Simple lamp layout

Abstract

To provide a high-voltage tungsten halogen lamp layout that is simplified in order to reduce the cost and prevent an arc in a lamp failure.SOLUTION: A lamp assembly comprises: a capsule in which a filament is arranged therein; a press seal that is extended from the capsule, and is constructed so as to hermetically seal the capsule; a first lead and a second lead which are electrically coupled to the filament in the press seal, and extended from the press seal; a first insulation sleeve that is coupled to the first lead in an external part of the press seal; a first conductive cap or a pin that is coupled to the first insulation sleeve; and a first fuse that is arranged in the first insulation fuse, and electrically couples the first lead to the first conductive cap or the pin.SELECTED DRAWING: Figure 3A

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE Embodiments of the present invention relate generally to an apparatus for thermally processing a substrate. More particularly, embodiments of the present invention relate to facilitating the use of high voltage tungsten halogen lamps as thermal radiation sources in rapid thermal processing (RTP) chambers or other lamp heated thermal processing chambers. [Background technology]

[0002] RTP of a substrate involves rapidly heating the substrate, typically by thermal radiation, in a controlled environment to a maximum temperature of approximately 1350° C. This maximum temperature is then held for a period of time that can range from less than a second to several minutes, depending on the particular process, after which the substrate is cooled to room temperature and ready for further processing.

[0003] High voltage tungsten halogen lamps, for example from about 40 volts to about 130 volts, are commonly used as sources of thermal radiation in RTP chambers. High voltage tungsten halogen lamps require a fuse in the circuit to prevent arcing and possible explosion in the lamp during lamp failure. Having a fuse inside the lamp capsule is difficult to implement due to the small capsule size and the possibility of contamination affecting the halogen cycle. Having a fuse inside the lamp press seal can cause undesirable cracks and fractures in the press seal. Therefore, it is desirable to incorporate the fuse outside the capsule and press seal. In current lamp designs, externally mounting the fuse to the capsule and press seal requires a number of additional components (e.g., stainless steel tube, ceramic potting compound, plugs) and requires the lead to be rigid enough to engage the heating assembly base of the RTP chamber.

[0004] It would therefore be desirable to provide a simplified high voltage tungsten halogen lamp design to reduce costs and prevent arcing during lamp failure. Summary of the Invention

[0005] In one embodiment of the present invention, a lamp assembly includes a capsule having a filament disposed therein, a press seal extending from the capsule and configured to hermetically seal the capsule, first and second leads, a third lead extending from the press seal, and a fuse electrically coupling the third lead to one of the first and second leads exterior to the press seal and the capsule. The first and second leads each extend from the press seal electrically coupled to the filament within the press seal. The third lead is electrically isolated from the first and second leads within the press seal.

[0006] In another embodiment, a lamp assembly includes a capsule having a filament disposed therein, a press seal extending from the capsule and configured to hermetically seal the capsule, first and second leads, an insulating sleeve coupled to the first lead exterior to the press seal, a third lead coupled to the insulating sleeve, and a fuse electrically coupling the first lead to the third lead. The first and second leads each extend from the press seal and are electrically coupled to the filament within the press seal.

[0007] In yet another embodiment, a lamp assembly includes a capsule having a filament disposed therein, a press seal extending from the capsule and configured to hermetically seal the capsule, first and second leads, an insulating sleeve coupled to the press seal, a third lead coupled to the insulating sleeve, and a fuse electrically coupling the first lead to the third lead. The first and second leads each extend from the press seal and are electrically coupled to the filament within the press seal. At least the first lead extends into the insulating sleeve.

