CA2119804A1 - Three-way lamp base using a push-on contact and method of forming same - Google Patents
Three-way lamp base using a push-on contact and method of forming sameInfo
- Publication number
- CA2119804A1 CA2119804A1 CA 2119804 CA2119804A CA2119804A1 CA 2119804 A1 CA2119804 A1 CA 2119804A1 CA 2119804 CA2119804 CA 2119804 CA 2119804 A CA2119804 A CA 2119804A CA 2119804 A1 CA2119804 A1 CA 2119804A1
- Authority
- CA
- Canada
- Prior art keywords
- insulating material
- annular contact
- lead wire
- forming
- lamp base
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J5/00—Details relating to vessels or to leading-in conductors common to two or more basic types of discharge tubes or lamps
- H01J5/50—Means forming part of the tube or lamps for the purpose of providing electrical connection to it
- H01J5/54—Means forming part of the tube or lamps for the purpose of providing electrical connection to it supported by a separate part, e.g. base
- H01J5/62—Connection of wires protruding from the vessel to connectors carried by the separate part
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J5/00—Details relating to vessels or to leading-in conductors common to two or more basic types of discharge tubes or lamps
- H01J5/50—Means forming part of the tube or lamps for the purpose of providing electrical connection to it
- H01J5/54—Means forming part of the tube or lamps for the purpose of providing electrical connection to it supported by a separate part, e.g. base
- H01J5/56—Shape of the separate part
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
- H01J9/00—Apparatus or processes specially adapted for the manufacture, installation, removal, maintenance of electric discharge tubes, discharge lamps, or parts thereof; Recovery of material from discharge tubes or lamps
- H01J9/24—Manufacture or joining of vessels, leading-in conductors or bases
- H01J9/30—Manufacture of bases
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Common Detailed Techniques For Electron Tubes Or Discharge Tubes (AREA)
Abstract
THREE-WAY LAMP BASE USING A PUSH-ON CONTACT
AND METHOD OF FORMING SAME
Abstract of the Disclosure A method of forming a base for a three-way lamp includes molding a shell and an eyelet at opposite ends of an insulating material. A radial shoulder is formed in the insulating material between the eyelet and shell and adapted to receive an annular contact after the insulating material has cured. Adjacent the shoulder, a recess is formed in the insulating material that communicates with a lead wire opening. This permits a lead wire to be fed through the opening, deformed outwardly into the recess, and the annular contact advanced over the eyelet into engagement with the radial shoulder. The lead wire and Annular contact are then subsequently secured together.
AND METHOD OF FORMING SAME
Abstract of the Disclosure A method of forming a base for a three-way lamp includes molding a shell and an eyelet at opposite ends of an insulating material. A radial shoulder is formed in the insulating material between the eyelet and shell and adapted to receive an annular contact after the insulating material has cured. Adjacent the shoulder, a recess is formed in the insulating material that communicates with a lead wire opening. This permits a lead wire to be fed through the opening, deformed outwardly into the recess, and the annular contact advanced over the eyelet into engagement with the radial shoulder. The lead wire and Annular contact are then subsequently secured together.
Description
TD 10,576 ~ 80~
T~ WAY IJ~P laAlB~ OM CO~S!AC:T
A~D ~T~OD OF FOR~ ~NB
Back~rou~ o~ th3 ~y~n~lQ~
This invention pert~ins to the art o~ lamp bases and more particularly to a base ~or a three-way lamp.
The invention is par~icularly applicabl~ to an incandescent lamp and a method of ~o~ming a thr~e-way lamp base using a push-on contact. Mowever, it will be appreciated that the invention has broader applications and may be advantageously e~ployed in other environments and applications.
Three-way lamps are well ~nown in the industry, the general characteristics of which are described in detail in commonly assigned U.S~ Patent Nos. 3,131,9~6;
4,556,822: and, 4,605,877. These type~ of lamp~
include a ~irst or minor filamen~ and a ~econd or ~a~or filament to provide three di tinct light levels by selectively supplying current t~ the filaments individually and simultaneou~ly.
The conventional three-way lamp base has three electrical contact surfac~s. The first contact is defined by an externally threaded, gen~rally cylindrical metal sh~ll tha~ extends axially fro~ a base of a glass envelope or bulb. Th~ threaded portion of the shell cooperates with a similarly threaded regio~ in an associated lamp socket to se~ure the lamp therein.
A second metal contact is of annular configuration and is typically radially and axially spaoed from the shell by an insulating material such as glass or a the~mosettin~ plastic. The annular contact, or ring contact, is positioned for engage~ent with an axially _D 10,576 2~ ~ 98 0~
ex~ending int~rmedia~e electrode or tang defined in the socket.
Lastly, an eyelet defines a third metal contact and is also axially and radially spaced ~rom the first and second contacts by the insulating naterial. It, too, is positioned for mechanical and electrical engagement with a central ~lectrode or tang extending from the socket.
