JP2010205727A - Lamp with outer seal, and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a bayonet bulb-shaped fluorescent lamp which eliminates the need for an adhesive and heat treatment in fixing a bayonet mouthpiece to the lamp. <P>SOLUTION: The bayonet bulb-shaped fluorescent lamp includes a discharge tube, a stabilizer circuit, and an outer seal 2 containing a portion encircling the discharge tube structure and an extension encircling the stabilizer circuit. The extension has a neck 8 for fixing the outer seal to the mouthpiece 6 of the lamp. The mouthpiece is of a bayonet type and has a mouthpiece shell 12 that has a receiving portion 13 for fixing the mouthpiece to the outer seal. The receiving portion of the mouthpiece shell includes a female screw 14, and the neck of the extension includes a male screw 9 mated with the female screw of the receiving portion of the mouthpiece shell. The mouthpiece 6 is fixed to the outer seal using a screw connection formed by the female screw and the male screw. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a lamp, and more particularly to a compact fluorescent lamp (CFL) that can replace a general purpose incandescent lamp. Even more specifically, the present invention relates to a lamp having a bayonet base, the lamp having an outer envelope and a ballast circuit within the outer envelope.

  The majority of known and commercially available low pressure discharge lamps are currently CFLs. These lamps are intended to replace incandescent lamps that are widely used in industrial and household applications. The main advantages of these lamps are low power consumption and long life. However, CFL is relatively expensive and has the disadvantage of large length dimensions. Many shapes have been proposed to solve the length dimension problem. Such solutions include a discharge tube configuration confined within a bulb-shaped outer envelope.

  U.S. Pat. No. 7,459,856 B1 discloses a compact fluorescent lamp including a discharge tube configuration inserted into a bulb-shaped outer envelope made of glass. A ballast circuit for supplying energy to the fluorescent lamp is disposed in the extension of the outer envelope. Known CFLs have an incandescent lamp profile on a standard Edison-type base.

  In addition, bayonet type caps are generally known in the art. The bayonet-type base is usually fixed to the lamp by two methods.

  -In the case of an incandescent lamp or other lamp with an outer envelope, the lamp assembly can withstand thermal stresses caused by the high temperatures during the die processing and because of its fragility (pressing the die into the glass bulb neck or If a mechanical connection is not possible (such as staking), the method is by using an adhesive. Such known fixing in the case of a bayonet-type base is disclosed, for example, in US Pat. No. 3,775,634.

  -Mechanical method in the case of CFL. A base is caulked to the housing, and the housing is made of flexible plastic.

  It has a fragile, eg glass outer envelope and the lamp assembly (such as an electronic ballast for starting and operating a low-pressure discharge lamp, or a control device for operating a low-voltage halogen lamp, an electronic transformer In the case of including heat sensitive components, none of the above options can be applied, and a dedicated base and so as to be able to properly secure between the base and the envelope. The glass neck of the outer sphere must be developed.

US Patent 3,775,634

  Thus, with a spherical outer envelope and a control unit (eg, ballast circuit or control device) inside, the outer envelope is made of glass or other fragile material, safe, cost effective and efficient There is a particular need for a lamp, in particular CFL, which is connected to the bayonet-type base in a conventional manner. There is a further need for a lamp, in particular CFL, in which the fixing of the base to the outer envelope is locked by locking means that resist displacement. There is also a need for a method of manufacturing such a lamp or CFL.

In an exemplary embodiment of the invention, the compact fluorescent lamp is
A discharge tube configuration formed by at least one discharge tube surrounding a discharge volume filled with discharge gas and having a fluorescent coating disposed on the inner surface of the tube, the tube having a continuous arc path; A discharge tube configuration further comprising an electrode formed and disposed at each end of the arc path;
-A ballast circuit that controls the current in the tube and is connected to the contact terminals by lead-out wires;
-An outer envelope comprising a large volume portion at least partially surrounding the discharge tube arrangement and an extension at least partially surrounding the ballast circuit;
The extension has a neck for securing the outer envelope to the lamp cap;
The base is a bayonet type and has a base shell, the base shell has a receiving part for fixing the base to the outer envelope;
-The receiving part of the base shell contains an internal thread, the neck part of the extension includes an external thread that fits into the internal thread of the receiving part of the base shell, and the base is externally sealed using a threaded joint formed by the internal and external threads. Fixed to the body.

