DE102016207026B4 - Making a Lamp - Google Patents

Abstract

A method for producing a lamp (L), in which- a lamp bulb (K) is provided with at least one external depression (R), - a base (S) made of plastic is pushed onto the lamp bulb (K) so that it has at least covers a depression (R), and- the base (S) is then deformed locally at a shaping region (U) into the at least one depression (R),- characterized in that the shaping region (U) is pneumatically stressed on the outside for shaping .

Description

The invention relates to a method for producing a lamp, in which a lamp bulb is provided and a plastic base is pushed over the lamp bulb. The invention also relates to a squeezing tool for carrying out the method. The invention also relates to a lamp, having a lamp bulb and a base pushed onto the lamp bulb. The invention is particularly applicable to the manufacture of LED retrofit lamps to replace fluorescent lamps, line lamps, etc.

To attach pin bases to tubular lamp bulbs of LED retrofit lamps to replace fluorescent lamps (e.g. of the T5 or T8 type), it is known to push the pin bases onto or into the lamp bulb at the end and to glue or cement them to the lamp bulb. The disadvantage here is that adhesive or putty has to be applied, which causes costs in relation to the material and handling. The putty also has to be heated out or the glue has to be dried for a long time, which has disadvantages in terms of production technology.

From the DE 199 28 419 C1 and the DE 1 036 384 A methods are known in which a base is formed into a recess of a piston.

It is the object of the present invention to at least partially overcome the disadvantages of the prior art.

This object is solved according to the features of the independent claims. Preferred embodiments can be found in particular in the dependent claims.

The object is achieved by a method for producing a lamp, in which a lamp bulb is provided with at least one external recess, a base is pushed over or onto the lamp bulb so that it covers the at least one recess, and the base then locally on a Forming area is formed into the at least one recess. According to the invention, the reshaping takes place in that the reshaping area is stressed pneumatically on the outside or is stressed mechanically on the outside by axial compression of the base.

This method has the advantage that material for the integral connection of the base to the lamp bulb, such as adhesive or putty, etc., can be dispensed with. Also, virtually no rest time is required after forming. In addition, the process is easy to implement in terms of production technology. As a result of the permanent deformation into the depression, a form fit or a form fit connection is achieved at least in a longitudinal direction, so that the base can no longer be pulled off the lamp bulb. The form-fitting connection consists in an interlocking of the two connection partners, with the connection partners not coming loose even without or with an interrupted power transmission.

The outside indentation may comprise one or more indentations or recesses considered in relation to the outside, in particular one or more indentations per piston opening. A depression can be locally limited in two dimensions, e.g. if it is in the form of a point-like depression. A recess can also be formed around the lamp bulb, e.g. in the form of an annular groove. The indentation can have been produced by reshaping the lamp bulb in the area of the indentation, but alternatively, for example, also by removing material. The recess may be discontinuous or continuous through the piston. A through depression can be a hole. The shape of the depression is basically free and can be e.g. punctiform, oval, linear, etc.

A deformed area can be understood to mean a partial area of the base which is arranged adjacent to the at least one depression. A deformed area can also be understood to mean a sub-area of the base that will be or has been locally deformed to engage in the recess.

The base is made of plastic, in particular at least in its at least one deformed area. This results in the advantage that the base can be deformed in a particularly simple manner, even if it has a not insignificantly small wall thickness in its deformed area. However, the base can also consist of metal, e.g. of a thin metal sheet, at least in its at least one deformed area. In general, the base can consist of a ductile or plastically deformable material, at least in its at least one deformed region.

In particular, the base can have a cylindrical basic shape, the piston-side end face of which is open and at least one mechanical and possibly electrical contact is present, e.g. protrudes, on the end face facing away from the piston. For example, the socket can be a bipin socket.

In one configuration, at least the forming area is heated before forming. This facilitates plastic deformability, especially when Umformbe rich in plastic, specifically thermoplastic.

