Abstract:
A lamp and socket assembly ( 10 ) comprises a housing ( 12 ) including a socket cavity ( 25 ). The socket cavity ( 25 ) is defined by side walls and a bottom wall ( 80 ). A vent hole ( 82 ) passes though the bottom wall ( 80 ) of the socket cavity. A lamp ( 16 ) has a lamp base ( 17 ). A lamp socket ( 14 ) is disposed in the socket cavity ( 25 ) and includes a through passage ( 42 ) for receiving the lamp base ( 17 ) and at least one retaining finger ( 38   a,    38   b ) for retaining the lamp base ( 17 ) in the through passage ( 42 ). An electrical contact insert ( 26 ) is received in the socket cavity ( 25 ). A plurality of electrical contacts ( 28 ) are received in and retained by the contact insert ( 26 ). A plurality of blade terminals ( 46 ) are interlocked with the contact insert ( 26 ), with respective ones of the contacts ( 28 ), and with the housing ( 12 ). A hydrophobic and/or oleophobic vent patch ( 83 ) is disposed in the socket cavity ( 25 ) and completely covers the vent hole ( 82 ) to permit trapped vapors and gasses to escape while repelling water and/or oil.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of priority to U.S. Provisional Patent Application No. 60/865,469 filed Nov. 13, 2006. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The subject invention relates to lamp socket assemblies and in particular to vented lamp socket assemblies of the type used in tail lights of automobiles and the like. 
         [0004]    2. Related Art 
         [0005]    All sealed automotive lamp assemblies must address pressure rises due to the heat generated by the lamp, material outgassing, as well as from moisture intrusion. According to prior art techniques, this problem is usually addressed through some type of vent system to equalize pressure within the enclosure and allow moisture to escape. Such vents most often take the form of a hole formed through the lamp housing. The hole is sometimes left open, but there is concern with dirt and excessive water intrusion such that manufacturers often cover the vent hole to prevent dirt and water from entering the lamp enclosure. The cover can be in the form of a tube, a hydrophobic membrane, or a combination hydrophobic vent with a cap-like construction. However, exposed hydrophobic vents are susceptible to damage affecting performance. Also, the manufacturing step of forming the hole in the lamp housing is a time consuming and expensive operation. 
         [0006]    Examples of vent systems that employ a hydrophobic memberant include U.S. Pat. No. 4,921,124 that describes a two-piece vent device with a hydrophobic membrane installed as a plug from the outside of an electronic control device. U.S. Pat. No. 5,800,183 discloses a socket for a sealed automotive lamp, where the socket includes a vent in its base fitted with a hydrophobic vent patch applied as a plug from the outside of the socket. U.S. Pat. No. 6,113,407 teaches a socket for an electrical connection that includes an externally applied hydrophobic vent patch. And, U.S. Pat. No. 6,210,014 discloses a sealed vehicle headlamp including externally applied hydrophobic vent patches in the side of a reflector housing. 
         [0007]    These prior art examples include many drawbacks and shortcomings. For examples, these prior art techniques are susceptible to abrasive damage and are not particularly conducive to fully automated manufacturing processes. These venting system are designed within the lamp constructions, which complicates the constructions and are thus more expensive. Furthermore, the visual impact of these externally applied vent patches are bothersome, and often compel some type of camouflaging feature to hide the vent patch. 
         [0008]    Accordingly, there is a need for an improved lamp assembly that eliminates the need to place a hole in the lamp housing, and also eliminates any form of exposed vent to damage. Such an improved lamp assembly should have an improved placement of the venting device, as well as an improved method for installing the venting device that is economical and readily incorporated into high-volume production operations. 
       SUMMARY OF THE INVENTION 
       [0009]    The present invention overcomes the disadvantages of the above described prior art by providing an improved lamp and socket assembly comprising a housing including a socket cavity. The socket cavity is defined by side walls and a bottom wall. A vent hole passes though the bottom wall of the socket cavity. A lamp has a lamp base. A lamp socket is disposed in the socket cavity and includes a through passage for receiving the lamp base and at least one retaining finger for retaining the lamp base in the through passage. An electrical contact insert is received in the socket cavity. A plurality of electrical contacts are received in and retained by the contact insert. A plurality of blade terminals are interlocked with the contact insert, with respective ones of the contacts, and with the housing. A hydrophobic and/or oleophobic vent patch is disposed in the socket cavity and completely covers the vent hole. 
