Light fixture with textured reflector

• US 9,476,566 B2
• Filed: 01/06/2012
• Issued: 10/25/2016
• Est. Priority Date: 01/06/2012
• Status: Active Grant

• Current Assignee: IDEAL Industries Lighting, LLC (Ideal Industries Incorporated)
• Original Assignee: CREE Incorporated (Wolfspeed, Inc.)
• Inventors: Lu, Dong, Nguyen, Nick Hoang, Durkee, John
• Primary Examiner(s): CARTER, WILLIAM JOSEPH
• Application Number:
  US13/345,215
• Publication Number:
  US 20130176721A1
• Time in Patent Office: 1,754 Days
• Field of Search: 362341-350
• US Class Current: 1/1
• CPC Class Codes: F21S 8/06 by suspension
• CPC Class Codes: F21V 13/04 the elements being reflectors and refractors for vehicle rear lights F21S43/40
• CPC Class Codes: F21V 15/013 the housing being an extrusion
• CPC Class Codes: F21V 29/777 the planes containing the fins or blades having directions perpendicular to the light emitting axis
• CPC Class Codes: F21V 7/0008 providing for indirect lighting
• CPC Class Codes: F21V 7/048 with facets structure
• CPC Class Codes: F21V 7/09 with a combination of different curvatures
• CPC Class Codes: F21V 7/24 characterised by the material
• CPC Class Codes: F21Y 2113/10 of different colours
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material

Abstract

A light fixture with a textured reflector is disclosed. Embodiments of the present invention provide for a lighting system in which LEDs face, and the majority of light form the LED light source is incident on, a textured back reflector while producing minimal glare and minimal imaging of the light source. Such a reflector may be referred to as a retro-reflector. The reflector for the light fixture can be made from a relatively inexpensive material such as polycarbonate, which without texturing has a specular or semi-specular surface. Further, a diffuse white layer to provide color mixing or prevent glare and reflections is not needed. The textured reflector can be textured by way of an imprinted pattern or by roughening, and can be extruded. A prismatic texture may be used. The texturing can also be spatially varied.

Claims

1. A lighting system comprising:

a textured, plastic reflector to reflect light, wherein the textured, plastic reflector includes a single surface comprising a substantially flat central region, a smooth transition to two parabolic regions on opposite sides of the relatively flat central region, and a plurality of pyramidal elements; and

a plurality of LEDs to emit light, the plurality of LEDs positioned to face opposite an illumination area of a room so that at least 70% of the light is incident on the textured, plastic reflector and is reflected into the illumination area.

2. The lighting system of claim 1 wherein the pyramidal elements are imprinted.

3. The lighting system of claim 2 wherein the textured, plastic reflector further comprises polycarbonate.

4. The lighting system of claim 3 wherein the plurality of LEDs further comprises at least two groups of LEDs, wherein one group, if illuminated, would emit light having a dominant wavelength from 435 to 490 nm, and another group, if illuminated, would emit light having a dominant wavelength from 600 to 640nm, one group being packaged with a phosphor, which, when excited, emits light having a dominant wavelength from 540 to 585 nm.

5. The lighting system of claim 4 wherein the one group, if illuminated, would emit light having a dominant wavelength from 440 to 480 nm, and the other group, if illuminated, would emit light having a dominant wavelength from 605 to 630 nm, one group being packaged with a lumiphor, which, when excited, emits light having a dominant wavelength from 560 to 580 nm.

6. The lighting system of claim 3 further comprising at least one lens plate proximate to the plurality of LEDs.

7. The lighting system of claim 6 wherein the textured, plastic reflector and the at least one lens plate are coextruded.

8. The lighting system of claim 2 wherein the pyramidal elements spatially vary relative to at least one of the position of the plurality of LEDs and a center of the textured, plastic reflector.

9. The lighting system of claim 1 wherein the textured, plastic reflector further comprises a roughening pattern.

10. The lighting system of claim 9 wherein the textured, plastic reflector further comprises polycarbonate.

11. The lighting system of claim 10 wherein the plurality of LEDs further comprises at least two groups of LEDs, wherein one group, if illuminated, would emit light having a dominant wavelength from 435 to 490 nm, and another group, if illuminated, would emit light having a dominant wavelength from 600 to 640 nm, one group being packaged with a phosphor, which, when excited, emits light having a dominant wavelength from 540 to 585nm.

12. The lighting system of claim 11 wherein the one group, if illuminated, would emit light having a dominant wavelength from 440 to 480 nm, and the other group, if illuminated, would emit light having a dominant wavelength from 605 to 630 nm, one group being packaged with a lumiphor, which, when excited, emits light having a dominant wavelength from 560 to 580 nm.

13. The lighting system of claim 10 wherein the roughening pattern spatially varies relative to at least one of the position of the plurality of LEDs and a center of the textured, plastic reflector.

14. The lighting system of claim 10 further comprising at least one lens plate.

15. The lighting system of claim 14 wherein the textured, plastic reflector and the at least one lens plate are coextruded.

16. The lighting system of claim 1 wherein the plurality of pyramidal elements are disposed on the relatively flat, central region and each of the parabolic regions.

17. A method of making a light fixture, the method comprising:

assembling an LED light source comprising a plurality of LEDs;

extruding a reflector configured to receive light from the LED light source, the reflector being extruded from plastic and including a single surface comprising a substantially flat central region and a smooth transition to two parabolic regions on opposite sides of the relatively flat central region;

applying at least one texture to the reflector, the at least one texture including a plurality of pyramidal elements; and

positioning the reflector and the LED light source in a fixture so that the plurality of LEDs face opposite an illumination area of a room and the reflector receives at least 70% of the light from the LED light source and reflects the light into the illumination area.

