Note: Descriptions are shown in the official language in which they were submitted.
1220504
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ELECTRIC LAMP ~ITH SELF-MOUNTING
FRAME-ASSEMBLY; AND METHODS OF CO~STR~CTING SAME
TECHNICAL FIEL~
This invention relates to electric lamps and more particularly
to such lamps having a self-mounting frame-assembly for supporting a
light-source capsule within an outer envelope.
BACK6ROUND ART
Under the existing art, the manufacture of a double-enveloped
electric lamp typically involves the following steps. A
light-source capsule having two lead-in ~ires is ~ounted on a glass
stem support. The capsule and stem are inserted into the outer
envelope. The glass stem support is flame sealed to the glass outer
envelope. The outer envelope is evacuated, a desired fill gas may
be introduced into the outer envelope, and the outer envelope is
hermetically sealed. A lamp base is mounted on and cemented to the
nec~ of the outer envelope. One of the capsule lead-in wires is
soldered to the insulated tip of the base. The second lead-in wire
is soldered or welded to the outer shell of the base.
The described manufacturing process is relatively costly. The
fabrication of a hermetic seal between the lead-in wires and glass
stem and between the ste~ and outer envelope requires considerable
technological skill and quality control.
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A double-enveloped electric lamp, of equivalent or improYed
quality compared with those currently available, which can be
manufactured by a process simpler and less expensive than the
procPss herein6efore described would constitute an advancement in
the art.
DISCLOSURE OF THE INVENTION
It is, therefore, an object of this invention to obviate the
deficiencies in the prior art.
It is another object of this invention to provide a
self-mounting frame-assembly for a double-enveloped electric lamp.
It is still another object of this invention to provide a
double-enveloped electric lamp which can be manufactured simply and
economically.
These objects are accomplished, in one aspect of the invention,
by the provision of an electric lamp comprising an outer envelope, a
frame-assembl~ within the outer envelope, and a light-source capsule
mounted on one end of the frame-assembl~. ~he lamp further
comprises mounting means operatively mounting the frame-assembly and
light-source capsule within the outer envelope by means of elastic
and frictional forces. Means are operatively connected to the lamp
for providing electrical power to the light-source capsule.
The lamp is manufactured by a method comprising the following
steps. An outer envelope is formed. A frame-assembly i5 fonmed. A
light-source capsule is constructed. The light-source capsule is
mounted on one end of the frame-assembly. The frame-assembly and
light source capsule are mounted within the outer envelope by means
of elastic and frictional forces. ~;eans for providing electrical
power to said light-source capsule from an external source are
operatively connected to the lamp.
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Double-enveloped electric lamps having a self~mounting
frame-assembly for supporting a light-source capsule within the
outer envelope may be manufactured more simply and economically than
double-enveloped lamps currently availabl;e without any sacrifice in
the quality of the lamps.
BRIEF DESCRIPTION OF THE DRAWlNGS
FIG. 1 is a sectional view of one embodiment of the invention;
FIG. 2 is an enlarged sectional plan view along line 2-2 of FIG.
1 with parts removed for clarity;
FIG. 3 is an enlarged sectional view of the neck-portion of the
outer envelope of the embodiment of the invention shown in FIG. l;
FlG. 4 is an enlarged pictorial view of a frame-assembly
employed in the embodiment of the invention shown in FIG. l;
FIG. 5 is a pictorial view of a threaded lamp base;
FIG. 6 is an enlarged elevational view of one clamp portion of
the frame-assembly shown in F16. 4;
FIG. 7 is a sectional view of another embodiment of the
invention;
FIG. 8 is an enlarged sectional plan view along line 8-8 of FIG.
20 7, with parts removed for clarity;
~ I6. 9 is an enlarged elevational view of the neck-portion of
the outer envelope of the embodiment of the invention shown in
FI6. 7;
FIG. 10 is a pictorial view of a frame-assembly employed in the
: 25 embodiment of the invention shown in FIG. 7;
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FIG. ll is a top v~ew of the frame-assembly used in the
embodiment of the invention shown in FIG. 7.
BEST MODE FOR CARRYING OUT THE INVENTION
For a better understanding of the present inventiorl, together
with other and further objects, advantages, and capabilites thereof,
reference is made to the following disclosure and appended claims
taken in conjunction with the above-described drawings.
