具体实施方式：
[0017]Overview
[0018]Various embodiments set forth an improved components of lighting fixtures or lighting elements and improved methods of manufacturing components of lighting fixtures and lighting elements.
[0019]In conventional light fixtures and light fixture manufacturing processes, lots of material is required to manufacture components of the light fixture. Having extra material can increase the manufacturing and shipping cost for the components of the light fixture. Additionally, parts of components often have to be manufactured separately and assembled together to form the components. This can increase the time needed to manufacture and assemble the light fixture components. Further, conventional lighting components are typically limited to a particular size and shape depending on the mold used to create the lighting component. This limits the variety and selection of lighting components available.
[0020]The proposed lighting fixture or lighting element provides components of a lighting fixture with less material than traditional lighting fixture. Additionally, the pieces of the components of the lighting fixture may be manufactured as one piece and do not have to be assembled together to form the components. Further, the various components are not limited to a particular size and shape and can be a variety of shapes and sizes.
[0021]Additionally, the proposed manufacturing process of the lighting fixture or lighting element may include three-dimensional (“3D”) printing. The use of 3D printers can provide a significant advantage over prior manufacturing techniques (e.g., molding) in that less material is required to manufacture a lighting component using a 3D printing process than is necessary to manufacture a similar design that is molded in a die. In accordance with some implementations described below, 3D printing processes also provide significant illumination design advantages for components of a lighting fixture.
[0022]In a first aspect, a lighting element is provided. The lighting element might include a lighting element cover. The lighting element cover might include a wall comprising an inner surface, an outer surface attached to the inner surface, and one or more voids located between the inner surface and the outer surface of the wall.
[0023]The lighting element might include, without limitation, a light, a lightbulb, a light fixture, a light element, a luminaire, a lamp, a wall light, a night light, and/or any other type of light source, and/or the like. The lighting element cover might be a cover, a shade, or a housing for the lighting element.
[0024]In some embodiments, a width, a size, or a shape of the one or more voids may vary. In a non-limiting example, an internal width of the one or more voids varies along at a height of the one or more voids. In various cases, the one or more voids are triangle-shaped, square-shaped, rectangular-shaped, trapezoid-shaped, moon-shaped, or star-shaped, or any other shape. In some cases, an interior of the one or more voids is isolated from an outside environment.
[0025]In various instances, at least one inner surface of the one or more voids is formed from at least one of a reflective material, a refractive material, or a self-luminous material, or the at least one inner surface of the one or more voids is coated in the reflective material, the refractive material, or the self-luminous material. Additionally or alternatively, the one or more voids may be filled with at least one of a reflective material, a refractive material, or a self-luminous material. In various other embodiments, at least one inner surface of the one or more voids is formed from a material having a first color or coated in a coating material in the first color, and the first color is different from a wall color of the wall. Additionally or alternatively, the one or more voids may be filled with a material having a first color different from a wall color of the wall. In some instances, the one or more voids may have both a reflective, refractive, or self-luminous material and be a different color from a wall color of the wall.
[0026]In some embodiments, the one or more voids comprise one or more structures suspended in the one or more voids. The one or more structures suspended in the one or more voids may be curved, drooped, swooped, etc. In some instances, the one or more suspended structures may be formed from a reflective material, a refractive material, or self-luminous material. In other instances, the one or more structures may be a different color from the one or more voids or from a wall color of the wall. In some cases, the one or more structures may be made from both a reflective material, a refractive material, or self-luminous material and be a different color from the one or more voids and/or from a wall color of the wall.
[0027]The lighting element might further include a light source and a connector. The connector might be attached to the lighting element cover and/or the light source. The connector might include a conductive element extending through the connector and configured to provide an electrical connection to the light source. The connector might be configured to provide an electrical connection directly to the light source via the conductive element or indirectly to the light source through one or more intermediary components of the light source connected to the conductive element. In some case, the connector might include a base of the lighting element, a cover of the lighting element, a mount for the lighting element, a suspended mount (e.g., a mount to suspend a lighting element from a ceiling or a wall) for the lighting element, a wall mount for the lighting element, a side fixture of the lighting element, and/or any other connector or component configured to provide an electrical connection to the light source or an intermediary component of the light source. In some cases, the one or more intermediary components might include another light source, a control unit, a power supply, a ballast, a driver, a switch, a wire, and/or one or more other electrical components capable of providing an electrical connection to the light source.
