Reflecting cover

Abstract

The utility model provides a reflecting cover which comprises a shell and a cover body structure arranged in the shell. Wherein the cover body structure is a deep drawing structural part formed by an aluminum base material composite reflecting sheet or a laser welding structural part formed by the aluminum base material composite reflecting sheet, so that the reflecting surface of the cover body structure is in a circumferential continuous form. The deep drawing structural part is of an integral hollow structure, splicing gaps in the axial side face can be completely eliminated, light is prevented from leaking from the gaps or stray light is prevented from being generated, it is ensured that the light is directionally reflected through the light reflecting face, and the light efficiency utilization rate is increased. According to the laser welding structural part, the splicing gap of the aluminum base material composite reflector can be controlled to be in the micron order, the effect is close to the seamless effect of the axial side face, the risk of light leakage is remarkably reduced, and the lighting effect treatment effect of the reflector is improved.

Description

reflector Technical Field

[0001] This utility model relates to the field of light effect accessories technology, and in particular to a reflector. Background Technology

[0002] In fields such as lighting and optical instruments, reflectors are important optical components. Their main function is to reflect and converge light emitted from a light source to improve light utilization and create a specific light distribution. The inner surface of the reflector is a reflective surface used to reflect light.

[0003] Currently, reflectors are typically composed of multiple reflective strips spliced ​​together. During installation, adhesives, clips, or other fixing devices are usually used to secure the strips to the housing, allowing the reflective surfaces of multiple strips to be joined together to form a complete reflective surface. Due to factors such as the processing precision of the strips, the installation process, and the material properties, gaps can easily occur between adjacent strips.

[0004] The presence of these gaps can adversely affect the performance of the reflector. For example, light may leak or scatter through the gaps, reducing the reflector's light utilization rate and preventing the formation of an ideal light distribution, thus affecting the lighting effect. In some applications with extremely high optical performance requirements, such as high-brightness lighting equipment, the presence of gaps can lead to serious optical defects, making it impossible to meet actual usage needs. Summary of the Invention

[0005] The purpose of this invention is to solve the technical problem in the prior art where reflectors are prone to gaps, which affects the light processing performance of the reflectors.

[0006] To solve the above-mentioned technical problems, this utility model provides a reflector, which includes:

[0007] The housing has openings at both ends and is hollow inside; the two ends of the housing with openings are respectively a light-inlet end and a light-outlet end, and the diameter of the housing gradually increases from the light-inlet end to the light-outlet end; the light-inlet end is used to connect to the lamp.

[0008] The cover structure is open at both ends and hollow inside. The diameter of the cover structure gradually increases from one end to the other. The inner wall of the cover structure forms a continuous reflective surface for reflecting light. The cover structure is disposed inside the outer shell. The light emitted by the lamp can enter the interior of the cover structure through the light inlet end and be reflected by the reflective surface before being emitted through the light outlet end.

[0009] The cover structure is either a deep-drawn structure formed by an aluminum substrate composite reflective sheet or a laser-welded structure formed by an aluminum substrate composite reflective sheet.

[0010] In some embodiments of this application, the cover structure is provided in multiple ways, and the multiple cover structures are sequentially spliced ​​and connected, and the multiple cover structures are arranged coaxially; the inner walls of the multiple sequentially spliced ​​cover structures are connected to form the reflective surface.

[0011] In some embodiments of this application, the curvature of multiple cover structures is different.

[0012] In some embodiments of this application, the reflecting surface extends in a gradually expanding parabolic shape in the direction from the light-inlet end to the light-outlet end.

[0013] In some embodiments of this application, the reflector further includes a snap-fit ​​component, which includes an annular snap-fit ​​body and a connecting portion disposed on the outer periphery of the snap-fit ​​body. The snap-fit ​​body is disposed at the light-inlet end of the housing, and the connecting portion is used for snap-fitting and fixing with the lamp.

[0014] In some embodiments of this application, the connecting portion is provided in multiple ways, and the multiple connecting portions are arranged at intervals along the circumference of the snap-fit ​​body.

[0015] In some embodiments of this application, the cover structure has three parts, namely a first cover, a second cover, and a third cover; the first cover and the third cover are respectively connected to both ends of the second cover;

[0016] The end of the first cover away from the second cover is positioned corresponding to the light-emitting end, and the end of the third cover away from the second cover is positioned corresponding to the light-incoming end.

[0017] In some embodiments of this application, the reflector further includes an annular convex edge, which is disposed around the periphery of the opening at one end of the first cover away from the second cover, and the convex edge abuts against the end face of the light-emitting end of the outer shell.

