Patent Publication Number: US-8123383-B2

Title: Modified reflector surface to redirect off-field side light onto field

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This is a continuation application of U.S. Ser. No. 11/333,133 filed Jan. 17, 2006, which claims priority under 35 U.S.C. §119 of a provisional application U.S. Ser. No. 60/644,688 filed Jan. 18, 2005, herein incorporated by reference in its entirety. 
     This application is also a non-provisional of the following provisional U.S. applications, all filed Jan. 18, 2005: U.S. Ser. No. 60/644,639; U.S. Ser. No. 60/644,536; U.S. Ser. No. 60/644,747; U.S. Ser. No. 60/644,534; U.S. Ser. No. 60/644,720; U.S. Ser. No. 60/644,636; U.S. Ser. No. 60/644,517; U.S. Ser. No. 60/644,609; U.S. Ser. No. 60/644,516; U.S. Ser. No. 60/644,546; U.S. Ser. No. 60/644,547; U.S. Ser. No. 60/644,638; U.S. Ser. No. 60/644,537; U.S. Ser. No. 60/644,637; U.S. Ser. No. 60/644,719; U.S. Ser. No. 60/644,784; U.S. Ser. No. 60/644,687, each of which is herein incorporated by reference in its entirety. 
    
    
     INCORPORATION BY REFERENCE 
     The contents of the following U.S. Patents are incorporated by reference by their entirety: U.S. Pat. Nos. 4,816,974; 4,947,303; 5,161,883; 5,600,537; 5,816,691; 5,856,721; 6,036,338. 
     I. BACKGROUND OF THE INVENTION 
     A. Field of the Invention 
     The present invention relates to lighting fixtures that produce high intensity, controlled, and concentrated light beams for use at relatively distant targets. One primary example is illumination of a sports field. 
     B. Problems in the Art 
     The most conventional form of sports lighting fixture  2  is a several feet in diameter bowl-shaped aluminum reflector with a transparent glass lens  3  suspended from a cross arm  7  fixed to a pole  6  by an adjustable knuckle  4  (see  FIG. 1B ). 
     This general configuration of sports lighting fixtures  2  has remained relatively constant over many years because it is a relatively economical and durable design. It represents a reasonable compromise between the desire to economically control high intensity light to a distant target while at the same time minimizing wind load, which is a particularly significant issue when fixtures are elevated out-of-doors to sometimes well over 100 feet in the air. A much larger reflector could control light better. However, the wind load would be impractical. A significant amount of the cost of sports lighting systems involves how the lights are elevated. The more wind load, the more robust and thus more expensive, the poles must be. Also, conventional aluminum bowl-shaped reflectors are formed by a spinning process. Different light beam shapes are needed for different fixtures  2  on poles  6  for different lighting applications. The spinning process for creating aluminum bowl-shaped reflectors is relatively efficient and economical, even for a variety of reflector shapes and light controlling effects. The resistance of aluminum to corrosion is highly beneficial, particularly for outdoors lighting. 
     In recent times, sports lighting has also had to deal with the issue of glare and spill light. For example, if light travels outside the area of the sports field, it can spill onto residential houses near the sports field. 
     II. SUMMARY OF THE INVENTION 
     It is therefore a principal object, feature, or advantage of the present invention to present a high intensity lighting fixture, its method of use, and its incorporation into a lighting system, which improves over or solves certain problems and deficiencies in the art. 
     Other objects, features, or advantages of the present invention include such a fixture, method, or system which can accomplish one or more of the following: 
     a) reduce energy use; 
     b) increase the amount of useable light at each fixture for a fixed amount of energy; 
     c) more effectively utilize the light produced at each fixture relative to a target area; 
     d) is robust and durable for most sports lighting or other typical applications for high intensity light fixtures of this type, whether outside or indoors. 
     A. Exemplary Aspects of the Invention 
     In one aspect of the invention, the spun aluminum reflector is replaced with a frame over which a high reflectivity reflecting surface can be placed. The relatively thin but high reflectivity surface can be mounted to the interior of the frame and shielded from the elements. Such a frame is economical, is robust, and can be mass produced economically. It also can be made with substantial precision so that they are consistent from one to the other. Also, by applying the reflecting surface separately to the frame, instead of having the reflecting surface and support the same thing (e.g. the spun aluminum reflector), different beam shapes and characteristics can be created by interchanging reflecting surfaces, rather than making different spun aluminum reflectors. 
