as) United States
`a2) Patent Application Publication co) Pub. No.: US 2012/0217897 Al
`(43) Pub. Date: Aug.30, 2012
`
`Gordinet al.
`
`US 20120217897A1
`
`(54)
`
`COMPACT AND ADJUSTABLE LED
`LIGHTING APPARATUS, AND METHOD AND
`SYSTEM FOR OPERATING SUCH
`LONG-TERM
`
`(75)
`
`Inventors:
`
`Myron Gordin, Oskaloosa, IA
`(US); Timothy J. Boyle, Oskaloosa,
`JA (US); ThomasA.Stone,
`University Park, IA (US)
`
`(73)
`
`Assignee:
`
`Musco Corporation, Oskaloosa, [A
`(US)
`
`(21)
`
`Appl. No.:
`
`13/399,291
`
`(22)
`
`Filed:
`
`Feb. 17, 2012
`
`Related U.S. Application Data
`
`(60)
`
`Provisional application No. 61/446,915, filed on Feb.
`25, 2011.
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`(2006.01)
`HOSB 37/02
`(2006.01)
`F21V 7/00
`(2006.01)
`F21V 19/02
`(2006.01)
`F218 8/00
`(52) US. Ch cece. 315/294; 362/145; 362/247; 29/428
`(57)
`ABSTRACT
`
`A lighting system is provided whereby long operating life can
`be reasonably ensured by taking into account requirements of
`the application, characteristics ofthe LEDs, characteristics of
`the fixture containing said LEDs, the desired numberof oper-
`ating hours, and—via developed relationships—taking an
`iterative approach to supplying powerto the LEDs. Through
`the envisioned compensation methodology and effective
`luminaire design, a relatively constant light level can be
`assured for a predetermined numberof operating hours (pos-
`sibly longer); this is true even if operating conditions change,
`known behavior of LEDsproves untrue over untested period
`of time, or some other condition occurs which would other-
`wise cause end-of-life prematurely and prevent the system
`from meeting the desired numberof operating hours.
`
`10
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`DETERMINE APPLICATION
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`REQUIREMENTS
`
`sy m9
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`
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`FIXTURE BEAMS
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`
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`S00"DETERMINE FIXTURE
`
`| REQUIREMENTS
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`ASSEMBLY
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`THERMAL CHARACTERIZATION
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`COMPACT AND ADJUSTABLE LED
`LIGHTING APPARATUS, AND METHOD AND
`SYSTEM FOR OPERATING SUCH
`LONG-TERM
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`[0001] This application claims priority under 35 U.S.C.
`$119 to provisional U.S. Application Ser. No. 61/446,915,
`filed Feb. 25, 2011 which is hereby incorporated by reference
`in its entirety.
`
`I. BACKGROUND OF THE INVENTION
`
`[0002] The present invention generally relates to light-
`emitting diodes (LEDs), and moreparticularly, to the design
`of a lighting apparatus and lighting system using such in a
`mannerthat maximizes the benefits of LEDsto satisfy diffi-
`cult lighting requirements.
`[0003] By now it is well known that the use of LEDs in
`generallighting applications yields substantial benefits: long
`operating life, high efficacy, and precise controlof light are at
`the forefront. However, it is also well known that to get the
`most out of LEDs a numberof factors must be considered:
`
`temperature (both ambient and junction) and luminaire
`design, for example. LEDs are quickly becoming the light
`source of choice for architectural or aesthetic lighting appli-
`cations (e.g., facade lighting, holiday lighting, indoor track
`lighting, etc.), but their usefulness in long-term, large-scale
`lighting applications has been more slowly realized. This is
`due, at least in part, to the tremendous efforts needed to
`control such things as ambient and junction temperature, as
`well as the efficiency of the luminaire design. In essence,
`becausethe benefits of operating LEDsare so closely coupled
`to the particulars of the lighting application, there is no such
`thing as a standard large-scale LED lighting fixture. Couple
`this with only a rudimentary understanding the industry has
`of how long LEDscan beoperated effectively, and it can be
`seen that there is significant room for improvementin theart.
