JP2011100615A - Fluorescent lamp and manufacturing method of fluorescent lamp - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fluorescent lamp capable of improving luminance as well as preventing falling-off of a phosphor film, and a manufacturing method of the fluorescent lamp. <P>SOLUTION: The fluorescent lamp 111 is provided with a glass tube bulb 101, a first phosphor layer 107 which is formed on the inner side of the glass tube bulb and has a large-particle phosphor 107a as a main component, a second phosphor layer 108 which is formed on the first phosphor layer 107 and has a small-particle phosphor 108a with the center particle diameter smaller than that of the large-particle phosphor 107a as a main component, a discharge gas 140 which is sealed inside the glass tube bulb 101, and a pair of electrodes 105 installed in the glass tube bulb 101. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a fluorescent lamp and a method for manufacturing the fluorescent lamp.

  As a technique for improving the luminance of a fluorescent lamp, it is known to increase the amount of phosphor used per lamp.

  In addition, in order to make the luminance uniform over the entire length of the fluorescent lamp, it has been proposed to increase the amount of phosphor attached to both ends of the glass tube to increase the thickness of the fluorescent layer (for example, Patent Document 1).

JP 2000-182567 A

  As described above, the luminance of the fluorescent lamp can be improved by increasing the amount of phosphor attached. However, when the amount of the phosphor adhered is increased, the phosphor film easily falls. In particular, when the phosphor film is formed of a phosphor having a large central particle size, the ground contact area with the glass tube is reduced and the phosphor film is easily dropped.

  On the other hand, when a phosphor having a small center particle diameter is attached to the glass tube so as to have the same film thickness as in the above case, the phosphors are strongly bonded to each other and the ground contact area with the glass tube is increased, so that it is difficult to fall. However, since the amount of the phosphor increases, the luminance is not improved due to light scattering inside the phosphor thin film.

  The present invention has been made paying attention to such problems, and an object of the present invention is to provide a fluorescent lamp and a method of manufacturing the fluorescent lamp that can prevent the phosphor film from dropping and improve the luminance.

In order to solve the above-described problem, a fluorescent lamp according to the first aspect of the present invention includes:
A glass tube valve,
A first phosphor layer mainly composed of a large particle phosphor formed inside the glass tube bulb;
A second phosphor layer mainly composed of a small particle phosphor having a smaller center particle diameter than the large particle phosphor formed on the first phosphor layer;
A discharge medium enclosed in the glass tube bulb;
A pair of electrodes provided in the glass tube bulb;
It is characterized by having.

In order to solve the above problems, a method for manufacturing a fluorescent lamp according to a second aspect of the present invention includes
Preparing a hollow glass tube bulb;
Preparing a first phosphor layer dispersion containing a large particle phosphor;
Preparing a second phosphor layer dispersion containing a small particle phosphor having a smaller center particle diameter than the large particle phosphor;
Applying and drying the first phosphor layer dispersion on the inner surface of the glass tube bulb to form a first phosphor layer;
Applying the second phosphor layer dispersion on the first phosphor layer and drying to form a second phosphor layer;
Firing the large particle phosphor and the small particle phosphor;
A step of enclosing mercury and a rare gas in the glass tube bulb and sealing an end portion of the glass tube.

  According to this feature, it is possible to improve the brightness of the fluorescent lamp and to prevent the phosphor film from falling.

(A) is longitudinal direction sectional drawing of the fluorescent lamp concerning 1st Embodiment, (b) is sectional drawing in the XX line of (a). It is sectional drawing which shows typically the cross section of the fluorescent substance layer formed inside the glass tube bulb of the fluorescent lamp concerning 1st Embodiment. (A) is longitudinal direction sectional drawing of the fluorescent lamp concerning 2nd Embodiment, (b) is sectional drawing in the YY line of (a). It is sectional drawing which shows typically the cross section of the fluorescent substance layer formed inside the glass tube bulb of the fluorescent lamp concerning 2nd Embodiment.

  Hereinafter, fluorescent lamps according to embodiments of the present invention will be described with reference to the drawings.

(First embodiment)
The fluorescent lamp 111 according to the first embodiment is a hot cathode fluorescent lamp. As shown in FIG. 1A, the fluorescent lamp 111 includes a glass tube bulb 101, an electrode 105, a first phosphor layer 107, a second phosphor layer 108, and a discharge gas 140.

