WO2010023682A1

WO2010023682A1 - Incandescent lamp and socket assembly

Info

Publication number: WO2010023682A1
Application number: PCT/IN2009/000394
Authority: WO
Inventors: Ramchandra Shrikrishna Bhagwat
Original assignee: Ramchandra Shrikrishna Bhagwat
Priority date: 2008-07-11
Filing date: 2009-07-10
Publication date: 2010-03-04

Abstract

The invention discloses an improved lamp assembly for automobile halogen lamps/bulbs which is simple to construct and easy to assemble. The invention also discloses a method of assembling incandescent lamp and socket assembly which is easy to manufacture. The incandescent lamp and socket assembly is constructed by assembling four subassemblies: a capsule (1) comprising filament (2), flat end (3) and projections (4); an adapter (5) comprising cylindrical surface (5') and flaps (6); a base socket (7) comprising base (8), horizontal fiat surface (9), and connection prongs (14); lugs (12) comprising flat end (10) and semi spherical surface (11).

Description

INCANDESCENT LAMP AND SOCKET ASSEMBLY

FIELD OF THE INVENTION

The present invention relates to incandescent lamps and socket assembly. The present invention particularly relates to incandescent automobile halogen lamps. The present invention also relates to the method of assembling incandescent lamp and socket thereof. The incandescent lamp and socket assembly of the present invention is simple to construct and easy to assemble.

BACKGROUND AND PRIOR ART OF THE INVENTION

The incandescent/halogen lamps used for the front lighting of an automobile need to have a typical characteristic, that is, precise location of the light source, the filament. The front lighting or the headlight of the automobile needs to have sufficient illumination spread in front of the automobile and at the same time this illumination spread should not create glare to up coming traffic. For this the alignment of the filament should be appropriate vis-a-vis the reference plane and the reference axis of the lamp assembly. The alignment/position of the filament of the lamp with respect to the reflector is of utmost importance for the required light distribution emanating from the headlight beam. This objective is achieved by the design of the head lamp beam and the precise position of the light source, the filament inside the automobile lamp or bulb.

Various attempts have been made in the past for achieving the precise positioning of the light source, the halogen; for example the present conventional assembly used described in Figure-1 (prior art) which comprises in combination, capsule, adapter and collar assembly and socket. The conventional assembly as described in Figure- 1 comprises a single ended capsule (1) having a press seal thereof. One or more filaments are located inside the capsule, and current connection leads extend from the press seal. A cylindrical cup portion (5) with a slit on the top portion thereof for receiving the press seal portion of said capsule is provided. The socket means is closed at one end with an insulated material in which the said current connection leads are embedded, the open upper portion of the socket means receives said cup in a snug yet adjustable manner. The socket has one or more vertical weld means for weldably connecting said socket means to said cup, and one or more horizontal weld means located between said vertical weld means. A pair of connection prongs extend outwardly and downwardly from said insulating material. There is also provided a hollow stepped ring with a stepped annular ring means and a flat collar means, the stepped ring means receiving in its hollow portion, the socket means in a sealed relationship. The said horizontal weld means is weldably sealed on the top surface of said stepped annular ring.

The disadvantages of the prior art lamp assembly of Figure- 1 is that during the assembly glass capsule (1) the filament (2) is fitted in the adaptor (5). During this fitment flaps (6) of the adaptor lock on the outward projections (4) on the flat end (3) of the glass capsule. This sub-assembly in the still inside the adjustment sleeve 7. The final position of the filament after the complete assembly of the lamp needs to be at precise level. The vertical distance from the reference plane of the base socket (10). For example in Figure- 1 which depicts a H7 lamp (H7 Lamp is a typical single filament automobile halogen lamp specified by the European specification E.C.E. regulation 37), the reference plane in such a case is formed by top surface of the three projected flat surfaces (13). During the assembling of the existing lamps such as shown in Figure-1, first the capsule (1) containing the filament (2) is fitted in the adaptor (5) and then this subassembly is placed inside the adjustment sleeve (7). The position of the subassembly of the capsule and the adaptor inside the adjustment sleeve is adjusted in such a way that the filament is made parallel to the reference axis (this is done by swiveliπg this sub assembly around two axes perpendicular to each other in a horizontal plane) and the filament is at a "predetermined level" from the secondary reference plane which is the bottom surface of the flat end (8) of the adjustment sleeve. This "predetermined level" is the final level of the filament from the reference plane of the lamp minus the height of the adjustment sleeve. Once the welding is done, this subassembly of filament holding capsule, adaptor and adjustment sleeve is then placed on the flat surface (11) of the base socket (10) and a lateral adjustment for the filament position with respect to reference axis is done by sliding the bottom surface of the flat end (8) of the adjustment sleeve on the flat surface (11) of the base socket so that the filament axis is aligned with the reference axis.

