Self-Supporting Softbox Reflector Without Support Rods
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Solution Overview
Problem
Conventional softboxes with funnel-shaped reflectors are complicated to manufacture and assemble due to the need for rod-like structures to support the spanning volume, which also results in low flexural rigidity of the wall material.
Innovation Solution
A self-supporting funnel-shaped reflector is designed using a stiffer wall material with a circumferential length difference between the proximal and distal edges, eliminating the need for additional supporting structures and allowing the material to provide structural rigidity through its geometry, made from thermoplastic materials like ABS or polyester fabric, and utilizing hook-and-loop fasteners for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rod-like structures are used to support the spanning volume of the reflector, then the structural stability is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent removes the rod-like supporting structures from the reflector system. By extracting these additional support elements, the design achieves structural stability through the wall material's inherent flexural rigidity alone, thereby reducing device complexity and manufacturing difficulty while maintaining the necessary structural integrity.
Solution Approach 2:
The patent changes the flexural rigidity parameter of the wall material to a specific range (1.0×10⁻³ N·mm to 1.0×10³ N·mm). This parameter modification enables the wall material itself to provide sufficient structural support without requiring additional rod-like structures, thus resolving the contradiction between stability and complexity.
2Stability of the object's composition
If rod-like structures are used to support the spanning volume, then the structural stability is improved, but the manufacturing and assembly complexity increases
Solution Approach 1:
The patent eliminates rod-like supporting structures from the design. By removing these additional components, the manufacturing and assembly processes are simplified, as only the wall material needs to be processed and assembled without the complexity of integrating and positioning support rods.
Solution Approach 2:
The wall material is designed to be self-supporting through its inherent flexural rigidity. This self-service capability eliminates the need for external rod-like supports, thereby simplifying both manufacturing and assembly operations while maintaining structural stability.
3Adaptability or versatility
If the wall material has low flexural rigidity, then the material flexibility and collapsibility are improved, but the structural support capability deteriorates
Solution Approach 1:
The patent optimizes the flexural rigidity parameter of the wall material to a specific range (1.0×10⁻³ N·mm to 1.0×10³ N·mm). This parameter optimization ensures that the material has sufficient structural support capability while maintaining the flexibility and collapsibility needed for adaptability, thereby resolving the contradiction between these properties.
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 simplifies manufacturing, enhances durability, and improves light diffusing quality with higher spectral reflectance, while maintaining collapsibility and robustness without requiring additional support elements.
Implementation Method 1
the reflector has a reflective inner surface
Implementation Method 2
the first edge of the first piece is attached to the second edge of the second piece by sewing, gluing, and/or an adhesive
Data Source
AI summary
A lighting device, such as a softbox 1 used for illumination in film locations, comprises a self-supporting funnel-shaped reflector 3 having a proximal edge 5 and a distal edge 7. A circumferential length of the funnel-shaped reflector at the proximal edge 5 is smaller than a circumferential length of the funnel-shaped reflector at the distal edge 7. The funnel-shaped reflector 3 is formed of a wall material 19 and the wall material is a thermoplastic material. The funnel-shaped reflector 3 includes plural corner lines 17 extending between the proximal edge 5 and distal edge 7, and wherein the corner lines 17 are formed by thermoplastic deformation of the wall material 19.