JP2004362980A - Manufacturing method for discharge lamp - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method, whereby flickering of a discharge lamp can be suppressed when it is lighted at its early stage, and as a result, the need for applying sputtering treatment can be lessened, and the luminous flux of the discharge lamp at the time of shipping a product can be enlarged. <P>SOLUTION: Electrodes 33, 34 and lead-in wires 35, 36 are first sealed to the end part of a glass tube 32, a rare gas and mercury are then introduced into the glass tube, and the hollow lead-in wire 36 coming out to the outside is sealed. Thereby, an impure gas generated in the heating and sealing process of the lead-in wires 35, 36 for the glass tube 32 is exhausted by subsequent evacuation, so as not to make the impure gas remain in the glass tube of a finished product. Therefore, there is no or little need for sputtering treatment to consume the impure gas before shipping the product, and the highly efficient discharge lamp whereby flickering is suppressed when it is lighted at the early stage is manufactured. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【表２】

これにより、ランプ初期点灯時のチラツキ発生数も出荷製品の初期光束も本実施の形態により製造した放電ランプの方が優れていることが実証された。
【００３１】
次に、本発明の第２の実施の形態の放電ランプの製造方法について、図８〜図１３を用いて説明する。図９に示すような内壁面に蛍光体層３１が形成され、かつ内部に希ガスと水銀が封入されたガラス管３２と、ガラス管３２の両端部それぞれに封装された一対の電極３３，３４と、電極３３，３４それぞれに一端が電気的に接続され、その中間部がガラス管３２の端部にガラスビード４２，４３により気密的に封着され、かつその他端部がガラス管３２の端部から外部に導出された導入線３５，３６とを備えた冷陰極放電ランプ３０Ａは、図８（Ａ）〜（Ｇ）に示す製造工程によって製造される。
【００３２】
この第２の実施の形態の放電ランプの製造方法でも、まず図８（Ａ）に示すように製品のランプ長とほぼ等しい長さのクリアガラス管３２を用意し、その内部に蛍光体層３１を塗布形成する。次に、同図（Ｂ）に示すようにガラス管３２の一端部（図の右側端）の蛍光体層３１を除去し、同図（Ｃ）に示すようにその蛍光体層３１を除去した一端部に中実の導入線３５接続済み、ガラスビード４２付きの電極３３で成るマウント５０を挿入し、ガラス管３２の一端部にガラスビード４２により気密的に加熱封着する。
【００３３】
続いて、図８（Ｄ）に示すようにガラス管３２の他端部（図の左側端）の蛍光体層３１を除去し、そこに図１０に示すような電極マウント５１を挿入する。この電極マウント５１は、図１０に示すように、中空の導入線３６の一端部に円筒台形状の電極３４を固定し、導入線３６の中間部にガラスビード４３を取り付けた構造である。
【００３４】
次に、図８（Ｅ）に示すように、ガラス管３２の他端部にガラスビード４３により電極マウント５１の導入線３６の部分を気密的に加熱封着する。この状態では、ガラス管３２の他端部から外部に出ている導入線３６によりガラス管３２の内外は空気の流通が可能な状態である。
【００３５】
続いて、図８（Ｆ）に示すように、ガラス管３２から外部に出ている中空の導入線３４の端部に真空排気装置３８を接続し、ガラス管３２内の真空引きを行う。そして所定の真空度まで排気できると、次に、同じ装置３８によって導入線３６を利用して放電媒体となる希ガスと水銀を必要量だけガラス管３２内に導入し、その後、導入線３６の外側端部をプレスその他の方法で封止し、切除する。これにより、図８（Ｇ）に示すような目的とする放電ランプ３０Ａが完成する。
【００３６】
このようにして製造した放電ランプ３０Ａは図９に示す断面構造である。ガラス管３２の一端部（右端部）の導入線３５は中実であるので、ガラス管３２のこちらの側の端部は閉塞状態である。またガラス管３２の他端部（左端部）に封着された導入線３６については、図１１に示したようにガラス管３２から外部に導出されている部分をプレスその他の方法で押し拉がせて形成された封止部３７によって封止され、閉塞されている。
【００３７】
このように、本発明の第２の実施の形態の放電ランプの製造方法でも、先に電極３３，３４、導入線３５，３６をガラス管３２の端部にガラスビード４２，４３によって加熱封着し、その後に中空の導入線３６を利用してガラス管３２内を真空排気し、また希ガス、水銀をガラス管３２内に導入し、その後に外部に出ている中空の導入線３６を封止するので、ガラス管３２に対する導入線３５，３６の加熱封着工程で発生する不純ガスをその後の真空引きによって排出し、完成品３０のガラス管３２内には不純ガスを残留させることがなくあるいは少なくできる。したがって製品出荷前にそれを消耗させるスパッタリング処理をする必要がなくあるいは少なく、初期点灯時のチラツキを抑えた高効率な放電ランプを製造することができる。
【００３８】
なお、中空の導入線３６に接続されている電極３４の構造については、導入線３６を通じてガラス管３２の内外の空気流通を阻害しない形状であればよくて、上記実施の形態で使用した円筒台形状のものに代えて、図１２に示すように平片リボン型の電極３４′を用いることができる。
【００３９】
また、上記の実施の形態では、ガラス管３２の一端部（右側端部）に封着するマウント５０の導入線３５には中実のものを用いたが、これに限らず、ガラス管３２の他端部に用いたマウント５１と同様の図１０に示したものを使用することができる。そしてこのマウント５１を使用する場合には、第１の実施の形態における図７に示すものと同様、少なくともガラス管３２の真空排気、希ガス・水銀導入の工程前に、中空の導入線３５の外側端部をプレスその他の方法で封止し、封止部を形成しておく。
【００４０】
さらに、中空の導入線３６については、そのランプ管３２内の端部側の内周面あるいは表面に不純ガス吸着用のゲッタとしてＺｒ化合物、エミッタとしてＬａ化合物、Ｂａ化合物、放電遅れ対策材料としてＣｓ化合物、Ｂａ化合物のうちの少なくとも１つを塗布しておくことができる。
