JP2013225459A - Lamp with e-shaped bayonet cap - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a lamp with a new solder-free e-shaped bayonet cap structure.SOLUTION: A lamp with an e-shaped bayonet cap comprises: a groove 40 formed at a screw part of a bulb neck 14 in an axial direction of the lamp. The bayonet cap includes a metal trunk screwing together with the bulb neck 14 having an insulator therein; and a metal eyelet fixed at a bottom part of the insulator exposed from an end portion of the trunk. A flag assembly made by intermediate part of coated wire is disposed in a space surrounded by the groove 40 and the metal trunk, along the groove 40. One lead wire from a light source part is electrically connected to the metal eyelet coming through inside space of the insulator, and the other lead wire is connected to one end of a wire of the flag assembly, the other end is electrically connected to the metal trunk outer peripheral portion. The flag assembly is held because of a size of the bulb neck groove bottom. A topmost of a screw valley in the bulb neck 14 is infilled just before reaching the groove 40, so that an inner side wall area of the groove 40 is widened and expanded upward and an escaping area is formed for the flag assembly to move.

Description

  The present invention relates to a lamp having an E-shaped base. More specifically, the present invention relates to a lamp having a solder-free E-shaped base structure.

  In many cases, a lamp is provided with a metal base attached to a glass outer bulb (also referred to as a “bulb”) and screwed into a socket (not shown) to supply power. FIG. 1 is a diagram illustrating the structure of a lamp cap. FIG. 1A shows an HID lamp 10 as an example of a lamp. Such a lamp base 12 is called an E-shaped base (also referred to as an “E base”). The E-shaped base has a plurality of sizes. The diameter of the screwed portion is written together with E, which represents Edison base, in mm, and expressed as E14, E17, E26, E39, and the like.

  As shown in FIGS. 1B to 1D, the E-shaped base 12 is composed of three main parts. Schematically speaking, the E-shaped base 12 has an outer shape of about 1/3 of a columnar shape, a male screw 26a is formed around it, a middle level of about 1/3 is formed into a convex spherical shape, and a lower level of about 1 /. 3 is formed with a cylindrical bottom portion having a diameter smaller than that of the upper portion, and has a generally truncated cone-shaped insulator 26 (see (B)), and a metal barrel portion (“shell”) incorporating the insulator 26 therein. 18 (see (C)) and a metal eyelet 28 (see (D)) attached to the lower part of the insulator 26. The truncated cone-shaped insulator 26 is made of ceramic, and a mortar-shaped space narrowed toward the truncated cone head is formed inside.

  A male threaded portion 14 a (see FIG. 2A) is formed on the neck portion 14 of the glass bulb 16 of the lamp 10. The metal body 18 (see FIG. 1C) is manufactured by shaping a plate-like metal into a screw shape by press working. That is, the shape of the metal barrel portion 18 is an internal thread shape in which the inner peripheral surface is screwed into the male screw portion of the valve neck portion 14 (that is, fitted by screw action), and the outer peripheral surface is fitted in the female screw portion of the socket. Male thread shape.

  A substantially truncated cone-shaped insulator 26 is incorporated inside the metal barrel 18. That is, the male screw 26a of the insulator 26 is screwed into the inner thread of the inner peripheral surface of the metal barrel portion 18 so that the insulator 26 is locked to the metal barrel portion 18 at the lower end portion, and the opening 18c. Until the cylindrical bottom portion 26d protrudes. Next, the metal eyelet 28 is inserted into the cylindrical bottom portion 26d, and the leg portions 28b and 28c are inserted into the openings 26b and 26c of the insulator 26, respectively, and fixed by caulking. Using the male screw portions 18a and 18b on the outer peripheral surface of the metal barrel 18, the socket is screwed into the female screw portion.

  As shown in FIG. 2A, for example, two lead wires 30a and 30b extend from a light source part (not shown) of a lamp such as an arc tube of an HID lamp. Each lead wire is led to the neck portion 14 of the bulb 16 by a beam member, a support column, a wire material or the like. One lead wire 30a is electrically connected to the metal eyelet 28 through a wiring hole (not shown) formed at the tip of the inner space of the E-shaped base insulator 26, and the other lead wire. 30b is electrically connected to the metal barrel 18 of the E-shaped base. When the lamp 10 is screwed into the socket, an electrical connection is established from the socket via (metal eyelet-one REIT line-light source part-the other lead wire-metal body part) to the socket, and the lamp 10 is connected to the socket. Power is supplied from and lights up.

