US3247954A

US3247954A - Method and means for assembling and packaging reflector-type lamps

Info

Publication number: US3247954A
Application number: US303268A
Authority: US
Inventors: Liberman Milton
Original assignee: Individual
Current assignee: Individual
Priority date: 1963-08-20
Filing date: 1963-08-20
Publication date: 1966-04-26
Anticipated expiration: 1983-04-26

Description

April 26, 1966 M. LIBERMAN 3,247,954 METHOD AND MEANS FOR ASSEMBLING AND PACKAGING REFLECTOR-TYPE LAMPS Filed Aug. 20, 1963 3 Sheets-Sheet 1 I NVEN TOR.

April 26, 1966 M. LIBERMAN' 3,24 METHOD AND MEANS FOR ASSEMBLING AND PACKAGING REFLECTOR-TYPE LAMPS Filed Aug. 20, 1963 3 Sheets-Sheet 2 1 N VEN TOR. /l //4 ra/v Z/BE/PM/FN (ET tr April 26, 1966 M. LIBERMAN 3,247,954

METHOD AND MEANS FOR ASSEMBLING AND PACKAGING REFLECTOR-TYPE LAMPS Filed Aug. 20, 1963 3 Sheets-Sheet 5 INVENTOR. M 7011/ Z/SEE/VIH ATTGR;

United States Patent 3,247,954 METHUD AND MEANS FOR ASSEMBLING AND PACKAGING REFLECTUR-TWE LAMPS Milton Liherman, 65 flewaue Road, East Rockaway, NX. Fitted Aug. 20, 1963, Ser. No. 303,268 (Ilaims. (Cl. lite-46) This invention relates to the assembly and packaging of reflector-type electric lamps, and more specifically, to a novel and improved method for manufacturing and packaging reflector-type electric lamps for storage and shipment.

The manufacture and packaging of electric incandescent lamps having external reflectors secured thereto has presented serious difficulties, particularly in instances where in the external reflector secured to the lamp is fabricated of a very thin fragile material. Heretofore, the reflectors were cemented to the lamps by a process requiring the utilization of jigs arranged to receive a number of reflectors. When the reflectors were inserted in the jigs, cement was applied at the points of contact with the lamp and then the lamp was inserted and held in alignment with the reflector. The reflectors and lamps remained in the jig until the cement hardened, whereupon each assembled lamp and reflector was then removed and suitably packaged. The adhesive found to be most useful for cementing a reflector to a lamp is an air drying adhesive that requires from twelve to twenty-four, hours to set. It is evident, therefore, that with the utilization of such ad hesives, mass production of a lamp and reflector combination requires an exceedingly large number of jigs and a substantial amount of space for the storage of the jigs with assembled lamps and reflectors. Furthermore, a separate operation is required for the removal of the lamps and reflectors from the jigs and insertion in protective packages. The procedure is relatively expensive and results in the addition of material cost to the finished product.

This invention overcomes the difiiculties heretofore encountered with known procedures for fabrication and packaging of lamps with external reflectors secured thereto and provides an improved method of manufacturing and packaging which greatly reduces the cost of the finished article, simplifies assembly, and avoids the need for storage space of a large quantity of lamps to permit the cement to set.

Another object of the invention resides in the provision of a novel and improved method for assembling external reflectors to incandescent lamps.

Still another object of the invention resides in the provision of a novel and improved package for incandescent lamps having external reflectors and wherein the reflector and lamp are assembled in the package itself and are immediately ready for shipment.

Still another object of the invention resides in a novel and improved package for incandescent lamps having external reflectors secured thereto.

A still further object of the invention resides in the provision of a novel and improved shipping and dispensing carton for packaged electric lamps having external reflectors secured thereto.

The above and other objects of the invention will become more apparent from the following description and accompanying drawings forming part of this application.

In the drawings:

FIGURE 1 is an exploded perspective view of a lamp and external reflector in position for assembly within a protective package in accordance with the invention.

FIGURE 2 is a perspective view of an assembled lamp and reflector within the package in accordance with the invention.

FIGURE 3 is a cross-sectional view of the lamp package in accordance with the invention and placed in a support for receipt of a lamp reflector.

FIGURE 4 is a cross sectional view of the lamp package of FIGURE 1 with a reflector seated therein.

FIGURE 5 is a cross-sectional view similar to FIG- URE 4 with the lamp inserted and cemented to the reflector.

