U.S. patent number 3,686,495 [Application Number 04/818,883] was granted by the patent office on 1972-08-22 for tensioner reflector sheet with press forms.
This patent grant is currently assigned to Crouse-Hinds Company. Invention is credited to Richard C. Medley.
United States Patent |
3,686,495 |
Medley |
August 22, 1972 |
TENSIONER REFLECTOR SHEET WITH PRESS FORMS
Abstract
A reflector of radiation that is formed in its place of intended
use by anchoring a sheet of the reflective material between fixed
abutments and thrusting spaced press forms into contact with the
sheet with sufficient force to conform the sheet elastically to the
contour of the press forms.
Inventors: |
Medley; Richard C. (Niles,
IL) |
Assignee: |
Crouse-Hinds Company (Syracuse,
NY)
|
Family
ID: |
25226678 |
Appl.
No.: |
04/818,883 |
Filed: |
April 24, 1969 |
Current U.S.
Class: |
362/223 |
Current CPC
Class: |
F21V
7/005 (20130101) |
Current International
Class: |
F21V
7/00 (20060101); F21v 007/10 () |
Field of
Search: |
;240/36,41.35,103,41.35E,41.5 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Peters, Jr.; Joseph F.
Claims
What is claimed is:
1. A reflector of radiation comprising a flexible sheet having a
reflecting surface, a frame member providing opposed abutments
spaced apart a fixed distance less than the distance between
opposite edges of said sheet when unflexed, said opposite edges of
said sheet being secured to said opposed abutments to arch said
sheet between said abutments, a press form having a convex edge
engaged with the concave surface of the sheet, and means connecting
said frame and said press form and urging said press form against
said sheet with force sufficient to place said sheet in tension
between said opposed abutments and to conform the sheet to the
contour of the press form thereby to determine the contour of the
reflective surface of the sheet.
2. The reflector of claim 1, in which the flexible sheet is metal
and the tensile stress induced therein by the press form is
maintained within the elastic limit of the said metal.
3. The reflector of claim 1, in which the flexible sheet is metal,
and in which the press form and the sheet have substantially the
same coefficient of thermal expansion.
4. The reflector of claim 1, in which the flexible sheet is a
light-colored ductile metal and has on its concave surface a
specular finish, said reflector including a second press form of
the same contour as the first and spaced from the first but
likewise so engaged with the sheet that said two press forms
determine the optical character of said reflective sheet between
the two press forms, and in which said press forms have
substantially the same coefficient of thermal expansion as said
sheet.
5. In a luminaire having a reflector for projecting light from an
essentially linear light source, a frame providing abutments fixed
relative to one another and in flanking relation to the axis of the
light source, a sheet of metal arched between and secured to said
abutments and having on its concave surface a light-reflective
finish, a pair of press-forms engaged with the concave surface of
the sheet at opposite ends of the light source, screws connecting
said press forms and said frame to urge said forms against said
sheet with force sufficient to place said sheet in tension between
said abutments and to conform the sheet to the contour of the press
forms thereby to determine the optical contour of the
light-reflective surface of the sheet.
6. In a luminaire according to claim 5, the frame including a case
enclosing the reflector and having a lens through which the light
emitted from the source is projected.
Description
This invention relates to reflectors of radiation and particularly
to a reflector which is caused to assume a predetermined geometric
shape as an incident to its installation into its use position. It
is here illustrated and described in connection with a luminaire,
but its use may well extend to other projectors and receivers of
radiated or broadcast energy.
It is an observed fact that metallic reflectors in luminaires or
the like that are subjected to high temperatures in normal usage
exhibit some tendency to distort in use, the effect being
particularly noticeable in those kinds of reflectors that might be
described as straight-line generated in geometric shape. This may
be due to the fact that a surface curved with respect to only one
reference plane is more subject to buckling than is a surface of
multiple-axis curvature, or it may be that distortion from whatever
cause is more noticeable on the usual intercept of visible
radiation beamed from a luminaire having a reflector of the
straight-line generated or linear element type.
In any case, it is the object of this invention to overcome the
distortion tendency, and to do so by actually forming the reflector
surface in situ, i.e., at the site of the intended use.
In the drawings:
FIGS. 1a and 1b in succession illustrate diagrammatically the
forming of the desired optical contour in a reflector surface by
its assembly with press forms which, in the assembly of the device,
causes the reflector sheet to assume the desired geometric
shape;
FIG. 2 is a fragmentary perspective view of a luminaire whose outer
casing is partially broken away to show a reflector in accordance
with the invention;
FIG. 3 is a side elevation of a complete luminaire embodying the
invention in a double or vertically stacked arrangement that is
more apparent from FIG. 4; and
FIG. 4 is a front elevation of the luminaire shown in FIG. 3.
