WO2025162757A1

WO2025162757A1 - A modular system comprising an elongated sheet metal structure

Info

Publication number: WO2025162757A1
Application number: PCT/EP2025/051365
Authority: WO
Inventors: Jacobus Petrus Johannes VAN OS; Marc Andre De Samber; Coen Theodorus Hubertus Fransiscus Liedenbaum
Original assignee: Signify Holding BV
Current assignee: Signify Holding BV
Priority date: 2024-01-30
Filing date: 2025-01-21
Publication date: 2025-08-07
Anticipated expiration: 2026-07-30

Abstract

There is provided a modular system (1), which comprises an elongated sheet metal structure (10) and one or more functional modules (20). Each functional module comprises a module support structure (22) and a functional element (30). The module support structure is configured to be mounted to the elongated sheet metal structure to support the functional element. The elongated sheet metal structure comprises an elongated reflective surface (12) that is curved perpendicular to an elongation direction (L), arranged to reflect electromagnetic radiation. The functional element has an operational direction range for emitting and/or receiving electromagnetic radiation. The functional element is placed such that the operational direction range faces the elongated reflective surface. The elongated sheet metal structure has a stiffness enabling it to resist deformation when supporting a weight of the functional modules in a mounted state.

Description

A MODULAR SYSTEM COMPRISING AN ELONGATED SHEET METAL STRUCTURE

FIELD OF THE INVENTION

The present invention generally relates to a modular system. More specifically, the present invention is related to modular systems interacting with electromagnetic radiation.

BACKGROUND OF THE INVENTION

Linear luminaires with long lengths made from polymers (plastics, papers etc.) tend to bend by gravity over time. Gravity force will introduce creep to the material and finally end up in deformation, sagging, from original shape in a way that is not acceptable for customers. Creep deformation is time and temperature dependent and can occur in metals (when close to melting temperatures) and in polymers. In general, materials will permanently deform well below their yield point when exposed to long-term stress and ill-suited temperature. Therefore, many track lighting solutions are made by extruded aluminum profiles which does not show this creep.

Metals used far below their melting temperature, do not show this creep deviation and therefore many ‘track lighting’ solutions are made by extruded aluminum profiles. Often the electronic system for conducting power to the light sources is integrated with the extruded profile.

US 5584566 A discloses a light fixture having a reflector and a lamp support portion. A first attachment portion is attached to an inside surface of the reflector at the lamp support portion. A light source is provided with a second attachment portion. The first and second attachment portions are detachably attachable together so that the light source can be detachably affixed to the inside surface of the reflector and lamp support portion.

If a lighting system architecture is considered, suspended over long length under a ceiling, one can consider the lighting system as build up with light engines with LEDs and optical/thermal solutions to convert electricity to the right level of artificial light. The lighting system typically further comprises mechanical parts to hold the light engines, e.g. extruded profiles, electrical conductors to provide the power and addressability to the light engines and aesthetic parts, e.g. cover parts etc.

Extruded aluminum profiles are typically designed as a relatively bulky support structure to which different components are mounted, requiring large mounting efforts. Moreover, each design of a luminaire typically requires a separately designed extrusion tool.

Today, luminaires are often also combined with different kinds of sensor techniques. Integration of such additional functionalities often calls for modification of the extruded aluminum profile design.

Moreover, sensors as well as light emitters have often sensitive parts that typically are exposed to directly to the spaces of interest. Such sensors may be vulnerable to fouling or damage, and accidental damaging or contamination are sometimes highly problematic.

It is therefore acknowledged that the concept of linear systems still need some improvements concerning for instance flexibility.

SUMMARY OF THE INVENTION

It is an object of the present invention to facilitate the design, production and mounting of systems having functionalities based on emission or sensing of electromagnetic radiation. It is also an object of the present invention to provide a flexibility to systems interacting with electromagnetic radiation to enable modifications and adaptions without need for changes in supporting parts. It is also an object of the present invention to provide systems offering improved damage protection for functional elements.

These and other objects are achieved by providing modular systems having the features in the independent claim. Preferred embodiments are defined in the dependent claims.

According to one aspect of the present technology a modular system comprises an elongated sheet metal structure and one or more functional modules. Each of the one or more functional modules comprises a module support structure and a functional element. The module support structure is configured to be mounted to the elongated sheet metal structure to support the functional element relative to the elongated sheet metal structure. The elongated sheet metal structure comprises an elongated reflective surface that is curved perpendicular to an elongation direction so as to present an at least partly concave surface to the functional element. The elongated reflective surface is arranged to reflect electromagnetic radiation. The functional element is provided at a non-zero distance from the elongated reflective surface. The functional element has an operational direction range for emitting and/or receiving electromagnetic radiation. The functional element is placed such that the operational direction range at least partly faces the elongated reflective surface. The elongated sheet metal structure has a stiffness enabling the elongated sheet metal structure to resist deformation when supporting a weight of the one or more functional modules in a mounted state of the modular system. In other words, the material and shape of the elongated sheet metal structure provides the elongated sheet metal structure with a stiffness sufficient to carry the weight of the one or more functional modules in a mounted state of the modular system without affecting the general shape elongated sheet metal structure. Preferably, the mounted state is a suspended state in which the modular system is fastened and suspended from a fastening surface. The elongated sheet metal structure is configure to resist deformation, wherein a direction of deformation may be defined as being perpendicular to the elongation direction, preferably in a direction of gravity.

