JP4221712B2 - Manufacturing method of discharge lamp - Google Patents

Description

  The present invention relates to a method for manufacturing a discharge lamp, and more particularly, to a method for loading an object to be filled in a discharge space of a discharge lamp such as a high-pressure mercury lamp called a high intensity discharge (HID) lamp.

The halogen encapsulated in the HID lamp is encapsulated in the lamp in a gaseous state as an organic halogen or in a solid state as a metal halide (for example, see Patent Documents 1 and 2) and encapsulated in a solid. In this case, the gas becomes a gas during the initial lighting, and a desired function is achieved.
As described above, the state of the halogen to be encapsulated can be selected from gas or solid. However, if gas is selected, it must be rendered harmless when discharged from the factory, and a detoxification device must be installed. Become. Moreover, since leakage from the equipment is also conceivable, the cost of incidental equipment such as a leak detection device is increased. In addition, due to the characteristics of the lamp, the object to be encapsulated may not be gasified, and the encapsulation in solid is increasing.

  A conventional method for manufacturing a discharge lamp in which a metal halide is enclosed in a lamp as an object to be encapsulated will be described with reference to FIGS. 3 (a) to 4 (i). A glass bulb 100 made of quartz glass having a spherical discharge part 1 and tube parts 2a and 2b provided on both sides thereof as shown in FIG. 3A is put into the lamp manufacturing process. The inside of the discharge part 1 is a discharge space 3, and the distal end part (left side in the figure) of the tube part 2a is open, and the distal end part (right side in the figure) of the tube part 2b is closed in a U-shape. It has been. The glass bulb 100 is disposed in the glove box. First, as shown in FIG. 3B, the electrode assembly 7 is inserted from the open end side (left side in the drawing) of the tube portion 2a. As shown in FIG. 5, the electrode assembly 7 has an external lead 9 attached to one end of a metal plate 8 made of molybdenum or the like, an internal lead 10 attached to the other end, and a discharge electrode at the tip of the internal lead 10. 11 is attached. As shown in FIG. 3B, the electrode assembly 7 is inserted into the tube portion 2 a so that the discharge electrode 11 faces the discharge space 3. In this state, the inside of the glove box is evacuated and then filled with decompressed Ar. In a state where the inside of the glass bulb is filled with decompressed Ar, the open end of the tube portion 2a is closed by irradiating a laser beam or the like, and Ar is enclosed in the glass bulb 100 (FIG. 3C).

Subsequently, the glass bulb 100 is taken out of the glove box, and the insertion portion of the electrode assembly 7 of the tube portion 2a is heated with a burner or the like to reduce the diameter of the tube portion 2a to form the sealing portion 4a [FIG. (D)]. Next, the distal end portion of the tubular body portion 2b is removed to form an opening serving as an open end in the tubular body portion 2b [FIG. 4 (e)]. Subsequently, the glass bulb 100 is again placed in the glove box, and as shown in FIG. 4 (f), the metal halide 5 made of mercury bromide (HgBr ₂ ) or the like from the open end side of the tube portion 2b. And a luminescent material 6 made of mercury or the like are introduced into the discharge space 3. Then, the electrode assembly 7 is further inserted into the tube portion 2 b so that the discharge electrode 11 faces the discharge space 3.

  Next, evacuation of the glove box and filling with reduced pressure Ar are performed again, and the inside of the glass bulb 100 is filled with reduced pressure Ar. Then, the end of the tube portion 2b is tip-off using an acid / hydrogen burner or the like and the tube The body part 2b is closed [FIG. 4 (g)]. Subsequently, outside the glove box, the insertion portion of the electrode assembly 7 of the tube portion 2b is heated with a burner or the like to reduce the diameter of the tube portion 2b to form the sealing portion 4b [FIG. 4 (h)]. Then, the tube portions 2a and 2b which are no longer necessary are removed to expose the end portions of the external leads 9 (FIG. 4 (i)). Finally, the cap is attached to the external lead, and the manufacturing process of the discharge lamp is completed.

  When manufacturing a high-intensity discharge lamp, as it is disliked that atmospheric components and water remain in the lamp, many operations are performed in the glove box as described above. In the manufacturing process described above, the step of inserting the electrode assembly 7 into the tube body, the step of introducing metal halide or mercury into the discharge space, the step of sealing Ar into the glass bulb, etc. Since the member including the encapsulated material easily adsorbs atmospheric components and moisture, and it is highly possible that these cannot be removed in the subsequent process, the work is performed in the glove box. This glove box is usually filled with an inert gas such as Ar, and has a structure in which the gas purity in the box can be constantly maintained by circulating the internal gas via a purifier capable of removing oxygen and moisture. ing.

