US2248543A - Reflector unit - Google Patents

Description

July 8, 1941.

C. H. MAHONEY ETAL REFLECTOR UNIT Filed Feb. 20, 1939 UharlesHMd/Mne VVi'lliam5.Brian/;

Patented July 8, 1941 REFLECTOR UNIT Charles Hallam Mahoney and William Stanley Brian, Owensboro, Ky., assignors to Ken-Rad Tube & Lamp Corp., Owensboro, Ky., a corporation of Delaware Application February 20, 1939, Serial No. 257,492

9 Claims.

This invention relates to reflecting units of the type generally known as reflector buttons which include a refractory lens and a mirror suitably assembled to be handled as a unit for gasket at the time of manufacture of the unit, against atmo'sphericattack in such a Way that no gases or moisture can reach the reflecting surface thereby maintaining the original high reflecting light rays when mounted in signs or reflecting power of the polished surface and, other supports. consequently, materially increasing the life of One of the principal objections todevices the unit as a whole. In that connection, the of this type is that the metallic mirror or reinvention contemplates the manufacture of a flector soon becomes tarnished in use, and the reflector button wherein the seal, such as sulefiiciency of the unit is consequently impaired. 10 phur free rubber is applied by precision machine The lens itself being made of glass, and usually methods whichaiford no opportunity for poor mounted in a protective casing or shell remains workmanship which would result in a poor seal unchanged and seldom becomes damaged, and, depending upon the skill of a particular worktherefore, ordinarily lasts much longer than the man. Where seals of cement or the like have reflector because it is not subject to deteriorabeen previously used, the operator may apply tion by the action of the elements or by moisture the cement poorly so that openings are left in or gases. However, on the contrary, the reflector the seal win some cases the operator may even at the inner end of the lens becomes gradually fail to put in the cement at all, or suflicient cetarnished by oxidation from aim-gases or moisment, according to his judgment. Moreover, ture entering the unit, or from condensation. the application ofcement or like sealing me- This is particularly true when a silver reflector diums by individual operators is a tedious and is used. Metallic silver when polished is the best chance operation. available reflector but in most cases due to its A further object of the invention is to protendency. to tarnish or corrode it has been largevide a construction which readily lends itself to ly replaced by other and cheaper metals such standard manufacturing practices thereby makas polished chromium or polished aluminum ing it possible to economically produce a unit of which, however, are of much lower reflective this type, that is, of the type wherein the reefilciency. r flector is hermetically sealed at the time of A primary object of the invention is to seal assembly so that at no time after it leaves the the reflector in' the shell or cup in a novel way factory is it necessary to disassemble any of the to therebyprevent deterioration of the reflector parts with the consequent danger of admitting surface.- While it has been hereto-fore proposed moisture or gases which will affect the reflector. to enclose the mirror or reflector in a shell, A general object of the invention is, thereand, also, in some cases to use a seal, neverthefore, to provide a reflector unit which is so conless, cement of one type or another has been structed when it is first made as to give longer used for a seal and, moreover, so far as is known, life and higher efficiency in use and in which no attempt has been previously made to herthe original efficiency of the reflecting surface metically seal the mirror under pressure. Ceis maintained even where silver is employed. ment and other seals heretofore employed are With the above and other objects in view not permanent because as the atmospheric temwhich will more readily appear as the nature of perature changes, the glass lens, the metal cup the invention is better understood, the same and the cement, each having different coeflicients consists in the novel construction, combination of expansion, change in their relative sizes, and, and arrangement of parts hereinafter more fully as a result at some temperature the seal is described, illustrated and claimed. broken. In addition, the small amount of air A preferred and practical embodiment of the sealed in with the mirror will also expand or present invention is shown in the accompanying contract with a change in temperature thereby drawing in which: tending to break the seal and set-up a breathing Figure 1 is a vertical sectional view of one action which tends to draw in some contaminatform of unit constructed in .accordance with the ing gas or' substance. Therefore, previous atpresent invention. tempts'to effect a seal are not sumciently ef- Figure 2 is a fragmentary sectional view ilfective to perform the intended function. lustrating a step in the making of the unit.

