JP3104528B2 - Discharge lamp ballast - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a discharge lamp ballast used for lighting a discharge lamp such as a fluorescent lamp.

[0002]

14 to 17 show a conventional resin-filled discharge lamp ballast. The ballast case shown in FIG. 1 includes a bottom plate 2, a case main body 3 secured thereto by a caulking piece 2 a, and a cylindrical body formed by the bottom plate 2 and the case main body 3 at both ends. The first end member 4 and the second end member 5 are provided. As shown in FIGS. 14 and 16, the ballast case 1 has a ballast body 6 built therein, and is filled with a filler 7 made of an insulating synthetic resin.

The ballast body 6 comprises a combination of an iron core 8 and a coil 9, and synthetic resin caps 10 for retaining the iron core 8 are fitted to both ends in the longitudinal direction thereof. I have. As shown in FIG. 14, the ballast body 6 has terminal bases 11a at both ends in the longitudinal direction. The terminal block 11a is integrally formed with a coil bobbin 11 made of a synthetic resin to which the coil 9 is mounted. A plurality of terminal fittings 12 to which the terminal of the coil 9 is connected are provided in parallel with the terminal block 11a. ing.

As shown in FIG. 14, a terminal block 13 is formed on each of the first and second end members 4 and 5, and a plurality of terminal fittings 14 are arranged on the terminal block 13 respectively. In addition, electrical components such as a capacitor 15 to be connected to necessary terminal fittings 14 are attached.

[0005] A forked end of the terminal fitting 14 (FIG. 1)
4 (B) are soldered and connected to the terminal fittings 12 of the ballast body 6, respectively, and the other ends of the terminal fittings 14 are leads inserted into the first and second end members 4, 5, respectively. Lines (not shown) are connected. As shown in FIG. 15, the corresponding two terminal fittings 12 and 14 are connected to the terminal fitting 1 by forked one end of the terminal fitting 14.
2 are arranged on one surface, and solder 16 is laid on them to be connected by soldering.
Such soldering connection is performed in the case main body 3 before the ballast case 1 is assembled. 14 and 16 shows a rubber bushing.

[0006]

The ballast body 6 and the end members 4, 5 are mounted on the case body 3, respectively, so that the ballast body 6 and the end members 4, 5 are individually positioned with respect to the case body 3. 3 has poor position accuracy in the longitudinal direction and the width direction, and the terminal fittings 12 and 14 to be soldered are often not properly arranged.

For this reason, in the soldering connection of the terminal fittings 12, 14, it is necessary to use a jig (not shown) to perform soldering in a positioning state by the jig. Therefore, there is a problem that the workability of soldering is poor depending on the time required for handling the jig, and there is a problem that periodic maintenance of the jig is required.

Further, since the terminal fittings 14 are soldered on only one surface of the terminal fittings 12, both terminal fittings 12, 1
There is a problem that the reliability of soldering between the four is low.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a discharge lamp ballast which can improve the workability of soldering and connecting a conductive metal member to a terminal metal member of a ballast body and can improve the reliability of the soldering.

[0010]

In order to achieve the above object, a discharge lamp ballast according to the present invention comprises a combination of an iron core and a coil, and a plurality of terminal fittings to which terminals of the coil are connected. The terminal block portions provided at both ends of the iron core are formed with a ballast body integrally formed on a coil bobbin made of a synthetic resin supporting the coil, and a gap is formed between the ballast body and the terminal block portion. Caps made of synthetic resin fitted to both ends of the core, and a plurality of ribs integrally projecting from the cap or the terminal block to partition the gap into a plurality of regions along the width direction of the core. A mounting base made of a synthetic resin having a plurality of slit-shaped engagement grooves fitted to these ribs and having an insertion piece inserted into the gap located at least at one end of the ballast body. Are installed side by side with this mounting base A first terminal portion disposed on one surface of the terminal fitting and an L-shaped bent from a position adjacent to the base of the first terminal portion at one end on the side of the insertion piece, and the other surface of the terminal fitting is bent. A second terminal portion disposed on the upper surface, and one end portion of the second terminal portion is connected to the terminal metal member by soldering, and the other end portion includes a plurality of conductive metal members to which lead wires are connected by soldering. It is.