[0028]In another aspect, a lighting element might include a light source, a light cover, and a connector. The light source might include a light, a lightbulb, a light emitting diode, a fluorescent light, an incandescent light, a halogen light, and/or the like. The light cover might include a wall comprising an inner surface, an outer surface attached to the inner surface, and one or more voids located between the inner surface and the outer surface of the wall. The connector might be attached to the light cover and the light source. The connector might include a conductive element extending through the connector and configured to provide an electrical connection to the light source. The connector might be configured to provide an electrical connection directly to the light source via the conductive element or indirectly to the light source through one or more intermediary components of the light source connected to the conductive element. In some case, the connector might include a base of the lighting element, a cover of the lighting element, a mount for the lighting element, a suspended mount (e.g., a mount to suspend a lighting element from a ceiling or a wall) for the lighting element, a wall mount for the lighting element, a side fixture of the lighting element, and/or any other connector or component configured to provide an electrical connection to the light source or an intermediary component of the light source. In some cases, the one or more intermediary components might include another light source, a control unit, a power supply, a ballast, a driver, a switch, a wire, and/or one or more other electrical components capable of providing an electrical connection to the light source.
[0029]In yet another aspect, a method of manufacturing a lighting element might be provided. The method of manufacturing might include forming a wall of a lighting element cover. Forming the wall of the lighting element cover might comprise forming an inner surface of the wall, forming an outer surface of the wall attached to the inner surface of the wall, and forming one or more voids between the inner surface and the outer surface of the wall.
[0030]In some instances, forming the wall might further include forming or depositing, using a three-dimensional (“3D”) printer, a first layer of material, forming or depositing, using the three-dimensional (“3D”) printer, one or more additional layers of the material on top of the first layer of the material or a preceding layer of the one or more additional layers, and bypassing, using the 3D printer, forming or depositing the material at one or more locations of the one or more additional layers between the inner surface and the outer surface of the wall.
[0031]In some embodiments, a width, a size, or a shape of the one or more voids may vary. In a non-limiting example, an internal width of the one or more voids varies along at a height of the one or more voids. In various cases, the one or more voids are triangle-shaped, square-shaped, rectangular-shaped, trapezoid-shaped, polygon-shaped, circular-shaped, tear-shaped, heart-shaped, moon-shaped, star-shaped, or any other shape or combination of shapes.
[0032]In various instances, at least one inner surface of the one or more voids is formed from at least one of a reflective material, a refractive material, or a self-luminous material, or the at least one inner surface of the one or more voids is coated in the reflective material, the refractive material, or the self-luminous material. Additionally or alternatively, the one or more voids may be filled with at least one of a reflective material, a refractive material, or a self-luminous material. In various other embodiments, at least one inner surface of the one or more voids is formed from a material having a first color or coated in a coating material in the first color, and the first color is different from a wall color of the wall. Additionally or alternatively, the one or more voids may be filled with a material having a first color different from a wall color of the wall. In some instances, the one or more voids may have both a reflective material, a refractive material, or a self-luminous material and be a different color from a wall color of the wall.
[0033]In some embodiments, the one or more voids comprise one or more structures suspended in the one or more voids. The one or more structures suspended in the one or more voids may be curved, drooped, swooped, etc. In some instances, the one or more suspended structures may be formed from a reflective material, a refractive material, or a self-luminous material. In other instances, the one or more structures may be a different color from the one or more voids or from a wall color of the wall. In some cases, the one or more structures may be made from both a reflective material, a refractive material, or self-luminous material and be a different color from the one or more voids and/or from a wall color of the wall.
[0034]Forming the one or more structures suspended in the one or more voids might include forming, using a three-dimensional (“3D”) printer, the one or more structures in the one or more voids by increasing an extrusion speed for extruding the one or more structures from the 3D printer as a 3D printer nozzle traverses over the one or more voids or slowing a nozzle speed of the 3D printer nozzle as the 3D printer nozzle traverses over the one or more voids.