In another exemplary embodiment of the invention, the lamp is
-A light source;
A control device for controlling the current of the light source and connected to the contact terminal by means of a lead-out wire;
-An outer envelope comprising a substantially spherical portion at least partially surrounding the light source and an extension at least partially surrounding the control device;
-The extension has a neck for fixing to the base;
-The base is a bayonet type and has a base shell with a receiving part for the neck part;
The base is fastened to the outer envelope by means of screw joints formed by screws in the neck and the receiving part, respectively.

In an exemplary embodiment of another aspect of the invention, a method of manufacturing a compact fluorescent lamp is proposed. This method
-Providing an outer envelope comprising a substantially spherical portion at least partially surrounding the discharge tube configuration and an extension at least partially surrounding the ballast circuit for controlling the current of the discharge tube configuration; The ballast circuit has a lead-out wire for connection to the contact terminal and the extension has a neck portion including a male thread;
-Providing a bayonet-type base having a base shell, the base shell including a receiving part with an internal thread;
-Inserting the end of the lead-out wire into the respective hole in the bottom part of the base;
Fixing the base to the outer envelope by screwing, thereby creating a screw joint with internal and external threads;
-Forming contact terminals at the ends of the lead-out wires.

  The disclosed CFL, lamp, and method allow for a secure and secure fixation between the base and the outer envelope. No adhesive or heat treatment is required to secure the bayonet-type base to the lamp, thereby achieving a simpler and less expensive design and assembly process. A further advantage of this lamp is that it is fully mechanically and electrically compatible with an incandescent lamp in the form of a bayonet bulb, thereby making it an efficient replacement lamp. The proposed lamp provides a certain level of protection against the environmental load caused by the outer envelope.

  The invention will now be described in detail with reference to the enclosed figures.

1 is a schematic view of a preferred embodiment of a low pressure discharge lamp, the base of which is partly in section. FIG. 2 is a schematic view of the lamp shown in FIG. 1 with an outer envelope in cross section. FIG. 3 is a schematic view of a base portion of a lamp, which is a partial cross-sectional view. It is the schematic of the nozzle | cap | die part of the lamp | ramp which has a locking means. It is the expanded sectional view seen along the plane AA of FIG.

  First, referring to FIGS. 1 and 2, a low-pressure discharge lamp 1 is shown. The lamp is preferably a CFL in which the outer envelope 2 surrounds the discharge tube structure 5 and the ballast circuit 7. The ballast circuit 7 is preferably mounted on a printed circuit board. The outer envelope 2 with the discharge tube configuration 5 and the ballast circuit 7 can be manufactured, for example, as disclosed in US Pat. No. 7,459,856 B1. The outer envelope 2 comprises a (preferably spherical) large volume part 3 surrounding the discharge tube arrangement 5 and an extension part 4 surrounding the ballast circuit and having a neck part 8 for connection to the bayonet-type base 6. Have. The neck portion 8 includes a male screw 9 for connection to the bayonet-type base 6.

  The discharge tube configuration 5 can include a single discharge tube or a plurality of elongated discharge tubes. The discharge tube is made of glass and encloses a discharge volume filled with discharge gas and has a fluorescent phosphor coating disposed on the inner surface of the tube. The end of the tube is hermetically sealed. The tube forms a continuous arc path with an electrode and a lead-in wire 10 connected to the electrode at its end. A lead-in wire 10 having a discharge tube configuration is connected to a ballast circuit 7 for controlling the discharge tube current. The ballast circuit 7 is further connected to an associated supply via a lead-out wire 11 connected to the contact terminal 15 of the lamp cap 6. The lead-out wires 11 are separated from one another and led to a base 6 for connecting the lamp to an associated supply via a socket. The lamp cap 6 is configured to fit into a socket, which socket can be of any conventional bayonet type normally used in lamps.

  In the illustrated embodiment, the compact fluorescent lamp includes a single tube discharge tube configuration 5 with a substantially straight end section and an intermediate portion between the end sections. The end section is at one end of the tube configuration and is substantially parallel to each other, with the middle portion having a coil shape wound around the main axis of the lamp.

  Alternatively, the discharge tube configuration may consist of straight tube members having a longitudinal axis substantially parallel to the main axis of the lamp, with adjacent tube members connected in series to form a continuous arc path. . Possible configurations may include shapes with 2, 4, or 6 individual discharge tube members depending on the required output luminous intensity. The discharge tube configuration can also include two separate elongated discharge tube members bent into substantially U-shaped lengths that form a continuous arc path. So that they are interconnected by a bridge. Possible configurations may include shapes with one or three individual discharge tubes bent into a U shape depending on the required output luminous intensity. The U-shaped discharge tube member can include a substantially parallel straight section defining the length of the discharge tube configuration and a curved intermediate section.

  Each discharge tube surrounds a discharge volume filled with a discharge gas. In the illustrated embodiment, they are cylindrical, but other suitable cross sections can be selected as well. Generally, the discharge tube is made of glass, but other suitable materials are also contemplated. The wall thickness of the discharge tube is preferably substantially constant, mainly from a manufacturing point of view, in order to ensure a uniform discharge in the discharge tube along the entire length.

  In order to provide visible light, the inner surface of the discharge tube is covered with a fluorescent phosphor layer. This phosphor layer is in the sealed discharge volume. The composition of such phosphor layers is known per se. This phosphor layer converts UV radiation into visible light. The phosphor layer is applied to the inner surface of the discharge tube before it is sealed.

  The discharge tube arrangement 5 and the printed circuit board of the ballast circuit 7 are held in the outer envelope 2 and are held against each other by a holding and protective shield 16 oriented in a plane substantially perpendicular to the main axis of the lamp. Retained. The retention and protection shield 16 includes a portion that receives and secures the discharge tube configuration 5 and the printed circuit board of the ballast circuit 7 to provide sufficient protection against mechanical vibrations and shocks.

  The outer envelope 2 is preferably made of glass, which ensures excellent transparency for a very long lifetime. Of course, other suitable materials are also conceivable. A material with good transparency is usually very hard and fragile, and conventional mechanical methods cannot be used to secure the base to the material. Because of the electronic control device, which is preferably a ballast circuit, conventional adhesives that require high temperature bonding processes cannot be used.

The base 6 is bayonet-shaped and has two parts: a substantially cylindrical lower part with two side pins;
A threaded upper portion that fits into the neck 8 of the outer envelope 2.

  In the preferred embodiment shown in FIG. 3, the base 6 has a base shell 12 and a receiving part 13 for fixing the base 6 to the outer envelope 2. The receiving portion 13 of the base shell 12 includes a female screw 14 that is a counterpart of the male screw 9 of the neck portion 8. Thereby, the base 6 is fixed to the outer envelope 2 using a screw joint formed by the female screw 14 and the male screw 9.

  The base 6 further has an insulator part 17 which is preferably made of glass (eg, vitrite) or plastic. The glass insulator part 7 is preferably formed by casting in the base shell 12, while the plastic insulator part 7 can be formed separately and then inserted into the base shell. The insulator portion 7 provides electrical insulation between the contact terminals 15 and between the contact terminals 15 and the base shell 12. The lead-out wire 11 is connected to the contact terminal 15 by soldering, and the soldering pad generated thereby preferably forms the contact terminal 15.

  In another preferred embodiment of the lamp 1, as shown in FIGS. 4 and 5, locking means are provided to lock the screw joint against unscrewing. The locking means preferably includes a recess 20 formed in the outer envelope 2 and a protrusion 21 that fits into the recess. The illustrated recess 20 has a cylindrical surface, but any suitable form can be used. The protrusion 21 is preferably formed on the threaded receiving portion 13 of the base shell 12 as a fold of the material of the base shell 12. The fold may have a bent edge 22 that is integrated with the receiving portion 13 of the base shell 12 and a cut edge 23 that is formed by cutting the receiving portion 13 of the base shell 12. Preferably, the fold is generated prior to the screwing step and positioned to coincide with the recess 20 in the fully screwed state. When screwed into place, a clamp joint is created by the clamping effect of folding. By slightly tightening the base from this position, the clamp joint is tightened, thereby providing a very hard lock and lock.

  Alternatively, the protrusion 21 can be formed of a soldering material introduced between the recess 20 and the corresponding wall of the base shell 12 and soldered to the wall.

  In a preferred method of manufacturing a compact fluorescent lamp 1, the following steps are performed. A preferably bulb-shaped outer envelope 2 is provided that includes a substantially spherical portion 3 that at least partially surrounds the discharge tube arrangement 5 and an extension 4 that at least partially surrounds the ballast circuit 7. The ballast circuit 7 has a lead-out wire 11 for connection to the contact terminal 15 of the associated supply base 6, and the extension 4 has a neck 8 that includes an external thread 9. In the next step, a bayonet-type base having contact terminals and a base shell is provided. The base shell includes a receiving portion having an internal thread. The lead-out wires 11 are joined together in the direction opposite to the screwing direction, and the end portions of the lead-out wires 11 are inserted into the respective holes of the bottom portion (which is the insulator portion 17) of the base 6. Thereafter, the base 6 is fixed to the outer sealing body 2 by screwing, whereby a screw joint is generated by the female screw 14 and the male screw 9. Finally, the lead-out wire 11 is soldered to the metal inner lining of the hole, thereby producing the contact terminal 15 as a soldering pad. Alternatively, the soldering step can be performed before the screwing step.

  In another preferred embodiment of the method, locking means are formed for locking the screw joint against unscrewing. For this purpose, the bulb-shaped outer envelope is preferably provided with a recess 20 on its outer surface, a projection 21 is formed on the thread receiving portion 13 of the base shell 12, and the projection 21 is screwed together with the outer envelope 2 and the base 6 together. It fits into the recess 20 at the position.

  Preferably, the protrusion 21 is formed as a fold of the material of the base shell 12 by making a cut in the receiving portion 13 and folding the material of the receiving portion 13 on one side of the cut. Alternatively, the protrusion 21 can be made of a soldering material as described above.

  While the present invention has been disclosed with reference to the drawings, it will be understood by those skilled in the art that the present invention is not limited to the illustrated and disclosed embodiments, and that other elements, improvements, and modifications are within the scope of the invention. It will be clear. For example, it will be apparent that several other forms of envelopes, discharge tubes, and bayonet type caps are applicable for purposes of the present invention. For example, the envelope can have a spherical shape or a T-shape. The number and configuration of discharge tube members in the lamp can also vary depending on the size of the lamp or the desired output. The bayonet-type base shell used to make the electrical connection to the power source can also be selected from any standard or non-standard type.

  This description, including the best mode, uses the examples to disclose the invention and to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples include structural elements that do not differ from the literal meaning of the claims, or equivalent structural elements that do not substantially differ from the literal meaning of the claims. If included, it is within the scope of the claims.

DESCRIPTION OF SYMBOLS 1 Low pressure discharge lamp, fluorescent lamp 2 Outer envelope 3 Large volume part 4 Elongation part 5 Discharge tube structure 6 Bayonet type base, lamp base 7 Ballast circuit,
8 Neck portion 9 Male screw 10 Lead-in wire 11 Lead-out wire 12 Cap shell 13 Receiving portion 14 Female screw 15 Contact terminal 16 Holding and protection shield 17 Insulator portion 20 Recessed portion 21 Protrusion 22 Bending edge portion 23 Cutting edge portion

Claims (12)

A discharge tube configuration (5) formed of at least one discharge tube surrounding a discharge volume filled with a discharge gas and having a fluorescent coating disposed on the inner surface of the tube, the tube being continuous A discharge tube configuration (5), further comprising an electrode that forms a complete arc path and is disposed at each end of the arc path;
A ballast circuit (7) that controls the current in the tube and is connected to the contact terminal (15) by a lead-out wire (11);
An outer envelope (2) comprising a large volume portion (3) at least partially surrounding the discharge tube arrangement (5) and an extension (4) at least partially surrounding the ballast circuit (7); Comprising
The elongated portion (4) has a neck portion (8) for fixing the outer envelope (2) to the base (6) of the lamp (1),
The base (6) is a bayonet type, has a base shell (12), and the base shell (12) fixes the base (6) to the outer envelope (2) (13 )
The receiving portion (13) includes a female screw (14), and the neck portion (8) of the elongated portion (4) is fitted to the female screw (14) of the receiving portion (13) of the base shell (12). A compact, wherein the base (6) is fixed to the outer envelope (2) using a screw joint formed by the female screw (14) and the male screw (9). Fluorescent lamp (1). The compact fluorescent lamp according to claim 1, wherein the outer envelope (2) is bulb-shaped and the large volume portion (3) is substantially spherical. A compact fluorescent lamp according to claim 1 or 2, wherein the outer envelope (2) is made of glass. The compact fluorescent lamp according to any one of claims 1 to 3, wherein a locking means is provided to lock the screw joint portion against unscrewing. The locking means includes a recess (20) formed in the outer sealing body (2) and a protrusion (21) fitted into the recess (20), and the protrusion (21) is the base shell (12). The compact fluorescent lamp according to claim 4, wherein the compact fluorescent lamp is formed on the threaded receiving portion. A bent edge (22) in which the protrusion (21) is formed as a fold of material of the base shell (12), and the fold is integrated with the receiving part (13) of the base shell (12); 6. A compact fluorescent lamp according to claim 5, having a cut edge (23) formed by cutting the receiving part (13) of the base shell (12). A light source;
A control device for controlling the current of the light source and connected to the contact terminal (15) by a lead-out wire (11);
An outer envelope (2) comprising a substantially spherical portion (3) at least partially surrounding the light source and an extension (4) surrounding the control device;
The elongated portion (4) has a neck portion (8) for fixing to the base (6),
The base (6) is a bayonet type and has a base shell (12) having a receiving part (13) for the neck part (8),
The lamp (1), wherein the base (6) is fixed to the outer envelope (2) using screw joints formed by screws of the neck part (8) and the receiving part (13), respectively. The lamp according to claim 7, wherein the receiving part (13) includes an internal thread (14) and the neck part (8) includes an external thread (9) that fits into the internal thread (14) of the receiving part (13). . In a method of manufacturing a compact fluorescent lamp (1),
A substantially spherical portion (3) at least partially surrounding the discharge tube configuration (5) and an extension at least partially surrounding the ballast circuit (7) for controlling the current in the discharge tube configuration (5) (4) including an outer envelope (2), wherein the ballast circuit (7) has a lead-out wire (11) for connection to a contact terminal (15), and the extension portion A step having a neck (8) in which (4) includes an external thread (9);
Providing a bayonet-type base (6) having a base shell (12), the base shell (12) including a receiving part (13) having an internal thread (14);
Inserting the end of the lead-out wire (11) into each hole in the bottom portion of the base (6);
Fixing the base (6) to the outer envelope (2) by screwing, thereby generating a screw joint with the female screw (14) and the male screw (9);
Forming the contact terminal (15) at an end of the lead-out wire (11). Locking means for locking the screw joint against unscrewing,
Providing a recess (20) on the outer surface of the outer envelope (2);
Forming the protrusion (21) in the thread receiving part (13) of the base shell (12), wherein the protrusion (21) includes both the outer envelope (2) and the base (6). The method according to claim 9, further comprising the step of fitting into the recess (20) in a screwed position. The protrusion (21) is formed as a material fold of the base shell (12) by making a cut in the receiving portion (13) and folding the material of the receiving portion (13) on one side of the cut. The method according to claim 10. 12. A method according to any one of claims 9 to 11, wherein, prior to the inserting step, the lead-out wire (11) is mated together in a direction opposite to the screwing direction.

Images