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: 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 double-layer electrode coil for a high intensity discharge (HID) lamp and a method of making the electrode coil are provided. A more stable layer of coils is made by front winding, instead of back winding, the layers of wire. The second layer of wire is entirely within a helical groove on the exterior surface of the first layer of wire. This arrangement is particularly stable and permits more rapid insertion of the electrode shank after removal of the mandrel.

Abstract: A double-layer electrode coil for a high intensity discharge (HID) lamp and a method of making the electrode coil are provided. A more stable layer of coils is made by front winding, instead of back winding, the layers of wire. The second layer of wire is entirely within a helical groove on the exterior surface of the first layer of wire. This arrangement is particularly stable and permits more rapid insertion of the electrode shank after removal of the mandrel.

Abstract: A double-layer electrode coil for a high intensity discharge (HID) lamp and a method of making the electrode coil are provided. A more stable layer of coils is made by front winding, instead of back winding, the layers of wire. The second layer of wire is entirely within a helical groove on the exterior surface of the first layer of wire. This arrangement is particularly stable and permits more rapid insertion of the electrode shank after removal of the mandrel.

Abstract: A long life, two filament tungsten halogen lamp having light transmissive envelope, a first filament with a first lead, second lead, filament coil; a second similar filament, and a fill material is disclosed. The filament coil has an increased wire weight, increased over what is commonly used. The fill material comprises a halogen for the tungsten halogen cycle, a getter, and the remainder is approximately equal portions of krypton and xenon. The basic life improvement comes from the heavier tungsten wire weight, combined with the heavier molecular weight of xenon and krypton. The new filament and fill gives a two filament tungsten halogen lamp yielding substantially longer lamp life.

Abstract: A multi-planar, one-piece wire insert for supporting a coil filament body in an electric incadescent lamp in which the wire insert includes a top leg disposed in a plane out of the main plane of the insert so as to permit the coil filament body, as wound, to fit (match) the insert directly without requiring alteration to the ends of the coil filament body and/or changing of the wound coil geometry.