[0018] In some embodiments of this application, the aluminum substrate composite reflector includes a substrate and a surface treatment layer disposed on the surface of the substrate. The surface treatment layer is disposed on the surface opposite to the substrate for light reflection. The surface treatment layer includes an anodized layer disposed on the surface of the substrate and a pure silver coating disposed on the surface of the anodized layer opposite to the substrate.

[0019] In some embodiments of this application, the thickness of the cover structure is 0.1mm-1.6mm.

[0020] As can be seen from the above technical solution, the beneficial effects of this utility model are as follows: In the reflector of this utility model, the reflector structure is a drawn structure formed by an aluminum substrate composite reflector or a laser-welded structure formed by an aluminum substrate composite reflector, making the reflective surface of the reflector structure circumferentially continuous. This drawn structure is an integral hollow structure, which can completely eliminate the splicing gaps on the axial sides, preventing light leakage from the gaps or the generation of stray light, ensuring that light is directionally reflected by the reflective surface, and improving the light efficiency utilization rate. This laser-welded structure can control the splicing gaps of the aluminum substrate composite reflector to the micron level, approaching the effect of seamless axial sides, significantly reducing the risk of light leakage and improving the light processing effect of the reflector. Attached Figure Description

[0021] Figure 1 is a structural schematic diagram of an embodiment of the reflector of this utility model.

[0022] Figure 2 is an exploded view of the reflector shown in Figure 1.

[0023] Figure 3 is a structural schematic diagram of another embodiment of the reflector of this utility model.

[0024] Figure 4 is a cross-sectional view of the reflector shown in Figure 3.

[0025] Figure 5 is an exploded view of the reflector shown in Figure 3.

[0026] Figure 6 is a flowchart of the manufacturing method of the reflector of this utility model.

[0027] Figure 7 is a schematic diagram of the manufacturing process shown in Figure 6.

[0028] Figure 8 is a magnified view of part A in Figure 7.

[0029] Figure 9 is a flowchart of another embodiment of the manufacturing method of the reflector of this utility model.

[0030] Figure 10 is a schematic diagram of the operation process of the manufacturing method shown in Figure 9.

[0031] The reference numerals in the attached drawings are explained as follows: 100, reflector; 10, outer shell; 101, light inlet; 102, light outlet; 20, cover structure; 201, reflective surface; 2011, first cover; 2012, second cover; 2013, third cover; 21, protruding edge; 30, snap-fit ​​part; 31, snap-fit ​​main body; 32, connecting part; 400, deep drawing die; 401, punch; 402, die; 403, pressing module; 500, circular blank; 600, plastic film; 700, cylindrical die; 800, roll material. Detailed Implementation

[0032] Typical embodiments embodying the features and advantages of this utility model will be described in detail in the following description. It should be understood that this utility model can have various variations in different embodiments, all of which do not depart from the scope of this utility model, and the descriptions and illustrations therein are for illustrative purposes only and not intended to limit this utility model.

[0033] In the description of this application, it should be understood that, in the embodiments shown in the accompanying drawings, the indications of direction or positional relationships (such as up, down, left, right, front, and back) are merely for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. These descriptions are appropriate when these elements are in the positions shown in the accompanying drawings. If the description of the positions of these elements changes, these directional indications also change accordingly.

[0034] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly specified.

[0035] Referring to Figures 1 and 2, one embodiment of this application provides a reflector 100, which can be used with a lamp to reflect the light emitted by the lamp. The reflector 100 includes a housing 10 and a cover structure 20.

[0036] The housing 10 has openings at both ends and is hollow inside. The two ends of the housing 10 with openings are a light inlet end 101 and a light outlet end 102, respectively. The diameter of the housing 10 gradually increases from the light inlet end 101 to the light outlet end 102. The light inlet end is used to connect to the lamp.

[0037] The cover structure 20 is an aluminum-based composite reflector. The cover structure 20 is open at both ends and hollow inside. The diameter of the cover structure 20 gradually increases from one end to the other. The inner wall of the cover structure 20 forms a circumferentially continuous reflective surface 201, which is used to reflect light. The cover structure 20 is located inside the outer casing 10. Light emitted by the lamp can enter the interior of the cover structure 20 from the light-inlet end and be reflected by the reflective surface 201 before exiting from the light-outlet end 102.

[0038] Among them, the cover structure 20 is a deep-drawn structural component formed by aluminum substrate composite reflective sheet or a laser-welded structural component formed by aluminum substrate composite reflective sheet.

