Self-standing reflector for a luminaire and method of making same

A luminaire assembly, comprising:

• a luminaire housing;
• a reflector mounted within said luminaire housing comprising a plurality of integral reflective panels formed from a single sheet of reflective material and folded along fold lines pre-formed in said sheet into abutting relationship to define a predetermined three-dimensional reflector shape, wherein at least one of said panels has free edges abutting adjacent free edges of an abutting panel upon folding of said panels, and cooperating discrete locking members formed proximate the free edges of said abutting panels to retain said reflector in said predetermined three-dimensional shape;
• a light source socket disposed within said reflector;
• and
• a light source mounted within said socket for emitting light upon energizing said source to produce a predetermined light distribution pattern defined by said reflector shape.

A method of making a self-standing reflector for a luminaire, comprising:

• forming a plurality of integral reflective panels from a single sheet of reflective material;
• folding at least one of said panels by hand along a fold line pre-formed in said sheet;
• curving at least one of said panels by hand to define a curved reflective surface;
• folding said curved panel along a fold line pre-formed in said sheet;
• abutting a free edge of said curved panel adjacent a free edge of an abutting folded panel;
• and
• locking said curved panel into engagement with said abutting folding panel through direct locking cooperation of said curved panel and said abutting folding panel.

A method of making a self-standing reflector for a luminaire, comprising:

• forming a plurality of integral reflective panels from a single sheet of reflective material;
• forming substantially non-linear free edges on at least two of said panels to be curved;
• curving at least two of said panels by hand to define curved reflective surfaces;
• and
• adjacently abutting said substantially non-linear edges of said curved panels to form a substantially contiguous curved reflective surface.

A method of forming a luminaire assembly, comprising:

• providing a luminaire housing;
• providing a single sheet of reflective material;
• forming a plurality of integral reflective panels from said single sheet of reflective material;
• folding at least one of said panels by hand along a fold line pre-formed in said sheet;
• curving a least one of said panels by hand to define a curved reflective surface;
• folding said curved panel along a fold line pre-formed in said sheet;
• abutting a free edge of said curved panel adjacent a free edge of an abutting folded panel;
• locking said curved panel into direct locking engagement with said abutting folded panel to define a reflector;
• mounting said reflector in said housing;
• providing a light source socket disposed within said reflector;
• and
• mounting a light source within said socket for emitting light upon energizing said source to produce a predetermined light distribution pattern.