US2575790A - Projector unit - Google Patents

Description

1951 R. K. BRAUNSDORFF 2,575,790

PROJECTOR UNIT Filed Dec. 30, 1949 6 INVENTOR.

REGINALD K. BRHUNSDORFF ZJQ M A T TORNE'Y Patented Nov. 20, 1951 PROJECTOR UNIT Reginald K. Braunsdorff, East Orange,

to Tang-Sol Lamp Works, Inc.,

signor N. J as- Newark,

N. J a corporation of Delaware Application December 30, 1949, Serial No. 135,967

6 Claims.

This invention relates to sealed electric lamp units and to the manufacture thereof.

One object of the invention is a sealed lamp unit comprising a reflector element and a baseless incandescent electric lamp bul A further object of the invention is a lamp unit of theabove indicated character which is further characterized by the low cost of manufacture, by the simplification of the electrical connections, by the high quality of the seal and by its rigidness and endurance.

Further objects of the after appear.

For a better understanding of the invention reference may be had to the accompanying drawings wherein Fig. 1 is a schematic sectional view of a sealed lamp unit embodying the invention;

Fig. 2 is a schematic view of another embodiment;

Fig. merit;

Fig. 3A is a schematic view of another embodiment; and

Fig. 4 is a schematic view of still another embodiment.

In one aspect the invention resides in a novel and improved lamp unit wherein the incandescent electric lamp bulb is directly fastened to the reinvention will herein- 3 is a schematic view of another embodiilector element and in a securely sealed manner 1 without the use of a conventional or standard base with the seal being of a character to prevent breathing.

Referring to the embodiment of Fig. 1, I have illustrated my invention as embodied in a projector unit comprising a reflector I of any suitable character as, for example, parabolic, or a combination of parabolic and other curvatures, and an electric incandescent lamp bulb 2. In this embodiment of the invention the reflector I which may be made of any suitable material, preferably metal, is formed with a centrally disposed inwardly extending tubular portion 3, terminating at any suitable point within the reflector depend ing upon the shape, dimensions, etc. of the bulb 2. The lamp bulb 2 which in the particular embodiment shown is of a conventional bulbous shape having a reduced sealed-in part 2 is fastened and sealed to the peripheral edge 3' of the reflector inward extension 3 in any suitable manner. For this purpose the bulb 2 is solder treated in the vicinity of the peripheral edge 3' of the reflector extension, that is the bulb 2 is treated in any manner in this zone to enable the soldering of the same to the metallic extension 3 of the reflector. This treatment of the bulb may consist of applying layers of metallic deposit on which is applied a coating of tin (known as tinning), to which the solder A is readily wetted.

The bulb having been treated, has applied thereto solder A and the soldering operation is completed by the application of heat in any suitable manner to the solder. The solder A is all the way around the bulb so as to form a tight seal at the peripheral edge 3 against breathing.

The focal point of the reflector is indicated at FC. In the manufacture of the bulb I can obtain a focal plane established at a distance, say of 1 inch-1V, inch, an opening into which the glass bulb rests on a conventional sealing head for pull down, and also on the same diameter in the stamped reflector. This opening may be determined and established accurately for both operations. A conventional sealing head pulldown permits an accurate control of L. C. L. Axial alinement may be regulated by tilting bulb in this opening. At the correct position heat may be applied to the reflector as, for example, by induction or otherwise to allow the solder to soften and fasten the bulb to the metal reflector at this point.

I have indicated a simple means for establishing electrical connection with the lamp unit. This comprises a disc 6 of any suitable material as, for example, fiber or plastic having a reduced tubular portion 5' on its inner end which makes a press fit with or is otherwise fastened to the inward tubular extension 3. This button or block 6 carries suitable electric terminals 1 and the lead-in wires 5 of the bulb 2 are soldered or otherwise fastened to these terminals.

In the embodiment of Fig. 2 the reflector I0 is indented at its rear central portion to form an integral outwardly extending tubular or cupshaped part II, the latter having a rounded peripheral edge H to which the bulb 2 is fastened in a manner to obtain a secure seal against breathing. Treating of the bulb 2 and the soldering of the same to the reflector may be as described above with respect to Fig. 1.

In this embodiment I have shown one of the lead-in wires 5 turned around the small end of the bulb and grounded to the reflector in the solder A. The other lead-in wire or weld 5 is electrically connected to a terminal l2 of a terminal block I3, this terminal l2 passing through an opening in the end of the extension ll of the reflector and being provided on the outside with a terminal Hi. The block I3 may be of any suitable insulating material as, for example, flber or plastic.

