EP2138761B1 - Method of producing a downlight reflector - Google Patents

Description

The present invention relates to a method for producing a rotationally symmetrical approximately pot-shaped downlight reflector having a highly reflective surface in which one starts from a metallic sheet material and this deformed according to the desired shape of the reflector, wherein from the flat material corresponding to a development of a rotating body blank created in strip form, this bends into a body of revolution and connects the ends of the strip together.

Rotationally symmetrical reflectors with highly reflective surfaces are used, for example, for so-called "downlights". These are usually round cup-shaped recessed luminaires, which are installed in suspended ceilings and often equipped with compact fluorescent lamps. The downlights can also be designed as surface-mounted lights. In the context of the present invention, "downlights" are in most cases understood to mean, for the most part, deep-radiating luminaires which radiate their light largely downwards. These "downlights" should also have a Lichtabstrahlcharakteristik that meets the current regulations regarding the illuminance and glare. Attention is drawn to the standard DIN EN 12464-1 (see "Lighting of workplaces indoors"). Reflectors of radiators, which may for example also be pivotable, should also be included in the present invention.

In order to achieve comparatively high illuminance levels (efficiencies), highly reflective surfaces are used for the downlight reflectors. The achievement of higher efficiencies is today due to the energy saving regulation a very important aspect with regard to the possibilities of marketing the downlights. The reflectors for the downlights are usually made of aluminum, which is coated by various methods to achieve the highly reflective surface. In principle, one can also directly use pure aluminum as starting material, which, however, often eliminates cost reasons. It is therefore customary to use aluminum alloys with a lower degree of purity and then to refine the surfaces by means of coating methods. One of the known methods is anodizing. However, only reflectivities in the range of about 75% to 87% are achieved. About 15 years ago, processes were also developed that make it possible to refine aluminum surfaces with a multi-layer system in such a way that even higher light reflections of more than 90% are possible. Such materials are sold under the name "Miro" ® commercially. In this regard, for example, the utility model DE 298 12 559 U1 the Fa. Alanod aluminum finishing GmbH & Co. and the references cited therein. More recently, a coating material from the company Alanod has been known which has an even higher light reflectance of up to 98% and is marketed under the name Miro-Silver®. The disadvantage, however, is that the so refined materials are very expensive, since the process for producing these surfaces are quite complex. A further disadvantage is that in certain coating methods, such as, for example, sputtering in rotationally symmetrical workpieces, shadow surfaces can arise due to uneven coating.

In the case of rotationally symmetrical reflectors for luminaires, in the prior art it is generally the case that the flat material is brought into the desired shape by deformation methods such as deep drawing or pressing. These deformation methods usually require a minimum material thickness of the starting sheet of about 1 mm. When processing the mentioned high-quality materials, there is already a cost aspect here. It would be advantageous if one had procedures that allow the use of thinner starting materials (sheets, coils).

In the DE 2 201 197 A a method for producing a vehicle lamp (a headlight) is known in which the lamp has a recess with approximately parabolic surface. This surface is not directly developable. The procedure here is that of a flat blank of a reflective foil which is cut in the form of a ring in which a segment is missing. The ring is then bent into a body of revolution having a frusto-conical shape. The thin film has a plurality of slits arranged in a certain pattern. Through these slots, it is possible to further deform the truncated cone in order to adapt the shape of that of the recess, wherein the film is pressed into the surface of the recess and is then glued to the surface of the recess.

The reflective sheet used here is a very thin material (it is referred to as a sheet), so that deformation or wrinkling occurs during deformation. For this reason, the film material is slit in order to deform it after the production of the rotating body can. The material thickness of the film used here will be at most about the order of 0.1 mm, comparable to ordinary paper. A curved from such a thin film rotational body is not self-supporting. One can therefore not form a self-supporting body of revolution from the flat material alone. On the contrary, this thin film material can only be used to line the inside of a self-supporting body of defined form (for example cup-shaped with a parabolic cross-section) in order to create a reflecting surface. Accordingly, in this known method, an outer housing with recess is additionally required, in which the film is glued.

