EP1115144A1 - Verfahren zur herstellung einer leuchtstofflampe und leuchtstoffsuspension - Google Patents

Verfahren zur herstellung einer leuchtstofflampe und leuchtstoffsuspension Download PDF

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Publication number
EP1115144A1
EP1115144A1 EP00927810A EP00927810A EP1115144A1 EP 1115144 A1 EP1115144 A1 EP 1115144A1 EP 00927810 A EP00927810 A EP 00927810A EP 00927810 A EP00927810 A EP 00927810A EP 1115144 A1 EP1115144 A1 EP 1115144A1
Authority
EP
European Patent Office
Prior art keywords
oxide
phosphor
metal oxide
fluorescent lamp
particles
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP00927810A
Other languages
English (en)
French (fr)
Other versions
EP1115144A4 (de
Inventor
Koji Kitamura
Hirokazu Tachibana
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Panasonic Corp
Original Assignee
Matsushita Electronics Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Matsushita Electronics Corp filed Critical Matsushita Electronics Corp
Publication of EP1115144A1 publication Critical patent/EP1115144A1/de
Publication of EP1115144A4 publication Critical patent/EP1115144A4/de
Withdrawn legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J61/00—Gas-discharge or vapour-discharge lamps
    • H01J61/02—Details
    • H01J61/38—Devices for influencing the colour or wavelength of the light
    • H01J61/42—Devices for influencing the colour or wavelength of the light by transforming the wavelength of the light by luminescence
    • H01J61/46—Devices characterised by the binder or other non-luminescent constituent of the luminescent material, e.g. for obtaining desired pouring or drying properties