As used herein, the term Ulight-source capsule" denotes a
halogen capsule of a tungsten halogen incandescent lamp; an arc tube
of an arc discharge lamp; or any light-emitting capsule within the
outer envelope of a lamp.
The term ~elastic~l herein is defined as the property of a body,
when defonmed, to return to its normal configuration automatically
as the deforming forces are rem~ved. The tenm Ufriction" herein is
defined to be the ~orce which opposes relative motion between two
touching bodies caused by the respective properties of the surfaces
of each body which are in contact ~ith each other. Neither
~elastic~ nor ~frictiona as used herein shall include any fonce
which opposes relative motion between two bodies caused by the
fusion of one body with the other, such fusion including any
glass-to-glass or glass-to~metal seal.
Referring to the drawings with greater particularity. FI6. l
shows one embodiment of the invention, being lamp 30 having a
longitudinal axis L and comprising outer-envelope 32, light-source
capsule 34, frame-assembly 36, and base 38. Outer-envelope 32 has a
neck-portion 40. Capsule 34 in this instance is a tungsten halogen
incandescent capsule with a first lead-in wire 42, a second lead-in
wire 44, and a tungsten filament 45 extending between the internal
terminantions of lead-in wires 42 and 44. Capsule 34 in this
embodiment is mounted on frame 36 by means of lead-in wire 42.
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FIG. 2 shows neck 40 having first groove 46 with inner-wall 47,
and second groove 48 with inner-wall 49, both grooves being fonmed
in neck ~0.
FIG. 3 shows that within groove 46, ridge 52 is formed adjacent
to the brim of neck 40; likewise, ridge S4 is fonlled adjacent to the
brim of neck 40 within groove 48. Annular ridge 50 circumscribes
neck 40 adjacent to the ends of grooves 46 and 48 remote from the
brim; ridge 50 is not confined within grooves 46 and 48.
Frame assembly 36 is il~ustrated in FIG. 4 and is characterized
herein as being the ~clamp-on~ type. This characterization
describes the manner in which frame-assembly 36 is mounted as will
be described below. As may be seen in FlG. l, frame 36, with
capsule 34 mounted thereon, is inserted into outer envelope 32
through neck 40 and positioned such that clamps 56 and 58 are
aligned with grooves 46 and 48, respectively. Frame 36 may be
pushed deeper into outer envelope 32. In so doing, clamp 56 will be
spread open by ridge 52. ~hen frame 36 has been fully inserted into
outer envelope 32, clamp 56 will spring back to its original shape
because of the inherent elasticity of the material from which clamp
56 is constructed. Clamp 56 0ay be characterized as ~clamping on~
to ridge 52. ~hen frame 36 is mounted, re-entrant portion 65 Of
clamp 56 clasps ridge 52. ln an identical manner, re-entrant
portion 67 of clamp 58 clasps ridge 54. ThuS, clamps 56 and 58,
through their re-entrant portions 65 and 67, exert elastic and
frictional forces against neck 40 of outer envelope 32 which
comprise the mounting means for frame 36 in this embodiment of the
invention.
FIG. 5 is a pictorial view of a lamp base 38 comprising threaded
shell 60 and insulated tip 62. In the embodiment of the invention
shown in FIG. l, base 38 is characterized as a "push-on" type. This
characterization describes the method of mounting base 38 on outer
envelope 32, which is accomplished by pushing base 38 over neck 40
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D-24,950
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and c~amps 56 and 58 toward ridge 50. In so mounting base 38, shell
60 ~ill compress prongs 64 and 66 toward inner walls 47 and 49,
respectively, thereby preventing clamps 56 and 58 from opening, as
well as insuring that clamps 56 and 58 will be tightly and securely
mounted on outer envelope 32. Base 38, when mounted, reinforces the
mounting means for frame 36.
Prongs 64 and 66 have sharply barbed tips 68 and 70,
respectively. When base 38 has been fully mounted, tips 68 and 70
will bite into shell 60. Base 38, ~hen mounted, will defon~ pror,gs
64 and 66 into grooves 46 and 48, respectively. Elastic forces
within these clamps will tend to return prongs 64 and 66 to their
unextended positions. The elastic forces cause tips 68 and 70 of
prongs 64 and 66, respectively, to press against shell 60 with
sufficient force to imbed the sharply pointed barbs into shell 60.
