GB2339715A

GB2339715A - Lamp body moulding method and automotive headlamp

Info

Publication number: GB2339715A
Application number: GB9915951A
Authority: GB
Inventors: Masaru Yamada
Original assignee: Koito Manufacturing Co Ltd
Current assignee: Koito Manufacturing Co Ltd
Priority date: 1998-07-22
Filing date: 1999-07-07
Publication date: 2000-02-09
Anticipated expiration: 2019-07-07
Also published as: DE19933240A1; DE19933240C2; GB2339715B; JP2000037736A; GB9915951D0

Description

2339715 LAMP BODY MOULDING METHOD AND AUTOMOTIVE HEADLAMP The present

invention relates to a moulding method that can be used to mould both a lamp body for a levelling type automotive headlamp that allows the optical axis to be adjusted up and down and a lamp body for a non levelling type automotive headlamp, and to an automotive headlamp comprising a lamp body moulded by the method.

Levelling type automotive headlamps are designed so that a reflector to which a light source is mounted is supported tiltably about a levelling axis within a lamp body and the reflector is tilted (pivoted) about the levelling axis by an automatically or manually operable levelling mechanism disposed between the reflector and the lamp body.

Non levelling type automotive headlamps that do not need to meet levelling specifications have a construction wherein a reflector to which a light source is mounted is supported tiltably about a levelling axis within a lamp body and wherein a reflector supporting member, for example, a tilting fulcrum constituting member that def ines tilting fulcrums for the reflector, is disposed between the reflector and the lamp body.

A conventional levelling type headlamp, and a conventional non levelling type headlamp as described above employ different members between the reflector and the lamp body. Therefore, even if headlamps of the two types have the same external appearance and form the same light distribution pattern, the lamp body configurations (particularly, the configuration of the sites for mounting the auto- levelling mechanism or the tilting fulcrum constituting member) cannot be made completely uniform, so that different lamp bodies moulded by different moulding apparatuses are used separately for the two types.

Different mould apparatuses are thus used to mould the respective types of lamp bodies. Therefore, the lamp body 2 production cost is correspondingly high, leading to an increase in the cost of automotive headlamps.

The present invention has been accomplished in view of the aforementioned problems of the conventional art. It is an object of the invention to provide a method that can mould both a levelling type lamp body and a non-levelling type lamp body by using a common mould apparatus, and an automotive headlamp comprising a lamp body moulded by the method.

To achieve the aforementioned object, there is provided a lamp body moulding method for moulding lamp bodies by using a mould apparatus comprising a first mould for moulding an inside of the lamp body, a second mould for moulding an outside of the lamp body, and a f irst and second interchangeable separate moulds for moulding a formation of the lamp body, the separate moulds being separable relative to the first and second moulds, wherein a levelling type lamp body or a non-levelling type lamp body is formed by selecting, as the separate mould, the first interchangeable separate mould for moulding a first formation, such as an actuator mounting hole, for mounting a levelling actuator or the second interchangeable separate mould for moulding a second formation, such as a cylindrical- tubular boss, for mounting a tilting fulcrum member.

A levelling type lamp body is moulded by using the first mould, the second mould and the first separate mould. A non-levelling type is moulded by using the first mould, the second mould and the second separate mould. That is, by interchanging the first separate mould and the second separate mould, both a levelling type lamp body and a nonlevelling type lamp body are moulded.

The invention also includes a moulding apparatus for carrying out the new method, the apparatus comprising the first and second moulds and the first and second interchangeable separate moulds.

3 A center axis of the actuator mounting hole moulded by said first separate mould preferably coincides with a center axis of the cylindrical-tubular boss moulded by the second separate mould.

Since the position at which the actuator mounting hole is formed in the levelling type lamp body coincides with the position at which the cylindrical- tubular boss is formed in the non-levelling type lamp body, the reflector for the levelling type lamp body and the reflector for the non-levelling type lamp body can be made interchangeable by causing the reflector supporting point provided by the actuator for the levelling type lamp body and the reflector supporting point provided by the tilting fulcrum constituting member for the non-levelling type lamp body to coincide with each other.

According to a further aspect of the invention, an automotive headlamp comprises a lamp body formed by the method when employing the first separate mould.