[0035]In various cases, the method might further include forming a connector attached to the lighting element cover. The connector might include a conductive element extending through the connector and be configured to provide an electrical connection to a light source. The connector might be configured to provide an electrical connection directly to the light source via the conductive element or indirectly to the light source through one or more intermediary components of the light source connected to the conductive element. In some case, the connector might include a base of the lighting element, a cover of the lighting element, a mount for the lighting element, a suspended mount (e.g., a mount to suspend a lighting element from a ceiling or a wall) for the lighting element, a wall mount for the lighting element, a side fixture of the lighting element, and/or any other connector or component configured to provide an electrical connection to the light source or an intermediary component of the light source. In some cases, the one or more intermediary components might include another light source, a control unit, a power supply, a ballast, a driver, a switch, a wire, and/or one or more other electrical components capable of providing an electrical connection to the light source.
[0036]Forming the connector might include forming or depositing, using a three-dimensional (“3D”) printer, a first layer of material for the connector, forming or depositing, using the 3D printer, one or more additional layers of material on top of the first layer of material or a preceding layer of the one or more additional layers for the connector, and forming or depositing, using the 3D printer, a conductive element in the material of the connector to create the electrical connection.
[0037]In the following description, for the purposes of explanation, numerous details are set forth to provide a thorough understanding of the described embodiments. It will be apparent to one skilled in the art, however, that other embodiments may be practiced without some of these details. Several embodiments are described herein, and while various features are ascribed to different embodiments, it should be appreciated that the features described with respect to one embodiment may be incorporated with other embodiments as well. By the same token, however, no single feature or features of any described embodiment should be considered essential to every embodiment of the invention, as other embodiments of the invention may omit such features.
[0038]Similarly, when an element is referred to herein as being “connected,”“coupled,” or “attached” to another element, it is to be understood that the elements can be directly connected, coupled, or attached to the other element, or have intervening elements present between the elements. In contrast, when an element is referred to as being “directly connected,”“directly coupled,” or “directly attached” to another element, it should be understood that no intervening elements are present in the “direct” connection between the elements. However, the existence of a direct connection or direct attachment does not exclude other connections or attachments, in which intervening elements may be present.
[0039]Likewise, when an element is referred to herein as being a “layer” or “stratum” it is to be understood that the layer or stratum can be a single layer or strata or include multiple layers or strata. When a layer or stratum is described as being coupled or connected to another layer or stratum, it is to be understood that the coupled or connected layers or strata may include intervening elements present between the coupled or connected layers or strata. In contrast, when a layer or stratum is referred to as being “directly” connected or coupled to another layer or stratum, it should be understood that no intervening elements are present between the layers or strata. However, the existence of directly coupled or connected layers or strata does not exclude other connections in which intervening layers or strata may be present.
[0040]Additionally, it should be understood that spatial descriptions (e.g., “above,”“below,”“up,”“left,”“right,”“down,”“top,”“bottom,”“middle,”“vertical,”“horizontal,” etc.) used herein are for purposes of illustration only, and that practical implementations of the structures described herein can be spatially arranged in any orientation or manner.
[0041]Furthermore, the methods and processes described herein may be described in a particular order for ease of description. However, it should be understood that, unless the context dictates otherwise, intervening processes may take place before and/or after any portion of the described process, and further various procedures may be reordered, added, and/or omitted in accordance with various embodiments.
[0042]Unless otherwise indicated, all numbers used herein to express quantities, dimensions, and so forth should be understood as being modified in all instances by the term “about.” In this application, the use of the singular includes the plural unless specifically stated otherwise, and use of the terms “and” and “or” means “and/or” unless otherwise indicated. Moreover, the use of the term “including,” as well as other forms, such as “includes” and “included,” should be considered non-exclusive. Also, terms such as “element” or “component” encompass both elements and components comprising one unit and elements and components that comprise more than one unit, unless specifically stated otherwise.