     In another aspect of the invention, at least a part of the main reflecting portion has a shape and orientation different from the portion which follows a surface of revolution. One example is an angular section below the lamp that diverges light more than the portion which follows the surface of revolution. This can be effective to place light on the target that otherwise would reflect from the bottom of the reflecting surface and spill outward and upward outside the target in the direction the fixture is aimed. A second example is an angular section placed to one side or the other of the lamp that diverges light more than the portion that follows the surface of revolution. This can be effective to shift back onto the target area light that otherwise tends to spill outward outside the target area sideways in an opposite direction from that side of the fixture. If appropriately used, each less converging part of the main reflecting surface can add light otherwise lost from the target, and thus increase the amount of light to the target per energy unit used. This can also allows minimization of number of fixtures. It can also reduce glare and spill light. These and other objects, features, advantages and aspects of the present invention will become more apparent with reference to the accompanying specification and claims. 
    
    
     
       III. BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A-G  are general diagrammatic views of a conventional sports lighting system and components. 
         FIG. 2  is a partially exploded view of a light fixture according to an exemplary embodiment of the present invention. 
         FIGS. 3A  and B are assembled views of  FIG. 2 . 
         FIGS. 4A  and B are assembled views of a slightly different embodiment according to the invention. 
         FIGS. 5A-C  are various views diagrammatically illustrating reflective inserts that can be positioned inside a reflector frame. 
         FIGS. 6A-V  are various views of one embodiment of a reflector frame. 
         FIGS. 7A-D  are various views of an alternative reflector frame. 
         FIGS. 8A-D  are various views of an alternative reflector frame. 
         FIGS. 9A-E  are various views of an alternative reflector frame. 
         FIGS. 10A-C  are various views of an alternative reflector frame. 
         FIGS. 11A-C  are various views of an alternative reflector frame. 
         FIGS. 12A-E  are various views of an alternative reflector frame. 
         FIGS. 13A-C  are various views of an alternative reflector frame. 
         FIGS. 14A-C  are various views of an alternative reflector frame. 
         FIGS. 15A-C  are various views of a reflective insert that can be removably positioned inside a reflector frame. 
         FIGS. 16A-C  are an alternative embodiment of a reflector insert. 
         FIGS. 17A-C  are an alternative embodiment of a reflective insert. 
         FIGS. 18A-C  are another alternative reflective insert embodiment. 
         FIGS. 19A-C  are another alternative embodiment of a reflective insert. 
         FIGS. 20A-C  are another alternative embodiment of a reflective insert. 
         FIGS. 21A-C  are another alternative embodiment of a reflective insert. 
         FIGS. 22A-C  are another alternative embodiment of a reflective insert. 
         FIGS. 23A-C  are another alternative embodiment of a reflective insert. 
     
    
    
     IV. DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     A. Exemplary Apparatus 
     Reflector frame  30  (cast aluminum type  413  e.g., see  FIG. 6A  and subparts) bolts to lamp cone  40 . Primary reflecting surface  32 , here comprising a number of high total reflectance rated side-by-side strips  120  (see  FIGS. 15-23  and subparts), is mounted inside reflector frame  30 . Reflector frame  30  has a main portion that follows a surface of revolution, but at least one differently oriented portion. Frame  30  is thus pre-designed to shift part of the light beam that will be generated by the reflecting surface once applied to frame  30 . A frame  230  for glass lens  3  is removably latched to the front of reflector frame  30 . Visor  70  is mountable to the lens frame and extends from the upper front of reflector frame  30  when in place. It includes high reflectivity strips  72  on its interior. 
     1. Reflector Frame  30  Generally 
       FIGS. 2 ,  3 A and B,  4 A and B, and  6 A and subparts, illustrate details of reflector frame  30 . It is die-cast aluminum (e.g., aluminum type  413 ). It could be made of other materials (e.g. powder-coated steel). Unlike state-of-the-art bowl-shaped spun aluminum reflectors, it does not have any surface that is intended for controlled reflection of light to the target area. Therefore, it does not require much post-casting processing. It provides the basic framework or support for primary reflecting surface  32 , which shapes and controls most of the light beam of fixture  10 . It does have basically a bowl-shape with an external surface that is substantially closed and smooth. 
