Abstract: A set of louvers adapted for use with a linear luminaire has a first wall, a second wall spaced from the first wall, and a plurality of louvers extending between the first wall and the second wall. Each of the plurality of louvers is fixed to the first wall and the second wall, and may be integrally formed with the walls, and each of the plurality of louvers is spaced from the others. First and second side portions depend from the first wall and the second wall. An internal cavity of the set of louvers is defined by bottoms of the plurality of louvers and the first and second side portions. Engaging structure is defined on inwardly-facing surfaces of the first and second side portions. Combinations including the set of louvers and a linear luminaire in which the set of louvers “snaps on” externally to the linear luminaire are disclosed.

Abstract: A strip of encapsulated linear lighting with a partially encapsulated electrical connector is disclosed, as are processes for manufacturing such strips of encapsulated linear lighting. In these processes, connecting structure is connected to a strip of linear lighting. A portion of the connecting structure is then sheathed in a stopper. The stopper is used to dam a vessel or channel, the dammed vessel or channel is filled with resin, and the resin is caused or allowed to cure. The stopper protects the connecting structure from resin during the encapsulation process and leaves its contacts unencapsulated and exposed. The connecting structure can be connected to external structures, like a power cable or another segment of encapsulated linear lighting, after manufacture. A joint between the connecting structure and another structure can be overmolded or otherwise protected.

Abstract: A linear luminaire includes a three-sided enclosure with a top that is at least translucent and a pair of depending sidewalls spaced apart by the top. The three-sided enclosure may be extruded from a plastic or, in some cases, co-extruded with two different materials so that the pair of sidewalls can be made of an opaque material. The three-sided enclosure may be open along a bottom aspect. An elongate rigid printed circuit board (PCB) carrying LED light engines is installed between the pair of sidewalls in slot structure defined on respective inner faces. The PCB may carry connecting structure staggered along the length of its underside. The PCB may also carry circuit components on its underside.

Abstract: A voltage-regulating drive circuit for an LED luminaire is disclosed. The drive circuit includes one or several series of LED light engines. A voltage source with a regulator is connected to the series of LED light engines to forward-bias the light engines. The circuit also includes a driver integrated circuit, which may drive the series of LED light engines using, e.g., pulse-width modulation (PWM). The circuit also includes a feedback circuit connected to the cathode end of the series of LED light engines. The feedback circuit receives a remainder voltage and creates a feedback output signal that upregulates or downregulates the regulator of the voltage source to keep a minimum operating voltage on the driver integrated circuit and to compensate for variations in forward voltages among LED light engines in the series.

Abstract: A linear luminaire having high ingress protection includes a light-generating assembly and a channel. The light-generating assembly is an elongate, self-contained, sealed optical assembly that includes all elements necessary to generate light and to direct, focus, or modify the generated light in a particular way. Typically, the light-generating assembly would include an outer optical element and a light source positioned within a cavity of the body of the light-generating assembly. The outer optical element may be a lens, diffuser, or other such element. The light source may be a strip of LED linear lighting, a string of connected LED modules, or any other suitable device. The light-generating assembly may optionally include a second optical element, such as a lens or diffuser, that is supported within the body. The ends of the body of the light-generating assembly may be sealed by fitted endcaps, by polymeric resin, or by other means.

Abstract: A method for making continuous encapsulated linear lighting is disclosed. In this method, a PCB is placed within a channel, and the channel is dammed by one or more stoppers. The dammed segment is filled and then caused or allowed to cure. The stoppers are then removed from their initial positions and moved along the channel. If one runs out of channel before the desired length of linear lighting is achieved, a second piece of channel is abutted to the previous segment of channel, the PCB is laid into it, and a segment is dammed, filled, and cured. The process continues iteratively until the desired length is achieved or more channel is required. The PCB may initially be cut to the full desired length and applied to the channel piecewise as needed.

Abstract: A channel system that includes a first channel section, a second channel section, and a hinge joint between the first and second channel sections is disclosed. The hinge joint allows the first channel section to fold against the second channel section for storage and shipping of the channel system. In one embodiment, the hinge joint itself includes a hinge member that extends between the two channel sections and bends hingedly to allow movement and two intermediate endcaps, which cap the channel sections on either side of the hinge joint. The hinge joint may be designed to “snap back” to a fully extended position. Mechanical securement structure may be added to the first channel section and the second channel section to improve force and retention during the “snap back” movement.

Abstract: An under-counter lighting system places a light-guide panel (LGP) or a set of LGPs under a countertop, or another such work surface, in order to backlight it. Specifically, a base layer is secured to a support, such as a cabinet. The base layer includes a support layer and a number of support posts attached to the support layer. An LGP layer includes the LGP or LGPs. Each of the LGPs has openings that correspond to positions of the support posts, such that the LGPs receive the support posts through their thicknesses. A countertop is secured to the tops of the support posts and may have a depending lip or other such feature sufficient to hide the base layer and the LGP layer. The resulting light, usually at least partially transmitted through the countertop itself, can serve as ambient light, task light, or accent light, depending on the installation.

