JP2004319443A - Wire connection structure, manufacturing method of wire connection structure, lamp, and manufacturing method of lamp - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a wire connection structure capable of securing a safe and rigid electric connection by restraining fluctuation of welding strength, a manufacturing method of the wire connection structure, a discharge lamp, and a manufacturing method of the discharge lamp. <P>SOLUTION: A conductive wire 1 formed of a metal material and a metal plate 2 formed of a metal material in which a content of a carbon atom is not detected by a composition analysis of combustion-infrared absorption method are connected. First, an end part of the metal plate 2 is bent to form a bent part 3 capable of pinching the conductive wire 1. Next, the conductive wire 1 is made pinched by the bent part 3. Then, a face of the bent part not contacting the wire 1 is heated to fusion bond the bent part 3 with the wire 1. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a connection structure between a conductive wire attached to various components and a terminal formed by a metal plate and a method of manufacturing the connection structure, and further relates to a lamp using the connection structure and a method of manufacturing the lamp.

  In recent years, as a method of connecting a lead wire attached to various parts to a terminal of a circuit board, a connector part, or the like, gas arc welding represented by TIG welding, instead of conventional soldering using lead, Wire connection methods such as laser welding have been widely adopted. This is because lead is a material having a high environmental load and is intended to be replaced with solder joint.

  Further, in such a connection method by welding, connection is performed exclusively by fusing a conductor to be connected to a circuit board, a connector component, or the like (for example, see Patent Document 1). 9A and 9B are views showing a conventional connection method and a connection structure by TIG welding. FIG. 9A is a perspective view showing a state before connection, and FIG. 9B is a cross-sectional view showing a state before connection. FIG. 9C is a sectional view showing a state after the connection.

  In the connection method and the connection structure shown in FIG. 9, one end of the conductor 51 is connected to a disk-shaped metal plate 52 having a through hole 55 formed in the center. FIG. 9 shows an example of a low-pressure mercury vapor discharge lamp in which a glass tube having a sealed end is joined to a base. The conducting wire 51 is a lead wire sealed to a glass tube (not shown), and one end of the conducting wire 51 located inside the glass tube is connected to a filament. The metal plate 52 is attached to a base 53 (only a part of which is shown) in which a through-hole 56 is formed, and the through-hole 55 formed in the metal plate 52 and the through-hole 56 formed in the base 53 are aligned. I have.

  As shown in FIGS. 9A and 9B, first, a conductive wire 51 made of a metal material is inserted into a through hole 55 formed in a metal plate 52 to be connected and a through hole 56 formed in a base 53. Insert When TIG welding is performed on the conductor 51 in this state, the tip of the conductor 51 is melted and the conductor 51 is connected to the metal plate 52 as shown in FIG. Note that an inexpensive iron alloy is used as a metal material for forming the conductive wire 51.

As described above, according to the connection method by welding shown in FIG. 9, the electrical connection between the lead wires attached to various components and the terminals and connector components of the circuit board can be reliably performed without using solder joining. Can be.
JP 2001-273851A (page 31, right column, paragraph 31)

  However, in the connection method shown in FIG. 9, welding is performed using a large current pulse current. For this reason, the shock at the time of welding is tremendous, and there is a problem that a welding part is blown off by this shock. In addition, sudden heating caused by welding causes a material spike in the conductive wire 51 or the metal plate 52 to be connected, and the finished shape of the welded portion becomes indefinite, and therefore, the welding strength varies. There are also problems.

  Furthermore, when the conducting wire 51 to which the welding current is directly applied is formed of a gold material having low thermal conductivity such as the above-described iron alloy, material bumping due to a local rapid rise in temperature is likely to occur, and the above-described problem is caused. The problem that the welded portion is blown off and the problem that the welding strength varies are even more remarkable.

  Further, an iron alloy usually contains a large amount of carbon atoms. For this reason, when the conductive wire 51 is formed of an iron alloy, the carbon atoms contained in the iron alloy forming the conductive wire 51 become soot 54 mainly due to the heat of fusion or the like caused by welding. Resulting in. In this case, as shown in FIG. 9C, the metal plate 52 around the welded portion is covered with soot 54 after the welding, and the soot 54 is spread widely around on the shielding gas. It is.

  Such soot 54 does not affect the welding strength. However, if the periphery of the welded portion is covered with the soot 54, there arises a problem that the appearance of a connection target such as a connector component represented by the base 53 shown in FIG. 9 or a circuit board is significantly impaired. . In addition, since soot also adheres to the tip of the electrode of the welding machine, there arises a problem that the discharge during welding is destabilized.

  Further, when there is another electrical connection portion or a conductor portion such as a circuit pattern near the welded portion whose periphery is covered with soot 54, this another electrical conductor is connected via the soot 54. The energization of the parts may occur, which may lead to malfunctions or failures of the device with this conductor part. In addition, when the soot 54 causes an energization mode called tracking, extreme heat is generated, so that a problem such as smoke or ignition around the welded portion may occur.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a connection structure, a method of manufacturing a connection structure, a lamp, and a method of manufacturing a lamp that can solve the above-described problems, suppress variations in welding strength, and ensure safe and strong electrical connection. It is in.

