Reflectors and reflector attachments for use with light-emitting diode (LED) light sources

A reflector is rotatably coupled to a light emitting diode (LED) module assembly. The reflector includes multiple alignment features that correspond with multiple notches provided in a reflector attachment coupled to a LED light source. The reflector can be made of a non-conductive substrate material, such as glass, and can have a non-conductive, reflective coating deposited on the inner surface of the reflector to allow the reflector to be more closely positioned to the LED light source. Reflector attachments can help to maintain precise reflector position during coupling with the LED light source. Media holders can be removably coupled to the light emitting portion of the reflector and provide for the quick mounting and placement of one or more optical media in the light path output by the reflector.

TECHNICAL FIELD

The present disclosure relates generally to reflectors and reflector attachments for use with light-emitting diode (LED) light sources. More particularly, the present disclosure relates to reflectors having nonconductive reflective coatings on a nonconductive reflector substrate, and to reflector attachments or adapters configured to maintain precise reflector position and to provide placement of optical media when coupled to an LED module assembly.

BACKGROUND

Reflectors for use with LED light sources typically are constructed from conductive, reflective materials, such as aluminum or vacuum metalized substrates. A number of disadvantages exist when using reflectors of this type. For instance, the use of conductive materials in the entire reflector generally requires that an isolation gap be maintained between the reflector and LED light source. The isolation gap required is based on a minimum creepage distance to protect against electric discharges on or close to an insulation surface and a minimum clearance distance to prevent dielectric breakdown between conductive parts by the ionization of air. This requirement for the isolation gap results in a reflector that is too far from the LED light source. The resultant gap reduces the ability to control light being emitted from the light source as efficiently and effectively, as some light is typically lost along the gap. In addition, in instances where the reflector needs to be easily and quickly replaced, the coaxial orientation and position of the reflector must be maintained after the reflector is replaced so that the beam control and light distribution is not affected.

In the case of metalized reflectors, these reflectors can include a plastic piece that is injection molded, and then metalized with a conductive material to achieve a reflective surface. A coating, such as a lacquer coating, must be applied to the metalized surface thereafter to protect the metallization. However, the coating generally degrades over time and the reflectivity diminishes as a result. In general, as the coating degrades, the color accuracy and total system efficiency is impacted. In addition, these metalized reflectors are conductive.

SUMMARY

According to one exemplary aspect, a luminaire can include an LED module assembly and a reflector. The LED module assembly can include a LED light source and a reflector attachment disposed about the LED light source. The reflector can be rotatably coupled to the reflector attachment and can include a non-conductive substrate having an interior surface and an exterior surface. A non-conductive reflective coating can be disposed on the interior surface of the reflector.

According to another exemplary aspect, a reflector system can include a reflector having an exterior surface and an alignment feature protruding out from the exterior surface. The alignment feature can include a channel. The system can also include a reflector attachment that has an opening for receiving a first end of the reflector, a groove that corresponds to the size and shape of the alignment feature, and a ledge adjacent to the grooves. The ledge can be sized to engage the channel of the alignment feature when the reflector is coupled to the reflector attachment.

According to still another exemplary aspect, a reflector for a LED light source can include a first light receiving aperture positioned along a first end of the reflector, a distal light emitting aperture positioned along a second end of the reflector, and an interior surface disposed between the first and second ends. The interior surface an define a light pathway through the reflector. The reflector can also include a flange member extending our from an exterior surface of the reflector adjacent to the second end. The reflector can also include a media holder removably coupled to the second end of the reflector, with at least a portion of the media holder positioned over the flange member. The media holder can include an annular-shaped body that includes a first protrusion, a second protrusion and a first channel. The first protrusion can be located adjacent to a top surface of the body portion and extends from the inner surface of the body portion. The second protrusion can be located adjacent to a bottom surface of the body portion and extends from the inner surface of the body portion. A media can be removably coupled to the media holder. The media can have an outer perimeter surface that is positioned within the first channel.

These and other aspects, features, and embodiments will become apparent to a person of ordinary skill in the art upon consideration of the following detailed description of illustrated exemplary embodiments exemplifying the best mode for carrying out the invention as presently perceived.

The drawings illustrate only exemplary embodiments of the invention and are therefore not to be considered limiting of its scope, as the invention 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 exemplary embodiments of the present invention. Additionally, certain dimensions may be exaggerated to help visually convey such principles. In the drawings, reference numerals designate like or corresponding, but not necessarily identical, elements.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The exemplary reflectors and reflector systems described herein have significant improvements over conventional reflector systems used with LED light sources. The reflectors described generally are constructed from a nonconductive material, such as borosilicate glass, and coated with a nonconductive reflective coating, are durable, and can maintain reflectivity over time without affecting the system's efficiency. The exemplary reflector systems described generally include a reflector and an attachment or adapter for allowing quick and easy removal and insertion of the reflector into the adapter, while allowing precise and consistent reflector positioning close to the LED. An exemplary reflector system also includes a media ring for quick attachment and removal of various optical filters to the light reflector. The invention may be better understood by reading the following description of non-limiting, exemplary embodiments with reference to the attached drawings wherein like parts of each of the figures are identified by the same reference characters.