`[0004] Consider an outdoor bridge spanning some length
`and accommodating some numberoflanes oftraffic in both
`directions; assumethis bridge is used heavily both day and
`night. For the safety of nighttime drivers, the road on the
`bridge must be illuminated; here lies an application that
`exemplifies the challenges faced by today’s lighting design-
`ers. Cost effectiveness suggests lighting fixtures should be
`affixed to existing structural features (e.g., to avoid the cost of
`support structures and the cost to shut down multiple lanes of
`traffic to erect said structures); however, mounting height and
`aiming of said fixtures must be considered so not to cause
`glare or create other adverse driving conditions(the difficulty
`of which is exacerbated becausetraffic flows in both direc-
`
`tions). The lighting designer must take into account place-
`ment of the fixtures, weight of the fixtures, and outward
`design ofthe fixtures to ensure both adequate distribution of
`light on and about the target area, and distributionofstresses
`onthepoles(e.g., because ofwind loading). At all times, there
`are competing design considerations. For example, LEDs
`offer the benefit of long life (a boon to cost effectiveness), but
`must be used in great quantity to produce the light needed (a
`detrimentto cost effectiveness). A plurality of light sources
`meansthe composite light projected therefrom can be pre-
`cisely controlled to suit the target area, but it also means
`
`additional optical elements for each light source (adding to
`the cost and weight of eachfixture).
`[0005] Additionally, there is a vested interest in designing
`the lighting system at the onset for long-term use; in the
`aforementioned example, it is simply not economically fea-
`sible to shut down multiple lanesoftraffic overthe life of the
`system to perform maintenance, re-lamp, etc. Thus, LEDsare
`a natural choice; their long life removes some concerns with
`long-term maintenance. However, because LEDs have such a
`long life they have not been fully tested; thus, there are no
`definitive answers as to how long LEDscan operate and how
`severely the light output will degrade over time due to thermal
`losses and lumen depreciation (not to mention initial effi-
`ciency losses due to driver inefficiencies and luminaire
`design). The Illuminating Engineering Society of North
`America IESNA) has recently recommendedstandards for
`testing LEDs (see IES LM-79) and measuring lumen depre-
`ciation (see IES LM-80), but the scope is limited and does not
`define or provide estimationsfor the lifespan of LEDs.
`[0006]
`Theart is at a loss; in the time it would taketo fully
`test an LED,the technology will have advanced andthe data
`will not be particularly useful. In the meantime, there are
`lighting applications that may benefit from the long life of
`LEDsprovidedthat long life can be assured. What is needed
`are means for reasonably assuring the long life of LEDs in a
`mannerthatis reliable and, unlike current maintenancestrat-
`egies, cost-effective for applications like the aforementioned
`bridge. Further, what is needed are means for reasonably
`assuring an acceptable light level oversaid life; there is little
`benefit to maintaining an LED lighting system long-term if
`the light is allowed to degrade to the point ofuselessness. Still
`further, what is needed is a standardized approach to devel-
`oping large-scale LED fixtures—particularly ones for out-
`door use—that can be used with said means for assuring the
`long life of LEDsso to address current needs. Thus, there is
`room for improvementin the art.
`
`Il. SUMMARY OF THE INVENTION
`
`[0007] Light-emitting diodes (LEDs) are anattractivealter-
`native to traditional light sources (e.g., metal halide, incan-
`descent, fluorescent, high pressure sodium) for many appli-
`cations for a variety of reasons, particularly applications
`wherelong life is desirable. That being said, many large-scale
`outdoorlighting applications are based on a budget and the
`budget assumes a certain number of operating hours before
`maintenance is performed or before the system has reached
`its end-of-life (EOL). This is problematic because the lon-
`gevity of LEDs is highly dependent on operating condi-
`tions—many of which cannot be closely controlled—thus
`limiting the ability to predict or assure a certain numberof
`operating hours. Further, LEDsare not fully characterized so
`their behavior long-term is not well understood.
`[0008]
`It is therefore a principle object, feature, advantage,
`or aspect ofthe present invention to improve overthe state of
`the art and/or address problems, issues, or deficiencies in the
`art.
