not limited to, indoors, outdoors, a parking garage, a kitchen or cooking space, a hallway, an entertainment room, an office space, a manufacturing plant, a warehouse, and a storage facility, any of which can be climate-controlled or non-climate- controlled. In some cases, the example embodiments discussed herein can be used in any type of hazardous environment, including but not limited to an airplane hangar, a drilling rig (as for oil, gas, or water), a production rig (as for oil or gas), a refinery, a chemical plant, a power plant, a mining operation, a wastewater treatment facility, and a steel mill.

Luminaires with example flexible circuit boards and other components can be directly or indirectly mounted onto any of a number of different structures. Such structures can include, but are not limited to, dry wall, wood studs, concrete, and ceiling tile. Indirect mounting of luminaires with example flexible circuit boards and other components can involve the use of cables, standoffs, conduit, and spacers. A user may be any person that interacts with luminaires. Examples of a user may include, but are not limited to, an engineer, an electrician, an instrumentation and controls technician, an operator, a property manager, a homeowner, a tenant, an employee, a consultant, a contractor, and a manufacturer’s representative. Luminaires with example flexible circuit boards and other components (including portions thereof) can be made of one or more of a number of suitable materials to allow the luminaires to meet certain standards and/or regulations while also maintaining durability in light of the one or more conditions under which the luminaires and/or other associated components of the luminaires can be exposed. Examples of such materials can include, but are not limited to, silicone, aluminum, stainless steel, fiberglass, glass, plastic, polymer, ceramic, and rubber.

Example flexible circuit boards and other components, or portions thereof, described herein can be made from a single piece (as from a mold, injection mold, die cast, or extrusion process). In addition, or in the alternative, example flexible circuit boards and other components (including portions thereof) can be made from multiple pieces that are mechanically coupled to each other. In such a case, the multiple pieces can be mechanically coupled to each other using one or more of a number of coupling methods, including but not limited to epoxy, welding, fastening devices, compression fittings, mating threads, snap fittings, and slotted fittings. One or more pieces that are mechanically coupled to each other can be coupled to each other in one or more of a number of ways, including but not limited to fixedly, hingedly, removeably, slidably, and threadably.

Components and/or features described herein can include elements that are described as coupling, fastening, securing, abutting against, in communication with, or other similar terms. Such terms are merely meant to distinguish various elements and/or features within a component or device and are not meant to limit the capability or function of that particular element and/or feature. For example, a feature described as a “coupling feature” can couple, secure, fasten, abut against, and/or perform other functions aside from merely coupling.

A coupling feature (including a complementary coupling feature) as described herein can allow one or more portions of an example flexible circuit board and/or other components to become coupled, directly or indirectly, to one or more other components of the luminaire and/or to a structure (e.g., a stud, dry wall, a beam). A coupling feature can include, but is not limited to, a clamp, a portion of a hinge, an aperture, a recessed area, a protrusion, a hole, a slot, a tab, a detent, and mating threads. One portion of an example flexible circuit board and/or other related components can be coupled to a component of the luminaire and/or to a structure by the direct use of one or more coupling features.

In addition, or in the alternative, a portion of an example flexible circuit board and/or other related components can be coupled to another component of the luminaire and/or to a structure using one or more independent devices that interact with one or more coupling features disposed on a flexible circuit board and/or other related components. Examples of such devices can include, but are not limited to, a pin, a hinge, a fastening device (e.g., a bolt, a screw, a rivet), epoxy, glue, adhesive, and a spring. One coupling feature described herein can be the same as, or different than, one or more other coupling features described herein. A complementary coupling feature as described herein can be a coupling feature that mechanically couples, directly or indirectly, with another coupling feature.

In the foregoing figures showing example embodiments of flexible circuit boards and other components for luminaires, one or more of the components shown may be omitted, repeated, and/or substituted. Accordingly, example embodiments of flexible circuit boards and other components for luminaires should not be considered limited to the specific arrangements of components shown in any of the figures. For example, features shown in one or more figures or described with respect to one embodiment can be applied to another embodiment associated with a different figure or description.

In certain example embodiments, luminaires that include example flexible circuit boards and other components are subject to meeting certain standards and/or requirements. For example, the National Electric Code (NEC), the National Electrical Manufacturers Association (NEMA), the International Electrotechnical Commission (IEC), the Federal Communication Commission (FCC), Underwriters Laboratories (UL), and the Institute of Electrical and Electronics Engineers (IEEE) set standards as to electrical enclosures, wiring, and electrical connections. Use of example embodiments described herein meet (and/or allow the luminaires to meet) such standards when applicable.

If a component of a figure is described but not expressly shown or labeled in that figure, the label used for a corresponding component in another figure can be inferred to that component. Conversely, if a component in a figure is labeled but not described with respect to that figure, the description for such component can be substantially the same as the description for a corresponding component in another figure. The numbering scheme for the various components in the figures herein is such that each component is a three-digit number or a four-digit number, and corresponding components in other figures have the identical last two digits.

In addition, a statement that a particular embodiment (e.g., as shown in a figure herein) does not have a particular feature or component does not mean, unless expressly stated, that such embodiment is not capable of having such feature or component. For example, for purposes of present or future claims herein, a feature or component that is described as not being included in an example embodiment shown in one or more particular drawings is capable of being included in one or more claims that correspond to such one or more particular drawings herein.