Accordingly, the present invention has pri- Figure 3 is a vertical sectional view of a unit marily in view a construction wherein the reembodying 'a modified form of construction. flect'or is hermetically sealed, with a resilient Figure 4 is another vertical sectional view 11- lustrating a further modification of the invention.

Similar reference characters designate corresponding parts throughout the several figures of the drawing.

Referring to Figure 1, it will be observed that the unit includes in its organization an outer shell or cup designated generally as I. This shell is preferably metal stamping and, therefore, impervious to moisture, gases and other elements which would tend to act adversely on a reflecting surface. The upper edge of the shell I is provided with a flange 2 which assists in mounting the unit in a suitable support such as the surface of a sign or the like. ,Within the shell I there is provided a pair of spacing rings 3 and 4 which in effect provide abutment means for limiting the inward movement of the lens. These rings are so arranged as to clamp between the adjacent edges thereof, the peripheral edge portion of a suitable polished reflector or mirror 5. The lower edge of the ring 3 rests on the bottom wall of the casing I and the upper edge of the ring 4 constitutes an abutment or stop for the lens 6.

The lens 6 is made of pressed or molded glass and its side wall is provided with an annular offset rib I. The outer surface of the rib snugly fits the inner surface of the shell, and, as

will be apparent from the drawing, this arrangement provides a space between the body of the lens and the inner surface of the shell, one side of said space being bounded by a shoulder formed by the rib. In other words, the construction is such that the annular rib on the collimating lens 6 cooperates with the shell to provide a cavity within the shell. This cavity is intended to receive a compressible sealing medium 8. This medium may be of any material suitable for the purpose, such, for example, as a rubber sealing ring which may be conveniently applied or fitted to the lens before it is placed in the shell.

After the lens and sealing material are fitted in the shell, :a compression ring is placed in placed on the glass body of the lens so as to the cavity between the lens and the shell as shown in Figure 2. This compression ring, designated generally as 9, includes a compression flange orring I0 and a sealing flange II, and when placed in the position shown in Figure 2 may be placed in a suitable compressing and sealing die whereby the entire ring 9 is forced into the cavity and against the sealing medium until the flange II abuts with the flange 2 of the shell.

The flange II may then be welded to .the flange 2 to permanently compress the sealing material and also permanently lock the lensin the shell. As will be observed from Figure 2, the flange 2 of the shell may be provided with suitable raised portions formed by pressing or displacing the metal of the flange to form lugs which assist in welding the flanges 2 and II together.

Under ordinary circumstances the sealing material 8 is compressed under a pressure of approximately 1500 pounds to the square inch thereby hermetically sealing the chamber'or space between the lower side of the lens and the metallic reflecting surface 5. It will thus be apparent that with a. seal of this type the reflector -5 is effectively shielded from attack by atmossilver as the reflector, or, on the other hand,

adequately protecting the polished surface of any metal of which the reflector may be made.

Figure 3 of the drawing illustrates a construction wherein the outer shell la is intended to receive the spacing rings 30!. and 4a having the reflector 5a clamped therebetween as previously described. The lens 6a is provided with a shoulder Ia to form a cavity between the body of the lens and the inner surface of the shell. The said shell, however, is formed differently at its upper edge than the upper edge of the shell I shown in Figure 1. That is to say, the upper edge 2a of the shell Ia, while having the flange portion thereof bent outwardly to form a shoulder for assisting in fitting the shell to a support, nevertheless, originally, said flange has the major portion thereof directed upwardly as shown by the dotted lines 21) in Figure 3. When the flange is in the condition shown by dotted lines it will be apparent that the shell Ia may receive the glass reflecting lens Ba having the sealing ring 8a fitted thereto and abutting with the shoulder provided by the annular rib Ia. After the lens is placed in the shell so that the lower edge of the rib rests against the upper edge of the upper spacing ring, a sealing ring I2 is placed against the otherwise exposed side of the sealing gasket 8a and then the portion 21) of the flange 2a is pressed or spun from the dotted-line position to the full-line position shown in Figure 3 thereby compressing the sealing gasket in final position. The effect of compressing the gasket 8a is to hermetically seal the chamber of the shell which houses the mirror or reflector 5a.