[0011]

In the discharge lamp ballast configuration, the mounting base supports a plurality of conductive fittings, and these conductive fittings are connected to one end of the ballast body terminal fitting by soldering, and to the other end by soldering connection. A conductive path between the lead wire to be used. The terminal block of the ballast body and the cap fitted to the longitudinal end of the iron core of the ballast body form a gap between them for supporting the mounting base. The mount is directly connected to and supported by the ballast body by inserting the insertion piece into the gap.

The plurality of engagement grooves formed in the insertion piece and the respective ribs formed in the cap or terminal block are fitted to each other to position the mounting table in the width direction of the ballast body. . In addition, the first and second terminal portions of each conductive metal fitting are both arranged on both sides of the terminal fitting as the mounting base is directly connected to the ballast main body, and the root of the second terminal part. And the tips of the terminal fittings abut against each other, thereby positioning the mounting table with respect to the longitudinal direction of the ballast body. By such positioning, one end of the conductive metal fitting is properly positioned with respect to the terminal metal fitting without using a jig.

Further, the terminal fitting and the conductive fitting are connected by soldering in the above-described positioning state associated with the direct connection, and in this soldering, the solder wraps around both sides of the terminal fitting, and the conductive fitting is provided on one surface thereof. Is soldered, and the second terminal of the conductive fitting is soldered on the other surface.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. 1 to 3 and FIG. 6, reference numeral 21 denotes a ballast case made of a steel plate. The ballast case 21 is provided at both ends in the longitudinal direction of each cylindrical case body 22 having both ends opened. , 24 are separately mounted. The case body 22 is formed by winding a single steel plate as shown in FIG. A silicone rubber seal material (not shown) is provided between the mating surfaces, and the mating surfaces are connected by a blind rivet (not shown) or the like.

At both ends in the longitudinal direction of the bottom wall portion 22a of the case main body 22, rubber bushings 25 are attached to penetrate the bottom wall portion 22a. The ballast case 21 is used by being attached to a steel plate chassis of a lighting fixture via a not-shown mounting bolt inserted into a through hole 25a (see FIG. 3A) of a pair of bushings 25 and a nut screwed thereto. In this mounting posture, the bottom wall portion 22a is positioned on the upper side.

The end plates 23, 24 are positioned and attached by beads (not shown) formed at the ends of the case body 22 so as to protrude from the inner surface. As shown in FIG. 6, a mounting support 26 is provided on each of the opposed side walls of the case body 22 at the end on the end plate 24 side. The support 26 is formed of a substantially L-shaped rib including an inclined portion and a vertical portion bent and connected to the inclined portion, and these ribs protrude from the inner surface of the case body 22.

As shown in FIG. 3B, the ballast case 21 has a ballast main body 27, a mount 28 directly connected to the main body 27, and a power factor improving or noise preventing device. The capacitors 29 to 31 and the like are accommodated, and a filler 32 is filled. Fill 32
Is an electrical insulator such as an unsaturated polyester resin,
Ballast body 27, mounting base 28, and capacitor 29
The space between the container 31 and the container such as the ballast case 21 is filled to embed the container. Thereby,
The container is held at a predetermined position, the moisture resistance is improved, and the heat radiation from the ballast body 27 to the ballast case 21 is improved. Reference numeral 33 in FIG. 3 denotes a protective tape made of a nonwoven fabric adhered so as to cover the bottom wall portion 22a side of the stabilizer main body 27 and the mounting stand 28.

