Reflector lamp having a multifunctional supporting member

Abstract: A multifunctional member and reflector lamp employing same for mounting a light-source capsule on the inside of the neck of the outer envelope, for optically aligning the capsule with respect to the reflector, for reflecting heat away from the base region of the lamp, for blocking convective heat transfer into the lamp neck, and for reflecting light incident on the member toward the lens. In performing these multiple functions, the member reflects heat back to the filament or light source which improves its efficiency, and the member redirects light toward the lens which improves the efficacy of the lamp. In a preferred embodiment, the multifunctional member is formed from stainless steel and has a bowl-shaped body with a somewhat flexible peripheral annular tab extending upward and outward conically. The peripheral tab may be crimped, slotted, or have a tapered thickness in order to provide flexibility sufficient for mounting. The bowl-shaped body preferably is paraboloidal having a focal center substantially coincident with the focal center of the reflector. In an alternate embodiment, the multifunctional member has a curvature matched to the curvature of the reflector and no peripheral tab s that the reflector has been optically extended to the press seal of the light-source capsule. A lamp constructed in accordance with the invention is particularly well suited for employing a heat-sensitive component, such as a diode, in the base region of the lamp..

Description: The invention herein relates to a reflector lamp employing a supporting member. More particularly, the invention relates to a reflector lamp having a supporting member which in addition to supporting the light-source capsule acts as a heat shield, light reflector, and alignment device. In a reflector lamp, heat from the light-source capsule may be detrimental to components in the base of the lamp, especially when the lamp is operated in the base-up position. The smaller the size of the lamp, the more severe is the heat problem. When the lamp is burned in an enclosing fixture, the heat problem may be even more severe because heat may be trapped within the fixture thus increasing the temperature of the internal lamp components. As a general principle in lamp design, the more heat reflected back to the light source, the more efficiently the light source will operate. In incandescent lamps, heat shields have been employed to reduce base temperature. In this regard, refer to US-A-4,480,212 corresponding to the international publication WO-A-84/00080, wherein a heat-reflecting and light-reflecting shield is employed in a single-enveloped A-line incandescent lamp between the filament and lamp base. See also US-A-1,425,967, US-A-3,209,188 and US-A-4,160,929. US-A-4,494,176, discloses a light-reflecting parabolic reflector section mounted behind the filament in a single-enveloped incandescent parabolic reflector lamp. The section extends the light-reflecting surface of the parabolic reflector into the region behind the filament. thereby improving the optical efficacy of the lamp. In projection lamps, it is known to employ a retention member mounted in the neck of the lamp for supporting and aligning a light-source capsule within the reflector. See US-A-4,156,901, US-A-4,219,870 and US-A-4,403,276. Thus, it is seen that the mounting, aligning, optically reflecting, and heat-reflecting functions are present in various types of reflector lamps, and that one or two of these functions may be performed by a mounting device for the light-source. It would be an advancement of the art if a simple and inexpensive lamp member were provided for a reflector lamp which ably performs all of these functions. Such a multifunctional member would enable improved performance, particularly in smaller sized lamps where space is an important factor, with no increase in cost. It is, therefore, an object of the invention to avoid the deficiencies of the prior art. Another object of the invention is to provide a combination supporting, mounting, aligning, heat-reflecting, convection blocking, and light-reflecting member for a reflector lamp. Still another object of the invention is to provide a simple and inexpensive multifunctional supporting member for a reflector lamp which will substantially improve lamp performance, particularly in smaller lamps where space is limited. Yet another object of the invention is to provide a multifunctional supporting member for a reflector lamp which will shield heat from the base region of the lamp such that one or more heat-sensitive components may be safely located within the base region of the lamp. These objects are accomplished. The present invention provides a reflector lamp having an outer envelope including a reflector having an aperture therein, a light-transmissive lens, and a neck joining said reflector about the perimeter of the aperture, a light-source capsule positioned within said aperture on a supporting member, so as to be optically aligned with respect to the reflector, and means-passing through said neck for providing electrical power to the light-source capsule; the supporting member being mounted on the neck within said outer envelope, and providing also means for reflecting infrared energy away