Based on a use of a sheet metal, both for carrying the weight of different functional elements attached thereto and for controlling the path of electromagnetic radiation to/from the functional elements, a simple, flexible and compact basic concept is achieved. The electromagnetic radiation part of the functional elements will be combined with the mechanical part of the sheet metal, making this concept a kind of ultimate simplicity modular system.

In other words, the optical reflecting sheet metal is bent to a specific shape to form a long profile. The long profile will have a reflective surface to reflect light in defined beam directions. The mechanical stability of the metal sheet will prevent over-time sagging and deformation without the need for additional support structure, leading to a highly simplified construction. The sheet metal thereby constitutes a mechanical backbone structure for the modular system. Different light modules and other functional modules on optical tracks of the sheet metal allows for customized light patterns. Such track constructions thereby allow for a characteristic luminaire design platform.

Reversibly mounted in the context of this invention needs to be interpreted in that the module support structure can be releasably mounted to the elongated sheet metal structure. The module support structure may be attached in a first position along the elongated sheet metal structure and may subsequently be detached to be attached again in a second position along the elongated sheet metal structure. Reversibly may further mean that both the module support structure and the elongated sheet metal structure remain unaltered and may be changed back to their original state. In other words, mounting the module support structure may not require any irreversible structural modifications, such as creating mounting holes in the sheet metal.

The module support structure is configured to be reversibly mounted at a (freely) selectable position along the elongation direction, thus in other words a position of choice or a desired position. In practice, the module support structure may be configured to be reversibly mounted in any position along the elongation direction, allowing for complete freedom in positioning. Alternatively the module support structure may be at least be mounted in any position within predetermined limits, or may be mounted to predetermined locations, offering a selection of possible positions.

The plurality of functional modules may be mounted in a linear configuration along the elongation direction. In other terms, a linear configuration means that the functional modules are arranged in a straight line, one after the other, along the length of the elongated sheet metal structure. The elongated sheet metal structure may have a first length LI extending in the elongation direction (L) and each of the one or more functional modules may have a module length LM extending in the elongation direction (L). The length of the elongated metal sheet structure LI may be at least three times longer, such as five times longer, especially more than 10 times longer than the module length of the one or more functional module.

Such an elongated sheet metal structure which is multiple times longer than the one or more functional modules attached to it allows for customized design using multiple light modules and other functional modules across an extended length, such as for large indoor spaces.

In examples, in which the modular system comprises multiple functional modules, the functional modules may each have different lengths. The functional modules of the one or more functional modules having the longest module length LM in the elongation direction may be considered to determine the minimum length of the elongated sheet metal structure.

The functional elements can be of different kinds, and different kinds of functional elements can be combined in a single modular system. One particularly useful functional element is a lighting element. To this end, in one embodiment, the functional element in at least one of the one or more functional modules is a lighting element. The modular system may then be considered as a modular luminaire system. Another particularly useful functional element is a sensing element. Therefore, in one embodiment, the functional element in at least one of the one or more functional modules is a sensing element. The modular system may then be considered as a modular sensor system. This can also be combined with lighting elements, giving a modular system having luminating as well as sensing functionalities. In a further embodiment, the sensing element is a sensor for sensing electromagnetic radiation impinging from the elongated reflective surface. In other words, a reverse optical pathway of e.g. luminaire optics is used for bringing monitoring information such as e.g., presence detection, towards the sensor. Furthermore, this reverse optical pathway may be provided by the very same reflective surface that may serve for distributing light from a lighting element, which reduces the need for separate optical arrangements for lighting and sensing, respectively.

The elongated sheet metal structure may further have a first width W 1 extending in a transverse direction, perpendicular to the elongation direction and the module support structure may have a module width WM extending in the transverse direction. The module width WM may be equal to or larger than the first width W 1.

A module support structure with a width being equal to or later than the width of the elongated sheet metal structure has the advantage that the module support structure may be mounted to a first edge and a second edge of the sheet metal structure or to the outer surface of the elongated sheet metal structure, for example by mounting means (such as mounting lips) located at one or both edges of the elongated sheet metal structure. Mounting the module support structure to an outer surface of the elongated sheet metal may have the advantage that the optical disturbances caused by the module support structure are reduced.

Since at least the main effect of the modular system relies on reflected light, a large part of the operational direction range faces preferably the elongated reflective surface, in order not to lose efficiency. At least 70%, such as at least 80%, especially at least 90% of the operational direction range may face the elongated reflective surface.

Furthermore, in order to provide an efficient modular system and to preserve the electromagnetic energy, the reflection of the elongated reflective surface may be high. To this end, the reflective surface may have a reflectance of at least 80%, such as at least 90%, especially at least 95%.

Many systems operate with different types of light and electromagnetic radiation, and the reflective surface may therefore be reflective for the intended wavelengths. In one embodiment, the reflective surface is reflective for electromagnetic radiation in the wavelength range of at least 100 nm to 1 mm, which involves most practically used light wavelengths.

The optical properties of the elongated reflective surface are provided by the reflectivity and the curved shape. The curved shape additionally provides the modular system with an additional stiffness that may be used for supporting purposes as well. This reduces the need for additional supporting structure that otherwise would have increased the complexity and/or weight. The elongated sheet metal structure has a first length LI. In one embodiment, being appropriate for most applications, the deflection of the elongated sheet metal structure perpendicular to the elongation direction is less than 1% of the first length in a mounted state of the lighting system.

The elongation shape of the reflective surface may be of different kinds. The present invention is well adapted to be used in applications having a linear structure, e.g. as typical (track) lighting systems. Therefore, in one embodiment, the elongation of the reflective surface is linear. However, the present ideas are not limited to this. In another embodiment, the elongation of the reflective surface is curved.