     Reflector frame  30  is thicker and stronger than a conventional spun aluminum reflector (an estimated 2 to 3 times stronger). Die-casting makes it economical to create different forms of reflector frame  30 . Ironically, while being much more robust (able to withstand things such as hail, baseballs, and other forces) than typical spun aluminum reflectors, it has more flexible in configuration and can result in smoother, more controlled lighting to the field. 
     As shown in  FIGS. 3A-B  and  4 A-B, bumps or projections  71 A and B extend from the outside of reflector frame  30 . These are ejector pins for die-casting so that the casting is not distorted. Die-casting provides for a very precise way to form the framework for the main fixture reflecting surface in an economical fashion. 
     When assembled, lamp  20  extends through opening  110  at the bottom or center of reflector frame  30  and is substantially centered in reflector frame  30 . High reflectivity reflecting surface  32  surrounds a substantial part of the glass envelope of lamp  20  around an arc tube. An orthogonal plane laterally across the middle of arc tube (its equator) projects substantially to reflecting surface  32 , but since arc tube in one embodiment is tipped up relative the center aiming axis of reflector frame  30  (the longitudinal axis of lamp  20  is generally along the center axis of reflector frame  30 ), part of its projected equator extends obliquely out the front opening of reflector frame  30 . 
     Reflector frame  30  is generally in the shape of a common sports lighting surface of revolution (parabola or hyperbola or combinations thereof) because it supports a main reflecting surface  32  that produces a controlled, concentrated beam. Such a beam needs to be controlled in both vertical and horizontal planes. As shown at  FIGS. 6A-V , a majority of reflector frame  30  (see reference numeral  102 ) follows a basic surface of revolution (e.g., parabolic or hyperbolic shape) between transition points  104  and  106 —approximately the upper 244° of the frame  30  in this example. When reflecting surface  32  is overlayed over this section  102  of frame  30 , fixture  10  captures and precisely controls a substantial part of the light energy from lamp  20  and concentrates it into a shape useful for sports lighting. 
     2. Lower Less Converging Section  108  of Reflector Frame  30   
     But reflector frame  30  includes another portion (see  FIG. 6A  and subparts, reference numeral  108 ) of a different nature. It is not in the same shape as the surface of revolution of portion  102 . In the version shown in  FIG. 6A , section  108  is approximately 116° and centered in the lower hemisphere of the interior of reflector frame  30 . When high reflectivity, primary reflecting surface  32  is applied over it, light is reflected in a less converging manner than from section  102 , the section which follows a consistent surface of revolution. 
     Thus, reflector frame  30  is intentionally cast to include at least one section which supports high reflectivity material at a different, and less converging, orientation to the light source  20  and is not part of the general surface of revolution simulated by the rest of the reflecting surface  32 , which is generally converging. This less converging part is easily designed and manufactured into fixture  10 , because reflector frame  30  is cast and the reflecting surface is added to it (see, e.g.,  FIGS. 5A-C ). Less converging section  108  is designed to redirect light from fixture  10  that otherwise would go off the athletic field and place it in a useful position for lighting the field. In essence, for normal aiming angles for sports lighting fixtures, light striking lower hemisphere less converging section  108  will be useable for lighting the field, as opposed to traveling horizontally or above horizontally and “spilling” off the field. 
     MUSCO® Corporation has previously altered part of the surface of revolution of ordinary conventional bowl shaped spun reflectors to alter the direction of light from that portion of the reflector. See, for example, U.S. Pat. No. 4,947,303, incorporated by reference herein. However, that method involved adding a separate insert piece over the spun reflector reflecting surface or mechanically peening or etching that part of the spun reflector to alter the reflecting properties of that part of the reflector. In fixture  10  of the embodiment of the invention, use of a cast reflector frame  30  allows nonreflecting supporting structure, separate from the reflecting surface, to be built into the reflector supporting framework. It avoids having a separate overlay piece or alteration of reflective surfaces. 
     3.Side Shift Sections  109  of Reflector Frame  30   
     Optionally, reflector frame  30  can have additional areas that can be modified to support reflecting surface  32  to diverge light like the less converging section  108  described above. Section  109  (see, e.g., side-shift portion  109 R in  FIGS. 7A-D ) differs in that it is on a lateral side of reflector frame  30  (and thus lateral to, or to one side of lamp  20  when in place). Its function is the same, however, to pull light that otherwise would go off field back onto the field. As indicated in the Figures, these side shift portions could be on either side reflecting frame  30  and could take different configurations. See reference numerals  109 L and  109 R of  FIGS. 7A-14C  for a variety of examples of different side shift configurations for fixture  10 . 