         [0010]    A method for venting moisture from the confines of a sealed lamp assembly through a vent opening in the socket is also contemplated. The method comprises the steps of: providing a housing having a socket cavity defined by side walls and a bottom wall; forming a vent hole though the bottom wall of the socket cavity; inserting a lamp socket in the socket cavity of the housing; inserting the base of a lamp in the lamp socket; forming a vent patch from a hydrophobic and/or oleophobic fabric material; and covering the vent hole with a vent patch applied from the inside of the socket cavity. 
         [0011]    The assembly and method according to this invention are particularly conducive to fully automated manufacturing processes which result in product being manufactured at minimal cost and effort. The internally applied vent patch is far less susceptible to abrasive damage, and therefore functions as intended over a generally longer service life than do comparable prior art examples. Furthermore, the subject technique has shown better moisture evacuation over prior art venting methods. The invention eliminates the need to design a venting system within the lamp construction, as taught by many prior art systems. Rather, the vent system is incorporated into the socket feature, thus making the design and construction of the lamp housing less costly. By eliminating the hole through the housing, as taught by prior art designs, a potential visual impact is also avoided. Likewise, there is no need to employ camouflaging features that hide unsightly vent patch. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    These and other features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description and appended drawings, wherein: 
           [0013]      FIG. 1  is a front elevational view of the lamp socket assembly according to the present invention; 
           [0014]      FIG. 2  is a top plan view of the socket assembly of  FIG. 1  rotated through 90°; 
           [0015]      FIG. 3  is a cross sectional view of the socket assembly of  FIG. 1  taken along line  3 - 3  of  FIG. 2 ; 
           [0016]      FIG. 4  is a cross sectional view of the lamp socket assembly of  FIG. 1  taken along line  4 - 4  thereof; 
           [0017]      FIG. 5  is a top plan view of the housing for the socket assembly of  FIG. 1 ; 
           [0018]      FIG. 6  is a cross sectional view of the housing of  FIG. 5  taken along lines  6 - 6  thereof; 
           [0019]      FIG. 7  is an enlarged detailed view of the upper portion of an energy director shown in  FIG. 5 ; 
           [0020]      FIG. 8  is a bottom plan view of the housing of  FIG. 5 ; 
           [0021]      FIG. 9  is a cross sectional view of an embodiment of a socket assembly according to the present invention with a different focal length; 
           [0022]      FIG. 10  is a top plan view of a body for the socket assembly of  FIG. 1 ; 
           [0023]      FIG. 11  is a section of the body of  FIG. 10  taken along line  11 - 11  thereof; 
           [0024]      FIG. 12  is a sectional view of the body of  FIG. 10  taken along line  12 - 12  thereof; 
           [0025]      FIG. 13  is a side view of the body of  FIG. 10  taken from the right hand side thereof; 
           [0026]      FIG. 14  is a bottom plan view of the body of  FIG. 10 ; 
           [0027]      FIG. 15  is a front elevational view of a terminal for the lamp socket assembly of  FIG. 1 ; 
           [0028]      FIG. 16  is a side elevational view of the terminal of FIG. taken from the left hand side thereof; 
           [0029]      FIG. 17  is a bottom plan view of the terminal of  FIG. 15 ; 
           [0030]      FIG. 18  is a side elevational view of another terminal for the socket assembly of  FIG. 1 ; 
           [0031]      FIG. 19  is a front elevational view of a blade terminal for the socket assembly of  FIG. 1 ; 
           [0032]      FIG. 20  is a side elevational view of the blade terminal of  FIG. 19 ; 
           [0033]      FIG. 21  is a top plan view of a contact insert for the socket assembly of  FIG. 1 ; 
           [0034]      FIG. 22  is a side elevational view of the contact insert of  FIG. 21 ; 
           [0035]      FIG. 23  is a cross sectional view of the contact insert of  FIG. 21  taken along line  23 - 23  thereof; 
           [0036]      FIG. 24  is a cross sectional view of the contact insert of  FIG. 21  taken along line  24 - 24  thereof; 
           [0037]      FIG. 25  is a cross sectional view of the contact insert of  FIG. 21  taken along line  25 - 25  of  FIG. 22 ; 
           [0038]      FIG. 26  is a top plan view of a flange seal for the socket assembly of  FIG. 1 ; 