  The glass tube bulb 101 has a straight tube shape, and the cross section of the glass tube bulb 101 is circular as shown in FIG. The glass tube bulb 101 is formed, for example, with an outer diameter of 24.5 mm, an inner diameter of 22.5 mm, and a total length of 225 mm.

  As shown in FIG. 2, the phosphor layer is composed of a first phosphor layer 107 whose main component is a large particle phosphor 107a and a second phosphor layer 108 whose main component is a small particle phosphor 108a. ing. The first phosphor layer 107 is formed on the glass tube bulb 101 (inner surface), and the second phosphor layer 108 is formed on the first phosphor layer 107 (inner surface). The first phosphor layer 107 and the second phosphor layer 108 are formed concentrically with the glass tube bulb 101.

  The large particle phosphor 107a contained in the first phosphor layer 107 has a center particle size of 7.5 μm or more, preferably 10 to 50 μm. Here, the particle size refers to, for example, one represented by a Stokes equivalent diameter by a sedimentation method, one represented by a circle equivalent diameter by a microscope method, and one represented by a sphere equivalent diameter by a light scattering method. The central particle size is, for example, the particle size distribution of the powder (distribution with respect to the particle size of the particles constituting the particle group), and the total mass larger than a certain particle size is 50% of that of the total powder. The particle size when occupied. These definitions and terms are well known to those skilled in the art, and are described in various documents such as JISZ8901 “Test Powder and Test Particles”.

  In the dispersion liquid for forming the first phosphor layer 107, the large-particle phosphor 107a is dispersed in the resin. Examples of the resin include an epoxy resin, a silicone resin, and a cellulose resin (methyl cellulose, ethyl cellulose, nitrocellulose). When dispersing the large particle phosphor 107a in the resin, the weight ratio of the large particle phosphor 107a to the total of the large particle phosphor 107a and the resin is 80 to 99.99% by weight, preferably 90% by weight or more. It is.

  The small particle phosphor 108a contained in the second phosphor layer 108 has a center particle size of about 5 μm. In the dispersion liquid forming the second phosphor layer 108, the small particle phosphor 108a is dispersed in the resin. When the small particle phosphor 108a is dispersed in the resin, the weight ratio of the small particle phosphor 108a to the total of the small particle phosphor 108a and the resin is 80 to 99.99% by weight, preferably 90% by weight or more. It is.

  In the present embodiment, the ratio of the center particle diameter of the large particle phosphor 107a to the center particle diameter of the small particle phosphor 108a is approximately 2: 1. 1 to 10: 1.

The first phosphor layer 107 and the second phosphor layer 108 convert ultraviolet rays irradiated from mercury in the discharge gas 140 into visible light. The first phosphor layer 107 is configured to contain one kind or two or more kinds of phosphors of a red light emitting phosphor, a green light emitting phosphor and a blue light emitting phosphor. The second phosphor layer 108 is a three-wavelength light-emitting phosphor containing a red light-emitting phosphor, a green light-emitting phosphor, and a blue light-emitting phosphor. For example, the red light-emitting phosphor is formed from Y ₂ O ₃ : Eu, the green light-emitting phosphor is formed from LaPO ₄ : Ce, Tb, and the blue light-emitting phosphor is formed from BaMg ₂ Al ₁₆ O ₂₇ : Eu. As described above, the first phosphor layer 107 is mainly composed of a large particle phosphor 107a having a center particle diameter of 10 to 50 μm, and the second phosphor layer 108 is a small particle phosphor having a center particle diameter of about 5 μm. The main component is 108a.

  The first phosphor layer 107 is mainly composed of a large particle phosphor 107a. Therefore, since the first phosphor layer 107 has a small amount of phosphor particles, the ground contact area with the glass tube bulb 101 is small and the first phosphor layer 107 is easily peeled off. On the other hand, the second phosphor layer 108 is mainly composed of a small particle phosphor 108a. Therefore, since the second phosphor layer 108 has a large amount of phosphor particles, the particles are strongly bonded to each other to form a dense film.