It is a further embodiment that the forming area is stressed pneumatically on the outside for forming, in particular is pressurized. This results in the advantage that the reshaping can be carried out in a particularly close contact with the indentation and, moreover, without contact. Pneumatic stress can be achieved by applying compressed gas, e.g. compressed air.

The pneumatic stress can advantageously be implemented in such a way that the base with the inserted lamp bulb is inserted into a tool (hereinafter referred to as “pneumatically forming” without restricting the generality) (referred to below as the “squeezing tool” without restricting the generality) that the at least one deformed area of the base is brought into a pneumatic connection with a compressed gas source, and the previously heated at least one deformed area is subjected to compressed gas by means of the compressed gas source via the pneumatic connection. This results in a particularly simple and reliable manufacturing structure.

In a further configuration, the pneumatically deforming squeezing tool has at least one compressed gas duct (also referred to as a compressed gas line) that can be connected to the compressed gas source and has at least one opening that opens out on an outside of the base, and the squeezing tool has at least one seal that has at least one opening and at least one associated deformation region axially delimited. In this way, pressure losses caused by a gap between the base and the crimping tool can be reliably avoided. The seal can protrude into the gap.

It is also an embodiment that the at least one seal is pressed against the base before or at the same time as the pressurized gas is applied. By pressing on, a contact pressure of the seal on the base and/or the squeezing tool is increased, as a result of which pressure losses through the gap can be avoided in a particularly reliable manner and particularly high pressures can be applied to the forming area.

It is an alternative or additional development that the compressed gas channel has a bypass or pressure branch. This is designed in such a way that, despite the compressed gas flowing through the bypass, the pressure of the compressed gas on the base is sufficient for deformation of the base. Consequently, the bypass is designed in such a way that excess pressure between the pressurized gas provided and the pressurized gas can be blown off to the base. The flow can advantageously serve to remove process heat and thereby reduce process time. The bypass or pressure branch can be implemented by means of a branch duct or an opening in the pressure gas duct. Alternatively, the seal can be designed to leak at pressures in excess of those required to deform the base.

It is also an embodiment that the base (in which the lamp bulb is inserted) is introduced into a receptacle of a squeezing device (referred to as “mechanically deforming” without restricting the generality) with a circumferential or lateral small clearance, and the base is then introduced by means of a mechanically deforming crimping tool is axially compressed. The material of the base compressed by the axial compression cannot deviate radially outwards due to the narrow play, but instead flows plastically into the at least one depression. This refinement can also be constructed in a particularly simple manner. Circumferentially tight play can be understood, in particular, as an arrangement of a side wall or lateral surface of a base that contacts a surrounding surface of the squeezing tool or is only at a small distance from it.

In a further development, the crimping tool has a heating device and the base is heated by means of the heating device in its at least one deformed region before the deformation. This enables a particularly compact arrangement with a very short time sequence of heating and forming, possibly even simultaneous heating and forming. Alternatively, the heating device can be a device that can be operated independently of the squeezing tool.

It is also an embodiment that heating areas of the heating device are located at the opening of the compressed air duct. This results in a particularly compact arrangement in the case of particularly small deformed areas. The heating areas can, for example, be electrically operated resistance heating conductors, e.g. heating coils or heating spirals.

The object is also achieved by a forming or squeezing tool, wherein the squeezing tool for carrying out the method is designed as described above.

So it is a further development that the squeezing tool is a pneumatically deforming one is squeezing tool. It can have a receptacle for inserting the base in such a way that at least one deformed area of the base can be brought into a pneumatic connection with a compressed gas source and the—advantageously previously heated—at least one deformed area can be pressurized with compressed gas by means of a compressed gas source via the pneumatic connection. This results in a particularly simple and reliable manufacturing structure.

For this purpose, the pneumatically deforming squeezing tool can have at least one compressed air channel which can be connected to the compressed gas source and has at least one opening opening out on an outside of the base. The pneumatically forming squeezing tool can also have at least one seal that axially delimits or surrounds at least one opening and at least one associated forming area. In this way, pressure losses through the gap can be reliably avoided.