Conventionally, th~ three cont~cts are held in place in a die or mold and the in~ulating material introduced into the mold~ The insulating ~aterial is pressed and sets up hard and thereby se~ures the three contacts in a fixed, desired ralation~ Typically, projecting tangs extend from both the ey~let and interm~diate contact to ~acilitate ~ecuring the~e contacts in the insulating material. The tangs are not always properly buried or mold~d in th~ insulating material and, on occasion, the l~mp base is rej~cted on that basis. The protruding tang may inhibit proper threading of a lead wire to the annular co~tact.
According to the prior art method o assembly, the lead wire is fed throu~h an opening in the annular contact and soldered thereto, Although the solder provides ~ secure interconnection, it is de~med undesirable for a number of other reasons. For example, it is expected that forthcoming regulations will limit the amount of lead-based solder that can be used because of environmental concerns. Moreover, solder is not the most desirabla material for use as a surface con~act with the tang of an assoriated la~p socket since it flows under high stress and its application is difficult to control. Fo~ example, an ~xcessive amount of solder can inhibit propex threading of the lamp base into an associated socket.
~D 10,576 ~ 21~0~
Accordingly, an alternative method ~or ~orming three-way lamp base is desired.
~u~marv o~ th~ ~o~t~QP
The present inven~io~ contemplate~ a new and improved base for a thre~ way lamp and a method nX
forming same that overcom~s all oP the above-referenced problems and o~hers and provides a simple, dimensionally accurate structure that provide~ good elec~rical contact be~ween the lead wire and annular contact, as well as good el~ctrical contact between the annular contact and associated lamp socket tang.
According to a more limit~d aspect of the invention, a method of forming the three-way lamp base includes molding an eyelet in a first 2nd of an insulating material and a shell in a second end of the insulating material. An annular contact is subseyuently advance~ onto th~ insulating material a~ter the molding opera~ion, and a lead wire ~onnected thereto.
According to another asp2ct of the inYention ~ the insulating material has a lead wire opening formed therein during the molding step.
According to yet another aspect of the invention, a depressed area is formed in the insulating material about the lead wire opening, the lead wire deformed into the depressed area, cut to size, and secured to the annular contact.
3 0 A principal advantage of the invention is the ability to dimensionally control the location of ~he annular contact.
. :~ : ..~.:
T D 1 Q , 5 / 6 2~98~
Another advantage of the invention is found in the good elec~rical connection between the sock~t tang and annular contact.
Still other advantages and benefits of the 5 invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed description.
~ri~f DQ3Criptio~ 0~ t~ ~ra~
Tha invention may take physical form in c~rtain parts and arrangements of parts~ preferred embodiments and a method of forming same to be described in detail in this specification and illustrated i~ the 15 accompanying drawings which for~ a part hereof, nd wherein:
FIGURE 1 is a longitudinal cross-sectional view of a lamp base formed in accordance with the teachings of ~ the subject inven~ion;
FIGURE 2 is a plan view of a preferred ~orm of annular con~act;
FIGURE 3 is a plan view of another preferred embodiment of the annular contact;
FIGURE 4 is a plan view of a third preferred 25 embodiment of the annular contact;
FIGURE 5 is a plan view of a fourth pre~erred embodiment of the annular contact;
FIGURE 6 is an elevational view of another preferred embodiment; and, FIGURE 7 is a flow chart representing the various steps in forming a lamp base in accordance with the subject inventionO
De ailed De~criDtion of th~ Pre~erre~
~. ~ : :. . . .
LD 10,576 2 ~ V ~
~bo~ t~ o~
Referring now to the drawings whQrein the showings are for purposes of illustrating the preferred 5 embodiments and method of asse~bly, and not for purposes of limiting same, the FIGURES show a three-way lamp base A.
~ ore partj.cularly, and with reference to ~IGURE 1, the lamp base include~ a ~irst contact or metal shell 10 that has a generally cyl~ndrical configuration, centered about a longitudi~al axi~ ~2. An external portion of the shell is preferably threaded at 14 to facilitate mati~g receipt in a thr~aded portion of an associated lamp socket. Details of the lamp socket are not illustrated nor described since they are readily known to one of ordinary skill in the art.
A first end 20 o the ~hell is mol~ed to a irst end 22 o~ an insulating material 2~. Pre~erably, the insulating material is a glas , or a thermosetting plastic if desired, that electrically insulates and mechanically secures the first end of the ~hell. Of course it will be recognized ~ha~ ~ill other materials than glass can be used as a suitable alternative for the insulating material. A second end 26 of the insulating material secures a metal eyelet 2~. As best seen in FIGURE 1, the ~yelet i~ centrally aligned along the longitudinal axis 12 and in~ludes one or more tangs 30 that aid in securing the eyelet ~o the insulating material. Moreover, the eyelet is axially and radially 33 spaced from the shell first end 20 by th~ insulating material.