Example embodiments of flexible circuit boards and other components for luminaires will be described more fully hereinafter with reference to the accompanying drawings, in which example embodiments of flexible circuit boards and other components for luminaires are shown. Flexible circuit boards and other components for luminaires may, however, be embodied in many different forms and should not be construed as limited to the example embodiments set forth herein. Rather, these example embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of flexible circuit boards and other components for luminaires to those of ordinary skill in the art. Like, but not necessarily the same, elements (also sometimes called components) in the various figures are denoted by like reference numerals for consistency.

Terms such as “first”, “second”, “above”, “below”, “inner”, “outer”, “distal”, “proximal”, “end”, “top”, “bottom”, “upper”, “lower”, “side”, “left”, “right”, “front”, “rear”, and “within”, when present, are used merely to distinguish one component (or part of a component or state of a component) from another. Such terms are not meant to denote a preference or a particular orientation. Such terms are not meant to limit embodiments of flexible circuit boards and other components for luminaires. In the following detailed description of the example embodiments, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.

Figs. 1A and IB show various views of a luminaire 100 according to certain example embodiments. Specifically, Fig. 1A shows an exploded perspective view of the luminaire 100, and Fig. IB shows a side view of the luminaire 100. The luminaire 100 in this case is in the form of a linear light fixture. The luminaire 100 of Figs. 1A and IB includes a printed circuit board (PCB) assembly 105, a bracket 140, a housing 150, and an optical device 130. The PCB assembly 105 includes a PCB 110 and multiple light sources 160 coupled to the PCB 110. The luminaire 100 can include one or more of any of a number of other components (e.g., end caps, mounting hardware) that are not shown in Figs. 1A and IB. The housing 150 of the luminaire 100 can have any of a number of shapes and/or features. For example, in this case, the housing 150 is generally U-shaped, having a bottom wall 151, a left side wall 153, and a right side wall 152 that form a cavity 155 with an open top side. The housing 150 in this case also includes atop wall 154 that extends laterally inward from the top of the right side wall 152 a relatively short distance (e.g., 1/8 the width of the bottom wall 151). The housing 150 is configured to house one or more of the other components of the luminaire 100. In this case, the optical device 130, the bracket 140, and the PCB assembly 105 are all positioned within the cavity 155 formed by the housing 150.

In some cases, the housing 150 and its various walls are substantially rigid so that the shape of the housing 150 cannot be altered by a user. Alternatively, the housing 150, including at least some of its various walls, can be flexible so that the shape of the housing 150 (or portions thereof) can be altered by a user. In such cases, the housing 150 (or portions thereof) can be made of an elastic or flexible material. For example, the housing 150 can be made of silicone. When the housing 150 is flexible, the housing 150 can maintain its altered shape or revert back to its default shape when the forces used to alter the shape of the housing 150 are no longer applied. The housing 150 (or portions thereof) can be made from one or more of any of a number of manufacturing methods, including but not limited to extrusion and injection molding.

The housing 150 can be or be part of a linear light fixture, as in this case. If the housing 150 in this example is flexible (e.g., bendable), then the housing 150 can be or be part of an arched or curved light fixture with some or all of the housing 150 curved along its length. In alternative embodiments, as discussed below with respect to Fig. 5, the housing 150 can be or be part of a closed-loop (e.g., circular, elliptical, oval) light fixture.

The optical device 130 of the luminaire 100 can include one or more features and/or components. For example, in this case, the optical device 130 can include a bottom surface 131, a left side surface 133, a right side surface 132, and a top surface 134. Running through the middle of the bottom surface 131, along the length of the optical device 130, in this case is a recess 135 that is configured to receive the light sources 160 therein when the luminaire 100 is assembled. The recess 135 can be continuous along the length of the optical device 130, as shown in Fig. 1A. Alternatively, the optical device 130 can have multiple recesses 135. For example, the optical device 130 can have one recess 135 (e.g., semi- spherical in shape) for each light source 160.

In this case, the optical device 130 is symmetrically configured along an axis that coincides with the length of the optical device 130 down the middle of the optical device 130. The optical device 130 is configured to manipulate the light emitted by the light sources 160 of the PCB assembly 105. The optical device 130 can be made of any of a number of materials (e.g., reflective material, refractive material) to generate a desired light dispersion pattern within a volume of space to which the light emitted by the light sources 160 of the PCB assembly 105 are directed. When the luminaire 100 is assembled, as shown in Fig. IB, the bottom surface 131 of the optical device 130 abuts against the top surface of the extensions 215 of the PCB 110 so that the bottom surface of the extensions 215 abut against the bottom wall 151 of the housing 150. In addition, the right surface 132 of the optical device 130 abuts against the bracket 140, which in turn abuts against the top surface of the body 121 of the PCB 110 so that the bottom surface of the body 121 abuts against the right side wall 152 of the housing 150.

In some cases, the optical device 130 is substantially rigid so that the shape of the optical device 130 cannot be altered by a user. Alternatively, the optical device 130, including at least some of its various portions, can be flexible (e.g., bendable) so that the shape of the optical device 130 (or portions thereol) can be altered by a user. In such cases, the optical device 130 (or portions thereol) can be made of an elastic or flexible material. For example, the optical device 130 can be made of silicone. When the optical device 130 is flexible, the optical device 130 can maintain its altered shape or revert back to its default shape when the forces used to alter the shape of the optical device 130 are no longer applied. The optical device 130 (or portions thereof) can be made from one or more of any of a number of manufacturing methods, including but not limited to extrusion and injection molding.

