Note: Descriptions are shown in the official language in which they were submitted.
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SELF-STANDING REFLECTOR FOR A LUMINAIRE
AND METHOD OF MAKING SAME
Field of the Invention
The present invention relates generally to luminaires and,
more particularly, to three-dimensional reflectors for such luminaires to
produce a light distribution pattern in an area to be illuminated, and its
method of manufacture.
Background of the Invention
Luminaires are designed to produce a predetermined light
distribution pattern in an area to be illuminated, such as in parking lots,
along roadways, or in other areas requiring broad illumination of a
surface. Luminaires generally include a housing or enclosure that
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supports a light socket, a high-intensity light source mounted in the
socket, a light reflector mounted behind and/or around the light source
and other electrical hardware necessary to energize the light source.
The illumination pattern created by the luminaire is generally defined by
the shape of the light reflector mounted in the luminaire, as well as the
position of the light source relative to the reflector. The reflector may
form a partial enclosure about the source of light so that the inner
surfaces of the reflector direct reflected light through an opening
formed in a lower portion of the luminaire housing.
In the past, one-piece reflectors have been fabricated by
molding or otherwise forming a flat piece of metal or other suitable
reflective material into a desired reflector shape. The reflector may be
formed by forming a sheet of reflective material between male and
female dies that have cooperating three-dimensional shapes defining
the reflector shape. Alternatively, the reflector may be formed by
hydroforming the sheet of reflective material over a three-dimensional
male form that defines the reflector shape as is well known in the art.
In another method, the reflector may be spun by contouring a sheet of
reflective material over a revolving male mandrel with a pressure tool
to conform the sheet to the shape of the mandrel. In yet another
method of fabricating reflectors, the sheet of reflective material may
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be formed using a press brake or other forming machine that
successively bends the sheet along predetermined fold lines into a
series of planar facets that approximate a desired curved surface of the
reflector.
Reflectors have also been fabricated from multiple sheets
of reflective material that have been individually shaped and formed
and then assembled together to form a reflector shape. The individual
parts of the multi-component reflector have either been joined together
through fastening hardware or other suitable structures prior to
mounting the assembled reflector in a luminaire housing, or the
reflector components have been mounted individually within the
luminaire housing to form the three-dimensional reflector shape within
the housing.
Forming the desired reflector shape using cooperating
male and female dies has a drawback that the dies are relatively
expensive to make and are difficult to modify if changes in the
reflector shape are required. Moreover, the sheet of material may not
draw easily and consistently to achieve the necessary depth and shape
of the reflector during deep drawing formations. Hydroforming or
spinning of reflectors have the disadvantage that most reflector
manufacturers do not have hydroforming or spinning capabilities
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in-house and must rely on outside contractors with that capability to
form the reflectors. Another disadvantage of reflectors machine-
formed into three-dimensional curved shapes, as by die-drawing,
hydroforming or spinning, is that the reflective finish on the reflector
must be applied in secondary operations, usually by polishing and
anodizing. Using a press brake to successively bend the sheet of
material has the drawback that many manufacturing steps or forming
operations are required to form the many planar facets that define the
reflector shape. Additionally, the series of planar facets formed by
press brake forming operations do not provide a substantially
continuous curve on the inner reflective surfaces of the sheet panels
that may be required to create a certain light distribution pattern. It
will also be appreciated by those skilled in the art that after reflectors
are formed into their three-dimensional shapes through the methods
above, significant warehouse space may be required to store the many
reflector shapes that may be used. Lastly, multi-part reflectors suffer
from the disadvantage that they may require storage and inventory of
many different reflector parts and fastening hardware, as well as
significant off-line subassembly prior to final fabrication of the three-
dimensional reflector.
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Thus, there is a need for a self-standing reflector and
method of making same that allows the reflector to be formed
relatively easily and consistently from at least one sheet of reflective
material.
There is also a need for a self-standing reflector and
method of making that allows the reflector to be rapidly formed from
at least one sheet of reflective material in relatively few manufacturing
steps or forming operations.
