Self-standing reflector for a luminaire and method of making same
First Claim
1. A self-standing reflector for a luminaire having a light source securable therein and an opening through which light from the source is emitted, comprising:
- a plurality of reflective panels formed from at least one sheet of reflective material and folded along fold lines pre-formed in said at least one sheet into abutting relationship to define a predetermined three-dimensional reflector shape, at least one of said panels being curved to define a curved reflective surface and having at least one free edge abutting adjacent a free edge of an abutting panel upon folding of said panels, wherein said curved panel has a discrete first locking member formed proximate the free edge thereof for locking engagement with a discrete second locking member formed proximate the free edge of said abutting panel, whereby said first and second locking members cooperate upon folding of said panels to retain said reflector in said predetermined three-dimensional reflector shape.
1 Assignment
0 Petitions
Accused Products
Abstract
A luminaire reflector formed from at least one sheet of reflective material is folded and curved by hand to form a self-standing reflector having a predetermined three-dimensional reflector shape. Each sheet of reflective material includes integral panels that are joined to adjacent panels through fold lines that allow the panels to be folded by hand. The panels have free edges that are folded and/or curved into abutting relationship. The panels include locking members and positioning tabs formed adjacent the free edges to retain the reflector in a predetermined three-dimensional reflector shape. Methods of making a self-standing reflector for a luminaire are also disclosed.
64 Citations
34 Claims
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1. A self-standing reflector for a luminaire having a light source securable therein and an opening through which light from the source is emitted, comprising:
a plurality of reflective panels formed from at least one sheet of reflective material and folded along fold lines pre-formed in said at least one sheet into abutting relationship to define a predetermined three-dimensional reflector shape, at least one of said panels being curved to define a curved reflective surface and having at least one free edge abutting adjacent a free edge of an abutting panel upon folding of said panels, wherein said curved panel has a discrete first locking member formed proximate the free edge thereof for locking engagement with a discrete second locking member formed proximate the free edge of said abutting panel, whereby said first and second locking members cooperate upon folding of said panels to retain said reflector in said predetermined three-dimensional reflector shape. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A self-standing reflector for a luminaire having a light source securable therein and an opening through which light from the source is emitted, comprising:
a plurality of reflective panels formed from at least one sheet of reflective material and folded into abutting relationship to define a predetermined three-dimensional reflector shape, wherein at least two of said panels are curved to define curved reflective surfaces and include substantially non-linear free edges abutting substantially non-linear free edges of abutting curved panels, whereby a substantially contiguous curved reflective surface is formed by said abutting curved panels. - View Dependent Claims (9, 10, 11)
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12. A self-standing reflector for a luminaire having a light source securable therein and an opening through which light from the source is emitted, comprising:
a plurality of reflective panels formed from at least one sheet of reflective material and folded into abutting relationship to define a predetermined three-dimensional reflector shape, wherein at least one of said panels has free edges abutting adjacent free edges of an abutting panel upon folding of said panels, said pair of abutting panels each including at least one positioning tab extending outwardly from a free edge thereof to overlie said other abutting panel and maintain abutting relationship of said free edges, and cooperating locking members formed proximate the free edges of said abutting panels to retain said reflector in said predetermined three-dimensional shape.
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13. A luminaire assembly, comprising:
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a luminaire housing;
a reflector mounted within said luminaire housing comprising a plurality of reflective panels formed from at least one sheet of reflective material and folded along fold lines pre-formed in said at least one sheet into abutting relationship to define a predetermined three-dimensional reflector shape, wherein at least one of said panels has free edges abutting adjacent free edges of an abutting panel upon folding of said panels, and cooperating discrete locking members formed proximate the free edges of said abutting panels to retain said reflector in said predetermined three-dimensional shape;
a light source socket disposed within said reflector; and
a light source mounted within said socket for emitting light upon energizing said source to produce a predetermined light distribution pattern defined by said reflector shape. - View Dependent Claims (14, 15, 16, 17, 18, 19)
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20. A method of making a self-standing reflector for a luminaire, comprising:
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forming a plurality of reflective panels from at least one sheet of reflective material;
folding at least one of said panels by hand along a fold line pre-formed in said at least one sheet;
curving at least one of said panels by hand to define a curved reflective surface;
folding said curved panel along a fold line pre-formed in said at least one sheet;
abutting a free edge of said curved panel adjacent a free edge of an abutting folded panel; and
locking said curved panel into engagement with said abutting folding panel through direct locking cooperation of said curved panel and said abutting folding panel. - View Dependent Claims (21, 22, 23, 24)
forming a first locking member proximate the free edge of said curved panel;
forming a second locking member proximate the free edge of said abutting folded panel; and
locking said first and second locking members.