Another configuration is that the pneumatically deforming squeezing tool is set up to press at least one seal against the base before or when the compressed gas is applied. By pressing on, a contact pressure of the seal on the base and/or the squeezing tool is increased, as a result of which, for example, pressure losses through the gap between the base and the squeezing tool can be avoided particularly reliably and particularly high pressures can be applied to the forming area.

It is also a development that the squeezing tool is a mechanically deforming squeezing tool. The mechanically deforming squeezing tool can have a receptacle into which the base of the lamp with the inserted lamp bulb can be inserted with a small amount of play around the circumference. The mechanically deforming squeezing tool is also set up to axially compress the base. For this purpose, the receptacle can have a stop for the free edge of the base on the lamp bulb side and a movable squeezing piston for pressing onto an end face of the base facing away from the lamp bulb. The squeezing piston can, for example, be driven mechanically, by an electric motor or pneumatically. To insert the base, the receptacle can be opened, e.g. hinged.

The object is also achieved by a lamp having a lamp bulb with at least one external depression and a base pushed onto the lamp bulb at least up to the at least one depression, the base being deformed locally into the at least one depression. The lamp can be designed analogously to the method and gives the same advantages.

In one configuration, the lamp bulb is a glass bulb. This has the advantage that it is not deformed when the base itself is deformed, not even when the deformed region has been heated beforehand. However, in principle, a lamp bulb made of plastic can also be used, e.g. made of thermoplastic with a higher deformation temperature than the base.

The lamp bulb can be transparent or translucent or opaque.

It is another configuration that the lamp bulb is a tubular lamp bulb. For example, this may have a T-type form factor, e.g., T5 or T8. The tubular lamp bulb can be equipped on both sides by means of a socket as described above.

It is also an embodiment that the at least one external depression has at least one row of local depressions distributed in a circumferential direction. These advantageously enable the base to be fastened to the lamp bulb in a particularly reliable and also non-rotatable manner. In this case, a circumferential direction can correspond in particular to an azimuthal direction in cylindrical coordinates.

The indentations can, for example, have been formed in the lamp bulb by forming. For example, a glass bulb may have been heated locally and then pressed in locally from the outside, e.g. using a stamp, roller, pin, etc.

It is yet another embodiment that the socket is a pin socket, in particular a bipin socket. The base can be of the G type, e.g. constructed analogously to the type G5 or G13.

It is also an embodiment that the lamp is a tubular semiconductor retrofit lamp to replace conventional tubular lamps, e.g. fluorescent lamps, line lamps, etc.

The semiconductor retrofit lamp can have at least one semiconductor light source. In one development, the at least one semiconductor light source includes or has at least one light-emitting diode. If several light-emitting diodes are present, they can light up in the same color or in different colors. A color can be monochrome (e.g. red, green, blue, etc.) or multichrome (e.g. white). The light emitted by the at least one light-emitting diode can also be infrared light (IR-LED) or an ultraviolet light (UV-LED). Several light-emitting diodes can produce a mixed light; eg a white mixed light.

The at least one light-emitting diode can contain at least one wavelength-converting phosphor (conversion LED). Alternatively or additionally, the phosphor can be arranged at a distance from the light-emitting diode (“remote phosphor”). The at least one light-emitting diode can be in the form of at least one individually housed light-emitting diode or in the form of at least one LED chip. Several LED chips can be mounted on a common substrate (“submount”). The at least one light-emitting diode can be equipped with at least one separate and/or common optic for beam guidance, e.g. at least one Fresnel lens, collimator, and so on. Instead of or in addition to inorganic light-emitting diodes, e.g. based on InGaN or AlInGaP, organic LEDs (OLEDs, e.g. polymer OLEDs) can generally also be used. Alternatively, the at least one semiconductor light source can have at least one diode laser, for example.

The semiconductor light sources can be arranged in particular on a strip-shaped printed circuit board, which is accommodated longitudinally in the lamp bulb and is connected to the sockets. It can be electrically connected to a lamp holder via only one base or via both bases, possibly via a driver accommodated in a base.

