US4241391A — Inner lamp-mount assembly for sealed-beam headlam…

Claim 1

Independent Claim 206 words

In an electric lamp unit having a housing and substantially rigid main conductors that extend into said housing, the combination of; a baseless incandescent lamp having an envelope that contains a filament which is connected to substantially rigid lead-in conductors that are anchored in and extend from an hermetic seal that terminates one end of said envelope and has two longitudinal side edges, and means mechanically and electrically coupling said incandescent lamp to said main conductors and suspending the lamp within said housing including a holder of sheet metal having (a) a first segment that defines a pocket of generally U-shaped cross-section and is in snug slip-fitted relationship with a side edge portion of the envelope seal, (b) a second segment of hollow tubular configuration that is fastened to one of said main conductors in overlying telescoped relationship therewith, and (c) a third segment that is fastened to one of the lamp lead-in conductors so that the associated main and lead-in conductors are electrically connected to one another by the sheet-metal holder, the said third segment of the sheet-metal holder extending laterally along the outer end of the envelope seal and constituting stop means for orienting the incandescent lamp in predetermined interfitted relationship with the holder.

Claim 2

Dependent Claim 206 words

In an electric lamp unit having a housing and substantially rigid main conductors that extend into said housing, the combination of; a baseless incandescent lamp having an envelope that contains a filament which is connected to substantially rigid lead-in conductors that are anchored in and extend from an hermetic seal that terminates one end of said envelope and has two longitudinal side edges, and means mechanically and electrically coupling said incandescent lamp to said main conductors and suspending the lamp within said housing including a holder of sheet metal having (a) a first segment that defines a pocket of generally U-shaped cross-section and is in snug slip-fitted relationship with a side edge portion of the envelope seal, (b) a second segment of hollow tubular configuration that is fastened to one of said main conductors in overlying telescoped relationship therewith, and (c) a third segment that is fastened to one of the lamp lead-in conductors so that the associated main and lead-in conductors are electrically connected to one another by the sheet-metal holder, the said third segment of the sheet-metal holder extending laterally along the outer end of the envelope seal and constituting stop means for orienting the incandescent lamp in predetermined interfitted relationship with the holder.

Claim 3

Dependent Claim 35 words

The electric lamp unit of claim 1 wherein the said second and third segments of the sheet metal holder are each joined to the associated main conductor and lamp lead-in conductor, respectively, by a weld.

Claim 4

Dependent Claim 74 words

The electric lamp unit of claim 1 wherein; said incandescent lamp is of compact size and has a vitreous envelope the hermetic seal whereof comprises a press seal of fused vitreous material that constitutes one end of the envelope, said lead-in conductors extend from the end of said press seal, and the said third segment of the sheet-metal holder comprises a tabular-shaped segment that extends laterally from the terminus of the tubular-shaped second segment.

Claim 5

Dependent Claim 74 words

The electric lamp unit of claim 1 wherein; the housing comprises a concave reflector component and a light-transmitting cover component that are secured to one another, said substantially rigid main conductors comprise stiff lead-support wires that are carried by and extend into the reflector component, and said compact incandescent lamp is disposed in predetermined optical relationship with said reflector component and thus produces a concentrated beam of light when the lamp unit is energized.

Claim 6

Dependent Claim 60 words

The electric lamp unit of claim 4 wherein; said concave reflector and cover components are hermetically joined along their peripheries and said lamp unit is thus of the sealed-beam type, said incandescent lamp is of the halogen-cycle type, and said hermetic seal comprises a press seal of generally rectangular shape that is formed on the end of the lamp envelope.

Claim 7

Dependent Claim 118 words

The sealed-beam lamp unit of claim 5 wherein; said halogen-cycle lamp contains a single filament and has a pair of substantially rigid lead-in wires that protrude from the end of the press seal, said reflector component carries a pair of inwardly-extending lead-support wires, and said sheet-metal holder comprises a pair of clip-like members that are disposed in slip-fitted, nested relationship with only the side edge portions of the press seal and are thus spaced from one another, each of said sheet-metal clip-like members being fastened to the associated lead-support wire and lamp lead-in wire and thereby providing a unitary mount assembly the parts whereof are retained in assembled relationship by the halogen-cycle lamp and its rigid lead-in wires.

Claim 8

Dependent Claim 78 words

The sealed-beam lamp unit of claim 6 wherein; the inner end portions of said lead-support wires are bent toward one another and are disposed adjacent to and extend along the respective side edge portions of the press seal, the tubular segments of the said metal clip-like members are welded to the enclosed end portions of the associated lead-support wires, and the tubular-shaped segments of said metal clip-like members overlie and are welded to the associated lamp lead-in wires.

