Heat shield

Abstract: A flashlight reflector assembly (1) including the substantially parabolic reflector (2) having on one surface a reflectorized material, having a hole (10) through its center as its converging end, and a plurality of support ribs (9) extending from the backside of the reflector wherein a stainless steel heat shield (3) is press fit into the back side of the reflector for protecting the reflector from over temperature conditions by reflecting heat back into the lamp and by conducting heat away from the converging portion of the reflector outward to the plurality of pins located behind the reflector reflecting surface.

Description: BACKGROUND OF THE INVENTION This invention relates to a reflector assembly which protects against over temperature conditions and subsequent distortion of a substantially parabolic reflector in the region near its converging end due to use of high temperature lamps. Conventional flashlights typically use a vacuum type lamp. These vacuum lamps do not produce temperatures sufficiently high to distort and degrade conventional plastic based reflectors. Also, although high temperature, usually gas-filled, lamps are known in the flashlight and portable lighting industry, it is common to use metal based reflectors with such lamps to thereby avoid the distortion problems which would otherwise be created with use of plastic based reflectors. OBJECTS OF THE INVENTION It is an object of the present invention to provide a heat shield for a plastic base reflector. It is a further object of the present invention to provide a heat shield and heat conducting member for use in conjunction with a flashlight reflector. It is a further object of the present invention to provide a plastic-bodied reflector which is capable of withstanding the high temperature environments produced by gas-filled, high temperature lamps. It is a further object of the present invention to provide a metal heat shield which reflects heat and light back into the lamp of a flashlight and also conducts heat away from a region near a flashlight lamp to prevent distortion of a reflector surface near the lamp. The present invention is directed to a flashlight reflector assembly according to claim 1. The reflector assembly includes a reflector with a reflectorised surface and a heat shield positioned so as to prevent extreme temperatures from a high temperature lamp causing distortions on the reflectorised surface of the reflector and thereby causing degradation of the reflected light beam. EP-A-0 071 585 discloses a reflector assembly as defined in the prior art portion of claim 1. This prior assembly is a vehicle headlight assembly in which a bulb is mounted in the conventional way with the filament in a glass envelope positioned well in advance of the reflector. The reflector assembly of the present invention, in contrast thereto, is for use in a flashlight having a high intensity xenon bulb which must be capable of location, when illuminated, with the filament retracted into the aperture at the centre of the reflector. With the present invention, as defined in claim 1, the heat shield has a portion which extends into the hole at the centre of the reflector with the lamp filament being positionable adjacent to and radially inwardly of the heat shield to provide substantially improved heat transfer than is possible with the heat shield of EP-A-0 071 585 where the lamp filament is positioned forwardly of the heat shield. While US-A-4 577 263 discloses an earlier construction of flashlight of the present applicants, it contains no suggestion of the problem of cooling a high temperature bulb such that the filament may be positioned within the hole at the centre of the reflector. The reflector is generally a parabolic type reflector having, preferably, a plastic type body with an aluminium reflectorised surface, although the reflector may be made of other materials. The heat shield of the present invention used in conjunction with the reflector is some other material which will reflect light and heat back into the lamp and which will also conduct heat from the lamp to remote regions of the reflector or to a non-reflector heat sink so as to prevent a path of heat from the lamp to areas of the reflector which could be damaged sufficiently to cause distortions in the reflectorised surface. In the later described and illustrated embodiment, the heat shield includes an annular disc of a predetermined thickness having a tubular portion extending perpendicular from the annular disc at its central hole and extending to a predetermined distance sufficient to provide substantial reflection of light and heat into the lamp as well as conduction of heat away from the lamp to prevent high temperature conditions in the body of the reflector near its reflecting surface. The heat shield is positioned at the converging end of the reflector and is also sized and positioned within the reflector so as to create air gaps between the bulb and the heat shield, between the heat shield and the reflector body in a direction radially outward from the filament of the lamp bulb and between the heat shield and the reflector body extending radially outward from the lower edge of the tubular portion where it merges with the annular disc portion of the heat shield and above the disc portion. The back side of the reflector is provided with insert, or recess areas sufficient to provide the air gaps between the heat shield and the reflector and inserts or recesses to provide for a tight fit at distal regions of the disc portion of the heat shield. Such regions of the reflector may be formed integral with the body and form a plurality of ribs which extend backward and away from the reflectorized surface of the reflector to not only anchor the heat shield, but also to act as heat sinks. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is an exploded, rear perspective view of a preferred reflector assembly of the present invention. Figure 2 is a cross-sectional view of the Figure 1 reflector assembly, shown with a lamp in a position as may be found during operation of a flashlight having a reflector assembly as shown in Figure 1. Figure 3 is a cross-sectional view of the Figure 1 reflector assembly without its accompanying heat shield. Figure 4 is a cross-sectional view of a heat shield of the Figure 1 reflector assembly, without the reflector. Figure 5 is a rear view of the Figure 1 reflector without the accompanying heat shield. Figure 6 is a cross-sectional view of a first alternate embodiment of a reflector assembly of the present invention. Figure 7 is a cross-sectional view of a second alternate embodiment of a reflector assembly of the present invention. Figure 8 is a cross-sectional view of a third alternate embodiment of a reflector assembly of the present invention. Figure 9 is a cross-sectional view of a fourth alternate embodiment of the reflector assembly of the present invention. Figure 10 is a cross-sectional view of a fifth alternate embodiment of a reflector assembly of the present invention. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS By reference to Figures 1-10 preferred embodiments of the reflector assembly of the present invention will be described. Referring to Figure 1 an exploded, rear perspective view of a preferred reflector assembly of the present invention is shown generally at 1. The reflector assembly includes a reflector body 2 having ribs 9, and heat shield 3 with a hole 11 in its center for insertion of a lamp. The reflector assembly 1 of the present invention may be used in conjunction with virtually any lighting product, but is preferably for use with flashlights of the type disclosed in U.S. Patent No. 4,577,263, U.S. Patent No. 4,656,565, and U.S. Patent No. 4,658,336. Also, the reflector assembly of the present invention is most preferably used in those flashlights having relatively high-intensity lamps which produce correspondingly high temperatures at the filament and adjacent to the lamp near the flashlight reflector. When such high temperature lamps, usually those filled with a gas such as xenon are used, sufficiently high temperatures adjacent the lamp are produced to cause distortions in the reflector surface and degradation of reflected light from reflectorized surfaces of conventional plastic body reflectors. Although it is known to use steel-body reflectors, such reflectors are relatively expensive and difficult to manufacture. Accordingly it is an object of the present invention to provide a plastic-bodied reflector which is capable of withstanding the high temperature environments produced by gas-filled, high temperature lamps. Referring to Figure 2, which is a cross-sectional view of the Figure 1 reflector assembly, including a typical flashlight lamp 4 placed in position as may be found during normal operation of a flashlight and which will produce the most severe temperatures at the converging region of the reflector body. The lamp 4 is shown having glass envelope 5, filament 6, and pins 7 and 8 for providing a source of light. The lamp 4 is shown as a bare base, bi-pin type lamp. The present invention may be used in conjuction with other types of lamps. Typically, the bulb 5 is filled with a gas such as xenon which may or may not be under pressure. As is well known, such gas-filled lamps produce a relatively bright light, with correspondingly relatively high temperatures at the filament and adjacent to the bulb 5, as shown at 57. A reflector 2 is shown with a reflectorized surface 16 on its concave surface for reflecting light emitted from filament 6 and for focusing the beam of light out through a lens, not shown. Reflectorized material 16 may be placed on the reflector body 2 by conventional means. Reflector body 2 is shown with a plurality of support ribs 9, which are also shown in Figures 1-3 and 5. The shield 3 of the present invention includes a disc portion 3A having near its central hole a tubular portion 3B of the disc body extending perpendicularly to form a short tubular or cylindrical portion 3B. The shield 3 may be press fit into the main body of the reflector 2 along and within recessed portions at edge 14, the recessed portions are radially inward of and adjacent to the outer edge of ribs 9. As also shown in Figure 2, a small air gap 13 exists between the outer periphery of bulb 5 and the inner periphery of tube portion 3B of shield 3. Also, as shown in Figure 2 another small air gap 12 is established between the outer periphery of the tube portion 3B of shield 3 and the inner periphery of the hole 10 which is in the center of reflector 2 adjacent to the tube portion 3B. Extending radially outward from the lower part of the tube portion 3B to a predetermined distance along the disc portion 3A of the back of the disc 3 a third air gap 17 is established between the upper surface of the disc portion 3A and the reflector 2 adjacent hole 10. The reflector body 2 is preferably made of a high temperature plastic material such as, for example, Ultem™. Other known, high temperature plastics may be used as the reflector body material. The reflector body material performs the functions maintaining a good, smooth surface for the reflector material 16 during extended operation with high temperature lamps. The reflector material 2 also function to provide a smooth surface, that is, a surface having relatively few or no flow lines or seams and to, provide for excellent optical