from said neck, means for blocking convective heat transfer to said neck, and means for reflecting light incident on said member toward said lens. Embodiments of the present invention will now be discussed by way of example only with reference to the drawings, in which: FIG. 1 is a cross-sectional view of an embodiment of the invention illustrating a parabolic aluminized reflector (PAR) lamp, particularly a PAR 20 lamp, having a supporting member mounted on and within the lamp neck. A flexible peripheral flange on the member is pressure mounted against the inner wall of the neck. FIG. 2 is a cross-sectional view of another embodiment of the invention, particularly a PAR 30 lamp, in which a supporting member is mounted on the lamp neck along the brim where the neck joins the reflector within the outer envelope. A flexible peripheral flange of the member is pressure mounted against the inner wall of the neck adjacent to the brim. FIG. 3 shows one embodiment of a supporting member in accordance with the invention. The member has an edge-crimped flange for flexibility in mounting and aligning the light-source capsule (shown in a dashed line). In the view, the member is partially cut away in order to show its bowl-shaped body and crimped flange. The light-source capsule snugly mounts into a receiving slot with pressure flanges in the center of the member. FIG. 4 shows an alternate embodiment of a°supporting member in accordance with the invention. The peripheral flange has radial slots defining plural fingers which provide flexibility in the flange for mounting and aligning the light-source capsule. FIG. 5 illustrates yet another embodiment of a supporting member in accordance with the invention in a partially cutaway view. The peripheral flange, shown in cross section, is tapered, being thinnest at the outermost edge of the flange in order to provide flexibility for mounting and aligning the light-source capsule. FIG. 6 illustrates still another embodiment of a supporting member in accordance with the invention in a partial cutaway view. In this embodiment, the member has a flat disk-shaped body with a crimped peripheral flange. FIG. 7 illustrates another embodiment of a supporting member in accordance with the invention. The cross-sectional view shows a member having a parabolic-shaped body and no peripheral flange. The body has a tapered thickness, being thinnest at its outer edge, in order to provide flexibility for mounting and aligning the light-source capsule. FIG. 8 illustrated yet another embodiment of a supporting member in accordance with the invention. In this view, the member is partially cut away to illustrate the bowl-shaped body and peripheral flange extending downward and outward conically from the periphery of the body. As used herein, the term "light-source capsule" includes a tungsten-halogen capsule, a metal-halide arc tube or capsule, a high-pressure sodium ceramic arc tube or capsule, and any other light-emitting capsule or arc tube mounted within an outer envelope of a lamp. FIG. 1 shows a PAR 20 lamp 10 comprising an outer envelope enclosing an interior. The outer envelope includes reflector 14 and light-transmissive lens 15. As used herein, reflector 14 includes a light-reflecting coating 17, such as aluminum, on the interior surface thereof. Alternately, light-reflective coating 17 may be a dichroic-type coating, which reflects visible light and transmits infrared energy through reflector 14. Reflector 14 has an aperture formed in it. Neck 12 joins reflector 14 about perimeter or brim 19 of the aperture. The inner surfaces of reflector 14 and neck 12 meet at brim 19. Preferably, coating 17 extends over brim 19 and inner wall 16 of neck 12. As will be noted below, an aluminized coating may assist in conducting heat away from the lamp neck and base region. In the embodiment of FIG. 1, the interior of neck 12 is shown as being cylindrical. Neck 12 may be tapered, shouldered, grooved, or otherwise shaped in other embodiments. Light-source capsule 18, e.g., a tungsten-halogen capsule, is mounted on a supporting member 30 on the interior of neck 12. Capsule 18 has press seal 34 at the base thereof which fits snugly into a receiving slot in member 30, as will be shown in greater detail below. Member 30 may be formed of a relatively stiff metal, such as stainless steel, aluminum, etc., or it may be formed from a non-metallic material, e.g. a ceramic, capable of withstanding the elevated temperature surrounding capsule 18. In the embodiment FIG. 1, member 30 is formed from stiff metal with flexible annular flange 31 extending upward, i.e., toward lens 15, and outward conically from the body of the flange. Member 30 is mounted on neck 12 by flange 31 pressing firmly against inner wall 16 of neck 12. As shown in the drawing, member 30 may be mounted at an appropriate distance below brim 19 within neck 12, an appropriate distance is determined by optically aligning capsule 18 such that the light source, e.g., coil 21, is substantially centred with respect to central axis A-A and focal center F of reflector 14. Flange 31 is somewhat flexible to permit member 30 with capsule 18 mounted thereon to be positioned and aligned, yet sufficiently stiff and inflexible so that the capsule assembly will remain properly aligned during shipping and use. As