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23. The method of claim 20 further comprising:
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forming a pair of panels;
forming at least one substantially non-linear free edge on each of said pair of panels; and
adjacently abutting said substantially non-linear edges of said panels by folding said panels into abutting relationship.
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24. The method of claim 23 further comprising:
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forming at least one positioning tab extending outwardly from the substantially non-linear free edges of said pair of panels; and
folding said pair of panels whereby said positioning tab of one of said abutting panel overlies the other abutting panel.
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25. A method of making a self-standing reflector for a luminaire, comprising:
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forming a plurality of reflective panels from at least one sheet of reflective material;
forming substantially non-linear free edges on at least two of said panels to be curved;
curving at least two of said panels by hand to define curved reflective surfaces; and
adjacently abutting said substantially non-linear edges of said curved panels to form a substantially contiguous curved reflective surface. - View Dependent Claims (26, 27, 28)
forming at least one positioning tab extending outwardly from the substantially non-linear free edges of said curved panels; and
folding said curved panels whereby said positioning tab of one of said curved panels overlies an abutting curved panel.
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29. A method of forming a luminaire assembly, comprising:
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providing a luminaire housing;
providing at least one sheet of reflective material;
forming a plurality of reflective panels from said at least one sheet of reflective material;
folding at least one of said panels by hand along a fold line pre-formed in said at least one sheet;
curving at least one of said panels by hand to define a curved reflective surface;
folding said curved panel along a fold line pre-formed in said at least one sheet;
abutting a free edge of said curved panel adjacent a free edge of an abutting folded panel;
locking said curved panel into direct locking engagement with said abutting folded panel to define a reflector;
mounting said reflector in said housing;
providing a light source socket disposed within said reflector; and
mounting a light source within said socket for emitting light upon energizing said source to produce a predetermined light distribution pattern.
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30. A self-standing reflector for a luminaire having a light source securable therein and an opening through which light from the source is emitted, comprising:
a plurality of reflective panels formed from at least one sheet of reflective material and folded along predetermined lines of bending in said at least one sheet into abutting relationship to define a predetermined three-dimensional reflector shape, at least one of said panels being curved to define a curved reflective surface and having at least one free edge abutting adjacent a free edge of an abutting panel upon folding of said panels, wherein said curved panel has a discrete first locking member formed proximate the free edge thereof for locking engagement with a discrete second locking member formed proximate the free edge of said abutting panel, whereby said first and second locking members cooperate upon folding of said panels to retain said reflector in said predetermined three-dimensional reflector shape.
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31. A luminaire assembly, comprising:
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a luminaire housing;
a reflector mounted within said luminaire housing comprising a plurality of reflective panels formed from at least one sheet of reflective material and folded along predetermined lines of bending in said at least one sheet into abutting relationship to define a predetermined three-dimensional reflector shape, wherein at least one of said panels has free edges abutting adjacent free edges of an abutting panel upon folding of said panels, and cooperating discrete locking members formed proximate the free edges of said abutting panels to retain said reflector in said predetermined three-dimensional shape;
a light source socket disposed within said reflector; and
a light source mounted within said socket for emitting light upon energizing said source to produce a predetermined light distribution pattern defined by said reflector shape.
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32. A method of making a self-standing reflector for a luminaire, comprising:
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forming a plurality of reflective panels from at least one sheet of reflective material;
folding at least one of said panels by hand along a predetermined line of bending in said at least one sheet;
curving at least one of said panels by hand to define a curved reflective surface;
folding said curved panel along a predetermined line of bending in said at least one sheet;
abutting a free edge of said curved panel adjacent a free edge of an abutting folded panel; and
locking said curved panel into engagement with said abutting folding panel through direct locking cooperation of said curved panel and said abutting folding panel.
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33. A self-standing reflector for a luminaire having a light source securable therein and an opening through which light from the source is emitted, comprising:
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a plurality of reflective panels formed from at least one sheet of reflective material and folded along predetermined lines of bending in said at least one sheet into abutting relationship to define a predetermined three-dimensional reflector shape; and
a plurality of backing members connected to said at least one sheet, each of said backing members having an edge defining one of the predetermined lines of bending in said at least one sheet.
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34. A method of making a self-standing reflector for a luminaire, comprising:
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forming a plurality of reflective panels from at least one sheet of reflective material;
operatively engaging a backing member with said at least one sheet so that an elongated edge of said backing member is positioned to lie coincident with a predetermined line of bending in said sheet; and
folding at least one of said panels by hand along said predetermined line of bending defined by said backing member.
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Specification