     Thus, this “side shift” or generally horizontal shifting of light, can be particularly useful in sports lighting. It can allow light that otherwise might be glare or spill light to be “pushed” or shifted back onto the field. It also allows either placement of additional light onto a certain area of the field without added more fixtures or, conversely, removing some light from a certain area. 
     As can be appreciated, the ability to reduce glare and spill from one fixture can be significant. Substantially eliminating what otherwise would be light that spills outside the field (e.g. onto a neighbor&#39;s property) or causes glare (e.g. to a driver on an adjacent street), even for one fixture, can be very beneficial. But moreover, shifting light from a plurality of fixtures in a given lighting system can cumulatively significantly cut down on glare and spill light. Furthermore, shifting light in combination with reduced intensity from the fixture(s) (at least during an initial operational period for the lamps of the fixtures) can produce a substantial reduction in glare and/or spill light. 
     The die cast reflector, and the ability to precisely form a wide variety of shapes (and thus wide variety of light shifting functions), allows much flexibility to “push” light to locations where it is beneficial for the lighting application and/or “pull” light away from where it would not be considered beneficial. An on-field example would be to shift more light just behind second base in a baseball field. Another example would be to decrease spill light from the end zone corner of a football field. Or both on-field and off-field light shifting could take place. It could be to either increase or decrease light at some part of the sports field, or redirect light that otherwise would go off the field so that it is added to the light going on the field. A designer can select the location and intensity of light virtually anywhere in a target space. While such things as beam width, distance to target, etc. have some bearing on the amount of light shift, the benefits described above can be enjoyed. Thus, a single fixture or a plurality of fixtures for a given lighting application can have a beam shifting or light shifting component such that a lighting application can be customized. 
     B. Assembly and Use 
     In practice, a set of fixtures  10 , such as described above, would be used in a sports lighting system customized for a particular sports field. Lighting specifications (usually including light quantity and uniformity minimums; and sometimes glare, spill, and halo light limitations) are usually prepared or known. As is well known in the art, computer software can design the lighting system, including what types of beams and beam shapes from how many fixtures at what locations are needed to meet the specifications. It can generate a report indicating number of fixtures, pole locations, beam types, and aiming angles to meet the design. 
     As described above, fixtures  10  can be assembled to produce a wide variety of beams and commonly used beam shapes for sports lighting. Using the report, a set of fixtures  10  can be pre-assembled at the factory. The appropriate reflector frame  30  for each beam type called for in the report can be pulled from inventory by the assembly worker. About one-half the reflector frames will include a side shift section  109  (and about one-half of those split between left shift and right shift) Likewise, the appropriate reflector inserts  120 , visor  70 A or B, and visor reflective inserts  72  will be pulled from inventory for each fixture according to its position and function in the report. 
     The assembly worker(s) will mount the appropriate reflective inserts  120  on the pins on each reflector frame  30 , and the appropriate visor reflective strips  72  on visor  70  for each fixture  10  (depending on the precise structure of visor  70 , mounting straps or brackets may first be secured to visor  70 ). Glass lens  3 , with anti-reflective coatings on both sides installed, is assembled into lens rim  230  with visor  70  attached. 
     Further description of reflector inserts  120 , options and alternatives, and how they can be mounted on different reflector frames  30  is set forth below. 
     1. High Reflectivity Primary Reflecting Surface  32  (Reflector Inserts  120 ) 
     Reflecting surface  32  is independent of reflector frame  30 . In this exemplary embodiment, reflecting surface  32  is made up of a set of elongated strips of high reflectivity sheet material which will be called reflector inserts  120 . The shape (e.g. width), specularity (e.g. more diffuse or more shiny), and surface (e.g. smooth, stepped, peens, texture) can be varied from insert  120  to insert  120 , or they all can be similar. 