Definitions

  • the present invention relates to a fluorescent lamp manufacturing method, and to an improvement in a phosphor suspension used in a phosphor film forming process thereof.
  • a phosphor suspension including a phosphor is applied to an inner surface of a glass tube, dried, and baked to form a phosphor film.
  • the phosphor suspension is conventionally composed of phosphor particles and minute particles of a metal oxide formed mainly from aluminum oxide, mixed together with water used as a dispersant.
  • the metal oxide is added to the phosphor suspension as a bonding agent to increase the connecting surface areas of neighboring particles. This increases both the connectivity of the phosphor particles and their ability to bond to the inner wall of the glass tube, thereby forming a phosphor film with a high film strength.
  • a metal oxide with a large specific surface area of around 100 m 2 /g is used.
  • An aluminum oxide with a high specific surface area such as Degussa AG's 'Aluminum Oxide C' (product name; specific surface area of around 100 m 2 /g) is one example of a metal oxide in general use.
  • the phosphor suspension one characteristic of the phosphor suspension is that phosphor particles usually sink down to the bottom of the suspension and harden at a pH value of less than pH8.
  • a fluorescent lamp manufacturing process is repeated at long intervals, it is extremely difficult to redisperse the phosphor once it has hardened in this way.
  • the phosphor suspension suddenly changes into a gel when the pH value exceeds pH10, and obtaining a uniform phosphor film is impossible if a gelled phosphor suspension is applied.
  • an appropriate amount of alkaline solution is conventionally mixed into the phosphor suspension in order to keep it in a range of no less than pH8 and no more than pH10.
  • the pH value of the phosphor suspension is kept in the range of no less than pH8 and no more than pH10 using such a prior art technique, the aluminum oxide tends to react with the alkaline solution over time and deteriorate, thereby causing degeneration of the phosphor suspension.
  • a phosphor film formed from such a degenerated phosphor suspension will have a particularly weak film strength, and is likely to become detached from the inner wall of the glass tube as a result of changes in pressure when the glass tube is evacuated or shocks occurring during transportation of the lamp.
  • the present invention has been developed to overcome such problems, and has as its object the provision of a phosphor suspension in which the deterioration over time that occurs after mixing is limited, and of a fluorescent lamp manufacturing method that uses such a phosphor suspension to form a phosphor film with a high film strength.
  • a fluorescent lamp manufacturing method of the present invention may be a manufacturing method for forming a phosphor film on an inner surface of a glass tube by applying a phosphor suspension including a phosphor and a metal oxide.
  • a pH value of the phosphor suspension is adjusted so as to be in a range of no less than pH8 and no more than pH10, and the metal oxide includes particles of aluminum oxide each having a specific surface area of no less than 1.5 m 2 /g and no more than 30 m 2 /g.
  • the specific surface area of the particles of aluminum oxide is set at no less than 1.5 m 2 /g and no more than 30 m 2 /g, this being smaller than the size conventionally used, the specific surface area that reacts to the alkaline solution is less. Therefore, deterioration in the phosphor suspension over time are restricted and the film strength of a phosphor film formed using such particles as a raw material is improved.
  • metal oxide particles may satisfy a condition 0.5 ⁇ b/a ⁇ 1.0, a ( ⁇ m) being a length of a metal oxide particle and b ( ⁇ m) being a breadth of a metal oxide particle.
  • metal oxide particles may satisfy a condition 0.05 ⁇ c ⁇ 1.00, c being an average diameter of a metal oxide particle.
  • the fluorescent lamp 100 is of the straight tube type, and uses a long slim glass tube 1 as an arc tube. Part of the external surface of the glass tube 1 has been cut away to show its internal structure.
  • the electrodes 2 have a tungsten coil 3 whose surface is coated with an emitter. Oxides such as barium, strontium, and calcium are conventionally used as emitters. Furthermore, a phosphor film 8 is formed on the inner surface of the glass tube 1, and appropriate quantities of mercury and an inert gas such as argon are enclosed within the tube.
  • a base pin 5 is connected to each of the outer ends of electrodes 2, and a voltage is applied from a stabilizer (not shown) to the electrodes 2 via the base pins 5.
  • Bases 6 hold the base pins 5 in place via plates 9, and also serve to protect each end of the glass tube 1.
  • the tungsten coil 3 heats up, causing electrons to be emitted from the emitter coating its surface.
  • the electrons collide with the mercury vapor enclosed in the tube, generating ultraviolet light.
  • the phosphor film 8 coating the inner surface of the glass tube 1 receives the ultraviolet light, and phosphor in the phosphor film 8 is excited, generating visible light.
  • the phosphor film 8 If the phosphor film 8 is not firmly attached to the inner surface of the glass tube 1, it will easily become detached if even a slight shock is felt during evacuation of the tube, assembly or transportation, thereby resulting in a defective product. Consequently, when the fluorescent lamp manufacturing process is performed, the phosphor film 8 needs to be formed so as to have a film strength of at least a certain level.
  • the phosphor film 8 is formed by coating the phosphor suspension explained hereafter over the inner surface of the glass tube 1 to form a layer of an approximately uniform thickness, and then drying and baking the phosphor suspension to form a phosphor film with an extremely high film strength.