  In addition to the electrical connection to the lamp 10, the E-shaped base 12 needs to be fixed to the neck portion 14 of the lamp 10 so that it does not loosen or fall off. The metal eyelet 28 of the E-shaped base 12 is fixed to the lower cylindrical bottom portion 26d of the insulator by caulking. On the other hand, the metal barrel 18 that holds the insulator 26 is screwed to the neck 14 of the valve 16. Therefore, when the user applies torque to the metal body 18 of the E-shaped base in the direction of loosening the screw from the neck 14 of the valve 16, the screwing is substantially loosened below a predetermined force, or It is necessary not to come off the neck portion 14.

  At present, the metal body 18 of the E-shaped base 12 is fixed to the valve neck 14 by using solder. As shown in FIG. 2A, a groove 40 extending in the lamp axis direction (that is, substantially perpendicular to the traveling direction of the thread and the thread valley) is formed in the threaded portion 14a of the glass bulb neck 14. Is formed. In the groove 40, the metal body portion 18 shown in FIG. 2B is screwed into the valve neck portion 14 with the other lead wire 30b being bent along the bottom of the groove. As shown in FIG. 2C, the end of the lead wire 30b exposed from the lip (upper end) 18d of the metal barrel 18 is folded back along the outer peripheral surface of the metal barrel 18 to slightly expose the groove. 40, molten high temperature solder is poured around the wire 30b inside the groove, and the groove 40 is filled with solder. Thereafter, the end portion of the lead wire 30 b is soldered to the outer peripheral surface of the metal barrel portion 18. High-temperature solder is solder that has a higher melting point by being lead-rich than eutectic solder.

  Thereby, the lead wire 30b is electrically and mechanically connected to the metal body 18 of the E-shaped base by solder. Furthermore, the lead wire 30b is mechanically fixed to the solder filled in the groove 40 and solidified. Therefore, when the user tries to turn the metal barrel 18 of the E-shaped base in the direction of loosening the screw from the valve neck 14, the metal barrel 18 is fixed to the groove 40 via the lead wire 30b. Since it is connected to the solder, it cannot be loosened. In other words, the metal body portion 18 of the E-shaped base is fixed to the neck portion 14 without being loosened or detached from the neck portion 14.

US Patent No. 6,791,250 B2 "SAEL AND FLAG ASSEMBLY FOR LAMP BASE SIDEWIRE WELDING" issued on Sep. 14, 2004 (Assignee: Eye Lighting International (US))

  However, solder is an alloy mainly composed of lead and tin, and lead is harmful to the human body and the environment. For this reason, there is a demand for the development of a means for fixing an E-shaped base that does not contain lead (ie, lead-free).

  One of the solder-free E-shaped bases is a fixing means disclosed in Patent Document 1. The patent holder, United States Eye Lighting International Co., Ltd. (hereinafter simply referred to as “ELI”) is in the relationship of the applicant's subsidiary. The inventor tried to introduce a solder-free E-type base fixing technique disclosed in Patent Document 1. However, as will be described in detail later, when the solder-free E-shaped base fixing technique disclosed in Patent Document 1 is introduced as it is into lamp manufacturing in Japan, there are some problems that have not occurred in the United States. Was found to occur.

  Therefore, an object of the present invention is to provide a lamp having a novel solder-free E-shaped base structure.

  In the lamp having the E-shaped base according to the present invention, a groove is formed in the threaded portion of the bulb neck portion of the lamp in the lamp axial direction, and the E-shaped base includes a metal body portion in which an insulator is incorporated. And a metal eyelet fixed to the bottom of the insulator exposed from the end of the metal barrel, the metal barrel being screwed into the valve neck, and the valve neck In the space surrounded by the groove and the metal barrel, a flag assembly made of a wire covered with a Teflon tube at the middle is disposed along the groove and extends from the light source part of the lamp. One of the lead wires is electrically connected to the metal eyelet through the internal space of the insulator, the other is connected to one end of the wire of the flag assembly, and the other end of the wire is Electrical and mechanical on the outer periphery of the metal barrel And the bottom width dimension of the groove of the valve neck part generally restrains the flag assembly, and the wall surface area inside the groove of the valve neck part is the uppermost part of the valve neck part. The groove is enlarged by filling the screw valley just before reaching the groove, and the groove of the valve neck portion is expanded upward to form a relief area in which the flag assembly can move.