That in the DE 2 201 197 In addition, reflective film material used is not "highly reflective" within the meaning of the definition of the present invention. At the beginning of the 1970s, materials with degrees of light reflection of more than 85%, in particular about 90% and more, were not yet known. By contrast, "highly reflective" materials according to the present invention are understood to mean those materials which preferably have a light reflectance of more than 85%, more preferably of about 90% or higher. These are usually thin sheets of a metallic support, such as aluminum, which has a mostly multi-layer coating to produce the high reflectance. Such coated metal sheets may comprise, for example, an intermediate layer of anodically oxidized or electrolytically shined aluminum, to which an optical multi-layer system is then applied. Such materials are for example in the DE 298 12 559 U 1 described. The metallic starting material for the use according to the invention has a total material thickness of at least about 0.2 mm, preferably at least about 0.3 mm. Such coated metal sheets are because of the complex coating process very high quality and expensive and they have very sensitive surfaces.

In the US 4,418,379 A. describes a luminaire, the reflector is made of a planar blank, but it is not a "downlight" because the lamp is not low beam and the lamp is not within the floor plan of the reflector, so that the light predominantly undirected and can be radiated even at very shallow angles. In this luminaire also the reflector is made of a material with a comparatively large material thickness of more than 1 mm.

The FR 1 091 837 A describes a lamp produced in a method of the type mentioned, are bent in the purely frusto-conical elements of the reflector from a flat blank. However, the ideal conical shape is not advantageous in terms of lighting technology, which is why it is proposed here to connect a plurality of truncated cone elements to one another. However, such joining processes are disadvantageous for the properties of the reflector, because it is difficult to obtain a transitionless uniform surface.

In the US 2007/070633 A1 a method is proposed in which one manufactures a reflector made of thin highly reflective sheet and uses a blank consisting of many individual segments. This is a highly complicated sheet metal blank and the segments must then be joined together. If the shape of the reflector in the production is to be changed only slightly, a new punching blank must be calculated and appropriate tools produced. This method is thus very complex and it does not lead to a reflector, which is an ideal body of revolution, because there are many edge lines and mounting points, which lead to uneven light emission of the reflector.

Finally, from the prior art, methods are known, as for example in the GB 1 253 992 A may be described in which the reflector is indeed bent from a flat thin film blank, but this reflector material is not self-supporting, but is held by a receiving ring. The film material is provided with an adhesive coating and glued into the receiving ring. This is an additional operation, which also involves the risk of wrinkles in the gluing process, which lead to irregularities in the surface of the reflector.

The object of the present invention is to provide a rational method for the production of rotationally symmetrical approximately pot-shaped luminaire reflectors with a highly reflective surface of the type mentioned, which makes it possible, starting from the thin coated high-quality starting materials with comparatively low material thickness comprising a reflector to produce an already stable in itself rotational body and which leads to a reflector with optimized photometric properties.

The solution to this problem provides a method for producing rotationally symmetrical, about cup-shaped luminaire reflectors with a highly reflective surface of the type mentioned above with the characterizing features of the main claim. According to the invention, starting from a continuous, full-surface, coated with an optically active material, highly reflective, thin metal sheet as a blank and bends out of this a self-supporting body of revolution, which forms the body of the reflector. Thus, the starting material according to the invention is continuous throughout and unlike the prior art it has no slots. Of course, due to the shape of the reflector to be produced, the blank may for example already have a cut-out, for example if a window is required for the radial passage of the luminous means inside the reflector or the like. However, this is not comparable to regular slitting which weakens the material. The reflector to be produced rather remains self-supporting and intrinsically stable. It is unlike the prior art no longer separate housing body needed to make the rotary body only self-supporting. This is self-supporting after the bending process, in itself very stable and resistant to unwanted

Deformation such as buckling or the like. The rotation body, which reflects the basic shape of the reflector can be handled easily due to these self-supporting properties and high stability in the subsequent processing operations and added to other lighting technology necessary components. On the other hand, if, as in the prior art, one starts from a thin film, which is also slotted, which does not lead to a self-supporting body of revolution after bending out of the development, these further operations are not possible. This film can not handle alone and only leads to a dimensionally stable body of revolution with a reflective surface, if the film is glued in a separate dimensionally stable housing. In addition, a slotted foil can not provide a reflector with a uniform highly reflective surface that meets the lighting requirements of the inside of a reflector body according to the present invention. The result of the slit in the prior art undesirable reflections, a poorer beam path and a higher loss of light.

