Abstract: Traditional methods of making headlamp coils have left a portion of the coils with slightly irregular forms. These irregularities can result in defects in the ultimate beam pattern. Accommodating these defects in robust lamp and headlamp optical systems can reduce the performance that might otherwise be available. The preferred coil is therefore continuously coiled as a straight body, and carefully cut into segments. Subsequently, legs are welded to the coil segment ends. The coil is then left substantially undistorted by the manufacturing process that would otherwise normally leave a portion of the coils distorted. The method particularly enables a functional center leg coil.

Abstract: An advanced forward lighting system may be made with a lamp having a first filament and a second filament extending perpendicular to the first filament. The second filament is partially hidden rearward and above the first filament. A reflector forms a main beam from the first filament light and a right or left cast supplemental beam from the second filament light. The second filament's position minimizes glare, and enables a simple advanced forward lighting system from a single standard lamp fitting both right and left side reflectors.

Abstract: An automotive headlamp bulb provides the two light or three filament sources in a single bulb. One source may be used to generate a standard headlamp beam, while the second source may be used to generate an augmenting side beam in response to a turning signal. A similar third filament may provide an augmenting beam to the opposite side, or farther to the same side. The single bulb eliminates the need for a second bulb, or a second reflector in an advanced headlamp system with turning light augmentation.

Abstract: An advanced forward lighting system may be made with a lamp having a first filament and a second filament extending perpendicular to the first filament. The second filament is partially hidden rearward and above the first filament. A reflector forms a main beam from the first filament light and a right or left cast supplemental beam from the second filament light. The second filament's position minimizes glare, and enables a simple advanced forward lighting system from a single standard lamp fitting both right and left side reflectors.

Abstract: An automotive headlamp bulb provides the two light or three filament sources in a single bulb. One source may be used to generate a standard headlamp beam, while the second source may be used to generate an augmenting side beam in response to a turning signal. A similar third filament may provide an augmenting beam to the opposite side, or farther to the same side. The single bulb eliminates the need for a second bulb, or a second reflector in an advanced headlamp system with turning light augmentation.

Abstract: Traditional methods of making headlamp coils have left a portion of the coils with slightly irregular forms. These irregularities can result in defects in the ultimate beam pattern. Accommodating these defects in robust lamp and headlamp optical systems can reduce the performance that might otherwise be available. The preferred coil is therefore continuously coiled as a straight body, and carefully cut into segments. Subsequently, legs are welded to the coil segment ends. The coil is then left substantially undistorted by the manufacturing process that would otherwise normally leave a portion of the coils distorted. The method particularly enables a functional center leg coil.

Abstract: A vehicle headlamp (10) has a first light source (12) for illuminating an area forward of the light source (12). The first light source (12) is preferably a filamented tungsten halogen capsule. The first light source (12) is arrayed along a longitudinal axis (14) and emits substantially white light. A second light source (16) in the form of a plurality of light emitting diodes is arrayed about the first light source (12), and the second light source (16) emits light in directions substantially normal to the longitudinal axis (14), for example, along an axis (16a) for providing essentially aesthetic illumination. The aesthetic illumination can be used with or without the first light source being illuminated.

Abstract: A sealing electrode for discharge lamp having electrically conductive cup, and an emitter pellet is disclosed. The cup seals a passage into the discharge lamp, and additionally supports the electrode pellet or tip for the discharge. The design enables the emitter, electrode and seal structure to be made separately off line, while also enabling the emitter to be protected from contaminants during subsequent assembly.

Abstract: A sealing electrode for discharge lamp having electrically conductive cup, and an emitter pellet is disclosed. The cup seals a passage into the discharge lamp, and additionally supports the electrode pellet or tip for the discharge. The design enables the emitter, electrode and seal structure to be made separately off line, while also enabling the emitter to be protected from contaminants during subsequent assembly.

Abstract: A sealing electrode for discharge lamp having electrically conductive cup, and an emitter pellet is disclosed. The cup seals a passage into the discharge lamp, and additionally supports the electrode pellet or tip for the discharge. The design enables the emitter, electrode and seal structure to be made separately off line, while also enabling the emitter to be protected from contaminants during subsequent assembly.