[0043]Specific Exemplary Embodiments
[0044]We now turn to the embodiments as illustrated by the drawings. FIGS. 1-9 illustrate some of the features of the method, system, and apparatus for implementing improved lighting components, as referred to above. The methods, systems, and apparatuses illustrated by FIGS. 1-9 refer to examples of different embodiments that include various components and steps, which can be considered alternatives or which can be used in conjunction with one another in the various embodiments. The description of the illustrated methods, systems, and apparatuses shown in FIGS. 1-9 is provided for purposes of illustration and should not be considered to limit the scope of the different embodiments.
[0045]With reference to the figures, FIG. 1 is a schematic diagram illustrating a cover 100 of a lighting element or lighting fixture, in accordance with various embodiments. The cover 100 may be a lampshade, a housing for a light, a shade for the light, and/or the like. The cover 100 might be a cover for a lighting element (e.g., a light, a lightbulb, a light fixture, a light element, a luminaire, a lamp, a wall light, a night light, and/or any other type of light source, and/or the like). It should be noted that the various components of cover 100 are schematically illustrated in FIG. 1, and that modifications to the various components and other arrangements of cover 100 may be possible and in accordance with the various embodiments. In addition, although FIGS. 1-7 are described as separate embodiments for ease of description, a person of ordinary skill would understand that various modifications to each embodiment may be applied to other embodiments.
[0046]The cover 100 might include a wall 105 and one or more voids 110 (illustrated as dashed lines). The one or more voids 110 might be located between an outer surface 115 of the wall 105 and an inner surface (not shown) of the wall 105 of the cover 100. The outer surface 115 of the wall 105 and the inner surface of the wall 105 might have a smooth surface. Alternatively, in other cases, the outer surface 115 of the wall 105 and an inner surface of the wall 105 might have a rough or bumpy surface. In some cases, the outer wall 105 may be formed from a same material or have a same color as the inner wall. In other cases, the outer wall 105 may be formed from a different material or have a different color than the inner wall.
[0047]In some cases, the one or more voids 110 might be invisible, nearly invisible, or imperceptible to a human eye when not illuminated by a light source. However, when illuminated by the light source (not shown in FIG. 1), the one or more voids 110 might be perceptible or visible to the human eye and provide different lighting effects.
[0048]In some instances, an interior of the one or more voids 110 may be isolated from an outside environment. In other words, because the one or more voids 110 are located between the outer surface 115 of the wall 105 and the inner surface of the wall 105, the one or more voids 110 might not be exposed to the environment surrounding cover 100. This prevents the collection of dust and debris within the voids 110.
[0049]In various embodiments, the size and shape of the one or more voids 110 may vary. Alternatively, in other cases, the one or more voids 110 may be uniform throughout cover 100. In various cases, the one or more voids are triangle-shaped, square-shaped, rectangular-shaped, trapezoid-shaped, polygon-shaped, circular-shaped, tear-shaped, heart-shaped, moon-shaped, star-shaped, or any other shape, or combination of shapes. In some instances, an internal width of the one or more voids 110 may vary. The internal width of the one or more voids 110 may vary in any direction (e.g., along a height, a length, a width, etc.) of the one or more voids 110.
[0050]In some cases, an inner surface (not shown) of the one or more voids 110 may be formed from a different material from the cover 100. In a non-limiting example, an inner surface of the one or more voids 110 may be formed from at least one of a reflective material, a refractive material, a self-luminous material, a luminescent material, an electroluminescent material, a glow-in-the-dark material, a combination of these materials, and/or the like. Additionally or alternatively, an inner surface of the one or more voids 110 may be formed from a different color or a combination of different colors from the wall 105. In some cases, an inner surface of the one or more voids 110 may be formed from both a reflective material, a refractive material, a self-luminous material, a luminescent material, an electroluminescent material, a glow-in-the-dark material and a different color material from the wall 105 of the cover 100. Each of these may be used to create a different lighting effect in cover 100.
[0051]Alternatively, in other cases, the one or more voids 110 might be filled with a different material from the wall 105. In a non-limiting example, the one or more voids 110 may be filled with at least one of a reflective material, a refractive material, a self-luminous material, a luminescent material, an electroluminescent material, a glow-in-the-dark material. Additionally or alternatively, the one or more voids 110 may be filled with a material that is a different color from the wall 105. In some cases, the one or more voids 110 may be filled with both a reflective material, a refractive material, a self-luminous material, a luminescent material, an electroluminescent material, a glow-in-the-dark material and a different color material from the wall 105 of the cover 100. Each of these may be used to create a different lighting effect in cover 100.
