Abstract: A replaceable automobile headlight lamp unit and headlight utilizing same wherein the unit's electric lamp (e.g., tungsten halogen) is securedly retained within a clamp member including an insulative base and a pair of spaced-apart retaining clips for grasping the lamp's press-sealed end portion. The base includes a curvilinear surface which mates with a surface having a similar configuration located within an insulative holder which also forms part of the invention. A pair of spaced contacts located within the holder pass through apertures within the base and are connected (e.g., welded) to the retention clips. A ball-joint arrangement is thus provided to enable facile alignment of the electric lamp relative to the holder prior to final securement between the holder and base components.

Abstract: A replaceable lamp unit (10) removably oriented within a glass or plastic reflector (13) of an automobile headlight. The unit includes a plastic cylindrical shaped holder (19) which is directly inserted within a rear opening (11) in the reflector. The holder includes a pair of spaced cavities (21, 23) separated by a common wall member (25) in which are located a plurality of electrically conductive eyelets (27). Fixedly positioned within each eyelet is a support wire (43) to which is connected a respective one of the lead-in wires (31) of the electric lamp (39) which forms part of the lamp unit. Connection between the eyelets and support wires is attained by soldering (45) and a quantity of sealant material (65) is thereafter added within the holder to provide a secondary seal. An automobile headlight utilizing the replaceable lamp unit is also described.

Abstract: A method of making a replaceable lamp unit (10) for use within an automobile headlight. The method comprises the steps of providing three spaced apertures (29) within a wall (25) of a plastic holder (19), positively securing a metallic eyelet (27) within each aperture, attaching a metallic support wire (43) to each of at least two lead-in wires (31) of an electric lamp (39), inserting the support wires within each of the eyelets, and thereafter soldering (45) the support wires to the respective secured eyelets. Precise alignment of the envelope (33) of the electric lamp is provided prior to the soldering operation. The soldering operation assures not only a sound electrical connection, but also provides both a hermetic seal between eyelet and support wire components and a means for maintaining the lamp support wire sub-assembly in fixed position with the holder.

Abstract: The coiled tungsten filament of an incandescent lamp is made more resistant to sagging by exposing the filament to a vaporized phosphorus atmosphere so as to form tungsten monophosphide on the filament. The filament is subsequently heated in order to dissociate the tungsten monophosphide and evaporate the phosphorus therefrom.