  In order to achieve the above object, the connection structure according to the present invention is a connection structure between a conductor and a metal plate, and the metal plate does not contain carbon atoms by composition analysis by a combustion-infrared absorption method. It is formed of a metal material, and an end of the metal plate surrounds a part of the conductive wire and is fused to a part of the surrounded conductive wire.

  Next, in order to achieve the above-mentioned object, a method for manufacturing a connection structure according to the present invention comprises a lead wire, a metal plate formed of a metal material containing no carbon atoms by composition analysis by a combustion-infrared absorption method. (A) a step of bending an end portion of the metal plate to form a bent portion capable of sandwiching the conductive wire; and (b) sandwiching the conductive wire in the bent portion. And (c) heating the surface of the bent portion that is not in contact with the conductive wire to fuse the bent portion to the conductive wire.

  Further, in order to achieve the above object, a lamp according to the present invention is a lamp having at least a glass tube and a base joined thereto, wherein a lead wire is attached to the glass tube, and the base is attached to the base. A power supply terminal and a metal plate for electrically connecting the power supply terminal to the lead wire are attached, and the metal plate is made of carbon by composition analysis by a combustion-infrared absorption method. It is formed of a metal material that does not contain atoms, and the end of the metal plate surrounds a part of the lead wire and is fused to a part of the surrounded lead wire. I do.

  Next, in order to achieve the above object, a method for manufacturing a lamp according to the present invention includes the steps of: attaching a base for attaching a power supply terminal and a metal plate connected to the power supply terminal; and attaching a lead wire. Wherein the metal plate is formed of a metal material that does not contain carbon atoms by composition analysis by a combustion-infrared absorption method. A step of bending the end of the metal plate to form a bent portion capable of sandwiching the lead wire; (b) a step of joining the glass tube to the base; and (c) a step of connecting the lead to the bent portion. And (d) heating from a surface of the bent portion that is not in contact with the lead wire to fuse the bent portion to the lead wire. .

  As described above, according to the connection structure, the method for manufacturing the connection structure, the lamp, and the method for manufacturing the lamp according to the present invention, it is possible to suppress variations in welding strength and secure a safe and strong electrical connection. . Further, according to the present invention, even when the conductive wire is formed of a metal material whose content of carbon atoms is recognized by composition analysis by a combustion-infrared absorption method, for example, iron or an iron alloy, the soot at the connection point is Can be suppressed. Further, according to the present invention, an iron alloy and a copper alloy, which have been considered particularly poor in welding compatibility, can be securely and firmly joined.

  In the connection structure according to the present invention, the conductor may be formed of a metal material whose content of carbon atoms is recognized by composition analysis by a combustion-infrared absorption method, for example, iron or an iron alloy. Further, the metal plate is formed of one or more metal materials selected from pure copper, phosphor bronze, beryllium copper alloy, titanium copper alloy, nickel silver, aluminum bronze, brass, copper, and copper. Is preferred. Further, it is preferable that a slit is formed at an end of the metal plate along a circumferential direction of the conductive wire.

  In the connection structure according to the present invention, the conductive wire is a lead wire attached to a glass tube constituting a lamp, and the metal plate connects a power supply terminal of the lamp and the lead wire. Preferably, the terminal is provided on a base joined to the glass tube.

  In the above-described method for manufacturing a connection structure according to the present invention, the conductor may be formed of a metal material whose content of carbon atoms is recognized by composition analysis by a combustion-infrared absorption method, for example, iron or an iron alloy. Further, the metal plate is formed of one or more metal materials selected from pure copper, phosphor bronze, beryllium copper alloy, titanium copper alloy, nickel silver, aluminum bronze, brass, copper, and copper. Is preferred. Further, it is preferable that a slit is formed at an end of the metal plate along a circumferential direction of the conductive wire.

  In the method for manufacturing a connection structure according to the present invention, the heating in the step (c) is preferably performed by arc welding using the metal plate as a grounded base material. Further, the conductive wire is a lead wire attached to a glass tube constituting a lamp, and the metal plate is a terminal connecting a power supply terminal of the lamp and the lead wire, wherein the glass tube It is preferable to adopt an embodiment in which the base is joined to the base.

In the lamp according to the present invention, the lead wire may be formed of a metal material whose content of carbon atoms is recognized by composition analysis by a combustion-infrared absorption method, for example, iron or an iron alloy. Further, the metal plate is formed of one or more metal materials selected from pure copper, phosphor bronze, beryllium copper alloy, titanium copper alloy, nickel silver, aluminum bronze, brass, copper, and copper. Is preferred. Further, it is preferable that a slit is formed at an end of the metal plate along a circumferential direction of the conductive wire.
Is also good. In addition, it is preferable to use an embodiment. Moreover, it is also preferable to set it as an aspect.