     One example of a reflector insert  120  is illustrated in  FIGS. 15A-C . It is made from 0.020 inch thick Anolux MIRO® IV anodized lighting sheet material (available from Anomet, Inc. of Brampton, Ontario, CANADA). It has high total reflectance (at least 95%). It can be formed into curved shapes.  FIG. 15B  shows one formed profile ready to be installed on pins  126  and  128  (see, e.g.,  FIG. 6D ). The material has a base layer of high purity aluminum chemically brightened to form a hard clear surface of oxide, with a super reflective vapor deposited as a thin film outer layer. This results in a relatively hard, durable surface that reflects a minimum of 95% of visible light rays incident upon it. The material comes in flat sheet form. Inserts  120  are cut out to desired shape and are flat. A thin plastic, self-adhering releasable protection sheet is added over the reflecting side to keep fingerprints or other foreign substances from the reflecting surface during handling. 
     The temporary protective release sheet can be placed over the reflective side of the strips  120  when manufactured. A score line can be manufactured into the sheet to allow “break and peel” removal of the release sheet. When a fixture  10  is assembled, the worker can install each strip  120  without worrying about fingerprints or other substances attaching to strip  120  (he/she can grasp an insert  120  and even touch both front and back sides without leaving fingerprints on the reflecting side. But at the appropriate time during assembly, release sheet can be quickly and easily removed by peeling it off. 
     When installed in position on reflector frame  30 , reflector insert  120  is basically captured between inner and outer pins  126  and  128 . It does not have to rely precisely on the solid surface of reflector frame  30  behind it to define its form, but reflector frame  30  does provide the basic support and shape for reflector inserts  120  because each insert is suspended on two pins on the bowl-shaped reflector frame  30 . 
     The material for inserts  120  has high consistency from piece to piece because it is made in large sheets under stringent and highly controllable manufacturing conditions. A subtlety of the material is that it is more efficient in reflecting light (thus more light that can be used to go to the field), but also its very high reflectivity results in much more precise control of the reflected light (it minors the light source more precisely). This adds greatly to the effectiveness and efficiency of fixture  10  in a sports lighting system for a sports field. 
     Alternatives for reflecting surface  32  is a silver coated aluminum are available from commercial sources (e.g. Alanod Aluminum, Ennepetal, Germany). This type of material can achieve higher reflectivity (perhaps 3 percent higher) than the previously described material, but is not as durable. 
       FIGS. 15A-23C  illustrate various examples of reflector inserts  120  that can be mounted to the interior surface of reflector frame  30 . The pre-manufactured, high reflectivity strips  120  do not need polishing or other processing steps that are many times required of spun aluminum reflectors. Therefore, another cost of conventional spun aluminum fixtures is avoided. And the color separation or striations that plague spun aluminum reflectors after polishing are avoided because strips  120  are flat in one plane (although mounted along a curve in another plane) and are not polished after manufacture. 
     In one exemplary embodiment, thirty-six inserts  120  (when 2 inches wide at base) are mounted on reflector frame  30 . The nature of each insert selected, and its position on frame  30  depends on the type of light beam desired for the fixture. Width, curvature when installed, and surface characteristics of inserts  120  can all be designed to produce the type and characteristics of a beam needed for that particular fixture for a particular field. 
     Inserts  120  can be custom designed for a fixture. Alternatively, an inventory of a limited number of styles, all capable of being installed on a pair of pins  126  and  128  of reflector frame  30 , and capable of producing many of the standard beam types needed for sports lighting, could be created. Specific reflective inserts  120  for each fixture for a lighting system for a field can be determined according to computerized programs and/or specifications for the field. Workers can therefore easily select and install the appropriate inserts  120  for a given fixture without experimentation or expertise in lighting design. They basically have to match an inventory item to the specification for that fixture. 
     Each insert has formed openings  122  and  124  (see, e.g.,  FIG. 15A ) towards opposite ends that are adapted to cooperate with a set of inner and outer mounting pins  126  and  128  on the interior of reflector frame  30 . The spacing and configuration of each set of openings  122  and  124  on each reflector insert  120 , and the corresponding set of inner and outer pins  126  and  128  on reflector insert frame  30 , allow quick and easy securement or removal of inserts  120 . They are positioned and secured without any fasteners. There is no need for tools. 
