Illumination – Light modifier – Reflector
Reexamination Certificate
1999-05-07
2001-07-03
Husar, Stephen (Department: 2875)
Illumination
Light modifier
Reflector
C362S350000, C072S082000
Reexamination Certificate
active
06254256
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a novel and useful light-scattering reflector and process for manufacturing the same.
Spin chucks are employed to form products which generally possess a unitary configuration, typically with a cavity. In general, the product is formed on a chuck by rotating the chuck about an axis and moving a roller or multiplicity of rollers one or more times along a sheet of material to pressure the sheet against the chuck. In this manner, the sheet, which may be metallic, conforms to the configuration of the chuck to produce the article.
For example, U.S. Pat. Nos. 4,117,704; 4,408,472; 4,953,376; 5,220,817; and 5,775,151 describe methods and apparatuses for using a spin chuck-type method to form articles.
U.S. Pat. No. 5,465,598 describes a method for forming an annular member by rotating a convex dye.
U.S. Pat. No. 5,640,867 shows a method and apparatus for forming a rim on a lamp reflector employing a roller which is also used to form the annular body on a spin chuck.
Lamp reflectors are often curvilinear in cross-sectional configuration. That is to say, reflectors for lamps may take forms other than right circular cylinders. In most cases, the inner surface of an annular lamp reflector is specular, reflecting or diffusing light from a lamp located at or near the inner chamber of the reflector. It has been found that it is highly desirable to alter the reflecting surface, normally the inner surface, of an annular reflector to achieve light scattering, which sometimes is referred to as “glow”. To accomplish this task, prior reflectors are normally formed on a spin chuck or by other methods followed by alteration of the inner surface of the reflector to create uneven surface texture. For example, the inner surface of lamp reflectors have been sandblasted or peened to produce roughness or bumps, respectively. Unfortunately, these method have produced a very bright type of reflection, which has been deemed to be undesirable. In addition, the inner surfaces of lamp reflectors formed on spin chucks have been subsequently chemically etched with an acid or base solution. However, the reflection, again, is very bright and, thus, undesirable. It has been proposed that the spin chuck itself be peened or sandblasted however prior attempts by others have resulted in lamp reflectors that become fixed to the spin chuck following formation by a roller through the spin chuck method. Such manufacturing problems are particularly vexing with curved reflectors.
Molding of reflectors from plastic-like material have met with the same problems in that textures on the mold prevent removal of the plastic reflectors from mold, rendering such processes as inoperable.
A reflector formed from a spin chuck method which possesses a reflecting inner surface capable of scattering or producing diffuse light would be a notable advance in the lighting industry.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a novel and useful reflector possessing light scattering capabilities, as well as a method of producing the same.
The reflector of the present invention is manufactured by conventional spin chuck methods. However, the spin chuck is initially treated to produce an etched surface having low profile depressions and protuberances, prior to formation of the reflector. The etching may take place chemically, utilizing a laser, by coining, and by way of other suitable processes. In most cases, the depth of etch on the spin chuck is less than 0.05 mm.
The reflector of the present invention includes a body, which may be a metallic body, that has an endless portion forming an endless outer surface, as well as an endless inner surface. The endless inner surface serves as the reflector for an illumination source such as a lamp. The body possesses an opening which communicates with the endless inner surface to permit light to escape from the cavity of the body for projection on a surface adjacent the reflector. The endless inner surface possesses a relatively fine pattern of depressions and protuberances derived from the etched surface of the spin chuck. In this way, the endless inner surface of the reflector may be easily removed from the spin chuck and is capable of scattering light. The problem is particularly vexing when the body forming the reflector is curved in cross-sectional configuration.
In most cases, the body forming the reflector is constructed of metallic material. However, other materials, which are capable of being bent against the spin chuck, may be employed. In any case, the relatively fine pattern of depressions and protuberances on the inner surface of the body are derived from the etched surface of the spin chuck, where the depth of etch ranges between 0.005 and 0.05 mm. In certain cases, the depth of etch on the spin chuck may range between 0.007 and 0.04 mm.
The light reflector of the present invention may also be formed such that the endless inner surface includes a first portion and an adjacent second portion. The adjacent second portion would lie next to the opening of the body and the relatively fine pattern of depressions and protuberances, derived from the etched surface of the spin chuck, would only be imparted to the second portion of the endless inner surface. It has been found that this construction produces reflected light from a source described as a “glow”, due to the scattering of light from the second portion of the endless inner surface of the body. The relatively smooth first portion of the endless surface does not interfere with this result.
The present invention may also be deemed to include a process for manufacturing a reflector for an illumination source which utilizes a spin chuck having an etched surface. The process includes etching a pattern on the spin chuck surface through chemical means, by utilizing a laser, by coining, and through other like methods. The body or sheet of material is pressed against the spin chuck surface which is rotated. The pressing causes the spin chuck surface to deform the body in conformance with the shape and surface characteristics of the spin chuck surface. The result is the production of a relatively fine pattern of depressions and ridges on an inner surface of the body, derived from the etched pattern on the spin chuck surface. A further step would be the removal of the formed body from the spin chuck without impediment due to the spin chuck surface.
It may be apparent that a novel and useful lighting reflector has been described.
It is therefore an object of the present invention to provide a light reflector manufactured using a spin chuck having an etched surface to produce a fine pattern of protuberances and depressions on a reflective surface of the reflector to scatter light.
Another object of the present invention is to provide a light scattering reflector that is easily manufactured in large quantities.
A further object of the present invention is to provide a light scattering reflector employed with an illumination source that produces the reflection that is pleasing to view.
Another object of the present invention is to provide a reflector which scatters light from an illumination source and utilizes a spin chuck, a surface of which has been etched to certain tolerances.
A further object of the present invention is to provide a reflector which is capable of scattering light emanating from an illumination source that is formed over a spin chuck having a chemically etched surface.
A further object of the present invention is to provide a reflector which scatters light from an illumination source that possesses a curvilinear configuration and is easily removed from the spin chuck after formation.
The invention possess other objects and advantages especially as concerns particular characteristics and features thereof which will become apparent as the specification continues.
REFERENCES:
patent: 1744907 (1930-01-01), Luce
patent: 4117704 (1978-10-01), Nakache et al.
patent: 4321105 (1982-03-01), Melonio et al.
patent: 4408472 (1983-10-01), Azarevich et al.
patent: 495
Bielen, Jr. Theodore J.
Husar Stephen
Prescolite Inc.
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