There is also a need for a self-standing reflector and
method of making same that allows the reflector to be formed from at
least one sheet of reflective material relatively quickly as needed at the
time and place of luminaire fabrication, thereby reducing the
warehouse space necessary to store many different reflector shapes.
There is yet also a need for a self-standing reflector and
method of making same that allows the reflector to be formed from at
least one sheet of reflective material with substantially continuous
curves on the inner reflective surfaces of the reflector and retained in a
predetermined three-dimensional shape.
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Summary of The Invention
The present invention overcomes the foregoing and other
shortcomings and drawbacks of luminaire reflectors and methods
heretofore known. While the invention will be described in connection
with certain embodiments, it will be understood that the invention is
not limited to these embodiments. On the contrary, the invention
includes all alternatives, modifications and equivalents as may be
included within the spirit and scope of the present invention.
In accordance with the principles of the present invention,
a self-standing reflector and method of making same is provided for
forming a reflector from at least one sheet of reflective material. Each
sheet of material is preferably formed in a single hit die press to form a
series of integral reflective panels. The sheets of reflective material
are adapted to be joined together so that the panels may be folded by
hand into edge-abutting relationship to define a predetermined three-
dimensional reflector shape. At least some of the panels may include
substantially non-linear free edges that abut substantially non-linear
free edges of abutting panels. Each sheet of material is relatively thin
to allow one or more of the panels to be curved by hand to define
curved reflective surfaces. In this way, the abutting curved panels
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form a substantially contiguous curved reflective surface within the
reflector.
The panels are preferably joined to adjacent panels
through perforated fold lines that preferably include a series of
elongated slots formed through the thickness of the sheet. The fold
lines are perforated to allow the sheet of material to be easily folded by
hand along the fold line to form the desired three-dimensional reflector
shape.
Alternatively, a backing member made of relatively stiff
sheet material may be attached to or otherwise operatively engaged
with the sheet of reflective material. The backing member and sheet
are positioned relative to each other so that at least one elongated
edge of the backing member is coincident with a predetermined fold
line in the sheet. Upon folding of a panel by hand, the edge of the
backing member defines a consistent line of bending in the sheet along
the predetermined fold line.
In an alternative embodiment of the present invention,
elongated notches are provided in the sheet to define at least one
generally narrow connecting web associated with at least one of the
panels. The connecting web defines a consistent line of bending in the
sheet that is coincident with a predetermined fold line.
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The panels may include locking members formed
proximate the panel edges that cooperate to provide locking
engagement between abutting panel edges for retaining the reflector in
its three-dimensional reflector shape. The locking members may
include a locking tab extending from one panel edge that is inserted
into a locking slot formed adjacent an abutting panel edge to form a
locking engagement between the abutting panels. Positioning tabs
may be formed to extend outwardly from free edges of the panels.
The positioning tabs of one panel overlie an abutting panel to maintain
abutting relationship of the abutting panel edges.
Thus, it will be appreciated that the reflector of the
present invention may be fabricated in one or more hits in a die press
that is relatively easy to modify in the event changes in the reflector
shape are required. The reflector may be stored flat until needed, and
readily assembled by hand for installation in a luminaire at the time and
place of luminaire assembly, thereby requiring less warehouse space to
store the various reflector shapes than would be required for storing
pre-formed three-dimensional reflectors. It will also be appreciated
that the reflector of the present invention provides a three-dimensional
reflector shape that may be easily and consistently formed from at
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least one sheet of reflective material without a press brake or similar
forming machine.
The above and other objects and advantages of the
present invention shall be made apparent from the accompanying
drawings and the description thereof.
Brief Description of the Drawings
The accompanying drawings, which are incorporated in
and constitute a part of this specification, illustrate embodiments of
the invention and, together with a general description of the invention
given above, and the detailed description of the embodiments given
below, serve to explain the principles of the invention.