A further modification of the invention is shown in Figure 4 of the drawing from which it will be observed that the shell 'Ib having the spacing rings 31? and 47) therein, and clamping the reflector 5b therebetween, is provided at its upper edge with an out-turned flange 2c. The lens 6b is provided with an annular rib 1b which fits snugly within the inner surface of the shell lb. In this instance the sealing gasket 8b is engage the shoulder of the rib "Ib which is farthest from the mouth of the shell. In other words, the compressible sealing gasket 8b is confined in the cavity or space bounded on opposite sides by the lens and the shell, and, also, by a shoulder of the rib and the upper edge of the spacing ring 4b. The outer shoulder of the annular rib 1b of the lens is engaged by a compression and locking ring t3 which presses the entire lens inwardly of the shell and effects com- .pression of the sealing ring by movement of the entire lens. When the ring I3 abuts with the flange '20 at the upper edge of the shell these parts are "welded together thereby securely holding the lens in the shell and at the same time permanently maintaining the rubber sealing ring 812 under compression thereby to effectually seal the chamber, in which the reflector 5b is mounted, from atmospheric attack.

In all of the constructions described, the resilient gasket such as sulphur free rubber will maintain a gastight joint between the glass lens and the metal cup at any temperature regardless of the expansion or contraction of any of the parts. Pressure alone, without the resilient gasket, would not insurea perfect seal at all temperatures to which reflector buttons are exposed.

In contrast to previ'ouspractice, the present unit is completely finished when it leaves the machine.

For example, where cements are employed, between the cup and the lens, as previously'set .forth, the time necessary to neatly center the lens in the cup and the extra labor necessary to remove the particles of cement from the exposed portions of the lens and cup, materially slow-up production and add to the cost. Moreover, where cements are employed, time is required for the cement to set. During this period the assembly must be carefully held in special trays which take up factory space, and in addition the loading and unloading of the trays consume more time and labor.

From the foregoing, it will be apparent that lens, and one of the shoulders of the rib onthe lens. This cavity receives the resilient com pressible sealing material, and, on compression of said material either by movement of a compressor ring, or by the movement of the lens itself, the compressible sealing medium becomes permanently compressed, thus, hermetically sealing the reflector housing chamber of the shell from all weather conditions and gases which would have a tendency to impair the efliciency of the reflector surface. In all forms of the invention the compression of the sealing medium is effected under high pressure, at the time of manufacture, and the metallic and glass parts of the unit need never be taken apart from the time they are finished at the factory until theyv are installed at the point of use.

Without further description, it is believed that the features and advantages of the invention will be readily apparent to those skilled in the art, and it will, of course, be understood that changes in the form, proportion and minor details of construction may be resorted to, without departing from the spirit of the invention and scope of the appended claims.

We claim:

1. In a reflector unit, an outer shell closed at its back and having an open mouth, a reflector within the shell, a lens having an annular rib, an annular member fitted within the shell and spacing the reflector from the lens, a second annular member fitted within the shell and held between the reflector and the back of the shell, a resilient sealing medium within the shell and engaging one shoulder of the rib, and annular means rigidly held at the mouth of the shell for permanently maintaining said sealing medium compressed to hermetically seal the reflector against atmospheric attack and to hold the lens in the shell, said rib and sealing medium being held between the first mentioned annular member and the said annular means rigidly held at the mouth of the shell.

2. A reflector unit, comprising, in combination, a tubular shell formed with a closed end wall and an open mouth and of uniform interior diameter from said wall to the mouth, a reflector within the shell, 2. lens including a cylindrical body having an annular rib of a diameter to fit within the shell below the open mouth thereof, an annular member within the shell and spacing the reflector from the lens,'a second annular member fitted within the shell between the reflector and the closed end wall of the shell, said annular' members cooperating to limit inward movement of the lens, an annular compressible sealing gasket between the inner surface of the shell and the cylindrical body. of the lens and engaging one side of the annular rib of the lens, and annular means rigidly held at the mouth of the shellfor compressing the rib of the lens and the gasket together thereby to'seal the reflector against infiltration ,of gases or other destructive matter.