           [0039]      FIG. 27  is an enlarged cross sectional view of the flange seal of  FIG. 26  taken along line  27 - 27  thereof; 
           [0040]      FIG. 28  is a top plan view of a locking wedge for use with an alternative embodiment of the lamp socket assembly according to the present invention; 
           [0041]      FIG. 29  is a side elevational view of the locking wedge of  FIG. 28 ; 
           [0042]      FIG. 30  is a cross sectional view of an alternative embodiment of a socket assembly including the locking wedge of  FIG. 28 ; 
           [0043]      FIG. 31  is a cross sectional view of a connectorless alternative embodiment of a socket assembly according to the present invention; and 
           [0044]      FIG. 32  is a cross sectional view of the socket assembly of  FIG. 31  along lines  32 - 32  of  FIG. 31 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0045]    Referring to the Figures wherein like numerals indicate like or corresponding parts throughout the several views,  FIGS. 1-4  show a preferred embodiment of the lamp socket assembly  10 . The assembly includes a base or housing  12 , a body  14 , and a bulb or lamp  16  shown here as a two-filament lamp. It should be noted that the lamp socket assembly of the present invention can accommodate lamps with various numbers of filaments. The lamp includes a lamp base  17  which is inserted into lamp socket assembly  10 . A flange seal  18  is provided for sealing the lamp socket assembly  10  to a panel, such as an automobile panel. A socket connector  20 , as best shown in  FIGS. 2 and 3 , is inserted into a socket  22 . Socket connector  20  includes electrical connector terminals (not shown) which are connected to wires (not shown) for connecting the lamp socket assembly to a source of electric power. 
         [0046]    It should be noted that, while not illustrated herein, the socket assembly may be used with a sealed light assembly, such as an automobile tail light assembly. Such assemblies include a lens and a housing wherein the lens is sonically welded to the housing. Thus, moisture cannot enter the assembly except through the access holes into which the socket assemblies are inserted. By providing proper sealing of the socket assembly access holes, such as disclosed for the socket assembly according to the present invention, the entire light assembly is sealed. Thus the lamps or light bulbs will be internal to the light assembly and will be completely sealed as further described hereinafter. It should also be noted that such light assemblies may be used not only for tail lights for automobiles but also for the turning lights, running lights, etc. Furthermore, such assemblies may also be used in other vehicles such as, for instance, boats. 
         [0047]    Flange seal  18  is seated on a mounting flange  24  and seals that flange and therefore the entire lamp socket assembly to an automobile panel. 
         [0048]    The housing base  12  includes a socket cavity  25  in which a contact insert  26  is received. Contact insert  26  includes a plurality of contacts  28 . The number of contacts  28  may vary depending upon whether the lamp socket assembly is intended for a single or double filament lamp. Contact insert  26  is captured in socket cavity  25  by means of body  14 . Body  14  is sonic welded or secured in some other suitable fashion to base  12  as further described hereinafter. 
         [0049]    Body  14  includes locking lugs  36   a ,  36   b , and  36   c . The locking lugs  36  are used to lock the entire socket assembly to a panel. Thus the panel would have only a relatively small opening therein including cut-out portions to accommodate locking lugs  36 . Each of the locking lugs  36  has a different shape so that the assembly is keyed to the opening in the panel and cannot be inserted incorrectly. The entire lamp socket assembly is thus inserted into the panel aperture and, in the case of an automobile tail light, is inserted with the assembly base  12  extending into the trunk space and the glass envelope of the lamp  16  extending outside the trunk space into the sealed tail light assembly. Seal  18  provides a moisture barrier for the aperture of the tail light assembly. Lamp  16  is retained in lamp socket assembly  10  by means of retaining fingers  38  which are integrally molded with body  14  and are resiliently hingedly connected to the main part of body  14 . Lamp base  17  includes a pair of grooves  39   a  and  39   b . Retaining fingers  38  which have matching projections thereon for engaging grooves  39   a  and  39   b  retains the lamp  16  securely in the lamp socket assembly. 