[0039] For the reflector 100 of this application, its cover structure 20 is a drawn structure formed from an aluminum-based composite reflective sheet or a laser-welded structure formed from an aluminum-based composite reflective sheet, so that the reflective surface 201 of the cover structure 20 has a circumferentially continuous shape. This drawn structure is an integral hollow structure, which can completely eliminate the splicing gaps on the axial sides, preventing light leakage from the gaps or the generation of stray light, ensuring that light is directionally reflected by the reflective surface, and improving the light efficiency utilization rate. This laser-welded structure can control the splicing gaps of the aluminum-based composite reflective sheet to the micrometer level, approaching the effect of seamless axial sides, significantly reducing the risk of light leakage and improving the light processing effect of the reflector 100.

[0040] In some embodiments of this application, as shown in Figures 3 to 5, multiple cover structures 20 may be provided, which are sequentially spliced ​​and connected, and arranged coaxially. The inner walls of the multiple sequentially spliced ​​cover structures 20 are connected to form a reflective surface 201.

[0041] The splicing and connection of multiple cover structures 20 can extend the reflective surface 201. The extension of the reflective surface 201 can increase the contact area with incident light, thereby collecting more light and reflecting it to the target area, and improving the overall intensity of the illumination.

[0042] In some examples, the curvatures of multiple dome structures 20 can be different. Multiple dome structures 20 with different curvatures are spliced ​​together to form a gradient curvature. By designing dome structures 20 with different curvatures in segments, light can be controlled in segments to achieve multi-level optical transformation of light, enabling the reflector 100 to meet the lighting needs of different scenarios.

[0043] In some embodiments of this application, the reflecting surface 201 extends in a gradually expanding parabolic shape in the direction from the light-inlet end 101 to the light-outlet end 102.

[0044] When the lamp is connected to the reflector 100, the light-emitting point of the lamp can correspond to the focal position of the parabola formed by the reflector 201. The parabolic reflector 201 can reflect all incident light rays into a beam of light parallel to the optical axis, achieving a collimation effect with zero divergence angle, so that the light rays incident on the lamp form parallel light and are emitted from the light-emitting end 102.

[0045] In some examples, the cover structure 20 may have three parts, namely a first cover 2011, a second cover 2012, and a third cover 2013. The first cover 2011 and the third cover 2013 are respectively connected to the two ends of the second cover 2012. The end of the first cover 2011 away from the second cover 2012 is set at the light output end 102, and the end of the third cover 2013 away from the second cover 2012 is set at the light input end 101.

[0046] The inner wall of the third cover 2013 is the front end of a parabola with a small radius of curvature, which can be used for the initial convergence of light. The inner wall of the second cover 2012 can be the middle section of an elliptical arc to reflect the converged light to the first cover 2011. The inner wall of the first cover 2011 can be the rear section of a freeform surface to achieve uniform diffusion of light.

[0047] In this example, the reflector 100 may also include an annular protruding edge 21, which is disposed around the periphery of the opening at one end of the first cover 2011 away from the second cover 2012, and the protruding edge 21 abuts against the end face of the light-emitting end 102 of the housing 10.

[0048] The protruding edge 21 is a ring-shaped structure that directly abuts against the end face of the light-emitting end 102 of the outer shell 10. It can ensure that the axial position of the cover structure 20 is fixed in the outer shell 10 through mechanical limiting, avoid coaxiality deviation caused by assembly error, and ensure the overall axial consistency after multiple cover structures 20 are spliced ​​together.

[0049] During the operation of the lamp, the contact between the protruding edge 21 and the housing 10 can provide lateral support, prevent the housing structure 20 from moving axially, maintain the stability of the reflective surface 201, and avoid the deviation of the light reflection path caused by structural displacement.

[0050] Furthermore, the contact between the protruding edge 21 and the end face of the outer shell 10 can fill the gap between the cover structure 20 and the outer shell 10, preventing light that has not been reflected by the reflective surface 201 from leaking directly from the edge of the light-emitting end 102, ensuring that all light is reflected directionally through the reflective surface 201, and improving the light efficiency utilization rate.

[0051] In some embodiments of this application, the aluminum substrate composite reflector may include a substrate and a surface treatment layer disposed on the surface of the substrate. The substrate is aluminum with a purity of not less than 99.85%, and the thickness of the substrate may be 0.02 mm to 1.5 mm.

[0052] A surface treatment layer is disposed on the surface of the substrate, and the surface treatment layer may include an anodized layer and a pure silver coating.

[0053] Specifically, an anodic oxide layer is formed on the surface of the substrate using an electrochemical anodizing process to create a dense alumina film. This alumina film provides electrical insulation, preventing electrochemical corrosion of the aluminum substrate upon contact with other metals. The thickness of the anodic oxide layer can range from 5 μm to 25 μm, and its surface can exhibit a microporous structure.

[0054] A pure silver coating is applied to the surface of the anodic oxide layer facing away from the substrate. The microporous structure of the anodic oxide layer provides anchoring points for the pure silver coating, improving the bonding strength between the pure silver coating and the anodic oxide layer. The thickness of the pure silver coating can be 0.1μm-0.5μm, and its visible light reflectivity is as high as 95%-98%, which can significantly improve the light utilization rate of the aluminum substrate composite reflector.