properties when coated with reflectorized material 16. The reflector body material must also be relatively strong and must exhibit minimal shrinkage, that is no more than about 1% mold shrinkage when solidifying from liquid to solid state. In order to minimize potential optical distortions when coated with reflectorized material 16, it is preferred that the material used for the reflector body have a heat deflection temperature of at least about 229°C (445°F), although materials having deflection temperatures as low as 196°C (385°F) are acceptable for the purposes of the present invention. The plastic body 2 of the reflector may be made with conventional injection molding techniques. In the absence of a means to remove excess heat, such as the reflector-heat shield assembly of the present invention, high temperature lamps, such as gas-filled lamps in may cause distortion on the reflectorized surface 16 of the reflector body. Typically, the reflectorized surface is a thin coating of aluminum which may become distorted where excess heat has caused distortions and/or bubble formation within the body of the reflector 2. Such distortions result in degradation of the reflected beam of light through the lens. The shield 3 is preferably made of a material which provides good reflection of light back into the bulb and also provides good conduction of heat from the tube portion 3B of the shield 3 to the disc portion 3A and then to the ribs 9 of the reflector body 2. Stainless steel, type 303, 304, or 316 is preferred. Other materials which function to provide acceptable reflection and conduction properties may be used in the present invention. The stainless steel heat shield 3 may be made by conventional machining or stamping processes. The heat shield 3 may also be made with burrs at the ends of the disc portion 3A, to prevent falling out, or rotation the shield 3 relative to the reflector 2. As shown in Figure 2, the filament 6 is positioned adjacent to and radially inward of tube portion 3B of the heat shield 3. In this position of maximum potential heat transfer to the reflector, and assuming no heat shield were in place, the temperatures reached from use of a gas-filled lamp such as a xenon lamp, could, in many instances, create temperatures high enough to cause melting of plastic reflector material and consequent distortion of the optical surface 16 on the reflector body 2 with consequent degradation in the optical characteristics of the beam emitted from the flashlight. It has been found that with a typical gas-filled lamp 6 that a temperature at filament 6 of approximately 224°C (435°F) may be achieved, depending upon the voltage, gas-fill and current used in the particular lamp application. Generally, it is desirable in flashlight applications to use as much power from the battery as available to give maximum brightness, or light, consistent with a predetermined useful battery expected lifetime. In the case of a three cell, AA sized flashlight wherein the three cells are oriented in series to provide approximately 4.5 volts of electric potential, it has been found that a lamp drawing approximately 400 milliamperes of current will result in a battery life of about 3 hours or more. With such design criteria, it has been determined that the equilibrium temperature of the bulb glass at 57 is at about 238°C (460°F.). With an equilibrium temperature maximum of about 238°C (460°F) at the filament, it is desired to achieve a corresponding equilibrium temperature in the reflector body which is low enough to prevent distortion and/or degradation of the reflector material, and in turn to prevent degradation of reflector performance. It has been determined that when the bulb glass temperature is about 238°C (460°F) as shown at 57, the corresponding temperature of the tube portion 3B of the heat shield is about 191°C (375°F). As heat is conducted from the tube portion 3B through the disc portion 3A of the heat shield 3, the temperature at the outer radial periphery of the disc portion 3A of the shield 3 where it contacts the reflector 2, at 14 is about 154°C (310°F). Also, at the inner periphery of the disc portion 3A of the heat shield 3, shown at 18, the temperature is approximately 177°C (350°F) under these conditions. One design criterion is to insure that at region or edge 14 temperatures do not reach a high enough temperature to cause degradation of the plastic reflector body 2. If this criterion is met at edge 14, then it can be safely assumed that no degradation of the reflectorized surface 16 will result due to generation of heat at the surface of the bulb glass, as shown at 57. It is noted that the air gap 12 shown radially outward of tube portion 3B of heat shield 3 and the air gap 17 located above a predetermined radius along the main portion 3A of the heat shield 3 prevent high temperature being reached in the corresponding adjacent regions of the plastic reflector body 2 because such air gaps permit only radiation type heat transfer as opposed to conduction heat transfer which would occur if the plastic reflector material touched the heat shield material in these regions. It is also noted that the stainless steel heat shield material is a relatively poor emitter, a poor electric conductor but is a relatively good light and heat reflector. Although the heat shield of the present invention is intended primarily for use with a plastic body reflector the heat shield may also used in conjunction with metal reflectors, or reflectors of other material where it is desired to have an additional means to remove heat from the region of the reflector near the lamp. It is noted that although an air gap 13 is shown between the heat shield 3 and the lamp 4, flashlight