The bracket 140 of the luminaire 100 can be configured to secure one or more components of the luminaire 100 within the cavity 155 of the housing 150. In other words, the shape, size, and/or other configurations of the bracket 140 can be designed to fill gaps within the cavity 155 of the housing 150 so that one or more components of the luminaire 100 are securely positioned relative to one or more of the other components of the luminaire 100. For example, as shown in Fig. IB, the bracket 140 is positioned between the body of the PCB assembly 105 and the right side surface 132 of the optical device 130 within the cavity 155 of the housing 150. More details of the PCB 110 of the PCB assembly 105 are provided below with respect to Figs. 2A through 3B.

In some cases, the bracket 140 is substantially rigid so that the shape of the bracket 140 cannot be altered by a user. Alternatively, the bracket 140, including at least some of its various portions, can be flexible so that the shape of the bracket 140 (or portions thereof) can be altered by a user. In such cases, the bracket 140 (or portions thereof) can be made of an elastic or flexible material. For example, the bracket 140 can be made of silicone. When the bracket 140 is flexible, the bracket 140 can maintain its altered shape or revert back to its default shape when the forces used to alter the shape of the bracket 140 are no longer applied. The bracket 140 (or portions thereof) can be made from one or more of any of a number of manufacturing methods, including but not limited to extrusion and injection molding.

As discussed above, the PCB assembly 105 of the luminaire 100 includes a PCB 110 and multiple light sources 160. The light sources 160 generate illumination. There can be one or more light sources 160 coupled to each of the extensions 215 of the PCB 110. For example, as shown in Fig. IB, light source 160-24 is coupled to extension 215-24 of the PCB 110. The light sources 160 illuminate using power and/or control signals provided to the light sources 160 through the PCB 110. Each light source 160 can use any type of lighting technology, whether currently known or developed in the future, including but not limited to light-emitting diode (LED), organic LED (OLED), plasma, and bioluminescence.

Each light source 160 can be configured (e.g., have a height, have a width) to fit within the recess 135 of the optical device 130 when the optical device 130 is positioned above the extensions 215 of the PCB 110. A light source 160 can be coupled to the PCB 110 in any of a number of ways. For example, a light source 160 can be soldered to the PCB 110. As another example, a light source 160 can have a coupling feature (e.g., an electrical connector) that couples to a complementary coupling feature on the PCB 110. A light source 160 can include one or more of a number of components, including but not limited to a bulb, a diode, a circuit board, a resistor, a capacitor, and a heat sink. When the luminaire 100 has multiple light sources 160, one light source 160 can have characteristics (e.g., color capability, temperature, technology type, shape, size) that are substantially the same as, or different than, one or more of the corresponding characteristics of one or more of the other light sources 160.

The PCB 110 is flexible so that its shape can be changed by a user. Figs. 2A through 2D show various views of the PCB 110 of the luminaire 100 of Figs. 1A and IB in a default state according to certain example embodiments. Figs. 3A and 3B show various views of the PCB 110 of the luminaire 100 of Figs. 1A and IB in a formed state according to certain example embodiments. Specifically, Fig. 2A shows a top view of the PCB 110 in its default state. Fig. 2B shows a side view of the PCB 110 in its default state. Fig. 2C shows a front view of the PCB 110 in its default state. Fig. 2D shows a detailed view of the PCB 110 in its default state of Fig. 2A. Fig. 3A shows a top view of the PCB 110 in a formed state. Fig. 3B shows a side view of the PCB 110 in a formed state.

Referring to Figs. 1A through 3B, the PCB 110 includes a body 211 and multiple extensions 215. When all of the extensions 215 and the body 211 are unbent (in this case, planar with the body 211), the PCB 110 is in its default state. When one or more of the extensions 215 and/or the body 211 is bent, the PCB 110 is in a formed state. The PCB 110 can have any of a number of discrete formed states. The body 211 of the PCB 110 includes one or more components and/or features. For example, in this case, the body 211 of the PCB 110 includes two connectors 219 (connector 219-1 and connector 219-2) and main circuitry 212 coupled to the connectors 219.

Each connector 219 on the body 211 of the PCB 110 can be positioned at any location on the body 211 so that each connector 219 can couple to a complementary connector (or other similar complementary coupling feature) when the components of the luminaire 100 are assembled. For example, in this case, connector 219-1 is located at one end of the body 211 , and connector 219-2 is located at the opposite end of the body 211. Each connector 219 can be configured to couple to another component (e.g., an end cap, another PCB 110, an electrical cable) of the luminaire 100. For example, as shown in Fig. 6 below, connector 219-1 can be configured to couple to a complementary connector disposed on the body of another PCB for the luminaire 100.

Each connector 219 can be configured to ensure a mechanical coupling of the PCB with another component of the luminaire 100 to secure the PCB 110 within the luminaire 100. In addition, or in the alternative, each connector 219 can be configured to facilitate the transfer of power, communication, control, and/or any other type of signal therethrough with the main circuitry 212 in the body 211 of the PCB 110. Each connector 219 can be or include any type of coupling feature. When the PCB 110 has multiple connectors 219, the configuration of one connector 219 can be the same as, or different than, the configuration of one or more of the other connectors 219. The body 211 of the PCB 110 can be flexible (e.g., bendable, resilient) along some or all of its length. In some cases, the flexibility of the body 211 can extend to one or more of the connectors 219 of the PCB 110.