Fig. 1 is a perspective view illustrating one embodiment
of a self-standing reflector assembled in accordance with the principles
of the present invention and installed in a luminaire housing;
Fig. 1 A is an enlarged cross-sectional view taken along
line 1 A-1 A in Fig. 1;
Fig. 2 is a top plan view of a sheet of reflective material
that has been formed for making the assembled reflector illustrated in
Fig. 1;
Fig. 2A is an enlargement of the circled area of Fig. 2;
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Fig. 3 is a perspective view showing the sheet of
reflective material illustrated in Fig. 2 being assembled to form the
reflector illustrated in Fig. 1;
Fig. 4 is a partial perspective view of the reflector
illustrated in Fig. 1, showing abutting free edges of a pair of abutting
panels;
Fig. 5 is an enlarged partial perspective view illustrating
one embodiment of a locking mechanism to engage abutting panels;
Fig. 5A is a partial perspective view illustrating an
alternative embodiment of the locking mechanism to engage abutting
panels;
Fig. 5B is a partial cross-sectional view through the
alternate locking mechanism shown in Fig. 5A, illustrating engagement
of the locking mechanism shown in an engaged position in Fig. 5A;
Fig. 6 is perspective view of an alternative reflector
assembled in accordance with the principles of the present invention;
Fig. 7 is a top plan view of a sheet of reflective material
that has been formed for making the assembled reflector illustrated in
Fig. 6;
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Fig. 8 is perspective view of yet another alternative
reflector assembled in accordance with the principles of the present
invention;
Fig. 9 is a top plan view of a sheet of reflective material
that has been formed for making the assembled reflector illustrated in
Fig. 8;
Fig. 10 is perspective view of still yet another alternative
reflector assembled in accordance with the principles of the present
invention;
Fig. 11 is a top plan view of a sheet of reflective material
that has been formed for making the assembled reflector illustrated in
Fig. 10.
Fig. 1 2A is a partial top plan view of a sheet of reflective
material including a backing member to define a predetermined fold line
upon folding of the sheet by hand;
Fig. 1 2B is a partial bottom perspective view of the sheet
of reflective material shown in Fig. 1 2A, illustrating folding of the
sheet at the predetermined fold line;
Fig. 1 2C is a view similar to Fig. 1 2A illustrating an
alternative embodiment of a predetermined fold line in the sheet of
reflective material; and
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Fig. 13 is a disassembled perspective view of a pair of
sheets of reflective material adapted to be joined together and folded
by hand to form an assembled reflector in accordance with the
principles of the present invention.
Detailed Description of Specific Embodiments
With reference to the figures, and to Fig. 1 in particular,
one embodiment of a self-standing reflector 10 assembled in
accordance with the principles of the present invention is shown
installed in a luminaire housing 12 (shown in phantom) of a luminaire
assembly 14. Luminaire assembly 14 includes the enclosed reflector
10, a light source socket 16 disposed within the reflector 10, and a
light source 18 mounted in the socket 16 for emitting light from an
opening 20 formed in the housing 12. A lens (not shown) may be
mounted on the underside of the luminaire housing 12 to cover the
opening 20. The reflector 10 is positioned behind and about the light
source 18 to direct reflected light in a predetermined light distribution
pattern through the opening 20.
In accordance with one aspect of the present invention,
the light source 18 is mounted in socket 16 with its longitudinal axis
21 aligned generally along an optical axis of the reflector 10 to provide
a "Type V" illumination pattern on a roadway or other surface to be
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illuminated. A "Type V" light distribution pattern has circular
symmetry, i.e., the illumination is essentially the same at all lateral
angles around the optical axis of the reflector of the luminaire at a
given distance from the light source. As those of ordinary skill in the
art will appreciate, luminaire housing 12 is preferably an enclosure that
may be formed in a variety of shapes and sizes, and is typically
mounted on a pole or other supporting structure to raise the luminaire
assembly 14 far enough above the ground to provide a broad light
distribution pattern on the ground. While not shown, it will be
appreciated that luminaire assembly 14 may also include a transformer,
capacitor or other electrical hardware (not shown) mounted in
luminaire housing 12 and connected to a source of power (not shown)
for energizing the light source 18 via suitable wiring 1 6a (Fig. 1)
connected to socket 16.