In association with a forward or rearward movement of the protruding rod, the reflector pivots (tilts) about the levelling axis to change the optical axis of the headlamp (reflector) upward or downward. The inclination of the axis in front-rear directions may be detected by an axle inclination sensor (for example, a gravity center shift detecting sensor). Based on a detection value from the axle inclination sensor, the actuator is driven. That is, the protruding rod of the actuator advances or withdraws to tilt and adjust the reflector so that the optical axis of the headlamp is always constant relative to the axle. 30 By turning the aiming screws, the reflector is tilted about a reflector -protruding rod junction portion, so that aiming adjustment can be performed. By turning the aiming screws, the reflector is tilted about a reflector-protruding rod junction port ion, so that aiming adjustment can be performed.

Two concentric annular ridge portions may be formed around the actuator mounting hole or the cylindrical- 4 tubular boss in the outside of the lamp body, and the two concentric annular ridge portions serve as an elastic seal member mounting groove or an actuator mounting-fixing portion in a levelling type headlamp, and as a lamp body reinforcing rib that backs up a wall adjacent to the cylindrical- tubular boss in a non-levelling type headlamp.

In the levelling type lamp body, when the actuator is mounted to the actuator mounting hole, an elastic seal disposed in the seal member housing groove is retained in a compressed state, thereby sealing the surrounding of the actuator mounting hole. The two ridge portions function as a site for mounting and fixing the actuator to the actuator mounting hole. For example, in a construction where the actuator is bayonet-engaged with the actuator mounting hole, the inner ridge portion is provided with cutouts that match engaging protrusions of the actuator, and the inner ridge portion serves as a stopper portion for stopping the engaging protrusions of the actuator, which is bayonetengaged with the actuator mounting hole via the cutouts.

In the non-levelling type lamp body, the two concentric annular ridge portions serve to increase the rigidity of a portion around the cylindrical- tubular boss against loads, such as the weight of the reflector or the like, that are transmitted via the tilting fulcrum constituting member, so as to prevent deformation of the lamp body. - A plate thickness of an region including the concentric annular ridge portions in the lamp body is preferably greater than a plate thickness of a region extending outwardly of said region.

Particularly in the levelling type lamp body, a portion around the actuator mounting hole receives, as loading, the weight of the actuator and, furthermore, the reaction of the force of driving the protruding rod of the actuator. However, since the plate thickness of the portion around the actuator mounting hole is sufficiently great, such loads can be sufficiently withstood.

In the accompanying drawings:

Fig. 1 is a front view of an auto-levelling type automotive headlamp according to a first embodiment of the invention;.

Fig. 2 is a horizontal sectional view of the headlamp, 5 taken on line IIII in Fig. 1; Fig. 3 is a horizontal sectional view of the headlamp, taken on line III- III in Fig. 1; Fig. 4 is a vertical sectional view of the headlamp taken on line IV-IV in Fig. 1; Fig. 5 is a perspective view of a bayonet engagement portion between an actuator mounting hole and an actuator unit; Fig. 6 is a vertical sectional view of a non-autolevelling type automotive headlamp according to a second embodiment of the invention; Fig. 7 is a sectional view of moulds for moulding an auto-levelling type lamp body; Fig. 8 is a perspective view of a separate mould for moulding an actuator mounting hole; Fig. 9 is a sectional view of moulds for moulding a non-auto-levelling type lamp body; and, Fig. 10 is a perspective view of a separate mould for moulding a cylindrical-tubular boss.

Figs. 1 to 5 illustrate a f irst embodiment of the invention.

In these drawings, reference numeral 10 represents a container- shaped lamp body made of a synthetic resin. Disposed in the lamp body 10 is a headlamp light source unit U (a reflector 20 with a light-source bulb 30 inserted thereto), together with a turn signal lamp bulb 30B and a clearance lamp bulb 30C. A front lens 18 is fitted to a front opening portion of the lamp body 10. Thus, the aforementioned components are integrated into a headlamp.

The light source unit U is formed by firmly fitting the bulb 3 0 f or f orming an approach beam and a travel beam, into a bulb insert hole 21 provided in a rearward vertex portion of the reflector 20 having a parabola shape.

