JP2009004205A - Coil-wound electrode manufacturing method, electrode mount manufacturing method, and discharge lamp manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil-wound electrode manufacturing method, by which the occurrence of coil displacement is prevented; an electrode mount manufacturing method; and a discharge lamp manufacturing method. <P>SOLUTION: The coil-wound electrode manufacturing method includes: a step of arranging a coil 3a3 with an inner diameter of r1; a step of inserting an electrode 3a2 with an outer diameter of R (R<r1) partway into the coil 3a3; a step for forming a diameter-reduced part 3a31 by pressing a coil 3a3 part, not inserted with the electrode 3a2, by a presser bar 83; and a step for inserting the electrode 3a2 into the coil 3a3 part including the diameter-reduced part 3a31. In the electrode 3a2 insertion step, the electrode 3a2 is inserted into the coil 3a3 while circumferentially rotating it in such a state that the coil 3a3 is being fixed. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a coil wound electrode, an electrode mount, and a discharge lamp manufacturing method used for automobile headlamps and the like.

  The discharge lamp is, for example, a lamp described in Japanese Patent Application Laid-Open No. 2005-339999 (hereinafter referred to as Patent Document 1). Sealing portions are formed at both ends of a discharge portion in which a discharge medium is sealed. An electrode mount is sealed to the stopper. In such a discharge lamp, the electrode is thermally expanded and contracted during lighting and extinguishing, so that a strong distortion is generated in the sealing portion, and this may cause a crack leak. Therefore, it is effective to wind a coil around the electrode shaft in order to alleviate the distortion of the sealing portion.

JP 2005-339999 A Japanese Patent Laid-Open No. 10-269941

  However, the process of winding the coil around the electrode shaft is a very difficult process. That is, since the coil is small in size, it requires a high level of technology to manage the positional accuracy for winding the coil, and even if the coil can be wound at a desired position on the electrode, Before the coil-wound electrode is incorporated into the discharge lamp, it is necessary to prevent the coil from being displaced. In order to solve this problem, Japanese Patent Application Laid-Open No. 10-269941 (hereinafter referred to as Patent Document 2) discloses a method in which a leg is extended and formed at one end of a coil, and the leg is welded to a metal foil. However, this method has problems such as a decrease in the sealing property between the metal foil and the sealing portion, and is not a suitable method.

  An object of the present invention is to provide a method for manufacturing a coil-wound electrode, an electrode mount, and a discharge lamp, which are less likely to be misaligned.

  In order to achieve the above object, the method of manufacturing a coil-wound electrode according to the present invention includes a step of arranging a coil having an inner diameter r1, and an electrode having an outer diameter R (R <r1) inserted halfway through the coil. And a step of pressing the coil portion in which the electrode is not inserted with a pressing means to form a reduced diameter portion, and a step of inserting the electrode into the coil portion including the reduced diameter portion.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the coil winding electrode which is hard to generate | occur | produce position shift, an electrode mount, and a discharge lamp can be provided.

(First embodiment)
Below, the manufacturing method of the discharge lamp which is one Embodiment of the discharge lamp of this invention is demonstrated with reference to drawings. First, the structure of the discharge lamp of the present invention will be described with reference to FIG.

  The discharge lamp has an airtight container 1 made of a material having heat resistance and translucency, for example, quartz glass. The hermetic container 1 has an elongated shape in the lamp axis direction, and a substantially elliptical discharge portion 11 is formed at a substantially central portion thereof. Plate-shaped sealing portions 12 a and 12 b are formed at both ends of the discharge portion 11.

  A discharge space 14 is formed inside the discharge part 11. The discharge space 14 is filled with a discharge medium composed of the metal halide 2 and a rare gas. As the metal halide 2, sodium iodide, scandium iodide, zinc iodide, indium bromide, and xenon are enclosed as the rare gas. In this discharge lamp, mercury is not enclosed.

  The electrode mounts 3a and 3b are sealed inside the sealing portions 12a and 12b. The sealed state is shown in FIGS. The electrode mounts 3a and 3b are formed by integrally forming metal foils 3a1 and 3b1, coil winding electrodes (electrodes 3a2 and 3b2, coils 3a3 and 3b3), and external lead wires 3a4 and 3b4.

  Metal foil 3a1, 3b1, for example, a thin metal plate made of molybdenum. The width is 1.2 to 1.8 mm, the length is 6.2 to 6.8 mm, and the thickness is 15 to 25 μm. Further, both ends in the width direction have a so-called knife edge shape in which the thickness of the end portion is thinner than that of the central portion.

  The electrodes 3a2 and 3b2 are triated tungsten electrodes obtained by doping tungsten with thorium oxide, and the diameter R thereof is 0.35 to 0.39 mm. The base end side is connected to the end portion of the metal foils 3a1, 3b1 on the discharge portion 11 side, and the tip end side is disposed in the discharge space 14 so as to face each other with a predetermined distance between the electrodes. ing.

  The coils 3a3 and 3b3 are made of, for example, doped tungsten, and are spirally wound around the shafts of the electrodes 3a2 and 3b2 sealed by the sealing portions 12a and 12b. However, the coils 3a3 and 3b3 are not wound around the shaft portions of the electrodes 3a2 and 3b2 connected to the metal foils 3a1 and 3b1, and the distance from the end of the foil is 0 to 1.0 mm in the direction of the discharge space 14. Wrapped. The coil specifications are as follows: the winding diameter (coil inner diameter) r1 is 0.36 to 0.40 mm, the total length is 2.0 to 4.0 mm, the coil diameter r ′ is 40 to 80 μm, and the inter-coil distance d1 is 0. 090 to 0.240 mm, and the coil pitch is about 150 to 400%.

  The external lead wires 3a4 and 3b4 are made of, for example, molybdenum, and are connected to end portions of the metal foils 3a1 and 3b1 on the opposite side to the discharge portion 11. The other end sides of the external lead wires 3a4 and 3b4 extend to the outside of the sealing portions 12a and 12b.

  One end of an L-shaped support wire 3c is connected to the lead wire 3b4 extending to the front end side. A sleeve 4 is covered with a support wire 3c parallel to the tube axis.

  On the outside of the airtight container 1 configured as described above, a cylindrical outer tube 5 having ultraviolet blocking properties is provided concentrically with the airtight container 1 along the tube axis. These connections are made by welding both ends of the airtight container 1 and the outer tube 5 together. A socket 6 is connected to one end of the outer tube 5 that covers the airtight container 1. These connections are made by the holder 7.

  Here, the manufacturing method of a coil winding electrode is demonstrated in detail using FIGS. In each figure, (a) is a side view and (b) is a front view.

  First, as shown in FIG. 4, the coil 3a3 is arranged on the mounting table 81 on which the V-shaped groove 811 is formed so that the outer peripheral surface is in contact with the V-shaped portion. Next, one end of an electrode 3a2 having a diameter R smaller than the inner diameter r1 of the coil 3a3 (for example, R = 0.37 mm, r1 = 0.38 mm) is held by a holding means (not shown), and as shown in FIG. The electrode 3a2 is inserted from the opening end of the coil 3a3. At that time, the glass holding plate 82 is disposed so as to contact the upper part of the coil 3a3 so that the coil 3a3 is fixed so as not to move, and the electrode 3a2 is arranged in the circumferential direction (preferably in the spiral direction of the coil 3a3). By inserting the coil 3a2 into the coil 3a2 while rotating it in the same circumferential direction), the electrode 3a2 can be easily inserted into the coil 3a3 without any trouble. In this insertion step, the electrode 3a2 is inserted in the middle of the coil 3a3, for example, up to about half the total length.

  Next, as shown in FIG. 6, after the pressing plate 82 is removed from the upper portion of the coil 3a3, the upper portion of the coil 3a3 portion where the electrode 3a2 is not inserted is pressed by the pressing rod 83 to form the reduced diameter portion 3a31. As shown in FIG. 7, the diameter-reduced portion 3a31 has a shape in which the upper half of the coil 3a3 is mainly elliptical, specifically, the upper portion is reduced in diameter and the side portions are somewhat expanded. Note that the pressure of the presser bar 83 in the diameter reducing step may be adjusted so that at least the inner diameter r2 of the reduced diameter portion 3a31 is smaller than the diameter R.

  And after arrange | positioning the holding | pressing plate 82 again on the coil 3a3 part containing the diameter-reduced part 3a31, while inserting the electrode 3a3 inserted to the middle in the circumferential direction, by inserting to the edge part of the coil 3a3, A coil wound electrode is obtained. At this time, when the electrode 3a2 passes through the reduced diameter portion 3a31, since the inner diameter r2 of the reduced diameter portion 3a31 is smaller than the diameter R of the electrode 3a2, a force is applied to the reduced diameter portion 3a31 in the direction of expanding outward. In addition, the inner diameter expands. However, the expansion of the inner diameter remains only up to the diameter R of the electrode 3a2, and the reduced diameter portion 3a31 generates a force for returning to the direction of the electrode 3a2. Therefore, the contact state between the outer surface of the electrode 3a2 and the inner surface of the reduced diameter portion 3a31 becomes strong, and the occurrence of misalignment of the coil can be prevented.

  Next, the coil-wound electrode manufactured by the above method was assembled into an electrode mount by the method of FIG. 3 of Japanese Patent Application Laid-Open No. 2006-196267. At that time, the electrode mount 3a in which the coil 3a3 was positioned at a predetermined position of the electrode 3a2 could be obtained without causing any positional deviation of the coil.

  Next, a process of incorporating the electrode mounts 3a and 3b and completing the discharge lamp will be described. FIG. 9 is a diagram for explaining a manufacturing method of one sealing portion of the discharge lamp, and FIG. 10 is a diagram for explaining a manufacturing method of the other sealing portion of the discharge lamp.

  First, the container 1 ′ in which the discharge part 11 is formed by a well-known method is arranged vertically as shown in FIG. 9A, and the electrode mount 3a is connected to the sealing part formation scheduled part 12a from the opening end on the lower side of the container 1 ′. Insert until '. Then, as shown in (d), after heating the sealing portion formation planned portion 12a ′ with the burner 91 to soften the glass as shown in (b) and then pinching with the pincher 92 as shown in (c), The sealing part 12a is formed.

  Next, as shown in FIG. 10A, the electrode mount 3b is inserted from the opening end on the upper side of the container 1 'to the sealing portion formation scheduled portion 12b'. Then, as shown in (b), an exhaust / gas introduction device 93 is attached to the opening end, and the inside of the container 1 'is evacuated, and then xenon or the like is sealed. Then, as shown in (c), the shielding plate 94 is disposed in the vicinity of the discharge portion 11, and the discharge portion 11 is discharged from the cooling nozzle 95 to cool the discharge portion 11 while discharging the liquid nitrogen, and the sealing portion formation scheduled portion 12 b ′ Is heated with a burner 96. And if the glass of sealing part formation scheduled part 12b 'softens, the sealing part 12b will be formed like (e) by pinching with the pincher 97 like (d), and the airtight container 1 will be completed. .

  In the discharge lamp manufactured as described above, there was no problem that the positions of the coils 3a3 and 3b3 were shifted or completely disconnected during the process. Further, the positional accuracy of the coils 3a3 and 3b3 was good, and a stable effect against the axial leak could be obtained.

  Here, 100 coil-wound electrodes were created for each of the three methods of the method of the present embodiment, the method of not performing the coil diameter reduction step, and the method of performing the electrode insertion step without fixing the coil, A test was conducted to verify the state of occurrence of defects when it was incorporated into a discharge lamp through the steps of FIGS. As a result, in the method of the present embodiment, the defect occurrence rate such as coil misalignment and coil disengagement is 1%, and in the method not performing the coil diameter reduction process, the electrode insertion process is performed without fixing the coil. The method performed was 50%, and it was confirmed that the method of the present embodiment is the most excellent.

  In addition, in the method of this Embodiment, the effect that workability | operativity improves can also be acquired. That is, since the coil used for the discharge lamp has a very small size, it is very difficult to manage the direction of the coil. For example, when a reduced diameter portion like the present invention is created in advance in a part of the coil, it is necessary to arrange the reduced diameter portion on the outlet side in the coil electrode insertion process in consideration of ease of electrode insertion. Since the diameter-reduced portion cannot be visually confirmed, it is a great effort to manage the coil arrangement direction every time. On the other hand, in the method of the present embodiment, since the coil winding electrode with little positional deviation of the coil can be obtained regardless of the arrangement direction of the coil, the workability is very high.

  Therefore, in the present embodiment, the step of arranging the coil 3a3 having the inner diameter r1, the step of inserting the electrode 3a2 having the outer diameter R (R <r1) halfway through the coil 3a3, and the electrode 3a2 are not inserted. A coil winding electrode manufacturing method comprising: a step of pressing the coil 3a3 portion with a pressing rod 83 to form a reduced diameter portion 3a31; and a step of inserting the electrode 3a2 into the coil 3a3 portion including the reduced diameter portion 3a31. Therefore, a predetermined position accuracy can be maintained until the lamp is completed, and a stable effect can be obtained with respect to axial leakage in the discharge lamp. In addition, since it is not necessary to manage the coil arrangement direction, workability can be improved. In the step of reducing the diameter of the coil 3a3, when the inner diameter of the reduced diameter portion 3a31 is r2, the coil 3a3 portion is pressed by the pressing bar 83 so that r2 <R, whereby the contact between the electrode 3a2 and the reduced diameter portion 3a31 is achieved. The state can be strengthened.

  In addition, in the step of inserting the electrode 3a2, the coil 3a3 is inserted into the coil 3a2 while rotating the electrode 3a3 in the circumferential direction in a state where the coil 3a3 is fixed by the V-shaped groove 811 and the holding plate 82. The electrode 3a2 can be easily inserted.

(Second Embodiment)
FIG. 11 is a diagram for explaining a coil used in the method of manufacturing a coil-wound electrode according to the second embodiment of the present invention. About each part of embodiment after this, the same part as each part of the manufacturing method of the coil winding electrode of 1st Embodiment is shown with the same code | symbol, and the description is abbreviate | omitted.

  In the present embodiment, a coil 3a3 in which a small diameter portion 3a32 having an inner diameter r3 smaller than the inner diameter r1 is formed in the vicinity of the end portion is used. Then, similarly to FIG. 8, an electrode insertion step of inserting the electrode 3a2 (R <r1, R> r3) having an outer diameter R from the opening end of the coil 3a3 is performed, so that a coil-wound electrode that is less likely to be misaligned is obtained. Obtainable. At this time, considering the ease of inserting the electrode 3a2 into the coil 3a3, it is desirable that the coil 3a3 is disposed so that the small-diameter portion 3a32 is positioned on the outlet side during the electrode 3a2 insertion step. Here, the coil as in the present embodiment can be obtained by forming a linear metal wire in a spiral shape so that only a part of the coil has a small inner diameter. As the shape, a perfect circle, an ellipse, etc. can be selected.

  Therefore, in the present embodiment, the step of disposing the coil 3a3 having the inner diameter r1 in which the small diameter portion 3a32 having the inner diameter r3 is formed, and the electrode 3a2 having the outer diameter R (R <r1, R The coil-wound electrode that is less prone to positional deviation of the coil can be provided by the method of manufacturing a coil-wound electrode comprising the step of inserting> r3) from the opening end of the coil 3a3. The small diameter portion 3a32 is formed near the end in the full length direction, and in the step of arranging the coil 3a3, the small diameter portion 3a32 is arranged on the outlet side in the insertion step of the electrode 3a2, thereby easily inserting the electrode 3a2 into the coil 3a3. can do.

(Third embodiment)
FIG. 12 is a diagram for explaining a coil used in the method of manufacturing a coil-wound electrode according to the third embodiment of the present invention.

  In the present embodiment, after the coil 3a3 is normally formed, a coil 3a3 is used in which a part near the end thereof is deformed to form an elliptical small-diameter portion 3a31 whose inner diameter in the minor axis direction is r3. When this coil 3a3 is used, the same effect as in the second embodiment can be obtained. Moreover, the small diameter part 3a31 can be formed easily.

  Therefore, in the present embodiment, the same effect as in the second embodiment can be obtained. Moreover, the small diameter part 3a31 can be formed easily.

The figure for demonstrating the structure of the discharge lamp of this invention. The figure for demonstrating the cross section of the Z1 part of FIG. The figure for demonstrating the cross section of the arrow direction of Z2-Z2 'of FIG. The figure for demonstrating the arrangement | positioning process of a coil. The figure for demonstrating the insertion process of the first electrode. The figure for demonstrating the diameter reduction process of a coil. Sectional drawing for demonstrating the diameter reduction state of a coil. The figure for demonstrating the insertion process of the electrode of the 2nd time. The figure for demonstrating the manufacturing method of one sealing part of a discharge lamp. The figure for demonstrating the manufacturing method of the other sealing part of a discharge lamp. The figure for demonstrating the coil used for the manufacturing method of the coil winding electrode of the 2nd Embodiment of this invention. The figure for demonstrating the coil used for the manufacturing method of the coil winding electrode of the 3rd Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Airtight container 11 Discharge part 12a, 12b Sealing part 3a, 3b Electrode mount 3a1, 3b1 Metal foil 3a2, 3b2 Electrode 3a3, 3b3 Coil 3a31 Reduced diameter part 3a32 Small diameter part 3a4, 3b4 External lead wire 81 Mounting base 811 Groove part 82 Press Plate 83 Presser bar

Claims (7)

Arranging a coil having an inner diameter of r1,
Inserting an electrode having an outer diameter R (R <r1) halfway through the coil;
Pressing the coil portion into which the electrode is not inserted by pressing means to form a reduced diameter portion; and
And a step of inserting the electrode into the coil portion including the reduced diameter portion.   2. The coil winding according to claim 1, wherein in the step of reducing the diameter of the coil, when the inner diameter of the reduced diameter portion is r2, the coil portion is pressed by the pressing means so that r2 <R. Electrode manufacturing method. Arranging a coil having an inner diameter of r1, in which a small diameter portion having an inner diameter of r3 is formed in part;
And a step of inserting an electrode having an outer diameter R (R <r1, R> r3) from the open end of the coil.   The said small diameter part is formed in the end part vicinity of a full length direction, and the said small diameter part is arrange | positioned in the exit side in the insertion process of the said electrode at the arrangement | positioning process of the said coil. Manufacturing method of coil winding electrode.   5. The insertion of the electrode according to claim 1, wherein the insertion of the electrode is performed while rotating the electrode in a circumferential direction with the coil fixed. 5. Manufacturing method of coil winding electrode.   A method for manufacturing an electrode mount, comprising the step of connecting the coil-wound electrode according to any one of claims 1 to 5 to one end of a metal foil.   And a step of sealing the sealing portion formation planned portion to form a sealing portion after the electrode mount according to claim 6 is inserted into the sealing portion forming planned portion formed at an end portion of the discharge portion. A method for manufacturing a discharge lamp.

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