FIGS. 1A-Dare different views of a reflector100according to one exemplary embodiment. Referring toFIGS. 1A-D, the exemplary reflector100includes a generally frusto-conical substrate102integrally coupled to a circular base104. While the exemplary substrate102is shown having a particular shape, the shape of the substrate102is not a limiting factor in the design and those of ordinary skill in the art will recognize that other shapes for the reflector substrate including, but not limited to, parabolic, conical, spherical, and free-form are within the scope and spirit of this disclosure. The substrate102includes a first end102a, a distal second end102b, and a side wall102cextending between the first and second ends102a,102b. The base104is coupled to the first end102aof the substrate102, and includes an opening104athrough which an LED (not shown) can be positioned and can emit light. In an exemplary embodiment, the reflector100is a reflector glare shield that diverts incident light downward towards the target area. By directing the incident light downward, the glare shield prevents incident light from projecting upwardly and outwardly and thereby producing glare. In certain exemplary embodiments, the second end102bis coupled to an optical media, the media comprising an optical filter (not shown). The side wall102cincludes a smooth or substantially smooth interior102ddefining a cavity102e(FIG. 1D), and a smooth or substantially smooth exterior102f. In certain alternate exemplary embodiments, the substrate102can have any suitable shape, such as rectangular, triangular, or oval, for use with an LED light source. In certain alternative embodiments, the interior102dcan include one or more facets (not shown) for mixing light emitted from an LED and/or to achieve a desired light distribution.

The reflector100also includes two alignment features106a,106b(collectively referred to herein as alignment features106). Generally, the alignment features106align and hold the reflector100in place with respect to a reflector attachment or adapter200(FIGS. 1A-D). In one exemplary embodiment, the alignment features106are keyed so that the alignment feature106ais larger in size than the alignment feature106bto allow for the reflector100to be coupled to the reflector attachment200in the same position every time. In alternate embodiments, the alignment features106are the same size. The alignment features106extend from the exterior102fof the substrate102proximate to the base104. The alignment features106generally include a rectangular front wall108a,108b(collectively referred to herein as front walls108), a four-sided top wall110a,110b(collectively referred to herein as top walls110), a first triangular side wall112a,112b(collectively referred to herein as first side walls112), and a triangular second side wall114a,114b(collectively referred to herein as second side walls112). The first and second side walls112,114extend orthogonally or substantially orthogonally from two opposing sides of the front wall108to the exterior102fof the substrate102, and the top wall110extends orthogonally or substantially orthogonally from the side of the front wall108proximate the base104to the exterior102fof the substrate102. The alignment features106also include a channel118a,118b(collectively referred to herein as channels118), extending along the front wall108from the first side wall112to the second side wall114. In certain exemplary embodiments, there are two alignment features106which are spaced180degrees apart from each other along the side wall102c. Alternatively, the spacing of alignment features106can be more or less. For example, in one alternative embodiment (not shown), the reflector100contains four alignment features106, each spaced apart 90 degrees from one another around the circumference of the exterior102fof the substrate102. In another exemplary embodiment (FIG. 4B), the reflector100contains three alignment features106, each spaced apart120degrees from one another around the circumference of the exterior102fof the substrate102.

In certain exemplary embodiments, the reflector100includes a nonconductive substrate with an interior coated with a nonconductive reflective material. In certain exemplary embodiments, the interior of the substrate is coated by plasma induced chemical vapor deposition. Suitable examples of materials for constructing the substrate include, but are not limited to, glass, such as borosilicate glass or tempered soda-lime glass, and plastic, such as plastic having a low shrinkage rate to maintain the tolerances of the reflective surface. Suitable examples of nonconductive reflective materials for coating the substrate include, but are not limited to, titanium dioxide and silicon dioxide. In certain exemplary embodiments, the nonconductive reflective material is a hard coating having a reflectivity of about 95 percent or greater. In certain exemplary embodiments, the nonconductive reflective coating has color correction capabilities. In certain exemplary embodiments, the coating is a multilayer coating having two or more layers of nonconductive reflective materials. In certain exemplary embodiments, the coating modifies the correlated color temperature (CCT) and enhances the color rendering index (CRI) to tune the LED spectral distribution.

FIGS. 2A-Dare different views of a reflector attachment or adapter200that can be used in conjunction with the reflector100according to one exemplary embodiment. Referring toFIGS. 2A-D, the exemplary reflector attachment200is ring-shaped and includes a base wall202, an opposing distal top wall204, an exterior side wall206extending from the top wall204to the base wall202, an interior side wall208opposing the exterior side wall206, and an opening210defined by the interior side wall208. In certain exemplary embodiments, the intersection between the top wall204and the exterior side wall206is curved. The reflector attachment200also includes openings212a,212b,212c(collectively referred to herein as openings212) extending from the base wall202and evenly spaced apart thereon. In certain exemplary embodiments, the openings212are through-holes. Alternatively, the openings212are threaded. The openings212are configured to receive a fastener, such as a screw (not shown) or other coupling device for coupling the reflector attachment200to an LED module assembly, mounting bar, substrate, or heat sink (not shown).