As shown in FIG. 3 to FIG.
7 includes, for example, an iron core 41 including a T-shaped iron core portion and a pair of L-shaped iron core portions disposed on both sides thereof, and coils 42 and 43 combined therewith. A coil bobbin 44 made of synthetic resin is fitted and attached to the T-shaped iron core, and coils 42 and 43 are attached to the bobbin 44, respectively. In FIG. 3B, reference numeral 45 denotes a pass core,
Reference numeral 6 denotes a filament coil.

As shown in FIG. 3 to FIG. 8, caps 55 made of a synthetic resin are slightly press-fitted at both longitudinal ends of the iron core 41. These caps 55 are provided to tighten and fix the combined T-shaped core and L-shaped core. As shown in FIG. 13, a plurality of ribs 56 are integrally formed on the outer surface of a fitting edge 55a extending in the longitudinal direction of the cap 55. Each rib 56 extends in the thickness direction of the cap 55. In this embodiment,
Although the ribs 56 are formed on each of the pair of fitting edges 55a extending in the longitudinal direction of the cap 55 in order to eliminate the mounting direction, the ribs 56 may be provided on only one of the fitting edges 55a.

The coil bobbin 44 has end flanges 44a and 44b at both ends in the longitudinal direction. A first terminal block 47 is integrally formed on one end flange 44a, and a plurality of terminal fittings 48 are attached to the terminal block 47 along the width direction of the iron core 41. Have been. The second terminal block 4 is provided on the other flange 44b.
9 are integrally formed, and the terminal block 49 is provided with an iron core 41.
Terminal fittings 50 arranged side by side along the width direction of
Is installed.

The first and second terminal block portions 47 and 49 form a narrow gap G with one fitting edge 55a of the cap 55, and are close to and opposed to the fitting edge 55a. . The gap G is partitioned into a plurality of regions by the ribs 56 as shown in FIG. In addition, terminal block 4
7 and 49 are supported by ribs 56 from the back side. Each of the terminal fittings 48 and 50 has a cut-and-raised piece formed thereon, and the coil 4
The terminals 2, 43, and 46 are connected by soldering in a state of being entangled with the cut-and-raised pieces.

As shown in FIG. 3, necessary ones of the terminal fittings 48 are connected to lead wires 51 by soldering, and these lead wires 51 pass through rubber bushes 52 attached to the end plate 23. It is drawn out of the case body 22. 3, reference numeral 53 denotes a terminal fitting 48 and a lead wire 51.
2 shows a solder connected with. Further, a capacitor 29 is connected to the pair of terminal fittings 48 which are also used for mounting the capacitor by soldering.
The capacitor 29 is insulated from the iron core 41 by a cap 55.

As shown in FIGS. 9 and 10, etc., the mounting base 28 is provided with an insertion piece 61 at one longitudinal end and a plurality of lead wire insertion holes 62 at the other end. In addition, a plurality of rib-shaped partitioning ridges 63 extending in the longitudinal direction and a bridge portion 64 orthogonal to the ridges 63 are provided therebetween.

The insertion piece 61 in the form of a thin plate has substantially the same thickness as the gap G, and has a plurality of slit-like engagement grooves 65 fitted into the ribs 56. Each engagement groove 65
As shown in FIG. 9, a taper 65a whose width gradually increases toward the tip end of the insertion piece 61 is formed at the entrance of the plug. By inserting the insertion piece 61 into the gap G with a slight press fit, the mount 28 is directly connected to the ballast body 27.

A number of conductive fittings 66 corresponding to the number of the terminal fittings 50 are mounted on the mounting base 28. As shown in FIGS. 10 and 11, the conductive metal fitting 66 has a soldering part 67 at one longitudinal end and a lead wire fixing part 68 at the other end.
Are formed by cutting and raising the oblique locking piece 69.