In the embodiment of Fig. 3 I utilize a metallic sleeve I for the assembly of the lamp bulb 2 and the reflector I6. This sleeve method is applicable to soldering the sleeve at its inner end to the lamp bulb or may be converted for conventional basing with lamp cementing. For instance, the lamp bulb 2 may be fastened and sealed to the sleeve l5 at the line I! by the soldering method as described in Fig. 2. This embodiment has a desirable focusing feature in that the sleeve I5 may be adjusted in or out in reference to the focal center of the parabolic reflector. Also with the end of the sleeve being open it permits a clinching or indenting operation for attaching to the reflector the indentations being indicated at l8. Any desired number of indentations I8 may be provided for retaining the sleeve in the reflector but ordinarily two or three such indentations are suflicient to accurately locate and fix the sleeve with reference to the reflector. Preferably the sleeve is made of comparatively thin stock which would effect a still further saving in cost. Any suitable tools or machine may be employed for performing this indenting operation as, for example, a machine resembling a conventional device used for crimping plastic button in basing. This may be made into a fully sealed lamp by merely pouring tar or other resinous material flush in the opening of the sleeve and about the edge of the tubular extension iii of the reflector. This is particularly suitable where the sleeve does not protrude beyond the end 01' the extension 16'. This embodiment may be provided with an external connector as shown in Fig. l.

The embodiment of Fig. 3A is generally similar to the embodiment of Fig. 3, the main difference being that instead of using the indentations 8 of Fig. 3 to fasten the reflector to the sleeve IS, in this embodiment I utilize a crimped or fluted construction, these crimps or flutes being formed in any suitable manner and being indicated generally at 20. This embodiment may be also provided with any suitable external connector as, for example, like that shown in Fig. 1.

In the embodiment of Fig. 4 the lamp bulb 2 is provided with a sleeve l5 similar to the sleeve l5 of Figs. 3 and 3A. The reflector I and the sleeve l5 are firmly fastened together by rolling the edge of the reflector extension 25 and the edge of the sleeve together. The edge of the extension 25 is provided with an outwardly upturned flange 26. An edge on the sleeve I5 is provided with an outwardly and upwardly rolled or turned portion 21 having a downwardly turned and interlocking flange 21, the latter interlocking with the upwardly turned flange 26 of the reflector extension.

Any suitable external connector may be provided for the embodiment of Fig. 4 as, for example, either of the connectors illustrated in the embodiments described above.

Any suitable cover or lens is provided for the lamp units. In Fig. 1 I have illustrated schematically such a cover or lens indicated at 30.

I claim:

1. A sealed projector lamp unit comprising a reflector having a tubular extension formed symmetrically about the axis thereof, a baseless miniature incandescent lamp bulb hermetically sealed and firmly secured to said extension at the meeting area of said bulb and extension and external electrical connecting means for said unit having at least one of the lead wires of the miniature bulb leading directly from the bulb to said electrical connecting means, said extension and bulb being coordinated to bring the bulb filament in the vicinity of the focal point of the reflector when the bulb is in contacting relationship with the extension.

2. In a projector lamp unit of the character set forth in claim 1 wherein the reflector tubular extension extends inwardly of the reflector with the neck of the bulb being soldered all the way around the periphery thereof to the inner edge of said extension.

3. In a projector lamp unit of the character set forth in claim 1 wherein the reflector tubular extension extends inwardly of the reflector with the neck of the bulb being soldered all the way around the periphery thereof to the inner edge of said extension and the electrical connecting means comprises an insulating plug supported in the extension.

4. In a projector lamp unit of the character set forth in claim 1 wherein the reflector tubular extension is formed outwardly of the reflector and the miniature bulb is sealed to the rounded shoulder formed between the reflector and the extension.

5. In a projector lamp unit of the character set forth in claim 1 wherein the reflector tubular extension is formed outwardly of the reflector and the miniature bulb is sealed to the rounded shoulder formed between the reflector and the extension and the electrical connecting means comprises an insulating plug carried within the outer end of the tubular extension.

6. A projector lamp unit comprising a reflector and a miniature incandescent lamp bulb mounted directly on the reflector without the conventional base, with the bulb being fastened and sealed to the reflector against breathing by a single ring of sealing material and a lens element for the unit.

REGINALD K. BRAUNSDORFF.

REFERENCES CITED The following references are of record in the flle of this patent:

UNITED STATES PATENTS Number Name Date 1,992,041 Roper et al. Feb. 19, 1935 2,253,616 Falge Aug. 26, 1941 2,317,035 Dana Apr. 20, 1943 2,454,270 Braunsdorif Nov. 23, 1948

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