The structural stiffness enables the elongated sheet metal structure to act as a support for the functional elements, for holding them at suitable non-zero distances from the reflective surface. In one embodiment, the non-zero distance is in the range of 1 mm to 50 mm. The support of the functional element is mediated by the one or more functional modules. In one embodiment, a functional module is configured to be reversibly mounted to the sheet metal structure. In another, alternative or complementary, embodiment, a functional module is configured to be displaceable along the elongation direction of the sheet metal structure. By using the sheet metal, not only as a reflective surface in the optical operation of the modular system, but also as the main supporting member for the functional elements, the functional elements can easily be provided in suitable positions with respect to the sheet metal.

The elongated reflective surface can be shaped in various ways. One approach is to use the space on both sides of the functional elements, thereby utilizing the available space in an efficient manner. In one such embodiment, the elongated reflective surface comprises two curved, elongated reflective surface portions. The elongated reflective surface portions are arranged side-by-side in a transverse direction, perpendicular to the elongation direction. The elongated reflective surface portions are separated by an edge, protruding towards the functional element(s). The edge may comprise a sharp bend line having a radius R being smaller than the thickness of the sheet metal structure. This double folding of the sheet metal assembly enables adaptation of the two reflective surface portions in separate ways. If a symmetric operation is requested, the different sides could be provided as mirror structures of each other. However, if different operations are requested in different directions, the two sides can be adapted separately.

The functional element may be positioned at the center of the elongated sheet metal structure in the transverse direction. In examples in which the elongated sheet metal structure comprises two reflective surface portions separated by an edge, the functional element may be positioned substantially below the edge.

The functional module may be involved in the structural support of the modular system, such as being further adopted for assisting in fastening of the entire modular system to other surfaces. In one embodiment, at least one functional module of the one or more functional modules thereby further comprises attachment means for fastening the modular system to a fastening surface. Also other components useful for the operation of the modular system or the functional elements can be incorporated into the functional modules. In one embodiment, at least one functional module of the one or more functional modules further comprises electronics, a driver, a heat sink and/or a controller.

In the present disclosure “one or more functional elements” also encompasses two or more functional elements or a plurality of functional elements.

In the present disclosure “functional module” refers to a physically delimitated unit comprising one or more functional elements.

In the present disclosure “module support structure” refers to mechanical parts bearing the weight of a functional module and defining a position of the functional module in space. The module support structure may also be referred to as module support frame, module support casing, module support fixture, module support body, or module support skeleton.

In the present disclosure “functional elements” refer to lighting elements, sensing elements or connector parts, for example LEDs or specific sensors.

In the present disclosure “lighting element” refers to any element that is capable of emitting light, such as visible light, infrared light or UV light. LED elements are non-exclusive examples of lighting devices.

In the present disclosure “sensing element” refers to any element that is capable of detecting a physical condition of its environment. A sensing element is therefore any element that, by being responsive to electromagnetic radiation, is able to detect physical conditions associated thereto. A non-exclusive example of a sensing element is a light sensor. The light sensor may for instance be a passive infrared sensor (PIR) and/or a visible light sensor.

In the present disclosure “operational direction range” refers to the range of directions from/to which a functional element receives/emits the electromagnetic radiation to which its function is associated. In other words, the operational direction range may be referred to as an operational window or operational angle. For example, an operation direction range of a lighting element is the direction range into which the lighting element emits light. Analogously, an operation direction range of a sensing element is the direction range from which the sensing element is capable to detect electromagnetic radiation.

The present technology thereby provides means to facilitate the design, production and mounting of systems having functionalities based on emission or sensing of electromagnetic radiation.

Further objectives of, features of, and advantages with, the present invention will become apparent when studying the following detailed disclosure, the drawings and the appended claims. Those skilled in the art will realize that different features of the present invention can be combined to create embodiments other than those described in the following.

BRIEF DESCRIPTION OF THE DRAWINGS

This and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing embodiment(s) of the invention.

Fig. 1 schematically shows a perspective view of an embodiment of a modular system,

Figs. 2A-D schematically show cross-sectional views of embodiments of a modular system,

Figs. 3-4 schematically show perspective views of embodiments of module support structures,

Fig. 5 schematically shows optical properties of an embodiment of a module system, and

Fig. 6 schematically shows two module support structures sharing a LED strip, Fig. 7 schematically shows two functional modules giving different beam directions,

Fig. 8 schematically shows an embodiment of a modular luminaire system,

Fig. 9 schematically shows an embodiment of a modular sensor system, Figs. 10A-B schematically show embodiments of a combined modular luminaire system and modular sensor system,

Figs. 11 A-B schematically show embodiments of positions of functional elements,

Fig. 12 schematically shows an embodiment of a module support structure with lamellas,

Fig. 13 schematically shows an embodiment of a modular system having a bent elongated sheet metal structure,

Fig. 14 schematically shows an embodiment of a modular system having a curved elongated sheet metal structure,

Fig. 15 schematically shows an embodiment of a tandem module support structure.

DETAILED DESCRIPTION

When searching for means to facilitate the design, production and mounting of systems having functionalities based on emission or sensing of electromagnetic radiation, it was concluded that complexity could be reduced by using parts of the systems that could serve several purposes. Parts interacting with electromagnetic radiation could be combined with mechanical parts responsible for the support rigidity of the system. Bending metal sheets increases the mechanical stiffness and prevents thereby bending and sagging problems. The bent, non-flat shape thus contributes to a higher resistance against bending than a flat sheet. The bent shape may also be utilized for its optical properties.