6 The light source unit U is supported in such a manner that the tilt thereof can be adjusted in upward, downward, leftward and rightward directions by an auto-levelling mechanism and an aiming mechanism that are formed by, as shown in Figs - 3, 4, a pair of right and left aiming screws 40, 50 extending horizontally forward through screw insert holes 12, 13 formed in a rear wall of the lamp body 10, nut members 25, 26 that are fitted into brackets 22, 23 formed in rearward upper portions of the reflector 20 and that are screwed onto the aiming screws 40, 50, respectively, and an auto-levelling actuator 60 disposed between the lamp body and a rearward lower portion of the reflector 20.

The auto-levelling actuator 60 has a unit structure (see Fig. 3) in which a protruding rod 62 protrudes forward from an actuator unit case 61 that houses therein a stepping motor and a gear mechanism (that are not shown).

As shown in Fig. 5, the actuator unit case 61 is fitted, by bayonet engagement, to an actuator mounting hole 14 formed in the rear wall of the lamp body 10. The protruding rod 62 extending forward through the actuator mounting hole 14 is connected at its front end portion to the reflector 20 by a ball j oint J. A ball portion 63 is f ormed in the front end portion of the protruding rod 62. A nut member 27 having a ball receiving portion 27a is fitted to a bracket 24 protruded from a rear face of the reflector 20.

The ball receiving portion 27a of the nut member 27 and the ball portion 63 form the ball joint J, which defines a tilting fulcrum of the reflector 20.

The nut members 25, 26 fitted into the brackets 22, 23 are formed from a synthetic resin, and have such a known elastic structure as to absorb loads in upward, downward, leftward and rightward directions relative to the brackets 22, 23. An axis passing through the nut members 25, 26 and represented by reference characters LxI (see Fig. 1) defines a levelling axis for auto-levelling (a tilting center axis about which the reflector 20 is tilted by driving the auto-levelling actuator 60).

7 More specifically, based on, for example, a signal from a gravity center shift detecting sensor (not shown) f or detecting a shift of the center of gravity of the vehicle in the front-rear directions, the auto-levelling actuator 60 advances or withdraws the protruding rod 62 to shift the position of the ball joint J forward or rearward so as to tilt the light source unit U about the levelling axis Lx1, so that an optical axis L of the light source unit U is always kept constant relative to the axle.

The pair of right and left nut members 25, 26 cooperating to define the levelling axis Lx1 of the reflector 20, and the auto-levelling actuator 60 for tilting the reflector 20 in up-down directions form the auto-levelling mechanism for automatically pivoting (tilting) the reflector 20 about the levelling axis Lx1 so as to adjust the optical axis L of the light source unit U (reflector 20) to a fixed position relative to the axle. The aiming screws 40, 50 are rotatably supported by the screw insert holes 12, 13 of the lamp body 10. 20 Threaded portions 42, 52 of the aiming screws 40, 50, extending forward, are screwed to the nut members 25, 26. Rear end portions of the aiming screws 40, 50, protruding rearward from the lamp body 10, are integrated with rotational operating portions 45, 55 that can be turned by using a rotating tool, such as a screw driver, a wrench or the like.

When the aiming screws 40, 50 are turned by using a rotating tool, the nut members 25, 26 move forward or rearward on the threaded portion 42, 52 so that the light source unit U (reflector 20) tilts upward, downward, rightward or leftward. For example, if the aiming screws 40, 50 are turned by substantially equal amounts, the light source unit U (reflector 20) tilts about a horizontal tilting axis Lx (see Fig. 1) passing through the ball joint J. If the aiming screw 40 is not turned. but only the aiming screw 50 is turned, the light source unit U (reflector 20) tilts about a vertical tilting axis Ly 8 passing through the nut member 25 and the ball joint 7. That is, the aiming screw 40 is an up-down adjusting aiming screw that tilts or adjusts the optical axis L of the light source unit U in up-down directions, and the aiming screw 50 is an up-down-right-left adjusting aiming screw that tilts or adjusts the optical axis L of the light source unit U in up-down and right-left directions.

Thus, the ball joint J defining the tilting fulcrum of the reflector 20, the aiming screws 40, 50 for tilting the reflector 20, and the nut members 25, 26 screwed to the aiming screws 40, 50 form the aiming mechanism for tilting or adjusting the optical axis L of the light source unit U (reflector 20) in the up- down and right-left directions.

The auto-levelling actuator 60 is fitted, by bayonet engagement, to the actuator mounting hole 14 by inserting the auto-levelling actuator 60 from the back side of the lamp body 10. The engagement of the bayonet engaging portions can be released by turning the actuator unit case 61 relative to the actuator mounting hole 14.