According to a preferred development of the invention, provision is made in particular for starting from a stress-hardened, rolled aluminum sheet as a blank. Such sheets as starting materials not only lead to self-supporting, but very dimensionally stable Rotationskörpem that avoid unwanted deformations such as buckling or the like in the further processing operations. The named starting material of the blank leads, in particular, to a rotational body which is somewhat under tension after the bending process. To illustrate only what is understood in the context of the present application under self-supporting and dimensionally stable, it should be noted that such a shaped truncated cone, for example, a deformation of the wall upon application of a force in the axial direction to the body, for example, 90 kg can withstand.

Thus, according to the invention, the blank is made into a strip shape corresponding to a development of a body of revolution, bent into a self-supporting body of revolution, and the ends of the strip are connected to one another. By the solution according to the invention, the usual forming process such as deep drawing or pressing the sheet material is bypassed. This has the advantage that the associated with such forming processes restrictions in the inventive solution omitted. For example, a sheet of lesser material thickness may be used as the starting material. Since the materials required for highly reflective surfaces are very expensive, this results in a very significant economic advantage. It is also advantageous if, according to the method of the invention, it is possible to start from a flat material which already has the desired highly reflective end surface than if first a flat material is formed and after the forming process a coating is performed which leads to a highly reflective material. For example, in certain coating processes (eg, using the Miro® method), shadow surfaces may form on the surfaces of the coated workpieces.

Furthermore, it is advantageous that the method according to the invention requires only a few simple manufacturing steps and therefore also permits efficient serial production. It should be noted that reflectors of this type are manufactured for downlights and the like in the luminaire manufacturers in large quantities, so that simplifications in the manufacturing process lead to time savings and great cost advantages.

In the bending of the self-supporting reflector base according to the invention from a blank corresponding to a development, on the other hand, the flat material is not exposed to excessive mechanical stresses. It is possible to use a comparatively thin starting material (preferably surface-coated aluminum with a material thickness of about 0.2 mm to about 0.8 mm), which already has the high-quality, highly reflective end surface. It is sufficient if, as usual, the flat material to be processed in the production phase is provided with a protective film, which is then peeled off.

The inventive method is particularly suitable for the processing of flat material made of aluminum or aluminum alloys, which is formed on its surface in particular by a single or multi-layer coating highly reflective. For example, the aforementioned "Miro" ® or "Miro-Silver" ® can be used.

Preferably, the procedure is such that the blank is made from a web or sheet of flat material, the blank is bent according to the shape of the desired reflector base body, and then the two ends of the bent blank are joined together in strip form, for example by gluing. It is preferable to bend the blank in strip form so that the two ends abut against each other, and then can stick a strip of a suitable material on the outside of the rotating body, which overlaps both ends of the strip and connects them together. It remains in this approach, only a minimal seam on the inside (visible side) of the reflector, which is not raised and therefore later optically barely perceived.

As lamps, fluorescent lamps are generally used in lamps of this type, in particular compact fluorescent lamps, which take up little space and are usually arranged so that they project into the reflector in the radial direction. The ballasts are usually housed outside the reflector. In order to enable such an arrangement of the fluorescent lamp, it is therefore advantageous if, according to a preferred embodiment of the invention, a window is provided in the reflector, through which the lamp can protrude radially into the reflector. This window can already be considered in the blank or can be introduced only after the bending and gluing of the reflector, for example by a punching operation with a stamp.

After bending the blank, the basic shape of the desired rotation body initially results, for example, this can be the shape of a truncated cone. However, for lighting reasons, it may be advantageous to choose for a reflector a surface line that does not run along a straight line, but along a curved line. For example, it may be advantageous to use an approximately pot-shaped rotational body with a rather spherical shape or a generatrix which at least partially follows approximately the shape of a parabolic branch.

According to the invention deforms, after forming the basic shape of the rotating body by bending from the blank, the rotary body in at least one further deformation step, namely in an embossing process. Here it is however a rather slight deformation for the stated purpose, compared with a deformation as in a forming process such as deep drawing or pressing. This subsequent deformation step is a "fine deformation" while the actual basic step of forming the body of revolution from the sheet material is simply by bending the blank.