  • the phosphor suspension in the present embodiment is formed from a mixture of phosphor particles, metal oxide used as a bonding agent, polyethylene oxide used as a binder to increase the viscosity of the phosphor suspension, pure water used as a dispersant, and ammonia used as a pH regulator, in the following proportions by weight and in the stated order: 1 : 0.013 : 0.009 : 1.850 : 0.0001.
  • the polyethylene oxide is dissolved in the pure water using an agitator. Then, the phosphor, metal oxide, and ammonia are added, in that order, and mixed together.
  • a phosphor suspension formed from such components has a final pH of 9, and viscosity of 40 mPas (when shearing speed is 20 s -1 ).
  • the phosphor is formed by compounding europium-activated yttrium oxide, cerium terbium-activated lanthanum phosphate, and europium-activated strontium halophosphate in the proportions of 40 : 50: 10 by weight in the stated order.
  • the metal oxide is aluminum oxide having an ⁇ -alumina crystal structure with a specific surface area of 15 m 2 /g and an average particle diameter of 0.1 ⁇ m (the ratio of breadth to length is 0.9).
  • FIG. 2 is a design drawing showing the condition of particles in the phosphor suspension coating the inner surface at this stage in the manufacturing process.
  • large particles of a phosphor 82 are suspended in a binder 81 of the phosphor suspension, and minute particles of a metal oxide 83 enter the gaps between particles.
  • the phosphor suspension attached to the inner surface of the glass tube 1 is then dried by applying air heated to a temperature of around 70°C. Then the glass tube 1 is heated in a gas furnace to a temperature of around 550°C to form the phosphor film 8 on the inner surface of the glass tube 1.
  • FIG. 3 is a design drawing showing the state of particles in the phosphor film 8 after baking.
  • the binder 81 vaporizes during baking, and the metal oxide 83 acting as a bonding agent melts, bonding neighboring particles of the phosphor 82 together, and attaching the phosphor 82 to the inner surface of the glass tube 1. This enables a phosphor film 8 that has a high film strength and does not easily become detached to be formed.
  • a fluorescent lamp 100 with a phosphor film 8 formed from a phosphor suspension having the above components is also referred to as 'the invention'.
  • the horizontal axis of the graph in Fig. 4 shows the value of the specific surface area used in each case, and the vertical axis shows the corresponding film strengths formed.
  • the method used to evaluate the film strength of the phosphor film involved vertically-sectioning each fluorescent lamp, and blowing high-pressure air onto the phosphor film via a stainless steel tube.
  • the stainless steel tube had an internal diameter of 0.5 mm and was positioned perpendicular to the phosphor film at a center of a vertical direction of the fluorescent lamp, with the end of the stainless steel tube from which the air is blown being 15 mm away from the phosphor film. Then the pressure at which the phosphor film became detached from the inner surface of the fluorescent lamp was recorded as an indicator of the film strength of the phosphor film, in units of kgf/cm 2 .
  • the phosphor film did not become detached if shocks were received during evacuation or transportation, provided that the film strength was at least 1.5 kgf/cm 2 . Therefore, this film strength of 1.5 kgf/cm 2 was used as a standard value when determining whether the film strength of the phosphor film in a particular fluorescent lamp was satisfactory, with fluorescent lamps having a film strength of at least 1.5 kgf/cm 2 being judged as satisfactory.
  • the specific surface area of the aluminum oxide is less than 1.5 m 2 /g, or exceeds 30 m 2 /g, it can be seen that the film strength of the phosphor film will not reach 1.5 kgf/cm 2 .
  • the film strength of the phosphor film in the case of the present invention was 1.73 kgf/cm 2 after 60 days, showing a drop of only 1% in comparison with the film strength after 1 day (1. 75 kgf/cm 2 ).
  • the film strength of the prior art was 1.15 kgf/cm 2 ) after 60 days, a drop of 36% in comparison with the film strength after 1 day (1.80 kgf/cm 2 ).
  • a metal oxide having a specific surface area in the range shown in this invention if used, a sufficiently high film strength can be obtained without the use of a metal oxide with a large specific surface area used in the prior art, and changes in the phosphor suspension over time limited, so that a phosphor film with a high film strength can be formed, regardless of the number of days that has passed since the phosphor suspension was mixed.
  • the pH value of the phosphor suspension should preferably be kept within a range of no less than pH8 and no more than pH9, in order to prevent deterioration over time, and obtain a higher film strength.
  • deterioration in the phosphor suspension over time is mainly caused by alkaline erosion of the metal oxide. Consequently, alkalinity should be kept at the lower end of the range of pH8 to pH10 that is required for the phosphor suspension.
  • particle size should preferably fulfil the relation 0.5 ⁇ b/ a ⁇ 1.0. This is because even in cases where the average diameter of metal oxide particles is identical, when b/a ⁇ 0.5, the specific surface area of the metal oxide is larger, and the transformation of the aluminum oxide into hydrogen proceeds at a marked rate. As a result, the film strength of the phosphor film shows a great amount of deterioration over time. Therefore, defining b/a by the above range limits the changes in film strength of the phosphor film over time.
  • metal oxide particles should preferably be of at least a certain volume, but if surface area is increased, there is more likelihood of deterioration occurring, as described above. If b/a is near to 1.0, that is a particle is nearly spherical, a small surface area can be achieved with the same volume. Consequently, the shape of metal oxide particles should preferably be within the range 0.5 ⁇ b/ a ⁇ 1.0.
  • an average diameter of aluminum oxide particles is c ⁇ m
  • the relation 0.05 ⁇ c ⁇ 1.00 should preferably be satisfied.
