Vehicle lamp having a molded lamp cap with integral current-supply conductors and dipping cap

Claim 2

A vehicle lamp, comprising: (a) a discharge device having a longitudinal axis and opposing ends, said discharge device having first and second lead-throughs each extending from a respective end along said longitudinal axis; (b) a one-piece insulative lamp base comprising a solid molding having a first face facing said discharge device, said first lead-through extending towards said first face and said second lead-through extending away from said first face; and (c) first and second current-supply conductors each having a portion molded in said lamp base securing said current-supply conductors in said lamp base, each said current-supply conductor extending away from said first face towards said discharge device, each current-supply conductor being connected to a respective lead-through for energizing said discharge device and supporting said discharge device with respect to said lamp base; and (d) each current-supply conductor having a portion defining lamp contacts extending from a portion of said lamp base other than said first face.

Claim 3

A lamp as claimed in claim 1, wherein said lamp has a molded insulative dipping cap aligned with and facing said discharge device for intercepting a portion of emitted light from said discharge device, and said second current-supply conductor comprises a first portion molded integrally in said dipping cap to secure said dipping cap with respect to said discharge device.

Claim 4

A lamp as claimed in claim 2, wherein said first portion has a rectangular cross-section for removing heat and equalizing the temperature in said dipping cap.

Claim 5

A lamp as claimed in claim 2, wherein said first portion further comprises vanes extending within said dipping cap for removing heat and equalizing the temperature in said dipping cap.

Claim 6

A lamp as claimed in claim 1, wherein said first current-supply conductor has a portion molded integrally within said dipping cap having a leg protruding from said dipping cap connected to said first lead-through, said first current-supply conductor portion having an elongate vane extending within said dipping cap for removing heat and equalizing the temperature in said dipping cap.

Claim 7

A lamp as claimed in claim 1, wherein said second current-supply conductor is enclosed by insulating material over substantially its entire length.

Claim 8

A vehicle headlamp, comprising: (a) a discharge device having a longitudinal axis and opposing ends, said discharge device having first and second lead-throughs each extending from a respective end along said longitudinal axis; and (b) a one-piece insulative lamp base having a reference point and a first face facing said discharge device, said first lead-through extending towards said first face and said second lead-through extending away from said first face; (c) an elongate molded dipping cap integral with said lamp base and aligned with said reference point extending from said lamp base aligned with and facing said discharge device for intercepting a portion of emitted light from said discharge device; (d) first and second rigid current-supply conductors, each said current-supply conductor having a portion molded integrally in said lamp cap securing said current-supply conductors in said lamp cap, each said current-supply conductor extending from said lamp cap towards said discharge device, said first current-supply conductor having a portion connected to said first lead-through, said second current-supply conductor having a first portion molded in said dipping cap extending substantially throughout the entire length of said dipping cap and a second portion connected to said second lead-through, said discharge device being supported by said lead-throughs, and (e) each current-supply conductor having a portion defining lamp contacts emerging from a portion of said lamp cap other than said first face, whereby said lamp may be assembled by aligning said discharge device with said reference point and connecting said discharge device to said current-supply conductors which are integral with said lamp base.

Claim 9

A vehicle headlamp, comprising: (a) a discharge device having a longitudinal axis and opposing ends, said discharge device having first and second lead-throughs each extending from a respective end along said longitudinal axis; and (b) a one-piece insulative lamp base having a reference point and a first face facing said discharge device, said first lead-through extending towards said first face and said second lead-through extending away from said first face; (c) an elongate molded dipping cap integral with said lamp base and aligned with said reference point extending from said lamp base aligned with and facing said discharge device for intercepting a portion of emitted light from said discharge device; (d) first and second rigid current-supply conductors, each said current-supply conductor having a portion molded integrally in said lamp cap securing said current-supply conductors in said lamp cap, each said current-supply conductor extending from said lamp cap towards said discharge device, said first current-supply conductor having a portion connected to said first lead-through, said second current-supply conductor having a first portion molded in said dipping cap extending substantially throughout the entire length of said dipping cap and a second portion connected to said second lead-through, said discharge device being supported by said lead-throughs, and (e) each current-supply conductor having a portion defining lamp contacts emerging from a portion of said lamp cap other than said first face, whereby said lamp may be assembled by aligning said discharge device with said reference point and connecting said discharge device to said current-supply conductors which are integral with said lamp base.

Claim 10

A lamp as claimed in claim 7, wherein said first portion of said second current supply conductor has a rectangular cross-section for removing heat from said dipping cap and equalizing the temperature distribution in said dipping cap.

Claim 11

A lamp as claimed in claim 8, wherein said first portion further comprises non-current-carrying heat conductive vanes integral with said current-supply conductor.

Claim 12

A lamp as claimed in claim 7, wherein said first current-supply conductor comprises a portion molded in said dipping cap having a current-carrying leg protruding from said dipping cap connected to said first lead-through and a heat conductive vane for equalizing the temperature distribution in said dipping cap.

Claim 13

A lamp as claimed in claim 8, wherein a said current-supply conductor has a portion having a rectangular cross-section connected to a respective said lead-through by a weld and comprises a rib extending transverse to said respective lead-through forming a pointed contact whereby welding of said welded connection is facilitated.

Claim 14

A lamp as claimed in claim 9, wherein a said current-supply conductor has a portion having a rectangular cross-section connected to a respective said lead-through by a weld, said portion comprising a rib extending transverse to said respective lead-through forming a pointed contact whereby welding of said welded connection is facilitated.

Claim 15

A lamp cap as claimed in claim 10, wherein a said current-supply conductor has a portion having a rectangular cross-section connected to a respective said lead-through by a weld, said portion comprising a rib extending transverse to said respective lead-through forming a pointed contact whereby welding of said welded connection is facilitated.

Claim 16

A lamp as claimed in claim 7, wherein said second current-supply conductor comprises a curved portion having the current-supply conductor substantially bent back on itself between said transverse portion and said dipping cap for reducing stress in said second current-supply conductor resulting from differing expansions between said lamp cap and said discharge vessel.

Claim 17

A lamp as claimed in claim 4, wherein said curved portion of said second current-supply conductor is U-shaped.

Claim 18

A lamp as claimed in claim 7, wherein said lamp contacts comprise tongue-shaped flattened portions extending from said lamp cap parallel to each other and transverse to said longitudinal axis.

Claim 19

A lamp as claimed in claim 16, wherein said concave face of said dipping cap faces in a direction transverse to said longitudinal axis of said lamp cap and said tongue-shaped lamp contacts extend in said transverse direction.

Claim 20

A lamp as claimed in claim 17, wherein said lamp further comprises a wall portion extending between said lamp contacts for enlarging the leakage path between said lamp contacts.

Claim 21

A lamp as claimed in claim 15, wherein said lamp further comprises a wall portion extending between said lamp contacts for enlarging the leakage path between said lamp contacts.

Claim 22

A lamp as claimed in claim 13, wherein said lamp further comprises a wall portion extending between said lamp contacts for enlarging the leakage path between said lamp contacts.

Claim 23

A lamp as claimed in claim 18, wherein said wall portion is asymmetric with said longitudinal axis so that an external plug for supplying lamp operating current can be connected in only one orientation.

Claim 24

A lamp as claimed in claim 21, wherein said lamp cap further comprises a shoulder for positioning the lamp with respect to an external reflector.