The main circuitry 212 can be or include leads, traces, etc. that are electrically conductive. The main circuitry 212 in the body 211 can be located along the top surface of the body 211, the bottom surface of the body 211, and/or embedded within the body 211. The main circuitry 212 can have any of a number (e.g., 2, 3, 4, 6) of conductors that are arranged in parallel with each other. For example, in this case, the main circuitry 212 has 3 conductors that are arranged in parallel with each other on the top surface of the body 211.

The multiple extensions 215 of the PCB 110 are configured to provide configurability of the PCB 110. A PCB 110 can have any number of extensions 215. In this case, the PCB 110 has 24 extensions 215 (extension 215-1, extension 215-2, extension 215-3, extension 215-4, extension 215-5, extension 215-6, extension 215-7, extension 215-8, extension 215-9, extension 215-10, extension 215-11, extension 215-12, extension 215-13, extension 215-14, extension 215-15, extension 215-16, extension 215-17, extension 215-18, extension 215-19, extension 215-20, extension 215-21, extension 215-22, extension 215-23, and extension 215-24).

Each of the extensions 215 of the PCB 110 extend from an outer perimeter along the length of the body 211. In certain example embodiments, each extension 215 includes localized circuitry 213 and one or more light source receivers 216 coupled to the localized circuitry 213. For example, as shown in the detail provided by Fig. 2D, extension 215-4 includes localized circuitry 213-4 and light source receiver 216-4. Extension 215-5 includes localized circuitry 213-5 and light source receiver 216-5. Extension 215-6 includes localized circuitry 213-6 and light source receiver 216-6.

The localized circuitry 213 of each extension 215 is also coupled to the main circuitry 212 of the body 211. Each light source receiver 216 of an extension 215 is configured to couple to (e.g., receive) a light source 160. When a light source receiver 216 couples to a light source 160, the light source can receive control, power, and/or any other type of signal to operate and illuminate. The localized circuitry 213 can be or include leads, traces, etc. that are electrically conductive. The localized circuitry 213 in each extension 215 can be located along the top surface of the extension 215, the bottom surface of the extension 215, and/or embedded within the extension 215. The localized circuitry 213 can have any of a number (e.g., 2, 3, 4, 6) of conductors that are arranged in parallel with each other. For example, in this case, the localized circuitry 213 has 3 conductors that are arranged in parallel with each other on the top surface of each extension 215.

Each extension 215 can be individually bendable relative to the body 211 of the PCB 110. Each extension 215 can have any of a number of shapes (e.g., rectangular (as in this case), oval, square, triangular) when viewed from above. Also, each extension 215 can have a length 222, a width 224, and a height 223. The shape, dimensions, and/or other characteristics of one extension 215 can be the same as, or different than, the corresponding shape, dimensions, and/or other characteristics of the other extensions 215 of the PCB 110. In certain example embodiments, adjacent extensions 215 of the PCB 110 are separated from each other by a distance 221 at the outer perimeter along the length of the body 211. In this case, the distance 221 of separation is the same between each pair of adjacent extensions 215. In alternative embodiments, the distance 221 of separation between at least one pair of adjacent extensions 215 can differ from the distance 221 of separation between another pair of adjacent extensions 215 of the PCB 110.

When the PCB 110 is in a formed state, as shown in Figs. IB, 3A, and 3B, all of the extensions 215 are bent relative to the body 211 of the PCB 110. Each extension 215 can be bent at any angle 229 (e.g., 35°, 125°) relative to the body 211. For example, in this case, each extension 215 is bent at any angle 229 of approximately 90° relative to the body 211. As such, as shown in Fig. IB, the body 211 of the PCB 110 abuts against the inside surface of the right side wall 152 of the housing 150, and the extensions 215 of the PCB 110 abut against the inside surface of the bottom wall 151 of the housing 150. This configuration allows the light 190 emitted by the light sources 160 to be directed downward into a volume of space 191 (e.g., a room, an office space) based on the amount of bend of the extensions 215 relative to the body 211. In this way, the direction that the light 190 is emitted from each light source (e.g., light source 160-24) can be customized by adjusting the angle 229 of the extension 215 relative to the body 211.

Depending on the material used for the extensions 215 and/or the body 211 of the PCB 110, an extension 215 can maintain its position relative to the body 211 when the extension 215 is bent. In alternative embodiments, an extension 215 can substantially return to its default position (in this case, substantially planar) relative to the body 211 when the force applied to bend the extension 215 is removed. In this case, all 24 extensions 215 (extension 215-1, extension 215-2, extension 215-3, extension 215-4, extension 215-5, extension 215-6, extension 215-7, extension 215-8, extension 215-9, extension 215-10, extension 215-11, extension 215-12, extension 215-13, extension 215-14, extension 215-15, extension 215-16, extension 215-17, extension 215-18, extension 215-19, extension 215-20, extension 215-21, extension 215-22, extension 215-23, and extension 215-24) are bent at an angle 229 of approximately 90° relative to the body 211.

Fig. 4 shows a system diagram of a PCB 410 according to certain example embodiments. Referring to Figs. 1 A through 4, the PCB 410 of Fig. 4 is a generic rendering of the PCB 110 discussed above. In this case, the PCB 410 has a body 411 with one connector 419-1, an optional second connector 419-2, and main circuitry 412, all of which are substantially similar to the body 211, the connectors 219, and the main circuitry 212 discussed above. In this case, the main circuitry 412 is depicted by a single conductor, but the main circuitry 412 can include multiple conductors. In this case, the body 411 is unbent (and so in a default state). The main circuitry 412 can be or include leads, traces, etc. that are electrically conductive.