         [0050]    Thus when the lamp socket assembly  10  is installed in a tail light assembly, the panel would be captured between the bottom surfaces of lugs  36  and the top of flange seal  18 . By compressing seal  18  to a predetermined pressure per square inch, the assembly would be properly sealed against moisture. 
         [0051]    It should also be noted that by changing the portion of body  14  which extends upwardly from lugs  36 , as shown in  FIG. 1 , the focal length of the lamp socket assembly can be varied. The focal length is the distance “a”, shown in  FIG. 1 , between the bottom of lugs  36  and the location of the lamp filament Thus one advantage of the instant lamp socket design is that, by simply changing the length of the body  14  and the length of the contact insert  26 , the focal length of the entire assembly can be varied while retaining the same base  12 . 
         [0052]    Body  14  includes a through passage  42  into which the lamp base  17  and the contact insert  26  is received. It can be seen in  FIG. 2  that contact insert  26  includes a pair of contact insert posts  40 , as further described hereinafter, between which lamp base  17  is received. Lamp base  17  includes contact wires  44  for contacting electrical contacts  28  to provide electric power to the lamp filaments. Blade terminals  46  in turn contact electrical contacts  28  as further explained hereinafter to provide the electrical connection between the wires leading up to the socket and contacts  28 . Blade terminals  46  are captured in socket cavity  25  by means of struck out tabs  48  in the blade terminals and shoulder  50  in cavity  25  of housing  12 . Thus, once the blade terminals  46  have been inserted into the assembly and capture contacts  28  therein, as explained hereinafter, the blade terminals  46  cannot be retracted or pulled out. 
         [0053]    The entire assembly includes further seals for reducing the risk that moisture will reach the interior of socket cavity  25  and possibly corroding the electrical contacts. As best seen in  FIG. 3 , wire seal  56  is provided in a cavity  57  of socket connector  20 . The wire seal includes a plurality of wire apertures through which the individual wires (not shown) extend. Seal  56  also includes ribs  64  to provide a positive moisture seal. Thus the risk that moisture will leak into the socket cavity past the connecting wires is substantially reduced. A ring seal  58  is provided around socket connector  20  to seal the socket connector  20  in socket  22  of base  12 . It should be noted that ribs  66  are provided to improve a positive seal. Socket wire seal  56  and ring seal  58  are preferably manufactured of a resilient and flexible material such as, for instance, silicone. Similarly, flange seal  18  is preferably manufactured of a resilient and flexible material such as silicone. By means of the three seals  18 ,  56 , and  58 , the interior of cavity  25  is substantially sealed against moisture, although there is always some risk that moisture will be able to enter socket cavity  25  from the ambient space. 
         [0054]    Referring now to  FIGS. 5-8 , the base or housing  12  of the socket assembly is shown. In particular, by referring to  FIG. 5 , it can be seen that a plurality of energy directors or ribs are provided on the bottom surface of the socket cavity  25 . By referring to the detailed partial view of  FIG. 7 , it can be seen that triangular portions  72  are provided on the top surfaces of the energy directors  70 . Energy directors  70  are used for welding the body  14  to base  12  by means of sonic welding. The provision of the energy directors  70  ensures secure attachment of the body and base. 
         [0055]    It should be noted, by reference to  FIG. 3 , that energy directors  70  extend axially upwardly in cavity  25  from the bottom wall  80  of the cavity. The number of energy directors  70 , their height and thickness as seen in  FIG. 6 , and their spacing is critical. 
         [0056]    As further illustrated in  FIG. 1 , the space between the bottom surface of lugs  36  and the top surface of mounting flange  24  must be closely held during the assembly of body  14  to housing  12  in order to achieve the proper compression of seal  18  in the mounting of lamp socket assembly in a panel (not shown). By selecting the proper height, thickness, spacing and number of energy directors, this space for accommodating the panel thickness can be closely held. 