`
`[0009] According to the present invention, a lighting sys-
`tem is provided whereby a numberof operating hours can be
`reasonably ensuredfor a particular combination of LED and
`fixture. Through the envisioned power compensation meth-
`odology andeffective luminaire design,a relatively constant
`light level can be assured for the defined lifespan of the
`system; this is true even if operating conditions change, the
`knownbehavior of LEDsproves untrue over untested periods
`
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`of time, or some other condition occurs which would other-
`wise cause EOL prematurely and prevent the system from
`meeting the desired numberof operating hours.
`[0010]
`Further objects, features, advantages, or aspects of
`the present invention may include one or moreofthe follow-
`ing:
`a. customizable LED modules for placement in
`[0011]
`customizable LED fixtures such that said fixtures are
`suitable for a variety of large-scale applications;
`[0012]
`b. methods of aiming said modules andsaid fix-
`tures so to produce a customized composite beam pat-
`tern on, at, or about a target area;
`[0013]
`c. means for ensuring a relatively constant light
`output over a predefined length of time;
`[0014]
`d. meansfor providing uplighting in addition to or
`as part of said customized composite beam pattern;
`[0015]
`e. arobust luminaire design suitable for outdoor
`use; and
`[0016]
`f. means to correct for undesirable operating con-
`ditions so to aid in ensuring the longevity of LEDs in
`said LEDfixtures.
`
`[0017] These and other objects, features, advantages, or
`aspects of the present invention will become more apparent
`with reference to the accompanying specification and claims.
`
`IH. BRIEF DESCRIPTION OF THE DRAWINGS
`
`From time-to-time in this description reference will
`[0018]
`be taken to the drawings whichare identified by figure num-
`ber and are summarized below.
`
`FIG. 1A illustrates an assembled perspective view
`[0019]
`of an LED module according to aspects of the present inven-
`tion.
`
`FIG. 1B illustrates the module of FIG. 1A in
`[0020]
`exploded perspective view.
`[0021]
`FIG. 1C illustrates the module of FIGS. 1A and B
`along section line A-A of FIG. 1A.
`[0022]
`FIG. 2 illustrates an enlarged isolated front view of
`the LED board of FIGS. 1A-C.
`
`FIG.7 illustrates two possible methodsofaligning
`[0033]
`module bars within a fixture housing according to aspects of
`the present invention.
`[0034]
`FIGS. 8A-Gillustrate multiple isolated views of a
`module bar according to aspects of the present invention.
`[0035]
`FIG. 9 illustrates an enlarged isolated perspective
`view of the module bar of FIGS. 8A-G with a plurality of the
`module of FIGS. 1A-Cinstalled.
`[0036]
`FIGS. 10A-C illustrate multiple isolated views of a
`fixture housing (aimed at 30° down from horizontal) accord-
`ing to aspects of the present invention.
`[0037]
`FIG. 10D illustrates an enlarged view of the fixture
`housing ofFIGS. 10A-C alongsection line A-A and including
`one module bar (see FIG. 8) and one LED module (see FIGS.
`1A-C) installed according to aspects ofthe present invention.
`[0038]
`FIG. 11A diagrammatically illustrates a prior art
`approach to illuminating a roadway.
`[0039]
`FIG. 11B diagrammatically illustrates one possible
`approach to illuminating a roadway according to aspects of
`the present invention.
`[0040]
`FIG. 12 illustrates in flowchart form one approach to
`designing a composite beam pattern according to aspects of
`the invention.
`
`FIG. 13 illustrates in flowchart form one approach to
`[0041]
`aiming an exemplary fixture to achieve the composite beam
`pattern designed according to the flowchart of FIG. 12.
`[0042]
`FIG. 14A illustrates an assembled perspective view
`of an LEDfixture according to aspects of the present inven-
`tion.
`FIG. 14Billustrates an exploded perspective view of
`[0043]
`the exterior components of the LED fixture of FIG. 14A.
`[0044]
`FIG. 14Cillustrates an enlarged view of Detail A of
`FIG. 14A.
`
`FIG. 14D illustrates the LED fixture of FIG. 14C
`[0045]
`along section line B-B; for clarity, some hatching has been
`omitted.