The PCB 410 of Fig. 4 has Z extensions 415, which includes extension 415-1, extension 415-2, extension 415-Y, and extension 415-Z. Each extension 415 has localized circuitry 413 and a light source receiver 416. Specifically, extension 415-1 includes localized circuitry 413-1 and a light source receiver 416-1. Extension 415-2 includes localized circuitry 413-2 and a light source receiver 416-2. Extension 415-Y includes localized circuitry 413-Y and a light source receiver 416-Y. Extension 415-Z includes localized circuitry 413-Z and a light source receiver 416-Z. The localized circuitry 413 and the light source receivers 416 of the extensions 415 of the PCB 410 of Fig. 4 can be substantially the same as the localized circuitry 213 and the light source receivers 216 discussed above. In this case, the localized circuitry 413 is depicted by a single conductor, but the localized circuitry 413 can include multiple conductors. The localized circuitry 413 can be or include leads, traces, etc. that are electrically conductive.

Adjacent extensions 415 (e.g., extension 415-Y and extension 415-Z) of the PCB 410 of Fig. 4 are separated from each other by a distance 421. The extensions 415 in this case have substantially the same configuration (e.g., rectangular shape when viewed from above in a default state, length 422, width 424, height 423) as each other. Each extension 415 is individually adjustable (e.g., bendable) relative to the body 411. Extension 415-1, extension 415-2, and extension 415-Y are unbent (in a default state), and so are substantially planar with the body 411. Extension 415-Z is bent at an angle (similar to angle 229) of approximately 90° relative to the body 211. As a result, since at least one of the extensions 415 and/or the body 411 is bent, the PCB 410 can be considered to be in a formed state.

Fig. 5 shows a top view of a subassembly 599 of another luminaire according to certain example embodiments. Referring to Figs. 1A through 5, the subassembly 599 of Fig. 5 includes a housing 550 and a PCB assembly 505, where the PCB assembly 505 includes a PCB 510 and 16 light sources 560. The housing 550 in this case has a circular (closed loop) shape when viewed from above. Otherwise, the housing 550 of Fig. 5 is substantially the same as the housing 150 discussed above. For example, the housing 550 has an inside wall 552 (similar to the right side wall 152), an outside wall 553 (similar to the left side wall 153), and a top wall 554 (similar to top wall 154) that extends inward a relatively short distance from the top of the inside wall 552.

Similarly, the PCB 510 and the light sources 560 of the PCB assembly 505 of Fig. 5 are substantially the same as the PCB 110 and the light sources 160 of the PCB assembly 105 discussed above. The base (similar to the base 211) of the PCB 510, including any connectors (similar to the connectors 219 and the connectors 419 above), is hidden from view and held in place within the housing 550 by the top wall 554 of the housing 550. The PCB 510 has 16 extensions 515 (extension 515-1, extension 515-2, extension 515-3, extension 515-4, extension 515-5, extension 515-6, extension 515-7, extension 515-8, extension 515-9, extension 515-10, extension 515-11, extension 515-12, extension 515-13, extension 515-14, extension 515-15, and extension 515-16) that are all bent at an angle (e.g., similar to angle 229) of approximately 90° relative to the body (e.g., similar to body 411), hidden from view of the top wall 554 of the housing 550, of the PCB 510. Each extension 515 is individually adjustable (e.g., bendable) relative to the body.

There is one light source 560 coupled to each extension 515. Specifically, light source 560-1 is coupled to extension 515-1, light source 560-2 is coupled to extension 515-2, light source 560-3 is coupled to extension 515-3, light source 560-4 is coupled to extension 515-4, light source 560-5 is coupled to extension 515-5, light source 560-6 is coupled to extension 515-6, light source 560-7 is coupled to extension 515-7, light source 560-8 is coupled to extension 515-8, light source 560-9 is coupled to extension 515-9, light source 560-10 is coupled to extension 515-10, light source 560-11 is coupled to extension 515-11, light source 560-12 is coupled to extension 515-12, light source 560-13 is coupled to extension 515-13, light source 560-14 is coupled to extension 515-14, light source 560-15 is coupled to extension 515-15, and light source 560-16 is coupled to extension 515-16.

The distance (similar to the distance 221 and the distance 421) between all adjacent extensions 515 is substantially the same. Further, based on the uniform curvature of the housing 550, the angle 589 formed between the side edges of adjacent extensions 515 (as between the side edges of extension 515-9 and extension 515-10 in Fig. 5) is substantially the same along the entire PCB 510. In this case, the angle 589 is acute when measured from within the space surrounded by the PCB assembly 505 and the housing 550. By contrast, the corresponding angle between adjacent extensions for the PCBs in Figs. 1A through 4 is substantially infinite because the side edges of the adjacent extensions are substantially parallel with each other. A cross-sectional view of the subassembly 599 can appear substantially similar to what is shown in Fig. IB above. While the subassembly 599 in this case has a single PCB 510, as an alternative, the subassembly 599 can have multiple (e.g., 2, 3, 4, 8) PCBs 510 that are coupled to each other end-to-end to form a closed loop. In such a case, the adjacent PCBs 510 can be connected to each other using the connectors. The subassembly 599 of the luminaire of Fig. 5 is without a bracket (similar to the bracket 140 above) and an optical device (similar to the optical device 130 above). When included with the subassembly 599 to form a luminaire, the bracket and the optical device can have the same cross-sectional characteristics as the bracket 140 and the optical device 130 discussed above, and their shapes when viewed from above can be in a closed loop circular form that allows them to be positioned within the cavity of the housing 550. Also, the localized circuitry (similar to the localized circuitry 213 and the localized circuitry 413 discussed above) are embedded within the extensions 515, and so are not visible. Similarly, the main circuitry (similar to the main circuitry 212 and the main circuitry 412 discussed above) can be embedded within the body of the PCB 510.