Figure 1 illustrates a schematic illustration of an embodiment of a modular system 1 interacting with electromagnetic radiation. The modular system 1 comprises an elongated sheet metal structure 10 and one or more functional modules 20 each comprising a module support structure 22 and a functional element 30. The module support structure 22 is configured to be mounted to the elongated sheet metal structure 10 to support the functional elements 30 relative to the elongated sheet metal structure 10. The elongated sheet metal structure 10 comprises an elongated reflective surface 12 being curved perpendicular to an elongation direction L. The curvature is such that it presents an at least partly concave surface 14 to the functional element 30. In other words, as viewed from the functional elements, at least a part of the elongated reflective surface 12 is concave.

The elongated reflective surface 12 is arranged to reflect electromagnetic radiation. In a preferred embodiment, the elongated reflective surface 12 is reflective for electromagnetic radiation in the wavelength range of at least 100 nm to 1 mm. In other embodiments, the reflectivity range can be different, but covering the operation wavelength range of the functional elements 30. For instance, for functional elements 30 operating with electromagnetic radiation in the visible light range, e.g. a lighting element, the elongate reflective surface 12 should preferably be reflective for electromagnetic radiation in the visible light wavelength range. In a preferred embodiment, the reflective surface has a reflectance of at least 95%. A polished and optionally coated metal surface may be used for this purpose.

As shown in Figure 1, the elongated sheet metal structure may have a first length LI extending in the elongation direction (L) and the one or more functional modules may have a second length L2 extending in the elongation direction (L). The length of the elongated metal sheet structure LI may be at least at least several times longer than the length of the longest functional module L2. The example of Figure 1 shows a modular system comprising a plurality of functional modules 20, in this case three functional modules 20, which are mounted in a linear configuration along the elongation direction of the elongated sheet metal structure 10.

In the embodiment of Figure 1, the elongation of the reflective surface 12 is linear. In other words, the functional modules 20 are placed one after the other in a straight line.

The elongated sheet metal structure 10 has a stiffness enabling the elongated sheet metal structure 10 to resist deformation when supporting a weight of the one or more functional modules 30 in a mounted state of the modular system 1. The elongated sheet metal structure 10 has a first length LI. In a preferred embodiment, the deflection of the elongated sheet metal structure 10 perpendicular to the elongation direction L is less than 1% of the first length in a mounted state of the modular system, and more preferably less than 0.5% of the length in a mounted state of the modular system and most preferably less than 0.2% of the length in a mounted state of the modular system. The length-to-thickness ratio of the elongated sheet metal structure 10 needed for achieving these criteria differs depending on e.g. the material used, the weight of the functional elements 30 and functional modules 20 and the shape of the elongated sheet metal structure 10.

Figure 2A illustrates a similar embodiment of a modular system 1 in cross- sectional view. Here it can be seen that the functional element 30 is provided at a non-zero distance D from the elongated reflective surface 12. The distance D can be adapted to the different kinds of functional elements 30 and may differ between functional elements 30 within a same functional module 20 as well as between functional elements 30 of different functional modules 20. In a typical case, the non-zero distance is in the range of 1 mm to 50 mm. The functional element 30 has an operational direction range 32 for emitting and/or receiving electromagnetic radiation. The functional element 30 is placed such that the operational direction range 32 at least partly faces the elongated reflective surface 12. In a preferred embodiment, at least 70% of the operational direction range 32 faces the elongated reflective surface 12.

In the embodiment of Figure 2A, the elongated reflective surface 12 comprises two curved, elongated reflective surface portions 16 A, 16B. The elongated reflective surface portions 16 A, 16B are arranged side-by-side in a transverse direction T, perpendicular to the elongation direction. The elongated reflective surface portions 16 A, 16B are separated by an edge 18, protruding towards the functional element 30 positioned centrally below the edge 18. The edge 18 comprises typically a sharp bend line preferably having a radius R being smaller than the thickness of the sheet metal structure. The sharp bend line is beneficial in the optical performance of the shape. In other words, the elongated reflective surface 12 has two parts with a respective shape and position relative the functional element 30. The ‘W’-shape for optical reflection defines the direction of the light beam. Narrow beams, for instance 2 x 30 degrees, are possible with acceptable loss in light efficacy. In this particular embodiment, a shape of one of the two elongated reflective surface portions 16A, 16B is a mirror shape, with respect of a mirror plane through the edge 18, of the other of the two the two elongated reflective surface portions 16 A, 16B. This gives symmetric reflected beam paths for the two elongated reflective surface portions 16A, 16B to/from an object, e.g. a functional element 30, positioned at the mirror plane.

The mounting lips 19 are optional for proper assembly. This part of the functional module can further be varied with additional bends to further increase the stiffness of the bare folded metal structure.

The folded sheet, i.e. the elongated reflective surface 12, may not be torsional stiff in itself. Adding a functional module 20 may improve the torsional stiffness significantly. The torsion might also be prevented by using a thicker metal sheet. Such design choice is typically linked to the required torsion stiffness and the length of the modular system.

In an alternative embodiment, as illustrated in Figure 2B, a shape of one of the two elongated reflective surface portions 16A, 16B is a non-mirror shape of the other of the two elongated reflective surface portions 16A, 16B. This gives different reflected beam paths for the two elongated reflective surface portions 16A, 16B to/from an object, e.g. a functional element 30. The two elongated reflective surface portions 16A, 16B may be a monolithic body, as in being shaped from the same metal sheet. However, the two elongated reflective surface portions 16A, 16B may also be two distinct metal sheet parts, offset by an offset O in a direction towards the functional element 30.