The conductive metal fittings 66 are arranged along the longitudinal direction of the mounting base 28 and on both sides thereof with the partitioning ridge 63 therebetween, so that the mounting base 2 is mounted.
8 are arranged side by side in the width direction. Each of the conductive fittings 66 is provided so as to pass through the bridge portion 64 and abut the lead wire fixing portion 68 on the stopper surface 28 a of the mounting base 28. Due to this abutment and the catch of the locking piece 69 on the bridge portion 64, the movement of each conductive fitting 66 in the longitudinal direction of the mounting base 28 is restricted. Stopper surface 2
A lead wire insertion hole 62 is opened in 8 a, and the opening end is connected to a lead wire fixing portion 68 of a necessary conductive fitting 66.

As described above, each of the conductive fittings 66 provided on the mounting base 28 exposes most of the portions other than the intermediate portion covered by the bridge portion 64 that prevents the detachment, and also includes the soldering portion 67 thereof. Are arranged so as to overlap the root side of the insertion piece 61. As shown in FIG. 12, the width A of the soldered portion 67 is smaller than the width B of the terminal fitting 50.

The soldering portion 67 is bent from a first terminal portion 67a having a forked shape and a position adjacent to the root of the first terminal portion 67a, for example, from the root located between the first terminal portions 67a. The second terminal portion 67b is formed. In the present embodiment, in order to further increase the connection strength of soldering described later, a pair of first terminal portions 67a is provided to form a forked shape. However, only one first terminal portion 67a may be provided. The second terminal portion 67b is formed by bending into an L-shape from a root portion that is substantially perpendicular to the first terminal portion 67a and a portion that is disposed substantially parallel to the first terminal portion 67a. 9 to 11, reference numeral 70 denotes a small hole provided on the soldering portion 67 side of each conductive fitting 66.

The core portion of the lead wire 71 inserted through the lead wire insertion hole 62 is inserted into the lead wire fixing portion 68 having a concave groove shape of the conductive metal fitting 66 and connected by soldering. In FIG. 3A, reference numeral 72 denotes solder for connecting the lead wire fixing portion 68 and the lead wire 71. The capacitors 31 and 32 are provided on the surface opposite to the surface of the mounting base 28 from which the respective conductive fittings 66 are mainly exposed, and these are held on the mounting base 28 via an adhesive tape 73. .
These capacitors 31 and 32 are connected by soldering by inserting lead legs into small holes 70 of necessary conductive fittings 66.

The mounting table 28, each conductive metal fitting 66,
The mounting base assembly formed by the lead wire 71 and the capacitors 31 and 32 has an insertion piece part of the mounting base 28 in a gap G formed between the second terminal base part 49 and the cap 55 opposed thereto. By inserting 61, it is supported in a state directly connected to the ballast body 27. This directly connected state is shown in FIG.

When the insertion piece 61 is slightly pressed into the gap G, the plurality of engagement grooves 65 formed in the insertion piece 61 are fitted into the respective ribs 56 formed in the cap 55. The mounting table 28 is positioned in the width direction of the ballast body 27. In this insertion, since there is a guiding action by the taper 65a of the engagement groove 65, each engagement groove 65 is easily positioned on each rib 56 and can be easily inserted.

As shown in FIG. 8, the forked first terminal portion 67a of the soldering portion 67 of each conductive fitting 66 is attached to the terminal protruding from the second terminal block 49 as shown in FIG. The second terminal portion 67b of the soldering portion 67 is disposed so as to overlap with one surface of the metal fitting 50, and the terminal metal fitting 5
0 facing the end face. That is, the terminal fitting 50
Is inserted between the first and second terminal portions 67a and 67b.
Moreover, the base of the second terminal portion 67b and the tip of the terminal fitting 50 abut against each other, whereby the mounting table 28 is positioned in the longitudinal direction of the ballast body 27.

Accordingly, with the insertion of the insertion piece 61 into the groove G as described above, the mounting table 28 is positioned in the longitudinal direction and the width direction, and is directly connected to the ballast body 27. Accordingly, the conductive fitting 66 can be properly positioned with respect to the terminal fitting 50. For this reason, a jig that requires regular maintenance and trouble of handling the jig can be eliminated.