FIGURE 6 is a cross-sectional view similar to FIGURE 5 with a retaining cover secured to the package and retaining the lamp and reflector in position therein.

FIGURE 7 is a cross-sectional view of a fragmentary portion of FIGURE 6 but with a modified retaining'cover.

FIGURE 8 is a bottom view of the lamp package showing a modified form of the opening which receives the lamp neck.

FIGURE 9 is a fragmentary cross-sectional view of a carton for receiving and holding a plurality of packaged lamps as shown in FIGURE 6.

FIGURE 10 is a cross-sectional view of a modified form of lamp package in accordance with the invention.

FIGURE 11 is a cross-sectional view of FIGURE 10 taken along the line 11-I1 thereof.

FIGURE 12 is a cross-sectional view of a modified carton for containing packaged lamps in accordance with the invention.

FIGURE 13 is a perspective view of a portion of a packing element for holding packaged lamps within the carton shown in FIGURE 12.

As pointed out above, the invention concerns the provision of an improved package which not only is adapted to receive and protect an incandescent lamp with an external reflector cemented thereto during shipment, but

also provides improved means for assembling a lamp and reflector and retaining the two in position one relative to the other so that the assembled lamp and reflector within the improved package can be immediately inserted into shipping cartons and shipped thus avoiding the normal storage time to permit the adhesive to set. With this invention, the lamps are so firmly held in contact with the associated reflector that the stresses to which the lamp and reflector may be subjected during shipment will not adversely affect the resultant article, and the cement will set and firmly adhere the lamp to the reflector during the course of shipment.

The improved lamp package in accordance with the invention is shown in FIGURES l and 2 and is generallytom 13. The bottom 13 includes an opening 14 which isadapted to snugly receive the neck 15 of the lamp 16. The upper portion 17 of the body or shell Ill is integrally formed with the portion 12 and is flared sharply outwardly andupwardly and terminates in a flanged or beaded edge 18. The lamp reflector 19, which may be formed of any suitable material having an internal reflective surface, has a curved annular portion 2% which is integrally joined about the edge 21 to a forwardly flared section 22 terminating in a beaded or rolled edge 23.

The portion 20 of the reflector has an enlarged opening 24 through which the neck 15 of the lamp extends and a plurality of tabs 25 carried about the edge of the opening 24 are utilized to cement the reflector to the lamp 16. The lamp 16 and reflector 19 are held in position within the body of the package 10 by a cover 26 which has a reverse flange 27 for engaging the flange 18 on the package and an embossed central portion 28 which engages the bulbous portion 29 of the lamp 16 and cooperates with the opening 14 to hold the lamp in alignment within the package.

The package in accordance with the invention is designed to receive a reflector of specific size and configuration, and for this purpose the package or shell 11 is arranged so that its internal diameter at the line of joinder 11 of the sections 12 and 17 is approximately equal to the outside diameter of the portion of the reflector at the point Where it joins the flared reflector portion 22. Furthermore, the portion 17 of the package body or shell should preferably extend above the front edge of the reflector 19 when the latter is inserted therein. In this way, the body will hold and align the reflector 19 within the body and upon insertion of the lamp 16, the cooperation of the cover with the opening 14 in the body will hold the lamp in precise and firm alignment with the reflector.

The assembly of the lamp and reflector within the package is illustrated more clearly in FIGURES 3 through 6. The shell 11 of the package in accordance with the invention is inserted in any suitable jig such as the jig 38 which has a central opening 31 adapted to receive the body portion 12 with the body portion 17 flaring outwardly and upwardly from the top surface 32 of the jig 30. When the shell 11 is in place within the jig as shown in FIG- URE 3, the reflector 19 is inserted within the body as shown in FIGURE 4. It will be observed that the junction 21 of the upper and lower sections of the reflector is in line with the junction 11 of the upper and lower sections of the shell 11, and both junctions are approximately in line with the top surface 32 of the jig 30. It will also be observed that the top edge 23 of the reflector is below the top edge 18 of the body 11. With this arrangement, the reflector is firmly seated within the body 11 of the package and is in precise alignment therewith, that is, the reflector and the package body are substantially concentric.