[0008] The present invention summarized above will now be described in more detail by reference to the embodiments, including those shown in the accompanying drawings, so that the above features of the present invention can be understood in detail. Of course, the present invention encompasses other equivalent embodiments, so it should be noted that the accompanying drawings are merely illustrative of typical embodiments of the present invention, and are not intended to limit the scope of the present invention. [Brief description of the drawings]

[0009] [Figure 1] 1 is a schematic cross-sectional view of an RTP chamber in which an embodiment of the present invention may be used. [Diagram 2] FIG. 2 (PRIOR ART) is a schematic cross-sectional view of a prior art tungsten halogen lamp assembly for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 3A] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 3B] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 3C] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 3D] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 3E] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 3F] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 4A] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 4B] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 4C] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 4D] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 4E] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 4F] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 5A] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 5B] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 5C] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 5D] 2 is a schematic diagram of a high voltage tungsten halogen lamp assembly design according to an embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 6A]2 is a top cross-sectional view of a high-voltage tungsten halogen lamp assembly design according to another embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 6B] 2 is a cross-sectional side view of a high-voltage tungsten halogen lamp assembly design according to another embodiment of the invention for use in an RTP chamber, such as the RTP chamber of FIG. [Figure 6C] FIG. 6B is a detailed view "C" of the fit between the sleeve and the press seal of FIG. 6A according to another embodiment. [Figure 6D] 2 is a top cross-sectional view of another embodiment of a high-voltage tungsten halogen lamp assembly design for use in an RTP chamber, such as the RTP chamber of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The present invention relates generally to a simplified high voltage tungsten halogen lamp for use as a thermal radiation source in a rapid thermal processing (RTP) chamber or other lamp heated thermal processing chamber. The embodiments include a lamp assembly design that includes an external fuse while reducing the part count and cost of prior art lamps. Additionally, the lamp embodiments described herein provide sufficient rigidity to handle the compressive forces of inserting the lamp into a heating assembly base while retaining the simplified fuse design.

[0011] 1 is a schematic cross-sectional view of an RTP chamber 100 in which an embodiment of the present invention may be used. The RTP chamber 100 includes a sidewall 102, a chamber bottom 104 coupled to the sidewall 102, and a quartz window 106 disposed over the sidewall 102. The sidewall 102, the chamber bottom 104, and the quartz window 106 define an interior volume 108 for processing a substrate 110 therein.

[0012] A slit valve door 116 may be formed through the sidewall 102 for transferring a substrate therethrough. The RTP chamber 100 is coupled to a gas source 118 configured to provide one or more process gases to the inner volume 108 during processing. A vacuum pump 120 may be coupled to the RTP chamber 100 for evacuating the inner volume 108 out.

[0013] A substrate positioning assembly 122 is disposed within the interior volume 108 and is configured to support, position, and / or rotate the substrate 110 during processing. In particular, the substrate positioning assembly 122 can be a non-contact substrate support device that utilizes fluid flow to support, position, and / or rotate the substrate 110.

[0014] A heating assembly 112 is disposed above the quartz window 106 and is configured to deliver thermal energy through the quartz window 106 toward the inner volume 108. The heating assembly 112 includes a plurality of lamps 114, such as high voltage tungsten halogen lamps arranged in a hexagonal pattern and controllable in zones to provide controlled heating to different zones of the inner volume 108. Each of the plurality of lamps 114 is inserted into a heating assembly base 117 for electrical connection to a power source (not shown).

[0015] 2 (PRIOR ART) is a schematic cross-sectional view of a prior art tungsten halogen lamp assembly 200 for use in an RTP chamber, such as RTP chamber 100. The lamp assembly 200 includes a quartz capsule 202 that houses a tungsten filament 204. Tungsten leads 206 extend from the filament 204 and are each attached (e.g., welded) to a molybdenum foil 208. Molybdenum leads 210 are attached (e.g., welded) to the molybdenum foil 208 and extend from the molybdenum foil. A quartz press seal 212 encapsulates the molybdenum foil 208 and creates an airtight seal around the periphery of the molybdenum foil 208. The molybdenum leads 210 extend out from the press seal 212 for electrical connection.

