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Патент USA US3094649

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3,094,640
June 18, 1963
D . S. GUSTIN
HARNESS FOR SUPPORTI NG HIGH PRESSURE ARC DISCHARGE
TUBE WITHI N OUTER ENVELOPE,‘ AND
LAMP FORMED THEREBY
2 Sheets-Sheet 1
Filed Dec. 19, 1960
DANIEL S. GUSTIN
INVENTOR.
8%,
A TORNEY
June 18, 1963
D. s. GUSTIN
3,094,640
HARNESS FOR SUPPORTING HIGH PRESSURE ARC DISCHARGE
TUBE WITHIN OUTER ENVELOPE, AND
LAMP FORMED THEREBY
Filed Dec. 19, 1960
2 Sheets-Sheet 2
DANIEL S. GUSTIN
INVENTOR.
AT ORNEY
United States Patent 0 " ice
3,094,640
Patented June 18, 1963
2
1
3,094,640
HARNESS FOR SUPPORTING HIGH PRESSURE
ARC DISCHARGE TUBE WITHIN OUTER ENVE
LOPE, AND LAMP FORMED THEREBY
Daniel S. Gustin, Londonderry, N.H., assignor to Sylvania
Electric Products Inc., a corporation of Delaware
Filed Dec. 19, 1960, Ser. No. 76,799
12 Claims. (Cl. 313-25)
harness of this invention before the various folding opera
tions.
FIGURE 3 is a top plan view taken along the lines
3—3 of FIGURE 4. vIn this figure the bulbous glass en
velope surrounding the arc tube is not shown.
FIGURE 4 is an illustration of a side elevational view
of the unitary arc tube harness according to this invention,
taken along the lines >4—4 of FIGURE 3.
In each of the ?gures, similar numerical designation
This invention relates to high-pressure, electric dis 10 will connote similar elements.
charge devices and more particularly to an improved arc
The invention will be illustrated with reference to a
high pressure mercury vapor lamp since it is generally
tube support generally called a harness.
used in such construction, but the harness can also be
High pressure electric discharge lamps are well known
used in ‘other similar devices.
and are described, for example, in United States Patent
As will be seen in FIGURE 1, the unitary harness 1
2,901,647 to M. J. Thomas et al. Such lamps comprise 15
for supporting the arc tube 15 is positioned generally
an inner arc tube mounted in a surrounding, light-trans
in the central portion of the bulbous envelope 3. In
mitting, outer envelope by an intermediate supporting
order to obtain the maximum e?iciency for the lamp, it
harness. The outer envelope may be left clear or may
is conventional practice to axially position the arc tube
be coated with phosphor material as desired.
In the manufacture of such lamps‘it has been found 20 15 in the bulbous envelope. However, if it is desired
to rearrange the positioning, this axial relationship may
that one of the more troublesome steps is the sub-as
be ‘changed. The harness '1 comprises the two elongated,
sembly operation of constructing the harness which holds
the arc tube in the outer envelope.
This harness gen
erally comprises a large number of structurally stable
spaced struts 5 and 7.
In most cases the struts 5, 7
can be substantially parallel, ‘but other con?gurations
bent wires and metal supporting brackets which are spot 25 can be used, if desired. The supporting cross arms 9 and
11 extend from one strut to the other and space them
welded together in separate steps. Each spot weld affords
apart. Tabs attached to these arms hold the arc tube
an opportunity for imperfection in lamp construction and
15 in the bulbous envelope 3 in a generally co-axial
accordingly it is desirable to eliminate such wires, brack
position. Tabs 17 and 18 which extend from the upper
ets, and spot welds. Furthermore, it is desirable to pre
supporting cross arm 9 serve as the upper attaching sup
pare as much as practical of the construction in a unitary
port for the arc tube. Extending from the lower sup
stamped-out design.
porting cross arm 11 is a generally U-shaped tab 19
For such reasons, attempts have been made to use a
which serves as the lower attaching support for the arc
single-wire arc tube support, wherein a metal wire is suit
tube. These tabs are folded over the flattened end por
ably bent and shaped to support the arc tube in the bulbous
envelope. Such constructions, however, are not entirely 35 tions ‘61 of the arc tube and rigidly attach the arc tube
to the harness. Also provided on each of the supporting
acceptable since there is not signi?cant diminution of the
cross arms are the stamped out guides 21 which are
number of spot welds required to fabricate the harness
adapted to engage the sides of the pinched portions 61
nor does it produce a structurally stable device.