  The discharge gas 140 is filled in the hollow portion of the glass tube bulb 101 and is composed of a predetermined amount of mercury vapor and a rare gas. The mercury vapor is for obtaining ultraviolet light that excites the first phosphor layer 107 and the second phosphor layer 108. The rare gas is for adjusting the pressure inside the glass tube bulb 101 to a predetermined reduced pressure atmosphere, and is a mixed gas of argon and neon. The ratio of argon to neon is, for example, 5% by weight for Ar and 95% by weight for Ne.

  The electrodes 105 are disposed at both ends of the glass tube bulb 101. The tip of each electrode 105 includes a filament 106. The electrode 105 energizes the filament 106. The filament 106 is coated with an electron-emitting material made of BaO, SrO, CaO, etc., generates heat when energized, and emits thermoelectrons for generating a discharge in the glass tube bulb 101.

  When a voltage is applied to the electrode 105 in the glass tube bulb 101, a discharge is generated between both electrodes 105 through the discharge gas 140 enclosed in the glass tube bulb 101. Along with the discharge, mercury in the discharge gas 140 emits ultraviolet rays (main wavelength 254 nm) by excitation radiation. The generated ultraviolet light is irradiated to the surrounding first phosphor layer 107 and the second phosphor layer 108, and the phosphor particles in the first phosphor layer 107 and the second phosphor layer 108 are excited, and visible light (wavelength) About 400 nm or more). When this visible light is emitted to the outside, a beautiful luminous flux of the fluorescent lamp 111 is obtained.

  Thus, in the present embodiment, the second phosphor layer 108 mainly composed of the small particle phosphor 108a is formed on (inside) the first phosphor layer 107 mainly composed of the large particle phosphor 107a. did. For this reason, since the second phosphor layer 108 holds the large particle phosphor 107a that is easily peeled off from the glass because the ground contact area is small, the phosphor does not fall and functions as a fluorescent lamp. Can be maintained for a long time.

  Moreover, in this embodiment, the 1st fluorescent substance layer 107 has the large particle fluorescent substance 107a as a main component. For this reason, in the phosphor film mainly composed of a phosphor having a small center particle diameter, the luminance cannot be improved due to light scattering inside the phosphor layer. On the other hand, in this embodiment, even if the phosphor layer is formed with the same film thickness, the amount of phosphor particles can be reduced, so that light scattering can be reduced and the luminance can be improved.

(Fluorescent lamp manufacturing method according to the first embodiment)
Next, a method for manufacturing a fluorescent lamp having the above configuration will be described.

  First, a hollow glass tube is cut into a predetermined length, and the inner surface of the cut glass tube is washed with pure water or the like to clean the inner surface of the glass tube.

Next, red light emitting phosphor Y ₂ O ₃ : Eu, green light emitting phosphor LaPO ₄ : Ce, Tb, and blue light emitting phosphor BaMg ₂ Al ₁₆ O ₂₇ : Eu for forming the first phosphor layer 107 are formed. A dispersion liquid (first phosphor layer dispersion liquid) in which the particles are dispersed in a dispersion medium is prepared.

Similarly, red light-emitting phosphor Y ₂ O ₃ : Eu, green light-emitting phosphor LaPO ₄ : Ce, Tb, and blue light-emitting phosphor BaMg ₂ Al ₁₆ O ₂₇ for forming the second phosphor layer 108: A dispersion liquid (second phosphor layer dispersion liquid) in which Eu particles are dispersed in a dispersion medium is prepared.

  Note that the dispersion may contain a binder component. Examples of the binder component include phenol resin, epoxy resin, acrylic resin, cellulose resin (such as methylcellulose, ethylcellulose, and nitrocellulose), PVP (polyvinyl alcohol), butyral resin, and silicone resin.

  When the binder component remains in the fluorescent lamp product, it becomes an impurity and may cause problems in the product life (durability), brightness (brightness), antireflection effect, etc. Volatilize so that it does not substantially remain.

  Then, the first phosphor layer dispersion is first applied to the inner surface of the glass tube bulb 101 and dried, and then the second phosphor layer dispersion is applied and dried. And it fires. As a coating method, a spraying method, a dip method, a suction method, a method of flowing a liquid into a glass tube valve, or the like can be used. As an application method, an electrostatic coating method or a sol-gel method using a solution in which a metal alkoxide is dissolved in an organic solvent can be used.

  Even when any of the above coating methods is used, in order to make the thickness of the layer in the entire glass tube bulb uniform, the management of the processing time, the management of the amount of the dispersion, etc. are performed.