[0016] The press seal 212 and molybdenum leads 210 are inserted into a stainless steel cylinder 214, and the molybdenum leads 210 are connected (e.g., welded) to a conductive pin assembly 216 that extends through the cylinder 214. A fuse 218 is installed in series between at least one of the molybdenum leads 210 and the conductive pin assembly 216. The cylinder 214 is then filled with a ceramic potting compound 215, and the end of the cylinder 214 is sealed with a plastic plug 220. The plastic plug 220 has a conductive pin 222 extending therethrough that is electrically connected to the conductive pin assembly 216. The conductive pin 222 is inserted into a heating assembly base, such as base 117 from FIG. 1, for connection to a power source.

[0017] The lamp assembly 200 includes features that have several drawbacks. For example, the lamp assembly 200 has several expensive parts, such as the stainless steel cylinder 214 and the plastic plug 220, that would be advantageous to eliminate. Furthermore, the ceramic potting compound provides sufficient rigidity to allow the fuse 218 connection to withstand the compressive force of inserting the lamp assembly 200 into the heater assembly base. However, the potting compound is a porous material and can introduce organic contamination into the RTP chamber. Therefore, a simplified lamp assembly design that eliminates the need for several parts of the prior art lamp designs is desirable.

[0018] 3A-3F are schematic diagrams of high voltage tungsten halogen lamp assembly designs according to embodiments of the invention for use in an RTP chamber, such as the RTP chamber 100 or other lamp heated thermal processing chamber. The lamp assembly 300 shown in each of these figures includes a quartz capsule 302 that houses a tungsten filament 304. Tungsten leads 306a, 306b extend from the filament 304 and are attached (e.g., welded) to molybdenum foils 308a, 308b, respectively. Molybdenum leads 310a, 310b are attached (e.g., welded) to and extend from the molybdenum foils 308a, 308b. A quartz press seal 312 encapsulates the molybdenum foils 308a, 308b and creates an airtight seal around the molybdenum foils 308a, 308b. Molybdenum leads 310 a , 310 b extend outwardly from the press seal 312 .

[0019] Each of the lamp assemblies 300 in FIGS. 3A-3B also includes a third lead 311 extending from the press seal 312. Each of the leads 311 includes a hook portion 313 at an end, which is encapsulated within the press seal 312 to provide better attachment and stability of the lead 311. In one embodiment, the hook portion 313 is a right angle bend in the lead 311. Each of the third leads 311 is electrically isolated from the leads 310a, 310b within the press seal 312 via the quartz material that comprises the press seal 312. Additionally, each of the lamp assemblies 300 includes a fuse 318 electrically connected between one of the leads 310a, 310b and the lead 311. The composition of the fuse 318 is made of metals from the same family used for lamp fuses, such as nickel, zinc, copper, silver, aluminum, and alloys thereof. Although shown as a wire or ribbon, the fuse 318 may include an insulating sheath.

[0020] 3A, lead 310a includes a curved portion 315 within press seal 312 and a straight portion 317 that extends from curved portion 315 through press 312 substantially parallel to lead 310b. A third lead 311 is slightly offset from lead 310a and extends from press seal 312 substantially parallel to lead 310b. A fuse 318 extends laterally between leads 311 and 310a such that the fuse 318 is substantially perpendicular to leads 311 and 310a.

[0021] In the embodiment shown in Figure 3B, the leads 310a, 310b each extend substantially parallel to one another from the press seal 312. The third lead 311 is embedded within the press seal 312 between the leads 310 and has a first straight portion 319 extending from the press seal 312 substantially parallel to the leads 310a, 310b. The lead 311 includes a curved portion 321 extending from the first straight portion 319 to an exterior of the press seal 312. The lead 311 includes a second straight portion 323 extending from the curved portion 321 substantially parallel to the lead 310b. The fuse 318 extends between the lead 310a and the curved portion 321 of the lead 311.

