Rectangular sealed beam headlamp unit

Claim 2

A reflector for a lighting unit comprising: a molded member having all surfaces thereon with a positive draft angle with respect to a mechanical axis substantially through the center of the unit; a paraboloidal reflecting surface on the member having an optical axis inclined with respect to the mechanical axis; means on said member defining a plane normal to said mechanical axis; a plurality of raised ferrule bosses formed on the rear surface of said member, said ferrule bosses having axes parallel to said mechanical axis and being offset with respect to the mechanical axis and said paraboloidal axis to provide equal ferrule boss heights as measured from said plane to compensate for the inclination between said axes thereby provide equal masses and prevent distortion due to differing cooling rates thereat.

Claim 3

A lighting unit comprising: a paraboloidal reflector member having a paraboloidal axis; a lens memberr secured to said reflector; means on one of said members defining a plane wherein a normal thereto is inclined a predetermined amount with respect to said paraboloidal axis; a plurality of raised ferrule bosses formed on the rear surface of said reflector, said ferrule bosses having axes parallel to said normal and being offset with respect to the paraboloidal axis to provide equal ferrule boss heights as measured from said plane, said equal ferrule boss heights reducing reflector distortion caused by heat sinks in the molding of the reflector caused by varying glass thickness; ferrules sealed to said ferrule bosses; filament means fixedly electrically connected to said ferrules; and terminal means attached to said ferrules adapted to be connected to a power source for providing energization of said filament means.

Claim 4

A lighting unit comprising: a paraboloidal reflector member having a paraboloidal axis; a lens memberr secured to said reflector; means on one of said members defining a plane wherein a normal thereto is inclined a predetermined amount with respect to said paraboloidal axis; a plurality of raised ferrule bosses formed on the rear surface of said reflector, said ferrule bosses having axes parallel to said normal and being offset with respect to the paraboloidal axis to provide equal ferrule boss heights as measured from said plane, said equal ferrule boss heights reducing reflector distortion caused by heat sinks in the molding of the reflector caused by varying glass thickness; ferrules sealed to said ferrule bosses; filament means fixedly electrically connected to said ferrules; and terminal means attached to said ferrules adapted to be connected to a power source for providing energization of said filament means.

Claim 5

A type 2 sealed beam headlamp unit for a motor vehicle comprising: a molded glass reflector, all surfaces of said reflector being formed with a positive draft angle with respect to a mechanical axis substantially longitudinally through the center of the reflector; a glass lens sealed to the reflector; a paraboloidal reflecting surface on said reflector, said reflecting surface having an optical axis inclined a predetermined amount with respect to said mechanical axis; a filament adapted to be positioned horizontally through the optical axis at the focal point of the paraboloidal reflecting surface, the portions of the reflecting surface above the horizontal plane through the center of the unit redirecting illumination from the filament to produce optically efficient images of the latter; three raised ferrule bosses formed on the rear surface of said reflector, said ferrule bosses having openings therein, the areas surrounding said openings being subject to distortion during the molding process, said opening having axes parallel to said mechanical axis and being offset with respect to both axes to provide substantially equal ferrule boss heights as measured from said rear surface and along said axes, said equal ferrule boss heights compensating for the inclination between said axes to thereby provide equal glass masses and prevent distortion due to differing cooling rates during the molding of said reflector; an exhaust tube located at the origin of a circle drawn through the three ferrule bosses, the openings being rotated with respect to said exhaust tube to place the distorted areas of the ferrule bosses at portions of the reflecting surface having mInimal interference with the optimum hot spot illumination; metal ferrules sealed to each of said bosses; and lead wires fixedly supporting said filament from said ferrules with the lead wires extending through said openings.

Claim 6

A type 2 sealed beam headlamp unit for a motor vehicle comprising: a molded glass reflector, all surfaces of said reflector being formed with a positive draft angle with respect to a mechanical axis substantially longitudinally through the center of the reflector; a glass lens sealed to the reflector; a paraboloidal reflecting surface on said reflector, said reflecting surface having an optical axis inclined a predetermined amount with respect to said mechanical axis; a filament adapted to be positioned horizontally through the optical axis at the focal point of the paraboloidal reflecting surface, the portions of the reflecting surface above the horizontal plane through the center of the unit redirecting illumination from the filament to produce optically efficient images of the latter; three raised ferrule bosses formed on the rear surface of said reflector, said ferrule bosses having openings therein, the areas surrounding said openings being subject to distortion during the molding process, said opening having axes parallel to said mechanical axis and being offset with respect to both axes to provide substantially equal ferrule boss heights as measured from said rear surface and along said axes, said equal ferrule boss heights compensating for the inclination between said axes to thereby provide equal glass masses and prevent distortion due to differing cooling rates during the molding of said reflector; an exhaust tube located at the origin of a circle drawn through the three ferrule bosses, the openings being rotated with respect to said exhaust tube to place the distorted areas of the ferrule bosses at portions of the reflecting surface having mInimal interference with the optimum hot spot illumination; metal ferrules sealed to each of said bosses; and lead wires fixedly supporting said filament from said ferrules with the lead wires extending through said openings.