In particular, ultra-high pressure mercury lamps for light sources for projectors, whose demand has been increasing rapidly, are much disliked by oxygen and moisture compared to other lamps, and it is necessary to work in a state where the moisture value is reduced to the limit. . In the state where the moisture value is reduced to the limit, static electricity is very easily generated, and the smaller the particle size and weight per one metal halide, the more difficult it is to handle. Conventionally, the metal halide adhering to the jig is lightly brought into contact with the tube wall, moved to the inner wall of the bulb, and then moved to a predetermined position. In this case, depending on the contact strength, the solid may be crushed and adhere to the tube wall and cannot be moved to a predetermined position, or a part of the solid remains on the tube wall and a predetermined amount of halogen cannot be enclosed. A malfunction occurred. If re-encapsulation is possible, the man-hour is generated, and if it becomes defective as it is, the materials and man-hours up to that point are wasted.
Japanese Patent Laid-Open No. 02-148561 Japanese Patent Laid-Open No. 03-040337

  An object of the present invention is to solve the above-mentioned problems of the prior art, and its purpose is to provide a method capable of efficiently introducing a minute object to be sealed into a discharge space without remaining on the tube wall. It is to be.

In order to achieve the above object, according to the present invention,
A first step of gripping the metal halide on the encapsulated material carrier;
A second step of electrically neutralizing a glass bulb having a discharge part and a tube part;
A third step of inserting from the tubular body portion of the glass bulb of a metal halide with the enclosure carrier into the glass in the bulb,
A fourth step of charging the discharge part of the glass bulb;
A fifth step of transferring the metal halide from the sealed object carrier side to the glass bulb side using static electricity;
A method for manufacturing a discharge lamp is provided.

Preferably, the static elimination and charging operations described above are performed using an electric circuit or using ions.

  The present invention provides a method for positively utilizing static electricity that has been regarded as useless in a glove box, and introducing metal halide, which is a fine particle, into the discharge space of a glass bulb. It is. According to the method for introducing a metal halide using static electricity of the present invention, loss due to adhesion of the metal halide to the tube wall can be suppressed, and the possibility of reintroduction can be reduced. It can improve and work efficiency can be improved.

Next, embodiments of the present invention will be described in detail with reference to the drawings. The present invention is characterized by a method for introducing a metal halide to be sealed into the discharge space, and other processes are not different from the conventional example described with reference to FIGS. 3 and 4. Only the method for introducing metal halide into the discharge space will be described below.
FIG. 1 is a sectional view in order of steps showing a first embodiment of the present invention. Each step shown in FIG. 1 is performed in a glove box. As shown in FIG. 1 (a), the tip of the insertion jig 13 is placed in a petri dish 12 containing the metal halide 5, and using the adhesiveness of the metal halide 5, the halogen that is to be encapsulated The metallized metal 5 is attached to the tip of the insertion jig 13. Individual metal halides 5 are weighed into the quantity enclosed in one lamp. The insertion jig 13 is a rod-shaped body made of molybdenum and having a polygonal or circular cross-sectional shape and an outer diameter smaller than the inner diameter of the tube portions 2a and 2b. If the insertion jig 13 is charged, it is difficult to take out one metal halide 5, so it is desirable to remove the charge from the jig. Moreover, it is desirable that high temperature heat treatment is performed in a vacuum.

  FIG. 1B shows a state in which the glass bulb 100 that has been processed to the state shown in FIG. The discharge portion 1 of the glass bulb 100 is in contact with a conductive brush 14 for charging the glass bulb 100 or for discharging. The conductive brush 14 is grounded via a switch 15 or connected to a power source. In the state shown in FIG. 1B, the conductive brush 14 is grounded, and the glass bulb 100 is neutralized. In this state, the insertion jig 13 holding the metal halide 5 is inserted into the tube portion 2b.

When the insertion jig 13 is inserted to a predetermined position, as shown in FIG. 1 (c), the switch 15 is switched to the power source side to charge the glass bulb 100. Thereby, the metal halide 5 leaves | separates from the insertion jig 13 with the static electricity of the charged glass bulb | ball, and is adsorb | sucked to a glass bulb | ball. After the metal halide 5 is adsorbed to the glass bulb 100, the switch 8 is again put on the ground side, the glass bulb is neutralized, and the insertion jig 13 is pulled out from the tube portion 2b. If the metal halide 5 does not reach the discharge space 3 at this time, the metal halide 5 adhering to the tube portion 2b is moved into the discharge space 3 (FIG. 1 (d)). .
In order to lighten the burden on the operator, the movement of the metal halide 5 to the glass bulb 100 and the movement of the metal halide 5 from the tube portion 2b to the discharge portion 1 can be imaged with a CCD camera. It is desirable to be able to detect movement.
Further, it is desirable that the switch 8 is switched to the ground side immediately after the metal halide moves to the inner wall of the glass bulb. This is because if the charge is more than necessary, the glass bulb adsorbs the floating matter remaining in the glove box, and the possibility that impurities will enter the lamp increases.