In certain exemplary embodiments, the interior side wall208includes two notches214a,214b(collectively referred to herein as notches214). In one exemplary embodiment, the shape of the notches214corresponds to the alignment features106; however other shapes that are accommodated by the alignment features106can also be used. The exemplary interior side wall208also includes ledges216a,216b(collectively referred to herein as ledges216). In certain exemplary embodiments, the ledges216are positioned adjacent to the notches214. In those exemplary embodiments, the ledges216are sized to engage the channels118of the alignment features106. Retaining elements, such as grip elements220a,220b(collectively referred to herein as grip elements220shown inFIG. 2D) are present on an underside surface of the ledges216. In certain exemplary embodiments, the grip elements220are protrusions, bumps, or detents. The alignment features106can be inserted into the corresponding notches214and the ledges216engage the channels118upon rotation of the reflector100. The reflector100can be held in place in the reflector attachment200by applying enough force to rotate the alignment features106past the grip elements220. To remove the reflector100from the reflector attachment200, the reflector100must be rotated with enough force applied to overcome the force of the grip elements220.

FIG. 3is a perspective side view of the reflector100(FIGS. 1A-D) coupled to the reflector attachment200(FIGS. 2A-D) according to one exemplary embodiment. The alignment features106are inserted into the corresponding notches214and rotated so that the ledges216engage the channels118of the alignment features106of the reflector100.

FIG. 4Ais a perspective view of a reflector400according to one exemplary embodiment.FIG. 4Bis a top plan view of the exemplary reflector400. The reflector400is the same as that described above with regard toFIGS. 1A-D, except as specifically stated below. For the sake of brevity, the similarities will not be repeated hereinbelow.

The reflector400includes three alignment features406a,406b,406c(collectively referred to herein as alignment features406). In one exemplary embodiment, the alignment features406are sized and shaped the same. Alternatively, the alignments features can have different sizes or shapes to “key” the reflector sides to certain grooves in the attachment. The alignment features406also include channels418a,418b,418c(collectively referred to herein as channels418) similar to channels118. In certain exemplary embodiments, the alignment features406are spaced 120 degrees apart from each other along the side wall102cof the substrate102. In an alternate embodiment, the alignment features406can be spaced apart at distances other than 120 degrees, even or uneven, from each other along the side wall102cof the substrate102. In alternate embodiments, greater or less numbers of alignment features406can be utilized and the spacing between those alignment features406can be even or uneven along the side wall102c.

FIG. 5A-Care different views of a reflector attachment500coupled to an LED module assembly, mounting bar, substrate or heat sink (collectively referred to herein as a LED module assembly550) according to one exemplary embodiment. In certain exemplary embodiments, the reflector500is the same as that described above with regard toFIGS. 2A-D, except as specifically stated below. For the sake of brevity the similarities will not be repeated hereinbelow.

As illustrated inFIG. 5A, an interior side wall508of the reflector attachment500includes three notches514a,514b,514c(collectively referred to herein as notches514). The shapes of the notches514correspond to the alignment features406. The interior side wall508also includes three ledges516a,516b,516c(collectively referred to herein as ledges516) adjacent to the notches514. The ledges516are sized to engage channels418of the alignment features406. The alignment features406can be inserted into the corresponding notches514and the ledges516engage the channels418upon rotation of the reflector400.

The reflector attachment500can be coupled to the LED module assembly550by seating the openings212into corresponding grooves552a,552b,552c(collectively referred to herein as grooves552) and securing the reflector attachment500to the LED module assembly550with fasteners, such as screws (not shown). The LED module assembly550also includes an LED light source560positioned in a center thereof, where the LED light source560emits light through the opening210when coupled to the reflector500. In certain exemplary embodiments, the LED light source560can be a discrete LED die, and array of LEDs, or a chip-on-board LED module. Further, the exemplary LED light source560can include LEDs emitting light in one color or more than one color. For example, a portion of the LEDs in the LED light source560can emit white light and another portion can emit non-white light. Examples of non-while light emitting LEDs include red, green, blue or amber LEDs.

FIG. 6is a side cross-sectional view of the reflector400(FIGS. 4A-B) coupled to the reflector attachment500and LED module assembly550(FIGS. 5A-C) according to one exemplary embodiment. The alignment features406are inserted into the corresponding notches514and rotated so that the ledges516engage the channels418of the alignment features406of the reflector400. Light from the LED light source560is emitted and reflected off of the interior102dof the reflector400, and through a reflector exit aperture602.

FIG. 7is a top plan view of a reflector attachment700according to one exemplary embodiment. In certain exemplary embodiments, the reflector700is the same as that described above with regard toFIGS. 2A-D, except as specifically stated below. For the sake of brevity the similarities will not be repeated hereinbelow.

An interior side wall708of the reflector attachment700includes three notches714a,714b,714c(collectively referred to herein as notches714). The shapes of the notches714correspond to the alignment features406(FIGS. 4A-B), with the exception that notch714ais larger than notches714b,714c. The reflector attachment700can be used in conjunction with the reflector400(FIGS. 4A-B) or with a reflector (not shown) having alignment features that are keyed to correspond to the notches714to control reflector orientation. The interior side wall208also includes three ledges716a,716b,716c(collectively referred to herein as ledges716) adjacent to the notches714. The ledges716are sized to engage channels418of the alignment features406. The alignment features406can be inserted into the corresponding notches714and the ledges716engage the channels418upon rotation of the reflector400.