【００４１】
加えて、第１の実施の形態及び第２の実施の形態において、中空の導入線３６の外側端部の封止部３７は、図１３に示すような構造の封止部３７′にすることもできる。この場合、導入線３６の端部を絞り、キャップ材を被せて封止部３７′としている。
【００４２】
次に、本発明の第３の実施の形態の放電ランプの製造方法について、図１４〜図１７を用いて説明する。図１５に示すような内壁面に蛍光体層３１が形成され、かつ内部に希ガスと水銀が封入されたガラス管３２と、ガラス管３２の両端部それぞれに封装された一対の電極３３，３４と、電極３３，３４それぞれに一端が電気的に接続され、その中間部がガラス管３２の端部にガラスビード４２，４３により気密的に封着され、かつその他端部がガラス管３２の端部から外部に導出された導入線３５，３６とを備えた冷陰極放電ランプ３０Ｂは、図１４（Ａ）〜（Ｇ）に示す製造工程によって製造される。
【００４３】
この第３の実施の形態の放電ランプの製造方法でも、まず図１４（Ａ）に示すように製品のランプ長とほぼ等しい長さのクリアガラス管３２を用意し、その内部に蛍光体層３１を塗布形成する。次に、同図（Ｂ）に示すようにガラス管３２の一端部（図の右側端）の蛍光体層３１を除去し、同図（Ｃ）に示すようにその蛍光体層３１を除去した一端部に中実の導入線３５接続済み、ガラスビード４２付きの電極３３で成るマウント５０を挿入し、ガラス管３２の一端部に気密的に加熱封着する。
【００４４】
続いて、図１４（Ｄ）に示すようにガラス管３２の他端部（図の左側端）の蛍光体層３１を除去し、そこに第２の実施の形態と同様の図１０に示すような電極マウント５１を挿入する。
【００４５】
次に、図１４（Ｅ）に示すように、ガラス管３２の他端部にガラスビード４３により電極マウント５１の導入線３６の部分を気密的に加熱封着する。この状態では、ガラス管３２の他端部から外部に出ている導入線３６によりガラス管３２の内外は空気の流通が可能な状態である。
【００４６】
続いて、図１４（Ｆ）に示すように、ガラス管３２から外部に出ている中空の導入線３４の端部に真空排気装置３８を接続し、ガラス管３２内の真空引きを行う。そして所定の真空度まで排気できると、次に、同じ装置３８によって導入線３６を利用して放電媒体となる希ガスと水銀を必要量だけガラス管３２内に導入し、その後、導入線３６の外側端部の中空部に耐熱性の合成樹脂４５を流し込んでガラス管３２を封止する。これにより、図１４（Ｇ）に示すように目的とする放電ランプ３０Ｂが完成する。
【００４７】
このようにして製造した放電ランプ３０Ｂは図１５に示す断面構造である。ガラス管３２の一端部（右端部）の導入線３５は中実であるので、ガラス管３２のこちらの側の端部は閉塞状態である。またガラス管３２の他端部（左端部）に封着された導入線３６については、図１６に示したようにガラス管３２から外側端部の中空部が合成樹脂４５によって閉塞されている。
【００４８】
このように、本発明の第３の実施の形態の放電ランプの製造方法でも、先に電極３３，３４、導入線３５，３６をガラス管３２の端部にガラスビード４２，４３によって加熱封着し、その後に中空の導入線３６を利用してガラス管３２内を真空排気し、また希ガス、水銀をガラス管３２内に導入し、その後に外部に出ている中空の導入線３６を封止するので、ガラス管３２に対する導入線３５，３６の加熱封着工程で発生する不純ガスをその後の真空引きによって排出し、完成品３０のガラス管３２内には不純ガスを残留させることがなくあるいは少なくできる。したがって製品出荷前にそれを消耗させるスパッタリング処理をする必要がなくあるいは少なく、初期点灯時のチラツキを抑えた高効率な放電ランプを製造することができる。
【００４９】
なお、中空の導入線３６に接続されている電極３４の構造については、導入線３６を通じてガラス管３２の内外の空気流通を阻害しない形状であればよくて、上記実施の形態で使用した円筒台形状のものに代えて、第２の実施の形態と同様に図１２に示すように平片リボン型の電極３４′を用いることができる。
【００５０】
また、上記の実施の形態では、ガラス管３２の一端部（右側端部）に封着するマウント５０の導入線３５には中実のものを用いたが、これに限らず、ガラス管３２の他端部に用いたマウント５１と同様の図１０に示したものを使用することができる。そしてこのマウント５１を使用する場合には、少なくともガラス管３２の真空排気、希ガス・水銀導入の工程前に、中空の導入線３５の外側端部の中空部を合成樹脂４５の充填によって封止しておく。
【００５１】
また、中空の導入線３６の封止方法としては、図１７に示すように、導入線３６の端部近くに窪み部４６を形成して内径を小さくし、封止チップ４７を導入線３６の端部から挿入することにより、ガラス管３２の内外の気圧差により窪み部４６内に密着させる方法を採用することもできる。
【００５２】
さらに、中空の導入線３６については、そのランプ管３２内の端部側の内周面あるいは表面に不純ガス吸着用のゲッタとしてＺｒ化合物、エミッタとしてＬａ化合物、Ｂａ化合物、放電遅れ対策材料としてＣｓ化合物、Ｂａ化合物のうちの少なくとも１つを塗布しておくことができる。
【００５３】
加えて、上記の第１〜第３の実施の形態のいずれにおいても、水銀を中空の導入線３６を通して導入する代わりに、予め電極３４に水銀合金を具備させたものを用い、この導入線３６の封止工程の後に、電極３４の部分を加熱することによって水銀合金から水銀蒸気を発生させ、ガラス管３２の内部に充満させる方法を採用することができる。
【００５４】
【発明の効果】
以上のように請求項１の発明によれば、先に電極、導入線をガラス管の端部に封着し、その後に希ガス、水銀をガラス管内に導入し、外部に出ている中空の導入線を封止するので、ガラス管に対する導入線の加熱封着工程で発生する不純ガスをその後の真空引きによって排出し、完成品のガラス管内に不純ガスを残留させることがなくあるいは少なく、したがって製品出荷前にそれを消耗させるスパッタリング処理をする必要がなくあるいは少なく、初期点灯時のチラツキを抑えた高効率な放電ランプを製造することができる。
【００５５】
請求項２の発明によれば、先に電極、導入線をガラス管の端部に封着し、その後に希ガスをガラス管内に導入し、外部に出ている中空の導入線を封止することにより、ガラス管に対する導入線の加熱封着工程で発生する不純ガスをその後の真空引きによって排出し、完成品のガラス管内に不純ガスを残留させることがなくあるいは少なく、したがって製品出荷前にそれを消耗させるスパッタリング処理をする必要がなくあるいは少なく、初期点灯時のチラツキを抑えた高効率な放電ランプを製造することができる。また、ガラス管内の電極に予め具備させた水銀合金を加熱することによってガラス管内に水銀を封入することができる。
【００５６】
請求項３の発明によれば、電極として、導入線の内部空洞がガラス管内までつながることを妨げない形状のものを用いるので、中空の導入線によってガラス管内を外部と確実に連通させることができ、ガラス管内の真空排気、ガラス管内への希ガス、水銀の供給を導入線を通じて外部から円滑に行える。
【００５７】
請求項４の発明によれば、中空の導入線の端部を機械的に押しひしがせることにより若しくはその中空部分に閉塞部材を充填することによって封止するので、中空の導入線をガラス管の端部に気密的に封着した後に、ガラス管内の真空排気、ガラス管内への希ガス、水銀の供給を中空の導入線を通じて外部から行い、その後に導入線を封止することにより希ガス、水銀漏れの恐れのない放電ランプを製造することができる。