  According to the present invention, a lamp having a novel solder-free E-shaped base structure can be provided.

FIG. 1 is a diagram illustrating the structure of a lamp cap. FIG. 2 is a diagram for explaining a fixing method of an E-shaped base using current solder. FIG. 3 is a diagram corresponding to FIG. FIG. 4 is a diagram corresponding to FIG. FIG. 5A is a diagram corresponding to FIG. FIG. 5B is a diagram corresponding to FIG. 6A is a diagram corresponding to FIG. 4A of Patent Document 1. FIG. 6B is a diagram corresponding to FIG. 4B of Patent Document 1. FIG. 6C is a diagram corresponding to FIG. 4C of Patent Document 1. FIG. 6D is a diagram corresponding to FIG. 4D of Patent Document 1. FIG. FIG. 7 is a diagram for explaining the presence / absence of annealing treatment after molding for ELI and domestic E-shaped die. FIG. 8 is a graph showing data obtained by placing a metal body sideways and applying a load F perpendicular to the axial direction to zero to 70 [N] for ELI and domestic E-shaped bases. FIG. 9 is a diagram for explaining the width dimension of the groove bottom formed in the bulb neck portion of the lamp according to the present embodiment and the side wall in the groove while comparing it with that before the change. FIG. 10 is a view for explaining the relief area of the flag assembly formed in the groove formed in the bulb neck portion of the lamp according to the present embodiment, as compared with before the change.

  Hereinafter, embodiments of a lamp having an E-shaped base according to the present invention will be described in detail with reference to the accompanying drawings. In the drawings, the same elements are denoted by the same reference numerals, and redundant description is omitted.

[Problems with ELI E-shaped caps and manufacturing in Japan]
(Constitution)
In order to facilitate understanding of the present embodiment, the structure of the ELI E-shaped base is briefly described first with reference to FIGS. 3 to 6D and the drawings of Patent Document 1 are shown in FIG. 3 (FIG. 1 of Patent Document 1), FIG. 4 (FIG. 2), FIG. 5A (FIG. 3), FIG. 5B (FIG. 4A), FIG. 6A (FIG. 4A), FIG. 6B (FIG. 4B), FIG. 6C (FIG. 4C), and FIG. 6D (FIG. 4D). In addition, in order to distinguish from the reference number of the drawing used in this application document, the reference number of the drawing of patent document 1 is changed to 3 digits by adding 100.

  As shown in FIG. 3, in the HID lamp 110, a metal body portion (metal screw base) 118 is screwed into a neck portion 114 of a bulb (outer protective coating) 116. An insulator 126 is attached to the metal body 118, and a metal eyelet 128 is attached to the lower end thereof. The lead wire 130a is welded to the eyelet 28 at the location X11. The lead wire 130b is welded to the flag assembly 160 at the point X12, the flag assembly 160 passes through the groove 140, and the tip thereof is welded to the metal barrel 118 at the welding point X13.

  FIG. 4 is an enlarged view of the neck portion 114 of the bulb 116, and a groove 140 is formed in the thread forming portion of the neck portion 114 along the lamp axis direction.

  The flag assembly 160 welds a metal round bar 162 and a flat metal piece 161 at locations X14a and X14b (see FIG. 5A), and wraps the overlapping metal piece 161 around the metal round bar 162 (see FIG. 5B). This portion is covered with a sleeve made of cylindrical polytetrafluoroethylene Teflon (trade name “Teflon” (registered trademark)) (see FIG. 6A), the metal piece 161 is processed (FIGS. 6B and 6C), and a metal round bar 162 and the metal piece 161 are formed into a final shape (FIG. 6D). This is called the flag assembly 160. As shown in FIG. 3, the flag assembly 160 is held within a groove 140 in the neck 114 of the valve.