  Subsequently, an electrode is provided inside the glass tube, mercury and a rare gas are sealed inside the glass tube, and the end of the glass tube is sealed.

  As a result, the fluorescent lamp 111 according to the first embodiment in which the first phosphor layer 107 is formed on the inner surface of the glass tube bulb 101 and the second phosphor layer 108 is further stacked thereon can be obtained. it can.

  Hereinafter, experimental results in the present embodiment will be described.

  A first phosphor layer dispersion and a second phosphor layer dispersion containing a three-wavelength light emitting phosphor having a center particle size shown in Table 1 were prepared. A first phosphor layer was formed on the inner surface of the glass tube bulb, and a second phosphor layer was stacked thereon to obtain glass tube bulbs (samples A to E) having the phosphor layer.

  The adhesion was examined by applying a predetermined impact from the outside of Samples A to E to examine the adhesion of the phosphor to the glass tube bulb. The case where the phosphor was not peeled off was marked as “◯”, and the case where the phosphor was peeled off was marked as “X”.

  When the brightness of a single fluorescent lamp containing a three-wavelength phosphor having a center particle diameter of about 5 μm, which is generally widely used for fluorescent lamps, is 100%, the glass tube bulbs of Samples A to E are used. When the brightness of the fluorescent lamp produced by the method was 98 to 102%, it was evaluated as ◯, when it was higher than 102%, ◎, and when it was lower than 98%, it was rated as x.

  Samples A to C were suitable for both adhesion and brightness. However, Samples D and E were not suitable for adhesion. Therefore, the brightness could not be evaluated.

(Second Embodiment)
In the first embodiment, the first phosphor layer 107 is applied on the glass tube bulb 101 (inner surface), and the glass tube bulb 101 and the first phosphor layer 107 are closely arranged. The protective film layer 102 is applied on the tube bulb 101 (inner surface), the glass tube valve 101 and the protective film layer 102 are closely arranged, and the first phosphor layer is formed on the protective film layer 102 (inner surface). It is also possible to arrange 107 and the second phosphor layer 108.

  A configuration example in which this configuration is applied to a hot cathode fluorescent lamp is shown in FIGS. As shown in FIG. 3B, the fluorescent lamp 111 has a protective film layer 102, a first phosphor layer 107, and then a second phosphor layer 108 on the inner surface of a glass tube bulb 101 having a circular cross section. Each layer is formed concentrically with the glass tube bulb 101.

  The protective film layer 102 suppresses the compound produced by the reaction between the glass tube bulb 101 of the fluorescent lamp and mercury enclosed in the lamp from adhering to the surface of the glass tube bulb. Moreover, it suppresses that glass deteriorates and discolors with the ultraviolet-ray which generate | occur | produces inside a fluorescent lamp.

The protective film layer 102 contains a fine particle oxide. As the fine particle oxide, oxides such as alumina (Al ₂ O ₃ ) and yttria (Y ₂ O ₃ ) can be used. The thickness of the protective film layer 102 is not particularly limited, but if it is thick, the transmittance is lowered, so that it is preferably 3 μm or less.

  The fluorescent lamp 111 having such a configuration can be manufactured, for example, by the following steps.

First, a dispersion liquid (protective film layer dispersion liquid) in which oxide particles such as alumina (Al ₂ O ₃ ) that will form the protective film layer 102 are dispersed in a dispersion medium is prepared. Further, the same first phosphor layer dispersion and second phosphor layer dispersion are adjusted as in the first embodiment.

  Then, a protective film layer dispersion is first applied and dried on the inner surface of the glass tube prepared in the same procedure as in the first embodiment. Next, the first phosphor layer dispersion is applied and dried, and then the second phosphor layer dispersion is applied and dried. Then fire.

  Subsequently, an electrode is provided inside the glass tube, mercury and a rare gas are sealed inside the glass tube, and the end of the glass tube is sealed.

  Thereby, the protective film layer 102 is formed on the glass tube bulb 101 (inner surface), the first phosphor layer 107 is further formed on the inner surface (inner surface), and the second phosphor layer is further formed on the inner surface (inner surface). It is possible to obtain the fluorescent lamp 111 according to the second embodiment in which 108 is stacked.

