KR20230118618A - Assembly and method for light emitting diode (LED) lighting fixtures in hot and hazardous locations using upright and sidelight lenses - Google Patents

Abstract

An embodiment of an LED light fixture assembly is provided. An LED luminaire assembly includes an LED assembly configured to emit light and a lens coupled to the LED assembly and forming a recess facing the LED assembly. The lens includes a sidewall defining an aperture sized to receive at least a portion of the LED assembly and a bottom opposite the aperture and coupled to the sidewall. The sidewall further includes one or more prisms positioned proximate the bottom and configured to direct light emitted from the LED assembly away from the bottom.

Description

Assembly and method for light emitting diode (LED) lighting fixtures in hot and hazardous locations using upright and sidelight lenses

Related Application Cross Reference

This patent application claims the benefit of U.S. Provisional Patent Application No. 63/124,342, filed December 11, 2020, titled "HARSH AND HAZARDOUS LOCATION LIGHT EMITTING DIODE (LED) LUMINAIRE ASSEMBLY AND METHOD WITH UPLIGHT AND SIDELIGHT LENS"; , the entire contents and disclosure of which are hereby incorporated by reference.

The field of the present disclosure generally relates to industrial luminaire assemblies for harsh and hazardous environments, and more specifically, light-emitting diodes (LEDs) for harsh and hazardous environments that provide sidelights and uplights. ) lighting apparatus and lens assembly and manufacturing methods.

To address the shortcomings of incandescent bulbs in traditional lighting configurations, there is a pressing need for more energy efficient and longer lasting light sources in the form of LEDs. LED luminaires are very efficient both in Lumens/Watt and in directing light towards the work surface. This high efficiency means that very little light is lost to the sides and above the luminaire, with ceilings and tops of interior walls considerably darker than work surfaces. However, certain installations in harsh and hazardous environments require some lighting on the ceiling above the pipe racks, other machines, or on the interior walls near the ceiling to see the surroundings. Therefore, improvement is required.

In one aspect, a light emitting diode (LED) light fixture assembly is disclosed. The assembly includes an LED assembly configured to emit light and a lens coupled to the LED assembly and defining a recess facing the LED assembly. The lens includes a sidewall defining an aperture sized to receive at least a portion of the LED assembly and a bottom opposite the aperture and coupled to the sidewall. The sidewall further includes one or more prisms positioned proximate the bottom and configured to direct light emitted from the LED assembly away from the bottom.

In another aspect, a lens for a light emitting diode (LED) assembly is disclosed. The assembly includes a sidewall defining an opening sized to receive at least a portion of the LED assembly and a bottom opposite the opening and coupled to the sidewall. The sidewall and the bottom define a recess toward the opening, and the sidewall further includes one or more prisms positioned proximate the bottom and configured to direct light emitted through the opening away from the bottom.

In another aspect, a method of manufacturing a light emitting diode (LED) light fixture assembly is disclosed. The method includes providing an LED assembly configured to emit light and a lens. The lens includes a sidewall defining an aperture sized to receive at least a portion of the LED assembly and a bottom opposite the aperture and coupled to the sidewall. The sidewall is formed proximate the bottom and further includes one or more prisms configured to direct light emitted through the aperture away from the bottom, the lens defining a recess. The method further includes engaging the LED assembly with the lens by directing a concave portion of the lens toward the LED assembly such that light emitted from the LED assembly is directed toward the bottom of the lens.

This patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
Non-limiting and incomplete embodiments are described with reference to the following drawings, in which like reference numbers refer to like parts throughout the various drawings unless otherwise specified.
1 is a polar diagram of a beam pattern of a known light emitting diode (LED) lighting fixture assembly.
2A is a front view of an exemplary light fixture assembly.
FIG. 2B is a side view of the light fixture assembly shown in FIG. 2A.
2C is a cross-sectional view of the luminaire assembly shown in FIG. 2A along line 2C-2C in FIG. 2B.
3A is a top perspective view of an exemplary lens for the light fixture assembly shown in FIG. 2A.
FIG. 3B is a bottom perspective view of the lens shown in FIG. 3A.
Figure 3c is a side view of the lens shown in Figure 3a.
FIG. 4A is an enlarged cross-sectional view along example line 4A-4A of a portion of the lens shown in FIG. 3A.
Figure 4b is a schematic diagram of light traveling through the lens shown in Figure 3a.
5 is a bottom view of the lens shown in FIG. 3A.
6A shows simulation results of an impact test for a lens with bullseye rings on the bottom of the lens.
6B shows simulation results of an impact test for a lens with bullseye rings and lenticular ribs on the bottom of the lens.
FIG. 7 is a polar diagram of beam diagrams of the known luminaire assembly of FIG. 1 and the luminaire assembly shown in FIG. 2A.
8 is a flowchart of an exemplary method of manufacturing the light fixture assembly shown in FIGS. 2A-6B.