Another proposed harness comprises ‘a pair of similar 40 of the arc tube and prevent its lateral movement in the
harness. The electrical contact cross arm 23 extends
stamped-out support members, which are spot welded in
between struts 5 and 7 and is positioned above the upper
numerous places after the arc tube has been positioned ,
supporting cross arm 9. One electrode or" the arc tube
between suitably shaped cross arms. This design was
is affixed to this cross arm. Generally the lead-in Wire
not entirely satisfactory since the number of spot welds
is not appreciably reduced. Furthermore, it makes no 45 25 may be inserted in a suitable stamped portion 27.
Although no welding is generally necessary for this at
provision for accommodating small variations in lengths
tachment, it may be utilized if desired. In addition to
from tube to tube.
When prefabricating a lamp using the unitary harness
providing an electrical contact, the cross arm 23 also in
creases the stability of the harness in the lamp and will
as proposed in this invention there are no spot welds
utilized to prepare the harness itself; only a few are nec 50 provide transverse support for the upper portion of struts
' 5 and 7. Although the cross. arm 23 is shown as a hori
essary for the attachment of the various electrical con
zontal bar, it is apparent that it may haveother shapes.
tacts. Furthermore, the harness is ‘shaped to each in_
The resilient bumpers or bulb spacers 29, 28, 6 and 12
dividual arc tube and small di?erences in the length of
each tube may be compensated without any difficulty.
are in contact with the upper tubular portion of the glass
Accordingly, an object of the present invention is the 55 envelope 3. These bumpers maintain co-axial position
ing of the harness and are tube even when the lamp is
fabrication of a structurally stable, unitary, stamped-out
subjected to shocks such as shaking and jarring. It is
arc tube harness requiring a ‘minimum number of welds.
highly advantageous to have such resilient spacers in the
An advantage of this invention is that the number of
lamp, and it is-quite important that they are a unitary
spot welds necessary has been reduced from twenty-two
to six, thus reducing the manual labor required to fabri 60 part of the stamped-out harness. Prior attempts to fab
ricate a stamped-out harness have not provided such in
cate the arc tube supports.
tegral resilient spacers and it was necessary to rigidly posi
Another advantage of this invention is the ease and
tion the upper portion of the harness in a protuberance
cheapness of mounting the arc tube and preparing the
in the glass envelope. It is apparent, however, that if it
harness.
Other objects and advantages of this invention will be 65 is desired to have an outer bulbous envelope of different
construction, the harness may be adapted to be rigidly
come apparent to those skilled in the art upon reading
the following speci?cation when taken in conjunction
with the accompanying drawings.
placed in the envelope without these bulb spacers. This
type of positioning is obtained by eliminating the bulb
spacers and extending the upper portion of the electrical
FIGURE 1 is an elevation view of a high pressure dis
charge lamp wherein the arc tube harness is shown po 70 contact cross arm 23 to generally ?t in a protuberance in
the envelope.
sitioned within a glass envelope.
To protect the resistor 37 and di?fuse heat vfrom the ends
FIGURE 2 is an illustration of the stamped arc tube
3,094,640
4
of the lamp, the heat shield 30 is positioned below the
arm 9. These guides may be bent to an angle of about
90° with respect to the supporting cross arm to provide
lateral support for the arc tube.
A U-shaped tab 19 extends from the lower cross arm
11. In the central portion of this tab an aperture 32 is
provided for the lead-in wires of the arc tube. The Wires
33 and 35 must be electrically insulated from the harness,
since the harness is used as a means for conducting elec—
lower cross arm ‘11. An aperture 31 is provided in the
central portion of the heat shield 30 so that the lead-in
wires 33 and 35 will not contact the harness. Through
the use of this aperture conventional tubular glass in
sulators around the wires 33 and 35 may be eliminated.
If additional insulation is desired, however, they may be
added.
