Abstract:
A lighting fixture employs one or more reverse parabolic reflectors and molded lenses in a faceplate to provide a variety of light output intensities and emission patterns. Some embodiments clip the reverse parabolic reflectors to fit within the outline of the faceplate without sacrificing significant light output.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     U.S. patent application Ser. No. 13/844,007 filed on Mar. 15, 2013, entitled “Configurable Lamp Assembly”, by Wilkinson and Calvin is incorporated here by reference. 
     FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     JOINT RESEARCH AGREEMENT 
     Not applicable 
     SEQUENCE LISTING 
     Not applicable 
     FIELD OF THE INVENTION 
     The present invention relates to the field of lighting fixtures, and in particular to lenses and reflectors for lighting fixtures. 
     BACKGROUND OF THE INVENTION 
     To achieve desired patterns of light emissions, lighting fixtures have used lenses and reflectors. Often, the area and volumetric constraints imposed on lighting fixtures preclude traditional arrangements of lenses or reflectors. 
     SUMMARY OF THE INVENTION 
     In one embodiment a lighting fixture has a light transmissive faceplate defining a perimeter or outline. One or more lenses are molded or placed into the faceplate. One or more clipped reverse parabolic reflectors referred to by the initials RPR or RPRs in the plural, fit into locations defined in the faceplate. The defined locations in the faceplate constrain the placement and angle of each clipped reverse parabolic reflector. This constraint permits the aiming of each reflector enabling a selected light emission pattern from the faceplate. The reverse parabolic reflectors are clipped in the sense that one or more are trimmed to fit within the perimeter of the faceplate. One or more light emitters, such as LEDs, (light emitting diodes) are centered in each lens and in each reverse parabolic reflector. In embodiments where the LEDs emit light in a substantially lambertian pattern, the lenses and reflectors are adapted to gather and redirect the light in the desired directions. 
     The molded lenses can be of the totally internal reflection type, or of the reflector type or a mix of the two. Other lens types are also possible. The totally internal reflection type of molded lenses are commonly referred to by the initials “TIR”. Molded reflective lenses also have a reflective coating applied to a portion of the lens. 
     In some embodiments, the clipped RPRs are clipped to increase the number of RPRs within the outline of the faceplate thus increasing the summation or total of the areas of the clipped RPRs within the outline of the faceplate. Clipped RPRs abbreviated as CRPR or CRPRs in the plural, are fixed together in some embodiments to form a cluster. The fixing to form a cluster can be accomplished in a number of ways including, adhesives, solvent welding and mechanical means. The faceplate can further seal against a lamp housing to seal the lenses, reflectors and light emitters from an outside environment. Thus the faceplate simultaneously performs several functions in that it has molded lenses, holds and orients lenses and parabolic reflectors, and seals against an external environment. 
     In one embodiment, the faceplate can be a single piece of polycarbonate or acrylic. Depending upon the embodiment and application, other material types are also applicable. For example, in critical applications a lens grade polycarbonate can be used while in less critical applications, an acrylic plastic might be suitable. 
     In other embodiments, the lighting fixture uses a faceplate that has a planar face. The planar faceplate has a closed perimeter. A number of molded lenses are molded into the faceplate within the perimeter of the faceplate. The faceplate further defines one or more locations for one or more CRPRs that fit into the locations for the CRPRs. In still other embodiments, some of the CRPRs are attached together forming a cluster prior to fitting into the defined locations in the faceplate. The CRPRs themselves have a defined planar area and are adapted to emit light along an axis perpendicular to this defined planar area. Within the faceplate each lens and RPR has a light emitter centered in each lens and in each CRPR. 
     In still other embodiments, the defined location for a CRPRs, aims light emitted from the CRPR at an angle other than perpendicular to the planar face of the faceplate. In yet other embodiments the molded lenses are adapted to emit light at an angle other than perpendicular to the planar face of the faceplate. This enables faceplates that aim the light from the reflectors in various desired directions. As discussed previously, the molded lenses can be of the totally internal reflection type, or of the reflector type or a mix of the two. Other lens types are also possible. Molded reflective lenses also have a reflective coating applied to a portion of the lens. 
