HID vehicle headlamp capsule assembly

Claim 2

An arc discharge headlamp capsule comprising: a) an arc discharge tube having a forward end with a forward lead, and a rear end with a rear lead, b) a wedge having an axis, an interior wall defining an interior passage formed to be conformal with the rear end of the arc tube, and a sloped exterior wall, positioned around the rear end of the arc discharge tube, with the exterior wall sloped away from the forward end of the arc tube, c) a retainer, having an axis, a sloped interior wall defining a central passage and an interior cavity substantially conformal with the exterior wall of the wedge, positioned around and mated to the wedge to substantially butt the exterior wall of the wedge to the interior wall of the retainer, d) a base supporting the retainer, e) means for electrically connecting the forward lead, and f) means for electrically connecting the rear lead.

Claim 3

The apparatus in claim 1, wherein the forward lead is coupled to a support rod that extends rearward through the retainer.

Claim 4

The apparatus in claim 1, wherein the exterior wall of the wedge has a generally conical form.

Claim 5

The apparatus in claim 1, wherein the wedge includes at least one axial rib formed on the exterior wall.

Claim 6

The apparatus in claim 4, wherein adjacent the axial rib of the wedge is a trough.

Claim 7

The apparatus in claim 4, wherein the axial rib has a blade like edge.

Claim 8

The apparatus in claim 1, wherein the wedge includes a plurality of axial ribs formed on the exterior wall.

Claim 9

The apparatus in claim 7, wherein adjacent each of the axial ribs is a trough.

Claim 10

The apparatus in claim 1, wherein the wedge includes an axial split wall joining the interior wall to the exterior wall thereby forming a expansion gap allowing expansion and contraction of the interior passage.

Claim 11

The apparatus in claim 1, wherein a portion of the exterior surface of the retainer adjacent the base has the form of a section of a sphere

Claim 12

The apparatus in claim 1, wherein a portion of the exterior surface of the retainer adjacent the base defines a ring channel extending around the retainer axis, and means for coupling the retainer to the base is positioned in the ring channel.

Claim 13

The apparatus in claim 1, wherein a portion of the exterior surface of the retainer adjacent the base has the form of a section of a sphere, and adjacent the spherical surface portion, the exterior surface of the retainer is also form to a define a ring channel extending around the retainer axis, and means for coupling the retainer to the base is positioned in the ring channel.

Claim 14

The apparatus in claim 12, wherein means for coupling the retainer to the base positioned in the ring channel is a metal ring fused along in at least one first place to the retainer, and fused in at least one second place to the base.

Claim 15

The apparatus in claim 13, wherein the exterior RF ring channel is formed to include at least one spreader comprising a region of a relatively greater diameter, adjacent regions of relatively less diameter.

Claim 16

The apparatus in claim 12, wherein the exterior RF ring channel is formed to include a plurality of spreaders comprising regions of a relatively greater diameter, adjacent regions of relatively less diameter.

Claim 17

The apparatus in claim 1, wherein the conical interior wall includes a lip edge formed transaxially around the interior wall having a height less than or equal to one percent of the diameter of the conical interior where the lip edge is positioned.

Claim 18

An arc discharge headlamp capsule comprising: a) an arc discharge tube having a forward end with a forward lead, and a rear end with a rear lead, b) a wedge having an axis, a interior wall defining an interior passage formed to be conformal with the rear end of the arc tube, and a substantially conical exterior wall, positioned around the rear end of the arc discharge tube, with the exterior wall sloped away from the forward end of the arc tube, having a plurality of axial ribs formed on the exterior wall, and adjacent each of the axial ribs is a trough, an axial split wall joining the interior wall to the exterior wall thereby forming a expansion gap allowing expansion and contraction of the interior passage c) a retainer, having an axis, a sloped interior wall defining a central passage and an interior cavity substantially conformal with the exterior wall of the wedge, positioned around and mated to the wedge to substantially butt the exterior wall of the wedge to the interior wall of the retainer, a portion of the exterior surface of the retainer adjacent the base has the form of a section of a sphere, and adjacent the spherical surface portion, the exterior surface of the retainer is also form to a define a ring channel extending around the retainer axis, d) a metal ring positioned in the ring channel of the retainer, fused in at least one first place to the retainer, and fused in at least one second place to a base, e) a base supporting the retainer, f) means for electrically connecting the forward lead, and g) means for electrically connecting the rear lead.

Claim 19

An arc discharge headlamp capsule comprising: a) an arc discharge tube having a forward end with a forward lead, and a rear end with a rear lead, b) a wedge having an axis, a interior wall defining an interior passage formed to be conformal with the rear end of the arc tube, and a substantially conical exterior wall, positioned around the rear end of the arc discharge tube, with the exterior wall sloped away from the forward end of the arc tube, having a plurality of axial ribs formed on the exterior wall, and adjacent each of the axial ribs is a trough, an axial split wall joining the interior wall to the exterior wall thereby forming a expansion gap allowing expansion and contraction of the interior passage c) a retainer, having an axis, a sloped interior wall defining a central passage and an interior cavity substantially conformal with the exterior wall of the wedge, positioned around and mated to the wedge to substantially butt the exterior wall of the wedge to the interior wall of the retainer, a portion of the exterior surface of the retainer adjacent the base has the form of a section of a sphere, and adjacent the spherical surface portion, the exterior surface of the retainer is also form to a define a ring channel extending around the retainer axis, d) a metal ring positioned in the ring channel of the retainer, fused in at least one first place to the retainer, and fused in at least one second place to a base, e) a base supporting the retainer, f) means for electrically connecting the forward lead, and g) means for electrically connecting the rear lead.