'
In the lower portion of the unitary harness a cross arm
tricity to the other electrode. Two additional guide
26 is provided to position the lamp in the bulbous en 10 means 21 are provided on the lower cross arm 21; when
velope. The structurally stable lead-in wire 39 is inserted
into the stamped-out portion 40 of the positioning cross
bent out in the appropriate Ibending operation these guides
will inhibit the lateral movement of the are tube in the
arm 26.
Spot welding may be utilized, if desired. This , harness.
construction will insure the uniform positioning of the
The heat shield 30 is positioned beneath the cross arm
harness in the lamp and will provide a structurally stable 15 11. An aperture 311 is stamped in the central portion
base for the assembly. If it is desired to rotate the harness
thereof for the passage of appropriate lead-in wires. The
90° about its longitudinal axis, the positioning of the
shield 30 is joined to the struts 5 and 7 and the support
stamped-out portion 40 may be offset ‘from the co-axial . ing cross arm 11 by means of the bendable portion 14.
so that there will be no electrical contact between the lead
The remainder of the heat shield is stamped through so
in wire 43 and the positioning cross arm 26.
20 that it may be bent to an angle of about 90°, with respect
In the sealing operations it is general practice to have
to the cross arm.
gases pass in and out of the aperture 49 of the re-entrant
stem press 46. A ba?le is provided to prevent gases from
Above the cross arm 9 is the electrical contact cross
member 19 may be modi?ed by providing elongations in
sheet, properly stamped and so designed whereby the
ruggedness of previous wire harnesses is exceeded, and
arm 23 having a stamped aperture 27. Indentations 10
directly contacting the bulbous glass envelope 3 as a
may be added to improve stability. The stamped aper
stream and dislodging some of the coated phosphor. This
ture is provided to permit the insertion of the lead-in
batiie is positioned directly in ‘front of the re-entrant 25 wire 25 of the are tube (shown in FIGURE 1). Above
aperture 49 and comprises the plate 45 and the stem 47.
the electrical contact cross arm is a series of four ?ngers
The stem 47 is bent around so that the plate may be placed
or bumpers 12, 6, 28 and 29'. The bumpers attached to
directly in front of the aperture 49.
the same strut are bent in opposite directions to a posi
The remainder of the lamp is of substantially conven 30 tion of about 90". As noted previously if it is desired
tional construction. The glass of the envelope 3 is sealed
to have a rigid construction rather than ‘the resilient con
to the threaded cap 53, which in turn is insulated from
struction of this invention this entire upper portion of
the electrical contact 55 by means of the insulating ring
the
harness, including the electrical contact 23, may be
57. In the same manner the arc tube ‘15 is of conven—
redesigned.
tional construction and comprises a light-transmitting en 35
In the lower portion of the unitary harness the plate
velope 59, normally fabricated of quartz, or similar heat
45 is shown attached to stem 47. To fabricate the har
resisting material. Seals 61 are conventionally provided
ness, plate 45 is bent 90° with respect to stem 47. The
at either end of the :arc tube. These seals may be either
stem 47 is then angled back to place the plate 45 in front
?attened, pinched portions or may assume a generally
of
the ire-entrant hole 41 (shown in FIGURE 1).
cylindrical shape. In the case of a seal having a generally
Thus the unitary harness is made of a single metal
cylindrical shape, the tabs l17 and the U-sha-ped support
order to suitably support the arc tube. Ribbon sealed
conductors are sealed in each of the pinched or sealed
substantial savings in manual labor are realized.
each of the lead-in wires 35, 33 and 25. At the other end
of the ribbon conductor the conventional electrodes 34
and starting electrode 36 are attached. For purposes of
electron emission a thorium sliver is desirably included as
part of the electrodes 34, which may be fabricated of
tungsten for example, by conventional electrode construc
Fur
thermore, the number of spot welds needed to fabricate
a lamp is markedly reduced.
‘FIGURES 3 and 4 are showings of the harness after
the bendable portions are aligned in their appropriate
positions. As is seen each of bumpers 12, 98, 6 and 28
portions 61. These conductors ‘are attached at one end to
are bent 90° in opposite directions so that they are in
50
substantially parallel alignment. The heat shield 30 is
bent upwardly about 90° and the plate 45 is bent 90° with
the stem 47 helically bent to properly position it in front
of the re-entrant hole.