During the molding operation, the sh~ll and eyelet are held in place and the insulating material fills the void or die cavity therebetween. The die cavity will :~ 10,~76 2~80~
assume any desired configuration between the eyelet and shell but typically has a slight frusto-conical or tapered configuration to the sidewalls 32a, 32b.
Further, the insulating material has a stepped con~iguration to axially and radially space the shell from the eyelet, in addition to providing a radial shoulder adapted to receive the annular contact as will be described in greater detail below.
More par~icularly, ~he ~irst end 22 of the insulating material is of substantially the same diameter as the first end of shell 10. In fact, the shell and insulating material form a radial shoulder 3 at the shell first end. Extending axially outward fro~
the shoulder, the insulating material has a irst reduced diameter portion 36 that extends toward the second end 26 of the insulating material and terminate~
at a second radial shoulder 38. This radial shvulder is disposed generally perpendicular to the longitudinal axis ~2 and has a sub tantially planar conformation ~or receipt of an annular contact ~0. Thu~, and as shown in a first preferred embodiment of the annular contact in FIGURE 2, the annular contact has an outer periphery 42 substantially identical to the minimum diame~er of the reduced diameter portion 3C adjacent the shoulder 38. The annular contact includes an inner periphery ~4 that has a diametrical dimension slightly less than a second reduced diameter portion ~6 of the insulating material. The second reduced diameter portion also extends axially a predetermined distance toward the eyelet so as to radially and axially separate the annular contact from the eyelet. Additionally, its axial outer end 26 has a chamfered ~dge 50 that facilitates alignment of the annular contact over the ~ . - . . . . .
:. ~ .
LD 10,576 211980~
second reduced diameter portion ~5 as will be de~cribed below.
According to the pre~erred method of assembly, the shell 10 ic placed at one end of a die and the eyelet 28, with i~s securing tang 3a extending toward the shell, positioned at the other end of the di~. The insulating material is introduced into the die and i~
pressed and allowed to setup and harden or cure, so that the shell and eyelet are then axially and radially spaced from one another by thQ insulating material~
The die i5 configured to fonm the first and secon~
reduced diameter por~ions 36, 4~, respec~ively as described above.
Moreover, a lead wire opening 56 is formed in the insula~ing material and terminat~s adjac~nt radial shoulder 38, more particularly a recessed area or cutout 58 thereof. As best shown in ~IGURES 2 - 4, the recessed area 58 has opposed side walls C0, 62 that diverge angularly outward or lie parallel as ~hey extend radially from the lead wire opening toward the periphery of ~he radial should~r 3~. Moreover, the recessed area 58 has an axial dimension measured fro~
the should~r 38 that receives a lead wire 6C therein.
Thus, the shaped base when readied to the lamp, has the lead wire 66 fed through the opening 5~ in a direction generally parallel with the longitudinal axis 12. The lead wire 66 is then wiped or deform~d radially outward into the recessed area 58 wherQ a terminal end 68 of the lead wire extends radially outward from the first reduced diameter portion 3C. T~e annular contact ~0 is then advanced axially over the ~econd reduc@d diameter portion ~6. The chamfered edge ~0 facilitates alignment of the annular contact relative ~o the lamp - - ~ - . ~. :
TD 10,576 ~- 21198~
base and assists in initial mechanical deformation of the inner periphery 4~ of the contact.
As shown in FIGURES 2 - 4, either the inner periphery of the contact or the outer periphery o~ the second reduced diameter portion 46 i~ modified to provide good torque resistance and ~rictional contact.
In FIGURE 2, circumferential relie~ are~s 70, 72 provide sufficient defor~ation of the inner p~riphexy of the annular contact as it is ~xially advanced over ~he second reduced diameter portîon 46. Additionally, if desired, the second redu~ed di~meter portion may include parallel flat surfaces ~or receiving the relief areas ~n, 72 to increase the ability to re~ist rotation when the annular contact is turned against the ocket tang.
Similarly, a series of radial cu~s 74 in the inner periphery of the contact sh~wn in FIGURE 3 provide a circumferentially continuous relief reqion. Moreov~r, the reduced diameter portion ~ of the insulating material may include relief areas ~6 to stake the inner diameter of the annular contact and resist rotation when the annular contact engages the socket tang.
Alternatively, and as shown in FIGURE 4, the reduced diameter portion ~6 may have a serrated peripheral configuration 80 about which the inner diamPter ~4 of the annular contact provides a tight mechanical fit.
In FIGURES 5 and 6, axially extending tab or tabs may be provided on the outer periphery of the annular contact. In FIGURE 5, the ta~s are circumferentially spaced apart and would cooperate with corresponding grooves formed in sidewall 32~ of ~e insulation material. Again, this arrangement would resist rotation of the annular contact when it engages the T D 10, 576 21~9~
socket tang. In the e~bodiment of FIGU~E 6, the tab or skirt 79 i5 circumferentially co~tinuous and ~or~s a cap-like structure whose outer skirt 79 extends axially over ~he sidewall 32~. Prefera~ly, the skir~ does not extend over the lead wire recess 5S.
