Method for constructing a one-piece bulbshield

摘要

A one-piece bulbshield is sized and shaped to be disposed into a preformed opening in a reflector of an automotive headlamp. The one-piece bulbshield includes a cup having a defined edge scroll and a pair of legs integrally formed onto the cup, each leg having a flexible, spring engagement foot. A method for manufacturing the one-piece bulbshield from a sheet metal strip using a progressive die press includes the steps of forming a primary outline of the legs and the cup of the bulbshield in the sheet metal strip. The primary outline of the cup of the bulbshield is then drawn. Having drawn the bulbshield, a final outline of the legs is formed into the primary outline of the legs of the bulbshield. The final outline of the legs of the bulbshield is then shaped. The defined edge scroll is then formed into the primary outline of the cup to yield a finished one-piece bulbshield which, in turn, is severed from the remainder of the sheet metal strip.