More specifically, as shown in Fig. 5, the actuator 60 is fitted into the actuator mounting hole 14 by bringing engaging protrusions 61a of the actuator unit case 61 into bayonet engagement with cutouts 15a and stopper protrusions 15b that are formed in an inner peripheral edge portion around the actuator mounting hole 14. Therefore, the actuator 60 can easily be attached to and detached from the actuator mounting hole 14. Reference characters 15cl, 15c2 represent first and second standing walls that form a pair of concentric annular ridge portions surrounding the actuator mounting hole 14. An annular groove 15d defined between the standing walls 15c,, 15C2 receives therein an O-ring 15e that is an elastic sealing member. for sealing the actuator mounting hole 14 when the actuator 60 is fitted to the actuator mounting hole 14. The inner standing wall 15c has the cutouts 15a at predetermined circumferential positions, and thus forms the stopper protrusions 15b for stopping the stopper protrusions 61a.

9 The peripheral edge portion of the actuator mounting hole 14 in the lamp body 10, where the standing walls 15c,, 15C2 are formed, has a plate thickness tl that is greater than a plate thickness t of other portions of the lamp body 10, as indicated in Fig. 3. Thus, a sufficient strength of the peripheral edge portion is secured. More specifically, the peripheral edge portion of the actuator mounting hole 14 receives the weights of the auto- levelling actuator 60 and the light source unit U, and also receives loads of reaction of the force that drives the protruding rod 62 during auto- levelling operation. The peripheral edge portion is provided with such a plate thickness as to sufficiently withstand the aforementioned loads without deforming.

Reference character 15C3 represents a third standing wall that is a ridge portion extending in the form of an arc outwardly of the second standing wall 15C2. The third standing wall 15C3 has a less height than the first and second standing walls 15cj, 15C2' When the actuator 60 is bayonet-engaged with the actuator mounting hole 14, a protrusion 60a of the actuator 60 comes into pressing contact with the third standing wall 15C3 so as to prevent cluttering between the lamp body 10 and the actuator unit case 61. 25 A turn signal lamp reflector 20B is disposed in a leftward portion of the inside of the lamp body 10 (leftward portion of the lamp body 10 when viewed from front), at a predetermined position such that the tilting of the headlamp reflector 20 is not impeded. The reflector 30 20B has a circular hole 21B. The bulb 30B inserted into a bulb insert hole 10b of the lamp body 10 extends forward through the circular hole 21B. Another circular hole 21C is formed in a right lower portion of the headlamp reflector 20 (when viewed from front). A front end portion of the bulb 30C inserted into a bulb insert hole 10C of the lamp body 10 is exposed forward through the circular hole 21C.

Fig. 6 is a vertical sectional view of a non-autolevelling type automotive headlamp according to a second embodiment of the invention, corresponding to Fig. 3.

A lamp body 10A of the headlamp of the second embodiment has a f orwardprotruding cylindrical- tubular boss 16 in place of the actuator mounting hole 14 of the lamp body 10 of the headlamp of the first embodiment. A center axis Z2 of the cylindrical- tubular boss 16 coincides with a center axis Z, of the actuator mounting hole 14 of the lamp body 10. A ball portion forming member 70, that is, a reflector tilting fulcrum constituting member, is disposed in the cylindrical - tubular boss 16. The reflector 20 is supported by the ball portion forming member 70, thus forming a non-auto-levelling type headlamp.

That is, the non- auto -levelling type headlamp, in which the reflector 20 is supported by a ball joint J, (a ball receiving portion 27a and a ball portion 73), is formed by a construction in which the opening of the actuator mounting hole 14 of the lamp body 10 of an auto- levelling headlamp is closed by a wall 11, and the ball portion forming member 70 is mounted to the forward protruding cylindrical- tubular boss 16, and a ball portion 73 formed in a front end portion of the ball portion forming member 70 is supported by the ball receiving portion 27a of the nut member 27 fitted into the bracket 24 of the reflector 20. The ball portion 73 of the ball joint ii has the same size as the ball portion 63 of the protruding rod 62 of the actuator 60 in the first embodiment. All the headlamp component members, such as the front lens 18, the reflector 20, the aiming mechanisms for tilting or adjusting the light source unit U in upward, downward, rightward and leftward, except for the autolevelling actuator 60, are the same as the headlamp component members used in the auto-levelling type headlamp of the first embodiment.