The ballast body 27 directly connected to the ballast body 27
And the mounting base assembly are mechanically and electrically connected by soldering the terminal fitting 50 and the conductive fitting 66 to each other. In FIG. 3, reference numeral 74 denotes solder that connects the terminal fitting 50 and the soldering portion 67 of the conductive fitting 66. In this soldering, the solder 74 wraps around both sides of the terminal fitting 50, and the first terminal 67 a of the conductive fitting 66 is soldered on one side, and the second terminal 67 b of the conductive fitting 66 is soldered on the other side.

As described above, since the both sides are connected by soldering, the reliability of soldering can be improved. Also,
In the above soldering, it is not necessary to use a jig as described above, so that the workability of the soldering can be improved.

In this embodiment, since the width A of the soldering portion 67 of the conductive fitting 66 to be soldered to the terminal fitting 50 is smaller than the width B of the terminal fitting 50, the terminal fitting 50 and the conductive fitting 66 are formed. Even if the position in the width direction slightly varies, the soldered portion 67 can be reliably overlapped with the terminal fitting 50 at the corresponding position, and the insulation distance between the adjacent terminal fitting 50 can be prevented from being reduced.

Incidentally, in the conventional example shown in FIG.
Since the terminal fitting and the fitting corresponding to the conductive fitting have the same width, if there is a variation in the position in the width direction, the insulation distance between adjacent terminal fittings is likely to be reduced.

On both sides in the width direction of the end of the mounting base 28 where the lead wire insertion hole 62 is provided (the end opposite to the insertion piece 61), engaging portions each having an inclined surface 75a are provided. 75 are formed. These engaging portions 75 are engaged with the mount support 26. Thereby, the mounting table 2
8 is opposite to the case piece 22
To stabilize the supporting state of the mounting base assembly.

In order to assemble the discharge lamp ballast having the above configuration, first, the lead wire 51 and the capacitor 29 are connected to the terminal fitting 48 of the ballast body 27 by soldering, and then the ballast is attached to the ballast body 27. The base assembly is directly connected, soldered and connected as described above, and furthermore, the protective tape 32 is adhered to form a storage assembly stored in the ballast case 21.

Next, the stored object assembly is accommodated in the case main body 22 from the end opening on the side where the mounting base support 26 is formed, and the mounting base 28 is mounted on the mounting base support 26.
Then, the lead wire 51 is passed through a rubber bush 52 attached to the end plate 23, and the end plate 23 is attached while closing the other end opening of the case main body 22.

Thereafter, an end plate 24 for closing the end opening is attached to the case body 22. Although not shown, the end plate 24 is connected to a lead wire 71 connected to the lead wire insertion hole 62.
3B, has an air vent hole also serving as a hole for the protection convex portion 28b, and a filler injection hole, and has an anchor portion 24a extending obliquely as shown in FIG. 3 (B). I have.

Lastly, the case body 22 is set up so that the end plate 23 becomes the bottom, and the filling material 32 is injected and filled from the upper end opening of the case body 22 so that the container assembly is embedded in the filling material 32. And this filling 3
2 is cured.

The discharge lamp ballast is assembled by the above procedure.

The present invention is not limited to the above embodiment. For example, the connection of the lead wire 51 to the terminal fitting 48 may be performed using the mounting base assembly. Further, the rib for positioning the mounting base assembly in the width direction may be formed integrally with the terminal base 49 or the like instead of being provided on the cap 55.

[0045]

As described in detail above, according to the discharge lamp ballast of the present invention, the mounting base on which the conductive metal member forming the conductive path between the lead wire and the terminal metal member of the ballast body is mounted. The insertion piece is inserted into the gap between the terminal block of the ballast body and the cap fitted to the longitudinal end of the iron core of the ballast body, and as the cap is directly connected to the ballast body, Alternatively, by fitting each of the ribs formed on the terminal block with the engaging groove of the insertion piece portion, the mounting table is positioned in the width direction of the ballast body, and the base of the second terminal portion of the conductive metal fitting. And the tip of the terminal fitting are brought into contact with each other, and the mounting base is positioned in the longitudinal direction of the ballast body. Positionable and therefore soldering of conductive fittings to terminal fittings It is possible to improve the connection workability. In addition, the first and second terminal portions of each conductive metal member are arranged facing both surfaces of the terminal metal member, and the first terminal portion and the second terminal portion of the conductive metal member are separately provided on both surfaces of the terminal metal member by soldering. Because of the configuration of soldering, the reliability of soldering can be improved.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a configuration of an entire discharge lamp ballast according to one embodiment of the present invention.

