JP2010251243A - Fluorescent lamp - Google Patents

Fluorescent lamp Download PDF

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JP2010251243A
JP2010251243A JP2009102037A JP2009102037A JP2010251243A JP 2010251243 A JP2010251243 A JP 2010251243A JP 2009102037 A JP2009102037 A JP 2009102037A JP 2009102037 A JP2009102037 A JP 2009102037A JP 2010251243 A JP2010251243 A JP 2010251243A
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tube
pair
portions
fluorescent lamp
outer diameter
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Shiro Iida
史朗 飯田
Katsushi Seki
勝志 関
Noriyuki Uchida
紀幸 内田
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Panasonic Corp
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Panasonic Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a fluorescent lamp having a high-watt-type planar double spiral shape and a good manufacturing yield. <P>SOLUTION: The fluorescent lamp includes a planar-double-spiral-shape light emitting tube having a discharge path formed between a pair of electrodes which is arranged at both ends of the tube, the discharge path being folded back around a tube center portion at a pair of bent portions extending from both sides of the tube center portion and then spirally turned approximately in one plane at a pair of turn portions extending from the pair of bent portions. Its rated lamp electric power exceeds 25W, and the light emitting tube satisfies a relationship of 0.6≤B/A≤0.95 between a tube outer diameter A of the widest portion of the turn portion and a tube outer diameter B of the narrowest portion of the bent portion in view from the direction perpendicular to the plane. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

本発明は、両管端部に一対の電極が配置され、前記一対の電極間に形成される放電路が、管中央部を中心として、前記管中央部の両側に延設された一対の屈曲部で折り返されたのち前記一対の屈曲部にそれぞれ延設された一対の旋回部において略一平面を渦巻状に旋回する平面二重渦巻形状の発光管を備えた所謂平面二重渦巻形の蛍光ランプに関する。   According to the present invention, a pair of electrodes are disposed at both ends of the tube, and a discharge path formed between the pair of electrodes extends from both sides of the tube central portion around the tube central portion. So-called plane double spiral fluorescent lamps having a planar double spiral shaped arc tube that spirally swivels substantially in one plane in a pair of swivel portions that are respectively extended at the pair of bent portions. Regarding lamps.

上記平面二重渦巻形の蛍光ランプ(二重渦巻形ランプ)は、発光管の外形が略円盤形状であるため薄型である。したがって、灯具を薄く設計することができ、天井や壁に取り付けられるダウンライトやウォールライト用の光源として好適である。また、円形の発光面を有する面光源となるため配光特性が好ましく、店舗や住宅の照明用に好適である。このような二重渦巻形ランプとしては、15Wや20Wの低ワットタイプのものが公知である(特許文献1)。   The flat double spiral fluorescent lamp (double spiral lamp) is thin because the arc tube has a substantially disk shape. Therefore, the lamp can be designed to be thin, and it is suitable as a light source for downlights and wall lights attached to a ceiling or a wall. Moreover, since it becomes a surface light source which has a circular light emission surface, a light distribution characteristic is preferable and it is suitable for the illumination of a store or a house. As such a double spiral lamp, a low wattage type of 15 W or 20 W is known (Patent Document 1).

特開2008−198493号公報JP 2008-198493 A

上記のような特長を有する二重渦巻形ランプは、低ワットタイプに限定されず、高ワット化してより広い用途に用いられることが望ましい。そこで、二重渦巻形ランプの高ワット化を試みたところ、製造歩留まりに関して高ワットタイプ特有の課題が明らかになった。具体的には、屈曲部における蛍光体層の剥離、および、旋回部における外観不良が原因となり、製造歩留まりが低下するという問題が生じた。   The double spiral lamp having the above-described features is not limited to the low wattage type, and it is desirable to increase the wattage and use it for wider applications. Therefore, when trying to increase the wattage of the double spiral lamp, problems specific to the high wattage type in terms of production yield were revealed. Specifically, there has been a problem that the production yield is reduced due to the peeling of the phosphor layer at the bent portion and the appearance defect at the swivel portion.

本発明は、上記した課題に鑑み、高ワットタイプの平面二重渦巻形でありながら製造歩留まりが高い蛍光ランプを提供することを目的とする。   The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a fluorescent lamp having a high manufacturing yield while being a high watt type planar double spiral.

上記目的を達成するため、本発明に係る蛍光ランプは、両管端部に一対の電極が配置され、前記一対の電極間に形成される放電路が、管中央部を中心として、前記管中央部の両側に延設された一対の屈曲部で折り返されたのち前記一対の屈曲部にそれぞれ延設された一対の旋回部において略一平面を渦巻状に旋回する平面二重渦巻形の発光管を備えた蛍光ランプであって、定格ランプ電力が25Wを超えており、かつ、前記発光管は、前記平面と直交する方向から見た場合に、前記旋回部における最も太い部分の管外径Aと前記屈曲部における最も細い部分の管外径Bとが、0.6≦B/A≦0.95の関係を満たすことを特徴とする。   In order to achieve the above object, a fluorescent lamp according to the present invention has a pair of electrodes arranged at both tube ends, and a discharge path formed between the pair of electrodes is centered on the tube center. A flat double spiral arc tube that is folded back by a pair of bent portions extending on both sides of the portion, and then swirls substantially in one plane in a pair of swiveling portions respectively extended to the pair of bent portions. The rated lamp power exceeds 25 W, and when the arc tube is viewed from the direction orthogonal to the plane, the tube outer diameter A of the thickest part in the swivel portion And the outer diameter B of the thinnest portion of the bent portion satisfy a relationship of 0.6 ≦ B / A ≦ 0.95.

本発明に係る蛍光ランプは、旋回部における最も太い部分の管外径Aと屈曲部における最も細い部分の管外径Bとが、0.6≦B/Aの関係を満たすため、蛍光体層の剥離による製品不良が生じ難く製造歩留まりが高い。また、前記管外径Aと前記管外径Bとが、B/A≦0.95の関係を満たすため、発光管の旋回部の外観不良による製品不良が生じ難く製造歩留まりが高い。   In the fluorescent lamp according to the present invention, the tube outer diameter A of the thickest portion in the swivel portion and the tube outer diameter B of the thinnest portion in the bent portion satisfy the relationship of 0.6 ≦ B / A. Product defects due to peeling are unlikely to occur and the manufacturing yield is high. In addition, since the tube outer diameter A and the tube outer diameter B satisfy the relationship of B / A ≦ 0.95, a product defect due to a defective appearance of the swivel portion of the arc tube hardly occurs, and the manufacturing yield is high.

