Patent ID: 8581482

Claim:
A method of making a PAR lamp comprising the steps of: (i) making a subassembly for the PAR lamp comprising the steps of (a) providing a base including a cup-shaped portion with a top edge having an extended flange projecting therefrom; (b) providing a plurality of electrical contacts and inserting the contacts into appropriate locations in a bottom of the cup-shaped portion; (c) providing a lamp capsule including a light source having dependent leads projecting from a base end; (d) inserting the base end of the lamp capsule into the cup-shaped portion and electrically and mechanically connecting the dependent leads to the electrical contacts; (e) providing a reflector having a funnel-shaped body with a substantially tubular neck; (f) filling the cup-shaped portion with a liquid cement to a depth that covers the base end of the lamp capsule; (g) fitting the reflector over the lamp capsule so that the tubular neck is submersed in the liquid cement; and (h) heating the subassembly such that the cement fixes the reflector in place; (ii) providing a funnel-shaped housing ( 50 ) including a tubular termination; (iii) providing a heat sink ( 54 ) to fit substantially in the tubular termination; (iv) providing an electronic ballast for the light source contained within the subassembly; (v) fitting the electronic ballast within the heat sink; (vi) providing an electrical EMI-reducing contact ( 58 ) having a proximal end contacted by the heat sink ( 54 ), a body portion aligned along an interior surface of the funnel-shaped housing and having a distal end provided with at least one sharp edge; and (vii) fitting the subassembly within the funnel-shaped housing in a manner whereby the sharp edge of the distal end makes electrical contact with the outer surface of the reflector and the proximal end makes electrical contact with one said dependent lead ( 34 ) through the heat sink ( 54 ).