When the reflector is in place within the body as shown .in FIGURE 4, a suitable adhesive is applied to the edges 25 of the tabs or supports 25 and the lamp 16 is then placed in position as shown in FIGURE 5. It will be observed that the top of the bulbous portion 29 of the lamp extends slightly above the edge 18 of the package body and the neck 15 of the lamp extends through the opening 14 in the bottom 13 of the package body. With this arrangement, the tabs 25 on the reflector 19 and the opening 14 accurately align the lamp with the reflector and the adhesive 33, applied to the edges 25 of the tabs, functions to bond the tabs to the bulbous portion 29 of the lamp. The adhesive is preferably an air drying adhesive, though it is evident that any suitable type of adhesive may be employed, as, for instance, epoxy resins and the like.

When the lamp ,16 is in position as shown in FIGURE 5, the cover 26 is applied as shown in FIGURE 6. The reverse flange 27 on the cover 26 interlocks with the flange 18 on the body or shell 11, and it urges the embossed portion 28 of the cover into firm engagement with the bulbous portion 29 of the lamp. In this way, the lamp is axially aligned with the body 11 of the package 10 and since the reflector 19 is also aligned with the body 11, the lamp will therefore be precisely positioned with respect to the reflector. The cover 26 places a slight stress on the lamp urging it firmly against the tabs 25 so that any jarring of the assembly as shown in FIGURE 6 will not displace the lamp relative to the reflector. As a result, the packaged reflector lamp as shown in FIG- URE 6 is ready for immediate shipment, even though the cement 23 has not actually set. Furthermore, with normal distribution processes, the time required for an article to be transported from the point of manufacture to the point of use usually involves at the minimum several days, with the result that an air drying resin requiring twelve to twenty-four hours will set by the time the lamp and reflector are removed from the package for use.

In the form of the invention described above, the bottom opening 14 in the shell 11 was an annular opening which snugly received the neck 15 of the lamp 16. If desired, an opening such as the opening 14' as shown in FIGURE 8 may be employed. With this arrangement, the tolerance of the opening is not critical since the inwardly extending salient'portions of the opening can be easily deflected upon insertion of the lamp and at the same time will effect precise alignment of the lamp within the body 11.

While packaged lamps in accordance with the invention may be housed in any suitable container for shipping, one form of container is shown in FIGURE 9 and is denoted generally by the numeral 34. The container which is shown in fragmentary form includes a top wall 35, a bottom wall 36 and

internal liners

37 and 38. The

liners

37 and 38 are each provided with a plurality of spaced triangularly shaped projections 39 which are disposed in parallel relationship transversely of the carton. The projections 39 on the liner 37 are spaced to slidably receive and hold the enlarged portions of the packages 10 with the bottom ends or bases of the lamps in spaced relationship to the projections 39 on the opposing liner 38. The liner 38 is similarly arranged with spaced projections or ribs 39 to receive packages 10 in an inverted position as clearly illustrated. With this arrangement, the packages are nested within the container and are securely held in position so that the container can be stored in any position. If desired, the container 34 can also be arranged so that lamps can be dispensed directly from the container without necessitating the removal and storage of the individual lamp shelves.

While the invention has been described in connection with a lamp of a single size, as shown for instance in FIGURES 1 through 6, it is possible to utilize the invention with a lamp 16 of somewhat smaller configuration, provided that the lamp when positioned in the reflector 19 has its filament properly aligned therewith. In the event the lamp is of smaller size, a modified cover can be utilized with the package 10 in order to secure the lamp firmly in position against the reflector 19. This form of the invention is shown in FIGURE 7, in which the cover is denoted by the numeral 26. The central portion of the cover is provided with a cylindrical element 40 carrying a curved wall portion 41 which contacts the smaller lamp 16. The curved wall portion functions in the same manner as the embossment 28 on the cover 26, except that it is displaced inwardly in order to compensate for the lamp size. A cover structure such as shown in FIG- URE 7 may be readily fabricated by any suitable embossing or other forming process.

The lamp package shown in FIGURE 10 is substantially identical to the package shown in previous figures, and corresponding elements of the embodiments of the invention shown in FIGURES 1 and 10 are denoted by like numerals with the numerals of FIGURE 10 primed. The

i base 13' of the package 10' shown in FIGURE 10 is provided with a central opening 43 to receive the lamp neck. The opening has a plurality of V-shaped cutouts 44 about the edge with the cutouts spaced one from the other to form short arcuate sections 45 therebetween for alignment of the lamp neck and to permit the portions 45 to be slight- 1y deflected and accommodate variations in diameter of the lamp neck. The rim 46 of the flared portion 17 is reversely formed to provide an inwardly extending headlike element 47 terminating in an outwardly extending flange 48. The cover 49 is provided wtih an annular depression 50 having a diameter which will receive the bulbous portion of the lamp and align it with the reflector 19. The periphery of the cover is provided with an inwardly formed peripheral recess 51 terminating in an outwardly extending flange 52. The recess 51 receives the inwardly extending bead-like portion 47 on the flared portion 17' of the shell and locks the cover in place with the

flanges

48 and 52 in overlying relationship and with the central portion of the cover engaging the bulbous portion of the lamp.

