Patent Application
20100214789
None
This invention pertains to a luminaire reflector assembly. More specifically the invention pertains to a luminaire reflector assembly and method of making the same wherein said the reflector assembly includes three-dimensionally curved reflective panels.
In forming luminaire reflectors, there are several limitations. First, lighting designers prefer a reflector to approximate a desired curvature to the extent possible. In order to form such curvature in typical press brake manufacturing methods, the press brake must be utilized to form each bend in a separate step or “hit” process. Therefore where additional bends are desired to more closely approximate a curve, the manufacturing process becomes more lengthy and expensive.
Moreover, with press brake reflector forming procedures, the formation process may only be accurate to the nearest half degree. In applications where high accuracy is required, a higher degree of accuracy through less tolerance in manufacturing maybe required to produce a luminaire which performs in an acceptable manner.
Current luminaire reflectors utilize segments which are bent in two dimensions. Upon forming these in the press brake, as previously described, the reflectors are typically stacked in until an entire batch of reflectors is formed. As a result of stacking, the lowermost reflectors in the stack carry large loads which often bend these lower reflectors changing them from the “formed” configuration. It would be desirable if the reflectors were stronger without changing material or the desirable optical performance of the reflector.
Given the foregoing deficiencies, it would be desirable to form a luminaire reflector which is bent three dimensionally in a single action and overcomes the above and other deficiencies.
A luminaire reflector assembly comprises a top pan having a light socket connected to one of an upper or lower surface of the top pan, the top pan having a plurality of spaced slits about the periphery of the top pan, a lower pan spaced from the top pan, the lower pan connected to the top pan by at least one strut, a plurality of reflective panels extending between the top pan and the lower pan, the plurality of reflective panels bent in a first direction by a punch and an elastomeric die pad, the plurality of reflective panels also bent in a second direction by the punch and elastomeric die pad. The luminaire reflector assembly wherein each of the plurality of reflective panels having at least one tab disposed at an upper end. The luminaire reflector assembly further comprising a flange disposed at a bottom end of said reflective panels. The luminaire reflector assembly wherein the at least one tab extends through the slot of the top pan. The luminaire reflector assembly wherein the flanges engage the bottom pan. The luminaire reflector assembly wherein the plurality of reflective panels further comprises a tab at a first end and a flange at a second end, said tab engaging one of the top pan and the bottom pan and the flange engaging the other of the top pan and the bottom pan. The luminaire reflector assembly wherein the plurality of reflective panels have at least one corner group disposed adjacent the at least one strut. The luminaire reflector assembly wherein the plurality of reflective panels includes a central group disposed between the struts. The luminaire reflector assembly wherein the plurality of reflective panels being free of visible bend lines along an inner surface.
A luminaire reflector assembly, comprises a bottom pan, a top pan spaced from the bottom pan, a plurality of reflector panels extending between the top pan and the bottom pan, a number of the plurality of reflector panels defining a reflector, the plurality of reflector panels being curved in three dimensions including a first curvature along a horizontal plane and a second curvature along a vertical plane wherein the plurality of reflective panels are curved three dimensionally by a punch and an elastomeric die pad. The reflector assembly wherein the reflector panels further comprise a tab extending from one of the upper end or the lower end of the reflector panels. The reflector assembly wherein the reflector panels further comprise a flange extending from the other of the upper end or the lower end of the reflector panels. The reflector assembly further comprises a lamp aperture in central area of the top pan. The reflector assembly further comprises a plurality of struts extending between the top pan and the bottom pan.
A reflector assembly comprises a top pan, a bottom pan spaced from the top pan, the bottom pan having an aperture disposed therein, the aperture having peripheral stepped regions, a plurality of reflectors panels extending between the top and bottom pans, the plurality of reflectors panels defining at least one reflector, each of the plurality of reflector panels having a first curvature along a horizontal plane and a second curvature along a vertical plane, the reflector panels disposed at varying distances from a centerline of the bottom pan due to the stepped regions within the bottom pan.
A method of manufacturing a luminaire reflector panel comprises the steps of cutting a blank to a preselected shape, placing the blank on a deformable elastomeric pad, the blank disposed between the pad and a male tool, pressing the male tool into the blank and elastic pad, and, forming a first curvature in the blank and a second curvature in the blank with the male tool so that the blank is bent three-dimensionally, positioning the formed blank to define the reflector.
A method of manufacturing a luminaire reflector panel comprises the steps of placing a reflective blank on a deformable elastomeric pad, the reflective blank disposed between the pad and a male punch, the male punch being having three dimensional curvature on a side facing the reflective blank, forcing the male tool into the reflective blank, forming the three dimensional curvature in the reflective blank, cutting the three-dimensionally curved reflective blank into a desired shape, positioning the reflective blank to define the reflector. The method wherein the reflective blank defines a reflector panel. The method further comprises the step of positioning the reflector panel between a top pan and a bottom pan. The method further comprises the step of forming multiple reflector panels. The method further comprises the step of positioning multiple reflector panels to define a complete luminaire reflector.
Embodiments of the invention are illustrated in the following illustrations.
It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.
Furthermore, and as described in subsequent paragraphs, the specific mechanical configurations illustrated in the drawings are intended to exemplify embodiments of the invention and that other alternative mechanical configurations are possible.