With reference to Figs. 1-5, reflector 10 is preferably
formed from a unitary single sheet of reflective material 22 (Fig. 2)
that may be die cut in a die press operation or otherwise formed using
methods known in the art. The sheet of reflective material 22 may be
polished anodized aluminum (also known as "specular aluminum"),
semi-specular aluminum, or other reflective material that has the
desired reflective and other structural properties for a reflector. The
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sheet 22 may have a thickness of about 0.020 in. to permit it to be
folded and curved by hand into a desired three-dimensional reflector
shape, as will be described in greater detail below. The sheet of
reflective material 22 is adapted to be folded and curved by hand at
the factory or at the installation site into the self-standing reflector 10
which may be then mounted into the luminaire housing 12. As will be
described in detail below, it is contemplated that one or more sheets of
reflective material may be joined together and folded by hand to form a
desired three-dimensional reflector shape in accordance with its
principle of the present invention.
In accordance with one aspect of the present invention as
best understood with reference to Fig. 2, the sheet of reflective
material 22 includes integral panels 24, mounting flanges 26a and
26b, and collar 28 that generally lie in a common plane after formation
of the sheet 22 from the die press or other forming operation. Each
panel 24 is formed with a pair of spaced elongated, substantially non-
linear free edges 30 that are adapted to abut a non-linear free edge 30
of an abutting panel when the panels 24 are folded to form the
assembled reflector 10 as shown in Fig. 1. As set forth herein, the
term "substantially non-linear" is used to describe that the free edges
of panels 24 are formed with generally continuous curves that are
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not defined by a series of connected linear segments. The panels 24
include positioning tabs 32 extending outwardly from the free edges
30 to aid in aligning abutting panel edges as described in greater detail
below with reference to Fig. 4. The panels 24 also include locking
members 34 formed proximate the free edges 30 to form an
engagement between abutting panels as described in greater detail
below with reference to Figs. 1, 4, 5, 5A and 5B.
The panels 24 are joined to the collar 28 through a fold
line 36, and the mounting flanges 26a and 26b are joined to respective
panels 24 through fold lines 38. Preferably, fold lines 36 and 38
include a series of elongated apertures 40 formed through the
thickness of sheet 22 to permit folding of the sheet 22 along the fold
lines 36 and 38 by hand. While a series of elongated apertures 40 are
illustrated in a preferred embodiment for forming fold lines 36 and 38,
it will be appreciated by those of ordinary skill in the art that fold lines
36 and 38 may be formed by smaller circular apertures, slits, score
lines or other bendable or yielding structures formed in the unitary,
single-piece sheet 22 without departing from the spirit and scope of
the present invention. While pre-formed fold lines are preferred, it is
contemplated that other structures formed into the sheet of reflective
material, or attached thereto, are possible to define predetermined fold
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lines or lines of bending in the sheet of reflective material upon folding
of the sheet by hand as will be described in detail below.
As best understood with reference to Fig. 3, assembly of
reflector 10 from the sheet of reflective material 22 is shown in
accordance with the principles of the present invention. Each of the
panels 24 is adapted to be folded by hand downwardly and inwardly
along fold line 36, and also curved by hand to form curved panels with
inside curved reflective surfaces as described in detail below. The
mounting flanges 26a and 26b are adapted to be folded by hand
upwardly along fold lines 38. The collar 28 is adapted to be folded by
hand upwardly along fold line 36, and may include slits (not shown)
that permit collar 28 to be folded upwardly. As the panels 24 are
brought into abutting relationship as shown in Fig. 4 to abut free edges
30, the panels are gently curved by hand to form curved reflective
surfaces on the inside surface of reflector 10. In a preferred abutting
relationship of panels 24, the positioning tabs 32 of one curved panel
overlie the abutting margin of the adjacent curved panel to maintain
abutting relationship of free edges 30. In this way, a substantially
contiguous curved reflective surface 42 (Fig. 1) is formed within
reflector 10 by the abutting curved panels 24. The panels 24 may
include elongated upsets or deformations 46 formed generally parallel
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to the longitudinal axis 21 of the panels on inner surfaces thereof to
modify the reflective pattern created by the panels 24.