FIG. 2 is a view showing the configuration of the discharge lamp ballast according to the embodiment, as viewed from the direction of arrow Z in FIG. 1;

FIG. 3A is a plan view showing a configuration of the discharge lamp ballast according to the embodiment with a part cut away in a state before filling is performed. (B) is a sectional view showing the configuration of the discharge lamp ballast according to the embodiment.

FIG. 4 is an exploded perspective view showing a configuration of a container assembly of the discharge lamp ballast according to the embodiment.

FIG. 5 is a perspective view showing a configuration of a container assembly of the discharge lamp ballast according to the embodiment.

FIG. 6 is an exploded side view of a configuration of a main part of the discharge lamp ballast according to the embodiment, with a part cut away.

FIG. 7 is a plan view showing a configuration of a main part of the discharge lamp ballast according to the embodiment.

FIG. 8 is a side view showing a configuration of a main part of the discharge lamp ballast according to the embodiment, with a part cut away.

FIG. 9 is a plan view showing a configuration of a mounting table provided in the discharge lamp ballast according to the embodiment.

FIG. 10 is a sectional view taken along the line YY in FIG. 9;

FIG. 11 is a perspective view showing a configuration of a conductive metal fitting provided in the discharge lamp ballast according to the embodiment.

FIG. 12 is a plan view showing the relationship between terminal fittings and conductive fittings of the discharge lamp ballast according to the embodiment.

FIG. 13 is a view showing the ballast main body with the cap of the discharge lamp ballast according to the embodiment fitted thereto, viewed from the end face direction.

FIG. 14A is a plan view showing a configuration of a discharge lamp ballast according to a conventional example with a part thereof being cut away in a state before filling is performed. (B) is a sectional view showing a configuration of a discharge lamp ballast according to the conventional example.

FIG. 15 is an enlarged view showing a portion X in FIG. 14 (B).

FIG. 16 is a partially cutaway view of the configuration of the discharge lamp ballast according to the conventional example when viewed from the end face direction.

FIG. 17 is a perspective view showing a configuration of a discharge lamp ballast according to the conventional example.

[Explanation of symbols]

 27: ballast body, 28: mounting base, 41: iron core, 42, 43: coil, 44: coil bobbin, 49: terminal block, 50: connection terminal, 55: cap, 56: rib, G: gap, 61 ... Insertion piece part, 65: engagement groove, 66: conductive metal fitting, 67: soldering part of conductive metal fitting, 67a: first terminal part of soldering part, 67b: second terminal part of soldering part, 71: lead wire , 72 ... solder.

Claims (1)

(57) [Claims] An iron core and a coil are combined, and a plurality of terminal fittings to which terminal portions of the coil are connected are arranged in parallel, and terminal blocks located at both ends of the iron core support the coil. A ballast body integrally formed on the synthetic resin coil bobbin; a synthetic resin cap formed at each end of the iron core by forming a gap between the terminal block and the cap; A plurality of ribs integrally projecting from the terminal block and partitioning the gap into a plurality of regions along a width direction of the iron core; A mounting base made of a synthetic resin having an insertion piece inserted into the gap located at least on one end side of the container main body; No. placed on one side of the bracket A first terminal portion and a second terminal portion which is bent in an L-shape from a position adjacent to the base of the first terminal portion and is disposed on the other surface of the terminal fitting; And a plurality of conductive fittings to which a lead wire is connected by soldering to the other end thereof.