In such an embossing process, for example, a facet embossing can be introduced into the surface of the rotational body. This has advantages, for example, with regard to the technical lighting properties of such a reflector. The image of the lamp in the reflector can be resolved, for example.

The downlights, for which the reflectors according to the invention are predominantly used, are predominantly recessed ceiling luminaires. For ceiling installation, a lower edge of the reflector is advantageous, which rests when installed on the underside of the suspended ceiling. A preferred constructive solution variant therefore further provides that in at least one subsequent step, a flanging ring is formed on the rotary body in the lower edge region so as to create this lower edge. The molding of such a flare ring is a simple process step that can be carried out on conventional conventional machines. Alternatively, but you can instead produce a ring, such as an approximately L-shaped ring as a separate item and push in a subsequent step on the lower edge region of the rotating body, said L-ring has a receptacle for the edge region of the rotating body and the Determines ring on the rotation body.

The rotating body of the downlight reflector can also be provided on the upper side with a lid, which serves as an upper cover. This cover may for example be provided with hole fasteners or slots for attachment. To connect such a lid with the bent from the blank rotation body, for example, on the blank of flat material in strip form, which is assumed to be formed at least one tab or later attached to the body of rotation at least one tab, and after bending the The rotational body is at least a plate-like on this above Lid fitted, which has at least one slot and rotary body and lid are then connected together such that the at least one tab engages through the at least one slot. Furthermore, it can be provided, in particular, that the cover overlaps the rotation body with a lateral edge of the cover and is connected to it to form a reflector.

It has already been mentioned that the method according to the invention makes it possible to use a flat material with a lower material thickness than starting material. It is preferably provided in the context of the invention that it is possible to use a flat material having a material thickness of less than 1 mm, preferably less than 0.8 mm, more preferably less than 0.6 mm, for example preferably of the order of about 0 , From 4 mm to about 0.3 mm and made from this corresponding to a development of the rotary body blank.

The present invention furthermore relates to a rotationally symmetrical, approximately cup-shaped, downlight reflector having a highly reflective surface which has been obtained from a metallic flat material by deformation in accordance with the desired shape of the reflector, the reflector being produced in a method according to one of Claims 1 to 14 has been.

The present invention furthermore relates to a luminaire, in particular recessed luminaire or surface-mounted luminaire, in particular downlight, which comprises such a reflector.

The features described in the dependent claims relate to preferred developments of the task solution according to the invention. Further advantages of the present invention will become apparent from the following detailed description.

• Figur 1 eine Ansicht eines Zuschnitts, der der Abwicklung des herzustellenden Rotationskörpers entspricht;
• Figur 1 a eine Ansicht eines ähnlichen Zuschnitts gemäß einer leicht abgewandelten Variante der vorliegenden Erfindung;
• Figur 2 eine Ansicht des Rotationskörpers nach dem Biegevorgang im Längsschnitt;
• Figur 2 a eine Draufsicht des Rotationskörpers von Figur 2;
• Figur 3 a eine perspektivische Ansicht des Reflektors nach dem Biegevorgang;
• Figur 3b eine entsprechende Ansicht wie in Figur 3 nach dem Klebevorgang;
• Figur 3c eine ähnliche Ansicht nach dem Ausstanzen eines Fensters;
• Figur 3d eine ähnliche Ansicht, die eine alternative Variante der Verbindung der Enden nach dem Biegen zeigt;
• Figur 4 einen Längsschnitt durch den Reflektor in einem späteren Stadium des Verfahrens;
• Figur 4 a eine Detailansicht des Reflektors im unteren Bereich entsprechend einem Ausschnitt von Figur 4;
• Figur 5 einen Längsschnitt eines fertigen Reflektors;
• Figur 6 einen Längsschnitt durch einen Reflektor mit Deckel gemäß einer weiteren beispielhaften Ausführungsvariante der Erfindung.