【００５８】
請求項５の発明によれば、中空の導入線として、そのガラス管内側の端部にゲッタ物質、エミッタ物質、放電遅れ対策物質のうちの少なくとも１つを塗布したものを用いるので、特別な工程なしに内部の不純物がなく、初期点灯速度が速い放電ランプを製造できる。
【００５９】
請求項６の発明によれば、中空の導入線としてその内径がφ０．５ｍｍ以上のものを用いるので、真空排気行程でガラス管内の空気の真空引きを効率的に行え、製造時間の短縮が図れる。
【図面の簡単な説明】
【図１】本発明の第１の実施の形態の放電ランプの製造方法の工程図。
【図２】上記第１の実施の形態の放電ランプの製造方法により製造した放電ランプの断面図。
【図３】上記第１の実施の形態で使用する電極マウントの断面図。
【図４】上記第１の実施の形態における中空の導入線を利用したガラス管の真空排気、希ガス・水銀導入工程の説明図。
【図５】上記第１の実施の形態により製造した放電ランプの端部の拡大断面図。
【図６】上記第１の実施の形態において、電極としてリボン型のものを具有するマウントを用いて製造した放電ランプの端部の拡大断面図。
【図７】上記第１の実施の形態において、ガラス管の両端に同じ中空の導入線接続の電極で成る電極マウントを用いて製造した放電ランプの断面図。
【図８】本発明の第２の実施の形態の放電ランプの製造方法の工程図。
【図９】上記第２の実施の形態の放電ランプの製造方法により製造した放電ランプの断面図。
【図１０】上記第２の実施の形態で使用する電極マウントの断面図。
【図１１】上記第２の実施の形態により製造した放電ランプの端部の拡大断面図。
【図１２】上記第２の実施の形態において使用する、電極としてリボン型のものを具有するマウントの拡大断面図。
【図１３】上記第２の実施の形態において、中空の導入線の外端部の封止方法の別例を示す断面図。
【図１４】本発明の第３の実施の形態の放電ランプの製造方法の工程図。
【図１５】上記第３の実施の形態により製造した放電ランプの断面図。
【図１６】上記第３の実施の形態により製造した放電ランプの端部の拡大断面図。
【図１７】上記第３の実施の形態において、中空の導入線の外端部の封止方法の別例を示す断面図。
【図１８】従来例の放電ランプの製造方法の工程図。
【図１９】従来例で用いる電極マウントの断面図。
【符号の説明】
３０，３０Ａ，３０Ｂ 放電ランプ
３１ 蛍光体層
３２ ガラス管
３３ 電極
３４ 電極
３５ 導入線
３６ 導入線
３７ 封止部
３８ 真空装置
４０ マウント
４１ マウント
４２ ガラスビード
４３ ガラスビード
４５ 合成樹脂
４６ 封止チップ
５０ マウント
５１ マウント[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a discharge lamp.
[0002]
[Prior art]
Conventionally, a glass tube 11 in which a phosphor layer 12 is formed on an inner wall surface as shown in FIG. 18J and in which a rare gas and mercury are sealed, and a pair of glass tubes 11 sealed at both ends of the glass tube 11, respectively. , And one end is electrically connected to each of the electrodes 15, 20. An intermediate portion is hermetically sealed to an end of the glass tube 11, and the other end is an end of the glass tube 11. The cold-cathode discharge lamp 1 including the introduction wires 13 and 18 led out of the apparatus has been manufactured by the manufacturing process as shown in FIGS.
[0003]
In this conventional method of manufacturing a discharge lamp, first, as shown in FIG. 1A, a phosphor layer 12 is applied and formed inside a clear glass tube 11. Next, the phosphor layer at the end of the glass tube 11 was removed as shown in FIG. 7B, and the lead wire 13 was connected to the end where the phosphor layer was removed as shown in FIG. Then, a mount 16 composed of an electrode 15 with a glass bead 14 is inserted and hermetically sealed to the end of the glass tube 11 with the glass bead 14. The mount 16 has the structure shown in FIG. The same applies to a mount 21 described later.
[0004]
Subsequently, as shown in FIG. 18 (D), a portion away from one end of the glass tube 11 by a predetermined length is heated to be depressed, and a recess 17 is formed to shrink the inner diameter of the portion of the glass tube 11 to a predetermined diameter. In advance, as shown in FIG. 7E, the mount 21 composed of the electrode 20 with the glass bead 19 connected to the other lead wire 18 is inserted up to the position of the recess 17. Further, as shown in FIG. 3F, the glass tube 11 is heated and depressed at a position further behind the mount 21 inserted into the glass tube 11, and a second depression 22 is formed. The inner diameter of is reduced to a predetermined diameter.