[0055] Furthermore, the surface of the aluminum-based composite reflector can be made to have mirror efficiency through mechanical or chemical polishing processes, thereby reducing light scattering. The aluminum-based composite reflector shown in this application has a reflectivity of 98%.

[0056] In some embodiments of this application, the thickness of the reflector structure 20 is 0.1mm-1.6mm. This thin-walled structure with a thickness of 0.1mm-1.6mm can further reduce the overall weight of the reflector 100, reduce the load on the mounting bracket, and improve product portability.

[0057] Furthermore, when multiple thin-walled cover structures 20 are spliced ​​together, such as by laser welding, the thinness can reduce the risk of thermal deformation, the weld is more uniform, and the inner wall of the spliced ​​multi-segment cover structure 20 is smooth, ensuring the effective reflection of light by the reflective surface 201.

[0058] In some embodiments of this application, the reflector 100 may further include a snap-fit ​​member 30. The snap-fit ​​member 30 includes an annular snap-fit ​​body 31 and a connecting portion 32 disposed on the outer periphery of the snap-fit ​​body 31. Multiple connecting portions 32 may be provided, and multiple connecting portions 32 are disposed at intervals along the circumference of the snap-fit ​​body 31 on the outer side of the snap-fit ​​body 31.

[0059] The snap-fit ​​body 31 is connected to the light-inlet end 101 of the housing 10, and the connecting part 32 is used to mate with the bayonet of the lamp so that the reflector 100 is connected to the lamp.

[0060] Furthermore, in this application, the cover structure 20 is a deep-drawn structural component formed from a sheet-like aluminum substrate composite reflective sheet or a laser-welded structural component formed from a roll-like aluminum substrate composite reflective sheet. This cover structure 20 can be manufactured by the manufacturing method described below.

[0061] As shown in Figures 6, 7, and 8, in some embodiments of this application, the manufacturing method may include the following steps:

[0062] S10 provides an aluminum-based composite reflector, which is cut into a circular blank.

[0063] S20, place the circular blank on the die of the deep drawing die, control the punch to descend to the bottom and fit with the bottom of the die, so that the circular blank forms a hollow part with one end open and the other end closed.

[0064] S30, gradually widen the diameter of the hollow part to form a flared structure with a gradually increasing diameter;

[0065] S40, remove the closed bottom of the flared structure to obtain a cover structure with open ends and a hollow interior.

[0066] The manufacturing method described in the above embodiments involves drawing a circular blank into a complete hollow part in one step using a deep-drawing die. This hollow part has continuous sides without any splicing. Compared to the prior art method of fabricating reflectors by splicing pieces together, the manufacturing method of this application effectively avoids the problem of multiple gaps on the axial sides due to insufficient fit at the splicing points, ensuring the continuity and integrity of the overall reflector structure and guaranteeing a high-quality and efficient reflective effect.

[0067] In step S10, the aluminum substrate composite reflector may include a substrate and a surface treatment layer disposed on the surface of the substrate. The substrate is aluminum with a purity of not less than 99.85%, and its thickness can be 0.02 mm to 1.5 mm.

[0068] A surface treatment layer is disposed on the surface of the substrate, and the surface treatment layer may include an anodized layer and a pure silver coating.

[0069] Specifically, an anodic oxide layer is formed on the surface of the substrate using an electrochemical anodizing process to create a dense alumina film. This alumina film provides electrical insulation, preventing electrochemical corrosion of the aluminum substrate upon contact with other metals. The thickness of the anodic oxide layer can range from 5 μm to 25 μm, and its surface can exhibit a microporous structure.

[0070] A pure silver coating is applied to the surface of the anodic oxide layer facing away from the substrate. The microporous structure of the anodic oxide layer provides anchoring points for the pure silver coating, improving the bonding strength between the pure silver coating and the anodic oxide layer. The thickness of the pure silver coating can be 0.1μm-0.5μm, and its visible light reflectivity is as high as 95%-98%, which can significantly improve the light utilization rate of the aluminum substrate composite reflector.

[0071] Furthermore, the surface of the aluminum-based composite reflector can be made to have mirror efficiency through mechanical or chemical polishing processes, thereby reducing light scattering. The reflectivity of the aluminum-based composite reflector or aluminum coil shown in this application can reach 98%.

[0072] For step S10, in some examples, a high-precision carbide mold can be used to precisely control the gap between the die and the punch, and then combined with a pressure ring and a counter-force device to achieve tear-free punching of the aluminum substrate composite reflector to obtain a circular blank.