Hereinafter, the present invention will be explained in more detail by means of embodiments with reference to the accompanying drawings. Showing:

• FIG. 1 a view of a blank, which corresponds to the development of the rotating body to be produced;
• FIG. 1 a is a view of a similar blank according to a slightly modified variant of the present invention;
• FIG. 2 a view of the rotating body after the bending process in longitudinal section;
• FIG. 2 a is a top view of the rotational body of FIG. 2 ;
• FIG. 3 a is a perspective view of the reflector after the bending process;
• FIG. 3b a corresponding view as in FIG. 3 after the gluing process;
• Figure 3c a similar view after punching out a window;
• 3d figure a similar view showing an alternative variant of the connection of the ends after bending;
• FIG. 4 a longitudinal section through the reflector at a later stage of the process;
• FIG. 4 a is a detail view of the reflector in the lower area corresponding to a section of FIG. 4 ;
• FIG. 5 a longitudinal section of a finished reflector;
• FIG. 6 a longitudinal section through a reflector with cover according to another exemplary embodiment of the invention.

First, on the FIG. 1 Reference is made, which shows a blank of the starting material, which corresponds to a development of the rotating body to be produced. One recognizes in FIG. 1 the blank 10, which is obtainable from a flat material such as a panel or the like of aluminum or an aluminum alloy, wherein the material has a highly reflective surface. For example, the required blank 10 is punched out of a material which virtually already has the required end surface at least on the later visible side, such as Miro®. The blank 10 is delimited by an upper edge line 11 which follows a curved line and a lower edge Edge line 14, which also follows a curved line, with a slightly different radius of curvature from the line of edge 11. Further, the blank has a first straight edge line 12 at one end and a second straight edge line 13 at its other end, the lengths of both lateral edge lines 12 and 13. The flat material of the blank 10 used is quite thin, for example in the range of 0.4 to 0.6 mm material thickness, so that it can be bent well.

The in FIG. 1 shown blank 10 is now bent so that a rotational body 20 of the in the Figures 2 and 3 shown type, in which the two lateral edge lines 12 and 13 of the blank then abut one another. This results in a truncated cone, which is bounded above by the edge line 11 and bounded below by the edge line 14. The plan view of the frustoconical rotational body 20 is in FIG. 2 a shown. Consequently, this truncated cone arises in only one bending step from the blank, without a forming process in the sense of conventional forming processes such as deep drawing, pressing or the like, in which stresses are built up in the workpiece and there are changes in strength.

In order to complete the downlight reflector serving as the top, you can, as in the FIG. 3 a is shown, put a plate-like lid 23 from above on the rotary body 20 and attach to this. The fastening can take place, for example, via tabs 26 on the rotary body 20, which engage in slots 24 in the cover 23. Alternatively, for example, protruding areas such as cams 27 or the like may be formed on top of the rotary body, which in holes 25 on an integrally formed ring of the lid 23 intervene. In the attached state, this ring can overlap the top of the rotation body on the outside of the lid.

The fixation of the truncated cone after bending can be done by a Klebefügeprozess. A first possibility for this is in the FIG. 3b shown. The state after bending is in FIG. 3 a shown. The two edge lines 12 and 13 abut against each other. It is now an example approximately rectangular strip of a similar material (optionally made of the same material or at least the base material aluminum foil) externally glued to the truncated cone, so that the strip 15, the two ends of the blank each covered over a certain width and best of all in that the joint line 16 runs approximately in the middle under the strip 15. The rotary body 20 after the bonding step is in FIG. 3b shown.

3d figure shows a possible alternative, in which you can not abut the two ends of the blank on impact, but the blank bends so far that the two ends overlap slightly. In this case, one can do without the previously described strip 15 and connect both ends of the blank directly together, for example by gluing. The overlap area is in 3d figure designated by the reference numeral 28.

In a further step, in Figure 3c is shown, then optionally a window 17 is punched into the rotary body 20, which later serves in the reflector to guide the lamp from the outside into the interior of the reflector. This can be done, for example, with a stamp, in particular in the reinforced by the glued strip 15 area or elsewhere. The rotary body 20 after the punching of the window 17 is in Figure 3c shown.

It will now be following the FIG. 1 a reference, the one opposite FIG. 1 slightly modified variant of the blank shows, which can be assumed in the production of the rotating body. The basic shape of the blank 10 is similar here as in the case of the previously FIG. 1 described variant. however Here are at the upper edge line several (in the example a total of 4) approximately semicircular projections 29 provided on the upper edge line 11, from which can be bent after bending the blank to the shape of the rotating body tabs, by means of which a cover for the reflector can be fastened , Slightly slits 30 are also preferably provided in the material slightly above the edge line 11, which areas represent a weakened area and can serve to facilitate the subsequent bending of these projections 29 by approximately 90 ° in order to form the tabs. There are in this variant from the outset tabs 26 present, formed from the projections 29, so that a fastening of a lid 23 can be made on the rotary body, similar to that in FIG. 3 a is shown. For this purpose, the lid 23 has a corresponding number of slots 24, through which the tabs 26 can be pushed through.

