Glass Reflector Bottom Opening via Die Lifting and Plunger Punching

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Solution Overview

Problem

Existing methods for producing glass or glass ceramic reflectors with openings in the bottom region often fail to maintain precision and require secondary treatments, making them unsuitable for mass production.

Innovation Solution

A method involving molding a reflector with a closed bottom at elevated temperature, lifting the bottom using a die, and punching out an opening with precise control using a plunger and die, supported by holding elements to prevent gaps and ensure accurate positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the bottom of the reflector is heated and an opening is punched out using a ram and die, then the opening can be produced in the softened state of the glass, but the tolerances regarding the opening frequently cannot be maintained without secondary treatment

Engineering Contradiction:

Improveopening productionVSAvoidopening tolerance

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The reflector bottom is lifted from below using a die before the opening is punched out. This preliminary lifting action ensures that no gap forms between the bottom of the reflector and the die, preventing glass filaments from being drawn during the subsequent punching operation and guaranteeing precise opening tolerances without secondary treatment

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of pressing the opening from the top onto the reflector bottom, the invention inverts the approach by lifting the bottom from below using a die. This inversion eliminates gap formation and prevents glass filaments, thereby achieving high precision in opening tolerances

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of manufacture

If drilling is used to produce the opening in the bottom area, then the opening can be produced, but a fire-polishing step is required subsequently to produce a smooth surface

Engineering Contradiction:

Improveopening productionVSAvoidprocess steps

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces the drilling process with a punching operation performed on softened glass. By lifting the bottom from below first and then punching the opening, the method eliminates the need for subsequent fire-polishing treatment while achieving both precise tolerances and smooth surfaces

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If the reflector is lifted by a large amount, then the opening can be punched out more easily, but the position of the opening cannot be controlled precisely

Engineering Contradiction:

Improvepunching operationVSAvoidopening position control

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The reflector bottom is lifted by a small amount only (between 0.1 and 3 mm) rather than a large amount. This partial lifting action is sufficient to eliminate gap formation and enable precise punching, while avoiding excessive lifting that would compromise position control. The small lifting distance maintains precise contact between the die and reflector bottom, ensuring accurate opening positioning

Inventive Principle:

Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method ensures precise and accurate production of openings in the bottom region without secondary treatments, maintaining high surface quality and tolerances, suitable for mass production and high-precision applications like high-energy light sources.

Implementation Method 1

heating up the reflector in the area of its bottom

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

molding a reflector being open to the outside and having a closed bottom in a mold at a temperature above transformation temperature

Methodology Applied

Scientific EffectTransformation temperature:

Data Source

PatentUS7765832B2Method of producing reflectors from glass or glass ceramics

Publication Date: 2010.08.03 AUER LIGHTING

AI summary

The invention provides a method of producing reflectors from glass or glass ceramics comprising the steps of: molding a reflector being open to the outside and having a closed bottom in a mold at a temperature above the transformation temperature; placing the reflector in a recess of a holder; heating up the reflector in the area of its bottom; lifting the bottom of the reflector from below using a die; punching out at least one opening from the bottom by moving at least one plunger into at least one matching opening in the die.