Light reflector apparatus and method of making

• US 4,570,203 A
• Filed: 02/19/1985
• Issued: 02/11/1986
• Est. Priority Date: 11/05/1982
• Status: Expired due to Fees

• Current Assignee: Eastman Kodak Company
• Original Assignee: Eastman Kodak Company
• Inventors: Daniels, Steven D., Stoneham, Jeffrey R., Erickson, John K.
• Primary Examiner(s): Moy, Magdalen Y. C.
• Assistant Examiner(s): Okonsky, David A.
• Application Number:
  US06/688,390
• Time in Patent Office: 357 Days
• Field of Search: 362/11, 362/12, 362/13, 362/3, 362/16, 362/296, 362/306, 362/347, 362/350, 362/341, 362/362, 362/217, 362/257, 362/317, 264/1.9, 354/145.1
• US Class Current: 362/16
• CPC Class Codes: B29C 45/14 incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles B29C45/1671 takes precedence
• CPC Class Codes: B29D 11/00596 Mirrors
• CPC Class Codes: B29D 11/00605 Production of reflex reflectors
• CPC Class Codes: B29L 2011/0083 Reflectors
• CPC Class Codes: F21S 41/37 characterised by their material, surface treatment or coatings
• CPC Class Codes: F21V 7/10 Construction

Abstract

Improved light reflector apparatus for use in an electronic flash unit or the like is formed by an injection molding operation, which causes both precise shaping of a reflector and accurate mounting of the reflector securely within a housing. A light-reflecting flexible sheet is placed in a mold so that its light-reflecting front surface is centrally positioned adjacent a mold forming surface. The forming surface, which is larger than the sheet, has a contour adapted for shaping the sheet to reflect light into a beam of illumination. Liquid plastic is injected into the mold under pressure against the opposite surface of the sheet, thus pressing its light-reflecting surface into intimate contact against the forming surface. Because the sheet is smaller, the border of the forming surface is not covered by the sheet. Plastic flows beyond outer edges of the sheet against the uncovered border of the forming surface. The intimate contact between the forming surface and the sheet blocks plastic from leaking therebetween onto the light-reflecting surface. The plastic solidifies to form a housing having a supporting body underlying the sheet and a shoulder, integral with the supporting body and contiguous with and surrounding outer edges of the sheet. The shoulder traps the sheet against the underlying supporting body for maintaining the contour of the sheet caused by the molding surface.

Claims

1. Light reflector apparatus for forming reflected light, emanating from a source of illumination, into a beam of illumination, said light reflector apparatus comprising:

(a) a metallic light-reflecting sheet having a first rearwardly facing surface, and a second forwardly facing surface defining an open-ended chamber shaped to reflect impinging light into a beam of illumination projected through the open end of said chamber; and

(b) a unitary plastic housing having (1) an underlying supporting body portion including a receiving surface complementary with respect to said first rearwardly facing surface of said light-reflecting sheet, and (2) a shoulder integral with said supporting body portion such that the shoulder is contiguous with and in intimate contact with outwardly extending edges of said light-reflecting sheet defining the open end of said chamber, said shoulder being a means of securing said sheet to said housing so as to secure said rearwardly facing surface of said sheet in intimate contact against said receiving surface of said underlying body portion, thereby to retain the shape of said light-reflecting sheet.

2. Light reflector apparatus as defined in claim 1 wherein said shoulder is both contiguous with and surrounds the outwardly extending edges of said light-reflecting sheet defining the open end of said chamber.

3. Light reflector apparatus for forming reflected light, emanating from a source of illumination, into a beam of illumination, said light reflector apparatus comprising:

(a) a metallic light-reflecting sheet defining an open-ended chamber shaped to reflect impinging light into a beam of illumination projected through the open end of said chamber; and

(b) a unitary plastic housing having (1) a supporting body including a receiving surface complementary with and underlying said light-reflecting sheet, (2) a shoulder integral with said supporting body such that the shoulder is contiguous with and in intimate contact with outwardly extending edges of said light-reflecting sheet defining the open end of said chamber, said shoulder being a means of securing said sheet to said housing so as to secure said sheet in intimate contact against said receiving surface of said supporting body, and

(3) elastic means integral with said supporting body for resiliently biasing an illumination source into engagement with a forwardly facing surface of said light-reflecting sheet.