As will be appreciated fro~ a review o~ FIGURE5 2 - 6, a number o~ different configurations can be used to provide mechanical retention of the annular contact on ~he insulating material. Once the annular contact is advanced into seated relation on the radial shoulder 38, the lead wire 66, particularly the terminal end 6~, is cut or trimmed to len~th so that it doe~ not extend radially outward from the outer periphery ~2 of the contact. The lead wire and annular contact ar~ then secur~d together, preferably by an arc welding operation that provides a ~ound electrical and mechanical interconnection. :~
This arrangement ~li~inate~ conventional tangs used in three-way lamp annular ~ontact arrangemen~s where the annular contact ls molded along with the eyelet and shell in the insulating material. If solder is used to interconnect the lead wire and annular contact, the connection i~ protected by the ~nnular contact. Alternati~ely, solder need not be used and the lead wire is welded to the a~nular contact. For example, welding can be any number of different types, such as resistant welding, arc welding, discharge welding, sonic welding, etc. Moreover, with some w~lding processes, it is desired to leave an extended lenyth of wire rather than cutting the lead wire as described above. Th~ welding will melt the wire and the molten end rolls up due to surface tension to a point where the wire no longer extends outsid~ the T D l0,576 ~ 80~
annular contact but has has fused into the annular contact material. Still other means o~ securing the lead wire to the annular contact are conte~plated and deemed to fall within the scop~ and intent o~ the subject invention.
This arrangement will place solder aw y ~rom being exposed for electrical contact with an associated socket tang. ~lso, lead solder~ are ~ot desired for environmental concerns. Instead, and according to the subject invention, a more desirable ~aterial that comprises the annular contac~ is assured better electrical contact with the socket tang. Th~
dimensional control problems associated with a soldered lead wire connections are also eliminated.
As the lamp base is threadQd into an associated socke~, torque resistance is requirRd from fric~ion~l engagement betwaen the annular contac~ and the socket tang. To assure sufficient torgue resistanc~, the outer edges of the reduced diameter portion ~5 can be roughened or shaped to enhance the torque resistance.
Alternatively, t~e annular contact can be formed o~ a slightly thicker material than prior art arrangements to address these concerns. Alternatively, various combinations of securing arrangements as shown or suggested by FIGURES 2 6 can be used to maximize the mechanical connection between the contaCt and insulating glass.
FIGURE 7 summarizes the various steps of forming a lamp ba~e using a push-on annular contact. As will be understood, the details of the method as described above are applicable to any one of the annular contact embodiments of FIGURES 2 - 6. Moreover, the particular configurations of the insulating ma~erial, contact , T.D 10,576 ~19~0~
etc. do not impact on t~ese s~ep~ as g~nerally outlined in FIGURE 7.
T~e invention has been described with reference to the preferred embodiments and method. Obviously, modi~ica~ions and al~erations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifi~tions and alterations incofar as they come within the scope of the appended claims or the equivalent~ thereof.
T~ WAY IJ~P laAlB~ OM CO~S!AC:T
A~D ~T~OD OF FOR~ ~NB
Back~rou~ o~ th3 ~y~n~lQ~
This invention pert~ins to the art o~ lamp bases and more particularly to a base ~or a three-way lamp.
The invention is par~icularly applicabl~ to an incandescent lamp and a method of ~o~ming a thr~e-way lamp base using a push-on contact. Mowever, it will be appreciated that the invention has broader applications and may be advantageously e~ployed in other environments and applications.
Three-way lamps are well ~nown in the industry, the general characteristics of which are described in detail in commonly assigned U.S~ Patent Nos. 3,131,9~6;
4,556,822: and, 4,605,877. These type~ of lamp~
include a ~irst or minor filamen~ and a ~econd or ~a~or filament to provide three di tinct light levels by selectively supplying current t~ the filaments individually and simultaneou~ly.
The conventional three-way lamp base has three electrical contact surfac~s. The first contact is defined by an externally threaded, gen~rally cylindrical metal sh~ll tha~ extends axially fro~ a base of a glass envelope or bulb. Th~ threaded portion of the shell cooperates with a similarly threaded regio~ in an associated lamp socket to se~ure the lamp therein.
A second metal contact is of annular configuration and is typically radially and axially spaoed from the shell by an insulating material such as glass or a the~mosettin~ plastic. The annular contact, or ring contact, is positioned for engage~ent with an axially _D 10,576 2~ ~ 98 0~
ex~ending int~rmedia~e electrode or tang defined in the socket.
Lastly, an eyelet defines a third metal contact and is also axially and radially spaced ~rom the first and second contacts by the insulating naterial. It, too, is positioned for mechanical and electrical engagement with a central ~lectrode or tang extending from the socket.
