JP2001229819A - Lamp with light shielding film and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a lamp with a light shielding film and its manufacturing method capable of restraining the dispersion of the light shielding film fixation and its fixation strength and fixing the light shielding film to the glass base material at a uniform fixation strength. SOLUTION: The lamp comprises a pair of electrodes 2 formed inside and a light emitting tube 1 equipped with a light emitter 1a sealing mercury, metal halide and initiation gas inside, and with sealing parts 1b installed at both ends of the light emitter 1a. The light emitting tube 1 is provided inside an outer tube 6. Light shielding films 11, 12 and 13 are provided on the external surface of the outer tube 6. The films 11, 12, 13 are stuck on the prescribed locations after turning its adhesive face to the outer tube 6 side and then these are cured and fixed on the external surface of the outer tube 6 by receiving the ultraviolet or infrared ray radiation sent by the lamp itself which is turned on.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] 1. Field of the Invention [0002] The present invention relates to a lamp having a light shielding film and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, a light-shielding film has been formed on the surface of a glass substrate such as an outer tube of a discharge lamp or a halogen bulb. Hereinafter, an example of a discharge lamp will be described. Practical use of discharge lamps having a low wattage of about 35 W is progressing, and since they are small in size and high in efficiency, they are used for applications such as headlights of automobiles and backlight sources of liquid crystal projectors.

When a discharge lamp is used as a light source for a headlight of an automobile or a backlight of a liquid crystal projector, it is used in combination with a reflector. In recent years, in order to prevent the reflecting mirror from being deteriorated by the irradiation of the ultraviolet light radiated from the discharge lamp, there has been known an outer tube using quartz for cutting off the ultraviolet light. Generally, in order to realize a proper light distribution by combining a reflecting mirror and a discharge lamp, it is required that the light emitting portion, that is, the position of the arc be regulated with extremely high precision with respect to the reflecting mirror. The arc, which is the light emitting portion of the discharge lamp, is affected by factors such as the shape and pressure of the arc tube, the tube voltage and the tube current, and thus it is difficult to mechanically control the arc like a filament of a light bulb or the like.

For this reason, there has been proposed a method of obtaining an accurate light distribution by forming a light-shielding film on an outer tube and optically cutting a part of an arc whose position is difficult to regulate. In this method, the light distribution depends not on the position of the arc but on the accuracy of the position of the light-shielding film. Therefore, it is required to apply the light-shielding film with high positional accuracy.

As a conventional lamp with a light-shielding film, there is a lamp provided with a light-shielding film made of a green sheet patterned in a predetermined shape on the surface of a glass substrate (Patent No. 2).
No. 891690). As a method of manufacturing such a conventional lamp with a light-shielding film, a green sheet is attached to the surface of a glass base material of the lamp, temporarily fixed by temporary firing, and then finally fired to be integrated.

[0006]

However, in such a conventional method of manufacturing a lamp with a light-shielding film, it is necessary to perform a firing operation as a step of attaching a green sheet as a light-shielding film to a glass substrate. Therefore, the firing furnace,
Strict control of the processing temperature and processing time by the burner, and furthermore, the uniformity of the temperature distribution in the firing furnace, etc. must be strictly controlled, so the control is complicated and stable temperature conditions for producing a uniform lamp. Was difficult to obtain easily. For this reason, the fixing strength between the glass base material and the light-shielding film varies, and there is a problem that the light-shielding film is peeled off in the completed discharge lamp, though it is only a small part. In addition, a large facility such as a firing furnace is required, which causes a problem that the cost is increased.

SUMMARY OF THE INVENTION The present invention has been made to solve such a problem, and eliminates the need to perform a firing operation as a step of attaching a green sheet to a glass substrate, thereby reducing the adhesion of the light-shielding film and the variation in the adhesion strength. An object of the present invention is to provide a lamp with a light-shielding film in which a light-shielding film is fixed to a glass substrate with a uniform fixing strength and a method for manufacturing the same.

[0008]

A method of manufacturing a lamp with a light-shielding film according to claim 1 of the present invention is a method of manufacturing a lamp with a light-shielding film in which a light-shielding film is formed on a surface of a glass substrate,
The light-shielding film is a green sheet patterned in a predetermined shape, and fixes the light-shielding film to the surface of the glass substrate by irradiation with infrared rays or ultraviolet rays.

