Abstract: A method of making a double ended lamp having a tubular envelope, a filament, and button contacts at opposite ends of the lamp is disclosed. By first forming a metallurgical bond between the button contacts, and a lead rods, a high quality bond may be formed that does not cause the lead rod to become embrittled. The button contact and lead rod assembly is then, if not already, incorporated into the filament assembly. The filament assembly is then accurately positioned in a tubular envelope and sealed in place. The lamp may then be finished by filling, coating, insulating, and so on in a standard fashion. The button contact as a result is accurately positioned with respect to the envelope, and is unlikely to separate from the lead because of crimp failure, or embrittled rod fracture.

Abstract: An electrodeless lamp may be formed with a capsule having a radiant energy transmissive material defining an approximately cylindrical enclosed volume having an external length less than 20.0 millimeters, and an outer diameter less than 8.0 millimeters. The enclosed volume is filled with a lamp fill excitable by a high frequency electromagnetic field to produce radiant energy. The small size capsule produces a particularly efficient, orientation tolerant arc discharge. The arc is then highly stable as to position, yielding a good optical source to design for. The temperature gradient is small, thereby yielding little thermal stress on the capsule. An electrodeless HID headlamp system may be formed with the efficient capsule from a radio frequency source operating from the power supply of a typical automobile. The headlamp system includes a high frequency power source, a transmission line, a coupler, an excitable lamp fill captured in a lamp capsule, a reflector and a lens.

Abstract: A low wattage metal halide capsule shape having a cylindrical shape geometry with asymmetrical regions behind the anode and cathode for direct current operation is disclosed. The disclosure concerns several arc tube geometries to encourage internal convective flow in small, direct current arc discharge lamps.

Abstract: A compact arc discharge lamp may be formed with an inner lamp capsule and an outer envelope. One or more of the leads to the inner capsule may be sheathed to insulate the lead from improper arc over. The sheath may passed through the seal of the outer envelope, so the gas state of the intermediate volume may be adjust before final sealing.

Abstract: A lighting lens having a multiplicity of lenticules is disclosed, and in particular the use of aspherical lenticules is disclosed. The lenticules are of two or more standard types, each type being defined be a different cross sectional curvature. The different lenticle types are distributed across one side of the lens in an intermixed pattern. By selecting two standard lenticule types, and determining a weighted ratio, a lens for a desired lighting pattern may be made without having to specifically design the individual lenticules, or the particular lenticle arrangement.

Abstract: A lamp base having an vibration adjustable support structure is disclosed. By supporting a bulb on a plastic clip having arms with fixed lengths, the rotational and axial location of the lamp may be fixed within a standard optical structure, such as reflector housing and lens system. The arms may then be oriented either radially, angularly, or as to thickness or width to control vibration transmission particular to a typical use. For example, standard bulbs, bases and reflector housings may be used with bulb holders variably tuned to accommodate the vibrations specific to particular vehicle models.

Abstract: A recessed fluorescent luminaire housing is described wherein the housing is formed from one piece with included coupling elements to permit quick assembly. The design provides flexibility for model changes without the need to redesign the main luminaire housing. The luminaire housing is made from a single piece sheet metal blank. The diffuser panel frame is made from two sheet metal blanks.

Abstract: A linear slider may be formed essentially from a block and two parallel shafts mounted through the block. The first shaft runs on coaxial bushings, while the second shaft runs in a single floating bushing. The floating bushing slides perpendicular to the first shaft. The first and second shafts are then coupled to slide as a pair. The first shaft is then free to run back and forth. The second shaft also runs back and forth, but prevents the first shaft from rotating, without binding between the two shafts. Seals and a lubrication system are added to assure a smooth, durable action.

Abstract: A glass lamp base may be formed by thinning the glass base in the area behind the point where the side lead is welded to the exterior surface of the screw. Thinning the glass behind the weld area helps assure that the remaining glass is firmly positioned to the back of the screw in the area of the weld, and has not slumped away from the screw. Assuring the glass backing is present, increases the likelihood of a successful weld, and functional lamp.

Abstract: A lamp base having a clipped together support structure is disclosed. Assembly and orientation of lamps is facilitated by a bulb that first clip couples to a bulb and the bulb holder is in turn clip coupled to a lamp base. Electrical connection is made through a duct traversing the bulb holder. By further enabling the bulb holder to lamp base coupling to be rotatable, the lamp pieces may be assembled in secure relation to each other in one operation, and quickly oriented in a second operation. An appropriate bond may be subsequently applied between the bulb holder and the lamp base to permanently fix the two pieces.

