Patent ID: 7578605

Claim:
A light shaping reflector system comprising: at least one reflector body having two side vanes formed about a top vane and about at least one intermediate vane, the two side vanes and the top and intermediate vanes having inwardly facing reflective surfaces, the top vane and the at least one intermediate vane each being positioned in a nominally horizontal plane, and the side vanes each being positioned in a nominally vertical plane, the side vanes comprising: a single, fiat sheet having a mounting hole configured to be attached to a forming tool for bending the sheet to form the side vanes; the sheet-is bent along a first left bend-line at approximately twenty degrees (20°) relative to the mounting hole so as to form a first left reflective sidewall; the sheet bent along one or more second left bend-lines so as to form a second left reflective sidewall at approximately negative twenty degrees (−20°) relative to the first left reflective sidewall, the second left reflective sidewall is positioned substantially parallel to an axis of the mounting hole; the sheet bent along a first right bend-line at approximately twenty degrees (20°) relative to the mounting hole so as to form a first right reflective sidewall; and the sheet bent along one or more second right bend-lines so as to form a second right reflective sidewall at approximately negative twelve degrees (−12°) relative to the first right reflective sidewall, the second right reflective sidewall is positioned at an angle of approximately eight degrees (8°) relative to the axis of the mounting hole; and at least one LED positioned within the reflector body substantially between the side vanes and substantially between the top vane and the at least one intermediate vane; whereby light emitted from the LED is cutoff downwardly by the intermediate vane and upwardly by the top vane and is directed off of the reflective surfaces of at least the top and intermediate vanes so as to collimate at least a portion of the light toward a far field target at substantially zero degrees relative to the optical axis of the LED, and whereby light emitted from the LED is cutoff laterally by the two side vanes and is directed off the reflective surfaces of the side vanes so as to concentrate the light in a substantially cone projection and amplify total luminance of the target.