US 7,322,870 B2Granted

Apparatus and process for finishing light source filament tubes and arc tubes

OwnerElmer G. Fridrichinventor

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Abstract

Manufacturing equipment and manufacturing process steps that improve upon prior art processes for the manufacturing of filament tube and arc tube light sources, their components and subassemblies, and lamps employing said light sources. A double ended, tipless filament tube or arc tube light source incorporates a drawn-down tubular body, and one piece foliated leads with spurs for process handling and for spudding into a filament with stretched-out legs. Bugled ends on the body provide a novel cutoff means, facilitate a flush-fill finishing process, and enhance mounting and support of the light sources in lamps. The foliated leads are made from a continuous length of wire in a process including foil hammering and two-bath AC electrochemical etching. Cost-reduced light source and lamp production enables affordable household consumer lamps, even when containing two series-connected halogen filament tubes. Safety benefits ensue from series connection, especially in combination with disclosed body and filament constructions.

Claims20

Dependent claims

A method for finishing a double ended light source in a finishing stand, wherein the light source comprises a body having first and second opposed ends for sealing around respective first and second lead wires;

and wherein the finishing stand comprises an approximately vertically oriented first finishing head positioned above, and substantially axially aligned with, an approximately vertically oriented second finishing head;
the method comprising the steps of:
providing a bugled end on each of the first and second opposed ends;
fixedly mounting an inner tube on each of the first and second finishing heads;
creating a closed system for finishing the body while it is sealed between the first and second finishing heads, by sealing the inside of the first bugled end against the inner tube of the first finishing head, and sealing the inside of the second bugled end against the inner tube of the second finishing head;
using clamshells to sealingly hold each of the first and second bugled ends against the respective inner tubes of the first and second finishing heads;
and
tolerating minor misalignment between the first finishing head and the second finishing head without placing any bending stress on the body, by:
spring biasing the clamshells against the respective first and second finishing heads;
allowing lateral movement of the clamshells relative to the respective inner tubes;
and
providing each of the clamshells with a center hole forming an annular spherical cavity wall, such that the curvature of the cavity wall matches the locus of points traced by outermost parts of the respective first or second bugled end as the respective first or second bugled end is tilted while pressed up against the respective inner tube.

9 more elements

Dependencies are inferred from the claim text.

Facts

Application: 10/702,011Filed 5 Nov 2003
Published: US 2005/0092025 A15 May 2005
Granted: 29 Jan 2008
Term ends: Not estimatedThe source records don’t support an estimate.

Classification19 codes

H01K 3/26
Apparatus or processes adapted to the manufacture, installing, removal, or maintenance of incandescent lamps or parts thereof: closing of vessels
C03B 23/049
Re-forming tubes or rods: by pressing
C03B 23/11
Re-forming tubes or rods: reshaping by drawing without blowing, in combination with separating, e.g. for making ampoules
C03C 27/02
Joining pieces of glass to pieces of other inorganic material; Joining glass to glass other than by fusing: by fusing glass directly to metal