Figure 2D illustrates another embodiment of a modular system 1 in cross- sectional view. This embodiment presents a single reflective surface portion 16.

The above embodiments have all utilized module support structures 22 in the shape of a frame, typically made of a polymer. Such a module support structure 22 may for example be produced using additive manufacturing. An embodiment of such a module support structure 22 is illustrated in Figure 3. This module support structures 22 comprises end plates 23 with a normal in the elongation direction L and side plates 24 with a normal in the transversal direction T. The end plates 23 present cuts 25 through which the elongated sheet metal structure is introducible. Alternatively, a part of the end plates 23 is removed, giving a remaining shape of the end plates 23 in conformity with the elongated sheet metal.

The functional element(s) may be attached to the module support structures 22, by a support beam 26. If there are more than one functional element in the functional module 20, they may be positioned relative to the intended elongated sheet metal structure in different positions. Typically, they are positioned at different positions in the elongation direction L, but they may also be positioned in different positions in the transversal direction T as well as in a height direction H, perpendicular to the elongation direction L and the transversal direction T.

If the modular system 1 is provided with more than one functional module 20, the functional elements supported by one of the functional modules 20 may be positioned in another position and/or direction in transversal direction T and/or height direction H relative to the elongated sheet metal structure compared to functional elements supported by another one of the functional modules.

As seen in Figure 1, module support structures 22 of different sizes may be used in a same modular system 1. The use of the frames or portioned optical shapes allows for large formats. By adding more optical shapes together, e.g. with specific extension connectors, this concept can be up to several meters long and act as a track system for e.g. multiple lighting modules.

However, other types of module support structures 22 are also feasible. The basic elongated sheet metal structure is still possible in a more ‘naked’ form. However, some construction for mounting the functional elements at the proper location may still be required. One such minimalistic embodiment is illustrated schematically in Figure 4. A “spider” module support structure 22A that will occur inside the optical pathway but is preferably designed in such a way that the light obstruction is minimal. Using a vertical knife-sharp geometry, similar with a ‘paper clip construction’ with extra bends, at repeated positions along the elongation direction L, a support beam for the functional elements can be provided with very small effect on the light paths. Such spider support would be much less obtrusive than the use of frames and may also be used for mounting the modular system to the ceiling or other mounting surface

One type of modular system according to the above described aspects may be a modular luminaire system. In the present technology, when applied to a luminaire, the optical part of the light engines will be combined with the mechanical part of the track, i.e. the elongated sheet metal structure 10, making this concept a kind of ultimate simplicity modular system. This modular system can be thus made from bended sheet metal with a high reflective layer. The modular system may have relatively long lengths, up to 1.5 meters or even more.

In one embodiment, at least one functional element of the at least one functional element in at least one of the one or more functional modules is a lighting element. Preferably, the lighting element comprises one or more light emitting diode - LED - and/or one or more LED filaments.

An optical simulation, as illustrated in Fig. 5, of light track configurations from a functional element 30, being a lighting element 34, shows a light pattern with a typical optical dark area 40, in the shape of a dark heart. This elongated reflective surface 12 of the modular system 1, in this embodiment more particularly a modular luminaire system 2, creates a light beam with adjustable angles and results in low glare levels. It is suggested, in some embodiments, to use this dark area 40 for accommodating various additional components. It may e.g. be possible for constructing heatsinking and/or electronical or any other functionality for the luminaire. This can thus be done without loss in optical efficacy.

The proposed architecture of the modular lighting system 2 consists typically out of the elongated sheet metal structure 10 which forms the mechanical backbone and may be a ‘thermal shield’ between the lighting element 34 and the surface to which it is attached, e.g. the ceiling. The lighting element 34, typically the LEDs 36, are positioned by the module support structures 22 relative to the elongated sheet metal structure 10. The LEDs 36 are typically pointing towards the elongated sheet metal structure 10. The module support structures 22 is partly outside the dark area 40 and will thus inevitably reduce the optical performance. Therefore, the amount of the module support structures 22 being outside the dark area 40 in the modular luminaire system 2 should preferably be as small as possible.

It has advantages to split the elongated reflective surface 12 in two curved, elongated reflective surface portions 16 A, 16B. Bending an elongated reflective surface 12 over a small diameter could reduce in cracking of the reflector top layer. Dividing the elongated reflective surface 12 in two halves may avoid this small diameter bending and may give an attractive sharp light feature. The improvement in light beam quality was immediately visible when prototypes were made according to this idea.

For reference, optical measurements show that adding reflectors costs approximately 30% of light, but it returns advantages concerning the beam shaping and low glare effect, both necessary in various applications. The light loss can be improved by accurate reflector design and LED positioning. Estimations are that finally, with on average 2 times bouncing off light on the reflector with 95%- 98% reflectivity, the total reflectivity can be in the order of 90%.

Preferably, all parts of the modular system 1 should be easy to assemble. Preferably, no screws are to be used, and the assembling should preferably be possible from one side. In other words, all parts of the functional modules 20 are preferably possible to be loaded into the module support structures 22 from one direction. Separation in the end-of-life state becomes straightforward. Reuse of the metal reflector is also possible.

If frames are used as module support structures 22, one or more frames could preferably be provided with a covering lid, forming closed boxes, and be used for embedding e.g. the LED drivers/connectivity features, such as end points/termination of the luminaire.