Fig. 6 shows a top view of a PCB 610 in a default state according to certain example embodiments. Referring to Figs. 1A through 6, the PCB 610 of Fig. 6 includes a PCB 710 and a PCB 810 that are coupled to each other in series. PCB 710 and PCB 810 are configured identically relative to each other. PCB 710 includes a body 711 and 12 extensions 715 (extension 715-1, extension 715-2, extension 715-3, extension 715-4, extension 715-5, extension 715-6, extension 715-7, extension 715-8, extension 715-9, extension 715-10, extension 715-11, and extension 715-12) that extend away from the right side along the length of the body 711. Each extension 715 is individually adjustable (e.g., bendable) relative to the body 711.

The body 711 of the PCB 710 includes a connector 719-1 located at the bottom end of the body 711, another connector 719-2 located at the top end of the body 711, and main circuitry 712 along the top surface of the body 711 running between the connectors 719 along the length of the body 711. Each of the 12 extensions 715 of the PCB 710 include localized circuitry 713 and a light source receiver 716. The localized circuitry 713 can be or include leads, traces, etc. that are electrically conductive. Similarly, the main circuitry 712 can be or include leads, traces, etc. that are electrically conductive. The connectors 719, the main circuitry 712, the localized circuitry 713, the light source receivers 716, and the other characteristics (e.g., the distance between adjacent extensions 715) of the PCB 710 are substantially the same as the corresponding components and characteristics of the PCBs discussed above with respect to Figs. 1A through 5. Similarly, PCB 810 includes a body 811 and 12 extensions 815 (extension 815-1, extension 815-2, extension 815-3, extension 815-4, extension 815-5, extension 815-6, extension 815-7, extension 815-8, extension 815-9, extension 815-10, extension 815-11, and extension 815-12) that extend away from the right side along the length of the body 811. Each extension 815 is individually adjustable (e.g., bendable) relative to the body 811. The body 811 of the PCB 810 includes a connector 819-1 located at the bottom end of the body 811, another connector 819-2 located at the top end of the body 811, and main circuitry 812 along the top surface of the body 811 running between the connectors 819 along the length of the body 811. Each of the 12 extensions 815 of the PCB 810 include localized circuitry 813 and a light source receiver 816. The localized circuitry 813 can be or include leads, traces, etc. that are electrically conductive. Similarly, the main circuitry 812 can be or include leads, traces, etc. that are electrically conductive. The connectors 819, the main circuitry 812, the localized circuitry 813, the light source receivers 816, and the other characteristics (e.g., the distance between adjacent extensions 815) of the PCB 810 are substantially the same as the corresponding components and characteristics of the PCBs discussed above with respect to Figs. 1A through 5.

To make the PCB 610 as one continuous component, connector 719-1 of PCB 710 and connector 819-2 of PCB 810 are coupled to each other. For this to occur, the configuration of connector 719-1 and the configuration of connector 819-2 complement each other. Also, in this case, the coupling of connector 719-1 and connector 819-2 provide both a mechanical coupling (to physically join PCB 710 and PCB 810 to form PCB 610) and an electrical coupling (to provide electrical continuity between the main circuitry 712 of PCB 710 and the main circuitry 812 of PCB 810.

Fig. 7 shows a top view of a subassembly 799 of yet another luminaire according to certain example embodiments. Referring to Figs. 1 A through 7, the subassembly 799 of Fig. 7 includes a housing 750 and a PCB assembly 905, where the PCB assembly 905 includes a PCB 910 and 5 light sources 960. The housing 950 in this case has a general S- shape when viewed from above. Otherwise, the housing 950 of Fig. 7 is substantially the same as the housings (e.g., housing 150) discussed above. For example, the housing 750 has an inside wall 752 (similar to the right side wall 152), an outside wall 753 (similar to the left side wall 153), and a top wall 754 (similar to top wall 154) that extends inward a relatively short distance from the top of the inside wall 752.

Similarly, the PCB 910 and the light sources 960 of the PCB assembly 905 of Fig. 7 are substantially the same as the PCBs (e.g., PCB 110) and the light sources (e.g., light sources 160) of the PCB assemblies (e.g., PCB assembly 105) discussed above. The base (similar to the base 211) of the PCB 910, including any connectors (similar to the connectors 219 and the connectors 419 above), is hidden from view and held in place within the housing 750 by the top wall 754 of the housing 750. The PCB 910 has 5 extensions 915 (extension 915-1, extension 915-2, extension 915-3, extension 915-4, and extension 915-5) that are all bent at an angle (similar to angle 229) of approximately 90° relative to the body (e.g., similar to body 411), hidden from view of the top wall 754 of the housing 750, of the PCB 910. Each extension 915 is individually adjustable (e.g., bendable) relative to the body.