     Building a light fixture, begins with the selection of the faceplate or planar fame, and the perimeter of the planar faceplate. Space constraints of the application may also dictate the perimeter shape and area of the planar faceplate. Space constraints may also dictate the depth of the entire lighting fixture. Further, the amount of light and light pattern can constrain the number of type of reflectors and lenses such as RPRs or CRPRs, TIR or molded reflective lenses. The desired light emission pattern can also determine the angle at which lenses and reflectors are molded into or placed in the faceplate. 
     To fit more surface area or light emitters into a given area, selectively clipping the edges on a RPR forms a clipped reveres parabolic reflector or CRPR. Clipped reverse parabolic reflectors enable more emitters and, in many cases, more reflector area within the planar faceplate. In other embodiments, CRPRs are fixed together to form a cluster prior to placement within the planar faceplate. 
     TIR and molded reflective lenses are molded into the planar faceplate along with locations for individual or clusters of RPRs or clusters of CRPRs. In embodiments where reflectors are molded into the planar faceplate, silvering or reflective coatings are added to selected areas. 
     Light emitters such as LEDs are placed behind or in the lenses and reflectors to illuminate the lighting fixture. Providing a lamp housing and sealing the faceplate or planar faceplate against a lamp housing provides further strength and seals against external contamination. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The summary above, and the following detailed description will be better understood in view of the enclosed drawings which depict details of preferred embodiments. Like reference numbers designate like elements. It should however be noted that the invention is not limited to the precise arrangement shown in the drawings. The features, functions and advantages can be achieved independently in various embodiments of the claimed invention or may be combined in yet other embodiments. 
         FIGS. 1A-1C  show an embodiment of a RPR. 
         FIGS. 2A-2D  show the design and an embodiment of a CRPR. 
         FIG. 3  shows an embodiment of a totally internal reflection or TIR optic. 
         FIG. 4  shows an embodiment of a molded reflector lens. 
       FIGS.  5 AE- 5 DE show exploded views of various embodiments of a planar frame or faceplate having a combination of molded lenses and CRPRs. 
       FIGS.  5 AP- 5 DP show plan views of various embodiments of a planar frame or faceplate having a combination of molded lenses and CRPRs. 
         FIGS. 6A and 6B  show embodiments of faceplates or planar frames sealed to a lamp housing. 
         FIGS. 7A and 7B  show an embodiment of a planar frame or faceplate with LEDs as light emitters. 
         FIG. 8  shows a side profile view of an embodiment of the light fixture with a selected emission pattern. 
         FIG. 9  shows a flowchart of one embodiment of a method for constructing a lighting fixture. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, reference is made to the accompanying drawings that form a part thereof, and in which is shown by way of illustration specific exemplary embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that modification to the various disclosed embodiments may be made and other embodiments may be utilized, without departing from the spirit and scope of the present invention. The following detailed description is therefore, not to be taken in a limiting sense. 
       FIG. 1A  shows one embodiment of a reverse parabolic reflector  100  hereafter referred to by the initials RPR or RPRs in the plural. The RPR has a parabolic reflector surface  110  and a front mirrored reflective surface  120 . A light emitter  130 , such as an LED, emits light depicted in  FIG. 1A  as a number of rays  150 ,  152 ,  154 ,  156 . The light rays  150 ,  152 ,  154 ,  156  are emitted from the front surface  140  of the RPR. The RPR surface  140  has a defined area and in many embodiments is planar. The light emitter  130  can be any of a number of light sources such a light emitting diode (LED), incandescent, halogen, fluorescent or others. Many LEDs emit light in a substantially lambertian pattern where the greatest portion of the light is emitted toward the front mirrored reflective surface  120  while the light emission tapers off as the angle increases away from perpendicular to the front surface  140  of the RPR  100 . The RPR emits light through the front surface  140  in a number of ways. Ray  152  results from a first reflection off of the front reflective surface  120  and a second reflection off of the parabolic surface  110 . Rays  154  and  156  result from an internal reflection off of the front surface  140  followed by reflection off of the parabolic surface  110 . In some embodiments the rays decrease in intensity with distance from the center of the RPR. Consequently, ray  152  is more intense than ray  154  which is more intense than ray  156 . 