[0022] In the embodiment shown in Figure 3C, the leads 310a, 310b each extend substantially parallel to one another from the press seal 312. The third lead 311 is embedded within the press seal 312 between the leads 310 and has a first straight portion 319 that extends from the press seal 312 substantially parallel to the leads 310a, 310b. The lead 311 includes a curved portion 321 that extends from the first straight portion 319 to an exterior of the press seal 312. The lead 311 includes a second straight portion 323 that extends from the curved portion 321 substantially parallel to the lead 310b. The second straight portion 323 of the lead 311 is substantially aligned with the lead 310a. Fuse 318 extends between lead 310a and second straight portion 323 of lead 311 such that lead 310a, fuse 318 and second straight portion 323 of lead 311 are substantially aligned.

[0023] 3A-3C each therefore eliminates several components (e.g., stainless steel cylinder, plug, ceramic potting compound) from prior art high voltage tungsten halogen lamps while providing a direct connection between leads 311, 310b to a heating assembly base, such as heating assembly base 117. Additionally, an additional third lead 311 provides stiffness to absorb compressive forces applied during insertion of lamp 300 into heating base 117 (i.e., prevents fuse 318 from undergoing compression).

[0024] Although Figures 3A-3C show only lead 310a being connected to fuse 318, either lead 310a or 310b can be connected to fuse 318. In another embodiment shown in Figures 3D-3F, two leads 311 are provided, with leads 310a and 310b each electrically coupled to fuse 318 in substantially the same configuration as shown in Figures 3A-3C, i.e., both leads 310b are connected to a further lead 311 in the same manner as lead 310a is shown and connected to lead 311. Additionally, each of leads 310b and 311 can be configured to fit into an externally supplied socket, for example a mating socket in a printed circuit board.

[0025] 4A-4F are schematic diagrams of high voltage tungsten halogen lamp assembly designs according to embodiments of the invention for use in an RTP chamber, such as the RTP chamber 100 or other lamp heated thermal processing chamber. The lamp assembly 400 shown in each of these figures includes a quartz capsule 402 that houses a tungsten filament 404. Tungsten leads 406a, 406b extend from the filament 404 and are attached (e.g., welded) to molybdenum foils 408a, 408b, respectively. Molybdenum leads 410a, 410b are attached (e.g., welded) to and extend from the molybdenum foils 408a, 408b. A quartz press seal 412 encapsulates the molybdenum foils 408a, 408b and creates an airtight seal around the molybdenum foils 408a, 408b. Molybdenum leads 410 a , 410 b extend outwardly from the press seal 412 .

[0026] In each of Figures 4A-4C, a conductive pin 414 is attached (e.g., welded) to the lead 410b. Additionally, an insulating sleeve 416 (e.g., a ceramic or plastic sleeve), a fuse 418, and a conductive pin 420 are attached to the lead 410a. The composition of the fuse 418 is made of metals from the same family used for lamp fuses, such as nickel, zinc, copper, silver, aluminum, and alloys thereof. The conductive pin 414, insulating sleeve 416, fuse 418, and conductive pin 420 provide a rigid conductive extension for inserting the lamp assembly 400 into the heating base 116.

[0027] In the embodiment shown in Fig. 4A, the insulating sleeve 416 has a thin metal layer 422 deposited over the inner surface 417 of the sleeve 416. The equivalent cross section (perpendicular to the current flow) of the metal layer 422 corresponds approximately to the equivalent cross section of the fuse wire or ribbon designed for this application. Similarly, the composition of the metal layer 422 is made of metals of the same family as those used for lamp fuses, e.g., nickel, zinc, copper, silver, aluminum and their alloys. The lead 410a and the conductive pin 420 are electrically connected, e.g., soldered or brazed, to the metal layer 422. The thin metal layer 422 is configured to serve as a fuse 418.

