Abstract: A base-up incandescent lamp (10) includes a coiled-coil filament (14) that has a primary wire (18) and a secondary wire (16), the primary wire (18) comprising an overwind that overlies the secondary wire (16) and provides a lower filament temperature and, therefore, less filament sag and a concomitant longer lamp life.

Abstract: A press sealed lamp with an internally pressed fuse is disclosed. The filament structure is conveniently formed so the fuse links across a looped section of the initial filament structure. The loop structure provides strength to the fused filament structure prior to sealing. After the lamp is sealed, a portion of the exposed loop is trimmed, thereby limiting the electrical connection to the path through the fuse.

Abstract: A small volume, high wattage press sealed lamp having envelope, filament, internal leads, seal foils, external leads, and blades is disclosed. The small volume, high wattage press sealed lamp increased conductivity due to a flat faced external lead forming one of the foil welds. The external lead is butt welded to blade stock at ninety degrees forming a highly conductive bond.

Abstract: A method of making a press sealed lamp with an internally pressed fuse is disclosed. The filament structure is conveniently formed so the fuse links across a looped section of the initial filament structure. The loop structure provides strength to the fused filament structure prior to sealing. After the lamp is sealed, a portion of the exposed loop is trimmed, thereby limiting the remaining electrical connection to the path through the fuse.

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: A improved projector lamp with an internal reflector may be made by forming the reflector from pure aluminum, or an aluminum alloy not including amounts of vaporizable materials. Anodized aluminum is not used. A pure aluminum reflector is mechanically polished and chemically etched to attain a high level of reflectivity. The quality of the surface finish is retained by enclosing the reflector in an oxygen free lamp. The high purity aluminum acts as a getter for oxygen, and other detrimental contaminants, thereby tending to extend the lamp life and maintain lamp output. Since aluminum is lighter weight than the previous reflector materials, the lamps do not suffer as much breakage during manufacture and shipping.

Abstract: An improved projector lamp with an internal reflector may be made by forming the reflector from pure aluminum, or an aluminum alloy not including amounts of vaporizable materials. Anodized aluminum is not used. A pure aluminum reflector is mechanically polished and chemically etched to attain a high level of reflectivity. The quality of the surface finish is retained by enclosing the reflector in an oxygen free lamp. The high purity aluminum acts as a getter for oxygen, and other detrimental contaminants, thereby tending to extend the lamp life and maintain lamp output. Since aluminum is lighter weight than the previous reflector materials, the lamps do not suffer as much breakage during manufacture and shipping.

Abstract: An improved lamp construction and associated method of manufacture of a lamp that includes a sealed capsule with lead-in wires and a ceramic base. A pair of sleeves each defining a lamp contact pin at one end thereof are swaged at the other end thereof to the lead-in wires to secure the sleeves thereto. The ceramic base has a bottom wall with a pair of holes therein for receiving respective sleeves with the contact pin ends thereof depending from the base bottom wall and with the swaged ends thereof defining a limiting wall for positioning of the sleeves in proper relation relative to the ceramic base. The cement is disposed in the ceramic base and cured to secure the sleeves and lead-in wires in the ceramic base.

Abstract: A high temperature tungsten halogen lamp having improved lamp strength so as to reduce lamp breakage. The ceramic base for supporting the press sealed end of the lamp's envelope has a top thereof including a pair of upwardly projecting members that extend above the press sealed portion to contact the bulb portion of the lamp envelope (or capsule). These corner projecting members enable enhanced support while at the same time providing a pair of windows therebetween to enable sufficient heat dissipation (thus preventing excessively high lamp seal temperatures). In accordance with the method of the invention the envelope is cemented to the ceramic base in a two-step operation including firstly cementing the base below the projecting members to bind the base to the envelope's press sealed portion and thereafter cementing the projecting members to the envelope's bulb portion.

Abstract: An improved fuse means for use within an electric incandescent lamp (e.g., tungsten halogen). The fuse is located within a ceramic base to which the press-sealed end of the envelope is affixed (e.g., cemented). The improved fuse means comprises a first conductive (e.g., nickel) wire segment of rectangular cross-sectional configuration and a second conductive (e.g., nickel) sleeve member crimped about an end portion of the first wire segment and including a flat region which in turn is fixedly secured (e.g., welded) to one of the lead-in wires projecting from the lamp's press-sealed end portion. In an alternative embodiment, a second sleeve member and conductive wire segment is utilized.

Abstract: A tungsten-halogen lamp having a tubular envelope of quartz or high silica glass has a press-seal at one end which is reduced in width by the removal of right-angled sections from opposite lower corners of the press. The lamp further includes a ceramic base having a slot with closed ends for accommodating the reduced width portion of the press-seal.

Abstract: A high voltage movie light including a plastic holder, a pair of spaced-apart incandescent lamp units positioned within the holder, and means for electrically connecting the lamp units to an external power source. Each lamp unit comprises a formed glass reflector and a tungsten-halogen lamp located within the reflector and having a planar, dual filament structure therein. The lamp units are positioned within the holder such that the planes occupied by the respective dual filament structures intersect at a predetermined angle, e.g. 90 to 110 degrees, in order that the light output from each unit will be centered on a respective diagonal of the rectangular subject field being illuminated by the movie light. Each unit produces a bimodal intensity distribution, thus further assuring increased illumination levels on the subject field. An incandescent lamp unit suitable for use in the movie light is also disclosed.