Conventionally, th~ three cont~cts are held in place in a die or mold and the in~ulating material introduced into the mold~ The insulating ~aterial is pressed and sets up hard and thereby se~ures the three contacts in a fixed, desired ralation~ Typically, projecting tangs extend from both the ey~let and interm~diate contact to ~acilitate ~ecuring the~e contacts in the insulating material. The tangs are not always properly buried or mold~d in th~ insulating material and, on occasion, the l~mp base is rej~cted on that basis. The protruding tang may inhibit proper threading of a lead wire to the annular co~tact.
According to the prior art method o assembly, the lead wire is fed throu~h an opening in the annular contact and soldered thereto, Although the solder provides ~ secure interconnection, it is de~med undesirable for a number of other reasons. For example, it is expected that forthcoming regulations will limit the amount of lead-based solder that can be used because of environmental concerns. Moreover, solder is not the most desirabla material for use as a surface con~act with the tang of an assoriated la~p socket since it flows under high stress and its application is difficult to control. Fo~ example, an ~xcessive amount of solder can inhibit propex threading of the lamp base into an associated socket.
~D 10,576 ~ 21~0~
Accordingly, an alternative method ~or ~orming three-way lamp base is desired.
~u~marv o~ th~ ~o~t~QP
The present inven~io~ contemplate~ a new and improved base for a thre~ way lamp and a method nX
forming same that overcom~s all oP the above-referenced problems and o~hers and provides a simple, dimensionally accurate structure that provide~ good elec~rical contact be~ween the lead wire and annular contact, as well as good el~ctrical contact between the annular contact and associated lamp socket tang.
According to a more limit~d aspect of the invention, a method of forming the three-way lamp base includes molding an eyelet in a first 2nd of an insulating material and a shell in a second end of the insulating material. An annular contact is subseyuently advance~ onto th~ insulating material a~ter the molding opera~ion, and a lead wire ~onnected thereto.
According to another asp2ct of the inYention ~ the insulating material has a lead wire opening formed therein during the molding step.
According to yet another aspect of the invention, a depressed area is formed in the insulating material about the lead wire opening, the lead wire deformed into the depressed area, cut to size, and secured to the annular contact.
3 0 A principal advantage of the invention is the ability to dimensionally control the location of ~he annular contact.
. :~ : ..~.:
T D 1 Q , 5 / 6 2~98~
Another advantage of the invention is found in the good elec~rical connection between the sock~t tang and annular contact.
Still other advantages and benefits of the 5 invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed description.
~ri~f DQ3Criptio~ 0~ t~ ~ra~
Tha invention may take physical form in c~rtain parts and arrangements of parts~ preferred embodiments and a method of forming same to be described in detail in this specification and illustrated i~ the 15 accompanying drawings which for~ a part hereof, nd wherein:
FIGURE 1 is a longitudinal cross-sectional view of a lamp base formed in accordance with the teachings of ~ the subject inven~ion;
FIGURE 2 is a plan view of a preferred ~orm of annular con~act;
FIGURE 3 is a plan view of another preferred embodiment of the annular contact;
FIGURE 4 is a plan view of a third preferred 25 embodiment of the annular contact;
FIGURE 5 is a plan view of a fourth pre~erred embodiment of the annular contact;
FIGURE 6 is an elevational view of another preferred embodiment; and, FIGURE 7 is a flow chart representing the various steps in forming a lamp base in accordance with the subject inventionO
De ailed De~criDtion of th~ Pre~erre~
~. ~ : :. . . .
LD 10,576 2 ~ V ~
~bo~ t~ o~
Referring now to the drawings whQrein the showings are for purposes of illustrating the preferred 5 embodiments and method of asse~bly, and not for purposes of limiting same, the FIGURES show a three-way lamp base A.
~ ore partj.cularly, and with reference to ~IGURE 1, the lamp base include~ a ~irst contact or metal shell 10 that has a generally cyl~ndrical configuration, centered about a longitudi~al axi~ ~2. An external portion of the shell is preferably threaded at 14 to facilitate mati~g receipt in a thr~aded portion of an associated lamp socket. Details of the lamp socket are not illustrated nor described since they are readily known to one of ordinary skill in the art.
A first end 20 o the ~hell is mol~ed to a irst end 22 o~ an insulating material 2~. Pre~erably, the insulating material is a glas , or a thermosetting plastic if desired, that electrically insulates and mechanically secures the first end of the ~hell. Of course it will be recognized ~ha~ ~ill other materials than glass can be used as a suitable alternative for the insulating material. A second end 26 of the insulating material secures a metal eyelet 2~. As best seen in FIGURE 1, the ~yelet i~ centrally aligned along the longitudinal axis 12 and in~ludes one or more tangs 30 that aid in securing the eyelet ~o the insulating material. Moreover, the eyelet is axially and radially 33 spaced from the shell first end 20 by th~ insulating material.
During the molding operation, the sh~ll and eyelet are held in place and the insulating material fills the void or die cavity therebetween. The die cavity will :~ 10,~76 2~80~
assume any desired configuration between the eyelet and shell but typically has a slight frusto-conical or tapered configuration to the sidewalls 32a, 32b.