The disadvantage of this assembly process is that there needs to be sufficient clearance between inside diameter (9) of the adjustment sleeve (7) and the outside diameter (5) of the adaptor so as to enable the swiveling adjustment as explained above to make the filament parallel to the reference axis. This clearance affects the quality of welding as proper contact is not possible between the cylindrical surfaces of the adjustment sleeve and the adaptor. If the clearance is reduced to have proper contact, then the swiveling adjustment is restricted.

U.S. patent no. 4,622,486 [Endo et al.) also has a similar disadvantage for swiveling adjustment as described above. The parts in consideration therein are referred by numerals 42, 52 and 56. It discloses (line 45, page 4) " when the supporting portion 52 is being moved on the base 56, the filament are positioned in a lateral direction ". During the description of the invention, there is no mention of the swiveling adjustment around two axes perpendicular to each other in a horizontal plane to correct and adjust the tilted filament. Moreover, another disadvantage here is that the lateral adjustment is made by sliding the flat ends of the capsule holder 52 over the flat surface of the intermediate member 56. But this adjustment is restricted by the opening in the intermediate member to receive flat end of the capsule 10a.

Indian Patent No. 196848 (Application no. 110/DEL/2000) discloses that the adaptor flaps are shed on the flat end of the adjustment collar. This sliding adjustment is restricted by the opening in the adjustment collar to receive the flat ends of the capsule. Sleeve with the flat surfaces (11) of the socket the precise positioning of the filament with respect to reference plane is achieved. Adjustment sleeve is sheet metal press part and does have some manufacturing tolerance. This tolerance and the variation in the light of the adjustment sleeve due to this tolerance create error in the precise positioning of the filament with respect to the reference plane.

It is also necessary that the filament should be parallel and/or aligned with respect to the reference axis of the base. In Figure- 1 which depicts H7 lamp construction the reference axis is perpendicular to the reference plane and passing through the center of the reference diameter outside diameter of the cylindrical portion (11).

During the assembly of the filament holding capsule, adaptor and adjustment sleeve, to make the filament fall on the reference axis, the sub-assembly of capsule and adaptor is tilted by swiveling this subassembly around two axes perpendicular to each other in a horizontal plane. However, the surfaces of the cylindrical portion of the adaptor (5) and the adjustment sleeve (9) to be welded after the adjustment are vertical and cylindrical and it is difficult to have proper contacts for the welding purposes. If there is no clearance between outside diameter of the adaptor and inside diameter of the adjustment sleeve, the swiveling adjustment as mentioned above is restricted. By providing clearance to make the swiveling adjustment the present invention overcomes the disadvantages of the prior art lamp assemblies. OBJECTS OF THE INVENTION

The primary object of the invention is to provide for an improved lamp assembly for automobile halogen lamps/bulbs which is simple to construct and easy to assemble. It is, therefore an object of the invention to provide for an improved lamp assembly for automobile halogen lamps/bulbs capable of adjustments of constituents parts during its assembly for the appropriate/precise positioning of the light source (filament) to optimum focus with respect to the reference plane and reference axis of the base socket, i.e., simultaneous lateral movement along the two axes perpendicular to each other in a horizontal plane and also swiveling adjustment around these two perpendicular axes.

Another object of the invention is to provide for an improved lamp assembly for automobile halogen lamps/bulbs having separate lugs which are contacted and weldably attached to the lamp assembly and thereby provide for the appropriate/precise positioning of the light source (filament) with respect to the reference plane and reference axis of the base socket.