(Problem and cause investigation)
In Japan, when an E-shaped base is manufactured according to ELI product and manufacturing standards and attached to the lamp, and a predetermined force is applied to the metal barrel 18 of the E-shaped base in the direction of loosening the screw, the flag assembly 60 Is pulled out of the groove 40 of the valve neck portion 14 with a certain probability, and the metal barrel portion 18 that is screwed into the valve neck portion 14 is loosened. Such a problem does not occur in an ELI lamp in the United States. This “predetermined force” means that, for example, an E39 base is loosened as a design value and can withstand a rotational torque of 3 Nm in order to prevent an accident at the customer's base.

  Therefore, as a result of investigating the cause of this problem, the present inventor has found the following. In addition, the term “manufactured in Japan” in this application document means that it is manufactured using materials, parts, etc. that are normally available in the domestic market. This includes cases where parts are used.

(1) Difference in hardness The metal body 118 of the ELI E-shaped base and the domestic metal body 18 are different in hardness. In particular, the domestic metal body 18 is sufficiently annealed after forming. Turned out to be soft.

  FIG. 7 is a diagram for explaining the difference in residual strain between the ELI (A) and domestic (B) metal barrels regarding the ELI and the domestic E-shaped base. As shown in FIGS. 7A and 7B, when the metal barrel 18 is cut at two locations along the axial direction, the ELI metal barrel 118 shown in FIG. It can be seen that it remains. On the other hand, in the domestic metal barrel 18 of (B), it can be seen that the cut portion is not expanded and the residual strain is removed.

  In response to this, a countermeasure plan for not performing the annealing treatment was examined. However, the annealing treatment has a problem that season cracks (natural cracks) occur in the metal barrel in the past, and as a countermeasure against this, the annealing treatment was performed to remove residual strain. Therefore, if the annealing process is not performed, the problem of season cracks may be reproduced, and thus this measure cannot be adopted.

(2) Difference in Elastic Yield Point When the ELI metal barrel 118 and the domestic metal barrel 18 are compared, the yield point changing from the elastic deformation region to the plastic deformation region is different. That is, it was found that the yield point strengths were different.

  FIG. 8 shows data obtained by placing a metal barrel sideways and applying a load F from 0 to 70 [N] perpendicular to the axial direction with respect to ELI and domestic E-shaped bases. The ELI metal barrel 118 is an elastic deformation region at least up to a load of 70 [N] (（in the graph), whereas the domestic metal barrel 18 is in a plastic deformation region near 20-30 [N]. It changed and it turned out that the yield point exists in 10-20 [N] vicinity (● of a graph).

  As described above, when the ELI metal body 118 and the domestic metal body 18 are compared, it has been found that the ELI body is relatively hard and the domestic body is relatively soft and easily plastically deformed.

  In a domestic E-shaped base, when a rotational torque is applied to the metal barrel in the direction of loosening the screw, the flag assembly 60 fixed to the metal barrel 18 presses the relatively soft metal barrel to cause plastic deformation. Thus, it was found that the gap assembly between the metal barrel portion 18 and the valve neck portion 14 was widened and the flag assembly 60 was pulled out from the groove 40.

  On the other hand, a countermeasure for deepening the bottom of the groove has been proposed so that the flag assembly 60 is not pulled out of the groove 40. As a result of applying rotational torque in the direction to loosen the metal barrel using an E39 base lamp, the design value 3Nm was satisfied, but at a certain rate, the glass on the wall surface in the groove (ie, the side of the groove) was cracked. There has occurred. When the bottom of the groove is deepened, the flag assembly 60 can move in the groove, and is pulled by the lead wire 30b to locally contact the glass on the side surface in the groove and contact before the metal barrel is deformed. It seems to damage the glass of the part. Based on these circumstances, the present embodiment described below has been developed.

[This embodiment]
The E-shaped base according to the present embodiment was changed as follows.

  (1) The width of the bottom of the groove 40 formed in the valve neck portion 14 is narrowed.

  FIG. 9 is a diagram showing the width W1 of the groove bottom after the change (A) in comparison with the width W2 of the groove bottom before the change (B). In the figure, it should be noted that contour lines are drawn in order to make it easy to understand the irregularities of the groove 40 of the glass neck portion 14 and the surrounding screw portion. The width W1 of the bottom after the change is relatively narrower than the width W2 of the bottom before the change (W1 <W2).

  When the width of the groove bottom is narrowed, the flag assembly 60 is entirely restrained in the groove from the beginning, and movement in the width direction is also restricted. Therefore, even if the flag assembly 60 is pulled by the lead wire 30b, it is considered that the glass is not damaged because the flag assembly 60 is closely adhered to the side glass portion in the groove.