  • the reason for this is when c ⁇ 0.05, the particles of aluminum oxide become too minute, and coagulate together, making it difficult to disperse particles in the phosphor suspension, and so use of such minute particles is impractical.
  • c>1.00 particles of aluminum oxide cannot fit satisfactorily into the narrow gaps between neighboring phosphor particles, markedly reducing connecting surface areas of neighboring phosphor particles. This in turn reduces bonding strength, and consequently the film strength of the phosphor film. Therefore, defining c using the above range facilitates dispersion and ensures that a phosphor film with a film strength that is sufficient for actual use can be obtained.
  • Aluminum oxide with an ⁇ -alumina crystal structure is preferable in order to further restrict changes in the film strength of the phosphor film over time.
  • the reason for this is that aluminum oxide having this structure is less likely to react with alkaline solution than a comparable ⁇ -alumina crystal structure, and so generation of changes causing deterioration in the phosphor film is also less likely.
  • the following experimental lamps were manufactured to demonstrate the effect of a fluorescent lamp manufacturing method when other metal oxides were added.
  • Aluminum oxide with a ⁇ -alumina crystal structure (specific surface area 15 m 2 /g, average particle diameter 0.1 ⁇ m, ratio of particle length to breadth 0.9) was used as the main component of the metal oxide in each case.
  • Each of (a) strontium oxide, (b) lanthanum oxide, (c) boron oxide, and (d) both lanthanum oxide and boron oxide were added to aluminum oxide, and the resulting mixtures included in the phosphor suspensions to form phosphor films in lamps A, B, C, and D respectively. In all other respects these lamps are identical to the invention.
  • the atomic ratio of aluminum oxide to strontium oxide in Lamp A is 1:0.02.
  • the atomic ratio of aluminum oxide to lanthanum oxide in Lamp B is 1:0.02.
  • the atomic ratio of aluminum oxide to boron oxide in Lamp C is 1:0.1.
  • the atomic ratio of aluminum oxide to lanthanum oxide is 1:0.02, and the atomic ration of aluminum oxide to boron oxide is 1:0.1 in Lamp D.
  • lamp E a fluorescent lamp using only aluminum oxide as the metal oxide.
  • Table 2 indicates that the film strengths of the phosphor films in Lamps A, B, C, and D have improved by 5%, 8%, 9%, and 14% respectively when compared with lamp E. This is believed to be due to the fact that addition of strontium oxide, lanthanum oxide, and boron oxide lowers the melting point of the metal oxide and improves the ability of the phosphor film to bond with the inner surface of the glass tube 1.
  • the main component of the metal oxide is aluminum oxide, and it is preferable to add one of the above mentioned additives at an atomic ratio of no less than 1:0.001 and no more than 1:1.00.
  • the reason for this is that when the atomic ratio of aluminum oxide to the additive is less than 1:0.001, the amount of additive is too small, so that a sufficient reduction in the melting point cannot be obtained, and the film strength of the phosphor film does not increase. If the atomic ratio is more than 1:1.00, however, the phosphor film becomes stained during the baking process, and luminous flux is reduced.
  • the total metal oxide content of the phosphor suspension should be no less than 1% and no more than 10% by weight of the phosphor content. The reason for this is that if the total metal oxide content is less than 1% by weight of the phosphor content, the amount of metal oxide is too small, and sufficient increase in connecting surface areas of neighboring particles cannot be obtained, so that the film strength of the phosphor film cannot be sufficiently increased. If, however, the total metal oxide content is more than 10% by weight, the metal oxide stains the phosphor film, reducing luminous flux.
  • the manufacturing method for the fluorescent lamp 100 mainly includes the following seven processes, as shown in FIG. 7: (a) phosphor suspension preparation process, (b) application process, (c) drying process, (d) baking process, (e) electrode attaching process, (f) sealing process, and (g) pin attaching process.
  • a phosphor suspension with the components described above is prepared ((a) phosphor suspension preparation process).
  • the glass tube 1 is stood up, and the phosphor suspension applied to the inner surface of the glass tube 1 by squirting it in via a nozzle ((b) application process).
  • the phosphor suspension attached to the inner surface of the glass tube 1 is dried by being blasted for five minutes with hot air heated to a temperature of 70°C ((c) drying process). Then the entire glass tube 1 is heated at a temperature of 550°C in a gas furnace for three minutes, forming a phosphor film on the inner surface of the glass tube 1 ((d) baking process). This causes the binder 81 to evaporate, and melts the metal oxide 83, bonding particles of phosphor 82 to each other and to the inner surface of the glass tube 1, forming a phosphor film that has a high film strength and will not easily become detached (see FIG. 3).
  • the electrodes 2, that are held by stems 4 are attached to each end of the glass tube 1((e) electrode attaching process). Then, the inside of the glass tube 1 is evacuated via an exhaust port 7, predetermined amounts of mercury and argon gas are introduced into the inside of the glass tube 1, and the exhaust port 7 sealed ((7) sealing process). Finally, the base pins 5 are attached to the electrodes 2, and the bases 6 fixed to either end of the glass tube 1 ((g) base attaching process), completing the fluorescent lamp 100 shown in FIG. 100.
  • the fluorescent lamp manufacturing method of the present invention uses a phosphor suspension in which deterioration over time is limited. As a result, a phosphor film with a high film strength can be formed even if a long period of time has passed since the phosphor suspension was mixed, providing favorable conditions for mass production of high quality fluorescent lamps.