[0052]An illustration of how the one or more voids 110 are formed in cover 100 is illustrated below with respect to FIG. 2.
[0053]FIGS. 2A-2E (collectively, FIG. 2) are schematic cross-sectional views of a portion of cover 200 (which may be similar to cover 100 of FIG. 1) as the cover 100 is being formed, in accordance with various embodiments. The schematic cross-sectional views of the portion of cover 200 may be cut along line A-A of FIG. 1. In a non-limiting example, FIGS. 2A-2E represent one example of how a void 205 can be created in cover 200. Other ways or methods may also be used to create voids 205. The cover 200 and/or void 205 may be created using a three-dimensional (“3D”) printing processes. It should be noted that the cover 200 is schematically illustrated in FIG. 2, and that modifications to the various components and other arrangements of cover 200 may be possible and in accordance with the various embodiments.
[0054]The cover 200 of FIG. 2 might be a cover, shade, or housing for a light element or lighting element (e.g., a light, a lightbulb, a light fixture, a luminaire, a lamp, a wall light, a night light, a chandelier, a ceiling light, and/or any other type of light source, and/or the like). The cover 200 might include a wall 202 having an outer wall surface 210 and an inner wall surface 215. The outer wall surface 210 may be attached to the inner wall surface 215. Attached to is defined herein as either directly or indirectly physically connected to, with any number of, or no intervening elements positioned between the outer wall surface 210 and the inner wall surface 215 which are attached to each other. The outer wall surface 210 and the inner wall surface 215 may be curved, angled, straight, or any combination curved, angled, or straight. The outer wall surface 210 and the inner wall surface 215 may also be smooth, bumpy, rough, and/or the like.
[0055]The outer wall surface 210 and the inner wall surface 215 may be formed by one or more layers 220 (e.g., layers 220a-220e). Although five layers are shown in FIG. 2, the cover 200 or the portion of the cover 200 might have more or less layers and should not be limited to only those layers shown in FIG. 2. By varying the number of layers 220, a height of the cover 200 might be adjusted.
[0056]Each layer 220 might include one or more strata 225 (e.g., strata 225a-225d). In a non-limiting example, each layer 220 might have one or more of an outermost stratum 225a, a second outermost stratum 225b, a second innermost stratum 225c, and an innermost stratum 225d. Although four strata are shown in FIG. 2, the cover 200 of the portion of the cover 200 might have more or less strata and should not be limited to only the strata shown in FIG. 2. By varying the number of strata 225, a thickness of the cover 200 may be adjusted. Additionally, the terms “stratum” and “strata” are used to avoid confusion with other portions of this specification where the term “layer” and “layers” are used. However, the strata 225 may themselves be one or more layers. Different hatching marks are used in FIG. 2 to identify portions of the wall 202 that are of the same stratum.
[0057]In some cases, the cover 200 may include one or more voids 205 located between the outer wall surface 210 and the inner wall surface 215. In various instances, the one or more voids 205 may be located between one or more strata 225. In some instances, there may be more than one void 205 across the strata 225. Thus, although only one void 205 is shown in FIG. 2, the cover 200 or a portion of the cover 200 may have more or less voids and should not be limited to the number of voids shown in FIG. 2.
[0058]Turning to FIG. 2A, FIG. 2A shows a cross-section of a cover 200 of with a first layer 220a being formed. The first layer 220a may be a base layer or bottom layer of cover 200. When the first layer 220a is a base layer, the first layer 220a may be used to attach the cover 200 to a lighting element, a base of a lighting element, or a light source. Alternatively, the first layer 220a may be located at another location within cover 200. The first layer 220a may be formed or deposited by a 3D printer.
[0059]The first layer 220a might be formed from four strata 225a-225d. For purposes of this example, each stratum 225a-225d may be formed or deposited in succession (e.g., first, forming the outermost stratum 225a, second, forming the second outermost stratum 225b, third, forming the second innermost stratum 225c, and fourth, forming the innermost stratum 225d). However, the layers 220 are not limited to formation based on the order listed above and may be formed in any other order. In some cases, the material used by the 3D printer to form each layer 220 and/or stratum 225 may harden before the next deposit sections are laid down.