  Further, in the lamp according to the present invention, the base is attached to a storage portion having a concave portion for storing an end portion of the glass tube, and to a side of the storage portion opposite to a side where the concave portion is formed. A shielding portion, wherein the metal plate is attached to the storage portion such that at least an end of the metal plate is exposed on a side of the storage portion opposite to a side on which the concave portion is formed; It is preferable that a portion of the end portion fused to the lead wire is insulated from the outside by the shielding portion.

  In the method for manufacturing a lamp according to the present invention, the lead wire may be formed of a metal material whose content of carbon atoms is recognized by composition analysis by a combustion-infrared absorption method, for example, iron or an iron alloy. Further, the metal plate is formed of one or more metal materials selected from pure copper, phosphor bronze, beryllium copper alloy, titanium copper alloy, nickel silver, aluminum bronze, brass, copper, and copper. Is preferred.

  In the method for manufacturing a lamp according to the present invention, the heating in the step (d) is preferably performed by arc welding using the metal plate as a grounded base material. Further, it is preferable that a slit is formed at an end of the metal plate along a circumferential direction of the conductive wire.

  Hereinafter, a connection structure, a method of manufacturing a connection structure, a lamp, and a method of manufacturing a lamp according to an embodiment of the present invention will be described with reference to FIGS. 1 to 7.

  First, a connection structure and a method of manufacturing the connection structure according to the present embodiment will be described with reference to FIGS. FIG. 1 is a perspective view illustrating an example of a connection structure according to the embodiment. FIG. 2 is a diagram illustrating an example of a method of manufacturing the connection structure according to the embodiment, and illustrates a method of forming the connection structure illustrated in FIG. 1. FIG. 3 is a perspective view illustrating another example of the connection structure according to the embodiment.

  2A is a perspective view showing a state before the connection between the conductor and the metal plate, and FIG. 2B is a sectional view showing a state before the connection between the conductor and the metal plate. 2C is a perspective view showing a state after the connection between the conductor and the metal plate, and FIG. 2D is a cross-sectional view showing a state after the connection between the conductor and the metal plate.

  As shown in FIG. 1, the connection structure in the present embodiment is a connection structure between a conductor 1 and a metal plate 2. In the example of FIG. 1, the conductive wire 1 is a wire having a diameter of about 0.5 mm and a circular cross section. The metal plate 2 is formed in a strip shape having a thickness of 0.3 mm, a width of 1.4 mm, and a length of 35 mm. The metal plate 2 is disposed so as to be orthogonal to the longitudinal direction of the conductor 1.

  As shown in FIG. 1, an end of the strip-shaped metal plate 2 on the conductor 1 side surrounds a part of the conductor 1 and is fused to a part of the enclosed conductor 1. As described above, in the connection structure shown in FIG. 1, the metal plate 2 and the conductor 1 are connected by fusing the end of the metal plate 2 to the conductor 1.

  The connection structure shown in FIG. 1 is formed by the method for manufacturing the connection structure shown in FIG. First, as shown in FIGS. 2 (a) and 2 (b), the end of the strip-shaped metal plate 2 on the side of the conductor 1 is bent in a U-shape to allow the conductor 1 to be sandwiched. 3 is formed, and the conductive wire 1 is sandwiched inside the bent portion 3. Next, heating is performed from a surface of the bent portion 3 that is not in contact with the conductive wire 1, that is, a surface outside the bent portion 3. As a result, as shown in FIGS. 2C and 2D, a connection structure in which the molten bent portion 3 is fused to the surface of the conductive wire 1 is obtained.

  1 and 2 (c), the bent portion 3 is fused to the conductor 1 with a uniform thickness, but the present invention is not limited to this embodiment. For example, as shown in FIG. 3, the thickness of the bent portion 3 fused to the conductive wire 1 may be non-uniform. In addition, in the example of FIGS. 1 to 3, the number of the conductive wires 1 to be fused to the bent portion 3 is one, but in the present invention, as a mode in which a plurality of the conductive wires 1 are fused to the bent portion 3 together, Is also good.

  Here, in the present embodiment, heating is performed by arc welding typified by TIG welding, and the bent portion 3 of the metal plate 2 serves as a base material. The arrows shown in FIGS. 2A and 2B indicate the directions in which the welding current is applied. Further, since the metal plate 2 is connected to the welding machine, the welding current surely goes to the metal plate 2. Therefore, unlike the connection method shown in FIG. 9 in the background art, the conductive wire 1 is not directly heated by the heat of welding, and most of the heat of the arc welding melts the bent portion 3 of the metal plate 2. Spent on

  As a result, the bent portion 3 of the metal plate 2 is melted so as to surround the conductive wire 1 as shown in FIGS. 2C and 2D, and the joint between the conductive wire 1 and the bent portion 3 is joined as if by soldering. Thus, the conductor 1 and the bent portion 3 are firmly joined.

  Further, in the present embodiment, the metal plate 2 is made of a metal material that does not contain carbon atoms by composition analysis by a combustion-infrared absorption method, that is, a metal material that is determined to contain substantially no carbon atoms. Is formed. In the present invention, the "combustion-infrared absorption method" is performed under the conditions defined in Appendix 4 of JIS G 1211-1995.