There is one light source 960 coupled to each extension 915. Specifically, light source 960-1 is coupled to extension 915-1, light source 960-2 is coupled to extension 915-2, light source 960-3 is coupled to extension 915-3, light source 960-4 is coupled to extension 915-4, and light source 960-5 is coupled to extension 915-5. The distance 921 (similar to, for example, the distance 221 and the distance 421) between all adjacent extensions 915 is substantially the same. A cross-sectional view of the subassembly 799 can appear substantially similar to what is shown in Fig. IB above.

Further, based on the various curvature of the housing 750, the angle 789 formed between the side edges of adjacent extensions 915 differs along the entire PCB 910. For example, the angle 789-1 formed between the side edges of extension 915-1 and extension 915-2 is acute when measured from the right side of the subassembly 799 (within the curvature of that portion of the housing 750). The angle 789-2 formed between the side edges of extension 915-2 and extension 915-3 is even less acute (larger than angle 789-1) when measured from the right side of the subassembly 799 (within the curvature of that portion of the housing 750).

In addition, the angle 789-3 formed between the side edges of extension 915-3 and extension 915-4 is acute when measured from the left side of the subassembly 799 (within the curvature of that portion of the housing 750). The angle 789-4 formed between the side edges of extension 915-4 and extension 915-5 is less acute (larger than angle 789-3) when measured from the left side of the subassembly 799 (within the curvature of that portion of the housing 750). In order of size, angle 789-4 is smaller than angle 789-3, which is smaller than angle 789-1, which is smaller than angle 789-2.

If the housing 750 is shapable along its length and/or if the PCB assembly 905 is removed from the housing 750, one or more of these angles 789 can be changed (e.g., increased, decreased) by manipulating (e.g., bending) the body of the PCB 910. In some cases, example PCBs discussed herein can be formed into non-planar (e.g., spiral-shaped, waves in the vertical and horizontal directions) configurations.

While the subassembly 799 in this case has a single PCB 910, as an alternative, the subassembly 799 can have multiple (e.g., 2, 3, 4, 8) PCBs 910 that are coupled to each other end-to-end to form, for example, a serpentine configuration or some other configuration with curved edges when viewed from above. In such a case, the adjacent PCBs 910 can be connected to each other using the connectors. The subassembly 799 of the luminaire of Fig. 7 is without a bracket (similar to the bracket 140 above) and an optical device (similar to the optical device 130 above).

Figs. 8A through 8C show various views of a PCB assembly 898 that includes another PCB 1010 according to certain example embodiments. Specifically, Fig. 8A shows a top-side perspective view of the PCB 1010. Fig. 8B shows a side view of the PCB 1010. Fig. 8C shows a front view of one of the extensions 1015 of the PCB 1010. Referring to Figs. 1A through 8C, the PCB assembly 898 includes the PCB 1010 with 14 extensions 1015 and 14 light sources 1060 coupled to the light source receivers (hidden from view) of the extensions 1015 of the PCB 1010.

Specifically, light source 1060-1 is coupled to the light source receiver of extension 1015-1, light source 1060-2 is coupled to the light source receiver of extension 1015-2, light source 1060-3 is coupled to the light source receiver of extension 1015-3, light source 1060-4 is coupled to the light source receiver of extension 1015-4, light source 1060-5 is coupled to the light source receiver of extension 1015-5, light source 1060-6 is coupled to the light source receiver of extension 1015-6, light source 1060-7 is coupled to the light source receiver of extension 1015-7, light source 1060-8 is coupled to the light source receiver of extension 1015-8, light source 1060-9 is coupled to the light source receiver of extension 1015-9, light source 1060-10 is coupled to the light source receiver of extension 1015-10, light source 1060-11 is coupled to the light source receiver of extension 1015-11, light source 1060-12 is coupled to the light source receiver of extension 1015-12, light source 1060-13 is coupled to the light source receiver of extension 1015-13, and light source 1060- 14 is coupled to the light source receiver of extension 1015-14.

The light sources 1060 and the PCB 1010 (including portions thereof such as the extensions 1015 and the body 1011) of the PCB assembly 898 of Figs. 8A through 8C are substantially the same as the light sources and the PCB (including portions thereof such as the extensions and the body) discussed above, except as described below. In this case, the main circuitry of the body 1011 and the localized circuitry of each of the extensions 1015 of the PCB 1010 of Figs. 8A through 8C are set below the top surface of (embedded in) the body 1011 and the extensions 1015, and so are hidden from view. Each extension 1015 can be individually adjustable (e.g., bendable) relative to the body 1011. In this case, the angle 829 between all of the extensions 1015 and the body 1011 is approximately 90°. Each extension 1015 is individually adjustable (e.g., bendable) relative to the body 101 E

In some cases, the body and/or one or more of the extensions of an example PCB discussed herein can include one or more of a number of features used for coupling to another component of a luminaire. For example, as shown in Fig. 8A, the body 1011 of the PCB 1010 can include one or more coupling features 856 (in this case, in the form of apertures that traverse the thickness of the body 1011) that can be used to directly or indirectly couple to complementary coupling features disposed on another component (e.g., a housing) of the luminaire.

In this case, there are a total of 14 coupling features 856 that are configured (e.g., in terms of size, in terms of shape, in terms of location relative to an adjacent extension 1015) identically to each other. In alternative embodiments, when there are multiple coupling features 856 on the body 1011 of the PCB 1010, one coupling feature 856 can have one or more characteristics that differ from one or more corresponding characteristics of one or more of the other coupling features 856.

