US 7,811,148 B2 · Light source bodies for filament tubes and ARC tubes

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. Bulged 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 process for manufacturing a light source body, the body comprising a central tipless bulb having a first outside diameter and the body being bookended by two diametrically opposed transitional portions each necking down to a tubular necked-in portion having a second outside diameter smaller than the first outside diameter;

the process comprising the steps of:
providing a length of tubing having an outside diameter no less than the first outside diameter;
forming a stretched-out portion of the tubing having the second outside diameter by heating the tubing while placing the tubing in tension;
moving to keep the heating constantly centered in the stretched-out portion;
cutting the stretched-out portion to form two necked-in portions:
one for a right end of a first light source body, and one for a left end of a second light source body;
and
advancing the tubing such that the forming, moving, and cutting steps can be repeated to form a right end necked-in portion for the second light source body, thereby completing formation of the second light source body.

5 more elements

A process for manufacturing a light source body, the body comprising a central tipless bulb having a first outside diameter that is bookended by two diametrically opposed tubular portions;

the process comprising the steps of:
providing a length of tubing having an outside diameter no less than the first outside diameter;
determining a leg portion of the tubing that extends between a first bulb and a second bulb;
and
cutting the leg portion by the steps of:
forming a cusped maria in the leg portion;
providing control such that the resulting cusped maria comprises two substantially duplicate bulged-out portions that join to form the vertex of a cusp;
and initiating a crack along the line of the cusp.

5 more elements

Dependencies are inferred from the claim text.

Light source bodies for filament tubes and ARC tubes

Life of this patent

Light source bodies for filament tubes and ARC tubes

Life of this patent

Abstract

Claims20