  Specifically, examples of the material for forming the metal plate 2 include copper alloys such as pure copper, phosphor bronze, beryllium copper alloy, titanium copper alloy, nickel silver, aluminum bronze, brass, copper bronze, and white bronze. Further, the metal plate 2 is formed by using two or more kinds of such pure copper and copper alloy, for example, even when formed by laminating a plurality of different types of copper alloy metal plates. good.

  As described above, in the present embodiment, the metal plate 2 that is melted at the time of connection is formed of a material that is determined not to substantially contain carbon atoms. For this reason, the generation of soot during connection is suppressed. Therefore, by using the connection structure and the method of manufacturing the connection structure of the present embodiment, the problem that the appearance of the connection portion is impaired and the problem that the device including the connection portion malfunctions or breaks down as described in the background art. In addition, the problem of occurrence of tracking can be solved. That is, according to the present embodiment, the conductor 1 and the metal plate 2 can be firmly connected while suppressing generation of soot.

  Further, in the present embodiment, the metal plate 2 is melted, but the conductive wire 1 is not melted. Therefore, the material for forming the conductive wire 1 is not particularly limited. The conducting wire 1 may be formed of a metal material containing many carbon atoms. Specifically, the material for forming the conductive wire 1 may be a metal material whose content of carbon atoms is recognized by composition analysis by a combustion-infrared absorption method, for example, iron or an iron alloy such as carbon steel or cast iron. Even in this case, the generation of soot in the connection portion is suppressed. Moreover, when the conductor 1 is formed of iron or an iron alloy, an increase in the cost of the conductor 1 can be suppressed.

  In addition, as a material for forming the conductive wire 1, copper, a copper alloy, stainless steel, or the like, which is specified as a conductive material by the Electrical Appliance and Material Safety Law, can be used. When the conductive wire 1 is formed of iron or an iron alloy, a film of copper or the like can be formed on the surface of the conductive wire 1 by plating or the like.

  Actually, the conductive wire 1 is fused on the surface of the portion in contact with the bent portion 3. However, unlike the connection method shown in FIG. 9 in the background art, since the metal is not melted to the extent that the original shape is not retained, the carbon atoms contained in the conductive wire 1 are suppressed from depositing as soot.

  Further, according to the connection structure and the method for manufacturing the connection structure of the present embodiment, the heat generated by the welding current is quickly diffused in the surface direction of the metal plate 2 without being concentrated at one place. This is remarkable when the metal plate 2 is formed of a copper alloy having high thermal conductivity.

  Therefore, compared to the example described with reference to FIG. 9 in the background art, it is possible to suppress that one portion is extremely heated in a short time and to suppress an impact at the time of welding. For this reason, it can suppress that a welding location is blown off and that welding strength varies. Furthermore, explosive welding progress when the conductive wire 1 is formed of a metal material having low thermal conductivity such as an iron alloy can be suppressed. As a result, a stable finished shape is obtained.

  In the present embodiment, the shape and size of the conductive wire 1 are not particularly limited. However, when the conductor 1 is a lead wire sealed to a glass tube constituting a discharge lamp as described later, the conductor 1 has heat resistance at the time of sealing, easiness of forming (forming), and discharge lamp. Considering the magnitude of the current used in the above, it is preferable that the cross section of the cross section having a diameter of 0.4 mm to 1.0 mm is a circular conducting wire.

  In the present embodiment, the thickness and shape of the metal plate 2 are not particularly limited. However, the metal plate 2 is formed in a strip shape or has a strip-shaped portion as shown in FIGS. 2A and 2B from the viewpoint that the bent portion 3 is easily formed. Preferably. Further, for example, when the metal plate 2 is a terminal of a base of a discharge lamp as described later, the thickness of the metal plate 2 is determined in consideration of the easiness of processing (forming) and the magnitude of current used in the discharge lamp. , 0.2 mm to 0.5 mm.

  By the way, when welding the bent portion 3 of the metal plate 2, the wire 1 may come off from the bent portion 3 if the holding of the wire 1 is unstable or an external force is suddenly applied. For this reason, in the present embodiment, it is preferable that the slit 14 is formed at the end of the metal plate 12 along the circumferential direction of the conductive wire 11 as shown in FIG.

  FIG. 4 is a perspective view illustrating another example of the metal plate used in the connection structure and the method of manufacturing the connection structure according to the embodiment, and FIG. 4A illustrates a state before the connection between the conductive wire and the metal plate. FIG. 4B shows a state after the connection between the conductive wire and the metal plate.

  First, as shown in FIG. 4A, a bent end portion 13 is formed by bending a strip-shaped end portion of the metal plate 12 in which the slit 14 is formed, and the conductive wire 11 is sandwiched inside the bent portion 13. However, due to the formation of the slit 14, the conducting wire 11 is sandwiched between both insides of the two bent portions 13a and 13b. The conductor 11 and the metal plate 12 are formed of the same material as the conductor 1 and the metal plate 2 shown in FIGS.