[0005]
Next, as shown in FIG. 18 (G), a mercury sleeve 23 is inserted and temporarily fixed so as to be received by the second recess 22, and then the other end of the glass tube 11 is evacuated to a vacuum device 24. Are connected, and the inside of the glass tube 11 is evacuated. When the air is evacuated to a predetermined degree of vacuum, the glass tube 11 is heated and cut by the heater 25 at a position closer to the end than the insertion position of the mercury sleeve 23 as shown in FIG. The portion is sealed, and the mount 21 and the mercury sleeve 23 are confined to the other end of the glass tube 11.
[0006]
Subsequently, as shown in FIG. 18I, the mercury sleeve 23 at the end of the glass tube 11 is heated by the high-frequency heater 26 to generate mercury vapor, and the mercury vapor is confined in the glass tube 11. Then, as shown in FIG. 7J, the portion of the hollow 17 of the glass tube 11 is heated and cut to remove the surplus portion 27 of the glass tube, and at the same time, is introduced into the end of the glass tube 11 by the glass bead 19. The line 18 is sealed. Thus, the cold cathode discharge lamp 1 is completed.
[0007]
[Problems to be solved by the invention]
However, in such a conventional method of manufacturing a discharge lamp, the glass bead 19 is welded particularly for sealing the electrode 20 and the lead wire 18 to the end of the glass tube 11, so that an impurity gas is generated and glass There is a problem that flicker occurs when the discharge lamp 1 is initially lit because it remains inside the tube 11. The only way to remove the impurity gas in the glass tube 11 is to consume it by sputtering, but for that purpose, it is necessary to turn on the completed discharge lamp for a long time and at a high current before shipping the product. As a result, there is a problem that the luminous flux is reduced to some extent at the time of product shipment.
[0008]
The present invention has been made in view of such a conventional technical problem, and can suppress flickering at the time of initial lighting of a discharge lamp.As a result, the necessity of a sputtering process can be reduced, and discharge at the time of product shipment can be reduced. An object of the present invention is to provide a method for manufacturing a discharge lamp capable of increasing the luminous flux of the lamp.
[0009]
[Means for Solving the Problems]
The invention according to claim 1 includes a glass tube in which a phosphor layer is formed on an inner wall surface and in which a rare gas and mercury are sealed, a pair of electrodes sealed at both ends of the glass tube, and the electrode. One end of the glass tube is electrically connected, an intermediate portion is hermetically sealed to the end of the glass tube, and the other end is provided with an introduction wire led out from the end of the glass tube. A method of manufacturing a discharge lamp for manufacturing a discharge lamp, wherein a hollow cylindrical body is used as a lead wire connected to at least one of the pair of electrodes, and the lead wire is inserted into an end of the glass tube. A glass tube is hermetically sealed, and the inside of the glass tube is evacuated through a hollow lead line sealed at an end of the glass tube, and after the rare gas and mercury are fed, the lead line is sealed. It is.
[0010]
In the method for manufacturing a discharge lamp according to the first aspect of the present invention, an electrode and a lead-in wire are first sealed to an end of a glass tube, and then a rare gas and mercury are introduced into the glass tube, and a hollow gas that has exited to the outside. By sealing the lead-in line, the impurity gas generated in the step of heating and sealing the lead-in line to the glass tube is exhausted by subsequent evacuation, and the amount of impurity gas remaining in the glass tube of the finished product is eliminated or reduced. It is possible to eliminate or reduce the necessity of performing a sputtering process for exhausting the product before shipping the product, and to manufacture a highly efficient discharge lamp with reduced flicker during initial lighting.
[0011]
The invention according to claim 2 includes a glass tube in which a phosphor layer is formed on an inner wall surface and in which a rare gas and mercury are sealed, a pair of electrodes sealed at both ends of the glass tube, and the electrode. One end of the glass tube is electrically connected, an intermediate portion is hermetically sealed to the end of the glass tube, and the other end is provided with an introduction wire led out from the end of the glass tube. A method of manufacturing a discharge lamp for manufacturing a discharge lamp, wherein a mercury alloy is provided in at least one of the pair of electrodes, and a hollow cylindrical body is used as a lead wire connected to at least one of the pair of electrodes. Using, the introduction line is inserted into the end of the glass tube and hermetically sealed, and the inside of the glass tube is evacuated through a hollow introduction line sealed at the end of the glass tube. After introducing the rare gas, seal the lead wire Is shall.
[0012]
In the method for manufacturing a discharge lamp according to the second aspect of the present invention, the electrode and the lead-in wire are first sealed to the end of the glass tube, and then the rare gas is introduced into the glass tube, and the hollow lead-in wire coming out of the tube. By removing the impurity gas generated in the process of heating and sealing the lead wire to the glass tube by subsequent evacuation, the residual gas is eliminated or reduced in the finished glass tube, and therefore the product is shipped. The present invention eliminates or reduces the necessity of performing a sputtering process for exhausting the same, and manufactures a highly efficient discharge lamp with reduced flickering during initial lighting. Also, mercury is sealed in the glass tube by heating a mercury alloy provided in advance in the electrode in the glass tube.
[0013]
According to a third aspect of the present invention, in the method for manufacturing a discharge lamp according to the first or second aspect, the electrode has a shape that does not prevent the internal cavity of the introduction wire from reaching the inside of the glass tube. By reliably connecting the inside of the glass tube to the outside by the hollow introduction line, the inside of the glass tube can be evacuated and the rare gas and mercury supplied to the glass tube can be smoothly supplied from the outside through the introduction line.
[0014]
According to a fourth aspect of the present invention, in the method for manufacturing a discharge lamp according to any of the first to third aspects, the hollow lead-in line is formed by mechanically pushing the end of the hollow lead-in or filling the hollow portion with a closing member. After the hollow introduction wire is hermetically sealed to the end of the glass tube, the vacuum evacuation of the glass tube and the supply of the rare gas and mercury into the glass tube are performed in a hollow manner. From the outside through the lead-in line, and then seal the lead-in line to manufacture a discharge lamp free from leakage of rare gas and mercury.