Further, the insulating material has a stepped con~iguration to axially and radially space the shell from the eyelet, in addition to providing a radial shoulder adapted to receive the annular contact as will be described in greater detail below.
More par~icularly, ~he ~irst end 22 of the insulating material is of substantially the same diameter as the first end of shell 10. In fact, the shell and insulating material form a radial shoulder 3 at the shell first end. Extending axially outward fro~
the shoulder, the insulating material has a irst reduced diameter portion 36 that extends toward the second end 26 of the insulating material and terminate~
at a second radial shoulder 38. This radial shvulder is disposed generally perpendicular to the longitudinal axis ~2 and has a sub tantially planar conformation ~or receipt of an annular contact ~0. Thu~, and as shown in a first preferred embodiment of the annular contact in FIGURE 2, the annular contact has an outer periphery 42 substantially identical to the minimum diame~er of the reduced diameter portion 3C adjacent the shoulder 38. The annular contact includes an inner periphery ~4 that has a diametrical dimension slightly less than a second reduced diameter portion ~6 of the insulating material. The second reduced diameter portion also extends axially a predetermined distance toward the eyelet so as to radially and axially separate the annular contact from the eyelet. Additionally, its axial outer end 26 has a chamfered ~dge 50 that facilitates alignment of the annular contact over the ~ . - . . . . .
:. ~ .
LD 10,576 211980~
second reduced diameter portion ~5 as will be de~cribed below.
According to the pre~erred method of assembly, the shell 10 ic placed at one end of a die and the eyelet 28, with i~s securing tang 3a extending toward the shell, positioned at the other end of the di~. The insulating material is introduced into the die and i~
pressed and allowed to setup and harden or cure, so that the shell and eyelet are then axially and radially spaced from one another by thQ insulating material~
The die i5 configured to fonm the first and secon~
reduced diameter por~ions 36, 4~, respec~ively as described above.
Moreover, a lead wire opening 56 is formed in the insula~ing material and terminat~s adjac~nt radial shoulder 38, more particularly a recessed area or cutout 58 thereof. As best shown in ~IGURES 2 - 4, the recessed area 58 has opposed side walls C0, 62 that diverge angularly outward or lie parallel as ~hey extend radially from the lead wire opening toward the periphery of ~he radial should~r 3~. Moreover, the recessed area 58 has an axial dimension measured fro~
the should~r 38 that receives a lead wire 6C therein.
Thus, the shaped base when readied to the lamp, has the lead wire 66 fed through the opening 5~ in a direction generally parallel with the longitudinal axis 12. The lead wire 66 is then wiped or deform~d radially outward into the recessed area 58 wherQ a terminal end 68 of the lead wire extends radially outward from the first reduced diameter portion 3C. T~e annular contact ~0 is then advanced axially over the ~econd reduc@d diameter portion ~6. The chamfered edge ~0 facilitates alignment of the annular contact relative ~o the lamp - - ~ - . ~. :
TD 10,576 ~- 21198~
base and assists in initial mechanical deformation of the inner periphery 4~ of the contact.
As shown in FIGURES 2 - 4, either the inner periphery of the contact or the outer periphery o~ the second reduced diameter portion 46 i~ modified to provide good torque resistance and ~rictional contact.
In FIGURE 2, circumferential relie~ are~s 70, 72 provide sufficient defor~ation of the inner p~riphexy of the annular contact as it is ~xially advanced over ~he second reduced diameter portîon 46. Additionally, if desired, the second redu~ed di~meter portion may include parallel flat surfaces ~or receiving the relief areas ~n, 72 to increase the ability to re~ist rotation when the annular contact is turned against the ocket tang.
Similarly, a series of radial cu~s 74 in the inner periphery of the contact sh~wn in FIGURE 3 provide a circumferentially continuous relief reqion. Moreov~r, the reduced diameter portion ~ of the insulating material may include relief areas ~6 to stake the inner diameter of the annular contact and resist rotation when the annular contact engages the socket tang.
Alternatively, and as shown in FIGURE 4, the reduced diameter portion ~6 may have a serrated peripheral configuration 80 about which the inner diamPter ~4 of the annular contact provides a tight mechanical fit.
In FIGURES 5 and 6, axially extending tab or tabs may be provided on the outer periphery of the annular contact. In FIGURE 5, the ta~s are circumferentially spaced apart and would cooperate with corresponding grooves formed in sidewall 32~ of ~e insulation material. Again, this arrangement would resist rotation of the annular contact when it engages the T D 10, 576 21~9~
socket tang. In the e~bodiment of FIGU~E 6, the tab or skirt 79 i5 circumferentially co~tinuous and ~or~s a cap-like structure whose outer skirt 79 extends axially over ~he sidewall 32~. Prefera~ly, the skir~ does not extend over the lead wire recess 5S.
