JP2008147198A - Compact self-ballasted fluorescent lamp and manufacturing method of arc tube - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a compact self-ballasted fluorescent lamp whose lamp efficiency is more improved than current lamps and whose rising characteristic at the lamp start-up is improved to the same level as general fluorescent lamps. <P>SOLUTION: The compact self-ballasted fluorescent lamp 1 includes an arc tube 2 composed of a curving glass tube 9 in an outer bulb 6. The glass tube 9 has a double helical shape having a turning-back portion nearly at the middle thereof between the ends thereof, and also a first circling portion circling and directing from the one end thereof to the turning-back portion and a second circling portion circling and directing from the turning-back portion to the other end thereof. Mercury in a single form nearly excluding amalgam form is enclosed in the glass tube 9. The cross-sectional shape of the glass tube 9 is nearly circular of 7.4 mm in inner diameter. The turning-back portion of the glass tube 9 is connected to the outer bulb 6 through a thermoconductive medium 15. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a bulb-type fluorescent lamp having a curved arc tube and a method for manufacturing the arc tube.

  In the age of energy saving, as a light source that replaces incandescent light bulbs, a bulb-type fluorescent lamp with high lamp efficiency and long life has been attracting attention. This bulb-type fluorescent lamp (hereinafter simply referred to as “lamp”) is provided with a curved arc tube, and there are two types with different design characteristics, with and without an outer bulb covering the arc tube. is there. Hereinafter, a lamp with an outer bulb is referred to as a bulb type, and a lamp without an outer bulb is referred to as a bulbless type.

  The difference between the two types is not only the presence or absence of the outer tube bulb, but the bulb type is enclosed in the arc tube in an alloy form containing mercury, bismuth Bi, indium indium, tin Sn, etc., so-called main amalgam form. On the other hand, in the bulbless type, mercury is sealed in the arc tube without taking the main amalgam form. Initially, the bulb type also contained mercury alone in the arc tube. However, when this type of lamp is turned on, because the arc tube is covered with the outer bulb, heat is trapped in the outer bulb, so the temperature of the arc tube rises excessively. There has been a problem that the mercury vapor pressure in the arc tube rises and the lamp efficiency is remarkably lowered. In the bulbless type, since the temperature rise of the arc tube during lighting is small and the decrease in lamp efficiency is small, mercury alone is still enclosed in the arc tube.

  In order to solve the above problem, techniques for suppressing the increase in mercury vapor pressure in the arc tube are described in Japanese Patent Publication Nos. 03-2016, 03-22017, 03-03018, and 03-24019. So many were proposed. However, these technologies are effective for low-power lamps such as the 9W type that replaces the incandescent bulb 40W, and when the 12W and 22W types replace the incandescent bulbs 60W and 100W, The temperature rise of the arc tube was large, and the increase in mercury vapor pressure could not be effectively suppressed.

  Against this background, as a technology that can support 12W and 22W varieties that replace incandescent bulbs 60W and 100W, we stopped enclosing mercury in an arc tube in a single form, and used the main amalgam form used in current products As a result, it has been found that if the main amalgam used in the lamp is BiIn, BiPbSn, InPb, BiIn, InPbSn, the lamp efficiency can be prevented from decreasing. In addition, the technique using this main amalgam form is introduced and has become mainstream about most present type with a valve | bulb.

As a result, a lamp efficiency of 68 lm / W has been realized in the 12 W type using the three U-shaped and four U-shaped arc tubes that replace the incandescent bulb 60 W type.
Japanese Patent Publication No. 03-22016 Japanese Patent Publication No. 03-22017 Japanese Patent Publication No. 03-24018 Japanese Patent Publication No. 03-24019

  As described above, various technologies have made great progress in improving lamp efficiency. However, since the main amalgam form is enclosed in the arc tube to suppress the decrease in lamp efficiency, there is a problem that the rise of the luminous flux at the start of the lamp is slow. This is because mercury is absorbed by the main amalgam when the lamp is extinguished, and the mercury vapor pressure at the time of starting the lamp is lower than that of a general fluorescent lamp, that is, a lamp using only mercury, so the luminous flux at the start is reduced. is there.

  The present invention has been made in view of the above-described problems, and improves the lamp efficiency over that of the current product and can improve the rising characteristics at the time of starting the lamp to the same level as that of a general fluorescent lamp. It is an object of the present invention to provide a method of manufacturing a lamp and an arc tube that can further improve lamp efficiency.

  In order to achieve the above object, a bulb-type fluorescent lamp according to the present invention includes a curved arc tube in an outer tube bulb, and a part of the arc tube is connected to the outer tube bulb via a thermally conductive medium. An amalgam having a mercury vapor pressure characteristic that is substantially combined with a mercury vapor pressure characteristic during operation of a simple substance form and mercury alone, in a bulb-type fluorescent lamp that is thermally coupled. Among the forms, the glass tube is sealed in at least one form, the cross-sectional shape of the glass tube forming the arc tube is substantially circular, and the inner diameter is 5 mm or more and 9 mm or less. In particular, the amalgam form having mercury vapor characteristics substantially equivalent to the mercury vapor pressure characteristics during lighting of the mercury alone is characterized by including one or more of ZnHg, FeHg, BiHg, BiSnHg, and SnHg.

  According to this configuration, since the mercury is sealed in the arc tube in the form of a simple substance, it is possible to obtain a rising characteristic equivalent to that of a general fluorescent lamp. Moreover, since the inner diameter of the cross section of the glass tube is 5 mm or more and 9 mm or less, the optical path from the ultraviolet radiation emitted from mercury atoms to the tube wall of the arc tube can be shortened, and the luminous flux emitted from the arc tube is maximized. The temperature can be raised. For this reason, the difference with the temperature of the arc tube during lamp operation is reduced, and the lamp efficiency higher than that of the current product can be obtained.

  The arc tube includes electrodes at both ends of the glass tube, the inner diameter of the glass tube is φi (mm), the distance between the electrodes in the arc tube is Le (mm), and each of them is an orthogonal coordinate (φi, Le), the (φi, Le) are points (5.0, 370), points (7.4, 275), points (9.0, 290), points (9.0, 360). And the points (5.0, 690) are defined within a range surrounded by the points. When this configuration is applied to the incandescent bulb 60W type, the lamp efficiency can be made higher than that of the current type, the lamp life can be guaranteed for 6000 hours, and the size of the lamp can be equal to or less than that of the incandescent bulb 60W type.

  Further, the arc tube is provided with electrodes at both ends of the glass tube, the inner diameter of the glass tube is φi (mm), the inter-electrode distance Le (mm) in the arc tube, and each is orthogonal coordinates (φi, Le ), The (φi, Le) is represented by points (5.0, 700), points (7.4, 530), points (9.0, 560), points (9.0, 620) and It is characterized by being defined within a range surrounded by points (5.0, 930). When this configuration is applied to an incandescent bulb 100W type, the lamp efficiency can be made higher than that of the current type, the lamp life can be guaranteed 6000 hours, and the lamp size can be made smaller than the current 22W type as an alternative to the incandescent bulb 100W type. .

  In addition, the arc tube is provided with electrodes at both ends of the glass tube, the inner diameter of the glass tube is φi (mm), the interelectrode distance Le (mm) in the arc tube, and orthogonal coordinates (φi, Le ), The (φi, Le) is the point (5.0, 800), the point (7.4, 570), the point (9.0, 600), the point (9.0, 670) and It is defined within a range surrounded by points (5.0, 1000). When this configuration is applied to a high luminous flux type 23W product that replaces the incandescent bulb 100W, the lamp efficiency can be improved to the current level, the lamp life can be guaranteed 6000 hours, and the size of the lamp is equal to or smaller than that of the conventional product. You can do it.

  The arc tube is provided with electrodes at both ends of the glass tube, the inner diameter of the glass tube is φi (mm), the interelectrode distance Le (mm) in the arc tube, and orthogonal coordinates (φi, Le ), (Φi, Le) is represented by points (5.0, 270), (7.4, 200), (9.0, 230), (9.0, 320) and It is defined within a range surrounded by points (5.0, 590). When this configuration is applied to a 7W product that replaces the incandescent light bulb 40W, the lamp efficiency can be made higher than that of the current product, the lamp life can be guaranteed for 6000 hours, and the size of the lamp can be made equal to or less than that of the conventional product. .

  And the said glass tube has a folding | turning part in the approximate center between the both ends of the said glass tube, and the said glass tube turns to the said folding | turning part, turning around the turning axis from one edge part. And a second swirl portion that swivels around the swivel axis of the first swivel portion from the turn-up portion to the other end portion, and the periphery of the turn-up portion is the outer tube. It is characterized by being coupled to the valve via the thermally conductive medium. In this configuration, the coldest spot of the arc tube when the lamp is lit is around the folded portion, and the heat of this part can be transferred to the outer bulb through the heat conductive medium, and the temperature of the coldest spot is It can be effectively reduced.

An arc tube having a spirally curved glass tube is provided, and the inner periphery of the cross section of the glass tube is noncircular. In particular, the glass tube is swiveled around a swivel axis, and a first diameter in a direction substantially perpendicular to the swivel axis is a second in a direction substantially parallel to the swivel axis on the inner periphery of the cross section of the glass tube. It is characterized by being smaller than the diameter.
Specifically, the cross-sectional shape of the glass tube is substantially elliptical, or the cross-sectional shape of the glass tube is a “<” shape. According to this configuration, the first diameter is smaller than the second diameter. For example, the shape of the inner periphery in the cross section of the glass tube is smaller than that of the circular shape having the same diameter as the second diameter. The optical path from the emitted ultraviolet radiation to the tube wall of the arc tube can be shortened, and the temperature at which the luminous flux emitted from the arc tube is maximized can be increased. Therefore, the difference from the temperature of the arc tube during lamp operation is reduced, and the lamp efficiency can be improved. Moreover, since the inner circumference of the first diameter is in a direction substantially perpendicular to the pivot axis, the inner circumference on the pivot axis side in the cross section of the glass tube is farther from the pivot axis than the inner circumference on the pivot axis side in the circular shape. The distance between the electrodes can be increased as compared with the circular shape, and the lamp efficiency can be improved.

  Further, when the first diameter is D1 (mm) and the second diameter is D2 (mm), the value of D2 is 5 mm or more and 9 mm or less, and the value of D1 is 3 mm or more and less than D2. It is characterized by. With this configuration, the optical path from the ultraviolet radiation emitted from the mercury atoms to the tube wall of the arc tube can be shortened, and the temperature at which the luminous flux emitted from the arc tube is maximized can be increased. For this reason, even if the temperature of the arc tube rises while the lamp is lit, a decrease in lamp efficiency can be suppressed. Moreover, when the second diameter is used, the electrode can be easily installed.

  Furthermore, the arc tube comprises electrodes at both ends of the glass tube, the distance between the electrodes in the arc tube is Le (mm), and when D1 and Le are represented by orthogonal coordinates (D1, Le), The (D1, Le) is a point (3.0, 445), a point (7.4, 275), a point (9.0, 290), a point (9.0, 360) and a point (3.0, 855) is defined within a range surrounded by each point. When this configuration is applied to the incandescent bulb 60W type, the lamp efficiency can be made higher than that of the current type, the lamp life can be guaranteed for 6000 hours, and the size of the lamp can be made the same size as the incandescent bulb 60W type.

  The arc tube includes electrodes at both ends of the glass tube, the distance between the electrodes in the arc tube is Le (mm), and D1 and Le are expressed by orthogonal coordinates (D1, Le). , (D1, Le) are points (3.0, 840), (7.4, 530), (9.0, 560), (9.0, 620) and (3.0). , 1085) is defined within a range surrounded by each point. When this configuration is applied to an incandescent bulb 100W type, the lamp efficiency can be made higher than that of the current type, the lamp life can be guaranteed 6000 hours, and the lamp size can be made smaller than the current 22W type as an alternative to the incandescent bulb 100W type. .

