Abstract: A microwave vehicle lamp having reflector housing, lens, light source, applicator card, and brace is disclosed. The light source and microwave power applicators are supported by a applicator card, which includes electrical couplings. The card is then adjustablly positioned along one portion in a slot formed in the reflector housing. An adjustable brace may be attached between the reflector housing and the applicator card to finally adjust the light source position for a preferred optical positioning. The brace is then soldered in place to rigidly hold the applicator card in place, yielding a microwave powered vehicle headlamp with a properly and securely positioned light source.

Abstract: An arc discharge headlamp capsule having arc tube, wedge, retainer, forward connector rod, insulating sleeve, RF ring, and base is disclosed. The wedge is formed to mate with an end of the arc tube, and be compressed along its exterior by the retainer. The wedge and retainer are sonically welded. The compressed wedge then gently, but firmly holds the arc tube. The thermal conduction from the arc tube is additionally consistent from lamp to lamp. The arc discharge headlamp capsule held by the wedge and retainer structure yields a lamp tube securely, and precisely held with even pressure.

Abstract: The present invention describes an apparatus and method for shutting off an electrodeless lamp such that it can be restarted instantaneously at any time. The method involves reducing the applied microwave power in a controlled way the moment the lamp is turned off. The reduction of power is accomplished by modulating the microwave power with an ever decreasing duty factor or a decrease of analog power. This reduction in power results continually in reduced light output and lamp cooling while maintaining partial ionization of the lamp fill. Circuitry to accomplish this is also presented.

Abstract: A reflector for coupling light from a light source into an optical waveguide includes input and output ends, a central axis and a reflecting surface disposed around the central axis. A light source, such as an arc lamp, is positioned on the central axis at the input end of the reflector. An input end of an optical waveguide is positioned on the central axis at the output end of the reflector. The reflecting surface has a first section adjacent to the input end with a first curvature that is concave toward the central axis, a second section adjacent to the output end with a second curvature that is concave away from the central axis, and an inflection section between the first and second sections. The first and second curvatures are selected to reflect light through the output end of the reflector within a prescribed range of angles that corresponds to the acceptance angle of the optical waveguide.

Abstract: A small volume, high wattage press sealed lamp having envelope, filament, internal leads, seal foils, external leads, and blades is disclosed. The small volume, high wattage press sealed lamp increased conductivity due to a flat faced external lead forming one of the foil welds. The external lead is butt welded to blade stock at ninety degrees forming a highly conductive bond.

Abstract: An adjustment linkage for vehicle headlamp having housing coupler, adjustment shaft, shaft seal, and threaded coupler for coupling to a pivotable reflector is disclosed. The adjustment linkage is designed to be operated by a Philipshead screwdriver used as a gearing. No permanent gear box is formed in the linkage. A minimal linkage is formed that is accessible from the top of the headlamp module by the length of the screw driver. The adjustment linkage is water sealed to accommodate rotation and pivoting of the linkage.

Abstract: A plug in lamp with spring side contacts having bulb, holder, lugs, and a seal is disclosed. The lugs have outwardly arced spring sections that are compressed during lamp insertion, thereby forming a latching mechanism to hold the lugs and lamp in place, while simultaneously providing electric power through the lugs. Sealing structures are disclosed that protect the welds, and others electrical features from environmental degradation.

Abstract: A high frequency applicator for energizing electrodeless lamps is described. The applicators are end cups electrically attached to the ends of phased feed points of a planar transmission line, and facing each other so as to form a gap between the end cups. The end cups each have a concave surface facing the gap which forces an electric field concentration in the vicinity of the end cups and in the gap between the opposing end cups. Such a field configuration is useful for energizing a lamp capsule placed within the gaps formed by the end cups. The end cups can be made of metal or metallized ceramic.

Abstract: A double envelope electric lamp having an outer envelope, support frame, inner capsule, threaded base, center contact, is disclosed. The support frame is formed with hooked ends that lie in shall grooves formed through the threads formed on the lamp neck. The exterior arms abut the metal base when the metal base is threaded onto the outer envelope. By making the exterior arms with a heavy wire, the positioning accuracy may be increased, and surprisingly, the threading torque may be reduced.

Abstract: A method of fabricating a filamented capsule from a tubular blank, and a mold used in such fabrication, is provided wherein a first filament is sealed in a first press seal in one end of the blank, and a preform designed to facilitate insertion and positioning of a second filament is formed in an opposite end of the blank, in a single pressing and blowing step.

Abstract: A method of making a press sealed lamp with an internally pressed fuse is disclosed. The filament structure is conveniently formed so the fuse links across a looped section of the initial filament structure. The loop structure provides strength to the fused filament structure prior to sealing. After the lamp is sealed, a portion of the exposed loop is trimmed, thereby limiting the remaining electrical connection to the path through the fuse.

Abstract: A vehicle lamp aiming device is disclosed having an adjustment shaft with a first marking, and a mounting nut with a second marking. One of the other of the markings is formed on a clip firmly, but still adjustably mounted to either the shaft or nut as the case may be. Initial proper alignment of the adjustment shaft amy be made with respect to the mounting nut. The vehicle lamp is then in proper alignment. The adjustable marking clip is then moved to set the lamp calibration. A replacement lamp may then be brought into proper alignment by threading the adjustment shaft to align the alignment marks. By using a firm clip, subsequent, inadvertent resetting of the clip may be avoided.

Abstract: A lamp lead with swaged indentations arranged around the circumference of the lead is disclosed. It has been discovered that the orientation of the locking indentation is significant in making a sound mechanical lock with the press seal of a lamp. By arranging the indentations around the lead, proper orientation of at least one of the indentations is always assured.

Abstract: A lamp bridge may be formed from a siliceous hollow tube positioned between and melted to bridge supports. The hollow tube melts more quickly, and more completely, and therefore bonds stress free and more durable to the bridge supports.

Abstract: A method of fabricating an arc discharge capsule from a tubular blank, and a mold used in such fabrication, is provided wherein a first electode is sealed in a first press seal in one end of the blank, and a preform designed to facilitate insertion and positioning of a second electrode is formed in an opposite end of the blank, in a single pressing and blowing step.

Abstract: An oxygen detector for use in a double envelope lamp is described. The detector may be formed by nitriding a metal surface to produce a metal piece with a first visual color or state. The surface thickness is sufficient to exclude oxygen during normal assemble, but thin enough to change colors during lamp operation if oxygen is present.