Abstract:
A lighting system and method are disclosed. Specifically, the lighting system includes a hybrid canopy that can provide an optimum light beam shape for a number of different lighting applications. The hybrid canopy is equipped with lighting clusters of different types, thereby enabling a broader beam output without sacrificing beam intensity or brightness.

Description:
FIELD OF THE DISCLOSURE 
       [0001]    The present disclosure is generally directed toward light sources. 
       BACKGROUND 
       [0002]    Light Emitting Diodes (LEDs) have many advantages over conventional light sources, such as incandescent, halogen and fluorescent lamps. These advantages include longer operating life, lower power consumption, and smaller size. Consequently, conventional light sources are increasingly being replaced with LEDs in traditional lighting applications. As an example, LEDs are currently being used in flashlights, camera flashes, traffic signal lights, automotive taillights and display devices. LEDs are also becoming more prevalent in residential, commercial, and industrial lighting applications. 
         [0003]    Canopy lighting is one type of lighting commonly used in commercial and industrial lighting applications. Currently available LED-based canopy lighting employs monolithic lighting techniques. Specifically, canopy lighting often employs multiple sub-units and it is the current practice to use the same type of sub-units within a single lighting canopy. Specifically, the sub-units often have the same distribution of LEDs and use the same type of reflector cup for every LED. This rigid design approach does not afford a design freedom and limits a canopy&#39;s usefulness across multiple lighting applications. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]    The present disclosure is described in conjunction with the appended figures: 
           [0005]      FIG. 1  is an isometric view of a first lighting canopy in accordance with embodiments of the present disclosure; 
           [0006]      FIG. 2  is an isometric view of a second lighting canopy in accordance with embodiments of the present disclosure; 
           [0007]      FIG. 3  is an exploded view of a third lighting canopy in accordance with embodiments of the present disclosure; 
           [0008]      FIG. 4  is a top view of a lighting cluster in accordance with embodiments of the present disclosure; and 
           [0009]      FIG. 5  is a flow diagram depicting a lighting method in accordance with embodiments of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0010]    The ensuing description provides embodiments only, and is not intended to limit the scope, applicability, or configuration of the claims. Rather, the ensuing description will provide those skilled in the art with an enabling description for implementing the described embodiments. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the appended claims. 
         [0011]    Although certain components will be described as being constructed with certain materials, those skilled in the arts will appreciate that any type of suitable material used for one component may be used for other components. For example, any one of the components described herein may be constructed of metal, steel, alloys, plastic (e.g., PET, PTFE, PVC, etc.), ceramic, glass, wood, rubber, or combinations thereof. 
         [0012]    With reference initially to  FIG. 1 , a first lighting canopy  100  will be described in accordance with embodiments of the present disclosure. The first lighting canopy  100  may also be referred to herein as a luminescence. The first lighting canopy  100  may include one or more components that enable the first lighting canopy  100  to provide light in a number of different lighting applications (e.g., residential, industrial, commercial, etc.). Furthermore, various components of the first lighting canopy  100  may be interchangeable with other similar types of components that will be described in further detail hereinafter. In particular, the components of the first lighting canopy  100  may be modular in nature and are, therefore, easily adaptable to a number of different lighting applications. In some embodiments, the first lighting canopy  100  may be considered a hybrid lighting canopy because it is capable of providing light sources of multiple types (e.g., light sources having different lighting properties). 
         [0013]    Non-limiting example components that may be included in the first lighting canopy  100  include a support structure  104 , a cover  108 , and a plurality of lighting clusters  116   a -N (where N is greater than or equal to one). In the embodiment depicted in  FIG. 1 , the first lighting canopy  100  comprises five lighting clusters  116   a - e . The lighting clusters  116   a - e  may each be positioned on the support structure  104  so that the lighting clusters  116   a - e  are evenly distributed across the major surface of the first lighting canopy  100 . 
         [0014]    In some embodiments, the cover  108  is provided with a plurality of recesses or holes  112   a -N (where N is greater than or equal to one). In the embodiment depicted in  FIG. 1 , the cover  108  comprises five recesses  112   a - e , where each recess is configured to receive or fit over a different lighting cluster  116   a - e , respectively. The cover  108  may be made out of any type of material such as polymers, glass, ceramics, etc. The cover  108  is used both to improve the aesthetic nature of the first lighting canopy  100  as well as cover various electronic components of the first lighting canopy  100  that provide electrical current to the light sources contained within the lighting clusters  116   a - e.    