     This decrease in light ray intensity means that areas of the front surface  140  of the RPR farther from the front mirrored reflective surface  120  contribute less overall illumination on a per area basis. Therefore, areas of the front surface  140  and the corresponding reflector surface  110  may be clipped or trimmed with a less loss of light output compared with areas closer to the front mirrored reflective surface  120  of the RPR  100 . Thus it is possible to select a cluster of clipped reverse parabolic reflectors or CRPRs whose summation of defined areas within the perimeter of the faceplate emit more light than non-clipped reverse parabolic reflectors of the same area. 
       FIGS. 1B and 1C  show a simplified view of this decrease in light emission with increasing distance from the center of the RPR  100 . In  FIG. 1C , the diameter of the RPR shown in profile in  FIG. 1B  is X. The majority of the light emission is within the area nearest the center of the RPR indicated in  FIG. 1C  as X/2. This is indicated by a relative light emission of 100%. The areas indicated by X/4, nearest the outer edges of the RPR emit less light as indicted by the lines tapering down from 100% to 50%. It is for this reason that the edges of RPRs can be clipped to form CRPRs without substantial loss of light output from the original RPR. 
       FIG. 2A  shows one embodiment of a square frame with a side equal to X This square represents one possible area and perimeter available for a lighting fixture faceplate. Other shapes are possible for various applications. The typical RPR however is round in shape as indicated by the inscribed circle of  FIG. 2A . The area of the square is X 2 , while the area of the inscribed circle is IF (X/2) 2 . Thus an area of X 2 −π(X/2) 2 =X 2 /4*(4−π) or 21% is unused. Additionally, if a single light emitter is allocated for each RPR, only one light emitter could be used in  FIG. 2A . 
       FIG. 2B  shows a square with side X divided into four equal sub-squares each with side X/2. This has the advantage of allowed four light emitters. However there is still the issue of fitting four round RPRs into the four square outlines of  FIG. 2 . 
       FIG. 2C  shows an embodiment of a circular RPR with four sides clipped to form a square. The round RPR has a diameter of X. The square inside the outline of the round RPR has a side of X/2. Four edges are trimmed off of the round RPR resulting in a square of side X/2 and area of (X/2) 2  or X 2 /4. The area lost due to trimming a circle of radius X/2 into a square of side X/2 is π (X 2 /4) minus (X/2) 2  or X 2 /4 (π−1) or about 68%. The CRPR of  FIG. 2C  enables four CRPRs to fit within a square of side X as shown in  FIG. 2B . Thus by clipping four RPRs to fit into a square of side X, results in an total area increase of X 2  over that of a single circle of area π(X/2) 2  or 27% This also enables four light emitters instead of one, increasing the total light output. Further, as discussed in conjunction with  FIG. 1 , the light emitted by a RPR typically decreases with increasing distance from the center of the RPR. Therefore, even though 68% of the circular area is lost in the clipping process, less than 68% of the light emission is lost. The combination of increased total area of the RPRs, increased numbers of light emitters and emission loss less than the area loss due to clipping results in an increase in light emission typically in excess of two times. 
       FIG. 2D  shows another embodiment of a clipped RPR  210  hereinafter referred by the initials CRPR. Again, the advantage of CRPR in  FIG. 2D  allows two CRPRs to be placed in a square faceplate  200  of side X. Without clipping, only one RPR of diameter X fits into a square of side X. By clipping two opposite edges by X/4, two CRPRs can be fit into a square of side X. This results in an area increase of 21% over the area of a single round RPR and over 95% of the area of the square of side X. Additionally two light emitters, not shown, one for each CRPR, are possible. Further, since the clipped areas are toward the outer edges of the RPRs, the higher light emission areas near the center of the RPR are left intact. In  FIG. 2D  there are six open areas without a RPR surface, four indicated as  220  and two indicated as  230 . These open areas  220  and  230  are available for other emitters as will be discussed below. 