shown in FIG. 1, base 24, e.g., an Edison-type base, is mounted on neck 12. Electrical lead-in wires 20 of capsule 18 pass through neck 12 into base region 25 wherein temperature-sensitive component 22, e.g. a diode, may be located. Lead-in wires 20 are coupled, through diode 22 on one lead-in, with the two poles of base 24, whereby means are provided for supplying capsule 18 with electrical power from an external source. Supporting member 30 has means for shielding base region 25 from radiational and convective heat transfer from capsule 18 and means for reflecting light from capsule 18 toward lens 15. Member 30 has a polished surface or coating, e.g., an aluminum coating, on it facing lens 15 such that both infrared energy and light are reflected away from neck 12. Member 30 is adapted to be sufficiently snug and airtight about brim 19 and press seal 34 so that convective heat transfer from capsule 18 into neck 12 below member 30 is effectively blocked. Preferably, infrared energy radiating from capsule 18 should be redirected to the light source, e.g., filament 21, so that the light source or filament will burn more efficiently due to the diminished electrical power required to heat the filament; and light emanating from capsule 18 onto member 30 should be reflected, directly or indirectly, through lens 15 so that the efficacy of lamp 10 will be improved. In embodiments wherein member 30 is formed from metal and an aluminized coating 17 is in contact with member 30, the metal member tends to conduct heat radially away from capsule 18 to coating 17 whereupon it is transferred to the body of reflector 14. This further assists in maintaining cooler temperatures in the base region of lamp 10 and in the press seal of capsule 18. The reduced press seal temperature may have a beneficial effect on lamp life. The foregoing objectives may be substantially realized by forming the body of member 30 into a bowl shape, preferably a paraboloid having a focal center coincident, or nearly so, with the focal center of the reflector. FIG. 2 shows a PAR 30 lamp in an alternate embodiment of the invention. The same reference characters are used in FIG. 2 to identify lamp components corresponding to those of FIG. 1. In the embodiment of FIG. 2, focal center F of reflector 14 is positioned such that supporting member 30 is mounted near brim 19. Ideally, the shape of member 30 should be an optical extension of the shape of reflector 14, which in this embodiment is paraboloidal, in which case the curvatures of the supporting member and reflector are matched. In the embodiment of member 30 of FIG. 2, the slope (near vertical) of peripheral flange 31 is approximately equal to that of inner wall 16 of neck 12. This slope provides a very rigid mount of member 30 in neck 12 and is preferred for that reason. The presence of flange 31. however, prevents the ideal optical extension of reflector 14 by member 30. With an alternate embodiment of the supporting member, such as is shown in FIG. 7 wherein the member does not have a peripheral flange, or in FIG. 8 wherein the peripheral flange extends below the body of the member, an ideal optical extension of the reflector by the supporting member may be substantially achieved by matching the curvatures of the body of the member and the reflector. FIGS. 3-8 show various embodiments of supporting member 30 which may be employed in lamp 10 and other reflector lamps in accordance with the invention. In FIGS. 3-8, the same reference characters are employed to identify corresponding lamp components; and to the extent lamp parts of FIGS. 3-8 are also identified in FIGS. 1 and 2, the reference characters of FIGS. 3-8 are the same as those of FIGS. 1 and 2. Referring now to FIG. 3, light-source capsule 18 in its mounted position on supporting member 30 is outlined in dashed lines forming capsule assembly 29. Circular member 30 comprises bowl-shaped body 35, e.g. a paraboloid having a focal center at a desired point on axis A-A, and a peripheral flange 31 extending upward, i.e., toward the top of capsule 18, and outward, i.e., away-from the body of capsule 18, in a frustoconical shape. Flange 31 is formed with a plurality of crimps 40. Body 35 has slot 32 centrally formed therein for receiving press seal 34 of capsule 18. Slot 32 has flanges 36 (in this embodiment there are four flanges associated therewith) extending substantially parallel to the walls of press seal 34. Capsule 18 is mounted on member 30 by inserting press seal 34 into slot 32, preferably until the bulbous portion of the capsule is flush against the body of member 30. Slot 32 is sized so that press seal 34 fits snugly into it. Tabs 36 are formed so that each tab presses firmly against the respective wall of press seal 34. In this way, capsule assembly 29 is constructed with a rigid and nearly airtight fit between capsule 18 and member 30. Tabs 36, although not required, are preferred particularly for keeping capsule 18 rigidly aligned with respect to central axis A-A. When mounted in a reflector lamp, such as lamp 10, axis A-A of capsule assembly 29 will be aligned with the central axis of the reflector lamp. Capsule assembly 29 may be mounted on neck 12 of lamp 10 as shown in FIGS. 1 and 2. In FIG. 1, supporting member 30 is disposed at an appropriate distance below brim 