本発明の一実施形態に係る蛍光ランプを示す斜視図1 is a perspective view showing a fluorescent lamp according to an embodiment of the present invention. 本発明の一実施形態に係る蛍光ランプを示す図であって、(a)は平面図、(b)は底面図、(c)は正面図、(d)は側面図It is a figure which shows the fluorescent lamp which concerns on one Embodiment of this invention, Comprising: (a) is a top view, (b) is a bottom view, (c) is a front view, (d) is a side view. ホルダ取り付け前の発光管を示す図であって、(a)は平面一部破断図、(b)は正面図It is a figure which shows the arc tube before a holder attachment, Comprising: (a) is a partially broken plan view, (b) is a front view 図3(a)におけるC−C線に沿った断面矢視図Cross-sectional arrow view along line CC in FIG. 発光管本体作製の全体の流れを説明するための図であって、(a)は加工前のガラス管を示す図、(b)は中間体を示す図、(c)は発光管本体を示す図It is a figure for demonstrating the whole flow of arc tube main body production, (a) is a figure which shows the glass tube before a process, (b) is a figure which shows an intermediate body, (c) shows an arc tube main body. Figure 巻回工程を説明するための図であって、(a)は成形治具を駆動装置に取り付けるステップを示す図、(b)は成形治具にガラス管を巻き付けるステップを示す図、(c)は成形治具からガラス管を外すステップを示す図It is a figure for demonstrating a winding process, Comprising: (a) is a figure which shows the step which attaches a shaping | molding jig to a drive device, (b) is a figure which shows the step which winds a glass tube around a shaping | molding jig, (c) Figure shows the step of removing the glass tube from the forming jig 成形治具を示す平面図Plan view showing the forming jig 平盤化工程を説明するための図であって、(a)は中間体を変形装置に設置するステップを示す図、(b)は中間体を加熱するステップを示す図、(c)は中間体に圧力を加え変形させるステップを示す図It is a figure for demonstrating a flattening process, Comprising: (a) is a figure which shows the step which installs an intermediate body in a deformation | transformation apparatus, (b) is a figure which shows the step which heats an intermediate body, (c) is intermediate | middle The figure which shows the step which deforms by applying pressure to the body B/Aの値と、蛍光体層の剥離による製造歩留まりの低下との関係を示す図The figure which shows the relationship between the value of B / A, and the fall of the manufacturing yield by peeling of a fluorescent substance layer B/Aの値と、旋回部の外観不良による製造歩留まりの低下との関係を示す図The figure which shows the relationship between the value of B / A, and the fall of the manufacturing yield by the external appearance defect of a turning part.

以下、本発明の実施の形態に係る蛍光ランプについて、図面を参照しながら説明する。
[蛍光ランプの説明]
図1は、本発明の一実施形態に係る蛍光ランプを示す斜視図である。図2は、本発明の一実施形態に係る蛍光ランプを示す図であって、(a)は平面図、(b)は底面図、(c)は正面図、(d)は側面図である。図1及び図2に示すように、本実施の形態に係る蛍光ランプ1は、定格ランプ電力が25Wを超える所謂高ワットタイプの二重渦巻形ランプであって、発光管10と当該発光管10を保持するホルダ20とを備える。
Hereinafter, fluorescent lamps according to embodiments of the present invention will be described with reference to the drawings.
[Description of fluorescent lamp]
FIG. 1 is a perspective view showing a fluorescent lamp according to an embodiment of the present invention. FIG. 2 is a view showing a fluorescent lamp according to an embodiment of the present invention, in which (a) is a plan view, (b) is a bottom view, (c) is a front view, and (d) is a side view. . As shown in FIGS. 1 and 2, the fluorescent lamp 1 according to the present embodiment is a so-called high watt type double spiral lamp having a rated lamp power exceeding 25 W, and includes an arc tube 10 and the arc tube 10. And a holder 20 for holding.

1.発光管
図3は、ホルダ取り付け前の発光管を示す図であって、(a)は平面一部破断図、(b)は正面図である。図3(a),(b)に示すように、発光管10は、両管端部11a,11bに一対の電極30a,30bが配置され、前記一対の電極30a,30b間に形成される放電路が、管中央部12を中心として、前記管中央部12の両側に延設された一対の屈曲部13a,13bで折り返されたのち前記一対の屈曲部13a,13bにそれぞれ延設された一対の旋回部14a,14bにおいて略一平面Dを渦巻状に旋回する平面二重渦巻形であって、前記管端部11a,11bは前記管中央部12を挟んで互いに対向している。発光管10の管中央部12には、ホルダ20とは反対側(照射面側)に膨出する膨出部分15が形成されており、当該膨出部分15がランプ点灯時には最冷点となる。
1. FIG. 3 is a view showing the arc tube before the holder is attached, in which (a) is a partially cutaway plan view and (b) is a front view. As shown in FIGS. 3 (a) and 3 (b), the arc tube 10 has a pair of electrodes 30a and 30b arranged at both tube ends 11a and 11b, and a discharge formed between the pair of electrodes 30a and 30b. A pair of roads that extend around the pair of bent portions 13a and 13b after the path is folded back by a pair of bent portions 13a and 13b extending on both sides of the tube center portion 12 with the tube center portion 12 as a center. In the swivel portions 14a and 14b, the tube end portions 11a and 11b are opposed to each other with the tube center portion 12 in between. A bulging portion 15 bulging to the opposite side (irradiation surface side) of the holder 20 is formed in the tube central portion 12 of the arc tube 10, and the bulging portion 15 becomes the coldest point when the lamp is lit. .

