Sheet Metal Reflector Assembly for Lighting
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Solution Overview
Problem
Existing reflector arrangements for lighting devices, particularly linear arrays, are complex to produce due to the need for individual fabrication and assembly of reflectors, which involves intricate connection techniques like gluing, soldering, or welding.
Innovation Solution
A reflector arrangement where multiple reflectors are formed from a single coherent sheet metal part with bent wing areas, allowing for simple cutting and bending to create a linear reflector trough with no need for complex connections, resulting in a stable and easy-to-produce design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If reflectors are individually fabricated and assembled, then manufacturing flexibility is maintained, but device complexity and production difficulty increase
Solution Approach 1:
Multiple reflectors are merged into a single coherent sheet metal part through bending operations. The patent describes forming multiple reflector structures from one continuous metal blank by creating bends at specific locations, eliminating the need to manufacture and assemble separate reflector components. This combining approach directly reduces assembly complexity while maintaining manufacturing flexibility.
Solution Approach 2:
The single sheet metal part is segmented into multiple reflector sections through bending lines. The patent specifies that bending lines can be straight or curved and are positioned to create distinct reflector segments while maintaining structural continuity. This segmentation allows each reflector to be formed independently through bending while remaining part of a unified structure.
2Productivity
If connection techniques like gluing, soldering, or welding are used, then reflector assembly is achieved, but production time and manufacturing complexity increase
Solution Approach 1:
The sheet metal part itself provides the connection function through its continuous structure. The patent describes how the unbroken metal blank naturally connects reflector sections without requiring external connection techniques. The material continuity acts as the connecting mechanism, eliminating the need for separate joining processes and significantly improving production efficiency.
3Stability of the object's composition
If multiple separate reflectors are assembled, then individual reflector optimization is possible, but structural stability decreases
Solution Approach 1:
The reflector sections are merged into a unified continuous structure from a single sheet metal blank. This merging provides inherent structural stability because there are no joints or connections that could fail. The continuous material structure ensures uniform mechanical properties throughout all reflector sections while maintaining the ability to optimize each section's geometry.
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 solution simplifies the production of reflector arrangements by eliminating the need for intricate connections and allows for a more stable and efficient design, enabling the creation of a large number of reflectors from a single piece, particularly beneficial for area lighting applications.
Implementation Method 1
The sheet metal part is bent to form at least one linear reflector trough, the reflector trough having a strip-shaped base and at least one side wall that is bent up at the side of it
Implementation Method 2
a reflector arrangement for a lighting device, which has a plurality of reflectors, each for at least one semiconductor light source
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
The invention relates to a reflector assembly (24) for a lighting device (31) comprising a plurality of reflectors (18, 19) for at least one semiconductor light source (27) each, wherein the reflectors (18, 19) are reflector sub-regions (18a, 18b, 19a, 19b) of a common, continuous sheet-metal part (11) and the reflector sub-regions (18a, 18b, 19a, 19b) have wing regions (21, 22) bent at least partially from the sheet-metal part (11; 41; 51). A lighting device (31) comprises at least one reflector assembly (24), wherein at least one semiconductor light source (27) is arranged on the sheet-metal part (11). A method is used to produce a reflector assembly (24), wherein the method comprises at least the following steps: introducing slits (23) into a sheet-metal part (11) in order to provide wing regions (20, 21) that can be bent from the sheet-metal part (11); and bending over the sheet-metal part (11) including bending out the wing regions (20, 21) in order to form at least one reflector (18, 19). The invention can be applied in particular to lamps for general lighting, in particular for area lighting.