A metallic reflector device having one or an array of individual reflector elements for positioning over a corresponding one or array of light sources, preferably comprising one or more light emitting diodes (LEDs). The metallic reflector device includes a planar base and a plurality of the reflector elements. The planar base has one or a plurality of apertures, each aperture having an edge that defines a proximal rim of the reflector element. Each reflector element includes an annular sidewall having an inner surface that extends from the proximal annular rim to a distal annular rim. The proximal annular rim defines a first opening through which direct and reflected light from a light source is emitted. The distal annular rim defines a second opening through which the light source is disposed. The inner surface of the annular sidewall is formed from the material of the planar sheet by mechanically deforming the planar sheet, such as by stamping or drawing.
1. A method of making a metallic reflector device having a base having one or more winged flanges extending therefrom, a plurality of proximate annular rims, and a plurality of reflector elements extending from the plurality of proximate annular rims to a plurality of distal annular rims, each defining an opening capable of accommodating a light source, one or more of the reflector elements comprising an annular sidewall extending from the proximate annular rim to the distal annular rim, the method of making comprising the steps of:
a) providing a sheet defining the base;
b) defining the openings; and
c) drawing an annular pattern in a material of the sheet surrounding each of the openings in a direction along an axial centerline through each of the openings, thereby forming (i) the proximate annular rims, and (ii) the annular sidewalls defining depressions in the material of the sheet to form the plurality of reflector elements; and
d) forming the one or more winged flanges along a longitudinal direction of the base opposite to the depressions.
2. The method of claim 1 wherein the depression is conical.
3. The method of claim 1 wherein the distal annular rim has a circular cross section.
4. The method of claim 1 wherein the angle of the annular sidewall between the centerline and the sidewall is about 40°-50°.
5. The method of claim 1 wherein the sheet is planar.
6. The method of claim 5 wherein the planar sheet is aluminum sheet metal.
7. The method of claim 1 wherein the step of drawing the annular pattern comprises drawing the proximate annular rim to have a circular cross section.
8. The method of claim 1 wherein the step of drawing an annular pattern comprises drawing the annular pattern to have a straight sidewall.
9. The method of claim 1 wherein the step of drawing an annular pattern comprises drawing the depression to be substantially conical using a support ring and punch.
10. The method of claim 1 further comprising the treating the material surrounding each of the openings with heat.