[0073] The circular blank obtained by the above punching method can avoid cracking during the deep drawing process caused by edge defects and meet the geometric requirements of high-precision reflectors for the initial blank.

[0074] In some examples, a fiber laser cutting machine can be used to melt or vaporize aluminum sheets by focusing a laser beam, and then cut them according to a preset trajectory using a CNC system to obtain a circular blank.

[0075] Circular blanks are obtained through laser cutting, without mold limitations, and can be quickly switched between cutting circular blanks of different diameters, making it suitable for processing small batches of products with multiple specifications. Furthermore, the heat-affected zone of laser cutting is relatively small, avoiding edge hardening and improving the material's plasticity in subsequent deep drawing steps.

[0076] In other examples, high-pressure water jets can be used to cold-cut aluminum-based composite reflective sheets to obtain circular blanks. This method generates no mechanical or thermal stress, ensuring a tight fit between the circular blank and the drawing die during deep drawing, thus guaranteeing the effectiveness of the deep drawing operation.

[0077] In addition, in step S10, after the circular blank is cut, the burrs or chamfers on the edge of the circular blank can be removed by rotating a grinding wheel or by electrochemical means.

[0078] Further, as shown in Figures 7 and 8, in this application, in step S20, the circular blank 500 made of aluminum substrate composite reflective sheet is placed on the concave die 402 of the deep drawing die 400, and the punch 401 is controlled to descend to the bottom and fit with the bottom of the concave die 401, so that the circular blank 500 forms a hollow part with one end open and the other end closed.

[0079] When the circular blank 500 is placed on the die 402 of the drawing die 400, the circular blank 500 can be placed in the center, and the central axis of the circular blank 500, the die 402, and the pressing module 403 of the drawing die can be ensured to coincide with each other through the assistance of the positioning pin or the centering device.

[0080] In some examples, a positioning structure can be provided on the surface of the die 402. The positioning structure can be a positioning ring, a positioning pin, or an annular groove, etc.

[0081] When the circular blank 500 is placed on the die 402 of the drawing die 400, the edge of the circular blank 500 can be placed in the positioning structure to ensure that the circular blank 500 does not shift during the drawing process and to ensure the drawing effect.

[0082] In some examples, step S20 can be repeated several times depending on the required depth of the cover structure, such as performing the drawing operation in 2-3 steps.

[0083] In this example, annealing is performed after each deep drawing operation. The annealing temperature can be 200℃-300℃, and the holding time can be 0.5h-1h. Annealing can eliminate the hardening caused by the deep drawing operation on the aluminum substrate composite reflector, restoring the material's plasticity.

[0084] In addition, during the deep drawing operation, a plastic film 600 can be placed on the surface of the aluminum substrate composite reflector 500 to protect the aluminum substrate composite reflector, avoid surface damage to the aluminum substrate composite reflector, and ensure the manufacturing quality of the reflector.

[0085] Furthermore, in this application, step S30 involves gradually widening the diameter of the hollow part to form a widened structure with a gradually increasing diameter.

[0086] In some examples, step S30 may include the following steps: placing the hollow part on the flaring punch of the drawing die, controlling the tapered die to descend to apply a radial force to the end of the hollow part, thereby causing the diameter of the hollow part to gradually widen to obtain a flared structure.

[0087] In this example, the conical design of the conical die allows the radial force on the end of the hollow part to gradually increase during the downward movement of the conical die. This causes the material of the hollow part to gradually expand outward from the end, avoiding material cracking or excessive thinning due to instantaneous stress concentration, and improving the stability and yield of the flaring process.

[0088] Furthermore, the shape guidance of the conical die allows for precise control of the taper of the flare, ensuring that the generatrix of the flare structure fits snugly against the conical surface of the die, forming a uniform, gradually expanding profile. This effectively meets the reflector's requirements for surface precision.

[0089] In this example, the downward movement of the tapered die generates a radial force that acts on the outer periphery of the hollow part, causing the material of the hollow part to expand uniformly along the circumferential direction. This avoids the problem of uneven wall thickness in the flared structure caused by excessive local drawing, and ensures the consistency of the mechanical strength of the flared structure.

[0090] In some examples, step S30 may include the following steps: placing the hollow part on the conical mandrel of the flaring mold, rotating the conical mandrel and applying radial pressure to the hollow part, and rolling the outer wall of the hollow part with rollers to make the hollow part fit against the rotating conical mandrel, thereby making the diameter of the hollow part gradually expand to obtain a flared structure.

[0091] In this example, by changing the tapered mandrel with different tapers, it is possible to quickly adapt to the requirements of various flaring angles without large-scale mold changes, thereby reducing process switching costs and making it suitable for the production of multi-specification cover structures.