Flexible LED strips may also be mounted over multiple module support structures 22. In other words, multiple module support structures 22 share one LED strip, as illustrated in Figure 6.

As illustrated in Figure 7, functional modules 20 with different optical effects can be provided on one elongated sheet metal structure 10. For instance, one functional module 20 could focus the light to left where others to the middle or right. All functional modules 20 use the same elongated sheet metal structure 10 but enter the light bundle from different positions.

In Figure 8, a part of a modular lighting system 2 is illustrated. Here, a part of the end plates 23 is removed, giving a remaining shape of the end plates 23 in conformity with the elongated sheet metal structure 10. The end plates 23 are furthermore provided with holes 26 through which a LED 36 filament can be introduced. Preferably, to position the LED 36 filament in the frame, the LED 36 filament can be wrapped with a thin metal wire as a coil 37. This coil 37 helps to keep the LED 36 filament straight and aligned with the module support structure 22. A cable guide 27 is provided underneath the LED 36, preferably within the dark area (c.f. Fig. 5).

By utilizing two curved, elongated reflective surface portions 16 A, 16B with an offset (c.f. Fig. 2C) or different shapes (c.f. Fig. 2B) different light effects can be created in a light bundle.

One type of modular system according to the above-described aspects may be a modular sensor system. In the present technology, when applied to sensors, it is suggested to use the optical pathway of the modular system, in a kind of reverse pathway compared to the modular lighting system, for capturing thermal or optical information with a sensor that is integrated in the modular system. The functional element is then a sensor that is hidden in the modular sensor system. This provides a first advantage that the sensor is less vulnerable to fouling or damage. Also, optimization for the sensor functionality, such as directionality, signal-to-noise quality etc., can be achieved.

Thus, in one embodiment, at least one functional element of the at least one functional element in at least one of the one or more functional modules is a sensing element. Preferably, the sensing element is a sensor for sensing electromagnetic radiation impinging from the elongated reflective surface.

In Figure 9, a modular system 1 in the shape of a modular sensor system 3 is illustrated schematically. A functional element 30 in the form of a sensing element 35 is positioned relative the elongated sheet metal structure 10 by the module support structure 22. The optical path 42 through which the sensing element 35 receives electromagnetic radiation is determined by the shape of the elongated reflective surface 12, and if two curved elongated reflective surface portions 16 A, 16B are used different objects at different positions can be detected by use of the two curved elongated reflective surface portions 16 A, 16B.

In one embodiment, at least one functional element comprises a light sensor. Preferably, the light sensor can be a passive infrared sensor (PIR) and/or a light sensor.

The modular sensor system 3 is thus based upon a concept in which the sensing elements 35 are ‘hidden’ and directed towards the elongated reflective surface 12. The elongated reflective surface 12 collects electromagnetic radiation impinging with a well- defined beam pattern that can be selected based on both the shape of the elongated reflective surface 12 and the positioning of the sensing elements 35 relative to the elongated reflective surface 12. There is thus a use of a same optics as in the luminaire case, but now in a reverse optical pathway direction. For optical sensing an Al-based elongated reflective surface 12 is optimal. For a PIR sensor, which is collecting M-IR information in the 5 - 15 pm range, Al is also an excellent reflector.

In other words, the sensed stimulus is provided to the hidden sensing element 35 via the reflective parts, i.e. the elongated reflective surface 12, of the modular system 1. Using optical optimizations such as applying meso- or micro-optics shaping in the elongated reflective surface 12 can increase signal strength by focusing the stimulus onto the area of the sensing element 35.

Since the same types of elongated reflective surfaces are useful both for modular luminaire systems and modular sensor systems, it is also possible to combine the two types of systems into a modular luminaire system having sensing abilities. One embodiment thereof comprises at least two functional modules, one provided with a sensing element and the other provided with a lighting element.

Fig. 10A illustrates a module system 1 being a modular luminaire system 2 as well as a modular sensor system 3. Here a number of module support structures 22 are provided, each one provided with either only sensing elements 35 or only lighting elements 34. Only a part of the module support structures 22 are illustrated in order to make the figure easier to interpret. In this embodiment the sensing elements 35 and the lighting elements 34 are thermally decouple, in order to prevent thermal crosstalk and hence prevent loss of sensitivity of the sensing functionality.

In another embodiment, at least one lighting element and at least one sensing element are provided within and attached to a same module support structure. Fig. 10B illustrates a module system 1 being a modular luminaire system 2 as well as a modular sensor system 3. Here a common module support structure 22 is provided, supporting both sensing elements 35 and lighting elements 34. Only a part of the module support structure 22 is illustrated in order to make the figure easier to interpret.

For reasons of e.g., thermal or optical crosstalk, the sensing functionality and its pathway from ground level to the module system might be decoupled from the lighting pathway. That might be done by separating the line-of-sight of the lighting and the line-of- sight of the sensing in the module system via either the optics in the module system and/or a partitioning of the sensing elements and the lighting elements.

For a PIR sensor, changing temperatures in the module system because of various driving modes of the LEDs or drivers might lead to misinformation or bad signal-to- noise. This means that providing the PIR sensor with a separate and possibly optimized attach location and hence separate heat sinking functionality would be a solution.

The same holds for optical sensors, as the generated light might fully blur the optical sensor. To this end, the optical sensors’ line-of -sight may still be at a location where the light bundle is thrown towards, but should not be in direct sight of the light engines. So, a solution is to have the two optical pathways overlapping only at the target area.