         [0057]    Base  12  also includes a key  74  which is used for properly orienting body  14  with regard to base  12 . Two contact insert keys  76  are also provided in cavity  25  to properly locate contact insert  26  in cavity  25 . Socket  22  includes a pair of windows or apertures  78  for securement therein of a pair of fingers (not shown) which are part of socket connector  20  and which lock socket connector  20  to housing  12 . 
         [0058]    As best shown in  FIGS. 3 ,  5 ,  6 ,  8 ,  9 ,  30 ,  31  and  33 - 35 , a vent hole  82  is formed in the bottom wall  80  for the purpose of equalizing pressure within the installed lamp enclosure, and for allowing any accumulated moisture or vapors to escape. Moisture can infiltrate the seals  56 ,  58 , or trapped vapors can be the natural result of material outgassing, or temperature differentials can result in the ingress or egress of air in the interstitial spaces between socket cavity  25  and lamp socket  14 . The vent hole  82  is covered on the interior side by a patch of hydrophobic and/or oleophobic membrane  83 . As is known in the art, hydrophobic membranes repel water from entering the lamp enclosure while permitting air, vapors and moisture to evacuate through the vent hole  82 , whereas an oleophobic membrane will repel oils. Such membranes can be made of woven fabric obtained commercially from companies like Gore and Nitto Denko. For example, a suitable hydrophobic and/or oleophobic material may be found by reference to U.S. Pat. No. 6,210,014 assigned to Gore Enterprise Holdings, the entire disclosure of which is hereby incorporated by reference. 
         [0059]    The decision whether to use a hydrophobic or oleophobic material for the membrane  83  is largely determined by the intended application. Ideal applications for a hydrophobic membrane vent patch  83  are those that are exposed to water. Using a hydrophobic type membrane allows the lamp assembly  10  to maintain a stable internal pressure while preventing water from contaminating the socket cavity  25 . By contrast, in applications where low surface tension fluids are more likely to come in contact with the lamp assembly  10 , an oleophobic membrane material is preferred. This is because low surface tension fluids have a smaller contact angle than high surface tension fluids like water. Low surface tension liquids can penetrate the pores of a hydrophobic membrane and result in total loss of airflow through the membrane. Oleophobic materials are specially designed to resist wet-out from low surface tension fluids, and can be obtained commercially from companies like Gore. In some applications, where both water and oil-based infiltration is likely, it would be possible to use both hydrophobic and oleophobic materials for the vent patch  83 . These may either be combined in one integrally woven material, or in a multi-layered form. 
         [0060]    The vent hole  82  can be formed in the bottom wall  80  by either a drilling or molding operation, after which the hydrophobic vent patch  83  is affixed such as by adhesive, sonic welding, or other appropriate technique. Preferably, although not necessarily, the vent hole  82  is round, and the vent patch  83  may also have a generally round shape. However, the vent patch  83  is formed considerably larger than the size of the vent hole  82  so that the vent patch  83  overlies the entirety of the vent hole  82  with overlapping edges. It is these overlapping edges that are glued, welded, or in some other manner affixed to the inner surfaces of the bottom wall  80 . In applications where the socket cavity  25  is generally cylindrical, such that it is centered about an imaginary axis that passes through the bottom wall  80  of said housing  12 , the vent hole  82  may also be aligned along imaginary axis. However, it is not critical that the vent  82  intersect the imaginary central axis of the socket cavity  25 , and instead be located at some other strategic location communicating with the socket cavity  25 . Furthermore, in some cases it may be desirable to include more than one vent hole  82  which is covered by a common vent patch  83  or each by dedicated vent patches  83 . 
         [0061]    The method for venting moisture from the confines of a sealed lamp assembly  10  through a vent hole  82  in the socket cavity  25  comprising the steps of: providing a housing  12  having a socket cavity  25  defined by side walls and a bottom wall  80 ; forming a vent hole  82  though the bottom wall  80  of the socket cavity  25 ; inserting a lamp socket  14  in the socket cavity  25  of the housing  12 ; inserting the base  17  of a lamp  16  in the lamp socket  14 ; forming a vent patch  83  from a hydrophobic and/or oleophobic fabric material; and covering the vent hole  82  with the vent patch  83  applied from the inside of the socket cavity  25 . 