Therefore, most component members are interchangeable between an autolevelling headlamp according to the first embodiment and a non-auto-levelling headlamp, according to the second embodiment.

Although not equipped with an auto-levelling mechanism for always keeping the optical axis of the light source unit U (reflector 20) constant relative to the axle, the non- auto- levelling type headlamp allows the optical axis of the light source unit U to be tilted or adjusted upward, downward, rightward or leftward, for example, if the optical axis of the light source unit U (reflector 20) has deviated. That is, as in the headlamp of the f irst embodiment, the light source unit U (reflector 20) can be tilted about the horizontal tilting axis Lx (see Fig. 1) passing through the ball joint J, or the vertical tilting axis Ly passing through the ball joint J, and the nut member 25.

Furthermore, the lamp body 10A has the same configuration as the lamp body 10 of the first embodiment, except that the cylindrical-tubular boss 16 is provided in place of the actuator mounting hole 14. That is, standing walls 15cl, 15C2 that are two concentric annular ridge portions are formed on the back side of the lamp body 10A at a position where the cylindricaltubular boss 16 is formed. The plate thickness t, of the region where the standing walls 15cl, 15C2 are formed is greater than the plate thickness t of a portion extending outwardly of that region.

The standing wall 15c, formed in the lamp body 10A extends annually without a cutout, unlike the standing wall 15c, in the first embodiment. Therefore, combined with the great thickness t, of the peripheral edge portion of the actuator mounting hole 14, the standing wall 15c, serves as a reinforcing rib that increases the rigid strength against the load transmitted from the reflector 20 by the cylindrical-tubular boss 16.

The auto-levelling type lamp body 10 provided with the actuator mounting hole 14 and the non-auto-levelling lamp body 10A provided with the cylindrical-tubular boss 16 can 12 be moulded by using a single mould apparatus as shown in Figs. 7 to 10.

In these drawings, a mould apparatus 80 for moulding a lamp body has a lower mould 81 that is a first mould for moulding the inside of a lamp body 10 (10A), an upper mould 82 that is a second mould for moulding the outside of a lamp body 10 (10A), and a first separate mould 86 for moulding the actuator mounting hole or a second separate mould 88 for moulding the cylindrical-tubular boss. The first separate mould 86 and the second separate mould 88 are separable from the lower mould 81. Reference numeral 84 represents a hole formed in the lower mould 81 for housing the separate mould 86 or 88.

The first separate mould 86 has protruding and recessed portions (see Fig. 8) f or moulding the cutouts 15a and the protrusions 15b in the inner peripheral edge portion around the actuator mounting hole 14 as shown in Fig. 5. The second separate mould 88 has protruding and recessed portions (see Fig. 10) for moulding a wall 11 (see Fig. 6) that closes an actuator mounting hole 14 and for moulding the cylindrical-tubular boss 16. Reference character 86a in Fig. 8 represents a site for moulding the stopper protrusions 15b in the inner peripheral edge portion around the actuator mounting hole 14 of the lamp body 10. Reference character 88a in Fig. 10 represents a site for moulding the cylindrical- tubular boss 16 of the non- auto- levelling lamp body 10A. The position of the center axis of the first separate mould 86 relative to the separate mould housing hole 84 coincides with the position of the center axis of the second separate mould 88 relative to the hole 84. The center axis Z., of the actuator mounting hole 14 in the lamp body 10 coincides with the center axis Z2 of the cylindrical -tubular boss 16 in the lamp body 10A.

To mould an auto-levelling type lamp body 10, injection moulding is performed with the first separate mould 86 set in the separate mould housing hole 84 of the 13 lower mould 81. An auto-levelling type lamp body 10 is thus moulded. To mould a non- auto- levelling type lamp body 10A, injection moulding is performed with the second separate mould 88 set in the separate mould housing hole 84 of the lower mould 81. A non- autolevelling type lamp body 10a is thus moulded. That is, either of the lamp bodies 10 and 10A can be moulded simply by interchanging the separate moulds 86, 88.

Although in the first embodiment, the auto-levelling actuator 60 is mounted to the actuator mounting hole 14 by bayonet engagement, the mounting of the auto-levelling actuator 60 is not limited to bayonet engagement, but may also be accomplished by other fixing means, such as screwing, protrusion-recess lance engagement, or the like.