       FIG. 3  shows an embodiment of a totally internal reflector  300  hereafter referred to as a TIR  300 . The TIR type optic does not rely on mirrored or silvered surfaces but rather reflections of the light internal to the material The light emitter  130  emits several light beams indicated by rays  350 ,  352  and  354 . Rays  350  shine from the center portion through the front surface  340  of the TIR, while rays  352  and  354  first internally reflect in the TIR material  360 . While rays  350 ,  352  and  354  are shown parallel to each other, still other embodiments of the TIR can direct rays at angle other than perpendicular to the TIR front surface  340 . Such divergent rays give a wider, flood type illumination. 
       FIG. 4  shows an embodiment of a reflector lens  400 . The body  420  of the reflector lens  400  holds a reflective surface  410  in various places. A light emitter  130  emits a number of light beams indicated by rays  450 ,  452 ,  456  and  458 . These rays exit the front surface  440  of the reflector lens  400  either directly or by first bouncing off of the reflective surface  410 . The shape of the body  420  determines at what angles the rays  450 ,  452 ,  456 ,  458  exit the front surface  440 . Thus the reflector lens  400  can emit a spot light type beam or a flood light type beam. While the rays  450 ,  452 ,  456 ,  458  are shown as direct or reflected, other embodiments may additionally use total internal reflection, also called TIR. Consequently, an infinite number of combinations of reflective surface, TIR, angle and direct emission are possible. In other embodiments a number of lens bodies  420  may be molded together to form a lens array with selectively applied reflective areas  410 . 
     FIGS.  5 AE- 5 DE show exploded views of embodiments of faceplates  500 A,  500 B,  500 C,  500 D with CRPR clusters  540 A- 540 D made with CRPRs  510 A- 510 D.  FIG. 510D  shows an embodiment with a cluster  540 D that has a combination of CRPRs  510 D and one non-clipped RPR  510 D. FIGS.  5 AP- 5 DP show plan views of assemblies  515 A- 515 D of faceplates  500 A- 500 D with CRPRs  510 A- 510 D and lenses  530 A- 530 D. Each faceplate  500 A,  500 B,  500 C,  500 D has a shape defined by an outline or perimeter  520 A,  520 B,  520 C,  520 D. The faceplates  500 A,  500 B,  500 C,  500 D are molded from a transparent material such as acrylic, glass or polycarbonate, although other materials are possible. Also molded into the faceplate are one or more molded lenses  530 A,  530 B,  530 C,  530 D. These molded lenses  530 A,  530 B,  530 C,  530 D can be of the TIR type shown in  FIG. 3 , the reflector type shown in  FIG. 4 , a hybrid type lens or a combination of lens types. In the case of reflector type lenses, a reflective coating is applied to selected areas of the faceplate to form the molded lenses  530 A,  530 B,  530 C,  530 D. The phrase molded lenses in this disclosure refers to either a TIR lens or a reflector type lens or a hybrid lens that combines the two types. 
     One or more CRPRs and/or RPRs  510 A,  510 B,  510 C,  510 D fit together to form a cluster of clipped RPRs  540 A,  540 B,  540 C,  540 D. Some embodiments have the RPRs of a cluster angled relative to each other to form a desired light emission pattern. The cluster  540 A,  540 B,  540 C,  540 D fit into the faceplate  500 A,  500 B,  500 C,  500 D. The faceplate  500 A,  500 B,  500 C,  500 D defines one or more locations  550 A,  550 B,  550 C,  550 D that act to orient the CRPRs or clusters. In some embodiments, these defined locations orient an individual CRPR while in other embodiments a defined location can orient a cluster. Depending upon the embodiment, the defined locations  550 A,  550 B,  550 C,  550 D can take the form of recesses, ridges, pegs or other features in the faceplate  500 A,  500 B,  500 C,  500 D to constraint the position, angle and orientation of the RPRs, CRPRs, or clusters. One or more light emitters  130  fit into each RPR, CRPR  510 A- 510 D and molded lens  530 A- 530 D. 