FIGURES 12 and 13 show a modified carton arrangement for receiving a plurality of packaged lamps or '10 as the case may be. The carton, generally denoted by the numeral 53, -is of conventional rectangular construction having a pair of spaced walls 54 and 55 for the reception of packaged lamps 10 or 10' as the case may be. The packaged lamps are supported within the container 53 by a plurality of elongated rectangular elements 56 having a top wall 57 with spaced openings 58 for the reception of the lamp bases. The side walls 5-9 and 60 include arcuate cutouts 61 aligned with the openings 58 and preferably terminating a short distance above the rear Wall 62 to provide elongated spacer members 63. When packing a plurality of lamps within the carton 53, a packing strip 56 may be first placed against one wall 54 in a corner of the carton. Lamps are then placed in the openings 58 of a second packing strip 56, and the strip together with the lamps is then positioned in the cart-on with the rims of the lamp packages engaging the openings 61 in the first strip. This procedure is then repeated, with each group of lamps being reversed within the carton until the carton has been completely filled. If desired, suitable additional spacing means may be provided at the ends of the carton to prevent the lamps from shifting within the carton.

The

packages

10 and 10, together with the cover, may of course be fabricated of any suitable material, though it has been found that plastic materials are most suitable,

since the material can be readily formed into any desired shape or configuration and can be made exceedingly thin and light in weight. It is possible, of course, :to fabricate the package of other materials, such as metals and the like.

While only certain embodiments of the invention have been illustrated and described, it is evident that alterations, modifications and changes may be made without departing from the true scope and spirit thereof as defined by the appended claims.

What is claimed is:

l. A package for an electric lamp having an envelope including a bulbous portion, a neck and a base secured to the neck and a reflector surrounding at least a portion of v the bulbous portion with at least part of the neck exposed,

comprising a double open-ended shell having an opening in one end for receipt of said reflector and an opening in the other end for snugly engaging the neck of said envelope, said shell having a configuration corresponding at least in part to said reflector and engaging at least a portion of said reflector t-o firmly align it therein with the neck of the lamp envelope extending through the opening in said other end of the shell, and a cover closing the opening in said one end of the shell, said cover including means engaging the bulbous portion of said envelope to retain the lamp envelope in alignment with said reflector and said shell.

2. A package for an electric lamp according to claim 1 wherein said reflector is formed of two annular portions of different curvature joined one to the other and forming an annular concavity and wherein said shell has an inwardly extending annular shoulder snugly engaging said annular concavity in said reflector.

6. A package for an electric lamp according to claim 1 wherein said cover includes a central embossed portion having a curvature corresponding generally to at least part of the bulbous portion of said envelope.

4. The method of assembling and packaging an electric lamp with anannular reflector cemented thereto comprising the steps of placing a reflector having tabs to be cemented to a lamp within a packaging shell having reflector and lamp receiving and aligning means, applying an adhesive to said tabs, placing a lamp in said reflector and in engagement with said tabs and lamp aligning means and then attaching a cover to said shell, said cover engaging said lamp to urge it into firm contact with said tabs and fixedly align said lamp and said reflector within said shell.

5. The method of assembling and packaging an electric lamp with an annular reflector wherein said lamp has an envelope including a bulbous portion, a neck extending from the bulbous portion and a base secured to said neck, and said reflector surrounds at least part of the bulbous portion with at least part of the neck exposed and includes tabs adapted to be cemented to said envelope, comprising the steps of forming an annular double open-ended shell having a portion adjoining one end thereof conforming generally to at least part of said reflector and having reflector receiving and aligning means and a lamp neck receiving opening at the other end thereof, inserting said refiector in said one end of said shell and in engagement with said reflector aligning means, applying an adhesive to said reflect-or tabs, inserting the neck portion of a lamp through said reflector and the lamp neck receiving opening until said lamp envelope engages said tabs and then enclosing said one end of said shell to hold said lamp in alignment with said reflector and shell and in firm engagement with said tabs.