`FIG. 15Aillustrates portions of an exemplary light-
`[0046]
`ing system according to aspects of the present invention.
`[0047]
`FIG. 15Billustrates an enlarged isolated perspective
`view ofthe exemplary fixture and exemplary knuckle of FIG.
`15A.
`
`FIGS. 3A-E illustrate multiple isolated views of the
`[0023]
`housing of FIGS. 1A-C.
`[0024]
`FIGS. 4A-C illustrate multiple enlarged isolated
`[0048] FIGS. 15C andDillustrate an isolated perspective
`
`views of the lens of FIGS. 1A-C.
`view, as well as along view line A-A, ofthe pole of FIG. 15A.
`[0025]
`FIGS. 5A-D illustrate multiple isolated views of the
`[0049]
`FIG. 15E illustrates an enlarged isolated assembled
`visor of FIGS. 1A-C.
`perspective view of the exemplary knuckle of FIG. 15B.
`[0050]
`FIG. 15Fillustrates a partially exploded view of the
`exemplary knuckle of FIG. 15E.
`[0051]
`FIG. 16 illustrates in flowchart form a method of
`operating the exemplary lighting system of FIGS. 15A-F
`according to aspects of the present invention.
`[0052]
`FIG. 17 diagrammatically illustrates one method of
`providing both uplighting and directional(i.e., task) lighting
`for an application according to aspects of the present inven-
`tion.
`
`FIGS. 5E-I illustrate isolated perspective views of
`[0026]
`some possible visors for use with the LED module of FIGS.
`1A-C.
`
`FIG. 6A illustrates an isolated assembled perspec-
`[0027]
`tive view of one possible design of pivot joint for use in the
`LED module of FIGS. 1A-C according to aspects of the
`present invention.
`[0028]
`FIG. 6B illustrates the pivot joint of FIG. 6A in
`exploded perspective view.
`[0029]
`FIGS. 6C and D illustrate multiple viewsofthe pivot
`joint of FIGS. 6A and B as it may appear in operation.
`[0030]
`FIG. 6E illustrates an assembled side view of an
`alternative pivot joint for use in the LED module of FIGS.
`1A-C.
`
`FIG. 18A illustrates an alternative to the module bar
`[0053]
`of FIG.8.
`
`FIG. 18Billustrates an alternative to the module bar
`[0054]
`and LED modulesof FIG.9.
`
`FIGS. 6F and G illustrate multiple viewsofa still
`[0031]
`further alternative pivot joint for use in the LED module of
`FIGS. 1A-C.
`
`FIG. 6H illustrates an assembled perspective view
`[0032]
`of a still further alternative pivot joint for use in the LED
`module of FIGS. 1A-C.
`
`IV. DETAILED DESCRIPTION OF EXEMPLARY
`EMBODIMENTS
`
`To further an understandingofthe presentinvention,
`[0055]
`specific exemplary embodiments according to the present
`invention will be described in detail. Frequent mention will be
`
`Petitioner Ensign
`Exhibit 1032 - Page 39 of 49
`
`Petitioner Ensign
`Exhibit 1032 - Page 39 of 49
`
`

`

`US 2012/0217897 Al
`
`Aug. 30, 2012
`
`made inthis description to the drawings. Reference numbers
`will be used to indicate certain parts in the drawings. The
`same reference numbers will be used to indicate the same
`
`parts throughout the drawings.
`[0056] Envisioned are apparatus, methods, and systems for
`reasonably ensuring operation of a large-scale outdoor LED
`lighting system over a defined period of timeat a relatively
`constantlight level. LEDs offer many benefits including long
`operating life, RoHS and LEED compliance, no restrike
`downtime, good color stability even across dimminglevels,
`and high efficacy to name a few. That being said, it is to be
`understood that aspects of the present invention could be
`applied to other lighting applications, other types of light
`sources, and the like. Further, while a variety of options and
`alternatives have been laid out, these are not to be considered
`limiting or all-encompassing.