Figure 11 A illustrates a cross-sectional view at the position of a lighting element 34. In this embodiment, the lighting element 34 is placed symmetrically with respect to the two elongated reflective surface portions 16 A, 16B. A symmetric light pattern 41 basically situated straight in front of the elongated reflective surface 12 is achieved. Figure 1 IB illustrates a cross-sectional view at the position of a sensing element 35. In this embodiment, the sensing element 35 is placed shifted with a distance S from the symmetry line with respect to the two elongated reflective surface portions 16 A, 16B. The sensing element 35 will thereby sense electromagnetic radiation impinging from a side position according to the optical path 42. A separation between illuminated and sensed areas is thus achieved. The sensing element 35 and the lighting element 34 are typically placed at different locations in the longitudinal direction, but in some embodiments, they may even be placed at a same longitudinal direction, just separated in the transversal direction by the module support structure 22. The target viewing direction of the sensors might also be far off from the light beam, allowing for early detection of e.g., upcoming presence detection.

In one embodiment, at least one module support structure comprises at least two functional elements, and wherein one of the at least two functional elements in the at least one module support structure is positioned in another transversal position and/or direction relative to the elongated reflective surface compared to another one of the at least two functional elements in the same module support structure.

In one embodiment, at least one functional element of the functional elements is positioned relative to the elongated reflective surface to give a different optical pathway, in a plane perpendicular to the elongation direction, compared to at least one other functional element of the functional elements.

For preventing crosstalk to the sensing element, e.g., an optical sensor, from a lighting element, there is also the option to use mechanical shields or lamellas. Figure 12 illustrates a module support structure 22 having two lamellas 28, shielding a volume therebetween. By such a design, a sensing element may be introduced into the volume without being disturbed by lighting elements provided on both sides. Thus, in one embodiment, the module support structure further comprises a lamella separating a lighting element and a sensing element.

The suggested partitioning options might allow to also have multiple sensing directions, both in longitudinal and transversal direction. This might be additionally beneficial for long linear module systems.

In Figure 13, an embodiment of modular system 1 having a bent elongated reflective surface 12 is illustrated. The elongated reflective surface 12 has a main portion 12A and an end portion 12B, where the elongation directions thereof differ by an angle. The main portion 12A accommodates LED 36 strips positioned by non-illustrated module support structures. The end portion 12B instead accommodates sensing elements 35. Due to the difference in direction of the main portion 12A and the end portion 12B, the sensing elements will target another area compared to what is illuminated by the LEDs 36. In other words, in this embodiment an odd-shaped reflector is used, i.e. a bended reflector end part, such that the line-of-sight direction of the sensor is pointed away from the generated light beam and e.g., allows to measure an object or event that is adjacent or away from the light functionality location.

The use of aluminum as the reflector material provides a wide range of shaping options. Bending is a first option, which could be very useful for 1 -directional module systems, e.g., in a long format. Next to that, in fact any 3D shape can be achieved when using deep drawing techniques on the aluminum sheet material.

Various variations in the line-of sight of the sensor can be achieved by making various reflector shapes. In one embodiment, the elongation of the reflective surface is curved.

In Figure 14, an embodiment of a modular system 1 having a curved elongated reflective surface 12. This curving can be e.g. of a wavy character or even of a circular shape. In this particular embodiment, functional elements 30 in the form of LED 36 strips are provided at the module support structure 22. LEDs 36 may be mounted on flexible strips 37 that are fastened to the module support structure 22. The flexible strips are easier to orient 90 degrees rotated with respect to the main extension of the elongated reflective surface 12. By then using two LEDs 36 back-to-back it will be easier to follow the wave or circle.

In other words, in one embodiment, the functional elements comprise LEDs arranged back to back on two opposite sides of a carrier.

Module support structures may also connect one elongated sheet metal structure to another one. The advantage of such a solution is that a more rectangular light module is formed where the metal mechanical optical element (elongated reflective surface) covers the whole surface and acts as a barrier shield for fire-safety. This construction will even pass the strict legislation on this item in for example USA without the need for additional metal plates in the construction.

Thus in one embodiment, a lighting arrangement is provided, comprising at least two modular luminaire systems according to the above-described principles. The two modular luminaire systems are provided in parallel transverse to the elongation direction or one after another in the elongation direction. Preferably, at least one module support structure is common to the at least two modular luminaire systems. One embodiment of such a tandem module support structure is schematically illustrated in Fig. 15.

The functional modules can furthermore be utilized also for other purposes. Heat production can sometimes be a problem in illumination arrangements. The functional modules may therefore also be provided with additional heatsink elements. For instance, in one embodiment, the frame has a central line where a LED strip is attached. Underneath the LED strip, heatsink elements could be arranged. In one particular embodiment, those heatsink elements are aluminum studs placed exactly underneath each LED.

In other words, in one embodiment, the modular system further comprising heat sinks provided in thermal contact with at least one functional element of the functional elements, wherein the at least one functional element that is in thermal contact with the heat sink being placed between the heat sink and the elongated reflective surface.

Also other functionalities that often are required in connection with illumination or sensing, such as electronics, drivers, controllers etc. are possible to be included in one or more functional modules together with the functional elements interacting with electromagnetic radiation. Additional functional modules having only such additional functionalities may also be provided.

In analogy with the above reasoning, in one embodiment, the modular system further comprises electrical circuitry provided in electrical contact with at least one functional element of the functional elements, wherein the at least one functional element that is in electrical contact with the electrical circuitry being placed between the electrical circuitry and the elongated reflective surface.