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  • Vessels And Coating Films For Discharge Lamps (AREA)
EP00927810A 1999-05-25 2000-05-19 Verfahren zur herstellung einer leuchtstofflampe und leuchtstoffsuspension Withdrawn EP1115144A4 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP14450199A JP3430971B2 (ja) 1999-05-25 1999-05-25 蛍光ランプの製造方法
JP14450199 1999-05-25
PCT/JP2000/003205 WO2000072356A1 (fr) 1999-05-25 2000-05-19 Procede de fabrication de lampe fluorescente et de suspension de phosphore

Publications (2)

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EP1115144A1 true EP1115144A1 (de) 2001-07-11
EP1115144A4 EP1115144A4 (de) 2003-08-27

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EP00927810A Withdrawn EP1115144A4 (de) 1999-05-25 2000-05-19 Verfahren zur herstellung einer leuchtstofflampe und leuchtstoffsuspension

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EP (1) EP1115144A4 (de)
JP (1) JP3430971B2 (de)
CN (1) CN1288705C (de)
WO (1) WO2000072356A1 (de)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6885144B2 (en) 2000-12-08 2005-04-26 Matsushita Electric Industrial Co., Ltd. Fluorescent lamp and method for manufacture, and information display apparatus using the same
WO2007013688A2 (en) * 2005-07-29 2007-02-01 Matsushita Electric Industrial Co., Ltd. Fluorescent lamp and backlight unit

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7282848B2 (en) * 2003-05-22 2007-10-16 General Electric Company Fluorescent lamp having phosphor layer that is substantially free from calcium carbonate
CN100355011C (zh) * 2003-09-25 2007-12-12 东芝照明技术株式会社 荧光灯、灯泡形荧光灯以及照明器具
KR20120109645A (ko) * 2005-06-14 2012-10-08 덴끼 가가꾸 고교 가부시키가이샤 형광체 함유 수지 조성물 및 시트, 그것들을 사용한 발광 소자
CN102683138B (zh) * 2012-05-11 2015-02-25 广东电力士照明科技有限公司 一种无极灯玻璃管壳的制造工艺

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0372560A2 (de) * 1988-12-08 1990-06-13 Kasei Optonix, Ltd. Verfahren zur Herstellung von Phosphoren

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JPS6041106B2 (ja) * 1977-08-08 1985-09-13 大日本塗料株式会社 顔料付螢光体およびその製造方法
JP2800433B2 (ja) * 1991-01-26 1998-09-21 日亜化学工業株式会社 蛍光体塗布液の製造方法及び放電ランプ
JPH0513047A (ja) * 1991-07-04 1993-01-22 Matsushita Electron Corp 蛍光ランプ
JP2760202B2 (ja) * 1992-02-17 1998-05-28 日亜化学工業株式会社 蛍光体塗布液および蛍光ランプ
JPH07320693A (ja) * 1994-03-31 1995-12-08 Hitachi Ltd 蛍光ランプ
JPH10212475A (ja) * 1997-01-31 1998-08-11 Toshiba Corp 蛍光体およびその製造方法

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0372560A2 (de) * 1988-12-08 1990-06-13 Kasei Optonix, Ltd. Verfahren zur Herstellung von Phosphoren

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Section Ch, Week 197915 Derwent Publications Ltd., London, GB; Class L03, AN 1979-28558B XP002246022 & JP 54 028784 A (DAINIPPON TORYO KK), 3 March 1979 (1979-03-03) *
DATABASE WPI Section Ch, Week 199842 Derwent Publications Ltd., London, GB; Class L03, AN 1998-489619 XP002246023 & JP 10 212475 A (TOSHIBA DENSHI ENG KK), 11 August 1998 (1998-08-11) *
See also references of WO0072356A1 *

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6885144B2 (en) 2000-12-08 2005-04-26 Matsushita Electric Industrial Co., Ltd. Fluorescent lamp and method for manufacture, and information display apparatus using the same
WO2007013688A2 (en) * 2005-07-29 2007-02-01 Matsushita Electric Industrial Co., Ltd. Fluorescent lamp and backlight unit
WO2007013688A3 (en) * 2005-07-29 2007-09-27 Matsushita Electric Ind Co Ltd Fluorescent lamp and backlight unit
CN101310362B (zh) * 2005-07-29 2010-12-08 松下电器产业株式会社 荧光灯和背光单元

Also Published As

Publication number Publication date
CN1288705C (zh) 2006-12-06
EP1115144A4 (de) 2003-08-27
JP3430971B2 (ja) 2003-07-28
CN1319249A (zh) 2001-10-24
WO2000072356A1 (fr) 2000-11-30
JP2000340181A (ja) 2000-12-08

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