As best understood with reference to Figs. 1, 4, 5, 5A
and 5B, the locking members 34 include a locking tab 48 formed
proximate a free edge 30 of the panels 24. Confronting and in registry
with the locking tabs 48 are locking slots 50 formed proximate a free
edge 30 of abutting panels 24. As shown most clearly in Fig. 2, each
panel 24 includes a locking tab 48 formed on one free edge 30 and a
locking slot 50 formed on the opposite free edge 30. In accordance
with one aspect of the invention as shown most clearly in Figs. 1, 4
and 5, the locking tabs 48 are formed as planar tabs 52 extending
outwardly from free edges 30 of the panels 24, while locking slots 50
are formed as slotted tabs 54 extending outwardly from free edges 30
of abutting panels 24. As the panels 24 are brought into abutting
relationship, the locking tabs 48 of one panel 24 are inserted in the
locking slots 50 of an abutting panel 24 and then folded backwardly to
form a locking engagement between the abutting panels 24.
Alternatively, as shown most clearly in Figs. 5A and 5B,
the locking tabs 48 are formed as detent tabs 56 extending outwardly
from free edges 30 of the panels 24, while locking slots 50 are formed
as slots 58 extending through the thickness of sheet 22 inwardly from
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free edges 30 of abutting panels 24. Detents 60 are stamped or
otherwise formed in the tabs 56 to form an upset surface 62
extending below the tab 56. As the panels 24 are brought into
abutting relationship, the locking tabs 48 of one panel 24 are received
in the locking slots 50 of an abutting panel 24 with the upset surfaces
62 of the detent tabs 56 engaging the slots 58 to form a locking
engagement between the abutting panels 24.
Additionally, as the panels 24 are brought into abutting
relationship, the mounting flange 26a of one panel 24 may overlie the
mounting flange 26b of an abutting panel 24 as shown most clearly in
Figs. 1, 4 and 5. Each of the overlying mounting flanges 26a includes
a foldable tab 64 extending outwardly from a free edge 66 of the
mounting flange, while the other underlying mounting flanges 26b
include notches 68 formed on free edges 66 that confront and are in
registry with the foldable tabs 64. As the panels 24 are brought into
abutting relationship, the tabs 64 are folded about the notches 68 to
capture a portion of the mounting flanges 26b between the folded tabs
64 and the overlying mounting flanges 26a. In this way, it will be
appreciated that the locking members 34, foldable tabs 64 and
notches 68 cooperate upon assembly of reflector 10 to retain the
reflector 10 in its self-standing three-dimensional reflector shape.
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Those of ordinary skill in the art will appreciate that other locking
structures and folding configurations are possible to form and retain
the reflector 10 in its self-standing reflector shape without departing
from the spirit and scope of the present invention.
With further reference to Fig. 1, luminaire assembly 14
includes a bracket 70 for supporting the light source socket 16 within
reflector 10 so that the socket 16 and light source 18 extend through
a circular aperture 72 (Figs. 1 and 2) formed in the sheet of reflective
material 22 with the longitudinal axis 21 of source 18 aligned generally
along the optical axis of reflector 10. Bracket 70 is channel shaped
and includes opposite spring flanges 74 that depend from a central
web 76. The socket 16 is mounted to central web 76 through suitable
fasteners 77 so that it extends through the aperture 72 into the
interior of reflector 10.
As best understood with reference to Fig. 1 A, each spring
flange 74 terminates in a T-shaped projection 78 that cooperates with
a respective T-shaped notch 80 (Figs. 1 and 2) formed in a pair of
opposite panels 24. To mount the bracket 70 on the reflector 10, the
spring flanges 74 are biased apart by hand so that enlarged heads 82
of the T-shaped projections 78 register with enlarged slots 84 of the T-
shaped notches 80 (Figs. 1 A, 2A and 3). After the T-shaped
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projections 78 are inserted into the T-shaped notches 80, the spring
flanges 74 are released to allow a narrow neck 86 of the T-shaped
projections 78 to travel into narrow slots 88 of the T-shaped notches
80 (Fig. 1 A). In this position, the enlarged heads 82 of the T-shaped
projections 78 are captured below a surface of the panels 24 as best
understood with reference to Fig. 1 A.
