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.