  (2) The side surface area in the groove formed in the valve neck portion 14 was enlarged. Specifically, as shown in the figure, the uppermost thread valley reaching the groove 40 from the left side is filled (that is, the thread valley is stopped immediately before the groove so as not to reach the groove). The side area was enlarged. As shown by an ellipse in FIG. 9A, the uppermost screw valley is filled so that the screw valley does not reach the groove. This increased the strength of the wall surface (inside the groove) glass in the groove.

  (3) The groove 40 was expanded upward to form a relief area 40a.

  First, by reducing the width dimension of the groove bottom, the flag assembly in the groove is restrained as a whole and is brought into close contact with the wall surface in the groove. Furthermore, the overall strength of the shoulder portion (side portion of the groove) could be increased by filling a part of the thread valley and expanding the wall surface area in the groove.

  Since the flag assembly 60 is covered with an elastic Teflon tube, the flag assembly 60 slightly moves in the groove when pulled by the lead wire 30b. In order to absorb this movement so as not to locally contact the wall surface glass in the groove, the groove 40 was expanded upward to form a relief area 40a. In addition to the groove that narrows the width of the groove bottom and fills the top screw valley (see FIG. 10B), the groove 40 is expanded upward as shown by a circle in FIG. A relief area 40a was formed.

  By allowing the flag assembly 60 to move slightly upward when the flag assembly 60 is pulled, the flag assembly 60 is not sandwiched between the metal body 18 and the neck 14 and is not affected by variations in these dimensions. I can do it.

  As a result of the experiment, even when a predetermined torque is applied in the direction of loosening the metal barrel 18 and the flag assembly 60 is pulled by the lead wire 30b, the metal barrel 18 is loosened and the shoulder of the valve neck 14 next to the groove. There was no damage to the part (wall surface part in the groove).

[Advantages and effects of this embodiment]
According to the above embodiment, the ELI E-shaped base fixing technology can be implemented even in Japan. As a result, a lamp having a solder-free E-shaped base structure can be provided.

[Summary]
As mentioned above, although the lamp | ramp provided with the E-shaped base which concerns on this embodiment was demonstrated, these are illustrations and do not restrict | limit the scope of the present invention. Additions, deletions, changes, improvements, and the like that can be easily made by those skilled in the art with respect to the present embodiment are within the scope of the present invention. The technical scope of the present invention is defined by the appended claims.

10, 110: Lamp, 12: E-shaped base, E-shaped base, 14, 114: Neck portion, valve neck portion, 14a: Male thread portion, 16, 116: Glass bulb, bulb, 18, 118: Metal barrel portion, 18a: part, 18c: opening, 26, 126: insulator, 26a: male screw, 26b: opening, 26d: cylindrical bottom part, 28: eyelet, metal eyelet, 28b, 28c: leg part, 30a, 30b, 130a, 130b: lead wire, wire rod, 40, 140: groove, 40a: relief area, 60, 160: flag assembly, 161: metal piece, 162: metal round bar,
W1, W2: Width, X11, X12, X13, X14a: Location, welding point

Claims (1)

In a lamp with an E-shaped base,
A groove is formed in the lamp axial direction on the threaded portion of the bulb neck of the lamp,
The E-shaped base includes a metal barrel portion in which an insulator is incorporated, and a metal eyelet fixed to the bottom of the insulator exposed from an end portion of the metal barrel portion. The body making part is screwed to the valve neck part,
In the space surrounded by the groove of the valve neck part and the metal body part, a flag assembly made of a wire material whose intermediate part is covered with a Teflon tube is disposed along the groove,
One of the two lead wires extending from the light source part of the lamp is electrically connected to the metal eyelet through the inner space of the insulator, and the other is connected to one end of the wire of the flag assembly. The other end of the wire is electrically and mechanically connected to the outer periphery of the metal barrel,
The width dimension of the bottom of the valve neck groove constrains the flag assembly as a whole,
The wall surface area inside the groove of the valve neck part is expanded by filling the uppermost thread valley of the valve neck part immediately before reaching the groove,
The bulb of the bulb neck portion is extended upward to form a relief area in which the flag assembly can move.

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