FIGS. 8A-Dprovide various views of a reflector attachment800according to an exemplary embodiment. In certain exemplary embodiments, the reflector attachment800is the same as that described above with regard toFIGS. 2A-D, except as specifically stated below. For the sake of brevity the similarities will not be repeated hereinbelow.

An interior side wall808of the reflector attachment800includes two notches814aand814b(collectively referred to herein as notches814). The shapes of the notches814correspond to the alignment features106(FIGS. 1A-D), however other shapes that are accommodated by the alignment features106can also be used. The exemplary reflector attachment includes a top wall804including ledges816aand816b(collectively referred to herein as ledges816). Ledges816extend from the top wall804in the direction towards the interior side wall808. In an exemplary embodiment, the ledges816are positioned adjacent to the notches814and are sized to engage the channels118of the alignment features106. The alignment features106can be inserted into the corresponding notches814and the ledges816engage the channels118upon rotation of the reflector100. The exemplary ledges816are flexible in the direction perpendicular to the surface of the top wall804. In an exemplary embodiment, the ledges816flex to engage the channels118of the alignment features106. In an exemplary embodiment, the bottom surface of the ledges816can exert pressure on the channels118to hold the reflector100in place.

In an exemplary embodiment, the ledges816are anchored to the top wall804at only one edge in a cantilever fashion. As illustrated inFIG. 8A, the ledges816can be anchored to the top wall804at base edge818parallel to the outer circumference of the reflector attachment800. Alternatively, the ledges816can be anchored to the top wall804at one of side edges820and822. In an alternate embodiment (not shown), the ledges816can be anchored to the top wall804at one or more of base edge818, side edge820, and side edge822. In an exemplary embodiment, the exterior edges of ledges816can include a chamfer and/or rounded edge surface. Ledges816can be the same thickness as the top wall804. In an alternate embodiment, ledges816are varying thickness, being thicker at the end anchored to the top wall804. In an alternate embodiment, the ledges816can be thicker at the end opposite the anchored end to engage the channels118of the alignment features106.

In certain exemplary embodiments, reflector attachment800may include an alignment feature for centering the reflector attachment800on the reflector100. These alignment features can include, for example, nodules832extending from the interior side wall834of the reflector. The size, shape, and spacing of the nodule832may be such that the exterior surface102fof the reflector100engages the nodules832and centers the reflector100in the reflector attachment800. In exemplary embodiments, the nodules832can have a round/curved, geometric, and/or any other shape for retaining the reflector100. For example, as illustrated inFIG. 8A, the nodules832can have a round shape.

In certain exemplary embodiment, reflector attachment800can include an alignment feature for aligning the reflector attachment800on the LED module (seeFIG. 5B,550). The LED module alignment features can include, for example, a projection836from the top wall804of the reflector attachment800. The projection836can extend from the top wall804in a direction towards the base wall802. The projection836can extend in the direction orthogonal or substantially orthogonal to the top wall804in the direction of the base wall802. The projections can be formed from a portion of the top wall804that is bent or otherwise formed to extend in the direction of the base wall802. For example, the projection836can be punched from the top wall804and bent downward toward the base wall802. In an exemplary embodiment, the projection836is sized and shaped to engage a corresponding depression on the LED module assembly (not shown). Accordingly, when the LED module is coupled to the reflector attachment800, the protection836mates with the corresponding depression on the LED module to ensure correct orientation of the openings812a,812bon the reflector attachment800with the LED module.

In an exemplary embodiment, the reflector attachment800includes a tongue838to align the reflector attachment838with the LED module assembly, mounting bar, substrate, or heat sink. The tongue838extends from the top wall804in a direction parallel and/or concurrent with the surface of the top wall804. An exemplary tongue838extends beyond the outer surface of the exterior side wall806and engages an interior surface of the LED module assembly, mounting bar, substrate, heat sink, and/or other device to which the reflector attachment800is mating.

FIG. 8Dis a perspective view of the reflector attachment800according to an exemplary embodiment and a LED module850. The exemplary reflector attachment800includes an exterior side wall822. In certain exemplary embodiments, the exterior side wall822may include notch824defining an opening826. The opening826may be sized and shaped to accommodate a wiring connector (FIG. 8D,870). The notch824may include retaining members828extending from a bottom surface of the notch824. The size, shape, and spacing of the retaining members828may be such that a wiring connector870can be restrained within the surface defined by the interior side wall (not shown) of the reflector attachment800by the retaining members828. In an exemplary embodiment, the retaining members828extend to the surface defined by the bottom wall830of the exterior side wall822. In an alternate embodiment, the retaining members828to extend beyond the surface defined by the bottom wall830. In a further exemplary embodiment, the retaining members828do not extend to the surface defined by the bottom wall830. In certain exemplary embodiments, the retaining members828can be removed, e.g., broken off, completely or partially to accommodate different size and shape connectors. In an alternate embodiment, the notch824does not include the retaining members828and is constructed as a single opening in the exterior side wall822.

In certain exemplary embodiment, the interior side wall of the reflector attachment matingly engages an exterior wall852of the LED module850. An exemplary LED module may include a socket854for receiving an electrical connector870for providing power and control signals to the LED driver within the LED module850.