• 1A zeigt als Schnittdarstellung in Seitenansicht einen Ausschnitt aus einem Lampenkolben mit stirnseitig aufgeschobenem Sockel sowie Heizelementen einer Heizvorrichtung;
• 1B zeigt als Schnittdarstellung in Seitenansicht ein erstes, mechanisch umformendes Quetschwerkzeug mit eingesetztem Sockel und Lampenkolben sowie die Heizvorrichtung; und
• 2 zeigt als Schnittdarstellung in Seitenansicht ein zweites, pneumatisch umformendes Quetschwerkzeug mit eingesetztem Sockel und Lampenkolben.

The properties, features and advantages of this invention described above, and the manner in which they are achieved, will become clearer and more clearly understood in connection with the following schematic description of exemplary embodiments, which will be explained in more detail in connection with the drawings. For the sake of clarity, elements that are the same or have the same effect can be provided with the same reference symbols.

• 1A shows a sectional representation in a side view of a section of a lamp bulb with a base pushed on at the end and heating elements of a heating device;
• 1B shows a sectional side view of a first mechanically deforming crimping tool with an inserted base and lamp bulb and the heating device; and
• 2 shows a sectional side view of a second, pneumatically deforming crimping tool with an inserted base and lamp bulb.

1A shows a sectional side view of a section of a tubular lamp bulb K with a base S pushed on at the end and heating elements H of a heating device V. The heating elements H can be heating coils, for example. The base S and the bulb K represent components of a tubular lamp L.

The bulb K is rectilinear with a longitudinal axis A. It is translucent and made of glass. On a longitudinal section B, where it is covered by the base S, it has several, e.g. three or four, punctiform depressions R arranged in a row in the circumferential direction around the longitudinal axis A, of which only two are indicated here. The longitudinal section B can also be referred to as a heating zone. The lamp vessel K is, for example, a T5 or T8 shaped lamp vessel.

The base S has a hollow-cylindrical basic shape, which is open on the bulb side and is at least predominantly closed on its end face T facing away from the lamp bulb K. It has a free edge F on its open side. The base S can be made of plastic, in particular thermoplastic.

In the area of the longitudinal section B, the base S is surrounded by the heating elements H practically all the way around.

To mount or assemble the lamp L, the base S can be pushed onto the lamp bulb K or--in kinematic reversal--the lamp bulb K can be inserted into the base S. The base S is then laterally on the outside of the lamp bulb K. Thereafter, the heating elements H can be positioned over the longitudinal section B. Subsequently, the heating elements H can be activated, eg for a few seconds, in order to heat the material of the base S in the longitudinal section A. Then the lamp bulb K with the locally heated base S can be introduced into a crimping tool 1, as follows with reference to FIG 1B shown.

1B shows a sectional side view of a mechanically forming crimping tool 1, into which the base S with the lamp bulb K are inserted, as well as the heating elements H of a heating device V.

Insertion may have been achieved, for example, by sliding the open crimping tool 1 onto the lamp bulb K and base S and then closing it. For this purpose, the crimping tool 1 can have a hinged housing.

Now the socket S is in circumferential close play or contact with a cylin such socket receptacle 2 of the crimping tool 1. The bulb K can be held in a clamping manner by the crimping tool 1 or serve as a non-clamping guide for the lamp bulb K. The base receptacle 2 has a step 3 serving as a stop for the free edge F of the base S on the piston side.

The end face T is mounted in the crushing tool 1 along the longitudinal axis A or axially displaceable. The squeezing tool 1 has the end face T of the base S opposite a pressing device 4 which has a squeezing piston 5 guided axially displaceably in the base receptacle 2 and a drive 6 for the axial movement of the squeezing piston 5, as indicated by the arrow. Consequently, the squeezing piston 5 can press on the end face T of the base S from the outside and compress the base S axially. The drive 6 can, for example, be a drive that operates mechanically, by electric motor, pneumatically, hydraulically, etc.