  Next, the same arc welding as shown in FIGS. 2A and 2B is performed only on the bent portion 13b. As a result, as shown in FIG. 4B, only the bent portion 13b is fused to the conductor 11, and the bent portion 13a sandwiches the conductor 11.

  As described above, if the bent portion 13 is divided into a plurality of portions by the slits 14 and one of the divided bent portions 13b is welded and the other bent portion 13a is not welded, the other bent portion 13a is not welded until welding is completed. Since the conducting wire 11 is sandwiched and held by the portion 13a, it is possible to avoid a situation in which the conducting wire 11 completely comes off the bent portion 13. Although the number of slits 14 is one in the example of FIG. 4, the present invention is not limited to this, and a plurality of slits 14 may be used.

  Further, in the present embodiment, the bent portion for fusing the conductive wire is not limited to the one formed by bending into a U-shape as shown in FIGS. 2 (a) and 2 (b). 5 and 6 may be formed.

  FIGS. 5 and 6 are views showing still another example of the metal plate used in the connection structure and the method for manufacturing the connection structure according to the embodiment. FIGS. 5A and 6A are perspective views, and FIGS. 5B and 6B are cross-sectional views. In the example shown in FIGS. 5A and 5B, the bent portion 23 of the strip-shaped metal plate 22 is formed by bending the end of the metal plate 22 into a U-shape. The bent portion 23 holds the conducting wire 21 by surface contact with the inside of the U-shaped portion. In this state, the same heating as in the example of FIGS. 2A and 2B is performed.

  In the example shown in FIGS. 6A and 6B, the bent portion 33 of the strip-shaped metal plate 32 is formed by bending the metal plate 32 at three places 33a to 33c. Specifically, the bent portion 33 bends the bent portion 33a farthest from the end surface of the metal plate 32 at an acute angle, and bends the bent portion 33c closest to the end surface of the metal plate 32 in the direction opposite to the bent portion 33a. A bent portion 33b between the bent portion 33a and the bent portion 33c is bent at a right angle in the same direction as the bent portion 33a. For this reason, according to the example shown in FIGS. 6A and 6B, since the conductive wire 31 is wrapped by the bent portion 33 formed at the end of the metal plate 32, the conductive wire 31 shown in FIGS. It will be more firmly held than in the example. In this state, the same heating as in the example of FIGS. 2A and 2B is performed.

  In addition, in the example of FIG. 2, the heating of the surface of the bent portion 3 that is not in contact with the conductive wire 1 is performed by arc welding, but the present embodiment is not limited to this. Heating methods other than arc welding include gas welding, electron beam welding, laser welding, plasma welding, high-frequency welding, friction welding, ultrasonic welding, and the like.

  However, arc welding and laser welding can be said to be preferable because they can be performed on small and precise objects, are low in cost, and can be performed reliably. Further, among these, arc welding, which has a margin in positional accuracy as compared with laser welding, can be said to be particularly preferable.

  Preferred welding conditions for heating by arc welding include conditions in which the welding current is set to 10 A to 30 A, the welding time is set to 60 ms to 100 ms, and the arc distance is set to 1 mm to 3 mm.

  Examples of the application of the connection structure and the method of manufacturing the connection structure according to the present embodiment include lamps represented by discharge lamps, and particularly preferred are lamps with built-in electronic circuits such as bulb-type fluorescent lamps. Can be Further, the connection structure and the method of manufacturing the connection structure of the present embodiment, when the connection structure and the connection method by low reliability brazing, soldering, caulking, etc. are used in a high-temperature and high-humidity environment, Instead it can be applied without problems.

  Next, a lamp and a method of manufacturing the lamp according to the present embodiment will be described with reference to FIGS. FIG. 7 is a perspective view showing the lamp according to the embodiment. The lamp shown in FIG. 7 is a low-pressure mercury vapor discharge lamp, which is generally called a compact fluorescent lamp. The lamp shown in FIG. 7 is an application example of the connection structure shown in FIG.

  As shown in FIG. 7, the lamp according to the present embodiment has glass tubes 47a and 47b having substantially circular cross-sectional shapes, and is joined to one end of the glass tubes 47a and 47b, and has a substantially elliptical columnar shape. And a base 45 formed at the bottom. Lead wires 41a and 41b are attached to the glass tube 47a, and lead wires 41c and 41d are attached to the glass tube 47b.

  In the example of FIG. 7, the lead wires 41a to 41d are formed of an iron alloy containing many carbon atoms, and have a diameter of 0.5 mm. The lead wires 41a and 41b are connected to a filament (not shown) enclosed in the glass tube 47a, respectively, and the lead wires 41c and 41d are respectively connected to a filament (not shown) enclosed in the glass tube 47b. I have. The glass tube 47a and the glass tube 47b are connected by bridge joining (not shown) or the like.