As illustrated inFIG. 8E, when assembled, the opening826of the reflector attachment800and the socket854of the LED module850aligned to receive the connector870. In an exemplary embodiment, the connector870is mated with the socket854. The LED module850and connector870pair are then lowered onto the reflector attachment800. The retaining members828of the reflector attachment800retain the connector870within the socket870.

FIG. 9is a perspective view of the reflector100(FIGS. 1A-D) coupled to the reflector attachment800(FIGS. 8A-E) according to one exemplary embodiment. The alignment features106are inserted into the corresponding notches814and rotated so that the ledges816engage the channels118of the alignment features106of the reflector100. Mounting screws couple the reflector attachment800and the LED module to the heat sink. In an exemplary embodiment, the mounting openings on the reflector attachment800and/or the LED module can include threads or can include non-threaded through holes.

FIGS. 10A-Cprovide various views of a reflector attachment1000according to an exemplary embodiment. The exemplary reflector attachment1000can be constructed from metal such as spring steel, stainless steep, or the like. In certain exemplary embodiments, the reflector attachment1000is the same as that described above with regard toFIGS. 2A-D, except as specifically stated below. For the sake of brevity the similarities will not be repeated hereinbelow.

As illustrated inFIGS. 10A-C, the exemplary reflector assembly1000is ring-shaped and includes a base wall1002, an opposing distal top wall1004, an exterior side wall1006extending from the top wall1004in the direction of the base wall1002, and an opening1010defined by the center opening of the reflector assembly1000. In certain exemplary embodiments, the intersection between the top wall1004and the exterior side wall1006is curved. In an alternate embodiment, the intersection between the top wall1004and the exterior side wall1006is chamfered.

The reflector attachment1000also includes openings1012aand1012b(collectively referred to herein as openings1012) extending from the base wall1002and evenly spaced apart thereon. In certain exemplary embodiments, the openings1012are through-holes. The openings1012are configured to receive a fastener, such as a screw (not shown) or other coupling device for coupling the reflector attachment1000to an LED module assembly, mounting bar, substrate, or heat sink (not shown). The size, shape, and spacing of the alignment tabs1026such that the exterior surface102fof the reflector100engages the alignment tabs1026and centers the reflector100in the reflector attachment1000. In an exemplary embodiment, the openings1012are flanked on each side with alignment tabs1026. When coupled, tabs1026align openings1012of the reflector attachment1000with the corresponding coupling point in the LED module assembly, mounting bar, substrate, or heat sink.

In certain exemplary embodiments, the top wall1004includes two notches1014aand1014b(collectively referred to herein as notches1014). In one exemplary embodiment, the shape of the notches1014corresponds to the alignment features106(FIGS. 1A-D), however other shapes that are accommodated by the alignment features106can also be used. As illustrated inFIGS. 10A and 10C, notches1014can include a downward facing tabs that engage the channels118of the alignment features106. The tabs extend in the direction orthogonal or substantially orthogonal to the top wall1004in the direction of the base wall1002. The downward facing tabs can be formed from a portion of the top wall1004that is bent or otherwise formed to extend in the direction of the base wall1002.

The top wall1004of the exemplary reflector attachment1000includes ledges1016aand1016b(collectively referred to herein as ledges1016). Ledges1016extend from the top wall1004in a direction toward opening1010. In an exemplary embodiment, the ledges1016are positioned adjacent to the notches1014and are sized to engage the channels118of the alignment features106. The alignment features106can be inserted into the corresponding notches1014and the ledges1016engage the channels118upon rotation of the reflector100.

As illustrated inFIGS. 10A and 10D, the exemplary ledges1016can be formed as L-shaped extensions from the top wall1004. In an exemplary embodiment, ledges1016can include an angular or V-shaped bend1018to provide ledges1016flexibility in the direction perpendicular or substantially perpendicular to the top wall1004. The reflector100can be held in place in the reflector attachment1000by rotating the alignment features106to engage the ledges1016. The angular or V-shaped bend can cause ledge1016to flex along the length of ledge1016that engages the channels118. For example, the ledge1016can flex along the length of the bottom edge1020. Because the ledges1016are flexible, they are able to accommodate for variations in channel118location during installation and assembly.

In an exemplary embodiment, the length of the ledge1016along the bottom edge1020engages the channels118. In this embodiment, the top and/or bottom surface of the ledges1016can exert pressure on the channels118to hold the reflector100in place at or proximate the angular or V-shaped bend1018. In an alternate embodiment, the reflector100can be held in place in the reflector attachment1000by applying enough force to rotate the alignment features106past the angular or V-shaped bend1018. In this exemplary embodiment, because the alignment features106are rotated past the bend1018, neither the top and/or the bottom surfaces of the ledges1016exert any pressure on the channels118. To remove the reflector100from the reflector attachment1000, the reflector100must be rotated with enough force to overcome the force of the angular or V-shaped bend1018.

