Two-bath electrolysis

Abstract

Manufacturing equipment and manufacturing process steps that improve upon prior art processes for the manufacturing of filament tube and arc tube light sources, their components and subassemblies, and lamps employing said light sources. A double ended, tipless filament tube or arc tube light source incorporates a drawn-down tubular body, and one piece foliated leads with spurs for process handling and for spudding into a filament with stretched-out legs. Bugled ends on the body provide a novel cutoff means, facilitate a flush-fill finishing process, and enhance mounting and support of the light sources in lamps. The foliated leads are made from a continuous length of wire in a process including foil hammering and two-bath AC electrochemical etching. Cost-reduced light source and lamp production enables affordable household consumer lamps, even when containing two series-connected halogen filament tubes. Safety benefits ensue from series connection, especially in combination with disclosed body and filament constructions.

1 . A method for electrolyzing a continuous length of metal, the method comprising the steps of: 
 firstly passing the length of metal through electrolysis fluid contained in a first bath that also contains a first electrode connected to a first pole of a power supply;    secondly passing the length of metal through electrolysis fluid contained in a second bath that also contains a second electrode connected to a second pole, opposite to the first pole, of the power supply; and    using the length of metal as an electrical conductor for completing the electrical circuit between the electrolysis fluid of the first bath and the electrolysis fluid of the second bath.    
     
     
         2 . The method of  claim 1 , further comprising the step of: 
 passing the length of metal through the first bath and through the second bath by passing through a plurality of seals below a fluid level of the electrolysis fluid such that each one of the plurality of seals allows passage of the length of metal while limiting fluid loss.    
     
     
         3 . The method of  claim 2 , further comprising the step of: 
 cooling the length of metal by providing a one of the plurality of seals such that the one seal maintains immersion of the length of metal in electrolysis fluid while the length of metal passes from the first bath to the second bath.    
     
     
         4 . The method of  claim 1 , wherein: 
 the power supply is an AC power supply.    
     
     
         5 . The method of  claim 1 , further comprising the step of: 
 moving the length of metal in one direction through the first bath and through the second bath.    
     
     
         6 . A two-bath electrolysis line for performing electrolysis on a continuous length of metal, the electrolysis line comprising: 
 a first bath containing electrolysis fluid filled to a fluid level, and a first electrode, the first electrode being connected to a first pole of a power supply;    a second bath containing electrolysis fluid filled to a fluid level, and a second electrode, the second electrode being connected to a second pole, opposite to the first pole, of the power supply;    a conveyance path such that the length of metal passes first through the electrolysis fluid in the first bath, and second through the electrolysis fluid in the second bath; and    a conductor of electrical current between the electrolysis fluid in the first bath and the electrolysis fluid in the second bath, the conductor being the length of metal.    
     
     
         7 . The electrolysis line of  claim 6 , further comprising: 
 a plurality of seals that allow passage of the length of metal through the first bath and through the second bath below the fluid level of the electrolysis fluid while limiting fluid loss.    
     
     
         8 . The electrolysis line of  claim 7 , wherein the plurality of seals comprises: 
 a plurality of grommet seals that are mounted within holes below the fluid level of the electrolysis fluid in each of the first bath and second bath, the holes being located in opposed ends of the first bath and in opposed ends of the second bath.    
     
     
         9 . The electrolysis line of  claim 8 , wherein: 
 a one of the plurality of grommet seals connects the first bath to the second bath.    
     
     
         10 . The electrolysis line of  claim 9 , wherein: 
 an end of the first bath abuts an end of the second bath; and    the one of the plurality of grommet seals is mounted within holes through the abutting ends.    
     
     
         11 . The electrolysis line of  claim 6 , wherein: 
 the power supply is an AC power supply.    
     
     
         12 . The electrolysis line of  claim 6 , further comprising: 
 an advancing device that moves the length of metal through the first and second baths.