Abstract: A wedge lamp and clip having exterior means for making electric connections to a lamp lead, and having pinning means for securely locating the lamp and clip in a base are described. By bringing the lamp lead out and folding it back over the lamp clip, the clip may directly and securely mate to the envelope extension, and multiple secure electrical and mechanical contacts may be made between the clip and the lamp lead. By making the clip conductive, the electric connection need not be made directly to the lamp lead, but may be made indirectly through the conductive clip. Mechanical stress between the lamp envelope and any support may also be mediated by the clip.

Abstract: A re-entrant radio frequency cavity geometry for a low-pressure microwave electrodeless lamp such as a compact fluorescent lamp is described. The re-entrant cavity makes use of the properties of a re-entrant coaxial cavity resonator. The electrodeless lamp may be fabricated to have a constant input impedance in both the on and off states. In addition, the lamp starts at a lower drive power than present high efficacy, compact fluorescent lamps.

Abstract: A fluorescent luminaire lens frame is described wherein the frame is formed from a U shaped element, and a cross bar. Each of the two elements are formed from single piece sheet metal blanks. The frame includes hinge elements on the free ends of the U extending beyond the cross bar that may be coupled to a luminaire housing. The frame joints are also structured with abutting and capturing structures to prevent rotation of the sides away from about a right angle.

Abstract: A lamp base having a floating rivet pin is described. Due to mechanical stress, sealed beam reflector leads may need mechanical strengthening; however, heat stress may be transmitted through the strengthening means. A rivet pin may be coupled in the lamp base having one face abutting the base, a shaft portion closely, but slideably positioned in a passage and a second face offset from the base. During thermal expansion of the lead, the second pin face may approach abutment with the base without stressing the seal structures. The floating rivet pin, secured by being snugly fit radially in the base passage to hold the floating pin, then resists the twisting that may occur during mounting.

Abstract: A method of aligning and gapping arc lamp electrodes is to form a single piece electrode preform with a number of breakable junctions formed therein. The single piece preform is then positioned in the lamp envelope and sealed in place. The central portion of the preform is then removed by causing the breakable junctions to give way. The central portion is then removed from the enclosed lamp cavity, and the lamp sealing is finished by known methods.

Abstract: A lighting lens having a multiplicity of lenticules is disclosed, and in particular the use of aspherical lenticules is disclosed. The lenticules are of two or more standard types, each type being defined be a different cross sectional curvature. The different lenticle types are distributed across one side of the lens in an intermixed pattern. By selecting two standard lenticule types, and determining a weighted ratio, a lens for a desired lighting pattern may be made without having to specifically design the individual lenticules, or the particular lenticle arrangement.

Abstract: A hooked arc discharge lamp electrode may be formed with electrodes slanting towards each other and towards the electrode roots. The hooking back of the electrode tips forms a gap between the electrode tip and the electrode shaft that prevents the arc from wandering across. The arc is then confined to a small area from the electrode tip area on the side away from the gap. The arc is prevented from wandering down the electrode shafts away from the optically ideal location, and to a potentially destructive position adjacent the envelope wall.

Abstract: A lamp with re-enforced tubular base pins is disclosed. A less expensive, high quality, high wattage lamp may be formed with re-enforced tubular base pins. The lamp comprises a lamp envelope having an enclosed means for producing light, a light transmissive envelope, and at least two electrical connections, a ceramic lamp base for holding the lamp envelope, and the two tubular pins. Each pin comprises an electrically conductive tube having an exterior surface along which a compressive coupling may be made, and an interior surface defining an internal volume. A fill cement is positioned in the internal volume of each base pin at least along the portions opposite where compressive coupling may be made to the exterior surface of the pin.

Abstract: An exterior lamp system for a vehicle having a reflector housing coupled by a vibration damping clip is described. The vibration damping clip may be formed a molded portion of a plastic lamp housing. The clip may take to the form of a reversing curve structure made from a flexible material. One end of the clip is coupled to the lamp housing, while the other end is in contact with the automobile. A damper formed from a vibration damping material, such as foamed plastic, is coupled between the first and second clip ends of the reversing curve to suppress vibration transmitted from the automobile to the lamp.