An exemplary reflector attachment1000includes retaining elements such as stop elements1022aand1022b(collectively referred to herein as stop elements1022). As illustrated inFIGS. 10A and 10C, stop elements1022can extend downward in the direction of the base wall1002. The stop elements1022can extend in a direction orthogonal or substantially orthogonal to the top wall1004in the direction of the base wall1002. In an exemplary embodiment, the stop elements1022can be formed from a portion of the top wall1004that is bent or otherwise formed to extend in the direction of the base wall1002. The intersection between the top wall1004and the stop elements1022can be curved. In an alternate embodiment, the intersection between the top wall1004and the stop elements1022is chamfered. As the reflector100is held in place on the reflector attachment1000, side walls112and/or114of the alignment features106engage the stop elements1022to prevent further rotation of the reflector100in the reflector attachment1000.

In an exemplary embodiment, reflector attachment1000includes an tongue1024to align the reflector attachment1000with the LED module assembly, mounting bar, substrate, or heat sink. The tongue1024extends from the top wall1004in a direction parallel and/or concurrent with the surface of the top wall1004. An exemplary tongue1024extends beyond the outer surface of the exterior side wall1006and engages an interior surface of the LED module assembly, mounting bar, substrate, heat sink, and/or other device to which the reflector attachment1000is mating.

In certain exemplary embodiments, the reflector attachments200,500,700,800, and1000are constructed from molded materials, including, but not limited to, plastic, glass-reinforced plastic, aluminum, zinc, magnesium, and the like, and sheet metal or machined (metal and non-metal) materials. In certain embodiments, the reflector attachments200,500,700,800, and1000have an exterior shape other than circular. One having ordinary skill in the art will recognize that the reflectors100,400and reflector attachments200,500,700,800, and1000may have any shape suitable for use with an LED light source.

FIG. 11is a perspective view of the reflector100(FIGS. 1A-D) coupled to the reflector attachment1000(FIGS. 10A-C) according to one exemplary embodiment. The alignment features106are inserted into the corresponding notches1014and rotated so that the ledges1016engage the channels118of the alignment features106of the reflector100. Mounting screws couple the reflector attachment100and the LED module to the heat sink. In an exemplary embodiment, the mounting openings on the reflector attachment100and/or the LED module can include threaded or non-threaded through holes.

FIG. 11Bis an exploded side view of a reflector attachment1000, LED module, and heat sink according to an exemplary embodiment.FIG. 11Billustrates an alternate exemplary mounting configuration for coupling the reflector attachment1000and the LED module to the heat sink. In the exemplary embodiment, the LED module is mounted to the heat sink using a first set of mounting screws. The reflector attachment1000is mounted to the heat sink, separate from the LED module, using a second set of mounting screws.

FIG. 11Cis an exploded side view of a reflector attachment, LED module, and heat sink according to an exemplary embodiment.FIG. 11C illustrates an alternate exemplary mounting configuration for coupling the reflector attachment1000and the LED module to the heat sink. In the exemplary embodiment, the LED module is mounted to the heat sink using a first set of mounting screws. The reflector attachment1000is mounted to the heat sink, separate from the LED module, using a second set of mounting screws. The second set of mounting screw engage or otherwise pass through a portion of the luminaire structure before mounting in the heat sink. In an alternate embodiment, the mounting screws do not engage the heat sink, rather they mount only to the portion of the luminaire structure.

FIG. 12A-Care different views of a media holder1200having an upper ring1220, a reflector1250, and a front ring1270according to one exemplary embodiment.FIG. 12Ais an exploded perspective view of the media holder1200according to one exemplary embodiment.FIG. 12Bis a perspective view of the media holder1200showing the upper ring1220coupled to the reflector1250according to one exemplary embodiment.FIG. 12Cis an assembled perspective view of the media holder1200according to one exemplary embodiment. The reflector1250is the same as that described above with regard toFIGS. 1A-D, except as specifically stated below. For the sake of brevity, the similarities will not be repeated hereinbelow.

The upper ring1220generally has an annular shape and includes a first end1222, an opposing second end1224, a side wall1226extending from the first end1222to the second end1224, and an opening or passageway1228defined by the side wall1226and extending from the first end1222to the second end1224. In certain exemplary embodiments, the first end1222includes a notch1230sized and shaped to correspond to a rib1260on the reflector1250; however other shapes that are accommodated by the rib1260can also be used. In certain exemplary embodiments, the first end1222includes a means for engaging and coupling to the front ring1270, such as threads1234. In certain exemplary embodiments, the opening1228has a size and shape corresponding to the second end102bof the reflector1250.

In certain exemplary embodiments, the reflector1250includes a rib1260positioned on the second end102b. In certain exemplary embodiments, the rib1260is a rectangular-shaped protrusion that corresponds to the shape of the notch1230in the upper ring1220. The upper ring1220can be coupled to the reflector1250by positioning the upper ring1220around the second end102bof the reflector1250such that the rib1260engages the notch1230(FIG. 12B).

In certain exemplary embodiments, the front ring1270generally has an annular shape and includes a first end1272, an opposing second end1274, a side wall1276extending from the first end1272to the second end1274, and an opening or passageway1278defined by the side wall1276and extending form the first end1272to the second end1274. An optical media (not shown) is positioned in the second end1274of the front ring1270. In certain exemplary embodiments, the first end1272includes a means for engaging and coupling to the upper ring1220, such as mating threads1284. In certain exemplary embodiments, the opening1278has an internal size (e.g. diameter) and shape corresponding to the external size (e.g. diameter) and shape of the upper ring1220. The front ring1270can be coupled to the upper ring1220by engaging the threads1234of the upper ring1220with the corresponding mating threads1284of the front ring1270(FIG. 12C). Once the front ring1270is coupled to the upper ring1220, the media (not shown) is held in place in front of the reflector1250.

