Abstract: A reflector lamp for use in a device (i.e., flashlight) that includes a reflector member having a reflecting portion and a base neck portion with an extending stub portion. A lamp capsule (i.e., low wattage tungsten halogen capsule) is disposed within the reflector member and has a pair of lead wires extending therefrom to be received at said stub portion. The stub portion includes oppositely disposed elongated slots of rectangular cross-section formed therein while the lead wires in turn each include, along at least a segment thereof, a workhardened rectangular cross-section of dimension sufficient to enable snug receipt thereof in one of the slots. The lead wires are thus capable of being disposed within the respective slots without the requirement of adhesive or glue therebetween. Further, the lead wires are disposed to a depth sufficient to maintain an interlock therebetween despite exertion of compressive forces imposed on the leads by respective contacts which open and close against the lead wires.

Abstract: A method of making a replaceable lamp unit for use in an automobile headlight. The method involves the steps of providing a metallic insert with a roughened (e.g., sandblasted) surface. Inserting this member a predetermined depth within a plastic (e.g., thermoplastic) holder, and applying radio frequency (RF) induction heating to the insert. The unit's lamp may then be attached directly (e.g., clamped by an extension of the insert) or indirectly (e.g., via a two-part, separate clamp which is secured about the lamp and is welded to a forward, curved surface of the insert). Use of a roughened surface enhances the bonding operation between plastic holder and metallic insert by substantially reducing the time (e.g., from about 38 to 85 percent) for such bonding to occur. Reducing time at this step in the operation also facilitates alignment of the insert and other elements of the unit.

Abstract: An improved replaceable lamp unit for use in an automobile headlight wherein the exterior surface of the unit's metallic insert is provided with a roughened surface (e.g., 125 RMS) such that an improved bond between the insert and the unit's plastic holder is possible. Alignment between the unit's lamp (e.g., tungsten halogen bulb) and holder, and thus the reflecting surfaces of the reflector in which the unit eventually will operate, is significantly improved, as is the time for attaining same. The roughened texture may be sandblasted, knurled, acid-etched or embossed.