3. A reflector unit comprising, in combination, a lens having an annular rib presenting inner and outer shoulders, a shell for receiving the lens, a plurality of rigid spacing rings fitted within the shell for limiting the inward movement of the lens, a reflector having its peripheral edge held between said spacing rings; a compressible sealing gasket confined between the inner surface of the shell, the outer surface of the lens, and the outer shoulder of the rib on the lens; and means carried by the shell for maintaining said sealing gasket permanently compressed within the aforesaid confining parts thereby hermetically to seal the reflector in the shell from atmospheric attack.

4. A reflector unit comprising, in combination, a shell open at one end and closed at the other, a reflector in the shell, a lens having an annular rib, abutment means within the shell for limiting inward movement of the lens and holding the reflector spaced from the lens, a rubber sealing gasket surrounding the lens at the outer side of said rib, means initially movable within the shell in a direction toward said abutment means to compress said rubber gasket against said rib hermetically to seal the portion of the shell in which the reflector is mounted, and means for securing the last mentioned means to the shell.

5. A reflector unit comprising, in combination, a cup-like shell having a flange at the mouth thereof, a lens body having an annular rib fitted in the shell, spacing rings within the shell for limiting the inward movement of the lens, a reflector having its peripheral portion held between the adjacent inner edges of said spacing rings,'a compressible sealing gasket confined in the cavity formed by the inner side of the shell, the outer side of the lens body and the shoulder formed at the outer side of the rib on the lens; and a sealing ring of angular cross-section having one flange thereof engaging and compressing said sealing gasket and the other flange secured to the flange of the shell.

6. A reflector unit, comprising, in combination, a cup-like shell having a flange at the mouth thereof, a lens body having an annular rib fitted in the shell, spacing rings within the shell for limiting the inward movement of the lens, a reflector having its peripheral portion held between the adjacent edges of said spacing rings; a Icompressible sealing gasket confined in the cavity formed by the inner side of the shell, the outer side of the lens body and the shoulder formed at the outer side of the rib on the lens; and a non-compressible sealing ring fitted in the space between the shell and the body of the lens, and said flange on the shell being bent inwardly to engage said ring to force the same against and compress the sealing gasket to hermetically seal the reflector against atmospheric attack and hold the lens in the shell.

7. A reflector unit comprising, in combination,

a cup-like shell having a flange at the mouth thereof, a lens including a cylindrical body having an annular rib presenting opposite shoulders and fitted within the shell, a plurality of spacing rings within the shell for limiting inward move? ment of the lens, a reflector having its peripheral edge portion held between adjacent edges of said spacing rings; a compressible sealing gasket located in the space defined by the inner surface of the shell, a portion of the outer surface of the cylindrical lens body, the inner shoulder of said annular rib and the outer edge of the outer spacing ring; and an annular element rigidly secured to the flange of the shell and engaging the shoulder of the lens rib opposite that engaging the sealing gasket.

8. A reflector unit including a metallic shell closed at its bottom and open at its mouth, a

flange projecting outwardly from the mouth of V the flange of the shell and welded to said flange to maintain said, rib and sealing medium compressed relative to said abutment means thereby hermetically to seal the reflector against atmospheric attack.

9. A gas tight and moisture-proof reflector unit including a metallic shell closed at its bottom and open at its mouth, a reflector within the shell, a lens having an annular rib presenting opposite shoulders and fitted within the shell from the openmouth thereof, annular abutment means in the shell for supporting the reflector, a ring for spacing the inner end of the lens from the reflector, said ring having its inner edge engaging the peripheral edge of the reflector, said annular abutment means and ring limiting the inward movement of the lens, a compressible sealing medium within the shell between the inner shoulder of the rib and the outer edge of said ring, and annular means se'cured to the mouth of the shell and engaging the outer shoulder of the rib to maintain said sealing medium confined under pressure between the ring and the inner shoulder of the rib hermetically to seal the reflector against atmospheric attack.

CHARLES I-IALLAM MAHONEY. WILLIAM STANLEY BRIAN.

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