In an exemplary embodiment, the reflector includes a reflector glare shield for preventing a halo effect around the second end102bof the reflector when light is being emitted therethrough. A reflector glare shield can also improve the aesthetics of the light fixture as well as protect the reflector from damage.FIG. 13Ais a perspective view of an exemplary reflector glare shield1350.FIG. 13Bis a perspective view of a reflector1300coupled to an exemplary reflector glare shield1350.

FIG. 13Cis a side view of a reflector1300and a side cross-sectional reflector glare shield1350. As illustrated inFIG. 13C, the reflector glare shield1350is coupled to the reflector1300according to one exemplary embodiment. The reflector1300is the same as that described above with regard toFIGS. 1A-D, except as specifically stated below. For the sake of brevity, the similarities will not be repeated hereinbelow.

In certain exemplary embodiments, the reflector glare shield1350generally has an annular shape and includes a base wall1352, an exterior side wall1354extending orthogonally from the base wall1352, an interior side wall1356opposing the exterior side wall1354, an opening1358defined by the interior side wall1356, a retaining wall1360, and a channel1362defined by base wall1352, the exterior side wall1354, the interior side wall1356, and the retaining wall1360. As illustrated inFIGS. 13A and 13B, in certain exemplary embodiment, the exterior side wall1354can include vertical grooves and/or channels to aid a user in gripping the reflector glare shield1350. In an alternate embodiment, the reflector glare shield1350can include any other configuration of surface texture, including a smooth surface.

As illustrated inFIG. 13C, in certain exemplary embodiments, the intersection between the base wall1352and the exterior side wall1354is includes an angled step-shaped portion. In alternate embodiments, the intersection between the base wall1352and the exterior side wall1354is curved, chamfered, or at an angle greater than or less than90degrees. In certain exemplary embodiments, the intersection between the base wall1352and the interior side wall1356is angled at greater than 90 degrees. In alternate embodiments, the intersection between the base wall1352and the interior side wall1356is step-shaped, curved, chamfered, or squared, or at an angle less than 90 degrees.

In certain exemplary embodiments, the channel1362is sized and shaped to correspond to a flange1302at the second end102bof the reflector1300; however other shapes that are accommodated by the flange1302can also be used. The reflector glare shield1350can be coupled to the flange1302of the reflector1300by any means known to one having ordinary skill in the art, including, but not limited to, snap-fit connection, clips, threads, screws, and the like. In certain exemplary embodiments, the retaining wall1360engages the upper edge of flange1302when the reflector glare shield1350is coupled to the reflector1300using a snap-fit connection. The reflector glare shield1350can be constructed from any material suitable for covering the flange1302, including, but not limited to plastic, silicon, and rubber.

In an exemplary embodiment, a reflector glare shield can be used to couple an optical filter to the light output from the reflector.FIG. 14is a side cross-sectional view of a reflector1400coupled to an exemplary reflector glare shield1450. As illustrated inFIG. 14, an optical media1460is located proximate the reflector1400to impact the light output. The optical media1460can include, for example, absorptive and/or interference (dichroic) glass (thin film) filters, hex cell louver, and/or glass lens. In an exemplary embodiment depicted inFIG. 14, the optical media1460includes a thin film filter. In an exemplary embodiment, the media1460is held between the reflector glare shield1450and the reflector1400. The media1460can include a single thin film filter or multiple thin film filters. As illustrated inFIG. 14, media1406located between the interior edge1452of the reflector glare shield1450and the interior edge1402of the reflector1400.

In an exemplary embodiment, the reflector includes a media holder for coupling an optical media to the light output from the reflector.FIG. 15Ais a perspective view of an exemplary media holder1550.FIG. 15Bis a perspective view of a reflector1500coupled to an exemplary media holder1550. The reflector1500is the same as that described above with regard toFIGS. 1A-D, except as specifically stated below. For the sake of brevity, the similarities will not be repeated hereinbelow.

FIG. 15Cis a cross-section view of an exemplary media holder1550. In certain exemplary embodiments, the media holder1550generally has an annular shape and includes a top wall1552, a base wall1554, an exterior side wall1556extending from the top wall1552to the base wall1554, an interior side wall1558opposing the exterior side wall1556, and top opening1560and bottom opening1562defined by the interior side wall1558. In certain exemplary embodiments, the exterior side wall1556extends orthogonally or substantially orthogonally from the top wall1552to the base wall1554. The interior side wall1558defining a bottom protrusion1564, a middle protrusion1566, and a top protrusion1568. In certain exemplary embodiments, each of the bottom protrusion1564, middle protrusion1566, and top protrusion1568extends in a direction orthogonal or substantially orthogonal from the surface of the interior side wall1558. In certain exemplary embodiments, the media holder1550includes a bottom channel1570and/or a top channel1572. The bottom channel1570can be defined by the bottom protrusion1564, the interior side wall1558, and the middle protrusion1566. The top channel1572can be defined by the middle protrusion1556, the interior side wall1558, and the top protrusion1568.