The sequence of illustrations of FIGS 1a and 1b indicate
diagrammatically how this invention is utilized. In essence, its
practice contemplates spaced opposed abutments 10 which are fixed
relative to one another. Between the two abutments there is
suspended a sheet 12 of flexible material, for example metal, at
least one surface of which is highly polished, in the case of a
luminaire application, or otherwise rendered reflective with
respect to the particular radiation with which this scheme is to be
employed. This sheet need have no previous forming insofar as its
optical character is concerned, the sheet 12 in the illustrations
of FIGS. 1a and 1b, having merely been formed slightly at its
opposite edges to form mounting flanges 14 which are punched to
facilitate assembly of the reflector sheet with the abutments in
any convenient manner, for example, by rivets, screws, bolts, or
the like.
The curve, therefore, which is assumed by the sheet 12 in the
illustrations of FIG. 1a is not any particular curve, but whatever
curve the sheet may take upon having been flexed from a flat
condition in being assembled with the abutments 10. It may be
equally feasible, however, to preform the sheet, if desired, to
give it an initial curvature which may approach as nearly as one
might wish to the desired final form, which is imposed upon the
sheet, and retained therein, by a pair of opposed curved press
forms 16.
The press forms are machined accurately to the desired final shape
of the surface of the sheet with which they are engaged, the press
forms 16 illustrated in FIGS 1a and 1b having a parabolic contour.
The length of that portion of the sheet which extends between the
abutments is at least slightly greater than the mating surface of
the press form in order that the resistance of the sheet, i.e., its
reaction to the force exerted upon the sheet by the press forms, is
carried to the anchoring abutments only through the sheet itself,
inasmuch as it is desired that the sheet be placed in tension
between the abutments in order to assure conformance to the contour
of the press form. The forces acting on the system of press form
16, reflector sheet 12, and anchoring abutments 10, are illustrated
by the arrows in FIG. 1b.
When the opposed press forms are assembled with the reflector sheet
as indicated in FIG. 1b, the mating surface of the reflector sheet
12 assumes the shape of the press form 16, which is inserted with
sufficient force to achieve this result. The amount of force
employed is such as to stress the sheet material only within its
elastic limit, as it is preferred to maintain the sheet in tension
between the abutments, i.e., to avoid such stretching as might
interfere with conformance of the sheet to the press forms at some
later time in the life of the device, e.g., as the material ages,
or under such design or operating conditions as might serve either
to relieve the tensile stress in the sheet, or conversely, to cause
that stress to exceed the elastic limit of the sheet material.
For example, in a particular application using a linear light
source 18 such as is indicated in FIGS. 2 and 4, which is of the
type referred to commonly as the "quartz-iodine" type, the
temperature of the lamp bases under standard ambient conditions
rises to 350.degree. C. This heat source induces high temperatures
in the surroundings, not only by virtue of conduction from the lamp
itself and its appurtenances, but also by direct radiation from the
source, which as a substantial element of radiation of a frequency
lower than the visible spectrum. If the design of the luminaire is
such as to promote substantial differences of temperature between
the press form and the sheet which constitutes the reflector, or if
the materials employed have substantially different rates of
thermal expansion, the initial stress may be quite important. For
example, if the reflector sheet were to expand more than the press
form, the tensile force at high temperature might be insufficient
to maintain the conformance of the reflector sheet to the press
forms. Conversely, if the press forms were to expand linearly more
than the sheet, they could induce tensile stress of magnitude
sufficient to give the sheet a permanent set, and thus to interfere
with its conformance to the press form at lower temperatures.
It is accordingly desired to maintain the stressed conformance in
the sheet at all times and under all conditions of operation within
the elastic limit of the sheet material, a condition which is
obviously most easily achieved under most circumstances by
employing as reflector sheet and press form materials substances
having the same thermal coefficient of expansion. In the
illustrated application, I have found it quite satisfactory indeed
to employ aluminum alloys of substantially identical thermal
coefficients of expansion.
A practical physical structure for achieving the aforementioned
conditions is illustrated by the luminaire 18 shown in FIGS. 2, 3
and 4. As illustrated, the luminaire comprises a rectangular box
which encloses two substantially identical reflector systems of the
kind just described in principle. They are stacked one above the
other in vertical array, and project the luminous radiation from
two pencil-like light sources 20 of the quartz-halogen type
outwardly through a flat "lens" 22 which may be optically null or
optically directional. The lens is secured in a peripheral frame
24, which is formed of T-shaped cross section, hinged along one of
its long edges at 26 to the rectangular box, and held tight to the
box along its opposite long edge by means of toggle clamps 28 of
the general type common in luggage.