         [0062]    The method according to this invention is particularly conducive to fully automated manufacturing processes which result in product being manufactured at minimal cost and effort. Furthermore, the subject technique has shown better moisture evacuation over prior art venting methods. The invention eliminates the need to design a venting system within the lamp construction, as taught by many prior art systems. Rather, the vent system is incorporated into the socket feature, thus making the design and construction of the lamp housing less costly. By eliminating the hole through the housing, as taught by prior art designs, a potential visual impact is also avoided. Likewise, there is no need to design camouflaging features that hide the vent hole. 
         [0063]    A further advantage of this invention is understood by a comparison to the prior art technique by which the vent hole was manually formed in a lamp housing, which substantially increased cost and slowed the production through-put. The subject invention eliminates this cumbersome process from the lamp housing manufacturing process. For the subject socket assembly  10 , the vent hole  82  can be fully automated into the manufacturing process at minimal cost and effort. And finally, testing has demonstrated that the subject technique provides better moisture evacuation over current production methods. 
         [0064]    Referring now to  FIGS. 10-14 , body  14  is shown. The body includes a through aperture or passage  42  and a pair of ribs  90  therein. These ribs guide lamp base  17  when it is inserted into the through passage  42 . Retaining fingers  38  are molded integrally with body  14  and are hinged at  106 . Fingers  38  are therefore resiliently connected and are biased inwardly into through passage  42  so that they firmly grasp a lamp base  17 . The fingers can move outwardly into spaces  92  located directly behind fingers  38 . Slots  93  are located immediately adjacent to fingers  38 . A key slot  94  is provided in body  14  to cooperate with key  74  in socket cavity  25  to properly orient body  14  during assembly thereof to base  12 . A further slot  96  is provided in the lower portion of body  14  for accommodating contact insert  26  during assembly thereof to base  12  and body  14 . One or more ribs  98  are provided on the bottom of body  14  for cooperating with energy director  70  and for welding body  14  to base  12 . Some of the energy directors  70  also contact bottom surface  100  of body  14  for securement thereto by means of sonic welding. 
         [0065]    By referring to  FIGS. 1 and 13 , it can be seen that lugs  36  include camming surfaces  102 . Camming surfaces  102  enable the lamp socket assembly to be properly assembled to an automobile panel or tail light housing by camming over the surface of the automobile panel or tail light housing to provide sufficient pressure between flange seal  18  and the panel or housing to form a proper seal. Lastly, shoulders  104  are provided in through passage  42  to accommodate and guide a lamp base  17  during its insertion thereof into through passage  42 . 
         [0066]    Base  12 , body  14 , and contact insert  26  and socket  20  may all be molded from a suitable insulating material such as, for instance, nylon which may be glass filled. This material is sufficiently rigid so that it cooperates properly with flexible resilient seals  18 ,  56 , and  58  to properly seal the structure against moisture as described hereinabove. 
         [0067]    Turning now to  FIGS. 15-18 , electrical contacts  28  for the lamp socket assembly  10  are illustrated. The contacts are constructed of a suitable conductive material, such as brass. The contacts include U-shaped bent portions  114  which have a window  116  therein for insertion of blade terminals  46  therethrough as shown in  FIGS. 3 and 4 . The contacts  28  include a contacting portion  118  and a bent portion  119  for contacting lamp contact wires  44 . U-shaped bent portion  114  includes a bottom leg  124  and an upper leg  126 . Upper leg  126  includes a struck out protrusion  122  for providing proper contact with blade terminal  46  during insertion thereof into the assembly. 
         [0068]      FIGS. 15 ,  16 , and  17  show a terminal for the assembly.  FIG. 18  shows a ground terminal for the assembly. The ground terminal has an offset portion  128  whereby the terminal may be inserted into the contact insert in one lateral location whereas the main body of the terminal is offset from that location for proper contact. 
         [0069]      FIGS. 19 and 20  show a blade terminal Blade terminal  46  is a planar terminal having two end portions  142 ,  144  which are somewhat thinner than central portion  146 . Central portion  146  includes a struck out tab  48  for preventing blade terminal  46  from being pulled out of the socket assembly once it has been assembled thereinto. End portion  144  is inserted into the base  12  through a window  116  of a contact  28  as further explained hereinafter. End portion  142  extends into socket  22  for contacting a terminal (not shown) in socket connector  20 . 