In certain exemplary embodiment, the exterior side wall1554can include vertical grooves, channels, and/or protuberance to aid a user in gripping the media holder1550. In an alternate embodiment, the media holder1550can include any other configuration of surface texture, including a smooth surface.

In certain exemplary embodiments, the intersection between the base wall1554and the bottom protrusion1564is angled at greater than 90 degrees. It is also contemplated that the intersection between the base wall1554and the bottom protrusion1564can be curved, chamfered, square, or at an angle less than 90 degrees. In certain exemplary embodiments, the intersection between the top wall1552and the top protrusion1568is curved. In certain exemplary embodiments, the profile of the bottom protrusion1564, middle protrusion1566, and the top protrusion1568is curved, geometric, and/or any other shape necessary for retaining the reflector1500and media1574to/within the media holder1550.

FIG. 15Dis a side view of a reflector1500and a side cross-sectional view of a media holder1550attached to the reflector1500, the medial holder including an media1574. In certain exemplary embodiments, the media1574includes a lens that is transparent, translucent, and/or may be shaded a particular color. In an exemplary embodiment, the media1574is held in the bottom channel1570when the media holder1550is coupled to the reflector1500. In certain exemplary embodiments, the bottom channel1570is sized and shaped to correspond to a flange1576at the second end102bof the reflector1500; however other shapes that are accommodated by the flange1576can also be used. In an alternate embodiment (not shown), the media1574is held in the bottom channel1570and the reflector1500is coupled to the media holder at the upper channel1572. In the alternate embodiment, the upper channel1572is sized and shaped to correspond to the flange1576of the reflector and the bottom channel1572is sized and shaped to correspond to the media1574.

The media holder1550can be removably coupled to the flange1576of the reflector1500by any means known to one having ordinary skill in the art, including, but not limited to, elasticity of the material making up the medial holder1550, snap-fit connection, clips, threads and the like. In an exemplary embodiment, the media1574is press-fit into bottom channel1570of the media holder1500. The media holder1550is then pressed onto the reflector1500. Flange1576is pressed past top protrusion1568, top channel1572, and middle protrusion1566to the bottom channel1570. When assembled, the bottom edge of the reflector1500/flange1576can contact the top surface of the media1574. In an alternate embodiment, the bottom edge of the reflector1500/flange1576is proximate, but not touching, the top surface of the media1574. A gap between the media1574and the reflector1500can exist without compromising the function of the media1574with respect to the light emitted from the LED module.

FIG. 15Eis a side view of the reflector1500and a side cross-sectional view of the media holder1550including multiple optical media (media1574and1578). In an exemplary embodiment, the media1574and media1578can include glass lens. Media1574and media1578can be the same or complementing type/style of optical media.

In an exemplary embodiment, media1574and media1578are held in the bottom channel1570when the flange1576is coupled to the media holder1550at top channel1572. In certain exemplary embodiments the bottom channel1570is sized and shaped to correspond to media1574and1578. In a further exemplary embodiment, channel1570is sized and shaped to correspond to lenses media1574,1578, and additional optical lenses (not shown). In certain exemplary embodiments, flange1576is held in the top channel1572of the media holder1550. The top channel1572is sized and shaped to correspond to the flange1576at the second end102bof the reflector1500. In an alternate embodiment (not shown), the bottom channel1570can hold one optical media element (media1574or media1578) and top channel1572can engage the flange1576. Additional or fewer media held in bottom channel1576and/or top channel1572are contemplated.

The media holder1550can be coupled to the flange1576of the reflector1500using the elasticity of all or a portion of the material making up the medial holder1550, a snap-fit connection, clips, threads, and the like. In an exemplary embodiment, media1574and1578are press fit into bottom channel1570of the media holder1500. Flange1576is pressed past the top protrusion1568to engage top channel1572. The top protrusion1568can exert a compressive force on the flange1576and/or second end102bof the media holder1550. To remove the media holder1550from the reflector1500, a force must be applied to overcome that which is applied by the top protrusion1568on the flange1576and/or second end section102b. The media holder1550can be attached to the reflector1500before or after the reflector1550is attached to the LED module thereby permitting quick attachment and removal of media1574and1578from the light output from the reflector1500.

As illustrated inFIG. 15E, the exemplary media holder1550includes a middle protrusion1566. The middle protrusion provides a gap between the top surface of media1574and the bottom surface of the reflector1500. In an alternate embodiment, middle protrusion1566can be configured such that the gap between the top surface of media1574and the bottom surface of the reflector1500is reduced or made greater depending on the optical properties required of the light output the LED module. In an alternate embodiment, media holder1550can exclude the middle protrusion1566. The depth of the bottom channel1570in the horizontal direction can be less than the depth of the top channel1572such that flange1576cannot engage the bottom channel1570and only fits the top channel1572. As a result, when assembled, media1574and1578are held in bottom channel1570and flange1576is in top channel1572, without a protrusion between.

The exemplary embodiments disclosed herein are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those having ordinary skill in the art and having the benefit of the teachings herein. While numerous changes may be made by those having ordinary skill in the art, such changes are encompassed within the spirit and scope of this invention. Furthermore, no limitations are intended to the details of construction or design herein shown. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present invention.