Light Reflector With Translucent Separating Disk And Embossed Fastening
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Solution Overview
Problem
Existing light reflectors with non-circular light sources face challenges in achieving uniform light distribution due to the complexity and cost of producing diffusers, and they often experience noise issues from loose fastening due to heat effects.
Innovation Solution
A light reflector design featuring a translucent separating disk firmly attached using material deformation embossings, allowing for cost-effective production and noiseless operation, with a manufacturing process that connects multiple reflector jacket pieces for customizable light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separating disk is attached using additional fastening means, then the separating disk is securely fixed, but the production becomes complicated and expensive
Solution Approach 1:
The attachment embossings are formed directly on the reflector jacket surface, merging the fastening function into the existing structure. The reflector jacket itself serves as both the structural component and the fastening mechanism, eliminating the need for separate fastening elements and simplifying production.
Solution Approach 2:
The reflector jacket performs the fastening function autonomously through its own surface deformations. The material of the reflector jacket is deformed to create attachment embossings that directly secure the separating disk, allowing the component to serve its own fastening needs without external assistance.
2Ease of manufacture
If the separating disk is loosely fastened, then the production is simpler, but disturbing noises arise during operation due to heat effects
Solution Approach 1:
The attachment embossings are formed in advance during the production process, creating pre-compression contact between the reflector jacket and the separating disk. This preliminary securing prevents the disk from loosening under subsequent thermal expansion and contraction during operation, cushioning against future noise problems.
Solution Approach 2:
The physical state of the reflector jacket material is changed through localized deformation to create permanent attachment points. The material undergoes plastic deformation to form embossings that mechanically interlock with the separating disk, changing from a smooth surface to a textured fastening surface.
3Adaptability or versatility
If multiple jacket pieces are used to form the reflector, then the light distribution can be customized, but the production complexity increases
Solution Approach 1:
The attachment embossing technique serves multiple functions: it secures the separating disk, connects multiple jacket pieces, and positions components accurately. This universal fastening method works for various assembly configurations, making the multi-part construction manageable despite its complexity.
Solution Approach 2:
The reflector jacket is divided into multiple detachable pieces that can be assembled separately and then connected through attachment embossings. This segmentation allows for customized light distribution profiles while maintaining production efficiency through modular manufacturing and assembly.
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
The solution ensures a noiseless and cost-effective production method for light reflectors with configurable light distribution, achieving homogeneous light mixing and emission, even with non-circular light sources, while preventing material abrasion and ensuring optimal positioning of the diffuser disk.
Implementation Method 1
a plurality of attachment embossings (11) formed on the reflector jacket surface (10) are present by which the light reflector (1) is permanently in contact with the separating disk (20)
Data Source
Figure 1a~1g
Figure 2a~2e
Figure 3a~3d
AI summary
The light reflector (1) has reflector casing whose interior portion is defined with light-permeable partition plate, to separate several reflector chambers (101,102). The plate is fixedly secured on the reflector casing by integrally formed attachment embossments (11). The reflector casing is produced by pressing process or injection molding process or deep-drawing process. The reflector casing is made of metal or light metal sheet, and also partially made of thermoplastically deformable plastic. Independent claims are included for the following: (1) lamp with bulb and light reflector; and (2) method for manufacturing light reflector.