[0015]
According to a fifth aspect of the present invention, in the method for manufacturing a discharge lamp according to any one of the first to fourth aspects, at least one of a getter material, an emitter material, and a discharge delay countermeasure material is provided at the inner end of the glass tube as the hollow lead wire. The present invention is characterized in that a discharge lamp having a high initial lighting speed with no internal impurities and without an extra step is manufactured without using any special process.
[0016]
According to a sixth aspect of the present invention, in the method for manufacturing a discharge lamp according to any one of the first to fifth aspects, the hollow introduction wire has an inner diameter of 0.5 mm or more, and is evacuated. With this, the air in the glass tube is evacuated efficiently and the production time is shortened.
[0017]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. 1A to 1G show a method of manufacturing a discharge lamp according to a first embodiment of the present invention.
[0018]
A glass tube 32 in which a phosphor layer 31 is formed on the inner wall surface as shown in FIG. 2 and in which a rare gas and mercury are sealed, and a pair of electrodes 33 and 34 sealed at both ends of the glass tube 32, respectively. And one end of each of the electrodes 33 and 34 is electrically connected, an intermediate portion is hermetically sealed to an end of the glass tube 32, and the other end is led out from the end of the glass tube 32. The cold cathode discharge lamp 30 including the introduction lines 35 and 36 is manufactured by the manufacturing steps shown in FIGS.
[0019]
In the method of manufacturing a discharge lamp according to the present embodiment, first, as shown in FIG. 1A, a clear glass tube 32 having a length substantially equal to the lamp length of a product is prepared, and a phosphor layer 31 is applied and formed therein. I do. Next, the phosphor layer 31 at one end (right end in the figure) of the glass tube 32 was removed as shown in FIG. 4B, and the phosphor layer 31 was removed as shown in FIG. At one end, a mount 40 consisting of an electrode 33 connected to a solid lead wire 35 is inserted, and the glass tube 32 is hermetically heated and sealed to one end.
[0020]
Subsequently, as shown in FIG. 1D, the phosphor layer 31 at the other end (the left end in the figure) of the glass tube 32 is removed, and an electrode mount 41 as shown in FIG. 3 is inserted therein. The electrode mount 41 has a structure in which a cylindrical trapezoidal electrode 34 is fixed to one end of a hollow introduction wire 36.
[0021]
Next, as shown in FIG. 1 (E), the portion of the lead wire 36 of the electrode mount 41 is air-tightly sealed to the other end of the glass tube 32 without a glass bead. In this state, the inside and outside of the glass tube 32 are in a state in which air can be circulated by the introduction line 36 extending from the other end of the glass tube 32 to the outside.
[0022]
Subsequently, as shown in FIG. 1F, more specifically, as shown in FIG. 4, a vacuum exhaust device 38 is connected to an end of a hollow lead-in wire 34 that is out of the electrode mount 41, and a vacuum in the glass tube 32 is formed. Make a pull. Then, when the gas can be evacuated to a predetermined degree of vacuum, the required amount of rare gas and mercury serving as a discharge medium is introduced into the glass tube 32 by the same device 38 using the introduction line 36. The outer end is sealed by a press or other method and cut off. Thus, the intended discharge lamp 30 is completed as shown in FIG.
[0023]
The discharge lamp 30 manufactured in this manner has a sectional structure shown in FIG. Since the introduction line 35 at one end (right end) of the glass tube 32 is solid, the end on this side of the glass tube 32 is closed. In addition, as for the introduction line 36 sealed to the other end (left end) of the glass tube 32, as shown in FIG. It is sealed and closed by the sealing portion 37 formed by the above.
[0024]
As described above, in the method of manufacturing the discharge lamp according to the first embodiment of the present invention, the electrodes 33 and 34 and the lead wires 35 and 36 are first sealed to the end of the glass tube 32, and then the hollow lead-in tube is formed. The inside of the glass tube 32 is evacuated using the wire 36, and a rare gas and mercury are introduced into the glass tube 32, and then the hollow lead-in wire 36 that is outside is sealed. Impurity gas generated in the heat sealing step of the introduction lines 35 and 36 is discharged by subsequent evacuation, so that the impurity gas does not remain in the glass tube 32 of the finished product 30 or can be reduced. Therefore, there is no or little need to perform a sputtering process for exhausting the product before shipment, and a highly efficient discharge lamp with reduced flickering at the time of initial lighting can be manufactured.
[0025]
Further, in the first embodiment, at least the glass mount 32 is not used for the electrode mount 41 on the hollow guide line 36 side, and the guide line 36 is directly sealed to the end of the glass tube 32. A temporary fixing step is not required, and the number of steps can be reduced. Further, since it is not necessary to insert a glass bead into the opening at the end of the glass tube 32 and the mount 41 of the electrode 34 and the lead wire 36 can be directly inserted, the inner and outer diameters of the lead wire are smaller than those of the mount with the glass bead. A large mount can be employed, thereby increasing the air flow capacity inside and outside the glass tube 32, and improving the efficiency of vacuum evacuation and rare gas / mercury filling work. For example, in the product examples shown in Tables 1 and 2 described later, those having an inner diameter of 0.5 mm or more can be used as the lead wire.
[0026]
Note that the structure of the electrode 34 connected to the hollow lead-in line 36 may be any shape that does not impede the air flow inside and outside the glass tube 32 through the lead-in line 36. Instead of the shape, a flat ribbon electrode 34 'can be used as shown in FIG.
[0027]
Further, in the above-described embodiment, a solid lead wire 35 of the mount 40 to be sealed to one end (right end) of the glass tube 32 is used. As described above, similarly to the mount 41 used at the other end of the glass tube 32, the mount shown in FIG. 3 can be used. When the mount 41 is used, at least before the steps of evacuating the glass tube 32 and introducing rare gas / mercury, the outer end of the hollow lead-in wire 35 'is sealed with a press or other method, and sealed. A stop 39 is formed.
[0028]
Further, with respect to the hollow lead-in line 36, a Zr compound as a getter for adsorbing impurity gas, a La compound and a Ba compound as an emitter, and a Cs as a discharge delay countermeasure material are formed on the inner peripheral surface or the surface at the end of the lamp tube 32. At least one of a compound and a Ba compound can be applied.