[0028] 4B, the insulating sleeve 416 has a thin metal trace 424 deposited along one side of the inner surface 417 of the sleeve 416. The lead 410a and conductive pin 420 are secured to the sleeve 416 in electrical contact with the trace 424, which acts as a fuse 418. The lead 410a and conductive pin 420 may be attached to the sleeve 416 using, for example, a ceramic compound, a high temperature epoxy, a high temperature phenolic, or shrink tubing. The trace 424 may extend axially a short distance across the entire inner diameter at the top and bottom of the insulating sleeve 416 to allow the sleeve 416 to be attached to the conductive pin 420 and lead 410a by soldering or brazing.

[0029] In the embodiment shown in Figure 4C, a wire fuse 418 is attached (e.g., welded, soldered) to the lead 410a and extends through the insulating sleeve 416. The fuse 418 is further attached (e.g., welded, soldered) to a conductive pin 420. The lead 410a and conductive pin 420 can be attached to the sleeve 416 using, for example, a ceramic compound, a high temperature epoxy, a high temperature phenolic resin, or shrink tubing. In any of the designs shown in Figures 4A, 4B, and 4C, the insulating sleeve 416 can be filled with low melting point glass beads or insulating particles to act as an arc-quenching Ballotini-type fuse.

[0030] 4A-4C each therefore eliminates several components (e.g., stainless steel cylinder, plug, ceramic potting compound) from prior art high voltage tungsten halogen lamps while providing connections between leads 410a, 410b and conductive pins 414, 420 to a heater assembly base such as heater assembly base 117. Additionally, the insulating tube configuration provides rigidity to absorb compressive forces applied during insertion of lamp assembly 400 into heater base 117.

[0031] While Figures 4A-4C each show a conductive pin 414 attached to lead 410b, in a further embodiment shown in Figures 4D-4F, lead 410b is attached to a further insulating sleeve 416 (e.g., a ceramic or plastic sleeve), a further fuse 418 and a further conductive pin 420 in the same manner as shown for lead 410a. Additionally, each of pins 414 and 420 can be configured to fit into an externally supplied socket, for example a mating socket in a printed circuit board.

[0032] 5A-5D are schematic diagrams of high voltage tungsten halogen lamp assembly designs according to embodiments of the invention for use in an RTP chamber, such as the RTP chamber 100 or other lamp heated thermal processing chamber. The lamp assembly 500 shown in each of these figures includes a quartz capsule 502 that houses a tungsten filament 504. Tungsten leads 506a, 506b extend from the filament 504 and are attached (e.g., welded) to molybdenum foils 508a, 508b, respectively. Molybdenum leads 510a, 510b are attached (e.g., welded) to and extend from the molybdenum foils 508a, 508b. A quartz press seal 512 encapsulates the molybdenum foils 508a, 508b and creates an airtight seal around the molybdenum foils 508a, 508b. Molybdenum leads 510 a , 510 b extend outwardly from the press seal 512 .

[0033] 5A-5B, a conductive pin 514 is attached (e.g., welded) to the lead 510b. Additionally, an insulating sleeve 516 (e.g., a ceramic or plastic sleeve), a fuse 518, and a conductive cap 520 are attached to the lead 510a. The composition of the fuse 518 is made of metals from the same family used for lamp fuses, such as nickel, zinc, copper, silver, aluminum, and alloys thereof. The conductive pin 514, insulating sleeve 516, fuse 518, and conductive cap 520 provide a rigid conductive extension for inserting the lamp assembly 500 into the heating base 116.

[0034] 5A, the end of lead 510a has an externally threaded portion 511. Insulating sleeve 516 has a matching internally threaded portion 517 that engages with the externally threaded portion 511 of lead 510a. Wire fuse 518 is electrically attached (e.g., welded, soldered) to lead 510a. Fuse 518 is also electrically connected (e.g., welded, soldered) to conductive cap 520. Cap 520 can be crimped onto an outer surface 522 of insulating sleeve 516 and can fit into a groove 524 formed in outer surface 522 of sleeve 516 to secure the connection.