Any attempted motion of base 38 away from ridge 50 or any attempted
rotation of base 38, clockwise or counter-clockwise, about neck 40
will be prevented by prongs 64 and 66 which, being imbedded in ~hell
60, will hold or Ulock'' base 38 securely in its mounted position.
Thus, in this embodiment of the invention, base 3B cooperates ~ith
clamps 56 and 58 and neck 40 in order to form locking means ~hereby
frame 36, base 38, and outer envelope 32 will remain securely
engaged despite jostling and use of laTp 30.
FIG. 6 is an enlarged elevational view of clamp 56 showing ang7e
A, which preferably is greater than 45. ~hen base 38 is b~ing
mounted, shell 60 depresses prong 64 into groove 46. Because of the
freedom of motion into groove 46, clamp 56 does not resist the
movement of base 38 over neck 40 toward ridge 50. For identical
reasons, clamp 58 does not resist the same movement of base 38.
~hen base 38 is fully mounted, any movement of base 38 ahay from
ridge 50 or any rotational movement of base 38 will be prevented by
clamps 56 and 58.
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In this embodiment of the invention, base 38 is threaded. The
thread on shell 60 is not essential to the locking means. A bayonet
type base or another type of lamp base with or without thread may be
employed with the sam~ locking means as described with this
S embodiment and the desired results will be obtained. Barbed tips 68
and 70 are fabricated from a material sufficiently sharp and durable
with respect to shell 60 that tips 68 and 70 will ~Ibiteu or imbed
themselves into shell 60 when base 38 is mounted on neck 40.
The contact of tips 68 and 70 with shell 60 can form a suitable
electrical connection between shell 60 and frame 36. In this
embodiment, frame 36 is constructed from an electrically conducting
material and lead-in 42 may be mounted on frame 36 such that a
suitable electrical connection, as well as an adequate structural
connection, is made between lead-in 42 and frame 36. Thus, lead-in
42 of capsule 34 is electrically connected, via frame 36 and shell
60, to one pole of an external power supply; the elastic nature of
frame 36 will assist in maintaining the electrical sontact
throughout the life of the lamp. The electrical circuit within lamp
30 is completed by electrically connecting lead-in 44 of capsule 34
to tip 62 of base 38, such as by soldering; tip 62 being
electrically insulated from shell 60 of h se 38. Shell 60 and tip
62 of base 38 are constructed from an electrically conducting
material.
FIG. 7 shows another embDdiment of the invention. Lamp 80 has a
longitudinal axis L and comprises outer envelope 82, light-source
capsule 84, frame-assembly 86, and threaded base 38. Outer envelope
82 has a neck-portion 90. In this instance, capsule 84 is a
tungsten-halogen incandescent capsule with a first lead-in wire 92,
a second lead-in wire 94, and a tungsten filament 95 extending
between the internal terminations of lead-in wires 92 and 94.
Capsule 84 is mounted on frame 86 by means of lead-in wire 92.
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Neck 90 is formed with a first-groove 96 and second-groove 98.
Groove 96 comprises three connecting grooves, namely
first-connecting groove 100, second-connecting groove 102, and
third-connecting groove 104. Groove 100 is formed in brim 114 of
s neck 90 and runs from the inside surface 116 to outside surface 118
where it connects with groove 102.
Neck 90 has thread 106 formed therein; the thread extends
approximately from brim 114 to ridge 117. Thread 106 is matched
with the inside thread of base 38 sLch that base 38 may be mounted
by being screwed onto neck 90. Groove 102 is fonned into outside
surface 118 and thread 106. Groove 102 proceeds from brim 114
toward ridge 117 running parallel to central axis L and traversing
thread 106 until groove 102 meets groove 104. Groove 104 is fo,rmed
in outside surface 118 and thread 106; it is perpendicular to groove
i5 102; it proceeds from groove 102 in the direction that thread 106
advances toward ridge 117.
Groove 98, comprising connecting grooves 108, 110, and 112, is
fonmed opposite groove 96 in neck 90. Grooves 104 and 112 both
point in the direction of advancing thread 106, i.e., in the
direction of rotation of base 38 when base 3B is being mounted on
neck 90.