図4は、図3(a)におけるC−C線に沿った断面矢視図である。図4に示すように、発光管10の屈曲部13a,13bの管断面は、略円形を略半円状に扁平させた扁平形状を有する。発光管10を平面Dと直交する方向Eから見た場合に(例えば、図2(a)や図3(a)に示すように平面視した場合に)、旋回部14a,14bの最も径の太い部分の管外径Aと、屈曲部13a,13bにおける最も径の細い部分の管外径Bとは、0.6≦B/A≦0.95の関係を満たしている。なお、本実施の形態において、旋回部14a,14b(発光管10における管端部11a,11b、管中央部12及び屈曲部13a,13bを除いた部分)は全域に亘って管外径が略均一であり、図3(a)に示す管外径Aの位置は一例であってその位置に限定されるものではない。   FIG. 4 is a cross-sectional arrow view taken along the line CC in FIG. As shown in FIG. 4, the tube cross sections of the bent portions 13a and 13b of the arc tube 10 have a flat shape obtained by flattening a substantially circular shape into a substantially semicircular shape. When the arc tube 10 is viewed from a direction E perpendicular to the plane D (for example, when viewed in plan as shown in FIGS. 2A and 3A), the diameters of the turning portions 14a and 14b are the largest. The outer diameter A of the thick portion and the outer diameter B of the thinnest portion of the bent portions 13a and 13b satisfy the relationship of 0.6 ≦ B / A ≦ 0.95. In the present embodiment, the swivel portions 14a and 14b (portions excluding the tube end portions 11a and 11b, the tube center portion 12 and the bent portions 13a and 13b in the arc tube 10) have substantially the same tube outer diameter. The position of the pipe outer diameter A shown in FIG. 3A is an example, and is not limited to that position.

発光管10を構成するガラスは、例えば、バリウム・ストロンチウムシリケートガラス(軟化点675℃の軟質ガラス)で形成されている。また、発光管10の内面には、例えば、赤色蛍光体(Y2O3:Eu)、緑色蛍光体(LaPO4:Ce,Tb)および青色蛍光体(BaMg2Al16O27:Eu,Mn)からなる希土類蛍光体によって蛍光体層18が形成されている。   The glass constituting the arc tube 10 is made of, for example, barium strontium silicate glass (soft glass having a softening point of 675 ° C.). Further, the inner surface of the arc tube 10 is made of a phosphor by a rare earth phosphor made of, for example, a red phosphor (Y2O3: Eu), a green phosphor (LaPO4: Ce, Tb), and a blue phosphor (BaMg2Al16O27: Eu, Mn). Layer 18 is formed.

発光管10の内部には、例えば、水銀が5mg封入されているとともに、緩衝ガスとしてのアルゴンガスが封入圧約300Paとなるように封入されている。なお、発光管10内に封入する水銀は、水銀単体の他に、例えば亜鉛水銀および錫水銀でも良く、ビスマス・インジウム水銀等のアマルガムであっても良い。また、封入ガスは、アルゴン、ネオン、クリプトン等の混合ガスでも良い。   For example, 5 mg of mercury is sealed inside the arc tube 10, and argon gas as a buffer gas is sealed so as to have a sealing pressure of about 300 Pa. The mercury enclosed in the arc tube 10 may be, for example, zinc mercury and tin mercury, or amalgam such as bismuth / indium mercury in addition to mercury alone. The sealed gas may be a mixed gas such as argon, neon, or krypton.

図3(a)に戻って、電極30aは、タングステン製のフィラメントコイル31と一対のリード線32a,32bとを備え、前記フィラメントコイル31が発光管10内部に収容される状態で、前記一対のリード線32a,32b部分においてビーズガラスマウント方式により一方の管端部11aに気密封着されている。さらに、管端部11aには、発光管10への希ガスを封入する際に用いられる排気管33が、先端部が封着された状態で気密封着されている。なお、他方の管端部11bにも、電極30aと同様の構成を有する電極30bが気密封着されているが、排気管33は気密封着されていない。   Returning to FIG. 3A, the electrode 30 a includes a tungsten filament coil 31 and a pair of lead wires 32 a and 32 b, and the filament coil 31 is accommodated inside the arc tube 10. The lead wires 32a and 32b are hermetically sealed to one tube end 11a by a bead glass mounting method. Further, an exhaust pipe 33 used when sealing the rare gas into the arc tube 10 is hermetically sealed at the tube end portion 11a with the tip portion sealed. An electrode 30b having the same configuration as that of the electrode 30a is hermetically sealed at the other tube end 11b, but the exhaust pipe 33 is not hermetically sealed.

蛍光ランプ1のサイズは、定格ランプ電力が大きくなるほど大型化する傾向にある。定格ランプ電力が25Wを超え50W以下(好ましくは30W以上50W以下)である場合、発光管10の外周径L(図3(a)参照)は130〜200mm、管長は900〜1600mmであり、電極30a,30b間の距離は860〜1560mmであり、旋回部14a,14bのそれぞれの巻層数は1.4〜2.1回、管外径は10〜13mm、隣接する管壁間の隙間は5〜9mmである。   The size of the fluorescent lamp 1 tends to increase as the rated lamp power increases. When the rated lamp power exceeds 25 W and is 50 W or less (preferably 30 W or more and 50 W or less), the outer diameter L (see FIG. 3A) of the arc tube 10 is 130 to 200 mm, the tube length is 900 to 1600 mm, The distance between 30a and 30b is 860 to 1560 mm, the number of winding layers of each of the swivel portions 14a and 14b is 1.4 to 2.1 times, the outer diameter of the tube is 10 to 13 mm, and the gap between adjacent tube walls is 5-9 mm.

また、定格ランプ電力が50Wを超え100W以下である場合、発光管10の外周径Lは200〜330mm、管長は1300〜2600mmであり、電極30a,30b間の距離は1250〜2550mmであり、旋回部14a,14bのそれぞれの巻層数は1.4〜2.1回、管外径は18〜22mm、隣接する管壁間の隙間は5〜9mmである。
また、定格ランプ電力が100Wを超え150W以下である場合、発光管10の外周径Lは360〜450mm、管長は2800〜3900mmであり、電極30a,30b間の距離は2750〜3850mmであり、旋回部14a,14bのそれぞれの巻層数は1.9〜2.4回、管外径は23〜28mm、隣接する管壁間の隙間は7〜11mmである。
When the rated lamp power is more than 50 W and less than 100 W, the outer diameter L of the arc tube 10 is 200 to 330 mm, the tube length is 1300 to 2600 mm, the distance between the electrodes 30a and 30b is 1250 to 2550 mm, The number of wound layers of each of the portions 14a and 14b is 1.4 to 2.1 times, the tube outer diameter is 18 to 22 mm, and the gap between adjacent tube walls is 5 to 9 mm.
When the rated lamp power is more than 100 W and not more than 150 W, the outer diameter L of the arc tube 10 is 360 to 450 mm, the tube length is 2800 to 3900 mm, the distance between the electrodes 30a and 30b is 2750 to 3850 mm, The number of wound layers of each of the portions 14a and 14b is 1.9 to 2.4 times, the tube outer diameter is 23 to 28 mm, and the gap between adjacent tube walls is 7 to 11 mm.