       FIGS. 9A   5 A- 12 E illustrate details about inner and outer pins  126  and  128  and how insert  120  can be mounted. The rectangular opening  122  ( FIG. 15A ) of a reflector insert  120  is brought vertically over an inner pin  126  until the plane of reflector insert  120  is at the level of slot  127  (e.g.,  FIG. 6M ) of inner pin  126 . Reflector insert  120  is then slid slightly forward relative to inner pin  126  so that the inner end of reflective insert  120  is held against movement. The outer wider end of reflector insert  120  is basically then snap fit over an outer pin  128 . The small tongue  125  (e.g.,  FIG. 15A ) extending into formed opening  124  of reflector insert  120  can deflect slightly but frictionally bites into pin  128  a bit and acts as a resilient force to hold reflector insert  120  into position on inner and outer pins  126  and  128 . Once mounted on a set of pins  126  and  128 , the curved shape of insert  120 , and the inherent resiliency of the material it is made of, resists further bending or movement back to a flat configuration, including a tendency to want to draw towards lamp  20 , a heat source, during operation. 
     Each reflector insert  120  essentially forms an individual small reflector of the light source (arc tube- and lamp  20 ). To create a highly controlled composite beam from a fixture  10 , accuracy of installation and position in reflector frame  30  is important. The pin-mounting method for reflector inserts  120  allows accurate placement and deters change of shape or position of inserts  120  once in place. But further, it makes assembly of inserts  120  into fixture  10  quick and easy. 
     As can be appreciated, different styles and configurations of reflector inserts  120  can be created for different lighting affects. This is not easily possible with spun reflectors. As indicated in  FIGS. 15A-23C , not only the precise curved profile, but also the width of reflector insert  120  can determine characteristics of the composite beam coming out of fixture  10 . The principles involved are described U.S. Pat. No. 6,036,338, incorporated by reference herein. Note that wider reflector strips  120  (for example see  FIG. 17A ) can include two pairs of inner and outer formed openings  122  and  124  and utilize two sets of inner and outer pins  126  and  128 . 
     As can be seen in  FIGS. 6D and 7D , pairs of inner and outer pins  126  and  128  are spaced differently for different parts of reflector frame  30 . For example, in the main portion  102  of reflector frame  30 , all pin pairs  126 / 128  are spaced equally apart a first distance. Pin pairs  126 / 128  in less converging portion  108  or side shift portion  109 , have shorter but equidistant spacing, because reflector inserts  120  for those sections are shorter and different in curvature. 
     Different beam characteristics from the same reflector frame  30  can be created by using different reflector inserts  120 . Examples of inserts  120  are shown in the drawings. These examples fall into three broad categories: (a) two inches wide at the lens end for a medium width beam (e.g.,  FIG. 22A ); four inches wide (lens end) for wider horizontal beam spread (e.g.,  FIG. 21A , where lighting is accomplished with less fixtures), and one inch (lens end) for quite narrow spread (usually for fixtures far away from target) (e.g.,  FIG. 15A ). Other configurations are, or course, possible. Different widths, specularity, shape, and reflecting surfaces can be designed for different lighting effects. Inserts  120  can be the same for a whole fixture  10 , or can vary. 
     On the other hand, the same reflector inserts  120  could be applied to differently shaped reflector frames  30 , without modification, and produce a different beam shape for fixture  10 .  FIG. 6A  and subparts illustrate a reflector frame and reflector inserts which would produce a medium reflector type  3  beam, such as is well-known in the art. As can be appreciated by those skilled in the art, other types of beams can be created with different shaped reflector frames  30  (e.g., wide reflector type  4 , narrow reflector type  2 , etc.) with the use of appropriate reflector inserts. 
     Additionally, less converging lower section  108  or less converging side shift section  109  can change the nature of the beam from fixture  10 . Different configurations for less converging section  108 , with or without a left or right side shift section  109  for a reflector frame  30  are illustrated in  FIGS. 7A-14C .  FIGS. 6A-V ,  12 A-E, and  9 A-E illustrate variations on a less converging lower hemisphere portion  108  such as previously described.  FIGS. 7A-D ,  10 A-C, and  13 A-C add what will be called a right side shift section  109  in addition to a downward less converging section  108 . Portion  109 R, on a lateral side of reflector frame  30 , has a shape different from the main portion  102 . It can also be different from the less converging portion  108 . As can be appreciated, by election of that shape, light incident upon primary reflecting surface  32  placed over side shift portion  109 R can be made less converging than main portion  102 . Such light would therefore tend to be directed more directly out and to the right of the page, e.g., when looking at the back of the reflector (i.e., the non-illustrated portion) in  FIG. 7A . For fixtures at aiming orientations to the target that otherwise would project light off of the target, section  109  can shift a substantial amount of that light back to the target. The typical side shift is approximately 60% of the 360° of the main reflector surface  32 . 