[0035] In the embodiment shown in FIG. 5B, the end of the lead 510a has a hollow portion 513 that is electrically connected (e.g., welded, soldered) to the fuse 518. The end of the insulating sleeve 516 has a first flange portion 515. The first flange portion 515 of the sleeve 516 is inserted into the hollow portion 513 of the lead 510a, and the wall 509 of the lead 510a is crimped over the first flange portion 515 of the sleeve 516 to secure the connection. The fuse 518 extends through the sleeve 516 and is electrically connected (e.g., welded, soldered) to the cap 520. The cap 520 may be crimped over the second flange portion 525 of the sleeve 516 to secure the connection.

[0036] 5A-5B each therefore eliminates several components (e.g., stainless steel cylinder, plug, ceramic potting compound) from prior art high voltage tungsten halogen lamps while providing connections between the leads 510a, 510b and the conductive pins 514 and cap 520 to a heater assembly base such as the heater assembly base 116. Additionally, the insulating tube configuration provides rigidity to absorb compressive forces applied during insertion of the lamp assembly 500 into the heater base 116.

[0037] 5A-5B, respectively, conductive pin 514 is attached to lead 510b, while in a further embodiment shown in Figures 5D-5E, lead 510b is attached to a further insulating sleeve 516, a further fuse 518 and a further conductive cap 520 in the same manner as shown for lead 510a. Additionally, pin 514 and conductive cap 520 may each be configured to fit into an externally supplied socket, for example a mating socket in a printed circuit board.

[0038] FIG. 6A is a top cross-sectional view and FIG. 6B is a side cross-sectional view of a high voltage tungsten halogen lamp assembly design according to another embodiment of the present invention for use in an RTP chamber, such as the RTP chamber 100 or other lamp-heated thermal processing chamber. The lamp assembly 600 includes a quartz capsule 602 that houses a tungsten filament 604. Tungsten leads 606a, 606b extend from the filament 604 and are attached (e.g., welded) to the molybdenum foils 608a, 608b, respectively. Molybdenum leads 610a, 610b are attached (e.g., welded) to the molybdenum foils 608a, 608b and extend from the molybdenum foils 608a, 608b. A quartz press seal 612 encapsulates the molybdenum foils 608a, 608b and creates an airtight seal around the molybdenum foils 608a, 608b. Molybdenum leads 610 a , 610 b extend outwardly from the press seal 612 .

[0039] A conductive pin 614 is attached (e.g., welded) to lead 610b. A fuse 618 is electrically attached (e.g., welded) to lead 610a. The composition of the fuse 618 is of the same family of metals used for lamp fuses, such as nickel, zinc, copper, silver, aluminum, and alloys thereof. A sleeve 616 is attached to the press seal 612 and has the pin 614 and fuse 618 extending therethrough. The sleeve 616 can be formed from a plastic material, such as a high temperature plastic. In one embodiment, the press seal 612 has a groove 613 formed in its outer surface 615. An engagement extension 617 is formed in the sleeve 616 such that, when mated, the extension 617 snaps into the groove 613 and is fixed in place. A conductive pin 620 is press-fit into the opposite end of the sleeve 616. Conductive pin 620 has a groove 621 formed therein that mates with an engaging extension 619 formed in sleeve 616 so that, when mated, extension 619 snaps into groove 621 and is fixed in place. Fuse 618 extends through a hole in conductive pin 620. Fuse 618 is electrically attached (e.g., welded) to conductive pin 620.

[0040] 6C is a detailed view "C" of the fit between sleeve 616 and press seal 612 according to another embodiment. In this embodiment, sleeve 616 may be formed from a ceramic material. Sleeve 616 has a groove 627 formed therein that generally matches groove 613 in press seal 612. The mating grooves (627, 613) are filled with a sealant material 629, such as ceramic potting compound, solder, metal wire or adhesive, to secure sleeve 616 and press seal 612 in place. A hole (not shown) may be formed in sleeve 616 for inserting sealant material 629.

