Method for assembling optical modules of a luminaire and optical assembly

An optical assembly comprising:

• a frame with at least one opening;
• a plurality of optical modules, each optical module of the plurality of optical modules being provided to an opening of the at least one opening;
• and
• a support means provided to each of the plurality of optical modules and/or to each of the at least one opening, said support means being configured for supporting the optical module at least partially within the opening of the frame;
• wherein each optical module is assembled to the frame by plastically reshaping a material portion in contact with the frame and the optical module, the plastic reshaping occurring under an application of heat and/or pressure;
• wherein, when the optical module is assembled to the frame, a first bottom surface of the optical module is substantially at a same level as a second bottom surface of the frame, said first bottom surface and second bottom surface being adapted for facing and being arranged on a support, said support carrying a plurality of light sources;
• and
• wherein each opening in the frame is delimited by a peripheral wall with at least one protruding portion of the support means configured for supporting at least one peripheral portion of the optical module.

A method for assembling optical modules, said method comprising the steps of:

• providing a frame with at least one opening;
• providing a plurality of optical modules to the frame, each optical module of the plurality of optical modules being provided to an opening of the at least one opening;
• providing a support means to each of the plurality of optical modules and/or to each of the at least one opening, said support means being configured for supporting the optical module at least partially within the opening of the frame;
• and
• assembling the plurality of optical modules to the frame by plastically reshaping a material portion in contact with the frame and the optical module, the plastic reshaping occurring under an application of heat and/or pressure;
• wherein the assembling comprises ultrasonic welding the plurality of optical modules to the frame;
• wherein the optical module and the frame are welded along joining surfaces which form shear joints;
• and
• wherein, when the optical module is assembled to the frame, a first bottom surface of the optical module is substantially at a same level as a second bottom surface of the frame, said first bottom surface and second bottom surface being adapted for being arranged on a support, said support carrying a plurality of light sources.