In assembling the lamp, a suitable are tube 59 is placed
The metal used in the unitary harness should be strong,
durable and heat resistant; it may be, for example, sheet 55 on the cross arms, the guides 121 having previously been
bent :out and the U-shaped tab 19‘ bent around the pinched
stock such as 10 mil nickel-plated iron. Although this
portion 61. The lead-in wires 33 and 35 are placed
metal is quite strong in itself, it is often desirable to
through the aperture 32 in the U-shaped tab 19. After
strengthen ‘the harness by adding indentations 10' and 22.
proper positioning is assured, the tabs 17' and 18 are bent
These indentations may be placed elsewhere on the har
60 around the upper portion 61 of the arc tube. This bend
ness where it is desired to have additional stability.
Reference is now made to FIGURE '2 which shows the
ing after positioning of the ‘arc tube is quite important,
stamped harness prior to its being bent into shape. The
since small differences in linear length of the arc tube
struts 5 and 7 have attached stiffening portions 4 and 8
will be compensated for and a rigid attachment of the
which were adapted to be bent to an angle of about 90°
arc tube to the harness will be insured. The electrical
with respect .to the struts. In this manner, although rela 65 lead 25 is placed in {the aperture 27 provided in the elec
tively thin and inexpensive sheet stock is used, the neces
trical contact cross arm 23 and spot welded if desired.
sary structural stability is obtained. The upper support
Although an aperture is shown, this lead may be directly
ing cross arm 9 has two tabs '17 and 18 extending from
spot welded to the electrical contact cross-arm if desired.
the upper portion thereof. These tabs are adapted to be
70 After the arc tube is positioned the electrical leads 33 are
bent around the pinched portion of the arc tube. Two
welded to lead-in wire 43. Electrical contact 55 has
tabs are used so that the lead-in wire 25 (as shown in
previously been welded to lead-in ‘wire 43 which in turn
FIGURE 1) may extend upwardly from the arc tube and
is welded to the heat shield 30. The harness with the
no changes need to be made in the arc tube design. Two
stem is then mounted in the bulbous envelope by con~
stamped-out guide means 21 are provided on the cross 75 ventional means. The cap 53 with insulation 57 and
tion methods. The are tube contains a selected charge
of mercury and an inert ionizable gas such as 20 and 25
mm. of mercury of argon.
3,094,640
electrical contact 55 are sealed to the bulbous envelope
and a ?nished lamp is produced.
It is apparent that changes and modi?cations may be
made within the scope of the instant invention.
It is
my intent, however, to be limited only by the scope of
the appended claims.
I claim:
1. A unitary harness for holding an arc tube compris
ing a single sheet metal frame stamped and shaped into
6
of said supporting cross arms, and means to position said
harness within 1a generally bulbous envelope.
9. A unitary harness ‘for supporting an arc tube having
?attened end portions comprising, a single sheet metal
frame stamped and shaped into a pair of elongated, sub
stantially parallel struts spaced from each other, a pair
of supporting cross arms transversely positioned between
said struts, means to affix the ends of said are tube to
said supporting cross arms said means comprising tabs
a pair of elongated struts spaced from each other, a 10 extending from said supporting cross arms adapted to be
folded around said ?attened ends, an electrical contact
pair of supporting cross arms positioned transversely be
cross arm positioned transversely between said struts
above the upper of said supporting cross arms, a heat
shield below the lower of said cross arms attached to
harness in a bulbous envelope.
2. A unitary harness for holding an arc tube com 15 and positioned between said struts, a re-entrant aperture
‘ba?le attached to the lower portion of said harness
prising a single sheet metal frame stamped and shaped
below the lower of said supporting cross arms, stiffening
into a pair of elongated struts spaced from each other,
means attached to each ‘of said struts positioned substan
a pair of supporting cross arms positioned transversely
tially parallel thereto and in an angular relationship
between said struts, means for attaching the ends ‘of said
tween said struts, means for attaching said arc tube to
said supporting cross arms and means to position said
arc tube to said cross arms, said means comprising tabs 20
therewith, resilient bulb spacers extending transversely
from each of said struts, and means to position said
harness within a generally bulbous envelope.
to fold about said ends and means to position said har
10. A high pressure discharge lamp comprising an arc
ness within a bulbous envelope.