[0041] 6A-6C thus eliminates several components (e.g., stainless steel cylinder, plug, ceramic potting compound) from prior art high voltage tungsten halogen lamps while providing connection between the leads 610a, 610b and the conductive pins 614, 620 to a heater assembly base such as the heater assembly base 117. Additionally, the plastic sleeve configuration provides rigidity to absorb compressive forces applied during insertion of the lamp assembly 600 into the heater base 117.

[0042] 6A-6B, conductive pin 614 is attached to lead 610b, while in a further embodiment shown in Figure 6D, lead 610b is attached to a further fuse 618 and pin 620 in a similar manner as shown for lead 610a. Additionally, pins 614 and 620 may each be configured to fit into an externally supplied socket, for example a mating socket in a printed circuit board.

[0043] While the forgoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, the scope of the invention being determined by the following claims.

Claims

1. 1. A lamp assembly comprising: a capsule having a filament disposed therein; a press seal extending from the capsule to hermetically seal the capsule; first and second leads, respectively, electrically coupled to the filament within the press seal and extending from the press seal; a third lead extending from the press seal, the third lead being electrically isolated from the first and second leads within the press seal; a fuse electrically coupling said third lead to one of said first and second leads that is external to said press seal and said capsule; A lamp assembly comprising:

2. 2. The lamp assembly of claim 1, wherein said first, second and third leads extend substantially parallel to one another from said press seal.

3. 2. The lamp assembly of claim 1, wherein the first lead includes a bent portion within the press seal and is electrically coupled to the third lead exterior to the press seal.

4. 2. The lamp assembly of claim 1, wherein said third lead includes a bent portion, said fuse being attached to said third lead within said bent portion.

5. a fourth lead extending from the press seal, the fourth lead being electrically isolated from the first, second and third leads within the press seal; a second fuse electrically coupling the fourth lead to the other of the first and second leads; and The lamp assembly of claim 1 further comprising:

6. 1. A lamp assembly comprising: a capsule having a filament disposed therein; a press seal extending from the capsule to hermetically seal the capsule; first and second leads, respectively, electrically coupled to the filament within the press seal and extending from the press seal; an insulating sleeve coupled to the first lead exterior to the press seal; a third lead coupled to the insulating sleeve; a fuse electrically coupling the first lead to the third lead; A lamp assembly comprising:

7. 7. The lamp assembly of claim 6, wherein said fuse comprises a metallic coating on an inner surface of said insulating sleeve.

8. 7. The lamp assembly of claim 6, wherein said fuse comprises a metallic trace on an inner surface of said insulating sleeve.

9. 7. The lamp assembly of claim 6, wherein said fuse includes a wire extending through said insulating sleeve.

10. a second insulating sleeve coupled to the second lead exterior to the press seal; a fourth lead coupled to the second insulating sleeve; a fuse electrically coupling the second lead to the fourth lead; 7. The lamp assembly of claim 6, further comprising:

11. 1. A lamp assembly comprising: a capsule having a filament disposed therein; a press seal extending from the capsule for hermetically sealing the capsule; first and second leads, respectively, electrically coupled to the filament within the press seal and extending from the press seal; an insulating sleeve coupled to the press seal, the insulating sleeve having at least the first lead extending therethrough; a third lead coupled to the insulating sleeve; a fuse electrically coupling the first lead to the third lead; A lamp assembly comprising:

12. 12. The lamp assembly of claim 11, wherein said insulating sleeve and said press seal have matching grooves formed therein, said matching grooves being filled with a sealant material to secure said insulating sleeve to said press seal.

13. 12. The lamp assembly of claim 11, wherein the insulating sleeve has a protrusion, the protrusion being snap-fit ​​into a groove formed in the press seal.

14. 12. The lamp assembly of claim 11, wherein the insulating sleeve has a protrusion, the protrusion being snap-fit ​​into a groove formed in the third lead.

15. a fourth lead coupled to the insulating sleeve; a second fuse electrically coupling the second lead to the fourth lead; and 12. The lamp assembly of claim 11, further comprising:

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