  Furthermore, the arc tube has electrodes at both ends of the glass tube, the distance between the electrodes in the arc tube is Le (mm), and D1 and Le are expressed by orthogonal coordinates (D1, Le). , (D1, Le) are points (3.0, 975), (7.4, 570), (9.0, 600), (9.0, 670) and (3.0). 1165) is defined within a range surrounded by each point. When this configuration is applied to a high luminous flux type 23W product that replaces the incandescent bulb 100W, the lamp efficiency can be improved to the current level, the lamp life can be guaranteed 6000 hours, and the size of the lamp is equal to or smaller than that of the conventional product. You can do it.

  The arc tube includes electrodes at both ends of the glass tube, the distance between the electrodes in the arc tube is Le (mm), and D1 and Le are expressed by orthogonal coordinates (D1, Le). , (D1, Le) are points (3.0, 330), points (7.4, 200), points (9.0, 230), points (9.0, 320), and points (3.0 725) is defined within a range surrounded by each point. When this configuration is applied to a 7W product that replaces the incandescent light bulb 40W, the lamp efficiency can be made higher than that of the current product, the lamp life can be guaranteed for 6000 hours, and the size of the lamp can be made equal to or less than that of the conventional product. .

  And the said glass tube has a folding | turning part in the approximate center between the both ends of the said glass tube, and the said glass tube turns to the said folding | turning part, turning around the turning axis from one edge part. And a second spiral part having a second turning part that is turned around the turning axis of the first turning part from the folded part to the other end part. According to this configuration, the limited space in the outer tube bulb can be used effectively, and for example, the distance between the electrodes can be made longer than that in which the arc tube has a U shape.

  Further, the arc tube is characterized in that mercury is sealed in a substantially single form without taking an amalgam form. According to this configuration, it is possible to improve the start-up characteristics at the time of starting the lamp, compared to the case where the amalgam form is enclosed in the arc tube. The glass tube further includes an outer tube bulb that includes the arc tube, and the glass tube is characterized in that the periphery of the folded portion is coupled to the outer tube bulb through a heat conductive medium. According to this configuration, the heat of the folded portion of the arc tube can be transmitted to the outer bulb through the heat conductive medium, and the temperature of the arc tube can be effectively reduced.

  In addition, the glass tube is characterized in that a portion for sealing the electrode has a circular cross section. According to this configuration, the electrode can be easily inserted into the glass tube and sealed regardless of the shape of the central portion of the glass tube. In addition, the distance between the folded portion of the glass tube and the outer tube bulb bonded by the heat conductive medium is 6.0 mm or less. According to this configuration, the heat of the folded portion of the arc tube can be effectively transmitted to the outer bulb.

  Furthermore, as the heat conductive medium, any one of metal, rubber, and resin is used. In particular, since the transmissive silicon resin is used as the heat conductive medium, the temperature of the arc tube can be lowered without impairing the appearance of the lamp. In addition, an extended portion that extends a bonding area with the heat conductive medium is formed in a portion of the arc tube that is connected with the heat conductive medium. According to this configuration, the temperature of the arc tube can be further reduced by 1 to 2 ° C., and the lamp efficiency during lamp operation can be improved.

  Further, the glass tube is characterized in that a gap between the folded portion and the first and second turning portions connected to the folded portion is smaller than an outer diameter of the folded portion of the glass tube. According to this configuration, the light emission distribution from the arc tube to the side opposite to the electrode side in the swivel axis direction is uniform. Further, a method of manufacturing a spiral arc tube by winding a softened glass tube along a spiral groove formed on the outer peripheral surface of a forming jig, wherein the groove has a non-circular cross-sectional shape. In particular, the cross-sectional shape of the groove is substantially coincident with a part of an ellipse having a major axis in a direction substantially parallel to the direction of the pivot axis. The surface shape is a character of “ku”. By manufacturing in this way, the inner periphery of the cross section of the glass tube forming the helical arc tube can be easily formed into a non-circular shape, in particular an elliptical “<” shape.

  Further, the groove portion has a double spiral shape from the top portion to the base portion of the forming jig, and the glass tube is wound around the forming jig in a state where the substantially central portion of the glass tube is positioned on the top portion. Since a double spiral arc tube is obtained, a double spiral arc tube can be easily formed. Further, when the glass tube is wound around the forming jig, a pressure fluid is sealed in the glass tube. For this reason, collapse of the glass tube in a softened state can be prevented.

  The bulb-type fluorescent lamp according to the present invention is a bulb in which a curved arc tube is contained in an outer bulb, and a part of the arc tube is thermally coupled to the outer bulb via a thermally conductive medium. A fluorescent lamp, wherein the mercury in the arc tube has at least one of an amalgam form having a mercury vapor pressure characteristic substantially equivalent to a mercury vapor pressure characteristic during lighting of the simple substance form and mercury alone. The glass tube forming the arc tube has a substantially circular cross-sectional shape and an inner diameter of 5 mm to 9 mm. In this configuration, since the mercury is sealed in the arc tube in the form of a simple substance, it is possible to obtain a rising characteristic equivalent to that of a general fluorescent lamp. And since the internal diameter of the cross section of a glass tube is 5 mm or more and 9 mm or less, the temperature from which the light beam emitted from an arc tube becomes the maximum can be raised. For this reason, the difference with the temperature of the arc tube during lamp operation is reduced, and the lamp efficiency higher than that of the current product can be obtained.

  Further, a method of manufacturing a spiral arc tube by winding a softened glass tube along a spiral groove formed on the outer peripheral surface of a forming jig, wherein the groove has a non-circular cross-sectional shape. It is arcuate. By manufacturing in this way, the cross-sectional shape of the glass tube forming the helical arc tube can be easily made non-circular.

Embodiments of a light bulb shaped fluorescent lamp according to the present invention will be described below with reference to the drawings.
(First embodiment)
1. 1) Overall Configuration FIG. 1 is a front view showing an overall structure in which a part of a bulb-type fluorescent lamp according to the present invention is cut out. This bulb-type fluorescent lamp 1 (hereinafter simply referred to as “Lamp 1”) is an 11 W type that is an alternative to the incandescent bulb 60W. As shown in the figure, the lamp 1 includes an arc tube 2 that bends in a spiral, a lighting circuit 3 for lighting the arc tube 2, a case 4 that houses the lighting circuit 3 and has a base 5; An outer tube bulb 6 that covers the arc tube 2 is provided.

2A is a front view showing a structure in which a part of the arc tube 2 is cut out, and FIG. 2B is a bottom view of the arc tube as viewed from below. The arc tube 2 extends downward from the opening of the case 4 (on the side opposite to the base 5), and the glass tube 9 forming the arc tube 2 is positioned between both ends so that both ends are located on the case 4 side. The folded portion 10 is folded at a substantially central portion.
The glass tube 9 turns around the turning axis A (hereinafter simply referred to as “around the turning axis A”) while turning around the turning axis A while turning around the turning axis A. It has a double spiral shape having a first turning portion 11a that is directed and a second turning portion 11b that is turned around the turning axis A from the turning portion 10 and that is directed to the other end portion. The first and second turning parts 11a and 11b turn the turning axis A about 5 times together.

  As described above, the state of turning around the turning axis A is referred to as “five turns”, for example, using the number of turns. Further, the glass tube 9 swivels around the swivel axis A while inclining at a predetermined angle (this angle is hereinafter referred to as “spiral angle”) with respect to the horizontal direction (direction orthogonal to the swivel axis A). Yes. Here, the reason why the spiral shape is selected as the shape of the arc tube 2 is that the distance between the electrodes of the arc tube 2, that is, the discharge path length can be made longer than the current U shape, and the arc tube 2 can be downsized as a whole. It is because it can plan.

  Electrodes 7 and 8 are sealed at both ends of the glass tube 9. As the electrodes 7 and 8, tungsten coil electrodes are used. The electrodes 7 and 8 are inserted into the glass tube 9 while being temporarily fixed by bead glass, and leads for the electrodes 7 and 8 are used. Wires 7 a, 7 b, 8 a, 8 b are sealed to the glass tube 9. For this reason, the inside of the glass tube 9 is hermetically sealed.

In this hermetically sealed glass tube 9, about 5 mg of mercury is sealed in a single form, and argon / neon gas is sealed as a buffer gas. The inner surface of the glass tube 9 is coated with a rare earth phosphor. The phosphor used here is a mixture of three types of Y ₂ O ₃ : Eu, LaPO ₄ : Ce ₂ Tb and BaMg ₂ Al ₁₆ O ₂₇ : Eu, Mn phosphors emitting red, green and blue light. It is.

Here, the mercury enclosed in the glass tube 9 is basically present in a form in which the mercury vapor pressure during the lighting operation of the arc tube 2 exhibits a vapor pressure value of substantially mercury alone. Therefore, the mercury enclosed in the manufacturing process of the arc tube 2 may be in a single form, or may be in a form such as zinc mercury where the mercury vapor pressure during the lighting operation exhibits a value close to that of the single mercury.
The end of the arc tube 2 on the side of the electrodes 7 and 8 is fixed to the lower surface of the holder 12, and an electrical component 13 for lighting the arc tube 2 is provided on the back of the holder 12 as shown in FIG. Is installed. In addition, the lighting circuit 3 for lighting the arc tube 2 is constituted by these electric components 13. The case 4 is made of synthetic resin and has a cylindrical shape that expands downward as shown in FIG. In the case 4, the holder 12 is inserted from the opening so that the lighting circuit 3 side is the back side, and the peripheral edge of the holder 12 is attached to the inner wall of the case 4 by appropriate attachment means such as an adhesive or a screw. . A base 5 for E26 is mounted on the upper portion of the case 4, that is, on the side opposite to the opening. In FIG. 1, the electrical connection between the arc tube 2 and the lighting circuit 3 and the electrical connection between the base 5 and the lighting circuit 3 are not shown.

  The outer bulb 6 is for covering the arc tube 2, and its opening is inserted inside the opening of the case 4, and the end on the opening side of the outer bulb 6 is inside the opening of the case 4. It is fixed by appropriate mounting means such as an adhesive and a screw. The outer tube valve 6 and the case 4 constitute an envelope. Hereinafter, the outer diameter of the outer appearance of the lamp 1, that is, the outer diameter of the outer bulb 6 is referred to as a lamp diameter φ, and the entire length of the lamp 1, that is, the entire length of the envelope including the base 5 of the case 4 is referred to as a lamp length L. The outer tube valve 6 in the present embodiment is made of glass and has a so-called A shape.

  The lower end portion of the inner wall of the outer bulb 6 and the lower end portion of the arc tube 2 are thermally coupled by a heat conductive medium 15. For this reason, even when the temperature of the arc tube 2 rises when the lamp 1 is turned on, the heat is transferred to the outer bulb 6 via the heat conductive medium 15, and the temperature of the arc tube 2, particularly the arc tube. The temperature rise at the lower end of 2 can be suppressed. Here, the reason for suppressing the temperature rise at the lower end of the arc tube 2 is that the temperature in the arc tube 2 can be reduced by lowering the temperature at the coldest location (hereinafter referred to as “cold spot location”). This is because the mercury vapor pressure is effectively reduced. In the case of the spiral arc tube 2 as in the present embodiment, the portion farthest from the electrodes 7 and 8, that is, the lower end of the arc tube 2 is the This is because it becomes a cold spot. The coldest spot is also the folded portion 10 of the glass tube 9.

  For the heat conductive medium 15, for example, a metal, a synthetic resin, rubber, or the like can be used. However, since the light emitted from the arc tube 2 is radiated from the outer tube bulb 6 to the outside, particularly downward, through the heat conductive medium 15, the heat conductive medium 15 is naturally excellent in light transmittance. Is good. Furthermore, considering the temperature rise of the arc tube 2, those excellent in heat resistance are good, and a specific material that satisfies these is a transparent silicon resin.

  2) Specific configuration A specific configuration in the present embodiment will be described. As shown in FIGS. 1 and 2, the glass tube 9 forming the arc tube 2 has a tube inner diameter φi of 7.4 mm and a tube outer diameter φo of 9.0 mm. The arc tube 2 has a distance of 340 mm between the electrodes, and the glass tube 2 is formed in a spiral shape that revolves around the revolving axis A by approximately 5 turns. The arc tube 2 has an outer diameter φh of 36 mm and a length Lh of 64 mm.