Claim 9

Dependent Claim 22 words

The sealed-beam lamp unit of claim 7 wherein each of said clip-like members is fabricated from a single piece of sheet metal.

Claim 10

Dependent Claim 105 words

The sealed-beam lamp unit of claim 5 wherein; said halogen-cycle lamp contains a single filament and has a pair of substantially rigid lead-in wires that protrude from the end of the press seal, said reflector component carries a pair of inwardly-extending lead-support wires, and said sheet-metal holder laterally extends around and grips the press seal and thus comprises a sleeve that locks the halogen-cycle lamp to one of the lead-support wires, one of the lamp lead-in wires being electrically connected to said holder and the remaining lamp lead-in wire being electrically isolated from said holder and connected directly to the other of said lead-support wires.

Claim 11

Dependent Claim 58 words

The sealed-beam lamp unit of claim 9 wherein; said sleeve comprises an extension of the said first segment of the holder, and said holder is fabricated from a single piece of sheet metal the free ends whereof are joined together along the side edge portion of the press seal which is opposite the tubular segment of the holder.

Claim 12

Dependent Claim 130 words

The sealed-beam lamp unit of claim 9 wherein; the inner end portions of said lead-support wires are bent toward and extend along the respective side edge portions of the press seal, the sleeve portion of said holder comprises a separate U-shaped band component of sheet metal that is fastened to the tubular segment of the holder at one side of the press seal and overlies and is mechanically coupled to the end portion of the lead-support wire located at the other side of the press seal, and the lead-support wire that is connected directly to one of the lamp lead-in wires is electrically isolated from the band component of the holder by an insulator that is interposed between the associated lead-support wire and overlying part of said sheet-metal band component.

Claim 13

Dependent Claim 55 words

The sealed-beam lamp unit of claim 11 wherein; said insulator is of sleeve-like configuration and disposed in telescoped relation with the end portion of the associated lead-support wire, and said metal band component extends around and clamps the sleeve-like insulator and end of the associated lead-support wire to the side edge of the press seal.

Claim 14

Dependent Claim 61 words

The sealed-beam lamp unit of claim 9 wherein; the end portion of the lead-support wire that is connected to said holder is disposed at and extends along one side of the press seal, and the end portion of the lead-support wire that is fastened directly to one of the lamp lead-in wires is disposed adjacent the end of the press seal.

Claim 15

Dependent Claim 22 words

The sealed-beam lamp unit of claim 13 wherein said sheet-metal holder, lamp lead-in wires, and lead-support wires are welded to one another.

Claim 16

Dependent Claim 134 words

The sealed-beam lamp unit of claim 5 wherein; the halogen-cycle lamp contains a pair of filaments that are connected to three substantially rigid lead-in wires that protrude from the end of the press seal, the reflector component has three inwardly-extending lead-support wires one of which is fastened directly to one of the lamp lead-in wires, and said sheet-metal holder comprises a pair of metal clip-like members that are disposed in slip-fitted nested relationship with only the side edge portions of the press seal and are thus spaced from one another, each of said metal clip-like members being fastened to the remaining pairs of lead-support wires and lamp lead-in wires and thereby providing a unitary mount assembly the parts whereof are retained in assembled relationship by the halogen-cycle lamp and its substantially rigid lead-in wires.

Claim 17

Dependent Claim 27 words

The sealed-beam lamp unit of claim 15 wherein one of the lamp lead-in wires is electrically connected to and is thus common to both of said filaments.

Claim 18

Dependent Claim 98 words

The sealed-beam lamp unit of claim 16 wherein; the lamp lead-in wire that is fastened directly to one of the lead-support wires protrudes from the medial part of the press seal and the end portion of said one lead-support wire is bent toward and located adjacent the end of the press seal, the end portions of the other main conductors are bent toward and located adjacent to the side edges of the press seal, and each of the said metal clip-like members have hollow tubular portions that are secured to the end portions of the connecting lead-supported wires.

Claim 19

Dependent Claim 63 words

The sealed-beam lamp unit of claim 17 wherein; the lamp lead-in wire that protrudes from the medial part of the press seal is the one that is electrically common to both of said filaments, and the remaining lead-in wires are connected to the ends of the respective filaments and protrude from the portions of the press seal which carry the associated clip-like members.

Claim 20

Dependent Claim 34 words

The sealed-beam lamp unit of claim 18 wherein each of said clip-like members is fabricated from a single piece of sheet metal and are welded to the associated lead-support wires and lamp lead-in wires.