As best understood with reference to Fig. 1, the bracket
70 includes a pair of upstanding ears 90 extending upwardly from the
central web 76 that allow the bracket 70 to be mounted to the
luminaire housing 14 through suitable fasteners (not shown) extending
through apertures 92 formed on the ears 90. The assembled reflector
10 is installed in luminaire housing 12 with the other necessary
electrical hardware. The mounting flanges 26a and 26b of reflector 10
form a rectangular mounting platform 94 that includes apertures 96 for
receiving suitable fasteners (not shown) to secure the reflector 10
within the luminaire housing 12.
Referring now to Figs. 6 and 7, an alternative
embodiment of a self-standing reflector 100 is shown in accordance
with the principles of the present invention. Reflector 100 is also
partially enclosed about a light source 102, and is particularly adapted
to provide a "forward throw" light distribution pattern in an area to be
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illuminated. Reflector 100 is formed from a sheet of reflective material
104 (Fig. 7) through a similar process as described above with
reference to reflector 10. Sheet 104 includes integral top panel 108,
side panels 110, rear panel 112, and mounting flanges 1 14 that are
adapted to be folded and curved by hand to form the assembled
reflector 100 shown in Fig. 6.
The pair of side panels 1 10 are joined to the top panel
108 through fold lines 1 16 that are similar in formation to the fold
lines 36 and 38 described in detail above to allow the side panels 110
to be folded by hand downwardly along the fold lines 116. Rear panel
1 1 2 is joined to top panel 108 through a fold line 1 18 that permits rear
panel 1 12 to be folded and curved by hand downwardly along the fold
line 1 18 into abutting relationship with the side panels 110. Each side
panel 1 10 includes a substantially non-linear free edge 120 that is
1 5 adapted to abut adjacent a free edge 122 of curved rear panel 1 12
when reflector 100 has been assembled. Locking tabs 124 are formed
on the free edges 120 of the side panels 1 10 to engage locking slots
126 formed adjacent free edges 122 of curved rear panel 112.
A light socket 128 is mounted to one of the side panels
110 with its longitudinal axis 121 aligned generally perpendicular to
the folded side panels 110. Each side panel 1 10 includes an
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elongated, apertured tab 130 that extends through a notch 132
formed on the free edges 120 of the curved rear panel 112. The tab
130 includes a grommet 134 mounted or formed in aperture 136 to
protect a power cord 138 that extends from a power source (not
shown) to the base of socket 128 as shown in Fig. 6. In its
assembled shape, reflector 100 is self-standing and adapted to be
mounted in a luminaire housing (not shown) through fasteners (not
shown) extending through apertures 140 formed in mounting flanges
114.
Another alternative embodiment of a self-supporting
reflector 200 in accordance with the principles of the present invention
is shown in Figs. 8-9. Reflector 200 is formed from a sheet of
reflective material 202 (Fig. 9) that includes integral rear panel 204
with a rear louver 206, corner panels 207, side panels 208, front panel
210, mounting flanges 212 and collar 214. The panels 204, 207,
208, 210, rear louver 206, and mounting flanges 212 are adapted to
be folded and curved by hand to form the assembled reflector 200
shown in Fig. 8. Reflector 200 is a self-standing reflector that is
particularly adapted to provide a "forward throw" light distribution
pattern from the perimeter of an area to be illuminated.
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As best understood with reference to Fig. 9, the panels
204, 207, 208 and 210 are joined to the collar 214 through fold line
216. Mounting flanges 212 are joined to corner panels 207 and side
panels 208 through fold lines 218. Front panel 210 includes a fold line
220 to allow the front panel 210 to be folded into a pair of planar
reflective surfaces 210a, 210b as shown in Fig. 8. A fold line 221 is
provided to allow rear louver 206 to be folded by hand downwardly
and inwardly from rear panel 204 to adjust the illumination pattern
created by reflector 200.