Accordingly, disclosed herein are industrial light emitting diode (LED) luminaire assemblies and methods that provide desirable emission of sidelights and uplights for installation in harsh and hazardous locations. The suboptimal lighting of industrial existing LED assemblies, which undesirably lack the sidelights and uplights required for a particular installation, is avoided and substantial benefits realized. Method aspects are in part obvious, and will be discussed explicitly in part in the following description.

Various types of lighting fixtures using LEDs have been developed for many types of commercial and industrial environments. More specifically, LED lighting fixtures have been developed for lighting operations in harsh and hazardous environments, such as being designed to be explosion proof. These lighting fixtures are configured to be shock- and vibration-resistant without filament or glass breakage, to start immediately with instant full light, to not shorten life span due to switching cycles, and to reduce disposal costs.

Luminaire assemblies operating in hazardous environments present an explosion hazard through ignition of ambient gas or vapor dust, cellulose or airborne debris. Such hazardous environments may occur, for example, in petroleum refineries, petrochemical plants, grain silos, wastewater and/or treatment plants among other industrial plants, where volatile conditions result in and heighten fire or explosion in the surrounding environment. see the danger The safe operation of lighting fixtures within predetermined temperature limits in which the intermittent or continuous presence of ignitable gases, ignitable vapors or ignitable dusts, or other combustible substances in the air may, if exceeded, create a fire or an ignition source capable of exploding. There are substantial concerns regarding the safe and reliable operation of these installations, including but not limited to: Accordingly, a number of standards have been promulgated regarding the use of electrical products in explosive environments to improve safety in hazardous locations by taking into account the assessed probability of explosion or fire hazard.

For example, "UL" (Underwriter's Laboratories) standard UL 1203 sets forth Explosion-Proof and Dust-Ignition-Proof Electrical Equipment standards for hazardous locations. Electrical equipment manufacturers can receive UL certification of compliance with applicable rating standards for hazardous locations, and UL certification is a measure of a manufacturer's ability to successfully market a product in the North American market or other markets that accept UL Standard 1203. is an important aspect of

The National Electric Code (NEC) generally classifies hazardous locations by class and division. Class 1 locations are where flammable vapors and gases may be present. Class II locations are where combustible dust may be found. Class III locations are hazardous due to the presence of easily ignitable cellulose or airborne debris. Considering Class 1, Category 1 covers where flammable gases or vapors are present under normal operating conditions, under frequent repair or maintenance operations, or where a breakdown or faulty operation of process equipment may also cause simultaneous failure of electrical equipment. do. Class 1 represents a greater explosion hazard than Class 2, for example where flammable gases or vapors are normally handled in closed systems, confined within suitable enclosures, or normally prevented by positive pressure mechanical ventilation.

The International Electrotechnical Commission (IEC) likewise defines hazardous locations as Class I, Zones 0, 1, or Class I, which denote locations where flammable gases or vapors are or may be suspended in sufficient quantities to form explosive or ignitable mixtures. Categorized by 2. As defined by IEC, a Class I, Zone 0 location is a location where an ignitable concentration of a flammable gas or vapor is present continuously or for a prolonged period of time. A Class I, Zone 1 location is a location where ignitable concentrations of flammable gases or vapors are likely to exist, or where flammable concentrations of vapors are likely to be present, either because of repair or maintenance operations or because of leakage or possible release of ignitable concentrations of flammable gases or vapors. A possible class I, location adjacent to a Zone 0 location.