[0092] The tapered surface of the tapered mandrel directly determines the generatrix shape of the flared structure. During rotation, the hollow part always fits the surface of the tapered mandrel, ensuring that the taper of the flared structure strictly follows the design parameters of the tapered mandrel and thus ensuring the surface accuracy of the flared structure.

[0093] Furthermore, during rotation, the rollers can apply continuous rolling pressure to the local material of the hollow part, causing the material to gradually conform to the conical mandrel during rotation, significantly reducing the risk of material breakage and ensuring the overall stability of the flared structure. Further, in this application, step S40 removes the closed bottom of the flared structure to obtain a cover structure with open ends and a hollow interior.

[0094] In some examples, a punch press can be used to remove the closed bottom of a flared structure. Specifically, a punch is fixed to the slide of the punch press, and a die is fixed to the worktable pad. The clearance between the punch and die is adjusted to a suitable value. Then, the slide is driven to move the punch downward, applying a shearing force to the closed bottom of the flared structure, causing the material to break and separate along the cutting edge of the die, thereby removing the closed bottom of the flared structure.

[0095] Using a punch press to remove the closed bottom of the flared structure is a fast method suitable for mass production, significantly improving production efficiency. Furthermore, positioning devices can be incorporated, such as positioning grooves or pins on the stamping die, to ensure the closed bottom of the flared structure is aligned with the center of the stamping punch, guaranteeing accurate punching position and ensuring the manufacturing quality of the cover structure.

[0096] In some examples, the closed bottom of the flared structure can be cut using a laser. Specifically, a clamp or vacuum adsorption device can be used to fix the flared structure, ensuring that the closed bottom is flat and aligned with the laser focus. Simultaneously, the height of the flared structure can be adjusted to ensure that the cutting plane is perpendicular to the laser beam. By controlling the laser head to move along a preset path, the material corresponding to the closed bottom of the flared structure rapidly melts or vaporizes at high temperature. This allows auxiliary gas to blow away residue from the cut, forming a continuous kerf, thereby removing the closed bottom of the flared structure.

[0097] Using laser cutting to create a flared structure for the closed bottom eliminates the need for custom molds, and the flared structure is not subjected to mechanical force during cutting, effectively preventing deformation at the opening and ensuring the precision and quality of the closed bottom removal process.

[0098] In other examples, the closed bottom of the flared structure can also be removed by methods such as wire electrical discharge machining, chemical etching, and electrolytic processing.

[0099] Furthermore, after completing step S40, the edges of the cut at the flared structure can be polished to remove burrs. This can be done through mechanical polishing, electrochemical polishing, ultrasonic polishing, or other methods to remove burrs and improve the overall quality.

[0100] In some embodiments of this application, a conical punch 401 can be directly used, as shown in Figure 7. The conical punch 401 can directly draw a circular blank to obtain a flared structure with a gradually changing diameter, thereby eliminating the need for step S30.

[0101] In this embodiment, the outer surface of the conical punch 401 can be set as an arc shape so that the extension trend of the inner wall of the flared structure is a gradually expanding parabola, thereby making the extension trend of the reflective surface of the manufactured reflector a gradually expanding parabola.

[0102] When the light emitted by the lamp passes through a reflective surface that extends in a gradually expanding parabolic shape, the light can form parallel light through reflection from the reflective surface.

[0103] Referring to Figures 9 and 10, another embodiment of this application provides a method for manufacturing a reflector, which includes the following steps:

[0104] Step S101: Provide an aluminum substrate composite reflective sheet and cut it into a set shape to obtain a roll material;

[0105] Step S102: Wrap the roll material around the outside of a cylindrical mold with a gradually increasing diameter, and fix the edges of the roll material at the joints.

[0106] Step S103: Laser welding is used to weld the edges of the joints of the coiled parts to obtain a hollow column with open ends.

[0107] Step S104: After welding is completed and cooling is achieved, the hollow column and the cylindrical mold are separated to obtain a cover structure with open ends and a hollow interior.

[0108] The manufacturing method described in the above embodiments involves winding a roll material onto a cylindrical mold with a gradually increasing diameter. The tapered guide of the cylindrical mold allows directional tensile stress to be generated at the edges of the roll material during circumferential bonding, ensuring that the edges of the aluminum roll material are tightly aligned and pre-tightened. Combined with laser welding, a hollow column with continuous sides and no multiple splices can be obtained. Compared with the prior art of using segmented splicing to manufacture reflectors, the manufacturing method of this application embodiment can effectively avoid the problem of multiple gaps on the axial side due to insufficient fitting precision at the splicing points, ensuring the continuity and integrity of the overall structure of the reflector and ensuring the high-quality and efficient reflective effect of the reflector.

