Rectangular halogen lamp unit and method of manufacture

摘要

A rectangular lamp unit and an integral bracket, replaceable as a unit upon bulb burn-out, including a one-piece plastic reflector closed by a rectangular lens with an integral peripheral mounting flange on the reflector adjacent the lens so that the unit can be mounted substantially flush on a mounting panel. The unit is manufactured by applying an epoxy adhesive to a lens recess in the reflector, joining the lens thereto, and then heating the assembly to cure the epoxy. During heating, evolved gases are released from the reflector through a vent hole that is sealed by a vent plug immediately after heating by inserting the plug coated with a silicone rubber sealant into the vent hole to form a thick seal ring and push sealant into irregularities in the hole. The sealant is cured by residual heat from the epoxy curing step.