As another example, as shown in Figs. 8A and 8C, each of the extensions 1015 include two coupling features 859 (e.g., coupling feature 859-1-1 and coupling feature 859-1- 2 for extension 1015-1) in the form of apertures that traverse the thickness of the extension body 857-1 on either side of the light source receiver. As yet another example, as shown in Figs. 8A and 8C, each of the extensions 1015 include four coupling features 858 (e.g., coupling feature 858-1-1, coupling feature 858-1-2, coupling feature 858-1-3, and coupling feature 858-1-4 for extension 1015-1) in the form of recesses along the outer perimeter of the extension body 857-1 of each extension 1015.

In this case, the coupling features 859 are configured (e.g., in terms of size, in terms of shape, in terms of location relative to the light source receiver) identically to each other. Similarly, the coupling features 858 are configured (e.g., in terms of size, in terms of shape, in terms of location on the extension body 857-1 relative to the light source receiver, in terms of location on the extension body 857-1 relative to each other) identically to each other. In alternative embodiments, when there are multiple coupling features (e.g., coupling features 858, coupling features 859) on the body 1011 of the PCB 1010, one coupling feature can have one or more characteristics that differ from one or more corresponding characteristics of one or more of the other coupling features.

Also, the shape of an extension of an example PCB can vary. For example, as shown in Figs. 1 A through 7, the extensions (e.g., extensions 215, extensions 415) can have a substantially rectangular shape when viewed from above. As another example, as shown in Figs. 8A and 8C, the extensions (in this case, extensions 1015) can have a substantially circular shape when viewed from above. In some cases, the characteristics (e.g., the shape when viewed from above, the size, the thickness) of one extension of an example PCB can differ from the corresponding characteristics of one or more other extensions of the PCB when the PCB has multiple extensions.

When included with the subassembly 799 to form a luminaire, the bracket and the optical device can have the same cross-sectional characteristics as the bracket 140 and the optical device 130 discussed above, and their shapes when viewed from above can be in a closed loop circular form that allows them to be positioned within the cavity of the housing 950. Also, the localized circuitry (similar to, for example, the localized circuitry 213 and the localized circuitry 413 discussed above) are embedded within the extensions 915 and the body of the PCB 910, and so are not visible. Similarly, the main circuitry (similar to, for example, the main circuitry 212 and the main circuitry 412 discussed above) can be embedded within the body of the PCB 910.

Example embodiments can be used to allow for flexible configurations of luminaires, such as linear light fixtures, curved light fixtures, and closed-loop light fixtures. Example embodiments can allow for shaping a luminaire at the time of installation without any adverse effects on lighting quality. Example embodiments can be used with luminaires having any of a number of sizes and/or features. Example embodiments can be used in new luminaire installations as well as retrofitting existing luminaires. Example embodiments also provide a number of other benefits. Such other benefits can include, but are not limited to, increased ease of maintenance, greater ease of use, increased reliability, modularity, ease of installation, and compliance with industry standards that apply to linear light fixtures.

Although embodiments described herein are made with reference to example embodiments, it should be appreciated by those skilled in the art that various modifications are well within the scope and spirit of this disclosure. Those skilled in the art will appreciate that the example embodiments described herein are not limited to any specifically discussed application and that the embodiments described herein are illustrative and not restrictive. From the description of the example embodiments, equivalents of the elements shown therein will suggest themselves to those skilled in the art, and ways of constructing other embodiments using the present disclosure will suggest themselves to practitioners of the art. Therefore, the scope of the example embodiments is not limited herein.

Claims

CLAIMS:

1. A luminaire (100) comprising: a housing (150, 550) that forms a cavity (155) with an open side therein; a printed circuit board (PCB) (110, 410, 510) disposed within the cavity, wherein the PCB comprises a body (211, 411) and a plurality of extensions (215, 415, 515) that extend from an outer perimeter along a length of the body, wherein the body comprises a connector (219, 419) and main circuitry (212, 412) coupled to the connector, wherein each extension of the plurality of extensions comprises localized circuitry (213, 413) and a light source receiver (216, 416) coupled to the localized circuitry, wherein the localized circuitry is further coupled to the main circuitry of the body, wherein each extension is bent relative to the body, and wherein two or more adjacent extensions of the plurality of extensions are separated from each other by a distance (221, 421) at the outer perimeter along the length of the body; a plurality of light sources (160, 560) each coupled to a corresponding light source receiver of the plurality of extensions of the PCB; and an optical device (130) disposed within the cavity between the plurality of light sources and the open side of the housing, wherein each of the plurality of light sources is disposed within at least one recess (135) of a bottom surface (131) of the optical device, wherein the bottom surface abuts the plurality of extensions, and wherein the recess receives light emitted by each of the plurality of light sources and redirects at least a portion of the light to one or more surfaces of the optical device (132, 133, 134).

2. The luminaire of claim 1, wherein the housing and the optical device are made of an elastic material.

3. The luminaire of claim 2, wherein the elastic material comprises silicone.

4. The luminaire of claim 1, wherein the housing and the optical device are bendable.

5. The luminaire of claim 1, wherein the body of the PCB abuts against a side wall of the housing, and wherein the plurality of extensions abut against a bottom wall of the housing.

6. The luminaire of claim 1, further comprising: a bracket (140) positioned within the cavity between the body of the PCB and the optical device, wherein the bracket is made of the elastic material.

7. The luminaire of claim 1, wherein the housing is curved along its length.

8. The luminaire of claim 1, wherein the housing forms a closed loop.