       FIGS. 6A and 6B  show embodiments of a faceplate  500  or planar faceplate  500  sealed to a lamp housing  600  to form a lighting fixture  50 . The faceplate  500 , depending upon embodiment, can be one of the faceplate embodiments of FIGS.  5 AP,  5 BP,  5 CP,  5 DP as well as other faceplate embodiments. The faceplate  500  performs several functions simultaneously. It provides a transparent or light transmissive surface to emit light from the reflectors and lenses, it holds the molded lenses, it orients and constrains the RPRs, CRPRs, and clusters, it seals against the lamp housing  600 . In some embodiments the sealing is accomplished by the use of adhesives while in other embodiments the sealing is accomplished with gaskets or seals  505 . 
       FIG. 7A  shows a frontal view of an embodiment of a rectangular faceplate  700  with a cluster  740  of two clipped RPRs  710 , six molded lenses  530  and eight light emitters  130 . This view is followed by a profile view  FIG. 7B  of the same faceplate  700 . A light emitter  130  is centered in each of the clipped RPRs  710  and molded lenses  530 . Other embodiments use a mix of clipped and non-clipped RPRs to form the cluster  740 . The molded lenses can be of the TIR type, reflector type, a hybrid or mix of the two types. 
       FIG. 8  shows profile view of an embodiment of a faceplate  800  with a cluster  840  of CRPRs  810  of which four are indicated. Two molded lenses  530  and six light emitters  130  are indicated. One or more light emitters  130  are centered in each of the CRPRs  810  and molded lenses  530 . Other embodiments use a mix of clipped and non-clipped RPRs either individually or in cluster like the cluster of  840 . The molded lenses  530  can be of the TIR type, reflector type, a hybrid or mix of the two types.  FIG. 8  further shows how the molded lenses can be molded into the faceplate at an angle so as to direct the light output at an angle from the perpendicular to the front surface of the faceplate. The dashed lines  850 ,  852 ,  854  depict light rays exiting an angle relative to the perpendicular  856  to the faceplate surface  880 . While the faceplate surface  880  is shown as flat or planar in  FIG. 8 , other embodiments employ a curved faceplate surface. 
       FIG. 9  is a flowchart  900  for one embodiment of a method for building a lighting fixture. The method begins with the selection of a faceplate or frame surface at  910 . The faceplate, also called a frame, can have a planar surface or a curved surface depending upon the allowable space and other requirements such as light output and light pattern. The outline or perimeter shape of the faceplate or fame is also selected at  920 . As seen in  FIGS. 2 ,  5 A,  5 B,  5 C,  5 D,  6  and  7 , the shape of the faceplate can be any shape and is determined by the application. Block  930  is where the application specifies the light output and pattern referred to as the requirements. In some cases for example, a spot light type beam is required, while other applications require a flood light. Still other applications may require a main spotlight with a smaller amount of light off-center from the main spotlight. The number and type of reflectors and lenses are chosen to provide the required light output and pattern at  940 . This can include specifying the number, the type and the angle and orientation of reflectors and lenses to meet the requirements of light output and pattern. Also at  940 , the type and number of light emitters are chosen. At  950  one or more of the RPRs is clipped to fit within the faceplate perimeter. As disclosed, clipping the edges of a RPR does not reduce the light output significantly, thus more RPRs and light emitters can fit into a given faceplate perimeter with a consequent increase in light output. At  960  the areas not occupied by RPRs can have molded lenses of the TIR or reflector type. These molded lenses can be angled relative to the surface of the faceplate to establish the required light emission pattern. During the molding of the faceplate, at  970  one or more locations are molded into the faceplate to orient and constrain the RPRs, clipped RPRs or cluster of RPRs. These molded locations help aim the light output of the RPRs and aid in assembly. At  980  one or more light emitters are placed in the center of each parabolic reflectors and lens. At  990  the faceplate, together with reflectors, lenses and emitters is sealed to a provided lamp housing. This sealing can be accomplished with adhesives, gaskets or other types of sealing methods. 
     Although this invention has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art, including embodiments that do not provide all of the features and advantages set forth herein, are also within the scope of this invention. Rather, the scope of the present invention is defined only by reference to the appended claims and equivalents thereof. 
     