19; in FIG. 2, member 30 is mounted on or near brim 19. In both embodiments, the position of capsule 18 and filament 21 is determined by the optical requirement of centring filament 21 (or the light source) with respect to axis A-A and focal center F of reflector 14. During lamp assembly, capsule assembly 29 is inserted into neck 12. Member 30 is sized such that inner wall 16 of the neck will compress flexible flange 31 toward capsule 18 when capsule assembly 29 is inserted into neck 12. As shown in FIG. 3, flange 31 may have crimps 40 formed in it to permit the bending of the flange. On the other hand, the thickness of member 30 and flange 31, shown in cross section in the drawing, should be such that the flange presses against wall 16 with sufficient force to hold the capsule assembly rigidly in place and aligned during the life of the lamp. In a preferred embodiment, member 30 is formed from stainless steel having a thickness of approximately 50µm to 100µm (0.002 to 0.004 inches). The thickness of member 30 depends on the type of material chosen for the member. The jagged external edges of crimps 40 assist in gripping inner wall 16 to form a permanent mount. In other embodiments, inner wall 16 may be tapered, growing more narrow as the wall approaches the base. This taper has the advantage that the mount of the supporting member grows tighter as the member is inserted deeper into the neck, so that a rigid mount is assured. FIG. 4 shows an alternate embodiment of member 30 wherein peripheral flange 31 has radial slots 44 formed or cut therein to define a plurality of radial fingers 46. The fingers provide flexibility in the marginal flange sufficient for mounting in neck 12. Body 35 may be bowl-shaped with slot 32 and tabs 36, as in the embodiment of FIG. 3. FIG. 5 shows another embodiment of member 30 wherein flange 31 is neither crimped nor slotted; the thickness of the flange is tapered being thinnest at edge 50, as shown in the cross-sectional view of flange 31 in the drawing. The taper provides flexibility to the flange sufficient for mounting in neck 12. Body 35 may be bowl-shaped with slot 32 and tabs 36, as in the embodiments of FIGS. 3 and 4. FIG. 6 shows still another embodiment of member 30 having a crimped peripheral flange 31. In this embodiment, body 52 of member 30 is flat. Surface 52 may be polished or have a coating on it so that it is reflective of both infrared energy and visible light. Slot 32 has two pressure tabs 60 on the longer sides of the rectangular slot, rather than the four tabs of the embodiments of FIGS. 3-5. FIG. 7 shows yet another embodiment of member 30 wherein member 30 does not have a peripheral flange. Body 35 has a tapered thickness being thinnest at outer edge 62, as shown in the cross-sectional view of the body in the drawing. The taper provides flexibility in the body sufficient for mounting in neck 12. In this embodiment, body 35 is bowl-shaped, preferably being a paraboloid whose curvature is matched to the curvature of the lamp reflector. As commented on above, this embodiment has the advantage that member 30 may extend the curvature of the reflector up to the press seal of the light-source capsule (because of the absence of the peripheral flange). In this optical sense, member 30 is ideal. Slot 32 is rectangular with. for example, two tabs 64 on the shorter sides of the slot. FIG. 8 shows another embodiment of a supporting member 30 well adapted to extending the curvature of the reflector. In this embodiment, flange 31 extends downward so that the periphery of body 35, when mounted, abuts the brim of the reflector. When the curvature of body 35 is matched to that of the reflector, the light-reflecting surface is extended to the press seal of the capsule. Flange 31, which extends downward, i.e., toward the lamp base, provides means for obtaining a rigid mount in the same manner as described in relation to other embodiments above. The flange may include crimps, slots, a tapered thickness, etc. Because the downward flange is below the reflecting surface, the reflecting surface of the supporting member is not offset from the lamp reflector as is the case with the upward flange of FIG. 2. Several embodiments of the supporting member have been illustrated, but these examples are by no means exhaustive. The supporting member is particularly well suited for a reflector lamp employing a light-source capsule. A capsule has significantly more size and mass than a filament alone. Therefore, the capsule requires more support to provide precision in alignment. The supporting member is also particularly well suited to a lamp having a heat-sensitive component located in the base region of the lamp. The supporting member is adapted for shielding the base region from heat so that operation of the component will be unimpaired. Also, the basing cement, solder, epoxy, etc., in the base region are protected from excessive heat. In performing its functions of reflecting heat and light away from the base region, the light source burns more efficiently and the luminous efficacy of the lamp is improved. The supporting member facilitates lamp construction. The light-source capsule is mounted on the supporting member by mechanical means. The capsule assembly is mounted and aligned on the inside of the lamp neck by mechanical means. After