         [0015]    As can be seen in  FIG. 1 , one or more of the lighting clusters may have one or more different light-distributing properties from others of the lighting clusters. In the example depicted in  FIG. 1 , the first lighting cluster  116   a  comprises a plurality of reflector cups  120  that are different in shape than the reflector cups  120  in the other lighting clusters  116   b - e . More specifically, the reflector cups  120  of the first lighting cluster  116   a  are configured with a circular shape whereas the reflector cups  120  of the other lighting clusters  116   b - e  are configured with a rectangular shape. In some embodiments, the varied nature of the reflector cups enables the hybrid first lighting canopy  100  to provide a more evenly distributed amount of light without sacrificing beam intensity. 
         [0016]    Although the first lighting cluster  116   a  is depicted as having reflector cups of a first type that are different from the reflector cups of the other lighting clusters  116   b - e , it should be appreciated that the lighting clusters may have other properties that are different to allow the lighting clusters to provide different beam shapes, thereby increasing the ways in which light is distributed by the lighting canopy  100 . As some non-limiting examples, one of the lighting clusters  116  may have a plurality of reflector cups of a first type (e.g., narrow angle reflector cups designed to emit light beams between 30 degrees and 60 degrees, wide angle reflector cups designed to emit light beams between 90 degrees and 120 degrees, oval shaped reflector cups, rectangular shaped reflector cups, square shaped reflector cups, multi-shaped reflector cups, no reflector cups) while another of the lighting clusters  116  may have a plurality of reflectors of a second type (e.g., any of the above-described types of reflector cups but different from the first type). 
         [0017]    Other light-shaping aspects of the clusters may vary in accordance with embodiments of the present disclosure. For instance, one of the lighting clusters  116  may have beam-shaping lenses of a first type whereas another of the lighting clusters  116  may have beam-shaping lenses of a second type. The first type may vary from the second type based on one or more of shape (e.g., domed, flat, multi-focal, etc.), material (e.g., epoxy, silicone, a hybrid of silicone and epoxy, phosphor, a hybrid of phosphor and silicone, an amorphous polyamide resin or fluorocarbon, glass, plastic, combinations thereof), tint/color, height, width, etc. Another light-shaping aspect that may vary from lighting cluster to lighting cluster is the number of light sources/reflector cups provided in different types of lighting clusters. For instance, one type of lighting cluster may have a first number of light sources/reflector cups whereas a second type of lighting cluster may have a second number of light sources/reflector cups. 
         [0018]    Further still, while the first lighting canopy  100  is depicted as having two different types of lighting clusters, it should be appreciated that the number of different lighting clusters may vary from anywhere between 2 and N. In other words, the first lighting canopy  100  (and any other lighting canopy described herein) may comprise two different types of lighting clusters up to N different types of lighting clusters. Using the example of  FIG. 1 , there may be 2, 3, 4, or 5 different types of lighting clusters without departing from the scope of the present disclosure. 
         [0019]    With reference now to  FIG. 2 , a second lighting canopy  200  will be described in accordance with at least some embodiments of the present disclosure. The second lighting canopy  200  may be similar or identical to the first lighting canopy  100  in that both canopies have a support structure  104  that mechanically supports a plurality of lighting clusters as well as provides electrical current to light sources in the lighting clusters. In fact, the second lighting canopy  200  may be the first lighting canopy  100  but with a different cover  208  that has a different number of recesses  212 . 
         [0020]    In some embodiments, the second lighting canopy  200  comprises a cover  208  with eight recesses or holes  212   a - h . Each recess  212   a - h  is configured to receive or fit around a different lighting cluster  216   a - h . As with the first lighting canopy  100 , the second lighting canopy  200  may have lighting clusters of different types. The non-limiting example of  FIG. 2  shows that a first and second type of lighting cluster are provided. The first and second lighting clusters  216   a,    216   b  are of a first type and have reflector cups  220  of a first type. The other lighting clusters  216   c - h  are of a second type and have reflector cups  220  of a second type. Although the lighting clusters depicted in  FIG. 2  vary based on reflector cup type, it should be appreciated that the way in which lighting clusters vary can be based on one or more of reflector cup properties, lens properties, material properties, number of light sources (e.g., LEDs), and combinations thereof. 