  In the present embodiment, since the protective film layer 102 is disposed in close contact with the upper surface (inner surface) of the glass tube bulb 101, the compound produced by the reaction between the glass tube bulb 101 and mercury adheres to the glass tube bulb surface. In addition, the glass is prevented from being deteriorated and discolored by ultraviolet rays generated inside the fluorescent lamp. Therefore, since the transparent glass tube bulb 101 is not colored, the luminance of the fluorescent lamp can be further improved as compared with the first embodiment.

(Other embodiments)
For example, Y ₂ O ₃ S: Eu, SrS: Eu, CaS: Eu, CaAlSiN ₃ : Eu, and La ₂ O ₂ S: Eu are used for the red light-emitting phosphor. be able to. As the blue fluorescent light emitter, ZnS: Ag, (Ba, Sr) MgAl ₁₀ O ₁₇ : Eu, Mn, (Ba, Sr, Ca, Mg) ₁₀ (PO ₄ ) ₆ Cl ₂ : Eu, or the like may be used. it can. Further, the green light emitting phosphor includes BaMgAl ₁₀ O ₁₇ : Eu, Mn, (MgCaSrBa) Si ₂ O ₂ N ₂ : Eu, Ba ₂ SiO ₄ : Eu, CeMgAl ₁₁ O ₁₉ : Tb, LaPO ₄ : Tb and ( Ce, Gd) MgB ₅ O ₁₀ : Tb or the like can be used.

  Moreover, it is not limited to the shape and size shown by the said embodiment, As other shapes of a glass tube, you may be bent in U shape, W shape, ring shape, etc. The size of a glass tube is desired The dimensions are acceptable.

  Moreover, in the said embodiment, although the protective film layer 102 was arrange | positioned closely on the glass tube valve | bulb 101 (inner surface), it is not limited to it. The protective film layer 102 may be disposed on the inner surface (the inner surface) of the second phosphor layer 108 as long as the hermeticity is maintained so that the mercury sealed in the lamp does not react with the glass tube bulb.

  In the above embodiment, an example in which the fluorescent lamp 111 is applied to a hot cathode fluorescent lamp has been described. However, the present invention is not limited to this, and can be applied to a cold cathode fluorescent lamp and an external electrode fluorescent lamp.

  In the above embodiment, the first phosphor layer 107 is configured to contain any one kind or two or more kinds of phosphors of a red light emitting phosphor, a green light emitting phosphor and a blue light emitting phosphor. It is not limited. It may be configured to contain only white light emitting phosphors, or it may be configured to contain two or more types of phosphors among red light emitting phosphors, green light emitting phosphors, blue light emitting phosphors and white light emitting phosphors. May be.

101 Glass tube bulb 102 Protective film layer 105 Electrode 106 Filament 107 First phosphor layer 107a Large particle phosphor 108 Second phosphor layer 108a Small particle phosphor 111 Fluorescent lamp 140 Discharge gas

Claims (5)

A glass tube valve,
A first phosphor layer mainly composed of a large particle phosphor formed inside the glass tube bulb;
A second phosphor layer mainly composed of a small particle phosphor having a smaller center particle diameter than the large particle phosphor formed on the first phosphor layer;
A discharge medium enclosed in the glass tube bulb;
A pair of electrodes provided in the glass tube bulb;
A fluorescent lamp characterized by comprising:   The fluorescent lamp according to claim 1, further comprising a protective film layer inside the glass tube bulb.   The fluorescent lamp according to claim 1 or 2, wherein a ratio of a center particle diameter of the large particle phosphor and a center particle diameter of the small particle phosphor is 1.5: 1 to 10: 1.   4. The fluorescent lamp according to claim 1, wherein the large particle phosphor has a center particle diameter of 10 [mu] m or more. Preparing a hollow glass tube bulb;
Preparing a first phosphor layer dispersion containing a large particle phosphor;
Preparing a second phosphor layer dispersion containing a small particle phosphor having a smaller center particle diameter than the large particle phosphor;
Applying and drying the first phosphor layer dispersion on the inner surface of the glass tube bulb to form a first phosphor layer;
Applying the second phosphor layer dispersion on the first phosphor layer and drying to form a second phosphor layer;
Firing the large particle phosphor and the small particle phosphor;
Sealing mercury and a rare gas in the glass tube bulb and sealing the end of the glass tube;
The manufacturing method of the fluorescent lamp containing this.

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