  A gap S between the folded portion 10 of the glass tube 9 and the first and second swivel portions 11a and 11b located at the lowest position folded by the folded portion 10 is as shown in FIG. 2 (b). Furthermore, since the tube outer diameter φo of the glass tube 9 is 9.0 mm, it becomes 4.5 mm. Therefore, the area of the portion that does not emit light (gap portion) is smaller in proportion to the area of the portion that emits light (both the turning portions 11a and 11b and the folded portion 10) in the bottom view of the arc tube 2. The distribution becomes substantially uniform and the so-called illuminance directly below the lower end of the arc tube 2 can be increased.

  The outer tube bulb 6 has an outer diameter φ of 55 mm and a length Lb of 58 mm, and the arc tube 2 is accommodated therein. Note that the length Lh (64 mm) of the arc tube 2 is longer than the length Lb (58 mm) of the outer tube bulb 6 (see FIG. 1). This is because it is attached to the case 4 in a state of being inserted into the case 4.

As for the overall size of the lamp 1, the lamp diameter φ is 55 mm, the lamp length L is 110 mm, and the lamp diameter of a general incandescent bulb 60W type is 60 mm, and the lamp length is 110 mm. The lamp length is the same, and it is smaller than the incandescent bulb 60W type. Next, the performance of the lamp 1 having the above configuration will be described.
When the lamp 1 is turned on with the lamp input 11 W with the base 5 facing upward (hereinafter simply referred to as “lighting on the base”), the luminous flux rise characteristic at the start of the lamp is equivalent to that of a conventional general fluorescent lamp. In addition, a luminous flux of 790 lm was obtained at a lamp current of about 75 mA, and a lamp efficiency of 71.9 lm / W, which is higher than the target of 70 lm / W, was obtained. At the same time, it was confirmed that the lamp life was 6000 hours or more.

  3) Manufacturing method of arc tube The manufacturing method of the arc tube 2 will be described here. 3 and 4 are diagrams for explaining a manufacturing process for manufacturing a double spiral arc tube using a forming jig. FIG. 3 is a view of the forming jig as viewed from the front. FIG. 4 is a forming jig. It is the figure which looked at from the upper part. First, as shown in FIGS. 3A and 4A, a forming jig 20 for forming is prepared. As shown in FIG. 3A, the forming jig 20 has a cylindrical shape, and has a spiral groove portion 25 on the outer periphery thereof. The groove 25 has a double spiral shape from the top of the forming jig 20 toward the root (the lower end of the forming jig 20).

  A top portion 21 which is one end (upper end) of the forming jig 20 is provided with a return portion 22 for forming the folded portion 16 of the arc tube 2 and a pressing portion 23 for preventing the glass tube forming jig 20 from being detached during winding. Are arranged symmetrically with respect to the center of the top of the forming jig 20 (a point passing through the axis of the forming jig) (see FIG. 4A). Note that 25a shown in FIGS. 3A and 4A shows the bottom surface of the groove portion 25 (the inner periphery of the spiral arc tube), and the top portion 21 of the bottom portion 25 in the spiral direction is shown. The end on the side is a return portion 22.

  On the other hand, the other end (lower end) of the forming jig 20 is a mounting portion 24 for mounting the forming jig 20 to the drive device. The driving device has a function of moving the forming jig 20 in the axial direction while rotating around the axis. Next, a straight tubular glass tube 30 having a circular cross section is prepared, and the entire glass tube 9 is heated and softened. The substantially central portion of the softened glass tube 30 is set between the return portions 22 of the top portion 21 of the forming jig 20 as shown in FIGS. Then, as shown in FIGS. 3C and 4C, in a state where both ends of the glass tube 30 are gripped, the forming jig 20 is rotated in the B direction around the axis and moved in the X direction. Thus, the softened glass tube 9 is wound around the forming jig 20 along the spiral groove 25. The amount of movement that moves in the X direction while the forming jig 20 rotates once is controlled so as to coincide with one pitch of the spiral shape of the groove 25 on the forming jig 20.

  At this time, the cross-sectional shape of the groove portion 25 has an arc shape so that the cross-section of the wound glass tube 30 is circular. During the winding of the glass tube 30, a pressure-controlled gas such as nitrogen is blown into the glass tube 30. The gas blowing may be performed after the glass tube 30 is wound along the groove 25 of the forming jig 20. In the present embodiment, a gas such as nitrogen is blown into the glass tube 30, but a liquid such as water or butyl acetate may be blown in place of the gas.

When the winding is completed and the temperature of the glass tube 30 is lowered, the forming jig 20 is rotated in the direction opposite to the rotation at the time of winding (the anti-B direction), and the glass tube 30 is removed from the forming jig 20. Therefore, when the forming jig 20 is rotated in the anti-B direction of FIG. 3, the glass tube 30 can be easily detached from the forming jig 20.
2. Contents of Study The present inventor made the following four specific targets in studying the lamp-type lamp 1.

a) The luminous flux rising characteristic at the time of starting the lamp is the same level as that of a conventional general fluorescent lamp (specifically, the luminous flux is 3 seconds after lighting at a room temperature of 25 ° C. (hereinafter also referred to as “immediately after lighting”). Set the value to 60% of steady lighting.
b) The external dimensions of the lamp 1 are reduced to less than or equal to the size of incandescent bulbs, particularly 60W types, that is, the lamp diameter φ is 60 mm and the lamp length L is 110 mm.

c) The lamp efficiency is 70 lm / W or higher, which is higher than the current lamp 68 lm / W.
d) The lamp life is set to 6000 hours or more defined by the Japan Electric Bulb Industry Association Standard JEL201.
The present inventor does not enclose the main amalgam form used in the current product in the arc tube 2 when proceeding with the study to achieve the above-mentioned target, but encloses mercury in a single form, We searched for a means that can suppress the decrease in lamp efficiency during lighting.

  1) Regarding the inner diameter of the tube First, the cause of the decrease in lamp efficiency during lighting is that when the mercury vapor pressure in the arc tube rises due to the temperature rise of the arc tube, mercury atoms in the discharge space increase and are released from certain mercury atoms. It is said that ultraviolet radiation is absorbed by other mercury atoms. For this reason, the present inventor reduces the rate of absorption of ultraviolet radiation by other mercury atoms by shortening the optical path from the ultraviolet radiation emitted from mercury atoms to the tube wall (inner circumference) of the arc tube. In other words, it was thought that if the tube inner diameter φi of the glass tube 9 forming the arc tube 2 is reduced, the decrease in lamp efficiency can be suppressed.

  Therefore, an experiment was conducted to specify the mercury vapor pressure that gives the maximum lamp efficiency at the tube inner diameter φi when the tube inner diameter φi of the glass tube 9 used for the arc tube 2 is changed in the range of 5 to 12 mm. Specifically, lamps having a glass tube 9 whose inner diameter φi was increased by 1 mm from 5 to 12 mm were manufactured, and experiments were performed on these lamps. Here, 5-12 mm was selected as the range of the tube inner diameter φi because if the tube inner diameter φi was smaller than 5 mm, it was difficult to install the electrodes 7, 8 in the arc tube 2, while the tube inner diameter φi was larger than 12 mm. This is because the arc tube 2 becomes large and it is difficult to reduce the size of the lamp 1.

Further, the inter-electrode distance Le corresponding to the tube inner diameter φi is determined so that the tube wall load we of the arc tube 2 is 0.13 W / cm ^{2 based} on the data from the conventional product. The reason for this is that the inventor has obtained from the result of the study on the lamp life characteristics performed by the present inventors that the lifetime of the lamp 1 can be guaranteed to be approximately 6000 hours if the value of the tube wall load we is 0.13 W / cm ^2. Because. The tube wall load we is a value obtained by dividing the arc tube input value by the surface area π × φi × Le of the inner peripheral surface of the arc tube 2. Here, the arc tube input value is calculated by multiplying the lamp input value (11 W) by the circuit efficiency (0.91) of the lighting circuit 3.

  In the experiment, a bulbless lamp was installed in a temperature-controlled thermostatic chamber to change the mercury vapor pressure in the arc tube. Specifically, in order to change the mercury vapor pressure in the arc tube, the temperature in the thermostatic chamber was changed, and the temperature at which the arc tube emitted the maximum luminous flux (hereinafter referred to as “maximum emission temperature T”) was measured. . The mercury vapor pressure at which the arc tube emits the maximum luminous flux is also referred to as the optimum mercury vapor pressure.

  The result is shown in FIG. As shown in the figure, the maximum light emission temperature T increases as the tube inner diameter φi decreases. In particular, it has been found that when the tube inner diameter φi is reduced to 5 mm, the maximum light emission temperature T increases to 65 ° C. From this, the temperature at the coldest spot where the temperature of the arc tube 2 is the lowest (hereinafter simply referred to as “cold spot temperature”), that is, the temperature at the lower end of the arc tube 2 is assumed to be the maximum luminous temperature. If they are substantially equal, there will be no reduction in lamp efficiency during lamp operation. Here, the coldest spot temperature is compared with the maximum light emission temperature. The temperature at which the mercury vapor pressure emits the maximum luminous flux is the maximum light emission temperature, and the temperature determining the mercury vapor pressure is the arc tube 2. This is because the coldest spot temperature.

2) Regarding the temperature of the arc tube The present inventors then searched for means for lowering the coldest spot temperature of the arc tube 2 during lamp operation. This is because, as described above, if the coldest spot temperature of the arc tube 2 during lamp operation can be reduced to 65 ° C. or less, a decrease in the lamp inner diameter φi of the arc tube 2 can be suppressed, thereby suppressing a decrease in lamp efficiency during lamp operation. Because.
Here, as a preliminary study, the size of the incandescent light bulb 60W type using the arc tube 2 in which the tube inner diameter φi of the glass tube 9 is 7.4 mm, the tube outer diameter φo is 9.0 mm, and the distance Le between the electrodes is 340 mm. The prototype lamp 1 having a lamp diameter φ: 60 mm and a lamp length L: 110 mm was turned on with a lamp input 11 W, and the temperatures of the arc tube 2 and the outer bulb 6 were measured. The lighting condition is lighting on the base. The shape of the outer bulb 6 was A type similar to the incandescent bulb 60W.

  From this measurement result, it was confirmed that the arc tube 2 had the lowest temperature at the lower end of about 75 ° C., and the coldest spot was formed at the lower end of the arc tube 2. From this, if the coldest spot temperature of the arc tube 2 can be lowered by 10 ° C. or more, the coldest spot temperature of the arc tube 2 during lamp operation and the maximum luminous temperature T that emits the maximum luminous flux can be substantially matched. it can. On the other hand, the temperature at the lower end of the outer bulb 6 facing the coldest spot of the arc tube 2 was about 50 ° C., and the temperature difference between the two was about 25 ° C.

Therefore, the present inventor considers that the temperature of the arc tube 2 is lowered if the heat of the arc tube 2 being lit can be transmitted to the outer bulb 6 covering the arc tube 2, and as shown in FIG. The means for thermally coupling the coldest spot 16 of the arc tube 2 and the outer bulb 6 facing the coldest spot 16 using a heat conductive medium is selected and its effective application The method was examined.
As described above, a material having excellent heat resistance and light transmittance was searched for the thermally conductive medium 15 and a transparent silicon resin was selected. Further, the use of this silicon resin does not impair the aesthetic appearance of the lamp 1 because it is transparent, and the silicon resin does not appear as a shadow on the outer bulb 6 after lighting. A distance d (see FIG. 1) between the lower end portion of the arc tube 2 and the lower end portion of the inner wall of the outer tube bulb 6 is set to 2 mm, and the lower end portion of the arc tube 2 is buried in silicon resin by about 2 mm. Here, in the lamp 1 used for the above measurement, when the distance d between the lower end portion of the arc tube 2 and the lower end portion of the inner wall of the outer bulb 6 is set longer than 6.0 mm, the rate of decrease in the coldest spot temperature decreases. I found out that Therefore, the distance d should be defined within a range of 6.0 mm or less.

  The distance d between the lower end portion of the arc tube 2 and the outer tube bulb 6 is configured so that heat is directly transferred from the lower end portion of the arc tube 2 to the outer tube bulb 6 in consideration of thermal conductivity. Good to do. However, since the arc tube 2 and the outer tube bulb 6 are made of glass with each other, some load such as an impact load acts on the lamp 1 when the lamp 1 is transported or when the lamp 1 is mounted on a lighting device. Can be damaged. Therefore, it is preferable that there is a slight gap between the arc tube 2 and the outer tube bulb 6. Since the gap is filled with silicon resin, even if the above load is applied to the lamp 1, the load can be absorbed to some extent by the silicon resin.

  The lamp 1 having the above configuration was turned on, and the temperature of the coldest spot temperature at the lower end of the arc tube 2 was measured. As a result of the measurement, it was found that the coldest spot temperature was 63 ° C., which was about 12 ° C. lower than that of the silicon resin not used (preliminary cold spot temperature: 75 ° C.). For this reason, the coldest spot temperature at the lower end of the arc tube 2 is set to a range of 60 to 65 ° C. by bonding the lower end of the arc tube 2 and the lower end of the outer bulb 6 with silicon resin. In this range of 60 to 65 ° C., the tube inner diameter φi at which the luminous flux emitted from the arc tube 2 becomes maximum is in the range of 5.0 mm to 9.0 mm.

  3) Miniaturization and lamp efficiency In the arc tube 2 having a thin tube inner diameter and the lamp 1 using silicon resin as described above, the size is the same as that of the incandescent bulb 60W type, the lamp efficiency is 70 lm / W or more, and the lamp life is 6000 hours. We examined to achieve the remaining goal of guaranteeing the above. The examination result is shown in FIG. 6, and if the tube inner diameter φi of the arc tube 2 and the interelectrode distance Le are within the hatched portion shown in FIG. 6, the lamp 1 that can achieve the above-described target can be obtained. Hereinafter, the explanation of FIG. 6 and the reason why the above-described goal can be achieved will be described.

  a) Lamp size reduction Line 1 in FIG. 6 is a line connecting the maximum inter-electrode distances in each tube inner diameter within a range that can be accommodated in the outer bulb 6 corresponding to the size of the incandescent bulb 60W. is there. That is, in order to reduce the size of the lamp 1, it is necessary to reduce the distance between the electrodes Le to reduce the size of the arc tube 2, and the outer tube bulb 6 (outer diameter φ55 mm) corresponding to the same size as an incandescent bulb. The maximum length of the arc tube 2 that can be accommodated within the length Lb 58 mm) is calculated, and the maximum inter-electrode distance Le is obtained. The value on the line 1 is the upper limit value of the interelectrode distance Le.

b) Lamp life Line 2 in FIG. 6 is a line connecting the electrode distance Le at each tube inner diameter where the lamp life is 6000 hours or more. In order to guarantee that the lamp life is 6000 hours or longer, the value of the tube wall load we of the arc tube 2 may be specified to be 0.16 W / cm ² or less by the inventors' examination on the lamp life characteristics. Has been obtained.
c) Lamp efficiency Line 3 in FIG. 6 is a line connecting the electrode distance Le at which the lamp efficiency is 70 lm / W. The distance Le between the electrodes on this line was experimentally determined so that the lamp efficiency was 70 lm / W. Specifically, the arc tube 2 is manufactured in a range where the tube inner diameter φi of the glass tube 9 is 5.0 mm to 9.0 mm, the distance Le between the electrodes of the arc tube 2 is changed in various ways, and is actually lit. The luminous flux is measured, and the interelectrode distance Le at which the lamp efficiency is 70 lm / W is obtained.

4) Summary From the above examination, the configuration of the lamp 1 according to the present embodiment is summarized. The arc tube 2 does not take the amalgam form, and mercury is sealed as a single unit form. 9 is defined in a range of 5.0 mm to 9.0 mm, and the lower end portion of the arc tube 21 and the lower end portion of the inner wall of the outer tube bulb 6 are coupled by a silicone resin so as to be capable of conducting heat.
In this way, since the mercury is enclosed in the arc tube 2 as a simple substance, the luminous flux rising characteristics equivalent to those of the general fluorescent lamp 1 can be obtained. In addition, by setting the tube inner diameter φi in the range of 5.0 to 9.0 mm, the temperature at which the maximum luminous flux is emitted can be set in the range of 60 to 65 ° C., so that the temperature of the arc tube 2 increases during lamp lighting. However, the temperature difference from the temperature at which the maximum luminous flux is emitted is reduced, and a decrease in lamp efficiency can be suppressed. Further, by reducing the tube inner diameter φi, the interelectrode distance Le can be increased, and the lamp efficiency can be improved. Furthermore, by combining the arc tube 2 and the outer bulb 6 using silicon resin, heat generated from the arc tube 2 during lamp operation can be transmitted to the outer bulb 6, and the temperature of the arc tube 2 can be controlled. Can be lowered.

In particular, as an alternative to the incandescent light bulb 60W, the lamp 1 can be equal to or smaller than the conventional incandescent light bulb 60W by defining the inter-electrode distance Le of the arc tube 2 within the hatched range of FIG. A lamp efficiency of 70 lm / W or more and a lamp life of 6000 hours or more can be achieved.
(Second Embodiment) In the first embodiment, an example in which the present invention is applied to the 11W type of the incandescent bulb 60W is shown. However, in this embodiment, the 21W type of the incandescent bulb 100W is substituted. It is applied to. In order to distinguish between the lamp in the present embodiment and the lamp 1 in the first embodiment, the numbers in the 200th series are used as the reference numerals of the components in the present embodiment, for example, the reference numerals of the lamps are 201. For this reason, although a code | symbol is attached | subjected to the structure, it may not show in figure (for example, the lamp | ramp 201, the outer tube | bulb valve 206).

Here, the basic configuration of the incandescent lamp 100W that is the replacement target of the lamp 201 in the present embodiment will be described. A general incandescent lamp 100W product has a lamp diameter φ of 60 mm and a lamp length L of 110 mm. Also, the current 22W lamp, which is an alternative to the incandescent lamp 100W, has a lamp diameter φ of 65 mm and a lamp length L of 140 mm. L is about 30 mm larger. Note that the current 22W lamp has a luminous flux of 1520 lm and a lamp efficiency of 69.1 lm / W.
1. Configuration FIG. 7 is a front view showing the entire arc tube showing the present embodiment. The basic configuration of the lamp 201 in the present embodiment is the same as that in the first embodiment, and the difference in configuration is that it replaces the incandescent bulb 100W, so that the lamp input increases from 11W to 21W and the 100W type In order to obtain approximately the same luminous flux, the distance between the electrodes of the arc tube 202 is increased. For this reason, as shown in FIG. 7, the spiral shape of the arc tube 202 is changed from approximately 5 turns of the first embodiment to approximately 7 turns.

  Also in the present embodiment, the tube inner diameter φi of the glass tube 209 is defined in the range of 5.0 mm to 9.0 mm for the same reason as in the first embodiment. Here, a specific configuration in the present embodiment will be described. The arc tube 202 has a glass tube 209 with a tube inner diameter φi of 7.4 mm, a tube outer diameter φo of 9.0 mm, and an interelectrode distance Le of 640 mm. The glass tube 209 is formed in a spiral shape of approximately seven turns, and the arc tube 209 has a diameter φh of 36 mm and a length Lh of 85 mm. On the other hand, the outer tube valve 206 has an outer diameter φ of 60 mm and a length Lb of 80 mm.

The lamp 201 as a whole has a lamp diameter φ of 60 mm and a lamp length L of 128 mm. Compared to the current lamp for 22 W type (lamp diameter φ: 65 mm, lamp length L: 140 mm), the lamp diameter is as follows. φ is 5 mm and lamp length L is 12 mm smaller, making it smaller than current products. Next, the performance of the lamp 201 having the above configuration will be described.
First, when the lamp is lit on the base with a lamp input of 21 W, the rising characteristic of the light beam at the time of starting the lamp shows the same characteristic as that of a conventional general fluorescent lamp, and a light beam of 1520 lm is obtained at a lamp current of about 100 mA. It became 72.4 lm / W which is 70 lm / W or more. At the same time, it was confirmed that the lamp life was 6000 hours or more.
2. Contents of study In this embodiment, the target is to reduce the size of the lamp for the current 22W type, the lamp outer diameter φ is set to 60 to 65 mm which is smaller than 65 mm of the current type, and the lamp length L is set to 140 mm of the current 22W type. Shorter 120-135 mm. The target of lamp efficiency was set to 70 lm / W, which is higher than the current 22W lamp (69 lm / W), as in the first embodiment. Note that the lamp life is set to 6000 hours or more, as in the first embodiment.

  Therefore, as in the first embodiment, the tube inner diameter φ of the glass tube 209 and the interelectrode distance Le of the arc tube 2 that can satisfy all of the target lamp size reduction, lamp efficiency improvement and lamp life guarantee are specified. Therefore, a trial manufacture and measurement of the lamp 201 were performed. FIG. 8 shows the result of the study, and if the relationship between the tube inner diameter φi of the arc tube 202 and the interelectrode distance Le is within the hatched portion shown in FIG. 8, the lamp 201 that achieves the above-described target can be obtained. Hereinafter, FIG. 8 will be described.

  1) Regarding lamp miniaturization Line 21 in FIG. 8 is a line connecting the maximum inter-electrode distances in each tube inner diameter within a range that can be accommodated in outer tube bulb 206 corresponding to the size of incandescent bulb 100W. . The inter-electrode distance Le is obtained by calculation or the like as in the first embodiment. Specifically, the outer tube bulb 206 (outer diameter 60 mm, length 80 mm) having the same size as the incandescent bulb 100W. The inter-electrode distance Le is obtained from the maximum length of the arc tube 202 that can be accommodated in the bracket. The value on the line 21 is the upper limit value of the interelectrode distance Le.

2) Lamp life The line 22 in FIG. 8 is a line connecting the interelectrode distance Le at which the lamp life is 6000 hours or more. In order to guarantee that the lamp life is 6000 hours or longer, the value of the tube wall load we of the arc tube 202 may be regulated to 0.16 W / cm ² or less, as in the first embodiment. The electrode distance Le is calculated from the wall load we.
3) Lamp efficiency The line 23 in FIG. 8 is a line connecting the interelectrode distance Le at which the lamp efficiency is 70 lm / W. This inter-electrode distance Le is obtained by experiments so that the lamp efficiency is 70 lm / W, as in the first embodiment.
(Third embodiment)
In the second embodiment, an example in which the present invention is applied to a 21 W type of an incandescent lamp 100W having a luminous flux of 1500 lm class has been shown. This is applied to the so-called high luminous flux type 23W type.

In the present embodiment, the current lamp for the incandescent lamp 100W alternative 22W type is also referred to as “current lamp”. In addition, in order to distinguish the lamp in this embodiment from the lamps 1 and 201 in the above-described embodiment, the reference numerals of the components in this embodiment are set in the 300s, for example, the lamps are indicated by 301. Although used, they are not shown.
The lamp shape and dimensions of the incandescent lamp 100W with the luminous flux of 1700 lm class as the alternative target in the present embodiment are the same as those of the lamp with the luminous flux of 1500 lm class, that is, the lamp diameter φ is 60 mm and the lamp length L is 110 mm.
1. Configuration The basic configuration of the lamp 301 in the present embodiment is the same as that in the second embodiment, and the difference in configuration is that it corresponds to a high luminous flux of 1700 lm, so that the lamp input increases from 21 W to 23 W, and That is, the interelectrode distance Le of the arc tube 302 is made longer. Also in the present embodiment, the tube inner diameter φi of the glass tube 9 is defined in the range of 5.0 mm or more and 9.0 mm or less for the same reason as the above embodiment.

  Here, a specific configuration in the present embodiment will be described. The arc tube 302 has a glass tube 309 having a tube inner diameter φi of 7.4 mm, a tube outer diameter φo of 9.0 mm, and an interelectrode distance Le of 680 mm. The glass tube 309 is formed in a spiral shape with approximately eight turns, and the arc tube 302 has a diameter φh of 36 mm and a length Lh of 95 mm. On the other hand, the outer tube valve 306 has an outer diameter φ of 60 mm and a length Lb of 90 mm (see FIGS. 1 and 2).

  The overall size of the lamp 301 is that the lamp diameter φ is 60 mm, the lamp length L is 138 mm, and the luminous flux is increased by 200 lm compared to the current lamp (lamp diameter φ65 mm, lamp length L140 mm, luminous flux 1520 lm). The length L is substantially the same, and a reduction in size of 5 mm is achieved with a lamp diameter φ. Next, the performance of the lamp 301 having the above configuration will be described.

First, when the lamp is lit on the base with the lamp input 23W, the luminous flux rising characteristic at the time of starting the lamp is improved to a level equivalent to that of the conventional general fluorescent lamp, and the luminous flux 1720lm is obtained, and the target lamp efficiency 74.8lm is obtained. / W was achieved. At the same time, it was confirmed that the lamp life was 6000 hours or more.
2. Contents of Study In the present embodiment, it was aimed to reduce the lamp outer diameter φ to 60 to 65 mm, which is smaller than the current 65 mm, particularly compared to the current lamp. Further, the target of the lamp efficiency and the lifetime was set to 70 lm / W or more and 6000 hours or more, respectively, similarly to the 1500 lm class 21W type lamp 201 according to the second embodiment.

  As in the second embodiment, in order to specify the tube inner diameter φi of the glass tube 309 and the interelectrode distance Le of the arc tube 2 that can satisfy all of the above-mentioned target lamp size reduction, lamp efficiency improvement and lamp life guarantee. In addition, a prototype of the lamp 301 and its measurement were performed. The examination result is shown in FIG. Here, if the relationship between the tube inner diameter φi of the arc tube 302 and the interelectrode distance Le is within the oblique line shown in FIG. 9, the lamp 301 that achieves the above target can be obtained.

Hereinafter, FIG. 9 will be described.
1) Lamp miniaturization The line 31 in FIG. 9 is such that the lamp diameter φ is substantially the same as that of the incandescent lamp 100W and the length L is substantially the same as that for the current 22W product type even if the shape of the lamp 301 is large. Is a line connecting the maximum inter-electrode distance Le at each tube inner diameter φi. Specifically, the interelectrode distance Le at each tube diameter φi is obtained from the maximum length of the arc tube 302 that can be accommodated in the outer tube bulb 306 having an outer diameter φ of approximately 60 mm and a length Lb of approximately 90 mm.

2) Lamp life The line 32 in FIG. 9 is a line connecting the interelectrode distance Le at which the lamp life is 6000 hours or more. This is calculated as the inter-electrode distance Le corresponding to the tube wall load we of the arc tube 302 of 0.16 W / cm ² , as in the first and second embodiments.
3) Lamp efficiency A line 33 in FIG. 9 is a line connecting the interelectrode distance Le at which the lamp efficiency becomes 70 lm / W, and this is obtained by experiments.
(Fourth embodiment)
In the first embodiment, the present invention is an 11W type replacing the incandescent bulb 60W, in the second embodiment the present invention is a 21W type replacing the incandescent bulb 100W, and in the third embodiment the present invention is incandescent. In the present embodiment, the present invention is applied to a 7W type that replaces the incandescent bulb 40W with a luminous flux of 500 lm.

In the present embodiment, the current lamp for the incandescent bulb 40W alternative 8W product type is also referred to as “current lamp”. In order to distinguish between the lamp in this embodiment and the lamps 1, 201, and 301 in the above embodiment, the reference numerals of the components in the present embodiment are set in the 400s, for example, the reference numerals of the lamps are set to 401. Although used, they are not shown.
The lamp shape dimensions of the incandescent bulb 40W as an alternative target in the present embodiment are a lamp diameter φ of 55 mm, a lamp length L of 98 mm, and a luminous flux of 485 lm. The 40 W incandescent bulb is widely used as a main product in the market together with the 60 W and 100 W incandescent bulbs. In addition, the shape of the bulb-type fluorescent lamp with an outer bulb in the 8W type that replaces the current incandescent bulb 40W has a lamp diameter φ of about 60 mm and a lamp length L of about 122 mm. The lamp performance is that the luminous flux is 500 lm and the lamp efficiency is 62.5 lm / W.
1. Configuration The basic configuration of the lamp 401 in the present embodiment is the same as that in the first to third embodiments described above. The difference in configuration is that the luminous flux corresponds to 500 lm, so that the lamp input is reduced to 7 W. At the same time, the interelectrode distance Le of the arc tube 402 is also shortened. Also in the present embodiment, the tube inner diameter φi of the glass tube 409 is defined in a range of 5.0 mm or more and 9.0 mm or less for the same reason as in the first embodiment.

  Here, a specific configuration in the present embodiment will be described. The arc tube 402 has a glass tube 409 with a tube inner diameter φi of 7.4 mm, a tube outer diameter φo of 9.0 mm, and an interelectrode distance Le of 250 mm. The glass tube 409 is formed in a spiral shape of approximately 3.5 turns, and the arc tube 409 has a diameter φh of 36 mm and a length Lh of 52 mm. On the other hand, the outer tube valve 406 has an outer diameter φ of 55 mm and a length Lb of 46 mm (see FIGS. 1 and 2).

  The overall size of the lamp 401 is such that the lamp diameter φ is 55 mm and the lamp length L is 98 mm, which is significantly smaller than the current lamp (lamp diameter φ60 mm, lamp length L122 mm). A size equivalent to a 40 W shape (lamp diameter φ55 mm, lamp length L98 mm) is achieved. Next, the performance of the lamp 401 having the above configuration will be described.

First, when the lamp input is turned on with a lamp input of 7W, the luminous flux rise characteristic at the time of starting the lamp is improved to the same level as that of a conventional general fluorescent lamp, the luminous flux is 510lm, and the lamp efficiency is 72.9lm / W. The target lamp efficiency was obtained. At the same time, it was confirmed that the lamp life was 6000 hours or more.
2. Contents of study In the present embodiment, the aim was to first reduce the lamp size to a shape substantially equivalent to the incandescent bulb 40W. Further, the targets of the lamp efficiency and the lifetime are set to 70 lm / W or more and 6000 hours or more, respectively, similarly to the lamps 1, 201, and 301 described in the first to third embodiments.

  As in the first to third embodiments, the inner diameter φi of the glass tube 409 and the interelectrode distance Le of the arc tube 402 that can satisfy all of the above-mentioned target lamp size reduction, lamp efficiency improvement and lamp life guarantee. In order to specify, the prototype of the lamp 401 and its measurement were performed. The examination result is shown in FIG. Here, if the relationship between the tube inner diameter φi of the arc tube 402 and the interelectrode distance Le is within the oblique line shown in FIG. 10, the lamp 401 that achieves the above target can be obtained.

Hereinafter, FIG. 10 will be described.
1) Regarding lamp miniaturization A line 41 in FIG. 10 is a line connecting the maximum interelectrode distance Le at each tube diameter φi so that the shape of the lamp 401 is substantially the same as that of the incandescent bulb 40W. Specifically, the interelectrode distance Le at each tube diameter φi is obtained from the maximum length of the arc tube 402 that can be accommodated in the outer tube bulb 406 having an outer diameter φ of approximately 55 mm and a length Lb of approximately 46 mm.

2) Lamp life The line 42 in FIG. 10 is a line connecting the interelectrode distance Le at which the lamp life is 6000 hours or more. This is calculated as the interelectrode distance Le corresponding to 0.16 W / cm ² of the tube wall load we of the arc tube 402, as in the first to third embodiments.
3) Lamp efficiency A line 43 in FIG. 10 is a line connecting the interelectrode distance Le at which the lamp efficiency becomes 70 lm / W, and this is obtained by experiments.
(Fifth embodiment)
In the above first to fourth embodiments, the arc tube 2, 202, 302, 402 made of a double spiral glass tube is applied, but the other three U-shaped and four U-shaped arc tubes are used. The lamp used was also examined. In addition, in order to distinguish the lamp in this embodiment from the lamps 1, 201, 301, and 401 in the above embodiment, the reference numerals of the respective components in this embodiment are set to the 500s, for example, the lamp numbers. Use it like 501.

  As a result, the basic configuration of the lamp 501 using the three U-shaped and four U-shaped arc tubes is similar to the lamps 1, 201, 301, 401 using the double spiral arc tube described above. 502 encloses mercury in a substantially single form, and defines the inner diameter φi of the arc tube 502 within a range of 5.0 mm to 9.0 mm, and (b) at least one of the three or four U-shaped glasses. The coldest spot 516 of the tube 509 and the part of the outer tube valve 506 facing the coldest spot 516 are thermally coupled by a thermally conductive medium such as silicon resin 515, and this coupled U-shape By cooling the coldest spot formed in a part of the glass tube, the start-up characteristics at the start of the lamp can be basically improved to the same level as that of a general phosphor. Lamp 1 with tubes 2, 202, 01 substantially equal to the luminous efficiency was found to be achieved.

  FIG. 11 is a diagram showing an overall configuration of a lamp 501 that is for an 11W product type that is an alternative to the incandescent bulb 60W according to the fifth embodiment and includes, for example, four U-shaped arc tubes 502, and FIG. (B) is a cross-sectional plan view taken along line XX of (a). Note that the XX line in (a) indicates that the lamp 501 according to the present embodiment, which has the largest outer diameter in the outer bulb 506, is characterized by three or four U-shaped glass tubes 509 passing through a series of discharge paths. In other words, it is constituted by a so-called bridge-joined arc tube 502. In FIG. 11, the U-shaped curved portion in which the coldest spot 516 is formed by the four U-shaped glass tubes 509 and the lower end portion of the outer tube valve 506 facing the U-shaped curved portion 516 are the thermal conductivity of the silicon resin 515. It is thermally coupled by the medium. The other lamp 501 has a configuration similar to that of the lamp 1 using the double spiral arc tube 2.

Here, in particular, the tube inner diameter φi and the interelectrode distance Le of the arc tube 502 are set within the hatched range in FIG. 6, so that, similarly to the case of using the double spiral arc tube 2, the lamp A lamp exhibiting an efficiency of 70 lm / W and a lamp life of 6000 hrs can be realized. A specific configuration of the lamp in the present embodiment will be described.
The arc tube 502 is composed of four U-shaped glass tubes 509. The tube inner diameter φi is set to 7.4 mm, the tube outer diameter φo is set to 9.0 mm, and the electrode tube distance Le is set to 340 mm. Further, the width b of the U-shaped glass tube 509 is 20 mm (see FIG. 11B). Further, the outer diameter φh of the outer appearance of the arc tube 502 is 46 mm, and the length Lh is 60 mm. The outer tube valve 506 has an outer diameter φ of 60 mm and a length Lb of 58 mm. Then, as the overall size of the final lamp 501, the lamp diameter φ is 60 mm and the lamp length L is 110 mm, which is substantially equivalent to the incandescent lamp 60W.

  In addition, you may comprise the arc tube 502 with the three U-shaped glass tube 509 instead of the four U-shaped. However, in this case, the length Lh of the arc tube 502 is increased from 60 mm to 73 mm, and thus the lamp length L is inevitably increased from 110 mm to 123 mm. When the lamp 501 is lit on the base with a lamp input of 11 W, the luminous flux rise characteristic at the start of the lamp is improved to a level substantially equal to that of a general fluorescent lamp, and the luminous flux is 780 lm and the lamp efficiency is 70.9 lm / W. Characteristics were obtained. In addition, it was confirmed that the lamp life was 6000 hrs or more.

  It should be noted that the lamp 501a for 21W type with a luminous flux of 1500 lm class instead of the incandescent lamp 100W (in order to distinguish it from the incandescent lamp 60W alternative, the reference numeral in which a is added to the lamp 501 is used) is similar to FIG. Equipped with four U-shaped arc tubes 502a having a basic configuration, and by setting the inner diameter φi of the arc tube 502a and the inter-electrode distance Le within the hatched area in FIG. 8, the double spiral arc tube 502a is formed. The lamp 501a exhibiting the same improvement in the luminous flux rise characteristic as that used and the lamp efficiency of 70 lm / W or more could be realized.

  However, as long as the four U-shaped arc tubes 502a are used, it is not broken that the overall shape of the lamp 501a is larger than when the double spiral arc tube 202 is used. For example, when the tube inner diameter φi of the arc tube 502a is set to 7.4 mm, the tube outer diameter φo is set to 9.0 mm, and the inter-electrode distance Le is set to 640 mm, the outer diameter φh of the outer tube of the arc tube 502a is 46 mm and length. Lh became 95 mm, and the outer tube valve 506 a at this time had an outer diameter φb of 65 mm and a length Lb of 90 mm.

The overall shape of the final lamp 506a was as large as 65 mm in lamp diameter φ and 140 mm in lamp length L. Here, in order to shorten the increased lamp length L to 128 mm, which is the same as the lamp 201 using the double helical arc tube 102, for example, five U-shaped arc tubes may be used.
(Sixth embodiment)
In each of the above embodiments, the target of the lamp efficiency is set to 70 lm / W or more. However, the present inventor has studied a technique for further improving the lamp efficiency without changing the size of the lamp. In order to distinguish between the lamp in the present embodiment and the lamp 1 in the first embodiment, the number 600 is used for the reference numerals of each component in the present embodiment, for example, the reference numeral 601 is used.

FIG. 12 is a diagram illustrating an overall configuration of an 11W product type lamp that replaces the incandescent lamp 60W according to the sixth embodiment. The basic configuration of the lamp 601 in the present embodiment is the same as that of the first embodiment, and the configuration is different in the first embodiment in that the cross section of the glass tube 9 forming the arc tube 2 is different. In contrast to the circular shape, in the present embodiment, the cross section of the glass tube 609 is elliptical.
1. Configuration and Characteristics of Lamp a) Type in which distance between electrodes is 340 mm A specific configuration in this embodiment will be described. The inner peripheral surface of the glass tube 609 forming the arc tube 602 has a tube short inner diameter D1 of 5.4 mm, a tube long inner diameter D2 of 7.4 mm, and the outer peripheral surface has a tube short outer diameter of 7.0 mm, which is outside the tube length. It has an elliptical shape with a diameter of 9.0 mm. The interelectrode distance Le in the arc tube 602 is 340 + β mm.

The above β changes at the position of the glass tube 609 that revolves around the revolving axis A. For example, if the position of the outermost periphery of the elliptical glass tube and the circular glass tube 9 are the same, β is the maximum (about 30 mm), and conversely the elliptical glass tube If the position of the innermost circumference with the circular glass tube is the same, β is minimum (approximately 0 mm).
D2 is 7.4 mm, which is equal to the tube inner diameter φi in the first and second embodiments. Similarly to the first embodiment, the arc tube 602 is formed in a spiral shape of approximately five turns, and has a diameter φh of 36 mm and a length Lh of 64 mm. The outer tube bulb 606 has an outer diameter φ of 55 mm and a length Lb of 58 mm, and the arc tube 602 is accommodated therein.

  The lamp 601 as a whole has a lamp diameter φ of 55 mm and a lamp length L of 110 mm, which is slightly smaller than the incandescent bulb 60W type (lamp diameter φ = 60 mm, lamp length L = 110 mm). It has become. On the other hand, the coldest spot 616 formed at the lower end portion of the arc tube 602 and the lower end portion of the inner periphery of the outer tube bulb 606 are connected via a transparent silicone resin 615. The distance d between the lower end portion of the arc tube 602 and the lower end portion of the inner circumference of the outer tube bulb 606 is 2 mm, and the lower end portion of the arc tube 602 is buried by silicon resin 615 by about 2 mm.

Next, the performance of the lamp 601 having the above configuration will be described. First, when the lamp is turned on with the lamp input 11W, the luminous flux rising characteristic at the time of starting the lamp shows the same characteristic as that of the conventional general fluorescent lamp, and the luminous flux 820lm is obtained at the lamp current of about 70mA, and the target 70lm / W is obtained. A lamp efficiency of 74.6 lm / W, greatly exceeding the above, was obtained.
This lamp efficiency is improved by about 4% with respect to the lamp efficiency of the lamp 1 in the first embodiment. In this way, by making the cross-sectional shape of the arc tube 602 elliptical, it is possible to improve the lamp efficiency even though the arc tube 2 has the same length as that of the first embodiment. This is because, in the arc tube 2 having the same surface area on the inner peripheral surface as the arc tube input per unit length, the optical path is shortened in the elliptical section compared to the circular section, so that the temperature at which the maximum luminous flux is emitted is much higher. To the side. As a result, a decrease in lamp efficiency caused by an increase in mercury vapor pressure in the arc tube 602 when mounted in the outer bulb 606 can be further suppressed, and the lamp efficiency is further improved accordingly. That is, in the bulb-type lamp 601, it can be said that it is advantageous to improve the lamp efficiency to use the arc tube 602 basically having an elliptical cross section.

  b) Type with a distance between electrodes of 365 mm A specific configuration in this embodiment will be described. The inner peripheral surface of the glass tube 609 forming the arc tube 602 has a tube short inner diameter D1 of 5.4 mm, a tube long inner diameter D2 of 7.4 mm, and the outer peripheral surface has a tube short outer diameter of 7.0 mm, which is outside the tube length. It has an elliptical shape with a diameter of 9.0 mm. The interelectrode distance Le in the arc tube 602 is approximately 365 mm. As in the first embodiment, the arc tube 602 is formed in a spiral shape of approximately 5 turns, and has a diameter φh of 36 mm and a length Lh of 64 mm.

  The lamp 601 as a whole has a lamp diameter φ of 55 mm and a lamp length L of 100 mm, which is smaller than the incandescent bulb 60W type (lamp diameter φ = 60 mm, lamp length L = 110 mm). Next, the performance of the lamp having the above configuration will be described. First, when the lamp is turned on with a lamp input of 11 W, the rise characteristic of the light beam at the time of starting the lamp shows the same characteristic as that of a conventional general fluorescent lamp, and a light beam of 810 lm is obtained at a lamp current of about 65 mA, resulting in 74.6 lm / W. The lamp efficiency was obtained.

  On the other hand, in the first embodiment, the cross-sectional shape of the glass tube 9 constituting the arc tube 2 is a circular shape having an inner diameter of 7.4 mm and an outer diameter of 9.0 mm, and the distance between the electrodes is 340 mm. As a result of lighting a certain lamp 1 on the base with a lamp current of 75 mA, the luminous flux was 790 lm and the lamp efficiency was 71.9 lm / W. By making the cross-sectional shape of the glass tube 609 elliptical as described above, the input current can be reduced by about 10 mA and the luminous flux can be reduced from a circular shape having the same inner diameter as the elliptical tube length. It was found that the lamp efficiency could be increased by 20 lm and the lamp efficiency could be increased by 2.7 lm / W.

  2. Manufacturing method of arc tube The manufacturing method of the arc tube 2 whose cross section of the glass tube 609 is elliptical is demonstrated. The arc tube 602 having an elliptical cross section in the present embodiment is manufactured using a straight tube-shaped glass tube 630 (not shown) having a circular cross section, similarly to the arc tube 2 having a circular cross section in each of the above embodiments. The That is, in the manufacturing process of the arc tube 602, the entire glass tube 630 is softened in a heating furnace, and the softened glass tube 630 is spirally wound around the forming jig 620 and processed.

  The difference from the fabrication of the circular cross-section arc tube 2 described in the first embodiment is that the control pressure of a gas such as nitrogen blown into the glass tube 631 during the molding process is different, and the glass tube 631 has an elliptical cross section. As shown in FIG. 13, the cross-sectional shape of the groove 625 of the synthetic jig 620 is an elliptical arc. The shape that matches the cross-sectional shape of the groove portion 625 is substantially parallel to the axial direction of the forming jig 620, specifically, an elliptical shape having a major axis in a direction inclined by a helical angle with respect to the axial direction.

Therefore, the softened glass tube 631 is pressed against the forming jig 620 by the gas blown during the forming process, and the arc tube 602 having an elliptical cross section can be easily obtained. Here, the both ends of the glass tube 631 after molding leave a circular cross section of the glass tube 630 before molding. For this reason, even if the tube short inner diameter D1 is 5.0 mm or less, the tube long inner diameter D2 at the end is 5.0 mm or more, so that the electrode can be installed.
3. Contents of study The present inventor, in order to more widely use a light bulb-type fluorescent lamp as an energy-saving light source that replaces an incandescent light bulb, regardless of the bulb type and the bulb-less type, Regardless of whether it is sealed in a single form or not, a method for further improving the lamp efficiency was studied.

  1) Elliptical shape The inventor first studied to reduce the inner diameter of the glass tube 9 in order to increase the maximum light emission temperature. In the first embodiment, when the tube inner diameter φi is smaller than 5 mm, there is a problem that the electrodes 7 and 8 cannot be installed in the glass tube 9. However, if the cross section of the glass tube is elliptical, specifically, if the elliptical long tube inner diameter D2 is 5 mm or more, the electrode can be inserted using the long tube inner diameter D2 even if the short tube inner diameter D1 is 5 mm or less. Thought.

Further, the inner circumference of the cross section of the glass tube 609 is elliptical, and in particular, the direction B of the tube short inner diameter D1 is inclined at a spiral angle α with respect to the horizontal direction (the direction perpendicular to the turning axis A of the glass tube 9). When the shape substantially coincides with (see FIG. 14), the shortest distance between the electrodes (distance between the electrodes) can be increased with respect to the circular shape having the same tube inner diameter as the elliptical tube length inner diameter D2.
Here, it will be described with reference to FIG. 14 that the distance between the electrodes increases when the cross section of the glass tube 9 is elliptical. First, FIG. 14 shows a diagram in which a predetermined position of the glass tube 9 and a position that is turned around a half circumference from this position are cut. In the cross section of the glass tube 609, an elliptical shape in which the tube short inner diameter D1 coincides with the direction B is indicated by a solid line, and a circle having a tube inner diameter having the same length as the tube long inner diameter D2 of this ellipse is represented by an imaginary line (first embodiment). This corresponds to the arc tube 2 in the embodiment.) In addition, both glass tubes 9 and 609 have shown the case where each center corresponds.

  Since the distance between the electrodes in the arc tubes 2 and 602 is generally obtained as the shortest distance connecting the electrodes in the arc tubes 2 and 602, the spiral trajectory having the shortest distance when the inner circumference of the cross section is elliptical. Is a circumference having a diameter L1, and a spiral orbit having the shortest distance when the inner circumference is circular has a circumference having a diameter L2. Thus, when comparing a circular shape and an elliptical shape having the same diameter and major axis, the distance between the electrodes is longer in the elliptical shape than in the circular shape. Moreover, since the arc tubes 2 and 602 are formed by rotating the glass tubes 9 and 609 a plurality of times around the rotation axis A, the difference in the distance between the electrodes is particularly large in the entire length of the arc tubes 2 and 602. Therefore, it was thought that the lamp efficiency could be improved.

  Further, the outer peripheral surface located on the outer side (opposite side of the turning axis A) in the elliptical arc tube 602 is located closer to the turning axis A than the outer peripheral surface of the outer side (opposite side of the turning axis A) in the circular shape, It was considered that the outer diameter of the overall shape of the arc tube 602 can be made smaller than that of the arc tube 2. As described above, by making the shape of the cross section of the glass tube 609 into an elliptical shape in which the direction of the tube short inner diameter D1 coincides with the direction B, the glass tube 609 emits from mercury atoms as compared with a circular shape having the same diameter as the major axis. It was thought that the lamp efficiency was improved because the optical path from the ultraviolet radiation to the tube wall as a whole could be shortened and the distance between the electrodes could be increased.

  Therefore, the inventor measured the lamp efficiency by changing the ratio of the tube short inner diameter D1 and the tube long inner diameter D2 to the elliptical cross section of the glass tube 609. The results are shown in FIG. 15 as the relationship between the ratio of the tube short inner diameter D1 / tube long inner diameter D2 (hereinafter referred to as “ratio D1 / D2”) and the lamp efficiency improvement ratio. From this result, it was found that as the ratio D1 / D2 decreases, the improvement rate of the lamp efficiency increases.

  The glass tube 609 used in the above test has a constant electrode distance of 400 mm, a tube long inner diameter D2 of 8.0 mm, and a tube short inner diameter of 7.4 mm, 6.7 mm, 6.1 mm, 5.3 mm, 4 mm, 4 mm Six types of 0.5 mm and 3.6 mm were used. The lighting conditions were lighting on the base and the lamp current was 90 mA. In particular, the cross-sectional shape of the glass tube 609 is elliptical, and the direction of the tube short inner diameter D1 is made to substantially coincide with the direction B, and the ratio (D1 / D2) between the tube short inner diameter D1 and the tube long inner diameter D2 is It has been found that when the value is 0.85 or less, the lamp efficiency is improved by 2% or more as compared with a circular shape whose cross section has a tube inner diameter D2. If the lamp efficiency is improved by 2%, the consumer can also see the difference in the luminous flux, and the product can be characterized.

  2) The setting of the specific configuration of the arc tube 602 having the above elliptical cross section with respect to the dimensions of the arc tube and the distance between the electrodes will be described. First, the dimension of the inner periphery of the glass tube 609 forming the arc tube 602 is preferably such that the value of the tube length inner diameter D2 is 5 mm or more and 9 mm or less. This is the same as the reason why the tube inner diameter φi of the glass tube 9 in the first embodiment is set to 5 mm or more and 9 mm or less. The value of the tube short inner diameter D1 is preferably 3 mm or more and less than the tube long inner diameter D2. This is because when the tube short inner diameter D1 is smaller than 3 mm, setting of the electrodes becomes difficult, and the reason why it is less than D2 is to make the inner periphery of the cross section of the glass tube 609 into a substantially elliptical shape. The electrode has a flat shape as shown in FIG. 2, and a space for storing the electrode needs about 5 mm × 3 mm in plan view.

  Next, a method for setting the dimensions of the arc tube and the distance between the electrodes will be described. First, the inner diameter of the straight tubular glass tube 630 used for the spiral arc tube 602 is determined. The electrode tube distance Le of the arc tube 602 may be set using the range defined in FIG. 6 for the arc tube 2 having a circular cross section in the first embodiment. That is, the inter-electrode distance Le may be determined using the value calculated as the tube inner diameter φi of the arc tube 2 as the tube minor inner diameter D1 of the arc tube 602 displayed in FIG.

  FIG. 6 does not show the range of the interelectrode distance Le when the tube inner diameter φi is 5 mm or less. However, the upper limit of the interelectrode distance Le when the tube inner diameter φi is 3 mm or more and less than 5 mm is the tube inner diameter φi. When the interelectrode distance Le is indicated by orthogonal coordinates (φi, Le), it is equal to or less than the line segment connecting (3.0, 1160) and (5.0, 690), and the lower limit of the interelectrode distance Le is a line. As long as it is equal to or larger than the line segment obtained by extending 2 until the tube inner diameter φi becomes 3.0 mm. That is, (φi, Le) is represented by point (3.0, 445), point (7.4, 275), point (9.0, 290), point (9.0, 360) and point (3.0 1160) may be defined within a range surrounded by the points.

  4). Regarding the end portion of the glass tube In each of the above-described embodiments, both end portions of the glass tube, that is, the end portion on the case side of the arc tube are in a direction substantially parallel to the rotation axis A of the spiral arc tube (the main surface of the holder). However, the both ends of the glass tube may be inclined so as to approach the pivot axis as they approach the holder. Thus, by making it inclined, the dimension of the turning axis direction of the arc tube can be made smaller than that of the arc tube 2 in the above embodiment.

5. In addition, the lamp 601 in the sixth embodiment described above is an 11W product arc tube as an alternative to the incandescent bulb 60W, and an example in which the cross section is elliptical is shown. Is applicable.
a) 21W type for incandescent bulb 100W replacement (added with a to the reference symbol) In this case as well, when setting the dimensions of the arc tube 602a, use FIG. 8 according to the above method And set it. That is, the short electrode inner diameter D1 of the glass tube 609a forming the arc tube 602a is defined, and the interelectrode distance Le may be determined from the value of D1. Note that FIG. 8 does not show the range of the interelectrode distance Le when the tube inner diameter φi is 5 mm or less. However, the upper limit of the interelectrode distance Le when the tube inner diameter φi is 3 mm or more and less than 5 mm is the tube inner diameter φi. When the interelectrode distance Le is indicated by orthogonal coordinates (φi, Le), it is equal to or less than the line segment obtained by extending the line 21 until the tube inner diameter φi becomes 3.0 mm. The lower limit of the interelectrode distance Le is the line 22 It may be longer than the line segment extended until the tube inner diameter φi becomes 3.0 mm. That is, (φi, Le) is represented by point (3.0, 840), point (7.4, 530), point (9.0, 560), point (9.0, 620) and point (3.0 , 1085) may be defined within the range surrounded by the points.

  b) Incandescent bulb 100 alternative high luminous flux type 23W type (b is added to the reference symbol) In this case also, when setting the dimensions of the arc tube 602b, the same method described above is used. Then, the setting may be made using FIG. That is, the short electrode inner diameter D1 of the glass tube 609b forming the arc tube 602b may be defined, and the interelectrode distance Le may be determined from the value of D1. Note that FIG. 9 does not show the range of the interelectrode distance Le when the tube inner diameter φi is 5 mm or less, but the upper limit of the interelectrode distance Le when the tube inner diameter φi is 3 mm or more and less than 5 mm is the tube inner diameter φi. When the interelectrode distance Le is indicated by orthogonal coordinates (φi, Le), it is equal to or less than the line segment obtained by extending the line 31 until the tube inner diameter φi becomes 3.0 mm, and the lower limit of the interelectrode distance Le is It may be longer than the line segment extended until the tube inner diameter φi becomes 3.0 mm. That is, (φi, Le) is represented by point (3.0, 975), point (7.4, 570), point (9.0, 600), point (9.0, 670) and point (3.0 , 1165) may be defined within a range surrounded by the points.

c) 7W type for incandescent bulb 40W replacement (added by adding c to the reference) In this case, when setting the dimensions of the arc tube 602c, the same method as described above is used. Setting may be performed using FIG. That is, the short electrode inner diameter D1 of the glass tube 609c forming the arc tube 602c may be defined, and the interelectrode distance Le may be determined from the value of D1. Note that FIG. 10 does not show the range of the interelectrode distance Le when the tube inner diameter φi is 5 mm or less, but the upper limit of the interelectrode distance Le when the tube inner diameter φi is 3 mm or more and less than 5 mm is the tube inner diameter φi. When the interelectrode distance Le is indicated by orthogonal coordinates (φi, Le), it is equal to or less than the line segment obtained by extending the line 41 until the tube inner diameter φi becomes 3.0 mm. The lower limit of the interelectrode distance Le is: It may be longer than the line segment extended until the tube inner diameter φi becomes 3.0 mm. That is, (φi, Le) is represented by point (3.0, 330), point (7.4, 200), point (9.0, 230), point (9.0, 320), and point (3.0 725) may be defined within the range surrounded by the points.
(Modifications) Although the present invention has been described based on the embodiments, it is needless to say that the contents of the present invention are not limited to the specific examples shown in the above embodiments. Various modifications can be implemented.
1. Regarding the external shape of the arc tube In the first to fifth and sixth embodiments, the arc tube is a spiral shape in which a glass tube is wound in a circumferential shape, that is, the shape when the arc tube is viewed in plan is circular. However, for example, the glass tube may be wound in an elliptical shape so that the shape of the arc tube in plan view is substantially elliptical. However, in order to do this, it is necessary to devise such as making the forming jig a split mold. Furthermore, the spiral shape of the arc tube is such that the pivot axis is the same as the central axis (vertical direction) of the base, but it may be, for example, a direction orthogonal to the central axis of the base.
2. Regarding the tube shape of the arc tube In the sixth embodiment, the inner peripheral surface of the cross section of the glass tube is non-circular, and in particular, the first diameter in the direction substantially perpendicular to the pivot axis on which the glass tube revolves. As an example of the shape that is smaller than the second diameter in the direction substantially parallel to the pivot axis, an elliptical shape is illustrated, but the first diameter is smaller than the second diameter, and the second diameter and the first diameter are Other shapes may be used as long as the ratio to the diameter is 0.85 or less.

  For example, in the cross section of the glass tube 909 as shown in FIG. 16 (a), the turning axis side of the arc tube 902 (hereinafter referred to as “the inside of the arc tube”) with respect to the line segment having the long diameter D2. The inner circumference located on the right side in FIG. 16 has an elliptical shape with a short diameter twice as large as D11, and is called the “outside of the arc tube” on the side opposite to the pivot axis of the arc tube 902 (hereinafter referred to as “the outside of the arc tube”). The inner circumference located on the left side in FIG. 16 has an elliptical shape with a minor axis twice as large as D12, that is, on both the inside and outside of the arc tube 902 with respect to the line segment having the major axis. The shape may be different. Furthermore, the inner circumference outside the arc tube 902 may be configured in a semicircular shape with a diameter D2 with respect to a line segment having a major axis D2 in the cross section of the glass tube 909.

  Even in such a case, the short diameter D1 (D1 = D11 + D12) is smaller than the long diameter D2, and the ultraviolet radiation emitted from the mercury atoms is less than the circular shape in which the cross section of the glass tube 909 has the inner diameter D2. The optical path to the wall is shortened, and the optimum mercury vapor pressure in the arc tube 902 having a cross section can be increased. In particular, in the shape where D11 is smaller than D12, the inner circumference inside the arc tube 902 is away from the turning axis of the arc tube 902 compared to an elliptical shape whose minor axis is twice that of D12. can do.

  Even in the case of such a shape, the cross-sectional shape of the groove portion 925 as shown in FIG. The cross section can be easily formed into the shape as described above. Further, in the cross section of the glass tube 909 as shown in FIG. 16B, the inner circumference located inside the arc tube 902 is triangular toward the inside of the arc tube 902 with respect to the line segment having the long diameter D2. It may be a shape that protrudes into the shape. Furthermore, the inner circumference outside the arc tube 902 may be configured in a semicircular shape with a diameter D2 with respect to the line segment with the long diameter D2.

  Even in such a shape, the cross-sectional shape of the glass tube 931 can be reduced by forming the cross-sectional shape of the groove 925 into a triangular shape as shown in FIG. The portion can be easily formed into a triangular shape as described above. 16 (a) and 16 (b), the inner circumference located outside the arc tube 909 is elliptical in the cross section of the glass tube 909 with respect to the line segment having the major axis D2. Such a shape is included in the elliptical shape in the present invention.

  Conversely, in the cross section of the glass tube 909 as shown in FIG. 16C, the inner circumference located inside the arc tube 902 is recessed outside the arc tube 902 with respect to the line segment having the long diameter D2. The shape of the letter “ku” is also acceptable. Furthermore, the inner circumference outside the arc tube 902 may be configured in a semicircular shape with a diameter D2 with respect to a line segment having a major axis D2. Here, a specific configuration of a lamp including the arc tube 902 having a cross-sectional shape of the glass tube 909 having a “<” shape and a lamp performance thereof will be described. In this arc tube 902, the cross-sectional shape of the glass tube 909 is a "<" shape, the short inner diameter D1 of the tube is 4.0 mm, the outer diameter D2 of the tube is 7.4 mm, and the distance between the electrodes is 380 mm. It has become. As in the sixth embodiment, the arc tube 902 is formed in a spiral shape with five turns, and has a diameter φh of 36 mm and a length Lh of 60 mm.

  As a whole, the lamp has a lamp diameter φ of 55 mm and a lamp length L of 100 mm, which is smaller than the incandescent bulb 60W type (lamp diameter φ = 60 mm, lamp length L = 110 mm). Next, the performance of the lamp having the above configuration will be described. First, when the lamp is turned on with the lamp input 11W, the luminous flux rising characteristic at the time of starting the lamp shows the same characteristic as that of the conventional general fluorescent lamp, and a luminous flux of 830 lm is obtained at a lamp current of about 71 mA, resulting in 75.5 lm / W. High lamp efficiency was obtained.

  This lamp efficiency is the same as that in the sixth embodiment described above. This is a 2.6% improvement over the lamp described in b) using a glass tube with an elliptical cross section. It has been confirmed that this lamp also has a lamp life of 6000 hours or more, like the lamps in the above embodiments. Even in the case of such a shape, the cross section of the glass tube 931 can be obtained by making the cross-sectional shape of the groove 925 as shown in FIG. It can be easily formed into a "<" shape.

Although the direction of the 1st diameter D1 in the cross section of each glass tube 609,909 shown in 6th Embodiment and FIG. 16 corresponds with the direction inclined by the turning angle with respect to the horizontal direction, this invention Then, such a case is also included in a direction substantially orthogonal to the turning axis. Moreover, in said embodiment and modification, although the inner periphery and outer periphery shape of glass tube 609,909 are made substantially the same, for example, the inner periphery shape is elliptical shape and the outer periphery shape is circular shape. Thus, the inner and outer peripheral shapes do not have to be the same.
3. About the enclosed form of mercury In each of the above embodiments, mercury is basically enclosed in the arc tube in a single form instead of the main amalgam, but in this case, a small auxiliary amalgam according to the prior art in the vicinity of the electrode, For example, a stainless steel mesh plated with indium In may be attached. That is, in the case of a small auxiliary amalgam, only a part of the enclosed mercury is adsorbed by this, and since sufficient mercury exists as a single substance in the arc tube, the rise characteristic of the light beam does not deteriorate.

  In each of the above embodiments, mercury is enclosed in the arc tube in the form of a simple substance. However, if the lamp efficiency is within a range that does not deteriorate so much as compared with the case where the mercury is enclosed in a single form, mercury is used. The main amalgam may be used with a slight addition. Here, the main amalgam is a main amalgam mainly composed of In and Pb, specifically BiIn, BiPbSn, InPb, BiIn, InPbSn, and the like.

Furthermore, although mercury is enclosed in a simple substance form, for example, it may take an amalgam form as long as it has characteristics substantially equivalent to mercury vapor pressure characteristics of mercury alone. As such, there is an amalgam form not containing In, Pb as a main component, specifically, ZnHg, FeHg, BiHg, BiSnHg, SnHg, etc., one of these may be used, Alternatively, a plurality of these may be used. Also in this case, other amalgams such as BiIn, BiPbSn, InPb, BiIn, InPbSn may be used as long as the lamp efficiency is within a range that does not deteriorate so much as compared with the case where mercury is sealed in a single form. .
4). Regarding the heat conductive medium In each of the above embodiments, the lower end of the arc tube and the lower end of the inner wall of the outer bulb are joined by silicon resin. I just need to be able to tell the side. That is, it is only necessary to be thermally coupled. For example, the silicon resin and the lower end of the arc tube need only be in contact with each other, and when the lamp is extinguished, the silicon resin and the arc tube are not in contact with each other. It may be expanded so as to be in close contact with the arc tube. However, when the silicone resin and the arc tube or the silicone resin and the outer bulb are not combined, the rate of temperature decrease of the arc tube is smaller than that of the combined one, but the temperature of the arc tube is decreased. This effect can be obtained to some extent.

  Also, in order to efficiently transfer the heat of the arc tube to the outer bulb, it is only necessary to increase the amount of heat transferred from the arc tube to the heat conductive medium, and the expansion part that increases the coupling area between the arc tube and the heat conductive medium May be provided in the arc tube. Specifically, as shown in FIG. 18, the extended portion includes a convex portion 18 in which a part of the lower end portion of the arc tube is bulged in a convex shape toward the outer tube bulb side, or an arc tube as shown in FIG. The large diameter part 19 etc. with which the diameter of the glass tube located in the lower end part of this is thick is comprised. 18 and 19 show an example in which the convex portion 18 and the large-diameter portion 19 are applied to the lamp 1 in the first embodiment.

  It has been confirmed that by providing these extended portions, the coldest spot temperature T of the arc tube is further reduced by 1 to 2 ° C., and the lamp efficiency is further improved accordingly. This extended part can be easily formed by heating and softening the corresponding part of the glass tube and injecting a pressure-controlled gas into the glass tube.

  The method for manufacturing a bulb-type fluorescent lamp and arc tube according to the present invention can be used to improve the lamp efficiency over the current product.

It is a front view which shows the whole structure which notched a part of the bulb-type fluorescent lamp in the 1st Embodiment of this invention. (A) is a front view which shows the structure which notched a part of arc tube in the 1st Embodiment of this invention, (b) is a bottom view of an arc tube. It is a front view for demonstrating the process of winding a glass tube around a shaping | molding jig in order to shape | mold the arc tube which shows the 1st Embodiment of this invention. It is a top view for demonstrating the process of winding a glass tube around a forming jig in order to shape | mold the arc tube which shows the 1st Embodiment of this invention. It is a figure which shows the relationship between the temperature which an arc tube emits the largest light beam, and a tube internal diameter. It is a figure which shows the relationship between the tube internal diameter of an arc_tube | light_emitting_tube, and the distance between electrodes of an arc_tube | light_emitting_tube as an incandescent lamp 60W substitute. It is a front view of the arc tube which shows the 2nd Embodiment of this invention. It is a figure which shows the relationship between the pipe | tube internal diameter of an arc_tube | light_emitting_tube, and the distance between electrodes of an arc_tube | light_emitting_tube as an incandescent lamp 100W substitute. It is a figure which shows the relationship between the internal diameter of an arc_tube | light_emitting_tube, and the distance between electrodes of an arc_tube | light_emitting_tube as a high luminous flux type 23W type | mold for incandescent lamp 100W substitution. It is a figure which shows the relationship between the tube internal diameter of an arc_tube | light_emitting_tube, and the distance between electrodes of an arc_tube | light_emitting_tube as an incandescent lamp 40W substitute. It is a front view which shows the whole structure which notched a part of bulb-type fluorescent lamp in the 5th Embodiment of this invention. It is a front view which shows the whole structure which notched a part of bulb-type fluorescent lamp in the 6th Embodiment of this invention. It is a longitudinal cross-sectional view which shows the state which wound the glass tube around the shaping | molding jig in order to shape | mold the arc tube in the 6th Embodiment of this invention. It is a figure for demonstrating the difference in the distance between electrodes in the cross-sectional shape of a glass tube in elliptical shape and circular shape. It is a figure which shows the relationship between the ratio of a tube short inner diameter and a tube long inner diameter, and the improvement rate of a lamp efficiency in a glass tube whose cross-sectional shape is elliptical. It is a figure which shows the modification of the shape of the cross section of the glass tube which forms an arc tube. It is a longitudinal cross-sectional view which shows the state which wound the glass tube around the shaping | molding jig in order to shape | mold the arc tube of a modification. It is a figure which shows the example which provided the expansion part in the edge part on the opposite side to the electrode side of an arc_tube | light_emitting_tube. It is a figure which shows the example which provided the expansion part in the edge part on the opposite side to the electrode side of an arc_tube | light_emitting_tube.

Explanation of symbols

1,501,601 Lamp 2,202,502,602,902 Arc tube 4 Case 5 Cap 6,506,606 Outer bulb 7,8 Electrode 9,209,509,609 Glass tube 10,210 Folded portion 15,515 , 615 Silicone resin 16, 516, 616 Coldest spot 20, 920 Molding jig 30 Glass tube A Swivel axis φi Glass tube inner diameter Le Distance between electrodes

Claims (23)

  An electric bulb-type fluorescent lamp comprising an arc tube having a spirally curved glass tube, wherein the inner periphery of the cross section of the glass tube is noncircular.   The glass tube is swung around a swivel axis, and a first diameter in a direction substantially orthogonal to the swivel axis is a second diameter in a direction substantially parallel to the swivel axis on the inner periphery of the cross section of the glass tube. 2. The light bulb shaped fluorescent lamp according to claim 1, wherein the light bulb shaped fluorescent lamp is smaller.   The light bulb shaped fluorescent lamp according to claim 2, wherein the glass tube has a substantially elliptical cross-sectional shape.   The bulb-type fluorescent lamp according to claim 2, wherein the glass tube has a cross-sectional shape of "<".   When the first diameter is D1 (mm) and the second diameter is D2 (mm), the value of D2 is 5 mm or more and 9 mm or less, and the value of D1 is 3 mm or more and less than D2. The bulb-type fluorescent lamp according to any one of claims 2 to 4. The arc tube comprises electrodes at both ends of the glass tube,
When the distance between the electrodes in the arc tube is Le (mm) and the D1 and the Le are expressed by orthogonal coordinates (D1, Le), the (D1, Le) is a point (3.0, 445), Specified within the range surrounded by the points (7.4, 275), (9.0, 290), (9.0, 360), and (3.0, 855). The bulb-type fluorescent lamp according to claim 5. The arc tube comprises electrodes at both ends of the glass tube,
When the distance between the electrodes in the arc tube is Le (mm), and D1 and Le are represented by orthogonal coordinates (D1, Le), the (D1, Le) is a point (3.0, 840), Specified within the range surrounded by the points (7.4, 530), (9.0, 560), (9.0, 620), and (3.0, 1085). The bulb-type fluorescent lamp according to claim 5. The arc tube comprises electrodes at both ends of the glass tube,
When the distance between the electrodes in the arc tube is Le (mm), and D1 and Le are expressed by orthogonal coordinates (D1, Le), the (D1, Le) is a point (3.0, 975), Specified within the range surrounded by the points (7.4, 570), (9.0, 600), (9.0, 670), and (3.0, 1165). The bulb-type fluorescent lamp according to claim 5. The arc tube comprises electrodes at both ends of the glass tube,
When the distance between the electrodes in the arc tube is Le (mm), and D1 and Le are represented by orthogonal coordinates (D1, Le), the (D1, Le) is a point (3.0, 330), Specified within the range surrounded by the points (7.4, 200), (9.0, 230), (9.0, 320), and (3.0, 725). The bulb-type fluorescent lamp according to claim 5.   The glass tube has a folded portion at substantially the center between both ends of the glass tube, and the glass tube has a first swivel portion toward the folded portion while turning around a swivel axis from one end portion; 10. A double spiral shape having a second swivel portion that turns from the folded portion around the swivel axis of the first swivel portion toward the other end portion. The bulb-type fluorescent lamp according to any one of the above.   The bulb-type fluorescent lamp according to any one of claims 1 to 10, wherein the glass tube has a circular cross section at a portion where the electrode is sealed.   The bulb-type fluorescent lamp according to any one of claims 1 to 11, wherein mercury is enclosed in the arc tube in a substantially single form without taking an amalgam form. An outer bulb containing the arc tube,
The bulb-type fluorescent lamp according to claim 10, wherein the glass tube has a periphery of the folded portion coupled to the outer tube bulb via a heat conductive medium.   14. The light bulb shaped fluorescent lamp according to claim 13, wherein a distance between the folded portion of the glass tube and the outer bulb connected by the heat conductive medium is 6.0 mm or less.   The bulb-type fluorescent lamp according to claim 13 or 14, wherein any one of metal, rubber, and resin is used as the heat conductive medium.   16. The light bulb shaped fluorescent lamp according to claim 15, wherein a transparent silicon resin is used as the heat conductive medium.   The extended part which expands the coupling | bonding area with the said heat conductive medium is formed in the part couple | bonded with the said heat conductive medium in the said arc_tube | light_emitting_tube, The any one of Claims 13-16 characterized by the above-mentioned. The described bulb-type fluorescent lamp.   The said glass tube is a clearance gap between the said folding | returning part and the 1st and 2nd turning part connected to this folding | returning part, The outer diameter of the folding | turning part of a glass tube is smaller, The Claim 13, 13 14. A light bulb-type fluorescent lamp according to any one of items 14 to 14. A method of manufacturing a spiral arc tube by winding a softened glass tube along a spiral groove formed on the outer peripheral surface of a forming jig,
The method of manufacturing an arc tube, wherein the groove has a non-circular cross-sectional shape.   The method of manufacturing an arc tube according to claim 19, wherein a cross-sectional shape of the groove portion substantially coincides with a part of an ellipse having a major axis in a direction substantially parallel to the turning axis direction.   The method of manufacturing an arc tube according to claim 19, wherein a cross-sectional shape of the groove portion is a "<" shape. The groove has a double spiral shape from the top of the forming jig toward the base,
The glass tube is wound around the forming jig in a state where the substantially central portion of the glass tube is positioned on the top portion to obtain a double spiral arc tube. The manufacturing method of the arc tube of description.   The method of manufacturing an arc tube according to any one of claims 19 to 22, wherein a pressure fluid is sealed in the glass tube when the glass tube is wound around the forming jig.

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