       
         
               
               
               
             
           
               
                   
               
               
                 Ref. 
                 Name and/or Description 
                 Figs. 
               
               
                   
               
             
             
               
                  50 
                 Lighting fixture 
                 6A, 6B 
               
               
                 100 
                 RPRs. Referred to by initials RPR. 
                 1A, 1B 
               
               
                 110 
                 Parabolic reflector surface: The 
                 1A 
               
               
                   
                 parabolically shaped reflective 
               
               
                   
                 surface of the RPR. 
               
               
                 120 
                 Front mirrored reflective surface: 
                 1A 
               
               
                   
                 The front reflective surface of 
               
               
                   
                 the RPR 
               
               
                 130 
                 Light emitter: Light source such 
                 1A 
               
               
                   
                 as an LED, halogen or incandescent 
               
               
                   
                 lamp, etc 
               
               
                 140 
                 Front surface of RPR 
                 1A 
               
               
                 150 
                 Light rays exiting RPR 
                 1A 
               
               
                 152 
                 Light rays: Exiting RPR after 
                 1A 
               
               
                   
                 front mirrored surface and 
               
               
                   
                 parabolic reflection 
               
               
                 154 
                 Light rays: Exiting RPR after a 
                 1A 
               
               
                   
                 surface reflection and reflection 
               
               
                   
                 off of parabolic reflector 
               
               
                 156 
                 Light rays: Exiting RPR after a 
                 1A 
               
               
                   
                 single parabolic reflection. 
               
               
                 200 
                 Square Faceplate 
                 2D 
               
               
                 210 
                 Clipped RPRs: RPRs with one or 
                 2D 
               
               
                   
                 more trimmed edges. 
               
               
                 220, 230 
                 Open area without RPR. 
                 2D 
               
               
                 300 
                 TIR: Totally internal reflection 
                 3 
               
               
                   
                 type lens. 
               
               
                 340 
                 Front surface of TIR 
                 3 
               
               
                 350 
                 Ray: Exiting TIR perpendicular to 
                 3 
               
               
                   
                 front surface of TIR lens. 
               
               
                 352 
                 Ray from TIR 
                 3 
               
               
                 354 
                 Ray from TIR 
                 3 
               
               
                 360 
                 Material of TIR 
                 3 
               
               
                 400 
                 Reflector lens: A type of lens 
                 4 
               
               
                   
                 relying at least partially on a 
               
               
                   
                 reflective surface 
               
               
                 410 
                 Reflector lens reflective surface: 
                 4 
               
               
                   
                 Reflective material applied to molded 
               
               
                   
                 body of lens 
               
               
                 420 
                 Reflector lens body: such as a molded 
                 4 
               
               
                   
                 polycarbonate or acrylic 
               
               
                 440 
                 Front surface of reflector lens 
                 4 
               
               
                 450 
                 Ray: Exiting reflector lens 
                 4 
               
               
                   
                 perpendicular to front surface of 
               
               
                   
                 reflector lens. 
               
               
                 452 
                 Ray: Exiting reflector lens at angle 
                 4 
               
               
                   
                 relative to the perpendicular to 
               
               
                   
                 front surface of reflector lens. 
               
               
                 456 
                 Ray: Exiting reflector lens at angle 
                 4 
               
               
                   
                 relative to the perpendicular to front 
               
               
                   
                 surface of reflector lens 
               
               
                 458 
                 Ray: Exiting reflector lens at angle 
                 4 
               
               
                   
                 relative to the perpendicular to 
               
               
                   
                 front surface of reflector lens 
               
               
                 500, 500A, 
                 Faceplate, also called a planar frame 
                 5A, 5B, 5C, 5D, 
               
               
                 500B, 500C, 
                 in some embodiments. 
                 6A, 6B 
               
               
                 500D 
               
               
                 505 
                 Seal or gasket between faceplate and 
                 6B 
               
               
                   
                 lamp housing 
               
               
                 510A, 510B, 
                 Clipped reverse parabolic 
                 5A, 5B, 5C, 5D 
               
               
                 510C, 510D, 
                 reflector(s) or CRPR(s). 
               