In the embodiment of FIG. 1 a there is another deviation from the variant of FIG. 1 , Namely, approximately rectangular notches 31, 32 are respectively provided in the upper region of the lateral edge lines 12, 13, so that a window 17 is already formed when bending the punched blank to form the rotating body, as shown in FIG Figure 3c is shown, so that in the variant of FIG. 1 a the subsequent step of punching this window 17 is omitted. As already mentioned, the window 17 serves to later introduce the lamp from the outside into the interior of the reflector during assembly of the luminaire.

It will now be following the FIGS. 4 and 4a and 5 Referenced. The rotational body 20 obtained after the bending step as described in FIG. 2 is shown, which has the shape of a truncated cone, in a possible variant of the method according to the invention in an embossing process subsequently deformed something, so that in FIG. 4 shown in which the generatrix 18 as compared to FIG. 2 recognizes no longer straight, but in a curved line. This has advantages in terms of the characteristic of the light emission of the reflector to be produced, which will not be discussed in detail here. Since the reflector is usually installed in a suspended ceiling, a lower outwardly projecting flange is needed in these cases, which then in the installed state at the bottom of the suspended ceiling not shown here to the plant comes. To produce such a lower flange can be produced by crimping a crimp ring. An alternative to this is the use of an approximately L-shaped ring 19, as in the FIGS. 4 and 4 a is shown. The enlarged view according to FIG. 4 a shows how the L-shaped ring 19, which has a receptacle 21, is slid over the lower end of the wall of the rotating body 20, so that the lower edge of the reflector is received by the receptacle 21. The L-shaped ring 19 can thus be held, for example by a clamp connection or by an adhesive bond to the reflector. The horizontal leg 22 of the L-shaped ring 19 then forms the aforementioned flange for installation on the suspended ceiling when installing the lamp. The finished reflector with mounted L-ring 19 (but without the lid) is in again FIG. 5 shown.

A rotationally symmetrical reflector as he, for example, in the FIGS. 3a or 5 can be used, for example, in a downlight or surface-mounted downlight of the type "downlight". For this purpose, this reflector is usually used in a light pot and attached by means of known methods to this light pot. The light box and the complete lamp are not shown in the drawings of the present application.

The in FIG. 3 A shown cover 23 of the downlight reflector can be varied by lighting fixtures on the underside of the lid to change the radiation characteristics of such a lamp. An embodiment of such a reflector is in FIG. 6 shown. There is shown a vertical section through such a reflector. It can be seen the rotating body 20 and the lid 23, which has a centrally extending in the diameter direction center edge 33 above the lamp 34. This Mittelkantung is approximately V-shaped and has two concave-shaped parabolic branches 35, 36. Through this Mittelkantung can reach that light emitted from the lamp 34 upwards light is not reflected directly back to the lamp, because this proportion of light is then through The parabolic branches are steered and directed laterally past the lamp either directly downwards or onto the inner lateral surface of the rotation body 20 and from there reflected and emitted downwards.

The lid 23 may also be flat on the underside. The lid usually has as in FIG. 6 illustrated a bent lateral edge 37 which engages over the rotational body 20 of the reflector (see FIG. 6 ) and, for example, for bonding both components can be glued to this. However, the cover 23 may also be concave or convex in itself to change the Lichtabstrahlcharakteristik. For example, a conical shape for the lid comes into consideration.

A very significant advantage of the present invention is that a higher efficiency of the lamp is achieved by the high reflection efficiency of the material used in a reflector according to the invention, in which such a reflector is used. This in turn makes it possible to reduce the number of lights when lighting a room or to operate the lights with weaker lamps, resulting in both cases, an energy savings.