The box serves as structure as well as outer casing, and is formed
of aluminum sheet which is bent to shape and flanged at its front
edges (FIG. 2) to form a seat 30 for the lens frame. For
convenience of manufacture, the box of the illustrated luminaire is
made in three pieces, a body sheet 32 which forms the back wall and
sidewalls, a top sheet 34 and a bottom sheet 36 which are assembled
to the body sheet by means of rivets through lapped seams. To aid
in shedding rain, the downturned flanges of the top sheet are on
the outside of the body sheet, whereas the upturned flanges of the
bottom sheet are on the inside of the body sheet.
Also shown in FIGS. 3 and 4 are the flanged enclosing cups 38 which
are secured to the sidewalls of the luminaire to cover holes
therein aligned with the axis of the tubular light source, thereby
to provide additional clearance for the tube sockets. The cups 38
are secured to the casing by means of rivets, and the flanges of
the cups are gasketed to keep out the elements.
Extending rearwardly from the back wall of the luminaire casing is
a junction box 40 to which the leads of the lamp sockets are
brought for connection to a supply conductor 42 from a suitable
power source.
The entire luminaire is adjustably supported in a yoke 44 in which
it is pivoted by means of sidewardly extending trunnions 46 upon
which the luminaire may swivel. Any desired position of adjustment
is maintained by tightening the nuts on the threaded terminal
portions of the trunnion. A protractor 48 is provided at the swivel
for convenient restoration of any preset alignment that may
necessarily be disturbed in the course of maintenance. A mounting
bracket 50 on the base or cross leg of the yoke is likewise
provided with a main pivot hole 52 as well as an arcuate slot 54
thereabout for pivotally mounting the yoke upon a suitable mating
support, and for maintaining any desired angular adjustment.
In the case of directive illumination of this sort, the necessary
alignment can be achieved by predetermined angulation from
established reference planes. It is also useful, however, to align
luminaires of this kind by visual sighting, and for that reason, a
bracket 56 is mounted on the outer casing for receiving a
telescopic sight of the kind used in riflery.
The earlier-described reflector arrangement of FIG. 1 is mounted
upon interior peripheral framing 58 which is secured to the inside
faces of the side and top and bottom walls of the outer casing by
means of rivets. The framing is of angle-shaped cross section to
provide an attaching flange 60 to secure the frame in place and to
add to the beam strength of the framing, the other angular flange
62 providing seats for the mounting of the press forms 16, as well
as anchoring abutments 10 for the secured ends of the reflector
sheet.
Because of the stacked, double arrangement in the illustrated case,
the reflector frame 58 is divided longitudinally into two parts by
a pair of cross members 64 of angle section that are joined
back-to-back by stitch rivets which unite and strengthen the
assembly. The flanges of the cross-members 64 and the end members
that are parallel to the plane of the frame provide the anchorages
10 for the reflector sheets 12 which are secured to those flanges
by means of rivets, of which there are three at each secured edge
in the illustrated case.
The press forms 16 in the illustrated case are also formed of
aluminum alloy plate of substantially greater thickness than the
reflector sheets 12, i.e., about one-eighth inch thick. As earlier
indicated, the specific plates shown are parabolic in form, the
parabolic contour ending at a chord perpendicular to the focal axis
to form a straight front edge 66. At the center of the front edge
of the press form, there is an angle flange 68 with a central hole
through which there is passed a machine screw 70 threaded in a
suitable hole in the facing flange 62 of the reflector frame 58.
The tightening of this screw provides a thrust in the direction of
the focal axis of the parabolic press form, causing it to tighten
its engagement with the reflector sheet as earlier described, and
causing the sheet to assume the contour of the press form. The
press form engages the reflector sheet a short distance inwardly
from the bowed edge of the sheet, (see FIG. 2) and the desired
perpendicular array of the press form with respect to the sheet is
maintained by means of a small tongue 71 which protrudes from the
curved surface of the press form 16 as an extension of the focal
axis to be received in a suitable rectangular positioning slot in
the reflector sheet. (See FIGS. 1a and 1b).
In the illustrated luminaire, it was found desirable to re-direct
light emitted sidewardly from the light source by means of plane
side reflectors 72 extending at an angle into the field of the
parabolic reflector. These are omitted in FIG. 2 as they would have
obscured the press forms, but are shown in FIG. 4. The side
reflectors are secured in place by means of a couple of screws
received in the two flanking holes 74 on the turned-over flange 68
of the press form, and the side reflectors themselves are provided
with rectangular holes 76 through which the pencil-like light
sources 20 can be inserted into their sockets 78 which are mounted
on the press forms themselves in positioning holes 80. Those
portions of the lamp sockets which receive the lamp bases float in
spring mountings so that the light source may be removed from the
sockets by sequential endwise movements of the tube.
With the foregoing arrangement I have found it possible to generate
and to maintain the desired optical form of the reflector with
greater accuracy and reliability than has heretofore been achieved
by other techniques of forming reflectors of metal.
* * * * *