Although worded slightly differently, IEC Zone 1 and NEC Division 2 actually converge to a common place in the assessment of hazardous environments in general. In view of modern environmental regulations and the intensive nature of Class 1 and Zone 0 applications, any lighting fixtures installed in these hazardous locations must operate reliably at temperatures that are safe for the ambient atmosphere. As such, conventional LED lighting fixtures for hazard locations include more extensive heat sink features to dissipate heat than other types of lighting fixtures, and heat sinks can significantly complicate lighting fixture assemblies and also for hazard location LEDs. This can make the cost of the lighting equipment undesirably high.

In addition to the hazardous locations discussed above, so-called harsh locations also require particular focus in the design of the lighting fixtures used with them. Harsh locations are not necessarily explosive and/or may involve temperature cycling, pressure cycling, corrosive elements in the atmosphere subjected to shock and/or mechanical vibration forces, etc. that are not typically present in non-harsh working environments. Of course, some locations where LED lighting fixtures are desirably employed are harsh and hazardous in nature, and therefore heavy-duty fixtures designed to withstand a variety of operating conditions that typical lighting features for other applications cannot withstand.

LED luminaire assemblies are high intensity discharge (HID) lighting in both lumens/watts and aim light towards the work surface with extreme efficiency so that very little random light is emitted to the side and over the luminaire assembly. More efficient than instrument assemblies or incandescent lights. In contrast, older technologies such as HIDs or incandescent lamps can advantageously emit light in all directions, allowing a significant portion of the light to be directed both beside and above the light fixture. In certain types of known industrial LED luminaire assemblies, negligible sidelights or uplights are emitted from the luminaire assembly such that the sidelights and/or uplights illuminate the luminaire assembly and part of the ceiling above the wall. In certain installations, such as desirable harsh and/or hazardous locations, it creates an undesirable visual effect sometimes referred to as the cave effect. These sidelights and uprights advantageously and preferably allow the operator to locate pipe racks, machinery, or other surroundings that would otherwise be obscured by the cavernous effect in order to perform necessary tasks and take appropriate steps to ensure safety in harsh or hazardous environments. make it look more natural.

1 shows a polar diagram 101 of a beam pattern 111 of a known industrial LED assembly 103 suitable for use in harsh and/or hazardous locations. The LED assembly 103 is suspended from the ceiling at the center of the polar pole, positioned a distance below the 0° position on the polar pole and facing the floor extending generally perpendicular to the 0° position. The wall can also be positioned at some distance from the LED assembly 103 and, in typical installations, extend generally perpendicular to a plus or minus 90° position on the pole table. Upright zone 105 is a zone above the -90°/90° position, where a line connecting a position in uplight zone 105 with LED assembly 103 forms an angle greater than or equal to 90° or less than -90°; , a line 109 extends perpendicular to the floor, starting from the center. As described herein, an uplight is light emitted from the LED assembly 103 in the uplight zone 105 . A sidelight is light emitted from the LED assembly 103 in a plus or minus 60°-90° zone (which may be referred to as a sidelight zone 107). As shown by beam pattern 111, LED assembly 103 emits negligible sidelights and no uplight, so that the area directly beneath LED assembly 103 is brightly illuminated while the ceiling and Walls are usually not illuminated and thus create a dark cave effect. In industrial installations, the cave effect can negatively affect workers' ability to view or inspect, for example, overhead pipes, machinery or equipment located near walls, or other items of interest to workers in the industrial installation. can

The LED light fixture assembly of the present invention disclosed herein is preferably configured to increase the sidelights and uplights in the light emitted from the LED light fixture assembly. The cave effect on the LED luminaire assembly is significantly reduced if the light emitted from the LED luminaire assembly is not removed to allow the operator to see the surroundings of the work area, in addition to the work area itself. Although described in the context of an industrial environment that may be harsh and/or hazardous in nature, at least some of the advantages of the LED luminaire assembly of the present invention may likewise contribute to environments that are not necessarily harsh or hazardous. The description in these aspects is provided for purposes of illustration and not limitation.