As will be appreciated fro~ a review o~ FIGURE5 2 - 6, a number o~ different configurations can be used to provide mechanical retention of the annular contact on ~he insulating material. Once the annular contact is advanced into seated relation on the radial shoulder 38, the lead wire 66, particularly the terminal end 6~, is cut or trimmed to len~th so that it doe~ not extend radially outward from the outer periphery ~2 of the contact. The lead wire and annular contact ar~ then secur~d together, preferably by an arc welding operation that provides a ~ound electrical and mechanical interconnection. :~
This arrangement ~li~inate~ conventional tangs used in three-way lamp annular ~ontact arrangemen~s where the annular contact ls molded along with the eyelet and shell in the insulating material. If solder is used to interconnect the lead wire and annular contact, the connection i~ protected by the ~nnular contact. Alternati~ely, solder need not be used and the lead wire is welded to the a~nular contact. For example, welding can be any number of different types, such as resistant welding, arc welding, discharge welding, sonic welding, etc. Moreover, with some w~lding processes, it is desired to leave an extended lenyth of wire rather than cutting the lead wire as described above. Th~ welding will melt the wire and the molten end rolls up due to surface tension to a point where the wire no longer extends outsid~ the T D l0,576 ~ 80~
annular contact but has has fused into the annular contact material. Still other means o~ securing the lead wire to the annular contact are conte~plated and deemed to fall within the scop~ and intent o~ the subject invention.
This arrangement will place solder aw y ~rom being exposed for electrical contact with an associated socket tang. ~lso, lead solder~ are ~ot desired for environmental concerns. Instead, and according to the subject invention, a more desirable ~aterial that comprises the annular contac~ is assured better electrical contact with the socket tang. Th~
dimensional control problems associated with a soldered lead wire connections are also eliminated.
As the lamp base is threadQd into an associated socke~, torque resistance is requirRd from fric~ion~l engagement betwaen the annular contac~ and the socket tang. To assure sufficient torgue resistanc~, the outer edges of the reduced diameter portion ~5 can be roughened or shaped to enhance the torque resistance.
Alternatively, t~e annular contact can be formed o~ a slightly thicker material than prior art arrangements to address these concerns. Alternatively, various combinations of securing arrangements as shown or suggested by FIGURES 2 6 can be used to maximize the mechanical connection between the contaCt and insulating glass.
FIGURE 7 summarizes the various steps of forming a lamp ba~e using a push-on annular contact. As will be understood, the details of the method as described above are applicable to any one of the annular contact embodiments of FIGURES 2 - 6. Moreover, the particular configurations of the insulating ma~erial, contact , T.D 10,576 ~19~0~
etc. do not impact on t~ese s~ep~ as g~nerally outlined in FIGURE 7.
T~e invention has been described with reference to the preferred embodiments and method. Obviously, modi~ica~ions and al~erations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifi~tions and alterations incofar as they come within the scope of the appended claims or the equivalent~ thereof.
Claims (19)
1. A method of forming a three-way lamp base having an eyelet, shell, and annular contact electrically insulated from one another by an insulating material, said method comprising the steps providing an eyelet and a shell;
molding said eyelet in a first end of said insulating material and said shell in a second end of said insulating material;
providing an annular contact;
advancing said annular contact on said insulating material after said molding step; and connecting a lead wire to said annular contact.
molding said eyelet in a first end of said insulating material and said shell in a second end of said insulating material;
providing an annular contact;
advancing said annular contact on said insulating material after said molding step; and connecting a lead wire to said annular contact.
2. A method of forming a three-way lamp base as defined in claim 1 comprising the further step of forming a lead wire opening in the insulating material during said molding step.
3. A method of forming a three-way lamp base as defined in claim 1 comprising the further step of forming a radial shoulder on said insulating material generally perpendicular to a longitudinal axis of said shell to receive said annular contact.
4. A method of forming a three-way lamp base as defined in claim 1 wherein said advancing step includes the further step of deforming an inner periphery of said annular contact to mechanically connect said annular contact to said insulating material.
5. A method of forming a three-way lamp base as defined in claim 1 wherein said connecting step includes the further steps of forming a lead wire opening in said insulating material during said molding step and forming a recessed area in said insulating material to receive said lead wire prior to said advancing step.
6. A method of forming a three-way lamp base as defined in claim 5 comprising the further step of deforming said lead wire into said recessed area for receiving said annular contact thereover prior to said connecting step.
7. A method of forming a three-way lamp base as defined in claim 6 comprising the further step of cutting said lead wire after said deforming step to prevent extension of said lead wire from said insulating material.
8. A method of forming a three-way lamp base as defined in claim 1 wherein said connecting step includes welding said lead wire to said annular contact.