               
                 515A, 515B, 
                 Assemble of faceplate with molded 
                 5A, 5B, 5C, 5D 
               
               
                 515C, 515D 
                 lenses, and various combinations of 
               
               
                   
                 RPR(s), CRPR(s) and cluster(s). 
               
               
                 520A, 
                 Perimeter also called an outline of 
                 5A, 5B, 5C, 5D 
               
               
                 520B, 520C, 
                 faceplate or planar frame 
               
               
                 520D 
               
               
                 530, 530A, 
                 Molded lens. The lenses, either TIR, 
                 5A, 5B, 5C, 5D 
               
               
                 530B, 530C, 
                 reflector, hybrid or other, 
               
               
                 530D 
                 molded into the faceplate 
               
               
                 540A, 540B, 
                 Clipped or non-clipped RPRs fitted 
                 5A, 5B, 5C, 5D 
               
               
                 540C, 540D, 
                 together to form a cluster. 
               
               
                   
                 Clusters can also have RPRs angled 
               
               
                   
                 relative to each other. 
               
               
                 550A, 
                 Defined location or area in faceplate 
                 5A, 5B, 5C, 5D 
               
               
                 550B, 550C, 
                 for RPRs, clipped RPRs or clusters. 
               
               
                 550D 
               
               
                 600 
                 Lamp housing 
                 6A, 6B 
               
               
                 700 
                 Faceplate 
                 7A, 7B 
               
               
                 710 
                 Clipped RPR also referred to as 
                 7A, 7B 
               
               
                   
                 CRPR 
               
               
                 740 
                 Cluster of CRPRs 
                 7A 
               
               
                 800 
                 Faceplate 
                 8 
               
               
                 810 
                 Clipped or non-clipped RPRs 
                 8 
               
               
                 840 
                 RPRs fitted together to form a 
                 8 
               
               
                   
                 cluster 
               
               
                 850, 852, 
                 Rays exiting faceplate at an 
                 8 
               
               
                 854 
                 angle 
               
               
                 856 
                 Ray exiting perpendicular to 
                 8 
               
               
                   
                 faceplate surface 
               
               
                 880 
                 Faceplate surface 
                 8 
               
               
                 900 
                 Method flowchart. 
                 9 
               
               
                 910 
                 Selecting a faceplate: Choosing 
                 9 
               
               
                   
                 a shape of the faceplate. 
               
               
                 920 
                 Selecting a perimeter or closed 
                 9 
               
               
                   
                 perimeter. Some embodiments 
               
               
                   
                 include an edge to which the lamp 
               
               
                   
                 housing will seal. 
               
               
                 930 
                 Determining the required light 
                 9 
               
               
                   
                 output and pattern. 
               
               
                   
                 The requirements. 
               
               
                 940 
                 Selecting a combination of RPRs, 
                 9 
               
               
                   
                 CRPRs, clusters and lenses per the 
               
               
                   
                 requirements 
               
               
                 950 
                 Selectively clipping RPRs, allowing 
                 9 
               
               
                   
                 more RPRs to fit within perimeter or 
               
               
                   
                 allowing room for lenses. 
               
               
                 960 
                 Molding one or more lenses into the 
                 9 
               
               
                   
                 planar frame. Molded lenses can be 
               
               
                   
                 of reflector or TIR type that are 
               
               
                   
                 molded as part of the faceplate 
               
               
                 970 
                 Mold one or more locations into the 
                 9 
               
               
                   
                 frame to constrain the orientation 
               
               
                   
                 of RPRs, CRPRs or clusters. 
               
               
                 980 
                 Placing one or more light emitters 
                 9 
               
               
                   
                 in each reflector or lens. 
               
               
                 990 
                 Seal faceplate or perimeter to 
                 9 
               
               
                   
                 lamp housing forming a seal