  As shown in FIG. 7, the base 45 is provided with four power supply terminals 43a to 43d that receive power from a socket of the lighting fixture, and metal plates 42a to 42d. The metal plates 42a to 42d electrically connect the power supply terminals 43a to 43d to the corresponding lead wires 41a to 41d. The power supply terminals 43a to 43d are formed in a pin shape, and are attached to the base 50 of the power supply terminal.

  In the example of FIG. 7, the metal plates 42 a to 42 d are formed of a metal material that does not contain carbon atoms by composition analysis by a combustion-infrared absorption method, for example, phosphor bronze, and has a thickness of 0.3 mm. . The base 45 includes a storage portion 46a having a concave portion (not shown) for storing the ends of the glass tubes 47a and 47b, and a shielding portion 46b attached to the opposite side of the concave portion of the storage portion 46a. It has. The shielding portion 46b is formed in a substantially elliptical shape so that its cross-sectional shape matches the cross-sectional shape of the storage portion 46a.

  The glass tubes 47a and 47b are joined to the concave portion of the storage portion 46a by an adhesive. The lead wires 41a and 41b attached to the glass tube 47a are drawn out to an opening 48a formed in the storage portion 46a with the tips bent in an L-shape. Similarly, the lead wires 41c and 41d attached to the glass tube 47b are also drawn out to the opening 48b formed in the storage portion 46a with the ends bent in an L shape.

  In the example of FIG. 7, the metal plate 42a connects the power supply terminal 43a to the lead wire 41a, and the metal plate 42b connects the power supply terminal 43b to the lead wire 41b. The metal plate 42c connects the power supply terminal 43c to the lead wire 41c, and the metal plate 42d connects the power supply terminal 43d to the lead wire 41d.

  Among the metal plates 42a to 42d, the metal plates 42a and 42d are configured in two parts. A temperature limiting element 44a for limiting an increase in the temperature of the glass tube 47a is connected between one of the divided metal plates 42a and the other. Similarly, a temperature limiting element 44b that limits a rise in the temperature of the glass tube 47b is connected between one and the other of the divided metal plate 42d. The temperature limiting elements 44a and 44b are thermal fuses, and are provided to prevent an overheating phenomenon that may occur rarely at the end of the lamp life.

  Further, in the example of FIG. 7, an opening 49 for exposing the power supply terminals 43 a to 43 d and a base 50 thereof is formed in the shield 46 b. The storage portion 46a is formed by injection molding (insert molding) using a molding die in which metal plates 42a to 42d are arranged in advance, and the metal plates 42a to 42d are embedded in the storage portion 46a. I have. The injection molding is performed so that at least the ends of the metal plates 42a to 42d connected to the lead wires 41a to 41d are exposed on the side opposite to the side where the concave portion of the storage portion 46a is formed.

  In the discharge lamp of the present embodiment thus configured, the connection between each of the metal plates 42a to 42d and the corresponding lead wire 41a to 41d is, as shown in FIG. 1 and the metal plate 2. That is, the end of each of the metal plates 42a to 42d surrounds a part of the corresponding lead wire 41a to 41d and is fused to a part of the surrounding lead wire.

  Further, as described above, the ends of the metal plates 42a to 42d that are connected to the lead wires 41a to 41d are exposed on the side opposite to the side where the concave portion of the storage portion 46a is formed. The lead wires 41a to 41d are drawn out to the side opposite to the side where the concave portion of the storage portion 46a is formed. Therefore, the portions fused to the lead wires 41a to 41d at the ends of the metal plates 42a to 42d are also exposed on the side opposite to the side where the concave portion of the storage portion 46a is formed.

  However, in the example of FIG. 7, the portions fused to the lead wires 41a to 41d at the ends of the metal plates 42a to 42d and the metal plates 42a to 42d are shielded by the shielding portions 46b, and therefore are insulated from the outside. The Rukoto.

  The lamp shown in FIG. 7 can be manufactured by using the method for manufacturing a lamp shown in FIG. FIG. 8 is a perspective view showing a method for manufacturing a lamp base and a lamp according to the embodiment, and FIGS. 8A to 8C show a series of main steps. The method for manufacturing the lamp shown in FIG. 8 is an example in which the method for manufacturing the connection structure shown in FIG. 2 is applied.

  First, as shown in FIG. 8A, a storage portion 46a provided with metal plates 42a to 42d is prepared, and the end portions of the metal plates 42a to 42d are provided at the ends of the storage plates 46a to 42d as shown in FIGS. Similarly, bent portions 40a to 40d capable of sandwiching lead wires 41a to 41d (see FIG. 7) are formed.

  In the example of FIG. 8A, after the bent portions 40a to 40d are formed on the metal plates 42a to 42d, the metal plates 42a to 42d on which the bent portions 40a to 40d are formed are arranged in advance in a molding die. The storage section 46a is manufactured by performing injection molding.

  In the example of FIG. 8, the bent portions 40a to 40d are formed so as to have a U-shaped cross section as in the example shown in FIG. 2, but the present invention is not limited to this. The bent portions 40a to 40d may be those shown in FIGS.

