Abstract: An arc discharge tube has electrodes supported by hollow electrode support tubes at each end. A slot is formed in the electrode support tube. One edge of the slot is depressed inwardly to form a concave surface. The slot is located adjacent to the end cap of the arc tube and provides access to the interior of the electrode support tube. After the electrode assembly is sealed into one end of the arc tube, amalgam particles are dispensed into the arc tube. The arc tube is agitated rapidly, causing the amalgam particles to pass through the slot and drop into the interior of the electrode support tube. The amalgam particles are isolated from heat during sealing of the other end of the arc tube.

Abstract: A lamp base inner shell including a washer-like base having a cylindrically wall attached at a first end to an outer periphery of the base. The cylindrical wall includes a threaded portion and a plurality of cut-out portions in a second end thereof which define an equal number of tabs, each tab having an indentation extending inwardly. At least one cut-out portion extends to the inner shell base. The inner shell is used to electrically connect and secure a lamp base shell to a lamp tube. The inner shell facilitates automated production of high intensity arc discharge lamps.

Abstract: A starting aid for high pressure sodium vapor lamps eliminates the need to mechanically connect an ignition wire to the lamp frame. The starting aid employs an ignition wire which is slidably clipped directly to the arc tube at one end and which is connected to a bi-metallic switch at the other end. The bi-metallic switch is mechanically and electrically connected to one power lead of the arc tube.

Abstract: An electrode feedthrough assembly for a ceramic arc tube of the type used in high pressure sodium arc lamps. The electrode feedthrough assembly is particularly useful in an external reservoir arc tube wherein an interior region of a feedthrough tube is utilized as a reservoir for the lamp fill material. The electrode feedthrough assembly includes a feedthrough tube, an electrode assembly attached to the feedthrough tube and a connection wire. The feedthrough tube has a closed end external to the arc tube. The feedthrough tube and the closed end thereof are formed in a single process, preferably by deep drawing, without welding, crimping or fusing. Passages to the interior of the feedthrough tube are provided by crimping the electrode support rod to the feedthrough tube with a six jaw crimping arrangement wherein two of the crimping jaws are shorter than the other four. The connection wire is attached to the feedthrough tube and includes a portion on the axis of the tube.

Abstract: A metal halide arc discharge lamp includes a sealed light-transmissive outer jacket, a light-transmissive shroud located within the outer jacket and an arc tube assembly located within the shroud. The arc tube assembly includes an arc tube, electrodes mounted within the arc tube and a fill material for supporting an arc discharge. The electrodes have a spacing such that an electric field in a range of about 60 to 95 volts per centimeter is established between the electrodes. The diameter of the arc tube and the spacing of the electrodes are selected to provide an arc having an arc diameter to arc length ratio in a range of about 1.6 to 1.8. The fill material includes mercury, sodium iodide, scandium tri-iodide and a rare gas, and may include lithium iodide. The lamp exhibits a high color rendering index, high lumen output and high color temperature.

Abstract: A halide discharge lamp has a an evacuated outer envelope including a getter comprising from about 60 to about 85 percent zirconium, from about 10 to about 20 percent vanadium, and from about 2 to about 10 percent manganese having an activation temperature of less than about 350 degrees Centigrade for reducing the tendency of the lamps to discolor during operation.

Abstract: A double-ended arc discharge lamp includes a sealed, light-transmissive outer jacket, a light-transmissive shroud mounted within the outer jacket and directly supported by the outer jacket, and an arc discharge tube mounted within the shroud. The arc tube is typically a metal halide arc discharge tube. In a preferred embodiment, the shroud includes an outwardly flared portion at each end. The outwardly flared portions space the shroud from the outer jacket and support the shroud within the outer jacket. The outwardly flared portions of the shroud can be affixed to the outer jacket by fusing. The outer jacket can be provided with inwardly extending dimples for locating the shroud with respect to the outer jacket. In another embodiment, the outer jacket includes reduced diameter portions near each end which are attached to the shroud.

Abstract: A lamp assembly includes a sealed lamp envelope enclosing a filament, a screw shell connected to the lower portion of the envelope, and electrical leads extending from the filament into the screw shell. The screw shell has a bottom opening, in which is mounted an electronic control module. The electronic module is retained in the screw shell by an insulator. A spring is compressed between the electronic module and an exhaust tube on the lower portion of the envelope. One electrical lead is electrically coupled from the module through the spring to the filament, allowing the module to control the filament. The insulator defines a cavity for retention of the electronic module in a fixed position.

Abstract: A holding fixture is used to hold single-ended or double-ended lamps within a chemical vapor deposition chamber. The holding fixture includes first and second wire mesh screens for holding lamps that are to be coated within the deposition chamber. A screen support is provided to secure and support each screen within the fixture. Spacers to secure the screens and supports together and provide spacing between such screens and supports. Holes may be cut in the screen to allow portions of the lamps to pass through screen. In addition, a housing may be provided for the holding fixture.

Abstract: A metal halide arc discharge lamp includes a sealed lamp envelope, an arc tube located within the lamp envelope, a generally cylindrical, light-transmissive shroud positioned around the arc tube, a frame comprising a single support rod extending between dome and neck regions of the lamp envelope, upper and lower clips for attaching the arc tube and the shroud to the frame, a resilient bulb spacer attached to a neck end of the frame and bearing against an inside surface of the lamp envelope for positioning the frame relative to the lamp envelope, and electrical leads for coupling electrical energy to the arc tube. The frame is mechanically supported within the lamp envelope in the neck region solely by the bulb spacer. Leakage currents between the frame and the electrical leads through the lamp stem are effectively eliminated.