In other words, in one embodiment, at least one functional module of the one or more functional modules further comprises at least one of electronics, a driver, a heat sink and a controller. The elongated sheet metal structure could also be part of the electrical system. For example, it could serve as the common ground of the system. In the case the elongated sheet metal structure is made of two parts, both these parts could be a different part of the electrical system. One part could constitute the common ground, the other + 24V for example.

In order to make the module system easy to mount and/or repair, the functional modules should preferably be releasable in an easy manner from the elongated sheet metal structure. This may e.g. be provided by the shapes of the module support structures, which for instance are adapted to fit to the shape of the elongated sheet metal structure. This could e.g. be the cuts through the end plates of the module support structures as described further above. It is preferred if mounting can be made without need of any screws. Furthermore, since the elongated sheet metal structure typically has a same crosssection shape along its entire length, the functional modules are typically displaceable along the elongation direction. This can be used in order to adapt the module system to different practical situations.

In other words, the one or more functional modules are configured to be reversibly mounted to the sheet metal structure, and/or displaceable along the elongation direction of the sheet metal structure.

Typically, the modular system is attached to a fastening surface, such as a ceiling or a wall. Therefore, attachment means are preferably provided which are configured for enabling attachment of the elongated sheet metal structure to a fastening surface, preferably to be mounted in a suspended state. The functional modules are already responsible for mechanically positioning the functional elements. The same components may also be used for such attaching purposes. In particular, the module support structures may be constituted as an integral part of such attachment means.

In other words, in one embodiment, at least one functional module of the one or more functional modules further comprises attachment means for fastening the modular system to a fastening surface.

The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims.

It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb “to comprise” and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In the device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. The various aspects discussed in this patent can be combined in order to provide additional advantages. Further, the person skilled in the art will understand that embodiments can be combined, and that also more than two embodiments can be combined.

Claims

CLAIMS:

1. A modular system (1), comprising: an elongated sheet metal structure (10), and a plurality of functional modules (20) each comprising a module support structure (22) and a functional element (30); wherein the module support structure (22) is configured to be reversibly mounted to the elongated sheet metal structure (10) at freely selectable positions along an elongation direction L of the elongated sheet metal structure, the module support structure being configured to hold the functional element (30) relative to the elongated sheet metal structure (10), wherein the elongated sheet metal structure (10) comprises an elongated reflective surface (12) being curved perpendicular to the elongation direction L so as to present an at least partly concave surface (14) to the functional element (30), the elongated reflective surface (12) being arranged to reflect electromagnetic radiation, wherein the functional element (30) is provided at a non-zero distance D from the elongated reflective surface (12), the functional element (30) having an operational direction range (32) for emitting and/or receiving the electromagnetic radiation, the functional element (30) being placed such that the operational direction range (32) at least partly faces the elongated reflective surface (12), wherein the plurality of functional modules is mounted in a linear configuration along the elongation direction, and wherein the elongated sheet metal structure (10) has a stiffness enabling the elongated sheet metal structure (10) to resist deformation when supporting a weight of the plurality of functional modules (22) in a mounted state of the modular system (1).

2. The modular system according to claim 1, wherein the elongated sheet metal structure (10) has a first length LI extending in the elongation direction L, each functional module of the plurality of functional modules (20) having a module length LM extending in the elongation direction L, and wherein LI > 3 LM.

3. The modular system according to any one of the preceding claims, wherein the functional element (30) in at least one of the plurality of functional modules (20) is a lighting element (34).

4. The modular system according to any one of the preceding claims, wherein the functional element (30) in at least one of the plurality of functional modules (20) is a sensing element (35).

5. The modular system according to claim 4, wherein the sensing element (35) is a sensor for sensing electromagnetic radiation impinging from the elongated reflective surface (12).

6. The modular system according to any one of the preceding claims, wherein the elongated sheet metal structure (10) has a first width W1 extending in a transverse direction, perpendicular to the elongation direction, wherein the module support structure (22) has a module width WM extending in the transverse direction, the module width WM being equal to or larger than the first width W 1.

7. The modular system according to any one of the preceding claims, wherein at least a subset of the functional elements (30) is arranged along a central elongation axis of the elongated sheet metal structure (10).

8. The modular system according to any one of the preceding claims, wherein at least one module support structure (22) comprises openings (25) for receiving the elongated sheet metal structure (10).

9. The modular system according to any one of the preceding claims, wherein at least 70% of the operational direction range (32) faces the elongated reflective surface (12).

10. The modular system according to any one of the preceding claims, wherein the plurality of functional modules (30) is further configured to be displaceable along the elongation direction L of the elongated sheet metal structure (10).

11. The modular system according to any one of the preceding claims, wherein the elongated reflective surface (12) comprises two curved, elongated reflective surface portions (16A, 16B) being arranged side-by-side in a transverse direction T, perpendicular to the elongation direction L, separated by an edge (18), protruding towards the at least one functional element (30).

12. The modular system according to any one of the preceding claims, wherein the elongated reflective surface has a reflectance of at least 95%.

13. The modular system according to any one of the preceding claims, wherein the elongated reflective surface (12) is reflective for electromagnetic radiation in the wavelength range of 100 nm to 1 mm.

14. The modular system according to any of the preceding claims, wherein at least one functional module (20) of the plurality of functional modules (20) further comprises attachment means for fastening the modular system (1) to a fastening surface.

15. The modular system according to any one of the preceding claims, wherein at least one functional module (20) of the plurality of functional modules (20) further comprises at least one of electronics, a driver, a heat sink and a controller.