  Next, as shown in FIG. 8B, the corresponding lead wires 41a to 41d are sandwiched inside the respective bent portions 40a to 40d. Specifically, first, the lead wires 41a and 41b attached to the glass tube 47a are passed through the opening 48a formed in the storage portion 46a, and the lead wire 41a is sandwiched by the inside of the bent portion 40a, and the lead wire 41b is inserted. It is sandwiched by the inside of the bent portion 40b. Similarly, the lead wires 41c and 41d attached to the glass tube 47b are passed through the opening 48b formed in the storage portion 46a, the lead wire 41c is sandwiched by the inside of the bent portion 40c, and the lead wire 41d is inserted into the bent portion 40d. Sandwiched by the inside. Thereafter, one ends of the glass tubes 47a and 47b are joined to a concave portion (not shown) of the storage portion 46a by an adhesive.

  Next, as shown in FIG. 8C, heating is performed from the surface of each of the bent portions 40a to 40d that is not in contact with the lead wires 41a to 41d, that is, the outer surface of each of the bent portions 40a to 40d. In the example of FIG. 8 as well, the heating is performed by TIG welding using the bent portions 40a to 40d as a base material with the metal plates 42a to 42d grounded, as in the example of FIG. 2C described above. . The welding current at this time is set to 30 A, and the welding time is set to 0.1 second.

  Thereafter, the discharge lamp is completed by attaching the shielding portion 46b shown in FIG. The connection between the conductive wire (not shown) of the temperature limiting element 44a and the metal plate 42a and the connection between the conductive wire (not shown) of the temperature limiting element 44b and the metal plate 42d are also shown in FIGS. (B) or FIGS. 8 (a) to 8 (c).

  As described above, according to the lamp and the method for manufacturing the lamp of the present embodiment, the lead wires 41a to 41d and the corresponding metal plates 42a to 42d are securely and firmly connected to each other with a stable welding shape and welding strength. Can be connected. In addition, since generation of soot from the lead wires 41a to 41d is suppressed and unintended energization and tracking can be suppressed, it is possible to provide a lamp which has few failures and operates stably.

  ADVANTAGE OF THE INVENTION According to the connection structure of this invention and the manufacturing method of a connection structure, the finished shape of a welding location can be stabilized, and also the generation | occurrence | production of soot in a welding location can be aimed at. For this reason, variation in welding strength can be suppressed, and more secure electrical connection can be obtained. In addition, the connection structure and the method for manufacturing the connection structure of the present invention can be applied to lamps represented by discharge lamps, other devices and devices that require electrical connection, and methods for manufacturing these devices. Can contribute to the improvement of

It is a perspective view showing an example of the connection structure concerning an embodiment. It is a figure which shows the manufacturing method of the connection structure concerning embodiment, FIG.2 (a) is a perspective view which shows the state before connection of a conductor and a metal plate, FIG.2 (b) shows the connection between a conductor and a metal plate. FIG. 2C is a cross-sectional view showing a state before the connection, and FIG. 2C is a perspective view showing a state after the connection between the conductor and the metal plate, and FIG. 2D is a cross-section showing a state after the connection between the conductor and the metal plate. FIG. It is a perspective view showing other examples of the connection structure concerning an embodiment. It is a perspective view showing other examples of the metal plate used for the connection structure and the manufacturing method of the connection structure concerning an embodiment. It is a figure which shows another example of the metal plate used for the connection structure and the manufacturing method of a connection structure concerning embodiment, FIG.5 (a) is a perspective view, FIG.5 (b) is sectional drawing. is there. It is a figure which shows another example of the metal plate used for the connection structure and the manufacturing method of a connection structure concerning embodiment, FIG.6 (a) is a perspective view, FIG.6 (b) is sectional drawing. is there. It is a perspective view showing the lamp concerning an embodiment. FIG. 8A is a perspective view illustrating a method for manufacturing a lamp base and a lamp according to the embodiment, and FIGS. 8A to 8C illustrate a series of main steps. 9A and 9B are diagrams illustrating a conventional connection method and a connection structure by TIG welding. FIG. 9A is a perspective view illustrating a state before connection, FIG. 9B is a cross-sectional view illustrating a state before connection, and FIG. (c) is a sectional view showing a state after the connection.

Explanation of reference numerals

1, 11, 21, 31 Conducting wire 2, 12, 22, 32, 42a to 42d Metal plate 3, 13, 13a, 13b, 23, 33, 40a to 40d Bending portion 14 Slit 33a to 33c Bending portion 41a to 41d Lead wire 43a-43d Power supply terminals 44a, 44d Temperature limiting element 45 Base for discharge lamp 46a Storage unit 46b Shielding unit 47a, 47b Glass tube 48a, 48b, 49 Opening 50 Base

Claims (25)

A connection structure between a conductor and a metal plate,
The metal plate is formed of a metal material containing no carbon atoms by composition analysis by a combustion-infrared absorption method,
A connection structure, wherein an end of the metal plate surrounds a part of the conductive wire and is fused to a part of the surrounded conductive wire.   The connection structure according to claim 1, wherein the conductive wire is formed of a metal material whose content of carbon atoms is confirmed by composition analysis by a combustion-infrared absorption method.   The connection structure according to claim 2, wherein the conductive wire is formed of iron or an iron alloy.   The metal plate is made of one or more metal materials selected from pure copper, phosphor bronze, beryllium copper alloy, titanium copper alloy, nickel silver, aluminum bronze, brass, copper, and copper. The connection structure according to claim 1.   The connection structure according to claim 1, wherein a slit is formed at an end of the metal plate along a circumferential direction of the conductive wire. The lead wire is a lead wire attached to a glass tube constituting a lamp,
The connection structure according to claim 1, wherein the metal plate is a terminal for connecting a power supply terminal of the lamp and the lead wire, and is provided on a base joined to the glass tube. A method for producing a connection structure between a conductive wire and a metal plate formed of a metal material containing no carbon atoms by composition analysis by a combustion-infrared absorption method,
(A) a step of bending an end of the metal plate to form a bent portion capable of sandwiching the conductive wire;
(B) a step of sandwiching the conducting wire in the bent portion;
(C) heating the surface of the bent portion that is not in contact with the conductive wire to fuse the bent portion to the conductive wire.   The method according to claim 7, wherein the conductive wire is formed of a metal material whose content of carbon atoms is confirmed by composition analysis by a combustion-infrared absorption method.   9. The method according to claim 8, wherein the conductor is formed of iron or an iron alloy.   The metal plate is made of one or more metal materials selected from pure copper, phosphor bronze, beryllium copper alloy, titanium copper alloy, nickel silver, aluminum bronze, brass, copper, and copper. A method for manufacturing a connection structure according to claim 7.   The method according to claim 7, wherein the heating in the step (c) is performed by arc welding using the metal plate as a grounded base material.   The method according to claim 7, wherein a slit is formed at an end of the metal plate along a circumferential direction of the conductive wire. The lead wire is a lead wire attached to a glass tube constituting a lamp,
8. The method according to claim 7, wherein the metal plate is a terminal for connecting a power supply terminal of the lamp and the lead wire, and is provided on a base joined to the glass tube. A lamp having at least a glass tube and a base joined thereto,
A lead wire is attached to the glass tube,
A terminal for power supply, and a metal plate for electrically connecting the terminal for power supply to the lead wire are attached to the base,
The metal plate is formed of a metal material containing no carbon atoms by composition analysis by a combustion-infrared absorption method, and the end of the metal plate surrounds and surrounds a part of the lead wire. A lamp fused to a part of the lead wire.   15. The lamp according to claim 14, wherein the lead wire is formed of a metal material whose content of carbon atoms is recognized by composition analysis by a combustion-infrared absorption method.   The lamp according to claim 15, wherein the lead wire is formed of iron or an iron alloy.   The metal plate is made of one or more metal materials selected from pure copper, phosphor bronze, beryllium copper alloy, titanium copper alloy, nickel silver, aluminum bronze, brass, copper, and white copper. The lamp according to claim 14.   The lamp according to claim 14, wherein a slit is formed at an end of the metal plate along a circumferential direction of the lead wire. The base has a storage portion in which a concave portion for storing an end of the glass tube is formed, and a shielding portion attached to a side of the storage portion opposite to a side in which the concave portion is formed,
The metal plate is attached to the storage portion so that at least an end thereof is exposed on a side opposite to the side on which the concave portion of the storage portion is formed,
15. The lamp according to claim 14, wherein a portion of the end portion of the metal plate fused to the lead wire is insulated from the outside by the shielding portion. At least a power supply terminal and a base to which a metal plate connected to the power supply terminal is attached, and a glass tube to which a lead wire is attached, wherein the metal plate is formed by a combustion-infrared absorption method. A method for producing a lamp formed of a metal material containing no carbon atoms by composition analysis,
(A) a step of bending an end of the metal plate to form a bent portion capable of sandwiching the lead wire;
(B) joining the glass tube to the base;
(C) a step of sandwiching the lead wire in the bent portion;
(D) heating the surface of the bent portion that is not in contact with the lead wire to fuse the bent portion to the lead wire.   21. The method for manufacturing a lamp according to claim 20, wherein the lead wire is formed of a metal material whose content of carbon atoms is recognized by composition analysis by a combustion-infrared absorption method.   22. The method for manufacturing a lamp according to claim 21, wherein the lead wire is formed of iron or an iron alloy.   The metal plate is made of one or more metal materials selected from pure copper, phosphor bronze, beryllium copper alloy, titanium copper alloy, nickel silver, aluminum bronze, brass, copper, and copper. A method for manufacturing a lamp according to claim 20.   The lamp manufacturing method according to claim 20, wherein the heating in the step (d) is performed by arc welding using the metal plate as a grounded base material.   21. The lamp manufacturing method according to claim 20, wherein a slit is formed at an end of the metal plate along a circumferential direction of the lead wire.

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