Thereafter, the steps shown in FIGS. 4E to 4I are executed to complete the lamp manufacturing process.
Table 1 shows a comparison between the defect rate when the metal halide is introduced into the discharge space by the conventional method and the method according to the present invention. Table 2 shows the time required for introducing a metal halide per 100 good products. Redo and rework are included in the required time. As is apparent from Tables 1 and 2, according to the present invention, the defect rate can be reduced and the work efficiency can be improved.

  FIG. 2 is a cross-sectional view in order of steps showing a second embodiment of the present invention. In the present embodiment, the ionizer 16 is used. The main body of the ionizer 16 is disposed outside the glove box, and the leading ends of the ion introduction tubes 17a and 17b extending from the ionizer 16 are led into the glove box.

  The steps from attaching the metal halide 5 to the insertion jig 13 and carrying it into the tube 2b shown in FIGS. 2 (a) and 2 (b) are shown in FIGS. 1 (a) and 1 (b). This is similar to the case of the first embodiment shown. At this stage, the glass bulb 100 is neutralized. When the insertion jig 13 is inserted to a predetermined position, ions are blown from the ionizer 16 through the ion introduction tube 17a to charge the vicinity of the discharge part 1 of the glass bulb 100 as shown in FIG. Thereby, the metal halide 5 is separated from the insertion jig 13 and is adsorbed by the glass bulb. After the metal halide 5 is adsorbed to the glass bulb 100, ions are sprayed from the ionizer 16 through the ion introduction tube 17b, and the glass bulb is neutralized. When the insertion jig 13 is pulled out from the tube portion 2b and the metal halide 5 does not reach the discharge space 3, the metal halide 5 attached to the tube portion 2b is put into the discharge space 3. To move.

  Although preferred embodiments have been described above, the present invention is not limited to these embodiments, and appropriate modifications can be made without departing from the scope of the present invention. For example, the charging / discharging method of the glass bulb is not limited to the method shown in the embodiment, and any charging / discharging method generally used can be adopted in the present invention. Further, in the embodiment, the rod-shaped body made of molybdenum is used as the insertion jig, but it may be a rod-shaped body of other refractory metal such as tungsten. Further, the insertion jig may have a suction function such as a dropper.

Sectional drawing of the order of the process which shows the 1st Embodiment of this invention. Sectional drawing of the order of the process which shows the 2nd Embodiment of this invention. Sectional drawing of the order of a process of a prior art example (the 1). Sectional drawing of the order of a process of a prior art example (the 2). The top view of an electrode assembly.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Discharge part 2a, 2b Tube part 3 Discharge space 4a, 4b Sealing part 5 Metal halide 6 Luminescent substance 7 Electrode assembly 8 Metal plate 9 External lead 10 Internal lead 11 Discharge electrode 12 Petri dish 13 Insertion jig 14 Conductivity Brush 15 Switch 16 Ionizer 17a, 17b Ion introduction tube 100 Glass bulb

Claims (12)

A first step of gripping the metal halide on the encapsulated material carrier;
A second step of electrically neutralizing a glass bulb having a discharge part and a tube part;
A third step of inserting from the tubular body portion of the glass bulb of a metal halide with the enclosure carrier into the glass in the bulb,
A fourth step of charging the discharge part of the glass bulb;
A fifth step of transferring the metal halide from the sealed object carrier side to the glass bulb side using static electricity;
A method for manufacturing a discharge lamp, comprising: After the fifth step, the production method of the discharge lamp according to claim 1, characterized by neutralizing the glass bulb. Method for producing a discharge lamp according to claim 1 or 2, characterized in that by using an electrical circuit static elimination from the charging or the glass bulb to the glass bulb. According to claim 1 or 2, characterized in that the connected conductive contact body discharges the ground or power through the switch from the charging or the glass bulb to the glass bulb in contact with the glass bulb Method of manufacturing a discharge lamp. Method for producing a discharge lamp according to claim 1 or 2, characterized in that by blowing static eliminator from charging or the glass bulb to the glass bulb, the ions from the outside into the discharge portion of the glass bulb. 6. The method of manufacturing a discharge lamp according to claim 5 , wherein charging to the glass bulb or discharging from the glass bulb is performed by blowing ions derived from an ionizer. After transition to the glass bulb side the metal halide from the enclosure bearing member, according to any one of claims 1 to 6, characterized in that moving the metal halide to the discharge lamp in the discharge space Method of manufacturing a discharge lamp. Method for producing a discharge lamp according to any one of claims 1 to 7, characterized in that to detect the moving state of the metal halide in the image processing apparatus. The method for manufacturing a discharge lamp according to any one of claims 1 to 8 , wherein the encapsulated material carrier is a metal rod-shaped body. The method for manufacturing a discharge lamp according to any one of claims 1 to 9 , wherein the encapsulated material carrier is neutralized prior to the first step. In the first step, the discharge lamp according to any one of claims 1 using the adhesion of the metal halide, characterized in that for gripping the metal halide to be sealed material bearing member 1 0 Production method. Wherein the enclosure bearing member manufacturing method of discharge lamp according to claim 1 1 0, characterized in that it has a suction function for the metal halide.

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