FIG. 10 is a pictorial view of frame-assembly 86 which is
characterized herein as being the ~slide-on~ type. This
characterization describes the manner in which frame-assembly 86 is
mounted. As may be seen in FI6. 7, frame 86, with capsule 84
mounted thereon, is inserted into outer envelope 82 through neck 90
and positioned such that formed-leg 120 is aligned with groove 96
and fo~ned-leg 128 is aligned with groove 98. lhiS is possible
because leg 120 of frame 86 has been preformed to match groove 96 of
neck 90 as follows: segment 122 fits into groove 100, segment 124
fits into groove 102; segment 126 fits into groove 104 at the
intersection of groove 102 and 104; and segment 126 protrudes
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tangentially from groove 104. In a similar manner, leg 128 of frame
86 has been preformed to match groove 98 of neck 90 such that
segment 130 fits into groove 108; segmRnt 132 fits into groove 110;
segment 134 fits into groove 112 at the intersection of grooves 110
and 112; and segment 134 protrudes tangentially from groove 112.
FIG. 11 is a top view of.frame-assembly 86 showing angles B and
C, each a right angle, which explains why segments 126 and 134
protrude tangentially from grooves 104 and 112, respectively, when
frame 86 is mounted on neck 90. Thus, frame 86 is mounted on outer
envelope 82 by "sliding on" frame 86 to neck 90 such that legs 120
and 128 fit into matched receiving grooves 96 and 98, respectively.
The threaded lamp base 38 also may be used with the lamp shown
in FIG. 7. Base 38 is mounted on neck 90 by screwing base 38 onto
thread 106 with frame 86 already fitted onto neck 90. In order to
mount base 38 fully, protruding segments 126 and 134 of frame 86
must be depressed into grooves 104 aod 112-, respectively. Base 38
is characterized as a Uscrew-on" base because of the method of
mounting. While depressed, segments 126 and 134 act as springs;
each segment exerts an elastic force against shell 60 of base 38.
m ese elastic forces do not i~pede the forward rotation of base 38
towRrd ridge 117 of neck 90, because both segments point in the
direction of the mounting rotation. However, if base 38 is rotated
in the direction of dismounting, barbed tips 136 and 138 of legs 1~0
and 128, respectively, will immediately bite into shell 60 and
prevent further rotation of base 38 in the dismount direction.
Thus, once base 38 is fully mounted, base 38 is ~locked~ penmanently
in place.
The mounting of base 38 also securely fixes frame 86. Base 38
depresses segments 126 and 134 tightly into grooves 104 and 112,
respectively, and the spring action of both of these segments
against shell 60 reinforces the security of the mounting means for
frame 86. The entire shell of base.38 also assists in the mounting
means for frame 86.
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In the embodiment shown in FI6. 7, the matched thread of neck 90
and base 38 permits base 3~ to be mounted by means of being screwed
on neck,90. Barbed tips 136 and 138 can be formed from a
suffice~tly sharp and durable material with respect to shell 60 to
insure that the tips will bite into or become imbedded into shell 60
whereby the locking means will be implemented.
In the embodiment shown in FIG. 7, frame 86 is constructed from
an electrically conducting material. The contact of tips 136 and
138 with shell 60 fonms a redundant electrical contact for one pole
of an electrical circuit. Electrical power from an external source
may be transmitted to capsule 8~ through frame 86 which is
electrically connected to lead-in wire 92. The circuit is completed
by electrically connecting lead-in wire 94 to tip 62 of base 38
which is electrically insulated from shell 60.
lS In a laboratory example of the em~odiment of FIG. 1, .020 inch
(.051 centimeters) thick nickel-plated stainless steel was used for
the fabrication of frame-assembly 36. Capsule 34 was mounted on
frame 36 by welding lead-in 42 to frame 36.
In a laboratory example of the emboaiment of FI6. 7, fra~e 86
~as constructed from .050 inch (1.27 centimeters) diameter
nickle-plated steel wire. Capsule 84 ~as mounted to frame 86 by
welding lead-in 92 to frame 86. In both embodiments, base 38 was an
Edison base. The frame assemblies ~ere constructed by welding the
respective component parts.
~n laboratory examples of both embodiments of the invention
disclosed in FIG. 1 and FIG. 7, the wall thickness of the
neck-portion of the outer envelope was greater than any of the other
walls of the outer envelope in order to provide additional strength
to the neck-portion of the lamps. The outer-envelopes ~ere fonmed
from soda-lime glass Yia a blow-molding manu~acturing process.
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While there have been shown what are at present considered to be
preferred embodiments of the invention, it will be apparent to those
skilled in the art that various changes and modifications can be
made herein without departing from the scope of the invention as
defined by the appended claims.
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