Abstract: Connector for a discharge lamp and ballast assembly, as well as a lamp assembly including the connector. The connector is a conductive ribbon that includes a plurality of pinch or wedge-shaped wire slots for receiving lead wires from the discharge lamp and from the power supply. The connector is made of a material and is suitably shaped to provide flexibility to accommodate thermal expansion and contraction of the lamp, yet provide for proper positioning of the lamp in a reflector housing or the like. Disassembly of the connections and replacement of the lamp is facilitated and does not result in permanent damage to the lamp.

Abstract: A flexible lamp tube support having lamp support end a coupling to hold a lamp tube on one end and a latching portion to couple into a through hole is disclosed. The flexible, soft body coupler is inexpensive, has low heat conduction, can securely hold the lamp and cushion the lamp. The simple construction is adaptable to differing lamp, housing, and through hole configurations.

Abstract: A lamp capsule with lug connectors, having a lamp bulb, a holder, and a lug is disclosed. The lamp capsule lead extends through the holder passage to fit closely with the lug foot. The lug foot is then rotary swaged to the lamp lead. The swaging mechanically and electrically seals the lead and the lug. An interference coupling is exactly formed along the lead by the swaging, so the lead and lug are precisely located and cannot move with reference to one another. The lug and lead are then tightly held and located with reference to the holder. The mechanical interference fit also forms an electrical connection that cannot separate like a cold weld. The swaging may additionally remove any excess exterior extension of the lead. As a result, the lug is quickly, accurately, and permanently coupled to the lamp lead, and holder preventing subsequent loosening or displacement that may effect lamp positioning or connection durability.

Abstract: A mechanical electrical connector for an electric lamp lead is disclosed. The connector is formed as a single piece from sheet metal and includes an electrical contact against which the lamp lead is pinched by an approximately perpendicularly extending clamp arm. The clamp arm may be further latched to lock the lead hard against the connector. The single piece connector yields an inexpensive, quickly attached, strong, and permanent mechanical support providing a secure electrical connection for an electric lamp lead.

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 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 relieved plastic lamp base has been discovered to substantially eliminated cracking of the captured press seal. The relieved base has a formed cavity for receiving the press seal of an electric lamp. The cavity has a first internal base wall to couple with a first exterior lamp wall of the lamp, a second internal base wall to couple with a second exterior lamp wall of the lamp and, cavity portion formed in the internal base wall intermediate the first interior wall and second interior wall of the lamp. The relief cavity is opposite a seam area of the press seal when the press seal is positioned in the lamp base. The relief accommodates excess material due to tool variations, tool wear, and press variations and thereby allows longer tool operation between tooling changes. The relief also accepts a wider variation in noncritical seal measurements. The relief lessens the likelihood of chipping the seal corner, and displaces the holding forces that tend to open a corner chip.

Abstract: A process of manufacture and an article produced by the process in the form of a lead glass substrate. The substrate is discretely marked during the manufacturing process by directing a flame upon it that is deficient in oxygen to provide a darkened or black marking in the glass surface. The invention is especially useful for marking electric lamps.

Abstract: An electric lamp including an insulative (e.g., plastic) base, an envelope located within the base and having a filament therein and a pair of conductors (e.g., nickel-iron alloy wires) projecting externally from the envelope, passing through the base and extending therefrom. Each conductor includes means (e.g., knurls) formed therein for removing undesirable surface material (e.g., oxide) from a respective contact located within a socket in which the lamp is positioned. Such removal, achieved during lamp insertion and eventual withdrawal, thus assures a sound electrical connection between the "cleaned" contact and a second lamp designed to replace the original. These features are particularly advantageous in the automotive field, especially that portion of the field involving taillight and similar assemblies.

Abstract: An electric, incandescent lamp including an electrically insulating (e.g., plastic) base which is securedly positioned on the lamp's sealed end portion without the need for adhesives or the like. The base functions to securedly retain the lamp's lead-in wires (a total of four in a dual filament lamp) in a preestablished alignment externally of the lamp's sealed end (from which the wires project) to thereby assure positive electrical connection thereto when the lamp and base are inserted within a corresponding electrical socket. The invention is ideally suited for use in a tail light assembly for an automobile.