tube, a transparent outer bulbous envelope around said
3. A unitary harness for holding an arc tube compris
ing a single sheet metal frame stamped and shaped into 25 tube but spaced therefrom, a unitary harness fabricated
of a single stamped and shaped sheet metal frame for
a pair of elongated, spaced-apart struts, a pair of sup
holding said tube, said harness comprising a pair of elon
porting cross arms transversely positioned between said
gated struts spaced from each other, a pair of supporting
struts, means for attaching said- are tube to said support
cross arms positioned transversely between said struts,
ing cross arms, a heat shield positioned between said
struts and below the lower of said supporting cross arms, 30 means for attaching said tube to said supporting cross
arms, and means ‘to position said harness in said bulbous
means to position said harness within a bulbous envelope.
envelope.
4. The unitary harness according to claim 3 wherein a
'11. A high pressure discharge lamp comprising, an arc
means forming an aperture is positioned in the central
tube,
a transparent outer bulbous envelope around said
portion of said heat shield.
5. A unitary harness for holding an arc tube compris 35 tube but spaced therefrom, a unitary harness fabricated
of a single stamped and shaped sheet metal frame for
ing a single sheet metal frame stamped and shaped into
holding
said tube, said harness comprising a pair of elon
a pair of elongated struts spaced from each other, a pair
gated struts spaced from each other, a pair of supporting
of supporting cross arms positioned transversely between
said parallel struts, means for attaching said are tube 40 cross arms transversely positioned between said struts,
extending from said supporting cross arms and adapted
to said supporting cross arms, an electrical contact cross
means for attaching said arc tube to said supporting cross
arm positioned between said struts ‘and above the upper
of said supporting cross arms, said are tube adapted to
be in electrical contact with said electrical contact cross
cross arms and adapted to fold about the ends of said
are tube, and means to position said harness within said
arm and means to position said harness within a bulbous 45
envelope.
6. A unitary harness for holding an arc tube compris
ing a single sheet metal frame stamped and shaped into
a pair of elongated, spaced apart struts, elongated spaced
arms comprising tabs extending ‘from said supporting
bulbous envelope.
12. A high pressure discharge lamp comprising, an arc
tube having ?attened end portions, a transparent outer
bulbous envelope around said tube but spaced therefrom,
a unitary harness fabricated of a single stamped and
shaped sheet metal frame ‘for supporting said are tube
apart stiffening means attached to each of said struts 50
comprising a pair of elongated, substantially parallel
and in an angular relation therewith, a pair of spaced
apart supporting cross arms transversely positioned be
struts spaced from each other, a pair of supporting cross
arms positioned between said struts, means to a?ix the
tween said struts, means for attaching said are tube
ends of said are tube to said supporting cross arms, said
to said supporting cross arms, and means to position said
means comprising tabs extending from said supporting
harness in a bulbous envelope.
55 cross arms adapted to be folded around said ?attened
7. A unitary harness adapted to hold an arc tube com
ends, ‘an electrical contact cross arm positioned trans
prising a single sheet metal frame stamped and shaped
versely between said struts above the upper of said sup
porting 'cross arms, a heat shield below the lower of said
between said struts, means to a?ix the ends of said are 60 cross arms attached to and positioned between said struts,
a re-entrant aperture ba?le attached to a positioning cross
‘tube to said cross arms, resilient bulb spacers attached
arm in the lower portion of said harness, stiffening means
to each of said struts and being positioned above the
attached to each of said struts positioned substantially
upper of said supporting cross arms and means to posi
parallel
thereto and in angular relationship therewith.
tion said harness in said envelope.
References Cited in the ?le of this patent
8. A unitary harness adapted to hold an arc tube com 65
into a pair of elongated struts spaced from each other,
a pair of supporting cross arms positioned transversely
prising a single sheet metal frame stamped and shaped
into a pair of elongated, spaced apart struts, a pair of
supporting cross arms positioned transversely between
said struts, means to a?ix said are tube to said support
ing cross arms, a re-entrant aperture baf?e attached to 70
the lower portion of said unitary harness below the lower
UNITED STATES PATENTS
{2,748,306
Thorington ___________ __ May 29, 1,1956
2,749,462
2,802,961
Kenty ________________ .._ June 5, 1956
Jenne _______________ .._ Aug. 13, 1957
2,951,959‘
Fraser _______________ .. Sept. 6, 1960
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