         [0021]    With reference now to  FIG. 3 , a third lighting canopy  300  will have its component parts described in further detail. It should be appreciated that the details described herein about the component parts of the third lighting canopy  300  may apply to component parts of the first or second lighting canopy  100 ,  200 . Moreover, any aspect described in connection with the first or second lighting canopies  100 ,  200  may apply to the third lighting canopy  300 . 
         [0022]      FIG. 3  shows in particular how the components of the lighting canopy  300  may be put together. It also depicts that various components of the lighting canopy  300  are modular and, therefore, may be replaced with other different components without completely replacing the entire lighting canopy  300 . In some embodiments, the components that may be included in the lighting canopy  300  include, without limitation, a mounting bracket  304 , a body  308 , a bracket plate  312 , a Printed Circuit Board (PCB)  316 , a power supply  320 , a plurality of reflector cup clusters  324 , a plurality of corner protectors  328 , a seal  332 , a cover  336 , and a plurality of fasteners  340 . 
         [0023]    The mounting bracket  304  may be configured to attach to sides of the body  308  via a plurality of fasteners  340 . The fasteners  340  may include one or more of screws, bolts, nuts, clasps, latches, friction fittings, tabs, flanges, or combinations thereof. The mounting bracket  304  may be constructed of metal, steel, alloys, or the like and may be used to mount the lighting canopy  300  on a wall, ceiling, or other surface that enables the lighting canopy  300  to direct light within an area to be light. The mounting bracket  304  may comprise a number of arcuate slots on the ends that interface with the fasteners  340  and body  308 , thereby enabling the body  308  and other parts connected thereto to be rotatably connected to the mounting bracket  304 . 
         [0024]    The body  308  may comprise heat-distributing components (e.g., one or more heat sinks) as well as mechanical features that enable the body  308  to connect to the mounting bracket  304 , the bracket plate  312 , the PCB  316 , the seal  332 , and the cover  336 . In some embodiments, the body  308  also comprises wires and/or circuitry that carries current from the power supply  320  to the PCB  316 . More specifically, the power supply  320  may comprise an AC-to-DC power converter and various other power-conditioning circuits that enable the power supply  320  to connect to an external AC power source, but provide DC power to the light sources (e.g., LEDs) mounted on the PCB  316 . Alternatively, the power supply  320  may comprise a DC power source that provides DC power to the light sources on the PCB  316 . 
         [0025]    As discussed in connection with  FIGS. 1 and 2 , a lighting cluster may include a plurality of light sources as well as a reflector cup cluster  324  that surrounds the plurality of light sources and shapes light emitted by the plurality of light clusters. As can be seen in  FIG. 3 , the light sources of a lighting cluster may be mounted on the PCB  316 . The light sources may correspond to LEDs. Any type of known LED may be mounted to the PCB  316  including, without limitation, Surface Mount Technology (SMT) LED, through mount LEDs, or combinations thereof. The pattern in which the light sources are mounted on the PCB  316  may correspond to the same pattern of reflector cups in a reflector cup cluster  324 . The reflector cup clusters  324  may be interchangeable and modular, which means that a reflector cup cluster  324  of one type may be replaced with a reflector cup cluster  324  of another type by simply removing the cover  336 , removing the fasteners  340  that mount the reflector cup cluster  324 , removing the reflector cup cluster  324 , then mounting a different reflector cup cluster  324  to the PCB  316  with the fasteners  340 . 
         [0026]    In some embodiments, the reflector cup clusters  324 , which are modular, may also have a different number of reflector cups. In some embodiments, this may require the light sources to also be modular or movable on the PCB  316 . Alternatively, a reflector cup cluster  324  may only replace another reflector cup cluster  324  if it has the same number or greater number of reflector cups. If the replacement reflector cup cluster  324  comprises a greater number of reflector cups, then either the additional reflector cups may be empty (e.g., without a light source) or additional light sources may be mounted to the PCB  316  where the reflector cups will be positioned. 
         [0027]    As can also be seen in  FIG. 3 , the reflector cup clusters  324  are configured to be mounted directly onto the PCB  316  after the light sources are in place. This means that the reflector cups of the reflector cup clusters  324  may have holes or recesses at their bottom surface that fit around the light source and mate with the top surface of the PCB  316 . 