2A-2C are views of an exemplary LED light fixture assembly 100 . 2A and 2B are front and side views of the LED light fixture assembly 100, respectively. FIG. 2C is a cross-sectional view of the LED light fixture assembly 100 along line 2C-2C of FIG. 2B. The LED light fixture assembly 100 includes an LED assembly 102 having one or more LEDs (not shown). The LED lighting fixture assembly 100 may further include a driver 106 and a driver housing 108 . A driver 106 is enclosed within the driver housing 108 and supplies power to the LEDs of the LED assembly 102 in a known manner. The LED light fixture assembly 100 may also include a heat sink 110 to dissipate heat generated by the LED assembly and/or driver 106 . The LED lighting fixture assembly 100 further includes a lens 112 . The lens 112 is configured to redirect light emitted from the LED assembly 102 to the side of the LED light fixture assembly 100 and onto the LED light fixture assembly 100 . In contemplated embodiments, assembly 100 is fabricated and assembled to meet the requirements of harsh and/or hazardous locations as described above.

In operation, driver 106 provides electricity to LED assembly 102 . As a result, the LED assembly 102 emits light toward the lens 112 . A portion of the light emitted from the LED assembly 102 is redirected by the lens 112 to the side of the LED light fixture assembly 100 and onto the LED light fixture assembly 100 . Accordingly, light emitted from the LED lighting fixture assembly 100 includes sidelights from the side of the LED lighting fixture assembly 100 and uplights above the LED lighting fixture assembly 100 . Accordingly, unlike the extreme table shown in FIG. 1, the LED lighting fixture assembly 100 emits light in the uplight zone 105 and the sidelight zone 107 to effectively reduce or eliminate the cave effect and poor or dangerous It avoids the associated drawbacks for installation in the environment.

3A-3C show an exemplary embodiment of lens 112 . 3A and 3B are top perspective and bottom perspective views of lens 112, respectively. 3C is a side view of lens 112 . Lens 112 is made of a translucent or transparent material such as glass or plastic. Lens 112 includes a sidewall 302 and a bottom 304 coupled to sidewall 302 .

In the exemplary embodiment, sidewall 302 defines an opening 306 opposite bottom 304 . The aperture 306 is such that, when the lens 112 is installed on the LED light assembly 100, the lens 112 forms a dome over at least a portion of the LED assembly 102. is sized to accommodate. Sidewall 302 slopes outward at end 308 proximate opening 306 and forms an upside-down flare with angle 303 to vertical line 305 (FIG. 3C). . An exemplary angle 303 is 12°, but larger or smaller angles are possible in other embodiments. The dimension of upper portion 320 of lens 112 is greater than the dimension of lower portion 322 of lens 112 . The inclined sidewall 302 refracts and diffuses light emitted from the LED assembly 102 that strikes the inclined sidewall 302 to provide sidelights. Sidewall 302 and bottom 304 form a recess 309 towards the opening. End 308 of sidewall 302 extends laterally from the center of lens 112 and may be formed into a flange 310 . Flange 310 is used to couple lens 112 to LED light fixture assembly 100 by which flange 310 is inserted into groove 220 of LED light fixture assembly 100 (see FIG. 2C ). .

In an exemplary embodiment, sidewall 302 further includes a lenticular ring 312 positioned on an outer surface of sidewall 302 . The interior surface 316 of the lens 112 is smooth, such that there are no protrusions or recesses. Sidewall 302 also includes one or more prisms 314 at a portion of the sidewall that merges with bottom portion 304 . The cross-section of the side wall is circular in the illustrated example, but may take other shapes such as rectangular, elliptical, or polygonal.

In an exemplary embodiment, lens 112 is manufactured as one piece. Lens 112 may be manufactured by molding.

4A is an enlarged cross-sectional view along line 4A-4A of FIG. 3A of a portion of lens 112, showing lenticular rings 312 and prisms 314. 4B is a schematic diagram of light traveling through a prism 314 of a lens 112 . In an exemplary embodiment, lenticular rings 312 are positioned on the outer surface of sidewall 302 and protrude from the outer surface. Lenticular rings 312 are convex. Lenticular rings 312 may be parallel to each other. In one example, the lenticular rings 312 are generally horizontal when the lens 112 is placed upright by itself. In some embodiments, neighboring or adjacent lenticular rings 312-l and 312-s have different radii of curvature. For example, lenticular ring 312-l has a radius of curvature of about 3.2 mm (0.125 in.), and lenticular ring 312-s has a radius of curvature of about 0.5 mm (0.02 in.). (see Fig. 3c). Neighboring lenticular rings with different radii of curvature also diffuse the light. In one example, the distance 315 between two adjacent lenticular rings 312-l having a larger radius is about 4.3 mm (0.17 in.) (see FIG. 3C).

In an exemplary embodiment, prisms 314 are convex. Prisms 314 are positioned proximate the junction between bottom 304 and sidewall 302 . The cross section of the prism is approximately triangular. An exemplary angle in a triangular cross section is 48° (see FIG. 3C ). The edge 317 of the prism 314 may be a curved surface curved along a direction perpendicular to the edge (FIG. 4B). In other words, the two surfaces of prism 314 intersect and form a rounded edge instead of a sharp edge. The rounded edge 317 helps diffuse the light that strikes the edge 317 . An exemplary radius of curvature of edge 317 is 0.8 mm (0.03 in.) (see FIG. 3C ). In one example, prism 314 is a total internal reflection (TIR) prism, where light is fully reflected as it travels from the medium of lens 112 into the air. For example, light 318 emitted from LED assembly 102 travels to sidewall 302 and is refracted by sidewall 302 . When the light 318 also travels to the interface 321 between the medium and air of the lens 112, the angle of incidence of the light 318 is greater than the critical angle of the lens 112 to the medium and air, and the light 318 is completely reflected by the silver interface 321. The reflected light 323 travels upward, providing an uplight to the LED light fixture assembly 100 . The lens 112 shown in FIGS. 3B and 4B includes two prisms. The number of prisms is determined by the amount of uprights and/or sidelights required depending on the design of the prisms 314 . The radius and spacing of the lenticular rings 312 may also be adjusted to achieve a desired amount of sidelighting. An exemplary distance between two adjacent prisms 314 is 2.2 mm (0.09 in.) (see FIG. 3C).

5 is a bottom view of lens 112 . In an exemplary embodiment, the bottom portion 304 is convex and may be formed as a spherical dome. Bottom 304 may include lenticular ribs 502 . Lenticular ribs 502 are located along the outer surface of bottom 304 . The lenticular ribs 502 diffuse the light and eliminate hot spots. The lenticular ribs 502 also strengthen the structure of the lens 112 and reduce stress during potential impact. Lenticular ribs 502 may be formed and grouped into a plurality of sections 504 . Sections can divide the bottom into equal sections 504 , which sections 504 have equal central angles 506 . The lenticular ribs 502 in one section 504 may be parallel to each other. The radii of curvature of the lenticular ribs in one section can vary. The spacing between neighboring lenticular ribs may also vary. The varying radii and spacing help diffuse the light emitted from the LED assembly 102 . The central lenticular rib or transverse ribs 502-c of each section 504 converge towards a point 510 located in the central region 505 of the bottom 304 surrounding the apex of the bottom 304. In one example, point 510 is the apex of bottom 304 . Central lenticular ribs 502 - c can divide section 504 into two subsections having the same central angle 506 . Bottom 304 may be of other shapes, such as a polyhedron. Base 512 of bottom 304 where bottom 304 and sidewall 302 intersect is spherical in the illustrated embodiment. Base 512 may be of other shapes, such as a polygon. Lenticular ribs may be shaped or formed in patterns other than those shown. Variations and adaptations of the shape, geometry, curvature, dimensions, and angular position of the described features are capable of realizing at least some of the described advantages.

6A and 6B show simulation results of a stress test of a lens 112-b with bullseye lenticular ribs and a lens 112-b-c with bullseye lenticular ribs and transverse ribs 502-c. Stress on the lens is simulated when a smooth steel sphere is dropped from a fixed distance onto the lenses 112-b and 112-b-c. The maximum stress on lenses 112-b-c is approximately 15% less than the maximum stress on lenses 112-b. Compared to the bullseye lenticular ribs, the transverse ribs 502-c are more resistant to impact from impact. It reduces the stress on the lens and reduces the likelihood that the lens will break from impact.

FIG. 7 is a polar table 700 that includes a comparison of the beam pattern 111 of the known light fixture assembly of FIG. 1 and the beam pattern 701 of the LED light fixture assembly 100 as described herein. The amount of uplight 702 is approximately 5% and the amount of sidelight 704 is approximately 18%, which is within the desired ranges of approximately 12% to 20% for sidelights and approximately 5% for uprights. Thus, more optimal lighting is created for harsh and hazardous locations, improving situational awareness and safety for workers who would otherwise be hampered by the cave effect caused by conventional LED light fixture assemblies.