Each of the panels 204, 207, 208 and 210 includes
substantially non-linear free edges 222 and locking members 224
formed adjacent the free edges 222 to permit the panels to be folded
and curved by hand and engaged in abutting relationship as shown in
Fig. 8 to retain reflector 200 in its self-standing reflector shape.
Panels 204, 207 and 208 also include positioning tabs 226 extending
from free edges 222 to maintain abutting relationship of the free edges
222. A light socket 228 and light source 230 are supported on a
bracket 232 to extend into the enclosed reflector 200 in a generally
vertical orientation. As described in detail above, reflector 200 is
adapted to be mounted within a luminaire housing (not shown) through
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fasteners (not shown) extending through apertures 234 formed in the
mounting flanges 212.
Yet another alternative embodiment of a self-supporting
reflector 300 in accordance with the principles of the present invention
is shown in Figs. 10 and 1 1. Reflector 300 is formed from a sheet of
reflective material 302 (Fig. 11) that includes integral top panel 304,
front panel 306, side panels 308, rear panel 310, and mounting
flanges 312. The panels 304, 306, 308 and 310, and mounting
flanges 312 are adapted to be folded and/or curved by hand to form
assembled reflector 300 shown in Fig. 10. As best understood with
reference to Fig. 10, reflector 300 is an enclosed, self-standing
reflector that is particularly adapted to provide a "Type III" light
distribution pattern on a surface to be illuminated. A "Type III" light
distribution pattern has generally oval symmetry around the luminaire.
The front panel 306, side panels 308 and rear panel 310
are joined to the top panel 304 through fold lines 314. Mounting
flanges 312 are joined to panels 306, 308 and 310 through fold lines
316. Each of the panels 306, 308 and 310 includes substantially non-
linear free edges 318 and locking members 320 formed adjacent the
free edges 318 to permit the panels to be engaged in abutting
relationship as shown in Fig. 10 to retain reflector 300 in its self-
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standing reflector shape. Each of the panels 306, 308 and 310
includes positioning tabs 322 extending from free edges 318 to
maintain the abutting relationship of the free edges 318 as described in
detail above.
As shown in Fig. 10, a bracket 324 is mounted to the
reflector 300 to support a light socket (not shown) and light source
(not shown) with their longitudinal axes 325 extending generally
parallel to the top panel 304. An aperture 326 (Fig. 11) is formed in
the rear panel 310 to allow the light socket (not shown) and light
source (not shown) to extend into the enclosure formed by reflector
300. The top panel 304 includes louvers 328 that are joined to panel
304 through fold lines 330. The louvers 328 are folded downwardly
by hand or by machine from the top panel 304 along fold lines 330 at
different angles to extend into the enclosure formed by reflector 300.
The louvers 328 are provided to modify the light distribution pattern
created by reflector 300. The reflector 300 is also adapted to be
mounted within a luminaire housing (not shown) through fasteners (not
shown) extending through apertures 332 (Fig. 11) formed in the
mounting flanges 312.
In accordance with an alternative embodiment of the
present invention, as shown in Figs. 1 2A and 12B, a sheet of
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reflective material 400 includes integral panels 402 that generally lie in
a common plane after formation of the sheet 400. At least one
backing member 404, preferably made of relatively stiff sheet metal
and having reflective properties, is attached or otherwise fastened to
an inner surface 406 of the sheet 400. Backing member 404 is
preferably planar and includes a pair of opposite elongated side edges
408a, 408b and a pair of end edges 410a, 410b (Fig. 12B). The
backing member 404 engages sheet 400 and is positioned relative to
the sheet 400 so that at least one of the elongated side edges 408a,
408b is coincident with a predetermined fold line or line of bending in
the sheet 400 upon folding of the sheet 400 by hand.
For example, as shown in Fig. 12B, backing member 404
is positioned so that side edge 408a is coincident with a predetermined
fold line or line of bending 412 associated with one of the panels 402.