Claim 21

Dependent Claim 173 words

In an electric lamp unit having a housing and substantially rigid main conductors that extend into said housing, a mount assembly comprising; a baseless type miniature incandescent lamp having an envelope that contains a filament which is connected to lead-in conductors that are anchored and extend from an hermetic seal that terminates one end of the envelope, said seal being of such configuration that it has a longitudinally-extending edge portion, means coupling the miniature incandescent lamp to the main conductors and retaining said miniature lamp at a predetermined location in said housing, said coupling means including a sheet-metal holder which constitutes a single component of the mount assembly and has (a) a first segment that is in snug slip-fitted embracing relationship with the said edge portion of the hermetic seal and (b) a second segment that is of hollow tubular configuration and is fastened to one of said main conductors in slip-fitted telescoped overlying relationship therewith, and means electrically connecting the sheet-metal holder to one of the lead-in conductors of the miniature lamp.

Claim 22

Dependent Claim 173 words

In an electric lamp unit having a housing and substantially rigid main conductors that extend into said housing, a mount assembly comprising; a baseless type miniature incandescent lamp having an envelope that contains a filament which is connected to lead-in conductors that are anchored and extend from an hermetic seal that terminates one end of the envelope, said seal being of such configuration that it has a longitudinally-extending edge portion, means coupling the miniature incandescent lamp to the main conductors and retaining said miniature lamp at a predetermined location in said housing, said coupling means including a sheet-metal holder which constitutes a single component of the mount assembly and has (a) a first segment that is in snug slip-fitted embracing relationship with the said edge portion of the hermetic seal and (b) a second segment that is of hollow tubular configuration and is fastened to one of said main conductors in slip-fitted telescoped overlying relationship therewith, and means electrically connecting the sheet-metal holder to one of the lead-in conductors of the miniature lamp.

Claim 23

Dependent Claim 96 words

The electric lamp unit of claim 20 wherein; said envelope is composed of vitreous material and the hermetic seal comprises a press seal of fused vitreous material that has two longitudinally-extending side edge portions, and said coupling means comprises a pair of spaced sheet-metal holders each of which has (a) a first segment that is disposed in snug slip-fitted embracing relationship with the respective side edge portion of the press seal and (b) a second hollow tubular-shaped portion that is in slip-fitted telescoped overlying relationship with selected ones of the main conductors and is welded thereto.

Claim 24

Dependent Claim 191 words

In an electric lamp unit having a housing and substantially rigid main conductors that extend into said housing, a mount assembly comprising; a baseless type miniature incandescent lamp having an envelope that contains a filament which is connected to substantially rigid lead-in conductors that are anchored in and extend from an hermetic seal that terminates one end of the envelope, said seal being of such configuration that it has two longitudinally-extending side portions, and means mechanically and electrically coupling said miniature incandescent lamp to the main conductors and retaining said miniature lamp at a predetermined location within said housing, said coupling means including a sheet-metal holder that constitutes a single component of the mount assembly and is fastened to one of the main conductors and has (a) a first segment that is in snug slip-fitted embracing relationship with a selected side portion of the hermetic seal and (b) another segment that extends laterally from the associated main conductor along the outer end of the hermetic seal and is fastened to one of the lamp lead-in conductors and thereby serves as an electrical-connecting and a spatial-orienting means for the miniature incandescent lamp.

Claim 25

Dependent Claim 191 words

In an electric lamp unit having a housing and substantially rigid main conductors that extend into said housing, a mount assembly comprising; a baseless type miniature incandescent lamp having an envelope that contains a filament which is connected to substantially rigid lead-in conductors that are anchored in and extend from an hermetic seal that terminates one end of the envelope, said seal being of such configuration that it has two longitudinally-extending side portions, and means mechanically and electrically coupling said miniature incandescent lamp to the main conductors and retaining said miniature lamp at a predetermined location within said housing, said coupling means including a sheet-metal holder that constitutes a single component of the mount assembly and is fastened to one of the main conductors and has (a) a first segment that is in snug slip-fitted embracing relationship with a selected side portion of the hermetic seal and (b) another segment that extends laterally from the associated main conductor along the outer end of the hermetic seal and is fastened to one of the lamp lead-in conductors and thereby serves as an electrical-connecting and a spatial-orienting means for the miniature incandescent lamp.

Claim 26

Dependent Claim 95 words

The electric lamp unit of claim 22 wherein; said envelope is composed of vitreous material and the hermetic seal comprises a press seal of fused vitreous material, and said mechanical and electrical coupling means comprises a pair of sheet-metal holders each of which has (a) a first segment that is disposed in snug slip-fitted embracing relationship with one of the side portions of the press seal and (b) a laterally extending portion that is fastened to a selected one of the lamp lead-in conductors and is seated against the outer end of the press seal.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1983-12-23	1984-06-23	1984-12-23	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1987-12-23	1988-06-23	1988-12-23	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1991-12-23	1992-06-23	1992-12-23	$7700.00	Window Closed / Lapsed

Inner lamp-mount assembly for sealed-beam headlamp and similar lighting apparatus

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