2.ホルダ
図1及び図2に戻って、ホルダ20は、発光管10の管端部11a,11bに外嵌される有底筒状の一対の口金部21a,21bと、前記発光管10の照射面側とは反対側を横切って前記一対の口金部21a,21bを連結する長尺板状の連結部22とを備える。
口金部21a,21bは、灯具側のソケット(不図示)に電気的に接続させて給電を受けるためのGタイプ(例えばG5タイプ)の口金であって、互いの開口の向きが反対となる姿勢で連結部22の長手方向両端に配置されており、それぞれの底壁には一対のピン23a,23bが設けられている。
2. 1 and 2, the holder 20 includes a pair of bottomed cylindrical cap portions 21 a and 21 b that are externally fitted to the tube end portions 11 a and 11 b of the arc tube 10, and an irradiation surface of the arc tube 10. And a long plate-like connecting portion 22 that connects the pair of base portions 21a and 21b across the opposite side.
The base parts 21a and 21b are G type (for example, G5 type) bases that are electrically connected to a socket (not shown) on the lamp side to receive power supply, and their orientations are opposite to each other. Are disposed at both ends of the connecting portion 22 in the longitudinal direction, and a pair of pins 23a and 23b are provided on each bottom wall.

口金部21a,21bの開口径は発光管10の管端部11a,11bの管外径よりも大きく、それら開口内にそれぞれ前記発光管10の管端部11a,11bが挿入された状態で、前記口金部21a,21bと前記発光管10との隙間に接着剤24b(口金部21a側の接着剤は不図示)が充填されて、それら口金部21a,21bと管端部11a,11bとが固着されている。また、図2(a)に示すように、口金部21a,21bと旋回部14a,14bも接着剤25a,25bより固着されている。なお、それら接着剤24b,25a,25bとしては、例えば、シリコーン樹脂、エポキシ樹脂、アクリル樹脂およびセメント等が用いられる。   The diameters of the cap portions 21a and 21b are larger than the tube outer diameters of the tube ends 11a and 11b of the arc tube 10, and the tube ends 11a and 11b of the arc tube 10 are inserted into the openings, respectively. The gap between the base parts 21a, 21b and the arc tube 10 is filled with an adhesive 24b (the adhesive on the base part 21a side is not shown), and the base parts 21a, 21b and the tube end parts 11a, 11b are connected. It is fixed. Moreover, as shown to Fig.2 (a), base part 21a, 21b and turning part 14a, 14b are also fixed by adhesive agent 25a, 25b. In addition, as these adhesive agent 24b, 25a, 25b, a silicone resin, an epoxy resin, an acrylic resin, cement etc. are used, for example.

[蛍光ランプの製造方法]
本発明の実施の形態に係る蛍光ランプ1の製造方法について図面を用いて説明する。ここでは、発光管10の屈曲部13a,13bの形状に関わる工程のみを詳細に説明し、他の工程については説明を省略するか簡略するに留める。
図5は、発光管本体作製の全体の流れを説明するための図であって、(a)は加工前のガラス管を示す図、(b)は中間体を示す図、(c)は発光管本体を示す図である。発光管10は、図5(a)に示すような直管状のガラス管300から図5(b)に示すような外観視略円錐体形状の中間体200を作製し、さらに、当該中間体200から図5(c)に示すような平面二重渦巻形の発光管本体100を作製し、得られた発光管本体100の両管端部101a,101bに電極30a,30bを気密封着して作製される。
[Method of manufacturing fluorescent lamp]
A method of manufacturing the fluorescent lamp 1 according to the embodiment of the present invention will be described with reference to the drawings. Here, only the process related to the shape of the bent portions 13a and 13b of the arc tube 10 will be described in detail, and the description of the other processes will be omitted or simplified.
5A and 5B are diagrams for explaining the overall flow of manufacturing the arc tube body, in which FIG. 5A is a diagram showing a glass tube before processing, FIG. 5B is a diagram showing an intermediate, and FIG. 5C is a light emission. It is a figure which shows a pipe | tube main body. In the arc tube 10, an intermediate body 200 having a substantially conical shape as shown in FIG. 5B is produced from a straight tubular glass tube 300 as shown in FIG. From FIG. 5C, a flat double spiral arc tube body 100 as shown in FIG. 5C is manufactured, and electrodes 30a and 30b are hermetically sealed on both tube ends 101a and 101b of the arc tube body 100 obtained. Produced.

加工前のガラス管300は、管断面が略円形であって、図5(a)に示すように、発光管10の管端部11a,11bになる端部301a,301bと、発光管10の管中央部12になる管中央部302と、発光管10の屈曲部13a,13bになる屈曲部303a,303bと、発光管10の旋回部14a,14bになる旋回部304a,304bと、ガラス管300巻回後に除去される除去部305a,305bとからなる。   The glass tube 300 before processing has a substantially circular cross section, and as shown in FIG. 5A, end portions 301 a and 301 b that become the tube end portions 11 a and 11 b of the arc tube 10, and the arc tube 10. A tube center portion 302 that becomes the tube center portion 12, bend portions 303a and 303b that become the bent portions 13a and 13b of the arc tube 10, swivel portions 304a and 304b that become the swivel portions 14a and 14b of the arc tube 10, and a glass tube It comprises removal sections 305a and 305b that are removed after 300 windings.