It is a further object of the invention to provide for a method of assembling incandescent lamp and socket assembly which is easy to manufacture. SUMMARY OF THE INVENTION

Accordingly, the present invention relates to an improved incandescent lamp and socket assembly comprising in combination:

(i) a single ended capsule having one or more filaments located inside the capsule, a flat end containing projections and electrical connection leads extending from the said flat end for supplying power to the filament;

(ii) an adapter means, with downwardly or upwardly extending side walls with a slit for receiving the said flat end of the capsule; wherein the adapter means has flaps in the inner portion complementary to the projections of the said flat end of the capsule for snugly fitting the capsule;

(iii) a base socket means, in which the said electrical connection leads are embedded, the upper portion receiving the said adapter means in a snug yet adjustable manner, a pair of connection prongs extending outwardly from the lower portion of the socket; and

(iv) a plurality of separate lugs having one flat end and another semi-spherical surface, wherein the said lugs are positioned outside the capsule-adapter-socket subassembly and weldably attached to said adapter and socket.

In a preferred embodiment of the invention, the said flat end of the said lugs is weldably attached to the flat horizontal surface of the base socket and the said semi- spherical surface of the said lugs is weldably attached to said outer side walls/cylindrical surface of the adaptor means.

In another preferred embodiment of the invention, the said lugs are contacted with the said adapter and socket in an adjustable manner, wherein the said semi spherical surface of the lugs make proper contact with the cylindrical surface of the adaptor even if the said adaptor is tilted or is exactly vertical.

In yet another preferred embodiment of the invention, the said lugs are fixed and weldably attached to the capsule-adapter-socket subassembly after appropriately positioning the filament with respect to the reference plane and reference axis of the base socket at a position of optimum focus.

The present invention also relates to a method of assembling incandescent lamp and socket assembly comprising:

(i) Inserting the flat end of the capsule containing filament and electrical connection leads through the upper portion of the adapter means to form a capsule-adapter subassembly, wherein the projections on the flat end of the said capsule gets locked with the complementary flaps of the said adaptor;

(ii) the capsule-adapter subassembly of step (i) is simultaneously adjusted along the vertical axis of the adaptor and along the two axes perpendicular to each other in a horizontal plane adjusted by lateral movement and swiveling adjustment around these two perpendicular axes in horizontal plane;

(in) after the adjustments of step (ii) the capsule-adapter subassembly is then moved inside the open space inside the inner diameter of the base socket to form a capsule- adapter-socket subassembly; (iv) the capsule-adapter-socket subassembly of step (iii) is simultaneously adjusted by vertical adjustment along the vertical axis parallel to the reference axis, swiveling adjustments around two axes perpendicular to each other and perpendicular to the reference axis, and the lateral adjustment along the two axes perpendicular to each other and perpendicular to reference axis so as to position the filament exactly at the required position of optimum focus;

(v) a plurality of separate lugs having one flat end and another semi-spherical end are brought together and weldably attached to the capsule-adapter-socket subassembly of step (iv) to form the complete incandescent lamp and socket assembly.

In a preferred embodiment the said lugs are weldably attached to the capsule- adapter-socket subassembly after appropriately positioning the filament with respect to the reference plane and reference axis of the base socket at a position of optimum focus.

In a further preferred embodiment, the said flat end of the lugs is preferably welded to the flat horizontal surface of the base socket and the said semi-spherical surface is preferably welded to the said cylindrical surface of the adaptor. BRIEF DESCRIPTION OF THE DRAWINGS

Figure- 1 : Prior art incandescent lamp assembly.

Figure-2: Exploded view of the Lamp assembly of the present invention. Figure-3: Exploded and enlarged view of the separate lug (12) of the present invention as shown and labeled in Figure-2.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides for an improved and simple to manufacture lamp assembly as shown in Figure-2 and Figure-3. The preferred embodiment of the present invention is described herein below with respect to the accompanying drawings. Figure-2 is an exploded view of the lamp assembly of the present invention. The preferred lamp of the present invention as depicted in Figure-2 is constructed by assembling following four subassemblies in the manner hereinafter described:

(i) a capsule (1) comprising filament (2), flat end (3) and projections (4); (ii) an adapter (5) comprising cylindrical surface (5') and flaps (6); (iii)a base socket (7) comprising base (8), horizontal flat surface (9), and connection prongs (14)

(iv)lugs (12) comprising flat end (10) and semi spherical surface (1 1). The capsule (1) containing filament (2) is fitted inside the adaptor (5), wherein the flaps (6) of the said adaptor gets locked on the projections (4) of the flat end (3) of the said capsule. The capsule also has electrical connection leads (13) extending from the said flat end (3) which provides power supply to the filament.