[0029]
Tables 1 and 2 show the results of measuring the initial lighting characteristics of the discharge lamp manufactured by the method of manufacturing the discharge lamp according to the first embodiment and the discharge lamp manufactured by the manufacturing method of the conventional example shown in FIG. ing.
[0030]
[Table 1]

[Table 2]

Thereby, it was proved that the discharge lamp manufactured according to the present embodiment is superior in both the number of flickers generated at the time of initial lamp lighting and the initial luminous flux of the shipped product.
[0031]
Next, a method for manufacturing a discharge lamp according to a second embodiment of the present invention will be described with reference to FIGS. A glass tube 32 in which a phosphor layer 31 is formed on the inner wall surface as shown in FIG. 9 and in which a rare gas and mercury are sealed, and a pair of electrodes 33 and 34 sealed at both ends of the glass tube 32, respectively. One end is electrically connected to each of the electrodes 33 and 34, an intermediate portion thereof is hermetically sealed to an end of the glass tube 32 by glass beads 42 and 43, and the other end is an end of the glass tube 32. The cold cathode discharge lamp 30 </ b> A including the introduction lines 35 and 36 led out of the unit is manufactured by the manufacturing steps illustrated in FIGS. 8A to 8G.
[0032]
In the method of manufacturing a discharge lamp according to the second embodiment, first, as shown in FIG. 8A, a clear glass tube 32 having a length substantially equal to the lamp length of a product is prepared, and a phosphor layer 31 is provided therein. Is applied and formed. Next, the phosphor layer 31 at one end (right end in the figure) of the glass tube 32 was removed as shown in FIG. 4B, and the phosphor layer 31 was removed as shown in FIG. A mount 50 composed of an electrode 33 with a glass bead 42 connected to a solid lead wire 35 at one end is inserted and hermetically sealed with a glass bead 42 at one end of a glass tube 32.
[0033]
Subsequently, as shown in FIG. 8D, the phosphor layer 31 at the other end (the left end in the figure) of the glass tube 32 is removed, and an electrode mount 51 as shown in FIG. 10 is inserted therein. As shown in FIG. 10, the electrode mount 51 has a structure in which a cylindrical trapezoidal electrode 34 is fixed to one end of a hollow introduction wire 36, and a glass bead 43 is attached to an intermediate portion of the introduction wire 36.
[0034]
Next, as shown in FIG. 8 (E), the portion of the lead wire 36 of the electrode mount 51 is air-tightly sealed to the other end of the glass tube 32 by a glass bead 43. In this state, the inside and outside of the glass tube 32 are in a state in which air can be circulated by the introduction line 36 extending from the other end of the glass tube 32 to the outside.
[0035]
Subsequently, as shown in FIG. 8 (F), a vacuum exhaust device 38 is connected to the end of the hollow lead-in wire 34 extending outside from the glass tube 32, and the inside of the glass tube 32 is evacuated. Then, when the gas can be evacuated to a predetermined degree of vacuum, the required amount of rare gas and mercury serving as a discharge medium is introduced into the glass tube 32 by the same device 38 using the introduction line 36. The outer end is sealed by a press or other method and cut off. Thus, the intended discharge lamp 30A as shown in FIG. 8 (G) is completed.
[0036]
The discharge lamp 30A manufactured in this way has a sectional structure shown in FIG. Since the introduction line 35 at one end (right end) of the glass tube 32 is solid, the end on this side of the glass tube 32 is closed. As for the introduction line 36 sealed to the other end (left end) of the glass tube 32, as shown in FIG. It is sealed and closed by the sealing portion 37 formed by the above.
[0037]
As described above, also in the method of manufacturing the discharge lamp according to the second embodiment of the present invention, the electrodes 33 and 34 and the lead wires 35 and 36 are first heat-sealed to the ends of the glass tube 32 by the glass beads 42 and 43. Then, the inside of the glass tube 32 is evacuated using the hollow lead-in line 36, and a rare gas and mercury are introduced into the glass tube 32, and then the hollow lead-in line 36 that has exited outside is sealed. Therefore, the impurity gas generated in the step of heating and sealing the introduction lines 35 and 36 to the glass tube 32 is exhausted by evacuation, and the impurity gas does not remain in the glass tube 32 of the finished product 30. Or less. Therefore, it is not necessary or necessary to perform a sputtering process for exhausting the product before shipment, and a highly efficient discharge lamp with reduced flickering at the time of initial lighting can be manufactured.
[0038]
Note that the structure of the electrode 34 connected to the hollow lead-in line 36 may be any shape that does not impede the air flow inside and outside the glass tube 32 through the lead-in line 36. Instead of the shape, a flat ribbon electrode 34 'can be used as shown in FIG.
[0039]
Further, in the above-described embodiment, although the solid introduction wire 35 of the mount 50 to be sealed to one end (right end) of the glass tube 32 is used, the invention is not limited thereto. The mount shown in FIG. 10 similar to the mount 51 used at the other end can be used. When this mount 51 is used, at least before the steps of evacuating the glass tube 32 and introducing the rare gas / mercury, as in the case of the first embodiment shown in FIG. The outer end is sealed with a press or other method to form a sealed portion.
[0040]
Further, with respect to the hollow lead-in line 36, a Zr compound as a getter for adsorbing impurity gas, a La compound and a Ba compound as an emitter, and a Cs as a discharge delay countermeasure material are formed on the inner peripheral surface or the surface at the end of the lamp tube 32. At least one of a compound and a Ba compound can be applied.
[0041]
In addition, in the first and second embodiments, the sealing portion 37 at the outer end of the hollow lead-in wire 36 is a sealing portion 37 'having a structure as shown in FIG. You can also. In this case, the end of the introduction line 36 is squeezed and covered with a cap material to form a sealing portion 37 '.
[0042]
Next, a method of manufacturing a discharge lamp according to a third embodiment of the present invention will be described with reference to FIGS. A glass tube 32 in which a phosphor layer 31 is formed on the inner wall surface as shown in FIG. 15 and in which a rare gas and mercury are sealed, and a pair of electrodes 33 and 34 sealed at both ends of the glass tube 32, respectively. One end is electrically connected to each of the electrodes 33 and 34, an intermediate portion thereof is hermetically sealed to an end of the glass tube 32 by glass beads 42 and 43, and the other end is an end of the glass tube 32. The cold-cathode discharge lamp 30B including the introduction lines 35 and 36 led out of the unit is manufactured by the manufacturing steps shown in FIGS.
[0043]
In the method of manufacturing a discharge lamp according to the third embodiment, a clear glass tube 32 having a length substantially equal to the lamp length of a product is first prepared as shown in FIG. Is applied and formed. Next, the phosphor layer 31 at one end (right end in the figure) of the glass tube 32 was removed as shown in FIG. 4B, and the phosphor layer 31 was removed as shown in FIG. A mount 50 consisting of an electrode 33 with a glass bead 42 and a solid lead wire 35 connected to one end is inserted, and the glass tube 32 is heat-sealed and sealed at one end.
[0044]
Subsequently, as shown in FIG. 14D, the phosphor layer 31 at the other end (the left end in the figure) of the glass tube 32 is removed, and as shown in FIG. 10 similar to the second embodiment. Insert the appropriate electrode mount 51.
[0045]
Next, as shown in FIG. 14 (E), a portion of the lead wire 36 of the electrode mount 51 is air-tightly sealed to the other end of the glass tube 32 by a glass bead 43. In this state, the inside and outside of the glass tube 32 are in a state in which air can be circulated by the introduction line 36 extending from the other end of the glass tube 32 to the outside.
[0046]
Subsequently, as shown in FIG. 14 (F), a vacuum exhaust device 38 is connected to the end of the hollow lead-in wire 34 extending from the glass tube 32 to the outside, and the inside of the glass tube 32 is evacuated. Then, when the gas can be evacuated to a predetermined degree of vacuum, the required amount of rare gas and mercury serving as a discharge medium is introduced into the glass tube 32 by the same device 38 using the introduction line 36. The glass tube 32 is sealed by pouring a heat-resistant synthetic resin 45 into the hollow portion at the outer end. Thus, the intended discharge lamp 30B is completed as shown in FIG.
[0047]
The discharge lamp 30B manufactured in this manner has a sectional structure shown in FIG. Since the introduction line 35 at one end (right end) of the glass tube 32 is solid, the end on this side of the glass tube 32 is closed. As for the introduction line 36 sealed at the other end (left end) of the glass tube 32, the hollow portion at the outer end from the glass tube 32 is closed by the synthetic resin 45 as shown in FIG. 16.
[0048]
As described above, also in the method of manufacturing the discharge lamp according to the third embodiment of the present invention, the electrodes 33 and 34 and the lead wires 35 and 36 are first heat-sealed to the ends of the glass tube 32 by the glass beads 42 and 43. Then, the inside of the glass tube 32 is evacuated using the hollow lead-in line 36, and a rare gas and mercury are introduced into the glass tube 32, and then the hollow lead-in line 36 that has exited outside is sealed. Therefore, the impurity gas generated in the step of heating and sealing the introduction lines 35 and 36 to the glass tube 32 is exhausted by evacuation, and the impurity gas does not remain in the glass tube 32 of the finished product 30. Or less. Therefore, it is not necessary or necessary to perform a sputtering process for exhausting the product before shipment, and a highly efficient discharge lamp with reduced flickering at the time of initial lighting can be manufactured.
[0049]
Note that the structure of the electrode 34 connected to the hollow lead-in line 36 may be any shape that does not impede the air flow inside and outside the glass tube 32 through the lead-in line 36. Instead of the shape, a flat ribbon-shaped electrode 34 'can be used as shown in FIG. 12, similarly to the second embodiment.
[0050]
Further, in the above-described embodiment, although the solid introduction wire 35 of the mount 50 to be sealed to one end (right end) of the glass tube 32 is used, the invention is not limited thereto. The mount shown in FIG. 10 similar to the mount 51 used at the other end can be used. When the mount 51 is used, at least before the steps of evacuating the glass tube 32 and introducing the rare gas / mercury, the hollow portion at the outer end of the hollow lead-in wire 35 is filled with a synthetic resin 45 to be sealed. Keep it.
[0051]
As a method for sealing the hollow introduction line 36, as shown in FIG. 17, a recess 46 is formed near the end of the introduction line 36 to reduce the inner diameter, and the sealing chip 47 is attached to the introduction line 36. By inserting the glass tube 32 from the end portion, a method of bringing the glass tube 32 into close contact with the depression 46 due to a pressure difference between the inside and outside of the glass tube 32 can be adopted.
[0052]
Further, as for the hollow lead-in line 36, a Zr compound as a getter for adsorbing impurity gas, a La compound and a Ba compound as an emitter, and a Cs as a discharge delay countermeasure material are provided on the inner peripheral surface or the surface on the end side in the lamp tube 32. At least one of a compound and a Ba compound can be applied.
[0053]
In addition, in any of the above-described first to third embodiments, instead of introducing mercury through the hollow lead-in line 36, an electrode having a mercury alloy in the electrode 34 in advance is used. After the sealing step, a method of generating mercury vapor from the mercury alloy by heating the portion of the electrode 34 and filling the inside of the glass tube 32 can be adopted.
[0054]
【The invention's effect】
As described above, according to the first aspect of the present invention, the electrode and the lead-in wire are first sealed to the end of the glass tube, and then the rare gas and mercury are introduced into the glass tube, and the hollow tube coming out of the outside is introduced. Since the lead-in wire is sealed, the impurity gas generated in the step of heating and sealing the lead-in wire to the glass tube is discharged by subsequent evacuation, and the impurity gas does not remain or remains in the finished glass tube, or less. There is no or little need to perform a sputtering process for exhausting the product before shipment, and a highly efficient discharge lamp with reduced flickering during initial lighting can be manufactured.
[0055]
According to the second aspect of the present invention, the electrode and the lead wire are first sealed to the end of the glass tube, and then the rare gas is introduced into the glass tube to seal the hollow lead wire coming out. As a result, the impurity gas generated in the heating and sealing step of the lead-in wire to the glass tube is exhausted by the subsequent evacuation, and the impurity gas does not remain in the glass tube of the finished product at all or is small, and therefore, is reduced before the product is shipped. It is not necessary or necessary to perform a sputtering process for exhausting the gas, and it is possible to manufacture a highly efficient discharge lamp in which flicker during initial lighting is suppressed. In addition, mercury can be sealed in the glass tube by heating a mercury alloy provided in advance in the electrode in the glass tube.