8 is a flow diagram of an exemplary method 800 of manufacturing an LED light fixture assembly. The method 800 includes step 802 of providing an LED assembly and a lens configured to emit light. The lens includes a sidewall and a bottom. The sidewall of the lens defines an aperture sized to receive at least a portion of the LED assembly. The bottom is positioned opposite the opening and is joined to the side wall. The sidewall further includes one or more prisms positioned proximate the bottom and configured to direct light emitted through the aperture away from the bottom, the lens forming a recess. The method 800 also includes a step 804 of coupling the LED assembly with the lens by directing a concave portion of the lens toward the LED assembly such that light emitted from the LED assembly is directed toward the bottom of the lens.

At least one technical effect of the LED light fixture assemblies and methods described herein is that (a) prisms redirect and provide uplight and sidelight emission of LED light; (b) lenticular rings positioned on the exterior of the lens to diffuse the LED light and provide sidelights; (c) Lenticular ribs are positioned on the bottom of the lens to diffuse the LED light and strengthen the structure of the lens.

It is now considered that the benefits and advantages of the inventive concepts have been fully illustrated with respect to the disclosed exemplary embodiments.

An embodiment of an LED light fixture assembly is provided. An LED luminaire assembly includes an LED assembly configured to emit light and a lens coupled to the LED assembly and forming a recess facing the LED assembly. The lens includes a sidewall defining an aperture sized to receive at least a portion of the LED assembly and a bottom opposite the aperture and coupled to the sidewall. The sidewall further includes one or more prisms positioned proximate the bottom and configured to direct light emitted from the LED assembly away from the bottom.

Optionally, one or more prisms are TIR prisms. An edge of one or more prisms is a curved surface along a direction perpendicular to the edge. The sidewall of the lens contains two prisms. The bottom of the lens further includes lenticular ribs located along an outer surface of the bottom. At least some of the lenticular ribs converge towards a point in the central region of the bottom. The sidewall of the lens further includes lenticular rings located on an outer surface of the sidewall and wrapped around the sidewall, the lenticular rings directing light emitted from the LED assembly to and away from the luminaire assembly. configured to direct Neighboring lenticular rings have different radii of curvature. The lens includes a smooth inner surface. The sidewall slopes outward at the end of the sidewall proximal to the opening and forms an upside-down flare. The luminaire assembly is configured to emit approximately 5% uplight. The light fixture assembly is configured to emit sidelights ranging from approximately 12% to approximately 20%.

An embodiment of a lens for a light emitting diode (LED) assembly is disclosed. The lens includes a sidewall defining an aperture sized to receive at least a portion of the LED assembly and a bottom opposite the aperture and coupled to the sidewall. The sidewall and the bottom define a recess toward the opening, and the sidewall further includes one or more prisms positioned proximate the bottom and configured to direct light emitted through the opening away from the bottom.

Optionally, one or more prisms are TIR prisms. An edge of one or more prisms is a curved surface along a direction perpendicular to the edge. The sidewall includes two prisms. The bottom of the lens further includes lenticular ribs located along an outer surface of the bottom, at least some of the lenticular ribs converging toward a point in a central region of the bottom. The sidewall of the lens further includes lenticular rings located on an outer surface of the sidewall and wrapped around the sidewall, the lenticular rings being configured to direct light emitted from the LED assembly beside and away from the lens, the lenticular rings being configured to direct light emitted from the LED assembly beside the lens and away from the lens. The rings have different radii of curvature. The sidewall slopes outward at the end of the sidewall proximal to the opening and forms an upside-down flare.

An embodiment of a method of manufacturing a light emitting diode (LED) light fixture assembly is disclosed. The method includes providing an LED assembly configured to emit light and a lens. The lens includes a sidewall defining an aperture sized to receive at least a portion of the LED assembly and a bottom opposite the aperture and coupled to the sidewall. The sidewall is formed proximate the bottom and further includes one or more prisms configured to direct light emitted through the aperture away from the bottom, the lens defining a recess. The method also includes coupling the LED assembly with the lens by directing a concave portion of the lens toward the LED assembly such that light emitted from the LED assembly is directed toward the bottom of the lens.