6. The method of assembling a lamp and surrounding reflector adapted to be cemented to the lamp and of packaging the assembled reflector comprising the steps of placing a lamp and the surrounding reflector with an adhesive disposed therebetween within a lamp and reflector receiving and aligning package and then securing said lamp and reflector in said package for shipment, said package protecting said assembly and holding said lamp and reflector in firm engagement and alignment while said adhesive sets and during shipment thereof.

'7. A jig and package for lamp and reflector assemblies wherein said lamp includes an envelope having neck and bulbous portions and wherein said reflector has tabs adapted to be cemented to the envelope and surrounds at least part of the bulbous portion with at least part of the neck exposed, comprising a shell having an enlarged refiector receiving opening in one end thereof and a small lamp neck receiving opening in the other end thereof, annular means within said shell for snugly receiving and aligning said reflector, said reflector having lamp attaching and aligning means whereby insertion of the lamp with the neck extending through said small opening and with the lamp engaging said attaching means automatically aligns the bulb and reflect-or within the shell and cover means having a central lamp engaging embossment closing said enlarged opening and urging said lamp in engagement with attaching means, said lamp being held in alignmerit with the reflector by said embossment and neck receiving opening.

8. A jig and package according to claim 7 wherein said reflector is formed with a shallow annular curved portion and an outwardly flared section joined one to the other and forming an annular trough-like groove, and said annular aligning means comprises an inwardly extending shoulder for engaging said annular groove in said reflector.

*9. A jig and package according to claim 8 wherein said shell is formed of a lower cup-like section having a generally cylindrical rim tapering downwardly and inwardly toward the bottom, the latter having the neck receiving opening therein, and an upwardly extending flared portion joined to the lower section and curving sharply outwardly therefrom to form said reflector receiving and aligning means, said upwardly flared portion having a larger diameter than the flared portion of said reflector.

10. A jig and package according to claim 8 wherein said shell is formed of a lower cup-like section having a. generally cylindrical rim tapering downwardly and inwardly toward the bottom, the latter having said neck receiving opening therein, an upwardly extending flared portion joined to the lower section and curving sharply outwardly therefrom to form said reflector receiving and aligning means, said upwardly flared portion having a larger diameter than the flared portion of said reflector, a peripheral cover-engaging bead about the outer edge of 7 3 the flared portion of said shell and wherein said cover ,77 12/ 1956 Williams 20665 closes the last said flared portion and engages said bead. 2,806,594 9/ v1957 Muller et a1 206-65 3,136,413 6/1964 Hall 20646 References Cited by the Examiner FOREIGN PATENTS UNITED STATES PATENTS 5 60,596 4/1954 France. 573,333 12/1896 Krimmel. (1st add. of 1,015,065) 2,03 1,851 2/1936 Plunkett 2061 2 102 3 .12 193 Conner. v LOUIS G. MANCENE, Primary Examiner.

2,545,762 4/1951 Brown 20646 10 THER-ON E. CONDON, Examiner.

Claims

1.A PACKAGE FOR AN ELECTRIC LAMP HAVING AN ENVELOPE INCLUDING A BULBOUS PORTION, A NECK AND A BASE SECURED TO THE NECK AND A REFLECTOR SURROUNDING AT LEAST A PORTION OF THE BULBOUS PORTION WITH AT LEAST PART OF THE NECK EXPOSED, COMPRISING A DOUBLE OPEN-ENDED SHELL HAVING AN OPENING IN ONE END FOR RECEIPT OF SAID REFLECTOR AND AN OPENING IN THE OTHER END FOR SNUGLY ENGAGING THE NECK OF SAID ENVELOPE, SAID SHELL HAVING A CONFIGURATION CORRESPONDING AT LEAST IN PART TO SAID REFLECTOR AND ENGAGING AT LEAST A PORTION OF SAID REFLECTOR TO FIRMLY ALIGN IT THEREIN WITH THE NECK OF THE LAMP ENVELOPE EXTENDING THROUGH THE OPENING IN SAID OTHER END OF THE SHELL, AND A COVER CLOSING THE OPENING IN SAID ONE END OF THE SHELL, SAID COVER INCLUDING MEANS ENGAGING THE BULBOUS PORTION OF SAID ENVELOPE TO RETAIN THE LAMP ENVELOPE IN ALIGNMENT WITH SAID REFLECTOR AND SAID SHELL.