[0009] Thus, without using a firing furnace or a burner, which has to strictly control the processing temperature and processing time, it is possible to easily control the irradiation intensity and time of infrared rays or ultraviolet rays radiated from the lamp, and to realize green. While changing the composition of the sheet, the green sheet can be fixed to the glass substrate, and the strength of the light shielding film itself is improved,
The fixing strength between the green sheet and the glass substrate can be improved, and a lamp with a light-shielding film can be manufactured uniformly and stably. In addition, since it is not necessary to use a large-scale facility such as a firing furnace, manufacturing costs can be reduced.

A lamp with a light-shielding film according to a fourth aspect of the present invention is a lamp with a light-shielding film having a light-shielding film formed on the surface of a glass substrate, wherein the light-shielding film is a green sheet patterned into a predetermined shape. And has a configuration in which it is fixed to the surface of the glass substrate by irradiation of infrared rays or ultraviolet rays.

As a result, it is possible to obtain a lamp with a light-shielding film in which there is no variation in the fixing strength of the light-shielding film and the strength of adhesion between the glass substrate and the light-shielding film is improved.

[0012]

FIG. 1 is a front view of a metal halide lamp for a 35W automobile headlight according to an embodiment of the present invention. FIG. 2 is a front sectional view of a plane including the axis 18 of the arc tube of the metal halide lamp shown in FIG.
FIG. 3 is a cross-sectional view taken along the line II in FIG. In FIG. 1, the internal structure of the transparent member is drawn by a solid line.

As shown in FIG. 1 and FIG. 2, the discharge lamp of this embodiment has a pair of electrodes 2 inside, and contains mercury, ScI ₃ and NaI as metal halides and xenon as a starting gas inside. A light emitting tube 1 made of a glass material containing SiO ₂ as a main component and having a sealed light emitting portion 1a and a pair of flat sealing portions 1b connected to both ends of the light emitting portion 1a, respectively. I have.

Each of the sealing portions 1b includes a metal foil 4 having one end connected to one end of the electrode 2 and the other end connected to one end of an external lead wire 3; It is sealed so as to be located inside.

As shown in FIG. 2, at least one sealing portion 1b of the arc tube 1 is provided with a cylindrical portion 5 which is continuous with the external lead wire 3 on the base 7 from the sealing portion 1b. It is derived through section 5.

The arc tube 1 is provided inside the outer tube 6, and the end of the outer tube 6 is sealed to the sealing portion 1 b or the cylindrical portion 5 of the arc tube 1, respectively.

The arc tube 1 has an end portion of the cylindrical portion 5 inserted into a hole 8 provided at the center of a base 7 made of a resin such as polyetherimide, and a holder 9 made of metal.
Is supported by the base 7. The external lead wire 3 leading out from the base 7 is connected to a power supply line 10 arranged on the side of the outer tube 6.

Light-shielding films 11, 12, and 13 are formed on the outer surface of an outer tube 6 made of a glass material containing SiO ₂ as a main component, and as shown in FIGS.
A pair of strip-shaped light shielding films 11 and 12 is formed in a region facing the electrode 2 and in a region located in the vicinity of the electrode 2.

Here, the light shielding films 11, 12, and 13 are green sheets, which are material sheets containing ceramics, glass, or the like as a matrix component. By preparing a material sheet in advance, it is easy to make the thickness of the light-shielding film uniform, and it is also easy to pattern the material into a predetermined shape by punching or the like in advance. From this,
The boundary between the light-shielding films 11, 12, and 13 has a steep step structure, so that the positional accuracy can be improved and the uniformity of the film thickness can be secured. Thereby, the light distribution characteristics during lighting can be improved. Further, the light-shielding films 11, 12, and 13
Since the green sheet is formed by sticking a patterned green sheet, the degree of freedom of the position where the light shielding film is formed is improved, unlike a conventional light shielding film formed by brush or ink jet. For this reason, the light-shielding film can be formed at an optimal position in consideration of the light distribution characteristics and the convenience of the manufacturing method, and the improvement of the light distribution characteristics, the simplification of manufacturing, and the cost reduction can be realized.

In FIGS. 1 and 2, light-shielding films 11 and 13 whose outlines are indicated by solid lines and whose areas are indicated by dots,
The light-shielding films 12 and 13 whose outlines are indicated by dots and whose outlines are indicated by dots are formed on the front side of the outer surface of the outer tube 6 and on the rear side of the outer surface of the outer tube 6, respectively. are doing. The light-shielding films 11 and 12 face away from each other, and as shown in FIG. 3, the light-shielding film 11 is formed in a region between the end 14 and the end 15 on the outer peripheral surface of the outer tube 6. Then, in the example of the present embodiment, the end 16 and the end 1
4 forms an angle γ of 165 degrees, and the end 17 and the end 15
It forms an angle δ in the range of 105 ° to 125 ° inside. Here, the vertices of the angles γ and δ are the axis 1 of the arc tube.
8 above.

As shown in FIGS. 1 and 2, the outer surface of the outer tube 6 is a region not facing the power supply line 10,
The light shielding film 13 is formed in a region corresponding to at least one of the pair of sealing portions 1b. In the present embodiment, the light-shielding film 13 includes a pair of electrodes 2 as shown in FIG.
The power supply line 1 on the outer surface of the outer tube 6 from a position forming an angle α of 45 degrees with a perpendicular to the outer tube 6 at a center point between the positions and a position forming an angle β of at least 70 degrees of the perpendicular.
3 to the side not facing. Here, the vertices of α and β are both on axis 18 of arc tube 1. When the light-shielding films 11, 12, and 13 are formed at these positions, only the effective light enters the reflector (not shown). Then, it becomes a beam and is projected outside through a headlight lens.

Next, a method for manufacturing a lamp with a light-shielding film according to an embodiment of the present invention will be described with reference to the method for manufacturing a metal halide lamp shown in FIG. 1 as an example.

As shown in FIG. 4, the light shielding films 11, 12, and 13 are formed by cutting a solid green sheet coated with an adhesive 19 on one surface into a concave shape in which the light shielding films 11, 12, and 13 are integrated (pattern). Ning) is formed. And
The light-shielding films 11, 12, and 13 are attached to the predetermined positions with the adhesive 19 surface facing the outer tube 6. Thereafter, the lamp itself to which the light-shielding films 11, 12, and 13 are attached is turned on, whereby the light-shielding films 11, 12, and 13 are cured by irradiation of ultraviolet light or infrared light emitted from the lamp itself, and Adhered to the surface.

As a method other than turning on the lamp itself to which the light shielding films 11, 12, 13 are fixed, the light shielding film 1
By turning on another lamp that emits ultraviolet light or infrared light in the vicinity of the lamp to which 1, 12, 13 is to be fixed, the light-shielding films 11, 12, 13 can be fixed to the surface of the outer tube 6. The emitted light may be both ultraviolet light and infrared light, depending on the light shielding film material.
Either one may be sufficient.

As the light shielding film material, an ultraviolet curing material represented by a polyimide material is included as a material. By containing an ultraviolet-curable resin in the light-shielding film material, the light-shielding film can be cured by irradiating ultraviolet light, and the durability of the light-shielding film can be improved, and the light-shielding film is strongly adhered to the glass substrate to which the light-shielding film is attached. Strength is obtained. A polyimide resin can be used as a component of the ultraviolet curing material. Further, an inorganic pigment for obtaining light-shielding properties may be contained. As a component of the inorganic pigment, a single metal such as iron, manganese, copper, chromium, and cobalt, or a single metal oxide, or an alloy of these metals, or a composite metal oxide composed of two or more types, or two or more types Can be used.
For example, Fe ₂ O ₃ , Fe ₃ O ₄ , MnO ₂ , CuO, Cr ₂
O ₃ , CoO or the like is used. However, the compounds shown here are only examples, and are not limited to these components. In general, the light-shielding film is of a dark color, but a red pigment, a blue pigment, or the like may be used. Although a polyimide resin material has been described as an ultraviolet curable material, the present invention is not limited to this material, and another ultraviolet curable material may be used.

Further, an organic binder component for obtaining flexibility and strength as a green sheet may be contained as a light shielding film material. Examples of the organic binder component include polyvinyl alcohol and polyacrylonitrile, but the present invention is not limited to these.

The green sheet is manufactured, for example, as follows. First, the light-shielding film material is uniformly kneaded by a roll mill into a paste, and then applied to a release surface of a first release film (for example, a polyethylene terephthalate film) by a doctor blade type coating machine. 100 μm (for example, about 20 μm)
Is formed. Next, the coating film is wound up on a roll together with the first release film, and an acrylic resin type pressure-sensitive adhesive is applied to the coating film by a gravure coating machine and dried to form a pressure-sensitive adhesive layer having a thickness of 10 μm each. Then, a second release film (for example, a polyethylene terephthalate film) is laminated on the pressure-sensitive adhesive layer to obtain a green sheet. By this method, a green sheet having a substantially uniform film thickness can be obtained. Note that a silicone-based adhesive may be used as the adhesive.

The green sheet adhered to the outer tube 6 can solidify the pressure-sensitive adhesive component on the surface of the light-shielding film by irradiating ultraviolet rays or infrared rays, thereby increasing the fixing strength of the light-shielding film to the glass substrate. it can. Furthermore, the composition change of the organic component (binder, ultraviolet curable material) and the glass frit in the light shielding film material can be caused, and the adhesion of the light shielding film to the glass substrate can be enhanced by the composition change. Note that, depending on the components forming the green sheet, the green sheet can be fixed to the glass substrate without using the adhesive 19.

In a lamp to which a light-shielding film is fixed by irradiation with ultraviolet light or infrared light, light-shielding films 11, 12, 13
Further heat treatment may be performed to increase the fixing strength between the outer tube 6 and the outer tube 6.

Further, this heat treatment is performed by using the light shielding films 11, 12, 1.
After fixing 3, the lamp itself may be turned on, or another lamp may be turned on nearby to perform the heat. At this time, the heat is preferably in the range of 600C to 1500C.

As described above, by using the method for manufacturing a lamp with a light-shielding film of the present invention, the lamp can be easily manufactured without using large equipment used in the conventional firing method and without performing complicated control. A lamp with a light-shielding film can be obtained uniformly and stably.

The present invention can be applied to a lamp other than the metal halide lamp, for example, a halogen bulb as long as the lamp requires a light shielding film, and the same effect can be obtained.

In the above example, the light shielding films 11, 12, 1
3 is provided on the outer surface of the outer tube, but the light shielding films 11, 12, 13
Is provided on at least one of the outer surface and the inner surface of the arc tube 1, and when the light shielding films 11, 12, 13 are provided on at least one of the outer surface and the inner surface of the outer tube 6, the same effect is obtained. Obtainable. Furthermore, the light shielding films 11, 1
2 and 13 may be provided in both the arc tube 1 and the outer tube 6.

In the above example, the positions where the light-shielding films 11, 12, 13 are added are limited. However, the present invention is not limited with respect to the positions where the light-shielding films are added, but according to the required characteristics of each lamp. It goes without saying that the additional position should be determined appropriately. Further, the application is not limited to the headlight.

[0035]

As described above, the method for manufacturing a lamp with a light-shielding film according to the present invention provides a method of radiating light from a lamp without using a firing furnace or a burner which requires strict control of processing temperature and processing time. By controlling the intensity of irradiation of infrared rays or ultraviolet rays and the time, the composition of the green sheet can be changed and the green sheet can be fixed to the glass substrate, and the strength of the light shielding film itself can be improved. The fixing strength with the glass substrate can be improved, and the lamp with the light shielding film can be manufactured uniformly and stably. In addition, since it is not necessary to use a large-scale facility such as a firing furnace, manufacturing costs can be reduced.

In the lamp with a light-shielding film of the present invention, there is no variation in the fixing strength of the light-shielding film, the adhesion strength between the glass substrate and the light-shielding film can be improved, and the light-shielding film can be prevented from peeling off. Can be.

[Brief description of the drawings]

FIG. 1 is a front view of a metal halide lamp for a 35W automotive headlight according to an embodiment of the present invention.

FIG. 2 is a sectional view of the metal halide lamp shown in FIG.

FIG. 3 is a sectional view taken along the line II of FIG. 1 and viewed from the direction of the arrow;

FIG. 4 is a perspective view showing an external shape of a green sheet used for manufacturing the metal halide lamp of FIG. 1;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Arc tube 2 Electrode 3 External lead wire 6 External tube 7 Base 10 Power supply line 11, 12, 13 Light shielding film

Claims (4)

[Claims] 1. A method for manufacturing a lamp with a light-shielding film having a light-shielding film formed on a surface of a glass substrate, wherein the light-shielding film is a green sheet patterned into a predetermined shape, and A method for producing a lamp with a light-shielding film, wherein the lamp is fixed to the surface of the glass substrate by irradiation of ultraviolet rays. 2. The light-shielding film is fixed to the surface of the glass substrate of the lamp to which the light-shielding film is to be fixed by irradiating infrared rays or ultraviolet rays emitted by lighting of the lamp itself to which the light-shielding film is to be fixed. The method for manufacturing a lamp with a light-shielding film according to claim 1, wherein: 3. The glass substrate of the lamp to which the light-shielding film is to be fixed by irradiating infrared light or ultraviolet light emitted by turning on a light source different from the lamp to which the light-shielding film is to be fixed. The method for manufacturing a lamp with a light-shielding film according to claim 1, wherein the lamp is fixed to a surface of the lamp. 4. A lamp with a light-shielding film having a light-shielding film formed on a surface of a glass substrate, wherein the light-shielding film is a green sheet patterned into a predetermined shape, and the glass substrate is irradiated with infrared rays or ultraviolet rays. A lamp with a light-shielding film, the lamp being fixed to a surface of the lamp.