[0056]
According to the third aspect of the invention, since the electrode has a shape that does not prevent the internal cavity of the introduction wire from reaching the inside of the glass tube, the inside of the glass tube can be reliably communicated with the outside by the hollow introduction wire. In addition, the evacuation of the glass tube and the supply of rare gas and mercury into the glass tube can be smoothly performed from the outside through the introduction line.
[0057]
According to the invention of claim 4, since the end of the hollow lead-in wire is sealed by mechanically pushing the end portion or filling the hollow portion with a closing member, the hollow lead-in wire is sealed by the glass tube. After sealing hermetically to the end, vacuum evacuation in the glass tube, rare gas into the glass tube, supply of mercury from outside through a hollow lead wire, and then rare gas by sealing the lead wire, A discharge lamp free from mercury leakage can be manufactured.
[0058]
According to the fifth aspect of the present invention, the hollow guide wire is formed by applying at least one of a getter material, an emitter material, and a discharge delay countermeasure material to the inner end of the glass tube. Therefore, a discharge lamp having a high initial lighting speed and no internal impurities can be manufactured.
[0059]
According to the invention of claim 6, since the hollow introduction wire having an inner diameter of 0.5 mm or more is used, the air in the glass tube can be efficiently evacuated during the evacuation process, and the manufacturing time can be reduced. .
[Brief description of the drawings]
FIG. 1 is a process chart of a method for manufacturing a discharge lamp according to a first embodiment of the present invention.
FIG. 2 is a sectional view of a discharge lamp manufactured by the method for manufacturing a discharge lamp according to the first embodiment.
FIG. 3 is a sectional view of an electrode mount used in the first embodiment.
FIG. 4 is an explanatory view of a vacuum evacuation and a rare gas / mercury introduction step of a glass tube using a hollow introduction line in the first embodiment.
FIG. 5 is an enlarged sectional view of an end of the discharge lamp manufactured according to the first embodiment.
FIG. 6 is an enlarged cross-sectional view of an end portion of the discharge lamp manufactured using the mount having the ribbon type electrode in the first embodiment.
FIG. 7 is a cross-sectional view of the discharge lamp manufactured in the first embodiment by using an electrode mount including the same hollow lead wire-connected electrodes at both ends of a glass tube.
FIG. 8 is a process chart of a method for manufacturing a discharge lamp according to a second embodiment of the present invention.
FIG. 9 is a sectional view of a discharge lamp manufactured by the method for manufacturing a discharge lamp according to the second embodiment.
FIG. 10 is a sectional view of an electrode mount used in the second embodiment.
FIG. 11 is an enlarged sectional view of an end of a discharge lamp manufactured according to the second embodiment.
FIG. 12 is an enlarged sectional view of a mount having a ribbon type electrode as an electrode used in the second embodiment.
FIG. 13 is a cross-sectional view showing another example of a method of sealing the outer end of a hollow lead-in line in the second embodiment.
FIG. 14 is a process chart of a method for manufacturing a discharge lamp according to the third embodiment of the present invention.
FIG. 15 is a sectional view of a discharge lamp manufactured according to the third embodiment.
FIG. 16 is an enlarged sectional view of an end of a discharge lamp manufactured according to the third embodiment.
FIG. 17 is a cross-sectional view showing another example of the method of sealing the outer end of the hollow lead-in line in the third embodiment.
FIG. 18 is a process chart of a conventional method for manufacturing a discharge lamp.
FIG. 19 is a sectional view of an electrode mount used in a conventional example.
[Explanation of symbols]
30, 30A, 30B discharge lamp
31 phosphor layer
32 glass tube
33 electrodes
34 electrodes
35 Introductory Line
36 Introductory Line
37 Sealing part
38 Vacuum equipment
40 mount
41 mount
42 glass beads
43 glass beads
45 Synthetic resin
46 sealing chip
50 mount
51 Mount

Claims (6)

A glass tube in which a phosphor layer is formed on the inner wall surface and in which a rare gas and mercury are sealed, a pair of electrodes sealed at both ends of the glass tube, and one end is electrically connected to the electrode A discharge lamp having an intermediate portion hermetically sealed at the end of the glass tube and an introduction wire having the other end led out from the end of the glass tube. The method of manufacturing
Using a hollow cylindrical body as a lead wire connected to at least one of the pair of electrodes, air-tightly sealing by inserting the lead wire into the end of the glass tube,
Through a hollow introduction wire sealed at the end of the glass tube, the inside of the glass tube is evacuated, and after introducing the rare gas and mercury, the introduction wire is sealed. Production method. A glass tube in which a phosphor layer is formed on the inner wall surface and in which a rare gas and mercury are sealed, a pair of electrodes sealed at both ends of the glass tube, and one end is electrically connected to the electrode A discharge lamp having an intermediate portion hermetically sealed at the end of the glass tube and an introduction wire having the other end led out from the end of the glass tube. The method of manufacturing
At least one of the pair of electrodes is provided with a mercury alloy,
Using a hollow cylindrical body as a lead wire connected to at least one of the pair of electrodes, air-tightly sealing by inserting the lead wire into the end of the glass tube,
A method for manufacturing a discharge lamp, comprising: evacuating the glass tube through a hollow introduction line sealed to an end of the glass tube, and sealing the introduction line after feeding the rare gas. . 3. The method for manufacturing a discharge lamp according to claim 1, wherein the electrode has a shape which does not prevent the internal cavity of the introduction wire from reaching the inside of the glass tube. The discharge according to any one of claims 1 to 3, wherein the hollow lead-in wire is sealed by mechanically pushing the end thereof or by filling the hollow part with a closing member. Lamp manufacturing method. The method according to any one of claims 1 to 4, wherein at least one of a getter material, an emitter material, and a discharge delay countermeasure material is applied to an inner end of the glass tube as the hollow introduction wire. Manufacturing method of discharge lamp. The method for manufacturing a discharge lamp according to any one of claims 1 to 5, wherein the hollow introduction wire has an inner diameter of 0.5 mm or more.

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