図6は、巻回工程を説明するための図であって、(a)は成形治具を駆動装置に取り付けるステップを示す図、(b)は成形治具にガラス管を巻き付けるステップを示す図、(c)は成形治具からガラス管を外すステップを示す図である。図7は、成形治具を示す平面図である。
ガラス管300から中間体200を作製する巻回工程では、図6(a)及び図7に示すような成形治具400が用いられる。成形治具400は、外観視略円錐体形状であって、その頂部付近には対向する一対の係止部401a,401bが設けられている。また、成形治具400の錘面には、係止部401a,401b間に中間点が位置し、中間点の両側がそれぞれ係止部401a,401bで折り返されたのち成形治具400の軸心Fを回転軸として二重螺旋状に旋回された形状を有する誘導溝402が形成されている。
6A and 6B are diagrams for explaining the winding process, in which FIG. 6A shows a step of attaching the forming jig to the driving device, and FIG. 6B shows a step of winding the glass tube around the forming jig. (C) is a figure which shows the step which removes a glass tube from a shaping | molding jig. FIG. 7 is a plan view showing a forming jig.
In the winding process for producing the intermediate body 200 from the glass tube 300, a forming jig 400 as shown in FIGS. 6A and 7 is used. The forming jig 400 has a substantially conical shape in appearance, and a pair of opposing locking portions 401a and 401b are provided near the top. Further, an intermediate point is located between the locking portions 401a and 401b on the weight surface of the forming jig 400, and both sides of the intermediate point are folded back by the locking portions 401a and 401b, respectively. A guide groove 402 having a shape spirally turned around F as a rotation axis is formed.

巻回工程では、まず、ガラス管300を加熱炉等で加熱、軟化させる。次に、ガラス管300の管中央部302を成形治具400の係止部401a,401b間に配置し、除去部305a,305bを移動可能に保持した状態で、駆動装置の駆動力により成形治具400を矢印Gで示す方向に回転させて、同時に上昇もさせて、旋回部304a,304bを誘導溝402に沿って二重螺旋状に巻き上げる。その際、旋回部304a,304bの扁平化を防止するとともに管中央部302の照射面側を膨出させて後述する膨出部分205を形成するために、ガラス管300内に圧力制御されたエア、窒素、アルゴン等のガスが吹き込まれる。   In the winding process, first, the glass tube 300 is heated and softened in a heating furnace or the like. Next, in the state where the tube center portion 302 of the glass tube 300 is disposed between the locking portions 401a and 401b of the forming jig 400 and the removing portions 305a and 305b are held movably, the forming treatment is performed by the driving force of the driving device. The tool 400 is rotated in the direction indicated by the arrow G, and is also raised at the same time, so that the swivel portions 304 a and 304 b are wound up in a double spiral shape along the guide groove 402. At that time, pressure-controlled air in the glass tube 300 is formed in order to prevent the swiveling portions 304a and 304b from being flattened and to bulge the irradiation surface side of the tube central portion 302 to form a bulging portion 205 described later. A gas such as nitrogen or argon is blown.

ガラス管300の屈曲部303a,303bは、成形治具400の係止部401a,401bに掛かって折り曲がり、その管断面が略円形から扁平形状に変形する(扁平化する)。扁平形状はその後の工程を経ても維持され、発光管10の屈曲部13a,13bの管断面も略同形の扁平形状になる。
屈曲部303a、303bはランプにしたときの放電路の一部となるため、その断面積は大きい方がよい。しかしながら、屈曲部303a、303bの断面積を大きくしようとすると、旋回部304a、304bのうち、屈曲部303a、303bに近接している部分も断面積が大きくなる。すなわち、旋回部304a、304bにおいて、管外径が不均一となり、外観不良が生じる。このような外観不良を防止するためには、発光管10におけるB/Aの値が0.95以下となるように屈曲部303a,303bの扁平化を制御しなければならない。なお、扁平化は、巻回工程において、ガラス管300の加熱温度やガスの吹き込み量を調整することによって制御可能である。
The bent portions 303a and 303b of the glass tube 300 are bent by engaging with the engaging portions 401a and 401b of the forming jig 400, and the tube cross section is deformed from a substantially circular shape to a flat shape (flattened). The flat shape is maintained even after the subsequent steps, and the tube cross sections of the bent portions 13a and 13b of the arc tube 10 are also substantially flat.
Since the bent portions 303a and 303b become a part of the discharge path when the lamp is used, the cross-sectional area is preferably large. However, if the cross-sectional areas of the bent portions 303a and 303b are increased, the cross-sectional areas of the swivel portions 304a and 304b that are close to the bent portions 303a and 303b also increase. That is, in the swivel portions 304a and 304b, the outer diameters of the pipes are not uniform, resulting in poor appearance. In order to prevent such an appearance defect, it is necessary to control the flattening of the bent portions 303a and 303b so that the B / A value in the arc tube 10 is 0.95 or less. The flattening can be controlled by adjusting the heating temperature of the glass tube 300 and the amount of gas blown in the winding step.

温度が下がってガラス管300が硬化した後は、図6の(c)に示すように、成形治具400から前記ガラス管300を取り外し、除去部305a,305bを除去して中間体200を完成させる。
次に、中間体200内に蛍光体縣濁液を流して内面に蛍光体懸濁液を塗布し蛍光体層18を形成する。屈曲部303a,303bは、管断面が扁平形状であり更に折り返されているため蛍光体懸濁液の流れが悪く、流れが悪いと内面に蛍光体懸濁液が余分に付着してしまうため、その部分だけ必要以上に蛍光体層18が厚くなる。特に、屈曲部303a,303bのコーナー上下の曲率半径Rが大きい部分(発光管10完成後の屈曲部13a,13bにおいて、図4に符号19a,19bで示す部分となる部分)は蛍光体懸濁液が余分に付着して蛍光体層が厚くなり易い。このように蛍光体層18が厚くなった部位は、後述する平盤化工程において剥離が生じ易い。
After the temperature is lowered and the glass tube 300 is cured, as shown in FIG. 6C, the glass tube 300 is removed from the forming jig 400, and the removal portions 305a and 305b are removed to complete the intermediate body 200. Let
Next, a phosphor suspension is poured into the intermediate 200 and a phosphor suspension is applied to the inner surface to form the phosphor layer 18. Since the bent portions 303a and 303b have a flat tube cross section and are further folded, the flow of the phosphor suspension is poor, and if the flow is poor, the phosphor suspension adheres excessively to the inner surface. The phosphor layer 18 becomes thicker than necessary only in that portion. In particular, the portions where the radius of curvature R above and below the corners of the bent portions 303a and 303b is large (the portions indicated by reference numerals 19a and 19b in FIG. 4 in the bent portions 13a and 13b after the arc tube 10 is completed) are phosphor suspended. The liquid adheres excessively and the phosphor layer tends to be thick. In this way, the portion where the phosphor layer 18 is thick is likely to be peeled off in the flattening step described later.

特に、蛍光ランプ1が高ワットタイプである場合、発光管10の管外径が大きいため屈曲部13a,13bの形状が安定し難く、屈曲部303a,303bにおいて蛍光体層が厚くなり剥離が生じ易い。これを防止するためには、発光管10におけるB/Aの値が0.6以上となるように屈曲部303a,303bの扁平化を制御しなければならない。なお、上述したとおり扁平化は制御可能である。   In particular, when the fluorescent lamp 1 is a high watt type, since the outer diameter of the arc tube 10 is large, the shapes of the bent portions 13a and 13b are difficult to stabilize, and the phosphor layer becomes thicker at the bent portions 303a and 303b, resulting in peeling. easy. In order to prevent this, it is necessary to control the flattening of the bent portions 303a and 303b so that the value of B / A in the arc tube 10 is 0.6 or more. As described above, the flattening can be controlled.

図8は、平盤化工程を説明するための図であって、(a)は中間体を変形装置に設置するステップを示す図、(b)は中間体を加熱するステップを示す図、(c)は中間体に圧力を加え変形させるステップを示す図である。
平盤化工程では、中間体200を再度加熱した後、圧力を加えて変形させ、外観視略円錐体形状から図5(c)に示すような外観視略円盤形状に変形させる。平盤化工程は、図8に示すような変形装置420を用いて行われる。変形装置420は、可動板421、固定板422、複数のガイド棒423および複数の規制部材424を備える。
FIGS. 8A and 8B are diagrams for explaining the flattening process, in which FIG. 8A shows a step of installing the intermediate body in the deformation device, FIG. 8B shows a step of heating the intermediate body, (c) is a figure which shows the step which applies a pressure to an intermediate body and deform | transforms.
In the flattening step, the intermediate body 200 is heated again, and is then deformed by applying pressure, so that it is deformed from a substantially cone shape in appearance to a substantially disk shape in appearance as shown in FIG. The flattening process is performed using a deformation device 420 as shown in FIG. The deformation device 420 includes a movable plate 421, a fixed plate 422, a plurality of guide bars 423, and a plurality of regulating members 424.

可動板421および固定板422は、例えばステンレス鋼製であって、中間体200挟んで上下に対向配置される。可動板421は、固定板422に対して略平行な状態を保ちながら上下に移動可能である。また、可動板421には、後に発光管10の膨出部分15となる中間体200の膨出部分205が収まるような貫通孔425が、前記可動板421の略中央に形成されている。   The movable plate 421 and the fixed plate 422 are made of, for example, stainless steel, and are opposed to each other up and down with the intermediate body 200 interposed therebetween. The movable plate 421 can move up and down while maintaining a state substantially parallel to the fixed plate 422. The movable plate 421 is formed with a through-hole 425 in the approximate center of the movable plate 421 so that the bulging portion 205 of the intermediate body 200 that will later become the bulging portion 15 of the arc tube 10 can be accommodated.

ガイド棒423は、固定板422の上面に立設され、可動板421の孔部(不図示)を貫通している。規制部材424は、固定板422の上面の四隅に配置されており、可動板421が前記固定板422に近づき過ぎるのを規制する。
まず、図8(a)に示すように、中間体200を可動板421と固定板422との間に配置する。中間体200は、固定板422の上面の略中央であって、前記中間体200の膨出部分205が可動板421の貫通孔425の真下となる位置に配置されている。このとき、可動板421における貫通孔425の周辺は、中間体200の旋回部204a,204bの一部に当接している。
The guide bar 423 is erected on the upper surface of the fixed plate 422 and passes through a hole (not shown) of the movable plate 421. The restricting members 424 are disposed at the four corners of the upper surface of the fixed plate 422 and restrict the movable plate 421 from being too close to the fixed plate 422.
First, as illustrated in FIG. 8A, the intermediate body 200 is disposed between the movable plate 421 and the fixed plate 422. The intermediate body 200 is disposed at a position approximately at the center of the upper surface of the fixed plate 422, and the bulging portion 205 of the intermediate body 200 is directly below the through hole 425 of the movable plate 421. At this time, the periphery of the through hole 425 in the movable plate 421 is in contact with a part of the turning portions 204 a and 204 b of the intermediate body 200.

次に、図8(b)に示すように、前記中間体200を加熱する。加熱温度は、中間体200の内面に塗布されている蛍光体層18を焼成可能な温度であって、これにより、中間体200の内面の蛍光体層18が焼成される。また、加熱された中間体200は塑性変形可能となり、可動板421が自重により下降し始める。つまり、中間体200の主に旋回部204a,204bが上下方向に圧縮され変形し始める。なお、可動板421の下降は、前記可動板421が規制部材424に当接すると止まる。   Next, as shown in FIG. 8B, the intermediate 200 is heated. The heating temperature is a temperature at which the phosphor layer 18 applied to the inner surface of the intermediate body 200 can be baked, whereby the phosphor layer 18 on the inner surface of the intermediate body 200 is baked. Further, the heated intermediate body 200 can be plastically deformed, and the movable plate 421 starts to descend due to its own weight. That is, the swivel portions 204a and 204b of the intermediate body 200 are compressed in the vertical direction and begin to deform. The lowering of the movable plate 421 stops when the movable plate 421 comes into contact with the regulating member 424.

このように平盤化工程では、蛍光体層18の焼成と中間体200の変形とがおこなわれるが、蛍光体層18が必要以上に厚く形成されている場合は、焼成された蛍光体層18が中間体200の変形によって内面から剥離してしまうおそれがある。
なお、加熱温度は、ガラス(軟質ガラス)の軟化点よりも低く設定されていることが好ましい。中間体200の温度が軟化点以上になると、ガラスが自重で変形するため前記中間体200の形状の保持が困難となる。また、ガラスの軟化点付近まで温度を上げると、中間体200の内面に形成された蛍光体層18の剥離がより酷くなる不具合が生じる。
As described above, in the flattening process, the phosphor layer 18 is baked and the intermediate body 200 is deformed. When the phosphor layer 18 is formed to be thicker than necessary, the baked phosphor layer 18 is formed. However, there is a risk of peeling from the inner surface due to deformation of the intermediate body 200.
The heating temperature is preferably set lower than the softening point of glass (soft glass). When the temperature of the intermediate body 200 is equal to or higher than the softening point, the glass is deformed by its own weight, so that it is difficult to maintain the shape of the intermediate body 200. Further, when the temperature is raised to the vicinity of the softening point of the glass, there arises a problem that the peeling of the phosphor layer 18 formed on the inner surface of the intermediate 200 becomes more severe.

図8(c)に示すように、可動板421が規制部材424に当接した状態になると、中間体200の発光管本体100への変形が完了する。
次に、発光管本体100に電極30a,30bを封着する。具体的には、発光管本体100の管端部101aに電極30aと排気管33を、管端部101bに電極30bをそれぞれ挿入し、前記管端部101a,101bをバーナーにより加熱軟化させ、ピンチブロックで加熱軟化箇所を圧壊封着する。
As shown in FIG. 8C, when the movable plate 421 comes into contact with the regulating member 424, the deformation of the intermediate body 200 into the arc tube main body 100 is completed.
Next, the electrodes 30 a and 30 b are sealed to the arc tube main body 100. Specifically, the electrode 30a and the exhaust pipe 33 are inserted into the tube end portion 101a of the arc tube main body 100, the electrode 30b is inserted into the tube end portion 101b, and the tube end portions 101a and 101b are heated and softened by a burner, and then pinched. Crush and heat the softened areas with a block.

このようにして作製された発光管10にホルダ20が取り付けられ、蛍光ランプ1が完成する。ホルダ20は、口金部21a,21bの開口に発光管10の管端部11a,11bを挿入し、口金部21a,21bと管端部11a,11bとの隙間に接着剤24bを流し込んで固着する。最後に、リード線32a,32bとピン23a,23bとを電気的に接続する。   The holder 20 is attached to the arc tube 10 thus manufactured, and the fluorescent lamp 1 is completed. The holder 20 inserts the tube end portions 11a and 11b of the arc tube 10 into the openings of the base portions 21a and 21b, and fixes the adhesive 24b by pouring the adhesive 24b into the gap between the base portions 21a and 21b and the tube end portions 11a and 11b. . Finally, the lead wires 32a and 32b and the pins 23a and 23b are electrically connected.

[歩留まり評価]
図9は、B/Aの値と、蛍光体層の剥離による製造歩留まりの低下との関係を示す図である。図9に示すように、旋回部14a,14bの管外径が9mmである低ワットタイプの蛍光ランプ(定格ランプ電力7W以上25W以下)、管外径が12mmである高ワットタイプの蛍光ランプ(定格ランプ電力25Wを超え50W以下、好ましくは30W以上50W以下)、管外径が20mmである高ワットタイプの蛍光ランプ(定格ランプ電力50Wを超え100W以下)、管外径が25.5mmである高ワットタイプの蛍光ランプ(定格ランプ電力100Wを超え150W以下)それぞれについて、B/Aの値の異なる蛍光ランプを種々作製し、それらの蛍光体層剥離に関する製品歩留まりを評価した。
製造歩留まりの評価では、屈曲部の内面における蛍光体層の剥離の有無を観察し、剥離が観察されなかったものを良品と、蛍光体層の剥離が観察されたものを不良品と判断し、良品率を求めた。不良品と判断される剥離の程度を具体的に説明すると、幅1mm×長さ3mm以上の剥離が生じた場合である。
[Yield evaluation]
FIG. 9 is a diagram showing the relationship between the value of B / A and the decrease in manufacturing yield due to the peeling of the phosphor layer. As shown in FIG. 9, a low watt type fluorescent lamp (rated lamp power of 7 W or more and 25 W or less) having a tube outer diameter of 9 mm of the swivel parts 14a and 14b, and a high watt type fluorescent lamp having a tube outer diameter of 12 mm ( A rated lamp power exceeding 25 W and 50 W or less, preferably 30 W or more and 50 W or less), a high watt type fluorescent lamp having a tube outer diameter of 20 mm (rated lamp power exceeding 50 W and 100 W or less), and a tube outer diameter of 25.5 mm. For each of the high watt type fluorescent lamps (more than the rated lamp power of 100 W and 150 W or less), various fluorescent lamps having different B / A values were produced, and the product yield regarding the phosphor layer peeling was evaluated.
In the evaluation of the production yield, the presence or absence of peeling of the phosphor layer on the inner surface of the bent portion was observed. The yield rate was determined. Specifically, the degree of peeling determined to be a defective product is a case where peeling of width 1 mm × length 3 mm or more has occurred.

評価の結果、高ワットタイプの蛍光ランプの場合は、0.6≦B/Aの関係を満たせば、製品歩留まりが90%以上であり、蛍光体層の剥離が生じ難いことがわかった。一方、低ワットタイプの蛍光ランプの場合は、0.6≦B/Aの関係を満たさなくても(B/A=0.56の場合でも)製造歩留まりが90%以上の場合があり、高ワットタイプの蛍光ランプ1のように、必ずしも0.6≦B/Aの関係を満たす必要がないことがわかった。   As a result of the evaluation, it was found that in the case of a high watt type fluorescent lamp, if the relationship of 0.6 ≦ B / A is satisfied, the product yield is 90% or more, and the phosphor layer is hardly peeled off. On the other hand, in the case of a low-wattage type fluorescent lamp, the production yield may be 90% or more even if the relationship of 0.6 ≦ B / A is not satisfied (even when B / A = 0.56). It was found that the relationship of 0.6 ≦ B / A is not necessarily satisfied as in the watt type fluorescent lamp 1.

図10は、B/Aの値と、旋回部の外観不良による製造歩留まりの低下との関係を示す図である。蛍光体層の剥離による製造歩留まりの評価と同じく、旋回部の管外径が9mm、12mm、20mm、25.5mmである蛍光ランプそれぞれについて、B/Aの値の異なる蛍光ランプを種々作製して、旋回部の外観不良に関する製品歩留まりを評価した。
製造歩留まりの評価では、平面視において旋回部の外観形状を観察し、外観形状の良いものを良品と、外観形状の悪いものを不良品と判断し、良品率が90%以上の場合を「○」、90%未満の場合を「×」とした。なお、旋回部の屈曲部から1ターン以内の領域において特に外観不良が生じ易かった。外観不良と判断される程度を具体的に説明すると、旋回部304a、304bの屈曲部から1ターン以内の領域での管外径の最大値が、端部301a、301bの管外径の1.2倍以上の場合である。
FIG. 10 is a diagram illustrating a relationship between the value of B / A and a decrease in manufacturing yield due to poor appearance of the swivel unit. Similar to the evaluation of the production yield by peeling off the phosphor layer, various fluorescent lamps having different B / A values were produced for each of the fluorescent lamps having tube outer diameters of 9 mm, 12 mm, 20 mm and 25.5 mm. The product yield concerning the appearance defect of the turning part was evaluated.
In the evaluation of the production yield, the appearance of the swivel part is observed in a plan view, and a product with a good appearance is judged as a non-defective product and a product with a poor appearance is judged as a defective product. ", The case of less than 90% was taken as" x ". It should be noted that an appearance defect was particularly likely to occur in a region within one turn from the bent portion of the turning portion. Explaining in detail the degree of appearance failure, the maximum value of the pipe outer diameter in the region within one turn from the bent part of the swivel parts 304a and 304b is 1. This is a case of 2 times or more.

評価の結果、高ワットタイプの蛍光ランプの場合は、B/A≦0.95の関係を満たせば、製品歩留まりが95%以上であり、旋回部の外観不良による製品不良が生じ難いことがわかった。
[変形例]
以上、本発明に係る蛍光ランプを実施の形態に基づいて具体的に説明してきたが、本発明の内容は、上記の実施の形態に限定されない。例えば、発光管は必ずしもホルダによって保持されていなくても良く、ホルダを備えず発光管の両管端部に口金だけが取り付けられた構成であっても良い。また、発光管の外観形状は、平面視において円形の渦巻形のものに限定されず、例えば、平面視において四角形などの多角形の渦巻形のものであっても良い。
As a result of the evaluation, in the case of a high watt type fluorescent lamp, it is found that if the relationship of B / A ≦ 0.95 is satisfied, the product yield is 95% or more, and the product defect due to the appearance defect of the swivel part is difficult to occur. It was.
[Modification]
Although the fluorescent lamp according to the present invention has been specifically described above based on the embodiment, the contents of the present invention are not limited to the above-described embodiment. For example, the arc tube may not necessarily be held by a holder, and a configuration in which only a base is attached to both ends of the arc tube without the holder may be employed. Further, the external shape of the arc tube is not limited to a circular spiral shape in a plan view, and may be, for example, a polygonal spiral shape such as a quadrangle in a plan view.

本発明の蛍光ランプは、放電路が管中央部を中心として略一平面を渦巻状に旋回する平面二重渦巻形の発光管を備えた蛍光ランプに利用できる。   INDUSTRIAL APPLICABILITY The fluorescent lamp of the present invention can be used for a fluorescent lamp provided with a flat double spiral arc tube whose discharge path swirls substantially in one plane around the center of the tube.

1 蛍光ランプ
10 発光管
11a,11b 管端部
12 管中央部
13a,13b 屈曲部
14a,14b 旋回部
30a,30b 電極
1 fluorescent lamp 10 arc tube 11a, 11b tube end
12 Tube central part 13a, 13b Bent part 14a, 14b Swivel part 30a, 30b Electrode

Claims (4)

両管端部に一対の電極が配置され、前記一対の電極間に形成される放電路が、管中央部を中心として、前記管中央部の両側に延設された一対の屈曲部で折り返されたのち前記一対の屈曲部にそれぞれ延設された一対の旋回部において略一平面を渦巻状に旋回する平面二重渦巻形の発光管を備えた蛍光ランプであって、
定格ランプ電力が25Wを超えており、かつ、前記発光管は、前記平面と直交する方向から見た場合に、前記旋回部における最も太い部分の管外径Aと前記屈曲部における最も細い部分の管外径Bとが、0.6≦B/A≦0.95の関係を満たすことを特徴とする蛍光ランプ。
A pair of electrodes are arranged at both ends of the tube, and a discharge path formed between the pair of electrodes is folded back by a pair of bent portions extending on both sides of the tube center portion with the tube center portion as a center. A fluorescent lamp comprising a planar double spiral arc tube that spirally swivels substantially in one plane in a pair of swivel portions respectively extending to the pair of bent portions;
When the rated lamp power exceeds 25 W and the arc tube is viewed from the direction orthogonal to the plane, the tube outer diameter A of the thickest part in the swivel part and the thinnest part of the bent part A fluorescent lamp characterized in that a tube outer diameter B satisfies a relationship of 0.6 ≦ B / A ≦ 0.95.
前記発光管の管長が900〜1600mm、前記一対の旋回部における管外径が10〜13mmであることを特徴とする請求項1記載の蛍光ランプ。   2. The fluorescent lamp according to claim 1, wherein a tube length of the arc tube is 900 to 1600 mm, and an outer diameter of the tube at the pair of turning portions is 10 to 13 mm. 前記発光管の管長が1300〜2600mm、前記一対の旋回部における管外径が18〜22mmであることを特徴とする請求項1記載の蛍光ランプ。 2. The fluorescent lamp according to claim 1, wherein a tube length of the arc tube is 1300 to 2600 mm, and an outer diameter of the tube at the pair of swivel portions is 18 to 22 mm. 前記発光管の管長が2800〜3900mm、前記一対の旋回部における管外径が23〜28mmであることを特徴とする請求項1記載の蛍光ランプ。 2. The fluorescent lamp according to claim 1, wherein a tube length of the arc tube is 2800 to 3900 mm, and a tube outer diameter of the pair of swivel portions is 23 to 28 mm.
JP2009102037A 2009-04-20 2009-04-20 Fluorescent lamp Withdrawn JP2010251243A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102915904A (en) * 2012-10-11 2013-02-06 福建永德吉灯业股份有限公司 External electrode flat fluorescent lamp

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102915904A (en) * 2012-10-11 2013-02-06 福建永德吉灯业股份有限公司 External electrode flat fluorescent lamp

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