`[0057]
`Itis believed that a comprehensive understanding of
`the present invention is best achieved byfirst understanding
`the components which, along with the envisioned methodol-
`ogy, form the envisioned long-term LEDlighting system;the
`remaining Specification is laid out as such, but is not intended
`to imply a specific assembly order or sequencing of events
`unless otherwise stated.
`
`[0058] Regarding terminology, it is to be understood that
`the terms “luminaire”and “fixture” are used interchangeably
`in this Specification and are intended to encompass the sum of
`modules and associated exterior components. A grouping of
`luminairesor fixtures (typically on the same elevating struc-
`ture) are referred to as an array, whereas the term “lighting
`system”refers to the sum of luminairesor fixtures, elevating
`structures, meansfor affixing luminairesorfixturesto elevat-
`ing structures, powerregulating components, control compo-
`nents, and the like. The term “reasonably ensure” is used
`throughout this Specification and is intended to mean assur-
`anceor near assurance of a condition, event, or the like except
`in cases of extreme operating conditions(e.g., driving LEDs
`far beyond rated capacities), extreme environmental condi-
`tions(e.g., blizzards), acts of God (e.g., earthquakes), or the
`like. The term “relatively constant light” is used throughout
`this Specification and is intended to meanlight that is per-
`ceived by the average human eye as constant, regardless of
`whethersaid light is constant from a lumen output standpoint.
`Lastly, the terms “beam output pattern”, “beam pattern’,
`“output pattern”, “light pattern”, “beam output”, and “light
`output pattern” are used interchangeablyin this Specification
`and are intended to define the shape, size, and/or nature of
`light emitted from a source. In some cases said source may
`comprise a single LED andin others cases said source may
`comprise a single fixture which housesa plurality of LEDs
`and associated devices which shapethe light projected there-
`from; when juxtaposed, the beams are often referred to as
`“individual” and “composite”, respectively.
`[0059] A. LED Modules
`[0060] Atthe core ofthe envisioned LED lighting system is
`a number of LED modules. As can be seen from FIGS. 1A-C,
`module 10 comprises a circuit board 200 which is seated in
`one end of a housing 300, housing 300 being affixed to pivot
`joint half 101 (e.g., via screws as shown or otherwise) so to
`encapsulate circuit board 200. LED module 10 further com-
`prises a lens 400 whichis seatedin the generally opposite end
`ofhousing 300, lens 400 being furtherpositionally secured by
`a visor 500; visor 500 may be affixed to housing 300 via
`screws (as shown) or otherwise.
`
`FIG.2 illustrates circuit board 200 in greater detail.
`[0061]
`Asillustrated, each LED module 10 comprisesa single board
`200 with a single LED 201 mounted thereon;in this example
`model XP-G or XM-L available from Cree, Durham, N.C.,
`USA,thoughother types, models, and brandsoflight source
`are possible, and envisioned. Circuit board 200 further
`includes a push-button terminal block 202(also referred to as
`a poke-in connector) to aid in the rapid replacement of an
`LEDifit fails; in this example model 1-1954097-1 available
`from Tyco Electronics, Berwyn, Pa., USA, though other mod-
`els and types of connectors are possible, and envisioned.
`Board 200 further includes cutouts 203 and hole 204 so to
`
`ensure board 200 is properly oriented within module 10,
`though this is not a limitation of the invention. If desired,
`board 200 could have multiple LEDs mounted thereon and
`connected in series; this would directly impact efficacy for a
`given powerinput, as well as the beam output pattern pro-
`jected therefrom,andis discussed in provisional U.S. Appli-
`cation Ser. No. 61/539,166 incorporated herein by reference.
`[0062]
`FIGS. 3A-E illustrate multiple views of housing
`300. Back surface 302 of housing 300 is adapted to receive
`circuit board 200 and secure board 200 in place via a bolt (or
`analogous devices) through holes 301, curved apertures 203
`(see FIG. 2), and into threadedblind holes in pivot half 101
`(see FIG. 6A); as one alternative, a nut and bolt combination
`(or analogous device) with through-holes could be used in
`lieu of threaded blind holes in half 101. Front surface 306 of
`
`housing 300 is adapted to receive lens 400 through aperture
`303 and permita limited rotation thereofvia track 304, as well
`as receive visor 500 via thread cutting screws through aper-
`tures 501 (see FIG. 5A) and into holes 305. Housing 300
`further includes a void 308 which acts as a wireway for the
`wiring associated with LED 201 anda post 307 which extends
`through hole 204 of board 200 so to ensure proper orientation
`of board 200.