[0060]Next, FIG. 2B shows a cross-section of the cover 200 with a second layer 220b or additional layer being formed. The second layer 220b may be formed or deposited on top of the first layer 220a. In some cases, the second layer 220b may be formed or deposited on top of the first layer 220a via a 3D printer.
[0061]FIG. 2B also shows the beginning of the formation of void 205 in cover 200. The void 205 may be formed between the outer wall surface 210 and the inner wall surface 215 of wall 202. In a non-limiting example, the void 205 may be formed between the outermost wall stratum 225a and the innermost wall stratum 225d.
[0062]In some cases, the void 205 may be created by not forming or depositing any material at one or more selected locations of cover 200. In a non-limiting example, in the second layer 220b, no material has been formed or deposited on top of the second outermost stratum 225b and the second innermost stratum 225c.
[0063]Alternatively, in other cases, the void 205 may be created by varying the width of the material deposited on a particular stratum (not shown). In a non-limiting example, the material that is deposited on top of the outermost strata 225a might have a smaller width than the outermost strata 225a. This technique may be used when there are only two strata (e.g., outermost strata 225a and innermost strata 225d), but is not limited to when there are only two strata.
[0064]Alternatively, in other cases, the void 205 may be formed using a combination of not depositing material on top of a particular stratum and also varying a width of material that is deposited on a different stratum. In a non-limiting example, in order to form void 205, the material that is deposited on top of the outermost strata 225a might have a smaller width that the outermost strata 225a and no material may be deposited on the second outermost stratum 225b.
[0065]Next, FIG. 2C shows a cross-section of a cover 200 of with a third layer 220c or additional layer being formed. The third layer 220c may be formed or deposited on top of the second layer 220b or preceding layer. In some cases, the third layer 220c may be formed or deposited on top of the second layer 220b via a 3D printer.
[0066]FIG. 2C also shows the continuing formation of void 205 in cover 200. The void 205 may be formed between the outer wall surface 210 and the inner wall surface 215 of wall 202. In a non-limiting example, the void 205 may be formed between the outermost wall stratum 225a and the innermost wall stratum 225d. The void 205 may be created by not forming or depositing any material at one or more selected locations of cover 200. In a non-limiting example, in the third layer 220c, no material has been formed or deposited on top of the second outermost stratum 225b and the second innermost stratum 225c.
[0067]Next, FIG. 2D shows a cross-section of a cover 200 of with a fourth layer 220d or additional layer being formed. The fourth layer 220d may be formed or deposited on top of the third layer 220c or preceding layer. In some cases, the fourth layer 220d may be formed or deposited on top of the third layer 220c via a 3D printer.
[0068]FIG. 2D also shows the continuing formation of void 205 in cover 200. The void 205 may be formed between the outer wall surface 210 and the inner wall surface 215 of the wall 202. In a non-limiting example, the void 205 may be formed between the outermost wall stratum 225a and the innermost wall stratum 225d. The void 205 may be created by not forming or depositing any material at one or more selected locations of cover 200. In a non-limiting example, in the fourth layer 220d, no material has been formed or deposited above the second innermost stratum 225c.
[0069]However, the fourth layer 220d does have material formed or deposited above the second outermost stratum 225b. In order to form or deposit material above the second outermost stratum 225b, material for the second outermost stratum 225b of the fourth layer 220d is formed or deposited so that the material adheres to the outermost stratum 225a of fourth layer 220d for structural support. Additionally, if the void 205 does not extend around an entire circumference or perimeter of the cover 200, the second outermost stratum 225b of the fourth layer 220d might further be supported by portions of the second outermost wall stratum 225b that are in front of or behind the void 205 of the second outermost stratum 225b of the fourth layer 220d.
[0070]In some cases, as shown in FIG. 2D, a thickness or a width (“W1” and “W2”) of the void 205 may vary along a height (“H”) of the void 205 as the one or more layers 220 are being deposited. For example, the void 205 has a first width W1 and a second width W2. By varying the width of the void 205, different lighting effects may be created (as shown in FIG.