         [0070]      FIGS. 21-25  show a contact insert  26 . Contact insert  26  includes a base  150  which is generally planar. A pair of walls  152  are integrally formed with base  150  and extend upwardly therefrom to form a groove  153  therebetween. Key slots  154  are provided at either end of base  150  for cooperating with keys  76  in socket cavity  25  of base  12  for properly orienting the contact insert  26  during assembly thereof to base  12 . Additionally a key aperture  160  is provided centrally of base  150  for proper orientation of the contact insert  26  during assembly thereof to base  12 . Base  150  includes a plurality of windows  156  and slots  158  for accommodating contacts  28  and blade terminals  46 . Posts  40  are formed integrally with and extend upwardly from base  50  for properly guiding a lamp base  17  into groove  153 . 
         [0071]      FIGS. 26 and 27  show the flange seal  18 . The flange seal comprises a flange  168  with a pair of upstanding ribs  164  at the outer perimeter thereof. An aperture  166  is provided in the flange seal for accommodating body  14 . 
         [0072]    Referring now to  FIGS. 1-3 , the lamp socket assembly is assembled as follows. Molded contact insert  26  is first assembled with a set of contacts  28 . The U-shaped bent portion  114  of each contact is inserted into the appropriate slot  158  of base  150  of the contact insert with the rounded portion  118  of the contact facing groove  153 . Since the material from which the contacts  28  are made is somewhat resilient, the contacts are resiliently retained in slots  158 . Contact insert  26  is then inserted into cavity  25  of base  12 . Because of the location of keys  76  and  82 , improper assembly of the contact insert  26  in base  12  is prevented. Body  14  is now inserted into socket cavity  25  and is properly oriented therein by means of key  74  and key slot  94 . Body  14  captures contact insert  26  in cavity  25  by engagement of contact insert base  50  in contact insert slot  96  of body  14 . Thus the contact insert is properly captured and is immovably fixed in socket cavity  25 . The assembly is now subjected to sonic welding or another suitable welding technique which is applied to bottom  80  of base  12 . Sonic welding is a well known process and therefore need not be explained further herein. The provision of energy directors  70  with upstanding triangular ribs  72  thereon provides proper guidance to the energy applied by the sonic welding process to provide melting of portions  72  and securement of body  14  to base or housing  12 . If sonic welding is used, as explained hereinbefore, the thickness and height of the energy directors  70  is critical for the particular spacing and number of energy directors shown. The energy directors are axially oriented with respect to the cavity  25  and body  14 . Thus as the body and housing are welded together, the energy directors will melt and the body  14  will enter the cavity  25  further. Sonic welding will be stopped when the distance between the bottom surface of lugs  36  and the top surface of mounting flange  24  is within prescribed limits. By proper design of axial energy directors  70 , the strength and uniformity of the sonic weld will be within acceptable tolerances. 
         [0073]    An appropriate number of blade terminals  46  are now inserted through windows  47  of base  12 , windows  156  of contact insert  26  and windows  116  of contacts  28 , thereby capturing the contacts  28  firmly in contact insert  26  and the contact insert in base  12 . Blade terminals  46  are retained in the assembly by means of tabs  48  which interlock with blade retaining shoulder  50  of base  12 . A socket insert  20  is now provided with seals  56  and  58  and with appropriate wires and contact terminals (not shown). Socket  20  is inserted into socket  22  to complete the assembly. It can thus be seen that the entire assembly is extremely simple and forms a sealed structure to prevent contamination and corrosion of the electrical contacts by moisture. Furthermore, it can be seen that the portion of the socket assembly extending into the trunk space of an automobile, namely base or housing  12 , is very small indeed. The typical extension of the base  12  into the trunk area is ½″ or less. 