LIST OF REFERENCE NUMBERS

10

cut

11

edge line

12

lateral edge line

13

lateral edge line

14

edge line

15

strip

16

surge line

17

window

18

generating line

19

L-shaped ring

20

body of revolution

21

admission

22

horizontal thigh

23

cover

24

slots

25

Holes for hole fixing

26

tabs

27

Cam for hole mounting

28

overlap

29

projections

30

slots

31

notches

32

notches

33

Mittelkantung

34

lamp

35

parabola

36

parabola

37

cover edge

Claims (13)

1. A method for producing a rotationally symmetrical, approximately cup-shaped downlight reflector, comprising a highly-reflective surface, in the case of which the starting point is a metallic flat material and the latter is deformed according to the desired shape of the reflector, wherein a cut (10) in the shape of strips, which corresponds to an unwinding of a rotational body (20), is created from the flat material, said cut being bent to form a rotational body (20) and the ends of the strip are connected to one another, characterized in that the starting point is a continuously holohedral aluminum sheet, which is surface-coated with an optically effective material and which has a thickness of less than 1 mm and at least 0.2 mm, comprising a light reflectance degree of above 90% as cut (10), said aluminum sheet already encompasses the highly-reflective surface, and a self-supporting rotational body (20) is bent therefrom, which forms the body of the reflector, and that the rotational body (20) is deformed even further from the cut (10) in at least a further deformation step, which is an stamping process, after embodying the base form of the rotational body (20) by means of bending.
2. The method according to claim 1, characterized in that the starting point is a tension-tight, rolled out aluminum sheet as cut (10).
3. The method according to one of claims 1 or 2, characterized in that the cut (10) in the shape of strips is bent such that the two ends rest against one another so as to be flush and a strip (15) made of a suitable material, which overlaps the two ends of the bent cut (10) and connects them to one another, is then adhered to the outer side of the rotational body (20).
4. The method according to one of claims 1 to 3, characterized in that, after forming the rotational body (20), at least one window (17) is introduced therein preferably by means of a stamping process or that a cut (10) is used, which, in the area of the lateral edge lines (12, 13), in each case encompasses notches (31, 32) in accordance with the shape of the window (17), which is to be created.
5. The method according to one of claims 1 to 4, characterized in that, after bending the rotational body (20), at least one plate-like cover (23) is attached thereto on the top and rotational body (20) and cover (23) are subsequently connected to one another.
6. The method according to one of claims 1 to 5, characterized in that a flanged ring is integrally molded to the rotational body (20) in the lower edge area in at least one subsequent step.
7. The method according to one of claims 1 to 6, characterized in that a ring (19), the cross section of which is approximately L-shaped and which comprises an accommodation (21) for the edge area, is slid across the lower edge area of the rotational body (20) in a subsequent step and the ring (19) is fixed to the rotational body (20).
8. The method according to one of claims 1 to 7, characterized in that the starting point is a flat material comprising a material thickness of less than 0.8 mm, more preferably of less than 0.6 mm and a minimum material thickness of preferably at least 0.3 mm.
9. The method according to one of claims 1 to 4 or 6 to 8, characterized in that at least one connecting link (26, 28) is integrally molded to the cut (10) made of flat material in the shape of strips, which is the starting point, or that at least one connecting link (26, 28) is later attached to the rotational body (20), at least one plate-like cover (23) is attached to the top of the rotational body (20) after bending the latter, said cover (23) encompassing at least one slit (24), and rotational body (20) and cover (23) are subsequently connected to one another such that the at least one connecting link (26, 29) reaches through the at least one slit (24).
10. The method according to claim 5 or 9, characterized in that the cover (23) overlaps the rotational body (20) with a lateral cover edge (37) and is connected thereto to form a reflector.
11. The method according to one of claims 9 or 10, characterized in that the cover (23) is flat, concave or deformed convexly, encompasses a cone-shape, encompasses a center tilt (33), in particular comprising parable branches (35, 36) or that the light emission characteristic of the cover (23) is changed by deforming the cover (23) or by fixtures in the cover area.
12. A rotationally symmetrical, approximately cup-shaped downlight reflector comprising a highly-reflective surface, which, starting at a metallic flat material, was obtained by deformation in accordance with the desired shape of the reflector, characterized in that the reflector was produced in a method according to one of claims 1 to 11.
13. A luminaire, in particular a recessed luminaire or surface-mounted luminaire, in particular downlight, characterized in that the latter comprises at least one reflector according to claim 12.

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