     Similarly,  FIGS. 8A-D ,  11 A-C, and  14 A-C illustrate variations of a left side shift. Section  109 L is added to reflector frame  30  to shift light that would otherwise converge towards the aiming axes of the reflector and then cross at axes to an off target site, and instead shift that portion of the light back to the target. 
     Note that  FIGS. 6-14  and sub parts illustrate but a few examples of configurations for portions  108  and  109 . Others are, of course, possible. 
     Beam customization is possible by taking advantage of the ability to easily build in variations to reflector frame  30 , such as less converging section  108  or side shift section  109 L or R. These sections of frame  30  can be readily manufactured with no or nominal extra cost because of the ability to cast frame  30 . Almost infinite beam shape possibilities exist also because of the ability to form any number of different reflective inserts  120  (with any number of reflective characteristics) that can be interchanged on frame  30 . 
     In addition to width of inserts  120 , other features may be modified to produce different reflective characteristics. For example, facets or other surface variations could be added to any insert  120  or portions thereof. One example is facets on inserts  120  used on side shift section  109 L or R. Another example is a stepped reflective surface. Another is a combination of facets or steps with smooth surfaces. Another is paint over a part of the reflective surface. Any of these could allow more customization and flexibility with regard to the shape and nature of the beam from fixture  10 . Examples of these types of surfaces for strip or sheet like high reflectivity material are described in U.S. Pat. No. 6,036,974. 
     Facets tend to diffuse light. Some inserts could have facets and some not in the same fixture  10 . This allows mixing and matching of light from each fixture, or relative to other fixtures in the system. An example use for faceted or stepped inserts is to remedy what is known in the art as “B pole phenomenon”. Stepped inserts in the upper 40%-60% of the fixture can be used to eliminate this problem. 
     The high reflectivity inserts not only increase the amount of light from the fixture over lower reflectivity reflecting surfaces like spun aluminum reflectors, but reduce glare and put more light on the field because of the precise control of light available with such efficient reflection. The reflector inserts  120  can be selected and mounted on the die cast reflector frame. The die cast reflector frame does not have to be changed for every desired change in light output. Although several different reflector frame styles can be made (e.g. left shift, right shift, no shift, etc.), it is not like spun aluminum reflectors where each beam shape requires specific manufacturing steps for each reflector. 
     An optional feature of inserts  120  is that they be stepped from inner end to outer end. One or more steps could serve to spread light in one direction (or take light away—e.g. reduce glare or spill). Each step can be formed over a die. They are a very efficient way to change the direction of light. They could be used instead of the side-shift version of the die cast reflector frame. They even could be put into conventional spun aluminum reflectors to shift light. 
     Just one insert could shift some of the light output of a fixture. For example, one stepped insert could spread light from one portion of the composite beam of a fixture (i.e. create a relatively small bump out from the perimeter of a generally circular beam. 
     Multiple stepped inserts could spread a larger portion, or all of the beam. Conversely, different shape stepped inserts could decrease the perimeter of a small, substantial, or whole beam. Steps would likely be no more than ¼ inch. More commonly they would be on the order of 0.080 or 0.160 inch in height per linear inch. Steps do not have to be constant in placement or height. 
     It can therefore be seen that selective use of inserts  120  can shift light from the beam of a fixture. This can be very useful for glare or spill light control. 
     It will be appreciated that inserts  120 , including the ability to change them out, provides substantial flexibility to fixture  10 . Using the same die cast or other reflector frame or main body, future modifications can be made. For example if the glare and spill light requirements for a certain lighting application become more severe after initial installation, inserts  120  could be changed to meet the new requirements. 
     The various beam shapes and configurations possible by shaping reflector frame  30  and selection of reflective inserts  120 , etc. has been described above. 
     D. Options and Alternatives 
     It will be appreciated the present invention can take many forms and embodiments. Variations obvious to those skilled in the art, which is defined solely by its claims. 
     There can be a slight overlap between inserts  120  (e.g. 0.060 inch).