The capsule-adapter subassembly is then adjusted along the vertical axis of the adaptor and at the same time adjusted by lateral movement along the two axes perpendicular to each other in a horizontal plane and also swiveling adjustment around these two perpendicular axes in horizontal plane. AU these adjustment namely along the vertical axis along and around the two axes perpendicular to each in horizontal plane are done simultaneously.

After these adjustments the capsule-adapter subassembly is fitted to the base socket (7) to form a capsule-adapter-socket subassembly. While the capsule-adapter subassembly is moved inside the open space inside the inner diameter of the base socket (7) all the adjustments, namely vertical adjustment along the vertical axis parallel to the reference axis, swiveling adjustments around two axes perpendicular to each other and perpendicular to the reference axis, and the lateral adjustment along the two axes perpendicular to each other and perpendicular to reference axis are made simultaneously so as to position the filament exactly at the required position of optimum focus from the reference plane and reference axis. All these adjustments are done simultaneously and without any restrictions while attaching the capsule-adapter subassembly to the base socket (7) and to bring the filament to appropriate/precise position with respect to the base socket (7), i.e., with the reference plane of the base socket and the reference axis.

Then a plurality of separate lugs (12) as shown in Figure-3, which have a flat end (10) and a semi-spherical surface (11) are brought together and affixed with the capsule-adapter-socket subassembly to form the complete incandescent lamp and socket assembly of the invention. The lugs are joined preferably by welding to the capsule-adapter-socket subassembly in an adjustable manner so as to make proper contact with both adapter and socket. The configuration of the lugs (12) is such that it provides flexibility for adjustment of the filament at a point of optimum focus, but at the same time it also rigidly holds the capsule-adapter-socket subassembly in place. The lugs (12) are contacted with the base socket (7) by keeping its' flat end (10) parallel to the flat horizontal surface (9) of the base socket (7). The lugs (12) are contacted with the adaptor (5) by bringing its' semi-spherical surface (11) in contact with the cylindrical surface (5') of the adaptor (5). In this arrangement the semi spherical surface (11) of the lugs (12) make good contact with the cylindrical surface (5') of the adaptor (5) even if the said adaptor is tilted or is exactly vertical. Moreover, the flat end (10) of the lugs (12) makes good contact with the flat surface (9) of the base socket (7). During such adjustment there is no restriction to the adjustment along the vertical and horizontal axes and around horizontal axes. When such adjustment is complete then welding is done between the spherical surface (1 1) of the lugs (12) and the cylindrical surface (5') of the adaptor (5). Simultaneously the welding is done between the flat surface (10) of the lugs (12) with the flat surface (9) of the base socket

(7).

In view of the foregoing, the improved incandescent lamp and socket assembly of the present invention comprises, in combination:

• a single ended capsule having one or more filaments located inside the capsule, a flat end containing projections and electrical connection leads extending from the said flat end for supplying power to the filament;

• an adapter means, with downwardly or upwardly extending side walls with a slit for receiving the said flat end of the capsule; wherein the adapter means has flaps in the inner portion complementary to the projections of the said flat end of the capsule for snugly fitting the capsule;

• a base socket means, in which the said electrical connection leads are embedded, the upper portion receiving the said adapter means in a snug yet adjustable manner, a pair of connection prongs extending outwardly from the lower portion of the socket; and • a plurality of separate lugs having one flat end and another semi-spherical surface, wherein the said lugs are positioned outside the capsule-adapter-socket subassembly and weldably attached to said adapter and socket.