9. A method of forming a three-way lamp base having an eyelet, a cylindrical shell having a longitudinal axis, and an annular contact that is axially and radially spaced from both said eyelet and shell by an insulating material, the method comprising the steps of:
molding said eyelet and said shell on opposite ends of said insulating material with a radially extending shoulder interposed between said eyelet and said shell, and said insulating material having a first diameter portion from said eyelet to said shoulder for receiving said annular contact thereover;
advancing said annular contact over said eyelet and said first diameter portion into engagement with said shoulder after said insulating material has hardened;
providing a lead wire that extends through said insulating material and exits said insulating material at said shoulder: and securing said lead wire to said annular contact.
molding said eyelet and said shell on opposite ends of said insulating material with a radially extending shoulder interposed between said eyelet and said shell, and said insulating material having a first diameter portion from said eyelet to said shoulder for receiving said annular contact thereover;
advancing said annular contact over said eyelet and said first diameter portion into engagement with said shoulder after said insulating material has hardened;
providing a lead wire that extends through said insulating material and exits said insulating material at said shoulder: and securing said lead wire to said annular contact.
10. A method of forming a three-way lamp base as defined in claim 9 wherein said molding step includes the step of forming an opening for said lead wire through said insulating material.
11. A method of forming a three-way lamp base as defined in claim 10 wherein said lead wire opening forming step includes the further step of forming a recess in said shoulder for receiving said lead wire beneath said annular contact.
12. A method of forming a three way lamp base as defined in claim 11 comprising the further step of deforming said lead wire into said recess.
13. A method of forming a three-way lamp base as defined in claim 12 comprising the further step of cutting said lead wire so that it does not extend outwardly from the first diameter portion.
14. A method of forming a three-way lamp base as defined in claim 13 wherein said securing step includes welding said annular contact to said lead wire.
15. A method of forming a three-way lamp base as defined in claim 9 wherein said securing step includes welding said annular contact to said lead wire.
16. A method of forming a three-way lamp base as defined in claim g wherein said advancing step includes the step of mechanically deforming an inner peripheral portion of said annular contact around said first diameter portion.
17. A base for a three-way lamp that includes first, second and third lead wires associated with first and second filaments, said base comprising:
a shell having a first end adapted for connection with said first lead wire and a second end spaced along a longitudinal axis from said first end;
an insulating material molded to said shell second end and having a stepped configuration defining first and second radial shoulders as it extends axially outwardly from said shell, said first radial shoulder including a recess receiving said second lead wire;
an annular contact received on said first radial shoulder and overlying said second lead wire, said annular contact and second lead wire being mechanically and electrically secured together; and an eyelet disposed on said second radial shoulder and secured to said insulating material.
a shell having a first end adapted for connection with said first lead wire and a second end spaced along a longitudinal axis from said first end;
an insulating material molded to said shell second end and having a stepped configuration defining first and second radial shoulders as it extends axially outwardly from said shell, said first radial shoulder including a recess receiving said second lead wire;
an annular contact received on said first radial shoulder and overlying said second lead wire, said annular contact and second lead wire being mechanically and electrically secured together; and an eyelet disposed on said second radial shoulder and secured to said insulating material.
18. A base for a three-way lamp as defined in claim 17 wherein said insulating material and said annular contact have cooperating surfaces that mechanically hold said annular contact against said first radial shoulder.
19. A base for a three-way lamp as defined in claim 17 wherein an inner periphery of said annular contact has plural relief areas that deform over said insulating material and hold aid annular contact against said first radial shoulder.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US4484293A | 1993-04-08 | 1993-04-08 | |
| US08/044,842 | 1993-04-08 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2119804A1 true CA2119804A1 (en) | 1994-10-09 |
Family
ID=21934625
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2119804 Abandoned CA2119804A1 (en) | 1993-04-08 | 1994-03-24 | Three-way lamp base using a push-on contact and method of forming same |
Country Status (2)
| Country | Link |
|---|---|
| CA (1) | CA2119804A1 (en) |
| GB (1) | GB2277580A (en) |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB963316A (en) * | 1961-08-28 | 1964-07-08 | Sylvania Electric Prod | Incandescent lamp base |
| US3296400A (en) * | 1966-03-07 | 1967-01-03 | John A Kienzle | Light bulbs, fuses and the like |
| US4398130A (en) * | 1979-12-27 | 1983-08-09 | General Electric Company | Arc lamp lighting unit with low and high light levels |
| US4348612A (en) * | 1981-02-06 | 1982-09-07 | Westinghouse Electric Corp. | Compact fluorescent lamp unit for three-way fluorescent lamp fixture |
| US4556882A (en) * | 1982-11-15 | 1985-12-03 | Eaton Corporation | Remote control circuit breaker system with on-off-tripped-problem status storage and indication |
| NL8902438A (en) * | 1989-01-31 | 1990-08-16 | Philips Nv | ELECTRIC LAMP. |
-
1994
- 1994-03-24 CA CA 2119804 patent/CA2119804A1/en not_active Abandoned
- 1994-04-06 GB GB9406811A patent/GB2277580A/en not_active Withdrawn
Also Published As
| Publication number | Publication date |
|---|---|
| GB9406811D0 (en) | 1994-05-25 |
| GB2277580A (en) | 1994-11-02 |
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