The material of the base S compressed by the axial compression, previously heated in the longitudinal section B and thereby plastically deformable there, is prevented by the squeezing tool 1 from deflecting radially outwards. It is consequently deformed locally plastically into the at least one depression R (shown enlarged), since the squeezing tool 1 deflects the axially applied force radially into the depressions R. The outside of the base S is mechanically stressed or subjected to a force.

The formed area of the base S corresponds to a formed area U. The formed areas U associated with the respective depressions R have approximately the same or complementary shape as the depressions R and approximately correspond to peripheral sections of the previously heated longitudinal section B.

The pressing device 4 keeps the base S under compression until the previously heated material of the base S has cooled down again and is thus solidified, but the associated rest time is only short, e.g. lasts 30 seconds. The squeezing piston 5 can now be retracted again, the squeezing tool 1 opened and the squeezing tool 1 e.g. retracted again.

The finished lamp L has a base S which has been deformed locally at its deformed areas U into the recess R. The base S is held in the axial direction on the lamp bulb K and is also positively secured against twisting.

The finished lamp L can, for example, be an LED retrofit lamp to replace conventional tubular lamps. For this purpose, the base S can be designed as a pin base, for example as a GU5 or GU13-compatible pin base. At least one strip-shaped printed circuit board (not shown) fitted with LEDs and which can be fed electrically via the base 2 can be accommodated in the lamp bulb K. The base 2 can have a driver (not shown) for converting the electrical energy received via the base S into electrical operating signals for operating the LEDs.

2 shows a sectional side view of a pneumatically deforming squeezing tool 11 with an inserted base S and lamp bulb K. The base S can be pushed into a base receptacle 12 of the squeezing tool 11 without the squeezing tool 11 having to be opened.

The squeezing tool 11 has a compressed air channel 13 that can be connected to a compressed gas source (e.g. a compressed air cylinder, not shown). The compressed air channel 13 has an opening 14 opening out on an outside of the longitudinal section B to be heated, so that the longitudinal section B, which covers the depressions R, can be subjected to the compressed air circumferentially on the outside when the compressed gas source is open. In the area of the opening 14 there are circumferential heating elements H of a heating device V, e.g. electrically operated heating spirals.

The squeezing tool 11 also has two seals in the form of O-rings 15 which delimit the opening 14 and the longitudinal section B of the base S axially. The opening 14 and the longitudinal section B are thus located axially between the O-rings 15. The O-rings 15 are inserted into respective annular grooves 16 of the crimping tool 11 which adjoin the base S.

The squeezing tool 11 also has a pressing device 17 which is intended to move two bodies 18 and 19 which, together with the compressed air channel 13, form the annular grooves 16 towards one another. The bodies 18 and 19 are arranged axially in front of and behind the compressed air channel 13, so that when the pressing device 17 is activated, the bodies 18 and 19 are pressed axially against the compressed air channel 13 and the annular grooves 16 narrow axially. As a result, the O-rings 15 are easily pressed out of the annular grooves 16 and press on the base S. This achieves a particularly pressure-resistant seal, which particularly reliably allows the compressed air to escape through a gap between the base S and the squeezing tool 11, even for higher pressures prevented. The pressing device 17 can have a mechanical, electric motor, pneumatically, hydraulically, etc. operating drive 20 for moving the bodies 18 and 19 have.

For forming the forming areas U of the base S into the depressions R, for example, the pressing device 17 can first be activated, then the heating elements H for heating the longitudinal section B of the base S can be activated (e.g. for a few seconds) and then an isostatic pressure can be applied from the outside Force to be applied to the longitudinal section B of the base S. In the area of the depressions R, the deformation regions U of the base located there will be deformed into the depressions R. The heating elements H can be deactivated again before or after the pneumatically effected reshaping. The application of pressure and the pressing device 17 for releasing the O-rings can then be deactivated again. Then, possibly after a short cooling period, the squeezing tool 11 can be returned again. The above steps can also be performed in a different order.

The finished lamp L can be used analogously to that indicated by in 1B be described mechanically deforming pinch tool 1 produced lamp L.

Although the invention has been illustrated and described in detail by the exemplary embodiments shown, the invention is not restricted thereto and other variations can be derived therefrom by a person skilled in the art without departing from the protective scope of the invention.