Abstract: A reflector lamp includes a temperature resistant, plastic, tubular neck extender. The neck extender is disposed between a reflector and a base and is attached to the reflector and the base. The extender can be attached to the reflector by clamping eyelets or, alternatively, by an adhesive. The resulting lamp can be used in recessed lighting fixtures.

Abstract: Filament supports for supporting and centering a filament in a double-ended lamp envelope include an inlead portion defining a central axis, a filament attachment portion and a centering portion interconnecting the inlead portion and the filament attachment portion. The centering portion contacts an inner surface of the lamp envelope at a plurality of discrete, circumferentially spaced-apart contact regions that are substantially equally spaced from the central axis. The filament supports are attached to opposite ends of the filament for accurately centering the filament within the lamp envelope. The filament supports are particularly useful in a tubular incandescent lamp capsule having an infrared reflective coating on its outer surface.

Abstract: An electric lamp assembly includes a sealed lamp envelope, a lamp capsule located within the lamp envelope, a cylindrical, light-transmissive shroud surrounding the lamp capsule, and a mounting arrangement for supporting the lamp capsule and the shroud within the lamp envelope. The mounting arrangement includes one or two supports rods parallel to the axis of the shroud and first and second clips for retaining the shroud and the lamp capsule. The clips prevent both axial and lateral movement of the shroud. The clips are attached to the support rods, typically by welding. In a preferred embodiment, a single clip at each end of the shroud retains both the shroud and the lamp capsule, and requires only a single weld to the support rod.

Abstract: A support base for a filament or a lamp capsule in a lamp includes a lamp base and a pair of leads extending from the base to the filament or lamp capsule. The base includes a layer of composite material that substantially surrounds the leads and supports them along parts of their lengths within the base. The composite material preferably includes glass beads covered by a layer of epoxy resin.

Abstract: A filament support for supporting and centering a filament in a double-ended lamp envelope includes an inlead portion defining a central axis, a filament attachment portion and a centering portion interconnecting the inlead portion and the filament attachment portion. The centering portion includes first and second arcuate segments for contacting an inner surface of the lamp envelope. The first and second arcuate segments are axially spaced apart and are interconnected by an axial segment. Filament supports are connected to opposite ends of the filament for accurately centering the filament in the lamp envelope. The filament supports are particularly useful in a tubular incandescent lamp capsule having an infrared reflective coating on its outer surface.

Abstract: A method for making an ultraviolet radiation starting source is described which includes providing a tube with an opening, inserting a molybdenum ribbon and a wire lead into the opening, and forming a seal near the opening. The ribbon and wire are provided in a continuous stream from a set of spools, and are cut after the seal is formed.

Abstract: A support for a filament or lamp capsule in a lamp having a base and a light-transmissive envelope includes a support ring that is inserted into the base. The ring can be pressed or otherwise secured into the base. The support ring includes at least one pair of tabs that extend radially inwardly. The tabs include mounting holes aligned generally in a direction extending upwardly from the base toward the envelope for receiving and supporting an electrical lead of the filament or lamp capsule. The tabs can be resilient to forcibly engage the lead of the filament or lamp capsule. Two pairs of tabs can be provided to support two leads of the filament or lamp capsule.

Abstract: A method for mounting a filament in a double ended incandescent lamp capsule. A filament assembly, including a filament, filament supports attached to each end of the filament and an external lead connected to each filament support, is located in a tubular lamp envelope. The position of the filament relative to the lamp envelope is determined, and the filament is moved to a predetermined position relative to the lamp envelope, if necessary. Then, the lamp envelope is heated sufficiently to cause the lamp envelope to deform into contact with at least one of the filament supports so as to securely anchor the filament support. The heating of the lamp envelope in regions of the filament supports can be performed simultaneously or at different times. One or both filament supports can be anchored by the tacking process.

Abstract: An arc discharge lamp having an arc tube mounted within a lamp envelope includes a thermal switch for controlling application of electrical energy to a starting electrode. The thermal switch is mounted between the arc tube and the lamp base with its longitudinal axis generally parallel to the central axis of the lamp envelope. The thermal switch is spaced from the central axis of the lamp envelope by a support rod and extends into an annular space between the lamp stem and the wall of the lamp envelope. As a result, the maximum temperature of the thermal switch during lamp operation does not exceed about 400.degree. C.

Abstract: A thermal switch assembly for use in electric lamps includes a bimetal element and a resilient conductor such as a tungsten wire. The conductor is mounted at an angle in the range of about 30.degree. to 45.degree. with respect to the plane of movement of the bimetal element and at an angle of about 90.degree. with respect to the longitudinal axis of the bimetal element. The edge of the bimetal element contacts the conductor at a closure temperature and moves with a sliding action along the conductor as the temperature increases above the closure temperature. As a result, the switch contacts are self cleaning. Since the switch components are subjected to very little stress at elevated temperatures, the switch assembly has a long operating life. The bimetal element and the conductor can be affixed to a mounting frame which facilitates installation of the thermal switch assembly.