lamps occasionally are inserted in a crooked fashion, or the pins may become bent during use and therefore the bulb may be tilted to one side and touch the heat shield 3. Such touching is acceptable, although, it is preferred that a small air gap exist between lamp 4 and the heat shield 3. What is more important is that air gaps 12 and 17 be maintained between the heat shield 3 and the reflector body 2. As shown in the Figure 1 preferred embodiment the disc portion 3A of the heat shield 3 extends out to and physically contacts the bottom of the ribs 9 of the plastic reflector 2. In this configuration the ribs 9 act not only as anchors, or physical supports for the metal shield and the reflector, but also function as heat sinks for heat transferred from the lamp filament 6 through the heat shield 3. Although it is preferred to have the heat shield 3 configured such that heat is transferred to the ribs 9, acceptable reflector assemblies may be constructed which do not provide for heat transfer to ribs but rather are of sufficient means to act as the heat sink, or will transfer heat to some other remote component which acts as a heat sink. Although the reflector assembly of the present invention may be used for virtually any flashlight or portable light application where it desired to remove excess heat from near the base of the reflector, the preferred embodiment is intended for use with a three cell, AA sized flashlight similar to that disclosed in co-pending application Serial No. 111,538. In such an application the diameter of the hole 11 in the heat shield 3 is approximately 4.31 mm (0.147 inches). The diameter of the heat shield itself is approximately 15.24 mm (0.600 inches). The thickness of the disc portion 3A of the heat shield 3 is approximately 0.02 inches, with the tube portion 3B of the heat shield 3 extending perpendicularly from the main disc body portion an additional 1.78 mm (0.070 inches). As shown in Figure 3, the first, or greater radius insert from the center out to edge 14 at the bottom of the reflector body has an diameter of approximately 15.24 mm (0.600 inches) to provide a tight, press fit of the heat shield 3 into the lower region of the reflector body 2. The smaller radius insert cavity which defines air gap 17, with edge 15, as shown in Figure 3, has a diameter of approximately 7.62 mm (0.300 inches). The depth of the insert shown at 14 is approximately 0.635 mm (0.025 inches) with a depth of the second insert, as shown at 15, of approximately 0.254 mm (0.010 inches). The diameter of the hole 10 through the reflector body 2, as shown in Figure 1, is approximately 4.75 mm (0.187 inches). Referring to Figures 6-10, several alternative embodiments of the heat shields are shown configured within the reflector 2. In general, the heat shield may vary in the dimensions of the diameter of the disc portion 3A, the thickness of the disc portion 3A, and the height, thickness and diameter of the tube portion 3B. For example, it may be seen that in Figure 6, the disc portion 3A has a second cylindrical portion 3C which extends downward from the main disc portion 3A to provide an extra heat sink and mechanical support. Referring to Figure 7, it may be seen that the disc portion 3A is of a smaller diameter than that of the Figure 1 embodiment disc portion 3A, but is of a greater thickness. Referring to Figure 8 it may be seen that the sizing of tube portion 3B of the heat shield is slightly longer than that as shown in the Figure 1 embodiment. Referring to Figure 9 it may be seen that the diameter of the main disc portion 3A is smaller than that of the Figure 1 embodiment, and the rising tube portion 3B is longer than that of the Figure 1 embodiment. Referring to Figure 10 it may be seen that the main disc portion 3A is even smaller than that of the Figure 9 embodiment.

Claims: A reflector assembly including: a lamp (4) including a filament (6); a reflector body (2) made of a first material; and a heat shield (3) made of a second material, said heat shield being positioned at a first end of the reflector and having a first portion (3B) thereof extending into a hole (10) formed in the centre region of the reflector; characterised in that the reflector assembly is a flashlight reflector assembly with the lamp filament (6) being positioned adjacent to and radially inward of said first portion (3B) of the heat shield (3). A reflector assembly according to claim 1, wherein the reflector (2) has a substantially parabolic shape. A reflector assembly according to claim 1 or 2, wherein the reflector material (16) is a high temperature plastic. A reflector assembly according to any one of claims 1 to 3, wherein the heat shield (3) material is stainless steel. A reflector assembly according to any one of claims 1 to 4, wherein the heat shield (3) includes a second portion (3A) comprising a main body portion of annular shape having an outer diameter and an inner diameter, and wherein the first portion (3B) of the heat shield comprises a tube extending perpendicular to the main body portion at the region of said inner diameter to form a cylindrical tube having a diameter equal to the second diameter of the main body portion. A reflector assembly according to any one of claims 1 to 5, wherein the reflector body has a first side, and wherein a plurality of ribs (9) extend outwardly from said first side of the reflector such that a or the second portion (3A) of the heat shield (13) matingly engages with said ribs (9) of said reflector.

Inventors: JOHNSON RALPH EMSLEY, MAGLICA ANTHONY, JOHNSON, RALPH EMSLEY, MAGLICA, ANTHONY
Applicants: MAG INSTR INC, MAG INSTRUMENT INC.
Application year: 1989
Main classification: F21V7
IPC codes: F21V15, F21L4, F21V29, F21V7