In general, "a", "an" etc. can be understood as a singular or a plural number, in particular in the sense of "at least one" or "one or more" etc., as long as this is not explicitly excluded, e.g. by the expression "exactly a" etc.

A numerical specification can also include exactly the specified number as well as a usual tolerance range, as long as this is not explicitly excluded.

Reference List

1

crimping tool

2

base mount

3

Step

4

pressing device

5

squeeze piston

6

drive

11

crimping tool

12

base mount

13

compressed air duct

14

opening

15

O-rings

16

ring grooves

17

pressing device

18

Body

19

Body

20

drive

A

longitudinal axis

B

longitudinal section

f

Free Edge

H

heating element

K

lamp bulb

L

lamp

R

deepening

S

base

T

face

u

forming area

V

heating device

Claims (14)

Method for producing a lamp (L), in which - a lamp bulb (K) with at least one external recess (R) is provided, - a base (S) made of plastic is pushed onto the lamp bulb (K) so that it has the at least covers a depression (R), and - the base (S) is then deformed locally at a deformation area (U) into the at least one depression (R), - characterized in that the deformation area (U) is pneumatically stressed on the outside for the deformation . procedure after claim 1 , in which the forming area (U) is heated before forming. 3. The method as claimed in one of the preceding claims, in which - the base (S) with the inserted lamp bulb (K) is introduced into a pneumatically deforming squeezing tool (11) in such a way that the at least one deforming region (U) is connected in a pneumatic manner ( 13) is brought with a compressed gas source, and - the at least one forming area (U) by means of Compressed gas source is acted upon by compressed gas via the pneumatic connection (13). procedure after claim 3 , wherein - the pneumatically deforming squeezing tool (11) has at least one compressed air channel (13) which can be connected to the compressed gas source as the pneumatic connection and has at least one opening (14) opening out on an outside of the base (S), - the pneumatically deforming squeezing tool ( 11) has at least one seal (15) which axially delimits at least one opening (14) and at least one associated forming area (U), and - the at least one seal (15) before or when the compressed gas is applied to the base (S ) is pressed. procedure after claim 4 , wherein - the pneumatically forming squeezing tool (11) has a heating device (V) and the base (S) is heated by means of the heating device (H, V) in its at least one forming area (B, U) before forming and - heating areas ( H) the heating device (V) at the at least one opening (14) of the compressed air channel (13). Method for producing a lamp (L), in which - a lamp bulb (K) with at least one external recess (R) is provided, - a base (S) made of plastic is pushed onto the lamp bulb (K) so that it has the at least covers a depression (R), and - the base (S) is then deformed locally at a deformation area (U) into the at least one depression (R), - characterized in that the deformation area (U) is used for deformation by axial compression of the Base is mechanically stressed on the outside. procedure after claim 6 , in which - the base (S) with the inserted lamp bulb (K) is introduced into a receptacle (2) of a mechanically deforming squeezing tool (1) with circumferentially narrow play, and - the base (S) then by means of the squeezing tool (1) axially compressed. Squeezing tool (1; 11), wherein the squeezing tool (1; 11) for carrying out the method according to one of Claims 1 until 7 is trained. lamp (L), comprising - A lamp bulb (K) with at least one external depression (R) and - A base (S) pushed up to at least the at least one recess (R) on the lamp bulb (K), wherein - the base (S) is deformed locally into the at least one recess (R) by external pneumatic stress or axial compression of the base. lamp (L) after claim 9 , wherein the lamp bulb (K) is a glass bulb. Lamp (L) after one of claims 9 until 10 , wherein the lamp vessel (K) is a tubular lamp vessel (K). lamp (L) after claim 11 , wherein the at least one outside depression (R) has at least one row of local depressions (R) distributed in a circumferential direction. Lamp (L) after one of claims 9 until 12 , wherein the socket (S) is a pin socket. Lamp (L) after one of claims 9 until 13 , wherein the lamp is a semiconductor retrofit lamp to replace conventional tubular lamps.

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