         [0074]    Referring now to  FIG. 9 , it can be seen that various assemblies with different focal lengths may be provided utilizing the same basic socket assembly design. By referring to the focal length “a” of  FIG. 1  and comparing this to the focal length “b” of  FIG. 9 , it can be seen that they are different. The focal length is defined as the distance from the bottom of lugs  36  to the filament location. The body  14  of the assembly of  FIG. 9  has a higher extension “c” extending beyond the top surface of lugs  36  (schematically illustrated) than the body  14  illustrated in  FIG. 1 . Therefore the focal length of the assembly of  FIG. 9  is different and longer than the focal length of the assembly of  FIG. 1 . By varying the distance “c”, the focal length of the structure can be changed in a very simple manner. Base  12  of the assembly  FIG. 9  is identical to the base  12  of the assembly of  FIG. 1 . Thus, the longer focal length of the assembly of  FIG. 9  is accompanied by an identical extension of base  12  into the trunk space of the automobile. The assembly of  FIG. 9  also utilizes a different contact insert  26  and contacts  28  than the assembly of  FIG. 1  in order for the lamp base  17  to be able to reach contacts  28 . The contacts  28  of  FIG. 9  also have longer extensions as can be seen by comparing the contacts  28  of  FIGS. 3 and 9 . Thus, it can be seen that the structure can be adjusted for a variety of focal lengths by the simple provision of a different body  14 , contact insert  26 , and contacts  28 . The extension of the assembly into the useable trunk space remains the same. 
         [0075]    Referring now to  FIGS. 28-30 , there is shown a further embodiment of the present invention including a locking wedge which locks together base  12  and body  14 . The locking wedge is inserted into a slot  172  of the socket connector  20 . The locking wedge includes a planar tab portion  176  having a pair of shoulders  178   a  and  178   b  which are keyed with respect to slot  172  so that the locking wedge can only be inserted in a desired orientation. Tab  176  includes a U-shaped slot  180  which forms a wedge locking tab  182  and which is so molded as to extend resiliently upwardly as shown in  FIG. 30 . Thus, wedge locking tab  182 , upon insertion of locking wedge  174  into slot  172 , will snap into space  183  to prevent the locking wedge from being pulled out of connector  20 . Stops  184  abut against connector  20  to prevent locking wedge  174  from being inserted too far into slot  172 . The purpose of the locking wedge is to prevent the resilient fingers  186  of connector  20  from being displaced upwardly and to ensure that locking tabs  188  of fingers  186  will engage with the connectors (not shown) to provide proper contact thereof with blade terminals  46 . 
         [0076]    Locking wedge  174  also includes a snout or protrusion  190  which, upon insertion of connector  20  into socket  22 , will be inserted into aperture  192  of housing  12  and aperture  194  of body  14 . Apertures  192  and  194  are aligned whereby snout  190  may be simultaneously inserted thereinto. 
         [0077]    Snout  190  ensures that body  14  will be locked in place, even if the weld connecting body  14  to housing  12  should fail. Thus, upon insertion of the socket connector  20 , the entire socket assembly is locked together. 
         [0078]    While the protrusion  190  is located on the locking wedge it should be noted that it could be placed elsewhere on the socket connector. 
         [0079]    Referring now to  FIGS. 31 and 32 , there is shown an alternative embodiment of the invention. These figures disclose a connectorless socket assembly. Instead of the use of a socket connector including contacts for connecting with blade terminals  46 , this embodiment does not use a socket connector. Rather, wires  198  are directly crimped to blade terminals  202  by means of crimps  200 . Alternatively, wires  198  could be soldered to the blade terminals  202 . The wires are sealed in socket  22  of housing  12  by means of a wire seal  56  as described hereinabove. In the assembly of this embodiment, the blade terminals are crimped to wires  198 , a seal  56  is then slipped over the blade terminals and wires  198 , the blade terminals  202  are then inserted into the socket assembly and the seal is placed into socket  22  to seal the wires  198 . Thus, in this particular version, a connector would be placed downstream of wires  198 . Further, several socket assemblies could be connected to a single connector. For instance, in a tail light assembly of an automobile, several socket assemblies such as, for instance, three, might be used whereas a single connector would be used to connect three socket assemblies to the wiring harness of the automobile. 
         [0080]    The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and fall within the scope of the invention. Accordingly the scope of legal protection afforded this invention can only be determined by studying the following claims.