         [0028]    In some embodiments, the PCB  316  is a conventional PCB  316  that comprises composites that are manufactured in accordance with the FR-4 and/or G-10 specification. It should be appreciated, however, that the PCB  316  may be rigid or flexible without departing from the scope of the present disclosure. 
         [0029]    The seal  332  may fit around the PCB  316  and protect various electrical components on both surfaces of the PCB  316  from environmental conditions. In particular, the seal  332  may mate with the outer edge of the body  308  and after the cover  336  is fastened to the body  308  with fasteners  340 , the cover  336 , seal  332 , and body  308  may protect the PCB  316  and its electrical components from harmful moisture and other damaging conditions. In some embodiments, the seal  332  is made of silicone or rubber, much like a rubber gasket. The cover  336  may comprise a suitable number of recesses or holes to accommodate the reflector cup clusters  324 . If the light-distributing properties of the light canopy  300  are to be altered, then it may be possible to replace one or more of the cover  336 , reflector cup clusters  324 , light sources, or PCB  316  with a different type of the same component. 
         [0030]    With reference now to  FIG. 4 , another type of lighting cluster  400  will be described in accordance with at least some embodiments of the present disclosure. The lighting cluster  400  may be used in any of the above-described lighting canopies  100 ,  200 ,  300 . The lighting cluster  400  may be configured with a number of different types of reflector cups. Specifically, the lighting cluster  400  may comprise a first reflector cup type  404 , a second reflector cup type  408 , and a third reflector cup type  412 . Although three reflector cup types are depicted on the lighting cluster  400 , it should be appreciated that a lighting cluster used in accordance with embodiments of the present disclosure may have a greater or lesser number of different reflector cup types. Specifically, any lighting canopy described herein may be provided with one, two, three, four, five, six, seven, eight, or more different types of reflector cups without departing from the scope of the present disclosure. The different reflector cup types may be different across one or more of size, shape, height/depth, reflectivity, material, lenses within the reflector cup, and the like. Accordingly, although the reflector cup types  404 ,  408 ,  412  are depicted as having different sizes and shapes, it should be appreciated that a lighting cluster may be provided with reflector cups of the same sizes and shapes, but with different reflective materials. For instance, some reflector cups may be coated with a highly-reflective material (e.g., metal or plastic coated with white paint) whereas other reflector cups may be less reflective (e.g., plastic coated with black or absorbing paint). 
         [0031]    In some embodiments, each reflector cup type  404 ,  408 ,  412  is configured to receive a light source  416 . In some embodiments, the light sources  416  may be different for different reflector cups. Specifically, some light sources  416  may be brighter or higher intensity than other light sources  416 . In other embodiments, some light sources  416  may be different shapes/sizes than other light sources  416 . 
         [0032]    The lighting cluster  400 , in some embodiments, may be made of metallic material to increase the reflectivity of each reflector cup type. Alternatively, the lighting cluster  400  may be manufactured of plastic or the like and may be coated with metallic or highly-reflective paint. 
         [0033]    With reference now to  FIG. 5 , a lighting method will be described in accordance with embodiments of the present disclosure. The method is initiated by determining a lighting application or area to be light (step  504 ). As noted above, the lighting application may vary from location to location and each location may require different lighting needs. The lighting needs may depend upon ambient lighting conditions, light requirements, and the like. 
         [0034]    Based on the lighting application, an optimal canopy configuration is determined (step  508 ). The optimal canopy configuration may require lighting clusters of a single type. However, many lighting applications may benefit from the use of a hybrid lighting canopy that comprises lighting clusters of different types. 
         [0035]    One or more lighting canopies are then configured with the determined optimal configuration (step  512 ). Specifically, the lighting canopy may be provided with a number of different lighting clusters that may or may not be of different types. In some embodiments, one or more of the lighting canopies  100 ,  200 ,  300 , or a lighting canopy having one or more lighting clusters with different light-directing features may be used. Since the lighting canopies may be configured to have modular reflector cups, the reflector cups may be interchanged to achieve the optimal lighting canopy design. 
         [0036]    The optimal lighting canopy is then installed in the lighting application area (step  516 ). The lighting canopy may be installed by mounting the lighting canopy to a wall, ceiling, or other surface with the mounting bracket  304  and one or more fasteners  340 . 
         [0037]    Specific details were given in the description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments. 
         [0038]    While illustrative embodiments of the disclosure have been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed, and that the appended claims are intended to be construed to include such variations, except as limited by the prior art.