`
`[0063] As envisioned, housing 300 is designed as the
`anchor point for LED module 10. For example, if an LED
`fails, the bolts can be removed from holes 301, the wiring cut,
`the defective board removed, a new board 200 seated against
`surface 302, the wiring reconnected via poke-in connector
`202, and the bolts through holes 301 re-secured; this can
`occurrapidly and without disturbing the precise alignment of
`pivot joint 100 or orientation of lens 400. Alternatively, if a
`lens needs to be replaced (e.g., to effect a different beam
`output pattern), visor 500 can be removed by removingthread
`cutting screws from now threaded holes 305, the old lens
`removed, a new lens 400 seated in aperture 303 of surface
`306, and the visor re-secured via the thread cutting screws
`through aperture 501 and into threaded holes 305; this can
`occur rapidly and without disturbing LED 201 or the align-
`mentof pivot joint 100.
`[0064]
`FIGS. 4A-C illustrate multiple views of lens 400.
`With regards to said figures—which illustrate a typical nar-
`row beam lens—lens 400 comprises a generally parabolic
`outer surface 401, an LED-adjacent face 402, and an emitting
`face 403. As is well knownin the art, through total internal
`reflection (TIR), light emitted from LED 201 enters face 402,
`is collimated, and projects outwardly from emitting face 403.
`Lens 400 further comprises a tab 404 so to (4) ensure proper
`seating between visor 500 (see reference number506 of FIG.
`5B) and housing 300 (see reference number 304), and (11)
`allow for easy rotation of lens 400 (e.g., for on-site adjust-
`ments).
`
`Petitioner Ensign
`Exhibit 1032 - Page 40 of 49
`
`Petitioner Ensign
`Exhibit 1032 - Page 40 of 49
`
`

`

`US 2012/0217897 Al
`
`Aug. 30, 2012
`
`[0065] The exact design of lens 400 will vary depending on
`the application, the aiming of a particular module 10, the
`numberand layout ofLEDs 201 on board 200, and the desired
`beam output, for example. In practice, every LED module 10
`could have a different lens 400, which may require a variety of
`sizes and shapes of aperture 303 in housing 300 and aperture
`505 in visor 500. As an example, for the board illustrated in
`FIG.2, the lens illustrated in FIGS. 4A-C may be mostappro-
`priate. Ifmultiple LEDs 201 are mountedto board 200—such
`as in aforementioned provisional U.S. Application Ser. No.
`61/539,166—the shape(but notthe function) of lens 400 can
`be expected to change, as well as the shape of apertures 303
`and 505. This is best illustrated by comparing the lens of
`FIGS. 4A-C ofthe present application (which is sized for a
`single LED) with the lenses of FIG. 2 (sized for two LEDsin
`a linear or“elliptical” array) and FIG. 6 (sized for four LEDs
`in a two-by-two or “quad”array) of provisional U.S. Appli-
`cation Ser. No. 61/539,166. As another example, any of a
`number of commercially available lenses could be used. For
`example, any ofthe FCPseries of lenses available from Fraen
`Corporation, Reading, Mass., USA could be used witha light
`shaping diffuser (e.g., any of those available from Luminit,
`Torrance, Calif., USA) to approximate a desired beam output
`pattern; in that example, however, visor 500 would likely
`need to be modified so to positionally affix a diffuser sheet.
`[0066]
`FIGS. 5A-D illustrate multiple views of visor 500.
`As envisioned, visor 500 comprises a center aperture 505
`through whichlight emitted from lens 400 is transmitted; said
`lightis redirected offreflective surface 507 towardsthe target
`area. Visor 500 further comprises short and long edges(ref-
`erence numbers 504 and 503, respectively) so to provide a
`distinct cutoff for light projecting to either side of module 10
`(e.g., to prevent shadowing which can occur whenlight from
`one module strikes anot