Abstract: A linear luminaire includes a channel with a bottom and sidewalls that arise from opposite sides of the bottom. A printed circuit board (PCB) including a number of LED light engines is mounted in the channel, and may be mounted on stand-offs away from the bottom of the channel. A mounting bracket is connected to an underside of the channel bottom. The linear luminaire also includes a base that can serve as a raceway for wires and cable. The base also has a bottom and sidewalls, and attaches releasably to the channel by means of cooperating engaging structures on the mounting bracket of the channel and portions of the sidewalls of the base.

Abstract: The disclosure relates to methods for connecting encapsulated linear lighting to power, including the use of through-hole mounting into flexible encapsulated linear lighting, and the creation of overmolds to protect electrical connections. The disclosure also relates to linear luminaires having channels that accommodate overmolds and allow electrical cables to exit the encapsulated linear lighting in desired, and controllable, directions.

Abstract: A drive circuit for an LED luminaire is disclosed. The drive circuit includes one or several series of LED light engines. A voltage source with a regulator is connected to the series of LED light engines to forward-bias the light engines. The circuit also includes an integrated circuit driver, which may drive the series of LED light engines using, e.g., pulse-width modulation (PWM). The circuit also includes a feedback circuit connected to the cathode end of the series of LED light engines. The feedback circuit receives a remainder voltage and creates a feedback output signal that upregulates or downregulates the regulator of the voltage source to keep a minimum operating voltage on the integrated circuit driver and also to compensate for variations in forward voltages among LED light engines in the series. A switching element, such as a bipolar junction transistor, protects the driver from high voltages.

Abstract: Methods for controlling power consumption and temperature in an LED luminaire are disclosed. The LED luminaire has one or more sets of LED light engines disposed on a printed circuit board (PCB), some or all of which are activated in response to an instruction or set of instructions. The instruction or set of instructions are processed to derive an indication of power consumption for each of the one or more sets of LED light engines. Power allocations for the one or more sets of LED light engines are adjusted to meet targets. This can be done by, e.g., ramping up or down the duty cycle of active sets of LED light engines by a uniform factor until the targets are met. Temperature control methods similarly ramp down the duty cycle of active sets of LED light engines uniformly over time if the measured temperature of the PCB exceeds limits.

Abstract: A linear luminaire includes a channel with a bottom and sidewalls that arise from opposite sides of the bottom. The channel has an upper compartment and a lower compartment, the sidewalls being of a shape and extent such that at opposite ends of the channel, the upper compartment overhangs the lower compartment in a longitudinal direction. An elongate, rigid printed circuit board (PCB) is mounted in the upper compartment of the channel, aligned along the longitudinal direction, the PCB extending to each of the opposite ends of the channel in the upper compartment and having one or more LED light engines mounted thereon. The PCB may be mounted on stand-offs, such that it is above the bottom of the channel and defines the boundary between the upper and lower compartments. The overhung upper compartment creates a cableway space when two linear luminaires are abutted end-to-end or are adjacent.

Abstract: Channels and channel covers for linear lighting are disclosed. The channels have an upper compartment for linear lighting and a lower compartment that may be used as a raceway, to engage parts, and for rear entry of wires. Endcaps for the channels may engage the lower compartment. Cover-lenses for linear lighting channels are also disclosed. The cover-lenses may include diffusing material and implement a thickness gradient in order to maximize the amount of diffusing material where the emitted light intensity is expected to be greatest. Diverging Fresnel features may be superimposed on the thickness gradient in order to counteract any converging effect of the thickness gradient and cause emitted light to spread more evenly.

Abstract: Channels and channel covers for linear lighting are disclosed. The channels have an upper compartment for linear lighting and a lower compartment that may be used as a raceway, to engage parts, and for rear entry of wires. Endcaps for the channels may engage the lower compartment. Cover-lenses for linear lighting channels are also disclosed. The cover-lenses may include diffusing material and implement a thickness gradient in order to maximize the amount of diffusing material where the emitted light intensity is expected to be greatest. Diverging Fresnel features may be superimposed on the thickness gradient in order to counteract any converging effect of the thickness gradient and cause emitted light to spread more evenly.

Abstract: A flexible cover for a linear lighting channel is described, as are enclosures and luminaires using this kind of flexible cover. The flexible cover has sufficient flexibility to be bent or coiled to a bend radius of 6 inches (15.2 cm) or smaller, and can thus be coiled for shipping and uncoiled for installation. Typically, the cover is made of a polymer that is at least translucent. Covers may be made in various shapes, including lens and prism shapes, and channels may be made with sidewalls that make complementary shapes in order to engage with and retain the covers.