Referring now in detail to the drawings, wherein like numerals indicate like elements throughout the several views, there are generally shown in
Referring initially to
As shown in the assembled view, the reflector 20 is engaged at the top by the top pan 12 and at the bottom by the bottom pan 14. The reflector 20 is generally circular, in a horizontal plane, in shape and with a varying radius through a vertical plane. Therefore the reflector 20, defined by the plurality of panels, for example panels 60,70, 80 of
Referring now to
The panels of reflector 20 depend from the top pan 12 (
Referring now to
Beneath the top pan 12 is the reflector 20. A plurality of reflective panels define the reflector 20, and each of the panels extend between the top pan 12 and the bottom pan 14. Each of the reflective panels is curved in three dimensions. This curvature is obtained through the use of a tool disposed on one side of the reflector panel and an elastomeric pad disposed on the opposite side of the reflector panel during a manufacturing process. The three dimension bending occurs with a single pressing action of the tool against a blank which eventually is formed into each reflector panel. The three dimensional bending of the reflective panels provides a highly desirable output for the reflector assembly 10 and the luminaire as a whole. Additionally, the three-dimensional bending provides a stronger shape for supporting the load of a plurality of stacked reflector panels. Thus the three dimensionally curved reflector panel is resistant to bending from the weight of the reflectors stacked above.
Beneath the reflector 20 is a bottom pan 14. The bottom pan 14 is generally square in shape, although alternative shapes may be utilized. The bottom pan 14 further comprises an opening 15 for light output. The lower light output opening 15 is generally circular in shape with steps of varying radius along the inner edge of the opening. Although, the output opening 15 comprises areas of varying radius, this is an exemplary embodiment and the steps may not necessarily be included in order to properly form the instant invention.
Referring now to
Referring again briefly to
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At the upper end of the corner reflector panel 60, the tabs 64 extend through the slits 44 in the top pan 12. Once the tabs 64 pass through the slits 44 near the corner area of the top pan 12, the portion of the tab 64 above the top pan 12 may be bent to secure the panel 60 to the top pan 12. In an alternative combination, a flange 68 may be located at the top of the panel 60 and the tabs 64 may be relocated to along the bottom edge. However, these constructions are merely exemplary and alternative structures, devices and means may be utilized to connect the corner reflector panel 60 to the top pan 12 and bottom pan 14.
Referring now to
The central reflector panel 70 also comprises a plurality of bend lines 79 extending from the upper edge 72 toward to the flange 78. This is an exemplary embodiment however. Alternatively, the reflector panel 70 may be formed so that bend lines may not be visible to provide smooth curvature for the three dimensionally curved panel 70. Additionally, the reflector panel 70 is generally wider from side edge 76 to opposite side edge 76 than the corner reflector panel 60.
Referring now to
Each of the reflective panels 60, 70, 80 are formed of reflective lighting sheet. Such reflective lighting sheet may be an aluminum sheet or a pre-paint material.
Referring now to
The top pan 12 further comprises a plurality of slots 44 which receive the tabs 64,74,84 of the reflector 20. Along the right hand edge of the top pan 12, the slots 44 are described for positioning of the various reflector panels 60, 70, 80. The two most central slots 44 receive the tabs 74 of the central reflector panel 70. The central panel 70 is given this name due to its central position along each edge of the top pan 12. The two slots 44 in each corner receive the tabs 64 of the corner reflector panels 60. The two remaining slots 44 between the corner slots 44 and the central slots 44 receive the intermediate reflector panel tabs 84. As best shown in
Referring to
A corner reflector panel 60 is positioned at a distance R4 on the bottom pan 14. As clearly seen from the figure, the radial distance R4 is greater than radial distance R3. These four panels represent generally one-eighth of the reflector 20 circumference. The remaining space about the bottom pan 14 is filled in similarly as described with the different reflector portions. In this design, the reflector panels 60, 70, 80 are spaced various radial distances from the center line of the aperture 50 to provide a desirable light output
Referring now to
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Thus in operation, one of a raw blank or a pre-cut blank is placed on the base 54 having the elastomeric pad 54. Once the blank is properly positioned and oriented, the tool 56 is forced downwardly to engage the blank and begins bending the blank into a three-dimensionally curved reflector panel, for example panel 60. Upon formation of the panel 60, the piece is removed and may be stacked. Due to the three-dimensional curvature, the reflector panel is stronger than a reflector having a two-dimensional curvature. Accordingly, the reflector is stronger and less likely to bend when positioned at the bottom of a stack of reflector panels. Additionally, once the reflector panel 60 is removed from the elastomeric pad 54, a blank may be positioned and oriented for formation.
Referring now to
Positioned between the top pan 112 and lower pan 114 is a reflector 120. The reflector 120 is three-dimensionally curved and formed in a process wherein the material is stamped and three-dimensionally curved with a single tool in a single action. Thus, the reflector 120 need not be formed by multiple bending processes, but instead formed in a single “hit” of a tool 56 (
Within the upper opening 119 of the top panel 112, are a plurality of upper reflector segments 117. These reflector segments 117 are curvilinear and direct light downwardly through the light output aperture 115. The upper segments 117 are angled relative to the vertical so as to direct light downwardly to a desired area. The segments 117 therefore may be pivotally adjustable and in accomplishing this task are depicted as being connected by rivets to connection elements 119 on the edge of the aperture 119 in the top pan 112.
Referring now to
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The foregoing description of structures and methods has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise steps and/or forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the claims appended hereto.