18. The method of claim 17 wherein the applying of the at least one texture to the reflector further comprises imprinting the pyramidal elements on the reflector.

19. The method of claim 18 wherein the imprinting of the reflector is accomplished while the reflector is being extruded.

20. The method of claim 18 wherein the imprinting of the reflector further comprises imprinting the reflector with a pattern that spatially varies relative to a center of the reflector.

21. The method of claim 17 wherein the plastic further comprises polycarbonate.

22. The method of claim 17 wherein the applying of the at least one texture to the reflector further comprises roughening an interior surface of the reflector.

23. The method of claim 22 wherein the extruding of the reflector further comprises extruding the reflector from polycarbonate.

24. The method of claim 23 wherein the roughening of the reflector further comprises roughening the reflector so that an imparted roughening of the surface spatially varies relative to a center of the reflector.

25. A textured reflector configured to receive at least 70% of light from a plurality of LEDs positioned to face opposite an illumination area of a room and reflect the light into the illumination area, the textured reflector further comprising plastic, a single surface including a substantially flat central region making a smooth transition to two parabolic regions on opposite sides of the substantially flat central region, and a plurality of pyramidal elements.

26. The textured reflector of claim 25 wherein the pyramidal elements are imprinted.

27. The textured reflector of claim 26 wherein the plastic comprises polycarbonate.

28. The textured reflector of claim 27 wherein the pyramidal elements spatially vary relative to a center of the reflector.

29. The textured reflector of claim 25 further comprising a roughened interior surface.

30. The textured reflector of claim 29 wherein the plastic comprises polycarbonate.

31. The textured reflector of claim 29 wherein a roughening of the interior surface spatially varies relative to a center of the reflector.

32. A method of retro-reflecting light into an illumination area, the method comprising:

energizing a plurality of LEDs facing opposite an illumination area of a room;

directing at least 70% of light from the LED light source to be incident on a single surface of a plastic reflector including texturing, a substantially flat central region and a smooth transition to two parabolic regions on opposite sides of the relatively flat central region, wherein the texturing comprises a plurality of pyramidal elements; and

reflecting at least a portion of the light incident on the texturing into the illumination area.

33. The method of claim 32 wherein the texturing further comprises a roughened surface.

34. The method of claim 33 wherein the roughened surface varies relative to at least one of the LED light source and a center of the reflector.

35. The method of claim 32 wherein the pyramidal elements spatially vary relative to at least one of the LED light source and a center of the reflector.

36. The method of claim 32 wherein the energizing of the plurality of LEDs further comprises energizing at least two groups of LEDs, wherein one group, when illuminated, emits light having a dominant wavelength from 435 to 490 nm, and another group, when illuminated, emits light having a dominant wavelength from 600 to 640 nm, one group being packaged with a phosphor, which, when excited, emits light having a dominant wavelength from 540 to 585 nm.

37. A lighting system comprising:

a pyramidal, plastic, textured retro-reflector to reflect light into an illumination area of a room, the plastic, textured retro-reflector including a single surface comprising a substantially flat central region and a smooth transition to two parabolic regions on opposite sides of the relatively flat central region; and

a plurality of LEDs to emit the light, positioned to face opposite the illumination area so that at least 70% of the light is incident on the pyramidal, plastic, textured retro-reflector.

38. The lighting system of claim 37 wherein the plastic, textured retro-reflector comprises polycarbonate.

39. The lighting system of claim 38 wherein the plurality of LEDs further comprises at least two groups of LEDs, wherein one group, if illuminated, would emit light having a dominant wavelength from 435 to 490 nm, and another group, if illuminated, would emit light having a dominant wavelength from 600 to 640 nm, one group being packaged with a phosphor, which, when excited, emits light having a dominant wavelength from 540 to 585 nm.

40. The lighting system of claim 39 wherein the one group, if illuminated, would emit light having a dominant wavelength from 440 to 480 nm, and the other group, if illuminated, would emit light having a dominant wavelength from 605 to 630 nm, one group being packaged with a lumiphor, which, when excited, emits light having a dominant wavelength from 560 to 580 nm.

41. The lighting system of claim 38 further comprising at least one lens plate proximate to the plurality of LEDs.

42. The lighting system of claim 41 wherein the plastic, textured retro-reflector and the at least one lens plate are coextruded.

43. The lighting system of claim 37 wherein the plastic, textured retro-reflector comprises a plurality of pyramidal elements that spatially vary relative to at least one of plurality of LEDs and a center of the pyramidal, plastic, textured retro-reflector.

44. The lighting system of claim 37 wherein a shape of the plastic, textured retro-reflector includes a smooth transition between the relatively flat, central region and each of the parabolic regions.

45. The lighting system of claim 44 wherein the plurality of LEDs further comprises at least two groups of LEDs, wherein one group, if illuminated, would emit light having a dominant wavelength from 435 to 490 nm, and another group, if illuminated, would emit light having a dominant wavelength from 600 to 640 nm, one group being packaged with a phosphor, which, when excited, emits light having a dominant wavelength from 540 to 585 nm.

46. The lighting system of claim 45 wherein the one group, if illuminated, would emit light having a dominant wavelength from 440 to 480 nm, and the other group, if illuminated, would emit light having a dominant wavelength from 605 to 630 nm, one group being packaged with a lumiphor, which, when excited, emits light having a dominant wavelength from 560 to 580 nm.

47. The lighting system of claim 37 further comprising a plurality of pyramidal elements disposed on the relatively flat, central region and each of the parabolic regions.