As is apparent from the above description, in the lamp body moulding method in conjunction with claim 1, both a levelling type lamp body and a non-levelling type lamp body can be moulded by using a common mould apparatus. Therefore, the method reduces the lamp body production cost, thereby contributing to a cost reduction of the headlamps.

In conjunction with claim 2, a reflector and other lamp component members, except for a lamp body, can be interchanged between a levelling type headlamp and a non- levelling type headlamp. Therefore, the headlamp production efficiency improves, contributing to a further cost reduction of the headlamps.

In conjunction with claim 3 or 4, the lamp body and reflector production costs are reduced, so that headlamps can be provided at low costs.

In conjunction with claim 5, in a levelling type headlamp, the two ridge portions effectively function as a seal member fitting groove and bayonet engagement fixing portions for the actuator, thereby providing a levelling type headlamp that is excellent in water proofness and that facilitates attachment and detachment of the actuator. In a non-levelling type headlamp, the two ridge portions 14 effectively function as reinforcing ribs that increase the rigid strength of the lamp body, thereby providing a nonlevelling type headlamp that is excellent in durability.

In conjunction with claim 6, deformation of the actuator mounting hole surrounding portion in a levelling type headlamp and deformation of the boss forming region surrounding portion in a non- levelling type headlamp are effectively prevented. Therefore, high durability of the headlamp is ensured. 10

Claims

1. A lamp body moulding method for moulding lamp bodies by using a mould apparatus comprising a first mould for moulding an inside of the lamp body, a second mould for moulding an outside of the lamp body, and a f irst and second interchangeable separate moulds for moulding a formation of the lamp body, the separate moulds being separable relative to the first and second moulds, wherein a levelling type lamp body or a non-levelling type lamp body is formed by selecting, as the separate mould, the first interchangeable separate mould for moulding a first formation, such as an actuator mounting hole, for mounting a levelling actuator or the second interchangeable separate mould for moulding a second formation, such as a cylindrical -tubular boss, for mounting a tilting fulcrum member.

2. A method according to claim 1, wherein a center axis of the actuator mounting hole moulded by the first separate mould coincides with a center axis of the cylindricaltubular boss moulded by the second separate mould.

3. A method of moulding a lamp body, substantially as described with reference to the accompanying drawings.

4. An automotive headlamp comprising a lamp body formed by the method when employing the first separate mould as described in claim 1 or claim 2, a levelling actuator mounted to an actuator mounting hole of the lamp body, a reflector to which a light source is inserted, the reflector being supported at three points that are provided by a pair of right and left aiming screws extending forward through the lamp body, and a protruding rod of the actuator that extends forward, wherein in association with forward and backward movements of the protruding rod, the reflector pivots about a levelling axis that is defined by a pair of 1G right and left supporting points of the reflector provided by the aiming screws.

5. An automotive headlamp comprising a lamp body formed by the method when employing said second separate mould as described in claim 1 or claim 2, and a reflector to which a light source is inserted, the reflector being supported at three points that are provided by a pair of right and lef t aiming screws extending f orward through the lamp body, and a tilting fulcrum constituting member mounted to a cylindrical- tubular boss of the lamp body and extending forward.

G. An automotive headlamp according to claim 4 or claim 5, wherein two concentric annular ridge portions are formed around the actuator mounting hole or the cylindricaltubular boss in the outside of the lamp body, and the two concentric annular ridge portions serve as an elastic seal member mounting groove or an actuator mounting-fixing portion in a levelling type headlamp, and as a lamp body reinforcing rib that backs up a wall adjacent to the cylindrical -tubular boss in a non- levelling type headlamp.

7. An automotive headlamp according to claim G, characterized in that a plate thickness of an region including the concentric annular ridge portions in the lamp body is greater than a plate thickness of a region extending outwardly of the region.

8. An automotive headlamp, substantially as described with reference to the accompanying drawings.

9. A moulding apparatus for forming a lamp bodies by the method according to any one of claims 1 to 3, the apparatus comprising the first and second moulds and the first and second interchangeable separate moulds.

17

10. A moulding apparatus for forming a lamp body, substantially as described with reference to Figures 7 to 10 of the accompanying drawings.