The construction of the present invention is very simple, easy to manufacture and is without any restriction/limitation for the appropriate/precise positioning of the light source, the filament, with respect to the reference plane and reference axis of the base socket. The configuration and adjustment of the lamp assembly is so simple that it can be conveniently employed with different forms of socket assemblies.

The disclosed configurations, arrangements, method and embodiments are examples only. Therefore, other suitable variations may be implemented to practice the invention. While, the lamp assembly and method of its construction is described herein as a preferred embodiment, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the scope of the invention. In particular the number, dimensions, shape, configuration and attaching means of separate lugs can be altered, reversed, modified and varied within the scope of the invention.

Claims

We Claim:

1. An improved incandescent lamp and socket assembly comprising in combination:

(i) a single ended capsule having one or more filaments located inside the capsule, a flat end containing projections and electrical connection leads extending from the said flat end for supplying power to the filament; (ii) an adapter means, with downwardly or upwardly extending side walls with a slit for receiving the said flat end of the capsule; wherein the adapter means has flaps in the inner portion complementary to the projections of the said flat end of the capsule for snugly fitting the capsule;

(iii)a base socket means, in which the said electrical connection leads are embedded, the upper portion receiving the said adapter means in a snug yet adjustable manner, a pair of connection prongs extending outwardly from the lower portion of the socket; and 0^v) a plurality of separate lugs having one flat end and another semi-spherical surface, wherein the said lugs are positioned outside the capsule-adapter- socket subassembly and weldably attached to said adapter and socket.

2. The lamp and socket assembly as claimed in claim 1, wherein the said flat end of the said lugs is weldably attached to the flat horizontal surface of the base socket and the said semi-spherical surface of the said lugs is weldably attached to said outer side walls/cylindrical surface of the adaptor means.

3. The lamp and socket assembly as claimed in claims 2 and 3, wherein the said lugs are contacted with the said adapter and socket in an adjustable manner, wherein the said semi spherical surface of the lugs make proper contact with the cylindrical surface of the adaptor even if the said adaptor is tilted or is exactly vertical.

4. The lamp and socket assembly as claimed in any preceding claim, wherein the said lugs are fixed and weldably attached to the capsule-adapter-socket subassembly . after appropriately positioning the filament with respect to the reference plane and reference axis of the base socket at a position of optimum focus.

5. A method of assembling incandescent lamp and socket assembly comprising: (i) Inserting the flat end of the capsule containing filament and electrical connection leads through the upper portion of the adapter means to form a capsule-adapter subassembly, wherein the projections on the flat end of the said capsule gets locked with the complementary flaps of the said adaptor;

(ii)the capsule-adapter subassembly of step (i) is simultaneously adjusted along the vertical axis of the adaptor and along the two axes perpendicular to each other in a horizontal plane adjusted by lateral movement and swiveling adjustment around these two perpendicular axes in horizontal plane;

(iii) after the adjustments of step (ii) the capsule-adapter subassembly is then moved inside the open space inside the inner diameter of the base socket to form a capsule-adapter-socket subassembly;

(iv) the capsule-adapter-socket subassembly of step (iii) is simultaneously adjusted by vertical adjustment along the vertical axis parallel to the reference axis, swiveling adjustments around two axes perpendicular to each other and perpendicular to the reference axis, and the lateral adjustment along the two axes perpendicular to each other and perpendicular to reference axis so as to position the filament exactly at the required position of optimum focus; (v) a plurality of separate lugs having one flat end and another semi-spherical end are brought together and weldably attached to the capsule-adapter-socket subassembly of step (iv) to form the complete incandescent lamp and socket assembly.

6. The method as claimed in claim 4, wherein the said lugs are weldably attached to the capsule-adapter-socket subassembly after appropriately positioning the filament with respect to the reference plane and reference axis of the base socket at a position of optimum focus.

7. The method as claimed in any preceding claim, wherein the said flat end of the lugs is preferably welded to the flat horizontal surface of the base socket and the said semi-spherical surface is preferably welded to the said cylindrical surface of the adaptor.

8. An improved incandescent lamp and socket assembly substantially such as hereinbefore described and with reference to the foregoing accompanying drawings.

9. A method of assembling incandescent lamp and socket assembly substantially such as hereinbefore described and with reference to the foregoing examples and accompanying drawings.