Although exemplary embodiments of components, assemblies, and systems are described, variations of the components, assemblies, and systems are possible to achieve similar benefits and effects. Specifically, the shapes and geometries of components and assemblies, and the relative positions of components in an assembly, may be changed from what is described and shown without departing from the described inventive concept. Also, in certain embodiments, certain components in the described assemblies may be omitted to accommodate the needs of certain types of light fixture assemblies and/or lenses or certain installations while still providing requisite performance and functionality.

The description thus set forth, including the best mode for enabling a person skilled in the art to practice the invention, including making and using any devices or systems, and performing any integrated methods, describes the invention. It is to do. The patentable scope of the present invention is defined by the present claims and may include other examples that may occur to one skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims (20)

A light-emitting diode (LED) lighting fixture assembly,
an LED assembly configured to emit light; and
A lens coupled to the LED assembly and forming a recess facing the LED assembly, the lens comprising:
a sidewall defining an opening sized to receive at least a portion of the LED assembly; and
comprising a bottom opposite the opening and coupled to the sidewall;
wherein the sidewall further includes one or more prisms positioned proximate the bottom and configured to direct light emitted from the LED assembly away from the bottom. The light fixture assembly of claim 1 , wherein the one or more prisms are total internal reflection (TIR) prisms. The lighting fixture assembly of claim 1 , wherein the edge of the one or more prisms is a curved surface curved along a direction perpendicular to the edge. The light fixture assembly of claim 1 , wherein the sidewall of the lens includes two prisms. The light fixture assembly of claim 1 , wherein the bottom of the lens further comprises lenticular ribs located along an outer surface of the bottom. 6. The light fixture assembly of claim 5, wherein at least some of the lenticular ribs converge toward a point in a central region of the bottom portion. The method of claim 1 , wherein the sidewall of the lens further comprises lenticular rings positioned on an outer surface of the sidewall and wrapped around the sidewall, the lenticular rings emitting the light emitted from the LED assembly. and configured to direct the light fixture assembly laterally and away from the light fixture assembly. 8. The light fixture assembly of claim 7, wherein neighboring lenticular rings have different radii of curvature. The light fixture assembly of claim 1 , wherein the lens comprises a smooth interior surface. The light fixture assembly of claim 1 , wherein the sidewall slopes outward at an end of the sidewall proximate the opening and forms an upside-down flare. The light fixture assembly of claim 1 , wherein the light fixture assembly is configured to emit approximately 5% uplight. The light fixture assembly of claim 1 , wherein the light fixture assembly is configured to emit sidelights in the range of about 12% to about 20%. A lens for a light emitting diode (LED) assembly,
a sidewall defining an opening sized to receive at least a portion of the LED assembly; and
a bottom opposite the opening and coupled to the sidewall;
wherein the sidewall and the bottom form a recess toward the opening, the sidewall further comprising one or more prisms positioned proximate the bottom and configured to direct light emitted through the opening away from the bottom. phosphorus, lens. 14. The lens of claim 13, wherein the one or more prisms are total internal reflection (TIR) prisms. 14. The lens of claim 13, wherein the edge of the one or more prisms is a curved surface curved along a direction perpendicular to the edge. 14. The lens of claim 13, wherein the sidewall comprises two prisms. 14. The lens of claim 13, wherein the bottom of the lens further comprises lenticular ribs located along an outer surface of the bottom, at least some of the lenticular ribs converging towards a point in a central region of the bottom. 14. The apparatus of claim 13, wherein the sidewall of the lens further comprises lenticular rings positioned on an outer surface of the sidewall and wrapped around the sidewall, the lenticular rings directing light emitted from the LED assembly to and away from the lens. wherein the lens is configured to direct away from the lens, wherein neighboring lenticular rings have different radii of curvature. 14. The lens of claim 13, wherein the sidewall slopes outward at an end of the sidewall proximate the aperture and forms an upside-down flare. A method of manufacturing a light emitting diode (LED) light fixture assembly, comprising:
providing an LED assembly configured to emit light and a lens, the lens comprising:
a sidewall defining an opening sized to receive at least a portion of the LED assembly; and
a bottom opposite the opening and coupled to the sidewall;
the sidewall further comprises one or more prisms formed proximate the bottom and configured to direct light emitted through the aperture away from the bottom, the lens forming a concave; and
coupling the LED assembly with the lens by directing the concave portion of the lens toward the LED assembly such that light emitted from the LED assembly is directed toward the bottom of the lens.

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