[0109] In step S101, the aluminum coil is made of the same material as the aluminum-based composite reflector described above, and will not be described in detail here. A coil of aluminum-based composite reflector can be provided and cut into the desired shape.

[0110] Specifically, the aluminum-based composite reflector can be cut into several rectangular or trapezoidal rolls using laser cutting or precision die-cutting equipment, according to the design dimensions of the reflector. A certain welding allowance, i.e., the overlap width of the edges, can be reserved during cutting to ensure sufficient welding area at the seams after winding.

[0111] Referring to Figure 10, in this application, step S102 involves wrapping the roll material 800 around the outside of the cylindrical mold 700, whose diameter gradually increases, and fixing the edges of the roll material 800 at the joints.

[0112] Before winding the roll material 800 onto the cylindrical mold 700, a release agent, such as a water-based release agent or an oil-based release agent, can be evenly applied to the surface of the cylindrical mold 700 to reduce demolding resistance, prevent the cylindrical mold 700 from sticking to the roll material 800, and facilitate the subsequent separation of the roll material 800 from the cylindrical mold.

[0113] The cylindrical mold 700 features a gradually increasing diameter, which not only matches the overall structural shape of the reflector but also allows the coil material 800 to withstand a certain axial stress during the forming process through its conical structure, preventing material wrinkles or localized bulges. Uniform stress distribution ensures consistent edge deformation during subsequent welding operations, preventing post-weld springback cracking caused by uneven stress, thus guaranteeing the sealing and integrity of the reflector structure's axial sides.

[0114] In some examples, step S102 further includes the following steps: taking several rolls of material 800, aligning one edge of the cut roll of material 800 with one edge of the cylindrical mold 700, and using an auxiliary tool to fix the roll of material 800 to the surface of the cylindrical mold.

[0115] Align one edge of the cut roll material 800 with the starting edge (such as the small diameter end) of the cylindrical mold 700 to ensure that the axial reference line of the roll material 800 is parallel to the generatrix of the mold, so as to ensure the welding accuracy of subsequent welding operations.

[0116] In this example, after the roll material 800 is wound around the cylindrical mold 700, the roll material 800 can be fixed to the surface of the cylindrical mold 700 using an auxiliary tool.

[0117] The auxiliary tools can be mechanical clamps, such as adjustable clamps, C-clamps, or spring clamps, which hold the edges of the roll material 800 by mechanical force. Auxiliary tools can also be magnetic devices, which can adhere to the surface of the cylindrical mold 700 and fix the roll material 800 by magnetic force. Auxiliary tools can also be vacuum adsorption devices, which use negative pressure to adsorb the roll material 800 onto the surface of the cylindrical mold 700. Finally, auxiliary tools can also be adhesive tape, which can temporarily bond the edges of the roll material 800 to the surface of the cylindrical mold 700.

[0118] In some examples, in step S102, the cylindrical mold 700 can be rotated and the roll material 800 can be wound around the surface of the cylindrical mold 700, the extension direction of the rotation axis of the cylindrical mold 700 is consistent with the direction of its own axis.

[0119] It can drive the cylindrical mold 700 to rotate at a constant speed so that the coil material 800 is wound along the generatrix at a constant linear speed. This can further reduce the overlap error of adjacent coil material 800, avoid the overlap fluctuation caused by uneven speed during manual winding, and ensure the subsequent welding effect.

[0120] Furthermore, by controlling the rotation angle, the busbar weld can be precisely positioned in the non-optical functional area of ​​the reflector to avoid the weld affecting the light reflection path of the main reflective surface, thus ensuring the effectiveness of the reflector in reflecting light.

[0121] Furthermore, in this application, in step S103, laser welding is used to weld the edges of the joints of the coil parts 800 to obtain a hollow column with open ends.

[0122] The aluminum-based composite reflector of this application has a thickness of 0.1 mm. For a coil of this thickness 800, when laser welding is used, the laser power is 300W-500W, the welding speed is 10m / min-20m / min, the spot diameter is 0.5mm-1mm, and the defocusing amount is -1mm-1mm.

[0123] During the welding process, inert gas protection devices, such as argon or helium, can be used to reduce weld oxidation and gas absorption, thereby improving the quality and performance of the welds on aluminum coils.

[0124] After step S103 is completed, proceed to step S104. After welding is completed and cooling is achieved, separate the hollow column and the cylindrical mold to obtain a cover structure with open ends and a hollow interior.

[0125] Cooling can be achieved through natural cooling or air cooling, but care should be taken to avoid internal stress or deformation of the hollow column due to excessively rapid cooling.