Upon folding of the panel 402 downwardly and inwardly by hand, as
represented by arrow 414, the side edge 408a defines a consistent
line of bending in the sheet 400 along the predetermined fold line 412
that is coincident with the side edge 408a. It is contemplated
that backing member 404 could be glued, riveted, screwed or attached
by any other suitable fastening structure or material to the sheet 400.
Additionally, while not shown, it is contemplated that the sheet 400
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and backing member 404 may be provided with pins, detents, tabs,
slots or any other suitable alignment structure that would aid in
registering the backing member 404 relative to the sheet 400 so that
at least one of the elongated side edges 408a, 408b is positioned
accurately to lie coincident with the predetermined fold line or line of
bending 412.
In an alternative embodiment, it is contemplated that
backing member 404 could be configured as part of a hand-held tool
(not shown) or, alternatively, as part of a work bench or table (not
shown), for example. According to this embodiment, the backing
member 404 and sheet 400 are positioned so that the backing member
404 operatively engages the sheet 400 and at least one of the
elongated side edges 408a, 408b is positioned accurately to lie
coincident with the predetermined fold line or line of bending 412.
Upon folding of the panel 402 downwardly and inwardly by hand, at
least one of the side edges 408a, 408b defines a consistent line of
bending in the sheet along the predetermined fold line 412. After
panel 402 has been folded to the desired position, either the backing
member 404 is moved relative to the sheet 400 to the next
predetermined fold line or, alternatively, the sheet 400 is moved
relative to the backing member 404 for the next panel fold.
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Alternatively, as shown in Fig. 1 2C, a sheet of reflective
material 500 includes integral panels 502 and elongated notches 504
that define a generally narrow connecting web 506 associated with at
least one of the panels 502. Each connecting web 506 is preferably
formed by a pair of opposing notches 504 of generally uniform width
that extend along a generally common axis and through the thickness
of the sheet 500. Upon folding of the panel 502 inwardly and
downwardly by hand, it will be appreciated that the connecting web
506 defines a consistent line of bending in the sheet 500 that is
coincident with a predetermined fold line 508 associated with the
panel 502.
Therefore, it will be appreciated by those of ordinary skill
in the art that use of backing member 404, in combination with sheet
400, or notches 504 in combination with connecting web 506,
provides the ability to consistently and reliably define predetermined
fold lines or lines of bending in the sheets 400 and 500, respectively,
without otherwise treating or forming sheets 400 and 500 to include
pre-formed fold lines as described above in connection with Figs. 1-1 1.
While a unitary single sheet of reflective material is
preferred for forming self-standing reflectors in accordance with its
principle of the present invention, it is contemplated that two or more
CA 02363920 2001-11-27
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sheets of reflective material may be joined together and folded to form
a self-standing reflector as described below. For example, as shown in
Fig. 13, two (2) identical sheets of reflective material 600 are adapted
to be joined together, as indicated by arrows 602, and folded by hand
into a self-standing reflector (not shown). It is contemplated that
sheets 600 could be joined together by adhesives, rivets, screws or
any other suitable fastening structure or material, as shown
diagrammatically by numbers 604. Of course, it will be appreciated
that in alternative embodiments, sheets 600 may not be identical, and
more than two (2) sheets of reflective material may be joined together
and folded by hand into a self-standing reflector in accordance with the
principles of the present invention. Additionally, while not shown, it is
contemplated that the sheets 600 may be provided with pins, detents,
tabs, slots or any other suitable alignment structure that would aid in
registering one of the sheets 600 relative to the other during the
assembly process.
While the present invention has been illustrated by a
description of various embodiments and while these embodiments
have been described in considerable detail, it is not the intention of the
applicants to restrict or in any way limit the scope of the appended
claims to such detail. Additional advantages and modifications will
CA 02363920 2001-11-27
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readily appear to those skilled in the art. The invention in its broader
aspects is therefore not limited to the specific details, representative
apparatus and method, and illustrative examples shown and described.
Accordingly, departures may be made from such details without
departing from the spirit or scope of applicants' general inventive
concept.
Having described the invention, what is claimed is:
