JP2001307626A - Method of manufacturing fluorescent lamp - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a fluorescent lamp capable of preventing detachment of a phosphor membrane. SOLUTION: The manufacturing method comprises a primary process in which a straight glass tube 1 is processed to make its both ends standing on different levels in a single spiral structure, with a process of forming a phosphor membrane in which the phosphor membrane is formed inside of a spiral glass tube 6, and a secondary process in which the spiral glass tube that has the phosphor membrane is processed to become circular in the same plane.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a fluorescent lamp.

[0002]

2. Description of the Related Art Fluorescent lamps, particularly ring-shaped fluorescent lamps, generally have a glass tube having electrode stem mounts at both ends and a phosphor film formed on the inner surface via a protective film. It has been known.

[0003] The electrode stem mount has an electrode bridged between two lead wires penetrating the stem, and an exhaust pipe.

Conventionally, a method of manufacturing such a ring-shaped fluorescent lamp is as follows.

First, a protective film is formed on the inner surface of a straight glass tube, and a phosphor film is formed on the protective film. afterwards,
Electrode stem mounts are sealed to both ends of the straight glass tube. Next, this straight tubular glass tube is heated and softened to a temperature equal to or higher than the softening temperature and processed into an annular shape. Then, the impure gas in the annular glass tube is exhausted from the exhaust pipe, and after the enclosure is sealed, the exhaust pipe is sealed.

[0006]

However, in such a conventional method for manufacturing a ring-shaped fluorescent lamp, a straight tube glass tube on which a protective film or a phosphor film is already formed is formed into a ring shape, that is, a ring-shaped glass tube is formed. Since the inside of the tube shrinks and the outside stretches, there is a problem that the phosphor film formed mainly on the outside of the annular glass tube is cracked and the phosphor film is easily peeled.

The present invention has been made in order to solve such a problem, and it is an object of the present invention to provide a method of manufacturing a fluorescent lamp capable of preventing a phosphor film from peeling off.

[0008]

According to the present invention, there is provided a method for manufacturing a fluorescent lamp, comprising: a primary processing step of processing a straight tubular glass tube into a single spiral so that both ends thereof are stepped; A phosphor film forming step of forming a phosphor film on the inner surface of the tube, and the spiral glass tube having the phosphor film formed thereon,
And a secondary processing step of processing into an annular shape along the same plane.

By using this manufacturing method, a straight tubular glass tube is preliminarily formed into a single spiral, a phosphor film is formed on the spiral glass tube, and then the spiral glass tube is processed into an annular shape. Therefore, the load on the protective film and the phosphor film generated during the processing of the glass tube can be reduced as compared with the conventional case where the glass tube is processed directly from a straight tube into an annular shape.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In a method of manufacturing a fluorescent lamp according to an embodiment of the present invention, each step is performed according to the flow shown in FIG. Hereinafter, each step will be described.

The first step is a primary processing step of processing the straight tubular glass tube 1 (see FIG. 2) into a single spiral.

In this primary processing step, as shown in FIG. 2, a concave surface 3 having a radius of curvature of 15 mm is provided on an outer peripheral portion having a width of 34 mm (hereinafter referred to as a rim portion 2), and both ends are arranged stepwise and fixed. A guide body 4 made of spiral ceramics or the like is used. The diameter of the guide body 4 is 3
15 mm. Further, the guide body 4 is fixed to a rotating shaft 5 connected to a motor (not shown) or the like, and rotates about the rotating shaft 5.

Next, the operation of the primary processing step will be described.

First, length 1020 mm, outer diameter 29 mm
A straight tubular glass tube 1 made of soda glass (thickness: 1.2 mm) and a guide body 4 are placed in a furnace (not shown).
The temperature in the furnace is set to be equal to or higher than the softening temperature of the straight glass tube 1, for example, 700 ° C.

[0015] One end of the straight tubular glass tube 1 is held by a chuck (not shown) or the like.

As shown in FIG. 2, after the one end of the straight tubular glass tube 1 is arranged in accordance with the one end of the rim portion 2 of the guide body 4, the straight tubular glass tube 1 is heated and softened. When the straight tubular glass tube 1 is softened, the guide body 4 is rotated in the direction A in FIG. 2 at a speed of 1.5 revolutions / sec, and as shown in FIG. Around the rim 2. Thereby, the straight tubular glass tube 1 is processed into a single spiral shape in which both ends are stepped (hereinafter, referred to as a single spiral shape).
Spiral glass tube 6).

The gap between the two ends of the spiral glass tube 6 is preferably 2 mm to 5 mm.

The spiral glass tube is heated to about 500 ° C.
Allow to cool and solidify.

After that, the guide body 4 or the solidified spiral glass tube 6 is rotated to remove the spiral glass tube 6 from the guide body 4 as shown in FIG.

Next, the second step, that is, the spiral glass tube 6
The process proceeds to a protective film forming step of forming a protective film (not shown) on the inner surface of the substrate.

As the dispersion 7 for forming the protective film, a mixture prepared by mixing deionized water, polyethylene oxide and alumina fine particles at a ratio of 95: 1: 4 is used.

As shown in FIG. 5, this dispersion 7 is poured into the spiral glass tube 6 from one end of the spiral glass tube 6.

In FIG. 5, reference numeral 8 denotes a nozzle from which the dispersion 7 is jetted.

Next, as shown in FIG.
After rotating the spiral glass tube 6 containing the liquid in the direction B in FIG. 6, as shown in FIG.
And the dispersion liquid 7 is applied to the entire inner surface of the spiral glass tube 6.

Then, from one end of the spiral glass tube 6,
The dispersion 7 is dried by blowing hot air of 0 ° C. for 3 minutes to form a protective film.

Next, the process proceeds to a third step, that is, a phosphor film forming step of forming a phosphor film (not shown) on the protective film.

A suspension (not shown) for forming a phosphor film includes a phosphor in which red (YOX), green (LAP) and blue (BAM) are mixed, alumina fine particles, and polyethylene oxide. And deionized water containing 2% in a ratio of 65: 2: 33.

The suspension is applied on the protective film formed on the inner surface of the spiral glass tube 6 in the same manner as in the protective film forming step, that is, by the method described with reference to FIGS.

After that, from one end of the spiral glass tube 6, 7
The applied suspension is dried by blowing hot air of 0 ° C. for 5 minutes. Further, the spiral glass tube 6 is baked for 3 minutes in a furnace (not shown) at 500 ° C. to form a phosphor film by sintering. By blowing hot air at about 500 ° C. into the spiral glass tube 6 at the time of forming the phosphor film by sintering, unnecessary organic substances in the phosphor film can be burned and removed.

Next, the process proceeds to a fourth step, that is, a sealing step of sealing the electrode stem mounts 9 and 10 (see FIG. 8).

As shown in FIG. 8, one electrode stem mount 9 has an electrode (not shown) extended between two lead wires 12 penetrating the stem 11 and an exhaust pipe 13 having an open end. And

The other electrode stem mount 10 has an electrode (not shown) provided between two lead wires 12 penetrating the stem 11 and an exhaust pipe 14 having a closed end.

Then, these electrode stem mounts 9,
10 is sealed to both ends of the spiral glass tube 6.

Next, the fifth step, that is, the spiral glass tube 6
Then, the process proceeds to a secondary processing step of processing into an annular glass tube 15 (see FIG. 10).

As shown in FIG. 9, a central portion of the spiral glass tube 6, that is, a twisted portion is heated and softened by a gas burner 16, for example. When the center of the spiral glass tube 6 is softened, one end of the spiral glass tube 6 is moved in the direction C in FIG. 9 and the other end of the spiral glass tube 6 is moved in the direction D in FIG. Thus, the spiral glass tube 6 is processed into an annular shape along the same plane as shown in FIG.
When the spiral glass tube 6 is processed into an annular shape, an inert gas such as an argon gas is flowed into the spiral glass tube 6 from the exhaust pipe 13 so that the spiral glass tube 6 can be processed into a highly accurate annular shape. it can.

Then, this annular glass tube 15 is
Cool down to ° C. and solidify.

In FIG. 10, the lead wire 12 and the exhaust pipe 14 are omitted.

Next, the process proceeds to a sixth step, that is, an exhaust sealing step.

With the annular glass tube 15 heated to 400 ° C., the impure gas in the annular glass tube 15 is exhausted from the exhaust pipe 13 having an open end, and is replaced with an inert gas, for example, argon gas. This operation is repeated several times so that the inert gas has a predetermined pressure. Finally, for example, zinc mercury particles (not shown) are introduced into the annular glass tube 15 from the exhaust pipe 13, and the exhaust pipe 13 is chipped off.

Thereafter, a base (not shown) and the like are attached by a conventional method to manufacture an annular fluorescent lamp.

According to the method of manufacturing a fluorescent lamp according to the embodiment of the present invention as described above, the straight tubular glass tube 1 is previously formed into a single spiral shape so that both ends are stepped, and then the straight tubular glass tube 1 is processed. Since a phosphor film is formed on the spiral glass tube 6 and then the spiral glass tube 6 is processed into an annular shape along the same plane, the glass tube is directly deformed from a straight tube to an annular shape as in the conventional case. As a result, the load on the protective film and the phosphor film generated during processing of the glass tube can be reduced, and as a result, cracking of the protective film and the phosphor film can be suppressed. Peeling of the body film can be prevented.

In the sealing step of sealing the electrode stem mounts 9 and 10 to both ends of the spiral glass tube 6, the electrode stem mounts 9 and 10 are processed so that both ends are stepped. Because they do not interfere with each other,
The electrode stem mounts 9 and 10 can be easily sealed to the spiral glass tube 6.

Next, the characteristics of a ring-shaped fluorescent lamp having a rated power of 40 W manufactured by using the manufacturing method of the first embodiment of the present invention (hereinafter, referred to as the present invention) were evaluated.

Therefore, in the product of the present invention, the change over time of the consumption of mercury sealed therein and the luminous flux maintenance rate (%)
Was examined, and the results as shown in FIGS. 11 and 12 were obtained.

The amount of mercury consumed is a value obtained by collecting only mercury effective for light emission from a lamp, measuring the amount of mercury recovered, and subtracting the amount of mercury recovered from the amount of mercury enclosed (5 mg). is there.

For comparison, a ring-shaped fluorescent lamp having a rated power of 40 W (hereinafter, referred to as a conventional product) manufactured by a conventional manufacturing method also shows a change with time of the consumption of mercury sealed therein and a luminous flux maintenance ratio ( %), And FIG.
And FIG. 12 respectively.

In FIGS. 11 and 12, the product of the present invention is indicated by symbol A and the conventional product is indicated by symbol B.

As is clear from FIG. 11, in the product of the present invention, the mercury consumption at the end of life of 6000 hours of lighting was about 2 mg. On the other hand, in the conventional product, the amount of mercury consumed after lighting for 6000 hours was about 3 mg.

The reason for this is that in the case of the conventional product, the protective film and the phosphor film peeled off, and as a result, mercury ions penetrated into the glass of the glass tube from the peeled portion, and It is considered that this was due to the reaction with sodium, one of the components, to form amalgam. On the other hand, in the case of the product of the present invention, it can be considered that the peeling of the protective film and the phosphor film could be prevented, so that mercury ions could be prevented from entering the glass of the glass tube.

Further, in the conventional product, the glass tube was colored black due to the reaction of sodium and mercury ions as glass components. On the other hand, no coloring of the glass tube was observed in the product of the present invention. This is presumably because in the case of the conventional product, the amalgam formed by the reaction between sodium and mercury ions is black.

Further, as is apparent from FIG. 12, in the product of the present invention, the luminous flux maintenance ratio after the lighting of 6000 hours at the end of the life was 93%. On the other hand, in the conventional product, 600
The luminous flux maintenance ratio at the time of lighting for 0 hours was 88%.

The reason for this is that, in the case of the conventional product, the amalgam does not contribute to the discharge,
It is considered that this was because the luminous flux maintenance factor was reduced due to the coloring of the glass tube. On the other hand, in the case of the product of the present invention, since the peeling of the protective film and the phosphor film could be prevented, the formation of amalgam can be suppressed, and as a result, the glass tube is not colored. It is considered that this is because the luminous flux maintenance rate was prevented from lowering.

As described above, the fluorescent lamp manufactured by using the fluorescent lamp manufacturing method according to the first embodiment of the present invention can reduce the amount of mercury consumed and improve the luminous flux maintenance rate. be able to.

Next, in a method of manufacturing a fluorescent lamp according to the second embodiment of the present invention, a method of manufacturing a fluorescent lamp according to the first embodiment of the present invention except that the secondary processing step is different. This is the same manufacturing method.

In the secondary processing step of the method for manufacturing a fluorescent lamp according to the present embodiment, as shown in FIG. 13, two molds 18 each having an annular groove 17 having a diameter of 300 mm on one surface are used. . The cross section of the groove 17 cut vertically is a semicircle with a radius of 15 mm.

In FIG. 13, the lead wire 12 is omitted.

Next, the operation of the secondary processing step will be described.

First, the spiral glass tube 6 and the mold 18
Is placed in a furnace (not shown). The temperature in the furnace is about 60
It is set to 0 ° C.

Note that one end of the spiral glass tube 6 is held by a chuck (not shown) or the like.

When the spiral glass tube 6 is softened, as shown in FIG. 13, the molding die 18 is moved in the direction E in FIG. 13 while blowing, for example, argon gas from the exhaust tube 13 into the spiral glass tube 6. The mold 18 is pressed against the spiral glass tube 6 by moving it in the direction F so that the spiral glass tube 6 is fitted into the groove 17. Thereby, the spiral glass tube 6 is processed into an annular shape along the same plane as shown in FIG.

Then, the annular glass tube 15 is set to about 500
Cool down to ° C. and solidify.

According to the method of manufacturing a fluorescent lamp according to the second embodiment of the present invention as described above, the straight tubular glass tube 1 is preliminarily formed into a single spiral so that both ends thereof are stepped. Thereafter, a phosphor film is formed on the spiral glass tube 6, and thereafter, the spiral glass tube 6 is processed into an annular shape along the same plane. As compared to the case where the glass tube is deformed, the load on the protective film and the phosphor film generated during the processing of the glass tube can be reduced, and as a result, cracking of the protective film and the phosphor film can be suppressed, and protection can be achieved. The peeling of the film and the phosphor film can be prevented, and the use of the mold 18 allows the spiral glass tube 6 to be processed into a high-precision annular shape.

In particular, since the annular groove 17 into which the spiral glass tube 6 is fitted is provided in the molding die 18, the spiral glass tube 6 can be machined into a more accurate annular shape.

Further, at the time of performing the secondary processing step, by blowing an inert gas into the spiral glass tube 6, the spiral glass tube 6 can be processed into a more precise annular shape.

In the above-described embodiment, the case where the softened straight tubular glass tube 1 is wound around the guide body 4 in the primary processing step has been described. However, the straight tubular glass tube 1 is fixed and rotated. The same effect as described above can be obtained by moving the guide body 4 up or down and winding the straight tubular glass tube 1 around the guide body 4.

In the above embodiment, the case where the straight tubular glass tube 1 is made of soda glass having a length of 1020 mm and an outer diameter of 29 mm has been described.
The present invention can be applied to glass tubes of other dimensions and made of other materials.

[0067]

As described above, the present invention can provide a method of manufacturing a fluorescent lamp which can prevent the phosphor film from peeling off.

[Brief description of the drawings]

FIG. 1 is a process diagram showing a schematic flow of a method of manufacturing a fluorescent lamp according to a first embodiment of the present invention.

FIG. 2 is a view showing a primary processing step (first step) in the same method for manufacturing a fluorescent lamp.

FIG. 3 is a view showing the first processing step (first step).

FIG. 4 is a view showing the same primary processing step (first step).

FIG. 5 is a view showing a protective film forming step (second step) in the method of manufacturing the fluorescent lamp according to the first embodiment of the present invention;

FIG. 6 is a view showing the same protective film forming step (second step).

FIG. 7 is a view showing the same protective film forming step (second step).

FIG. 8 is a view showing a sealing step (fourth step) in the method for manufacturing a fluorescent lamp according to the first embodiment of the present invention.

FIG. 9 is a view showing a secondary processing step (fifth step) in the same method for manufacturing a fluorescent lamp.

FIG. 10 is a view showing the secondary processing step (fifth step).

FIG. 11 is a diagram showing mercury consumption (mg) with respect to lighting elapsed time (hour).

FIG. 12 is a diagram showing a luminous flux maintenance ratio (%) with respect to a lighting elapsed time (time).

FIG. 13 is a view showing a secondary processing step in the method for manufacturing a fluorescent lamp according to the second embodiment of the present invention;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Straight tubular glass tube 2 Rim part 3 Concave surface 4 Guide body 5 Rotation axis 6 Spiral glass tube 7 Dispersion liquid 8 Nozzle 9,10 Electrode stem mount 11 Stem 12 Lead wire 13,14 Exhaust tube 15 Annular glass tube 16 Gas burner 17 Groove 18 Mold

 ────────────────────────────────────────────────── ─── Continuing from the front page (72) Inventor Yasuhiro Inoka 1-1, Komachi, Takatsuki-shi, Osaka Matsushita Electronics Co., Ltd. F-term (reference) 5C012 EE02 5C028 EE05 EE08

Claims (6)

[Claims] A first processing step of processing a straight tubular glass tube into a single spiral so that both ends thereof are stepped;
A phosphor film forming step of forming a phosphor film on an inner surface of the spiral glass tube; and a secondary processing step of processing the spiral glass tube having the phosphor film formed thereon into an annular shape along the same plane. A method for manufacturing a fluorescent lamp. 2. The method for manufacturing a fluorescent lamp according to claim 1, wherein in the secondary processing step, the spiral glass tube is pressed into a molding die to be processed into an annular shape. 3. The method according to claim 2, wherein the molding die is provided with an annular groove into which the spiral glass tube is fitted. 4. The method of manufacturing a fluorescent lamp according to claim 1, wherein an inert gas is blown into the spiral glass tube when performing the secondary processing step. 5. The method according to claim 1, further comprising forming a protective film on an inner surface of the spiral glass tube.
A method for manufacturing the fluorescent lamp according to claim 4. 6. The method according to claim 1, further comprising a sealing step of sealing an electrode stem mount at both ends of the spiral glass tube on which the phosphor film is formed. A method for producing the fluorescent lamp as described in the above.