[0126] When separating the hollow column and the cylindrical mold 700, tools such as demolding spatulas and demolding hooks can be used. Starting from the edge of the hollow column and the cylindrical mold 700, force is applied evenly along the circumference to gradually separate the hollow column from the cylindrical mold 700. After demolding, the hollow column can be trimmed, such as removing burrs and flash, and smoothing welds, to meet the usage requirements and design standards of the cover structure.

[0127] In this embodiment, the outer surface of the cylindrical mold 700 can be set to be arc-shaped so that the extension trend of the inner wall of the hollow cylinder is a gradually expanding parabola, thereby making the extension trend of the reflective surface of the prepared reflector a gradually expanding parabola.

[0128] When the light emitted by the lamp passes through a reflective surface that extends in a gradually expanding parabolic shape, the light can form parallel light through reflection from the reflective surface.

[0129] The reflector of this application has a structure that is either a drawn structure formed from sheet-like aluminum composite reflective sheets or a laser-welded structure formed from roll-like aluminum composite reflective sheets, resulting in a circumferentially continuous reflective surface. This drawn structure is an integral hollow structure, completely eliminating seams on the axial sides, preventing light leakage or stray light generation, ensuring directional reflection of light from the reflective surface, and improving light efficiency. This laser-welded structure can control the seams of the aluminum composite reflective sheets to the micrometer level, approaching a seamless effect on the axial sides, significantly reducing the risk of light leakage and improving the reflector's light processing efficiency.

[0130] Although the present invention has been described with reference to several typical embodiments, it should be understood that the terminology used is descriptive and exemplary, and not restrictive. Since the present invention can be embodied in many forms without departing from the spirit or essence of the invention, it should be understood that the above embodiments are not limited to any of the foregoing details, but should be interpreted broadly within the spirit and scope defined by the appended claims. Therefore, all variations and modifications falling within the scope of the claims or their equivalents should be covered by the appended claims.

Claims

1. A reflector, characterized in that, include: The outer shell has openings at both ends and is hollow inside. The two ends of the outer shell with openings are respectively a light-inlet end and a light-outlet end. The diameter of the outer shell gradually increases from the light-inlet end to the light-outlet end. The light-inlet end is used to connect to the lamp. The cover structure has an aluminum substrate composite reflector with openings at both ends and is hollow inside. The diameter of the cover structure gradually increases from one end to the other. The inner wall of the cover structure forms a circumferentially continuous reflective surface, which is used to reflect light. The cover structure is located inside the outer shell. The light emitted by the lamp can enter the interior of the cover structure from the light-inlet end and be reflected by the reflective surface and emitted from the light-outlet end. The cover structure is a deep-drawn structure formed by the aluminum substrate composite reflector or a laser-welded structure formed by the aluminum substrate composite reflector.

2. The reflector according to claim 1, characterized in that, The cover structure is provided in multiple ways, and the multiple cover structures are spliced ​​and connected in sequence, and the multiple cover structures are arranged coaxially; the inner walls of the multiple sequentially spliced ​​cover structures are connected to form the reflective surface.

3. The reflector according to claim 2, characterized in that, The curvatures of the various cover structures are not the same.

4. The reflector according to claim 1 or 2, characterized in that, In the direction from the light-inlet end to the light-outlet end, the reflective surface extends in a gradually expanding parabolic shape.

5. The reflector according to claim 1, characterized in that, The reflector also includes a snap-fit ​​component, which includes an annular snap-fit ​​body and a connecting portion on the outer periphery of the snap-fit ​​body. The snap-fit ​​body is located at the light-inlet end of the housing, and the connecting portion is used to snap and fix it to the lamp.

6. The reflector according to claim 5, characterized in that, The connecting parts are provided in multiple ways, and the multiple connecting parts are arranged at intervals along the circumference of the snap-fit ​​body.

7. The reflector according to claim 1, characterized in that, The cover structure has three parts, namely a first cover, a second cover, and a third cover; the first cover and the third cover are respectively connected to the two ends of the second cover; the end of the first cover away from the second cover is set to the light-emitting end, and the end of the third cover away from the second cover is set to the light-incoming end.

8. The reflector according to claim 7, characterized in that, The reflector also includes an annular convex edge, which is disposed around the periphery of the opening at one end of the first cover away from the second cover, and the convex edge abuts against the end face of the light-emitting end of the outer shell.

9. The reflector according to claim 1, characterized in that, The aluminum substrate composite reflector includes a substrate and a surface treatment layer disposed on the surface of the substrate. The surface treatment layer is disposed on the surface of the substrate and is used for light reflection. The surface treatment layer includes an anodized layer disposed on the surface of the substrate and a pure silver coating disposed on the surface of the anodized layer that is disposed on the surface of the substrate.

10. The reflector according to claim 1, characterized in that, The thickness of the cover structure is 0.1mm-1.6mm.

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