Reflector for automotive exterior lighting

• US 6,106,137 A
• Filed: 02/20/1998
• Issued: 08/22/2000
• Est. Priority Date: 02/20/1998
• Status: Expired due to Fees

• Current Assignee: Lorin Industries
• Original Assignee: Lorin Industries, Inc.
• Inventors: Adams, Edward R., Adams, John F., Wakeling, Philip O.
• Primary Examiner(s): Shafer, Ricky D.
• Application Number:
  US09/026,924
• Time in Patent Office: 914 Days
• Field of Search: 359/838, 359/850, 359/851, 359/853, 359/855, 359/867, 359/869, 359/896, 29/463, 29/469.5, 29/609, 362/236, 362/237, 362/240, 362/241, 362/247, 362/249, 362/800, 257/98, 72/326
• US Class Current: 362/237
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21V 7/00 Reflectors for light sources characterised by cooling arrangements F21V29/505
• CPC Class Codes: F21V 7/10 Construction
• CPC Class Codes: Y10S 362/80 Light emitting diode

Abstract

A reflector particularly adapted for use in automotive light assemblies and other point light source applications. The reflector includes two nested aluminum discs. Each disc defines a plurality of semi-circular holes and includes a half-cone or other partial revolved surface extending from each hole. The half-cones of the first disc extend through the stamped holes of the second disc. The semi-circular holes on the two discs cooperate to define circular holes, and the half-cones at each circular hole cooperate to form full cones. Preferably, the disks are identical; and the first disc is rotated 180° for nesting with the second disc. When the reflector is incorporated into a light assembly, LEDs or other point light sources are positioned within each full cone, and a lens is mounted over the reflector.

Claims

1. A light assembly comprising:

a reflector including first and second discs, each disc including a front side and a back side, each disc further including a plurality of mini-reflector portions each associated with one of a plurality of hole portions, said mini-reflector portions extending from the back sides of said discs, said first and second discs being nested with said back side of the first disc facing said front side of the second disc, each of said mini-reflector portions on the first disc cooperating with a respective mini-reflector portion on the second disc to form a mini-reflector;

a light source associated with each of said mini-reflectors; and

a lens covering the front side of the first disc.

2. The assembly of claim 1 wherein each of said mini-reflector portions extending from said first or second discs forms a partial revolved surface and each of said mini-reflectors forms a full revolved surface.

3. The assembly of claim 1 wherein each of said mini-reflector portions is formed from a segment stamped from said first and second discs, each of said discs defining an aperture formed by removal of said segment, said aperture of the first disc being met by said front side of the second disc and said aperture of the second disc being met by said back side of the first disc when said first and second discs nest.

4. The assembly of claim 1 further comprising:

a third disc overlying said front side of the first disc, said third disc defining a plurality of apertures each aligned with one of said mini-reflectors.

5. A light reflector comprising a first disc and a second disc each having an aperture and including a partial revolved surface associated with said aperture and extending from its respective disc and aligned with said aperture, said first disc and said second disc nesting with one another to form the light reflector, said aperture of said first disc and said aperture of said second disc cooperating to form a joined aperture defined by said first and second discs, said partial revolved surfaces meshing to form a full revolved surface surrounding said joined aperture, said first disc and said second disc further cooperating to prevent any joined apertures in the first disc and the second disc in areas unaligned with at least one of said full revolved surface.

6. The reflector of claim 5 further comprising:

a third disc overlying a front side of said first disc, said third disc having a plurality of apertures each aligned with at least one of the said full revolved surface.

7. A light reflector comprising:

a first disc and a second disc, said first disc including a first protrusion extending from a front side of said first disc, said second disc including a second protrusion extending from a front side of said second disc, said first disc and said second disc nesting to form the light reflector, said first and second protrusions meshing to form a joined protrusion extending from a front side of the light reflector, wherein said first disc and said second disc each define a plurality of first apertures, said first apertures cooperating to form a joined aperture, said protrusion extending from said first disc stamped from a segment of said first disc, said protrusion extending from said second disc stamped from a segment of said second disc, said first disc and said second disc each defining a plurality of second apertures formed by the removal of said segment of said first disc and said segment of said second disc, respectively.

8. The light reflector of claim 7 wherein said second apertures of said first disc are met by said front side of said second disc and said second apertures of said second disc are met by a back side of said first disc when said first disc and said second disc are nested.

9. The light reflector of claim 7 wherein said protrusion extending from said first disc forms a first partial revolved surface, said protrusion extending from said second disc forms a second partial revolved surface, said first and said second partial revolved surfaces meshing to form a full revolved surface when said discs are nested, said full revolved surface extending from said front side of said light reflector, said full revolved surface encircling said joined aperture.

10. The light reflector of claim 7 further comprising:

a flat disc overlying said front side of said joined disc, said flat disc having a plurality of apertures, each aligned with a full revolved surface.