Claim 7

A rectangular sealed beam headlamp unit for a motor vehicle comprising: a molded glass reflector having a substantially rectangular frontal profile, said reflector having all surfaces thereon formed with a positive draft angle with respect to a mechanical axis substantially longitudinally through the center of the reflector; a paraboloidal reflecting surface on said reflector having substantially forwardly projecting planar side walls terminating with a rectangular peripheral flange; a first filament adapted to be supported at a horizontally position on the optical axis at the focal point of the reflecting surface; a second filament adapted to be supported at a position parallel to the first filament; said paraboloidal reflecting surface having an optical axis inclined with respect to said mechanical axis, said reflecting surface receiving illumination from the filament for redirection therefrom with the portions of the reflecting surface lying above horizontal plane through the center of the unit producing optically efficient hot spot images of the first filament; a generally rectangular glass lens having a rectangular peripheral lip sealed to said peripheral flange of said reflector, said lens distributing illumination from the reflecting surface outwardly in a desired illumination pattern; an exhaust tube formed in the rear surface of the reflector; a plurality of ferrule bosses formed on said rear surface and equally radially spaced with respect to said exhaust tube, said ferrule bosses having openings therein surrounded by distorted reflecting surfaces, said exhaust tube being positioned with respect to said rear surface at a location that establishes equal ferrule boss heights as measured in a plane normal to said mechanical axis to thereby provide equal glass masses and prevent distortion due to different cooling rates of the masses during molding of the reflector, said openings of said ferrule bosses having axes parallel to the mechanical axis, two of the openings being located on a line through said exhaust tube and rotated substantially 25* from a horizontal plane through said exhaust tube and the third opening being located substantially 25* from the vertical plane through said exhaust tube along a line perpendicular to and below the line joining the first two-mentioned openings whereby said distorted areas are placed at portions of the reflecting surface having minimal interference with the production of optically efficient hot spot images of the filament; metal ferrules fusion sealed to the rear surface of said ferrule bosses about said openings; lead wires extending through the openings and fixedly connected to said ferrules, said lead wires supporting said filament at said positions whereby rotating the openings and providing equal ferrule boss masses provides a rectangular reflecting surface having minimal distortion and interference with the production controlled hot spot images of the filament.

Claim 8

A rectangular sealed beam headlamp unit for a motor vehicle comprising: a molded glass reflector having a substantially rectangular frontal profile, said reflector having all surfaces thereon formed with a positive draft angle with respect to a mechanical axis substantially longitudinally through the center of the reflector; a paraboloidal reflecting surface on said reflector having substantially forwardly projecting planar side walls terminating with a rectangular peripheral flange; a first filament adapted to be supported at a horizontally position on the optical axis at the focal point of the reflecting surface; a second filament adapted to be supported at a position parallel to the first filament; said paraboloidal reflecting surface having an optical axis inclined with respect to said mechanical axis, said reflecting surface receiving illumination from the filament for redirection therefrom with the portions of the reflecting surface lying above horizontal plane through the center of the unit producing optically efficient hot spot images of the first filament; a generally rectangular glass lens having a rectangular peripheral lip sealed to said peripheral flange of said reflector, said lens distributing illumination from the reflecting surface outwardly in a desired illumination pattern; an exhaust tube formed in the rear surface of the reflector; a plurality of ferrule bosses formed on said rear surface and equally radially spaced with respect to said exhaust tube, said ferrule bosses having openings therein surrounded by distorted reflecting surfaces, said exhaust tube being positioned with respect to said rear surface at a location that establishes equal ferrule boss heights as measured in a plane normal to said mechanical axis to thereby provide equal glass masses and prevent distortion due to different cooling rates of the masses during molding of the reflector, said openings of said ferrule bosses having axes parallel to the mechanical axis, two of the openings being located on a line through said exhaust tube and rotated substantially 25* from a horizontal plane through said exhaust tube and the third opening being located substantially 25* from the vertical plane through said exhaust tube along a line perpendicular to and below the line joining the first two-mentioned openings whereby said distorted areas are placed at portions of the reflecting surface having minimal interference with the production of optically efficient hot spot images of the filament; metal ferrules fusion sealed to the rear surface of said ferrule bosses about said openings; lead wires extending through the openings and fixedly connected to said ferrules, said lead wires supporting said filament at said positions whereby rotating the openings and providing equal ferrule boss masses provides a rectangular reflecting surface having minimal distortion and interference with the production controlled hot spot images of the filament.