completion of the electrical circuit and mounting of the base and lens by standard techniques, the result is a shock-resistant structure adequate for a commercial product. For results in a laboratory examples of reflector lamps having a supporting member in accordance with the invention, reference is made to the following Tables I and II corresponding to the PAR 20 and PAR 30 lamps shown in FIGS. 1 and 2, respectively. The temperature data of Tables I and II were measured using K-type thermocouples bonded to lamp components with epoxy. All lamps were operated at 120 volts of alternating current in tightly enclosing fixtures in the vertical base-up position. The lamps were operated for at least two hours prior to recording temperatures so that steady state conditions were obtained. The ambient temperature about the exterior of the fixtures was 24°C. The data of both Tables demonstrate that the steady state operating temperatures of the base and within the base region, i.e., about the diode within the base region, are substantially reduced in lamps having a supporting member in accordance with the invention than in comparable lamps without the supporting member. Each table has five columns. The first column contains the wattage of the light-source capsule. The second and fourth columns contain the observed temperatures in prior art lamps wherein the light-source capsules were supported in an open lamp neck by means of the lead-in wires. The third and fifth columns contain the observed temperatures for lamps having a supporting member in accordance with the invention. As may be seen from Tables I and II, the steady state temperatures in lamps in accordance with preferred embodiments of the invention are significantly reduced, more so in the smaller PAR 20 lamp. A temperature difference of 10°C is considered to be significant in view of temperature tolerances of lamp components such as diodes, basing cement, solder, etc. A reflector lamp according to the present invention may provide an advancement of the art by a simple and inexpensive lamp member provided in a reflector lamp which ably performs all of the functions of support, alignment, shielding and reflecting. Such a supporting member would enable improved performance, particularly in smaller sized lamps where space is an important factor, with no increase in cost. In preferred embodiments the member may provide a heat shield to the base region of the lamp such that one or more heat-sensitive components may be safely located within the base region of the lamp.

Claims: A reflector lamp having an outer envelope including a reflector (14) having an aperture therein, a light-transmissive lens (15), and a neck (12) joining said reflector about the perimeter of the aperture, a light-source capsule (18) positioned within said aperture on a supporting member (30), so as to be optically aligned with respect to the reflector (14), and means passing through said neck for providing electrical power to the light-source capsule; the supporting member (30) being mounted on the neck (12) within said outer envelope, and providing also means for reflecting infrared energy away from said neck, means for blocking convective heat transfer to said neck, and means for reflecting light incident on said member toward said lens. A reflector lamp as claimed in claim 1 characterised in that said supporting member (30) has a bowl-shaped body (35). A reflector lamp as claimed in claim 2 characterised in that the focal center of said bowl-shaped body (35) is substantially coincident with the focal center of said reflector (14). A reflector lamp as claimed in claim 3 characterised in that the curvature of said bowl-shaped body (35) is matched with the curvature of said reflector (14). A reflector lamp as claimed in claim 1 wherein said supporting member (30) has a flat body (52). A reflector lamp as claimed in any of claims 2 to 5 characterised in that said supporting member (30) has a flexible annular flange (31) extending from the periphery of said body (35; 52). A reflector lamp as claimed in claim 6 characterised in that said annular flange (31) has a tapered thickness being thinnest at the outer edge of said flange. A reflector lamp as claimed in claim 6 or 7 characterised in that said annular flange (31) is radially slotted such that a plurality of fingers (46) are formed in said flange. A reflector lamp as claimed in claim 6 or 7 wherein said flange (31) is crimped. A reflector lamp as claimed in any of the preceding claims characterised in that said light-source capsule (18) has a press seal (34) at an end thereof and said supporting member (30) has a slot (32) formed therein for receiving and securely mounting said light-source capsule (18) on said member. A reflector lamp as claimed in claim 10 characterised in that said slot has tab means (36) associated therewith for engaging said press seal (34) of said light-source capsule. A reflector lamp as claimed in any preceding claim wherein a diode (22) is located within said neck (12) on the opposite side of said supporting member (30) to said light-source capsule (18).

Inventors: BENSON TIMOTHY A, GAGNON PETER R, BENSON, TIMOTHY A., GAGNON, PETER, R.
Applicants: GTE PROD CORP, GTE PRODUCTS CORPORATION
Application year: 1988
Main classification: H01K1
IPC codes: H01K1