JP3132660B2 - Lamp device and lamp device manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] 1. Field of the Invention [0002] The present invention relates to a lamp device having a base and a method of manufacturing the same.

2. Description of the Related Art Conventionally, for example, in a fluorescent lamp device in the form of a light bulb, there has been known a fluorescent lamp in which a fluorescent lamp is mounted on a holder together with a lighting circuit board, and a base for power supply is attached to the holder. The base of this fluorescent lamp device has an eyelet on one side, a cylindrical shell on the other side and a thread cut on the surface, and the bases are electrically insulated by an insulating portion.

[0002] A pair of conductors electrically connected to a lighting circuit board are connected to the base so as to supply power to the lamp. These conductive wires are respectively connected to an eyelet and a shell, and techniques such as soldering and arc welding are used for connection to the eyelet.

[0003] Normally, an eyelet has a flat portion having a through hole formed substantially at the center. The conducting wire is connected at this flat portion by performing soldering or arc welding while being inserted through the through hole.

However, the above-described method for connecting the eyelet to the conductor has the following problems.

[0004] Since solder is now widely recognized as a harmful material, it is preferable to refrain from using it as much as possible.

[0005] On the other hand, when the eyelet and the conductor are connected by arc welding, in order to perform a mechanically strong connection, it is necessary to increase the amount of the eyelet and the conductor to be melted and perform welding. May be melted too much to form holes. Thus, if a hole is made in a part of the welded portion, the connection strength of the conductive wire is greatly reduced.

In order to obtain sufficient welding strength without melting a large amount of the eyelet, a method of drawing out the leading end of the lead wire longer outside the base and melting all the drawn-out portion has been studied. ing. However, according to this method, the conductive wire material that has hardened after welding tends to spread in a deviated range with respect to the through hole of the eyelet. And such unevenness of the molten material also reduces the connection strength between the eyelet and the conductor.

Further, when such a welded portion protrudes too much from the eyelet, the welded portion is pressed against a terminal of a lamp socket for supplying power to the lamp device.
There is a possibility that the welding may be broken. When the welded portion is broken, a poor contact with the terminal of the lamp socket naturally occurs easily.

[0008] Further, the eyelet is heated when welding the conductive wire, and at this time, almost the entire eyelet is heated to a high temperature. As a result, the heat may be transmitted to an insulating portion formed of glass or the like that insulates the eyelet and the shell, causing a crack or the eyelet to be separated from the insulating portion.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and has a relatively simple structure, capable of performing welding between a conducting wire and a base, and having a high strength welded portion and a method of manufacturing the lamp device. The purpose is to provide.

According to the first aspect of the present invention, there is provided a lamp device comprising: a lamp body for leading first and second conductors; an eyelet; a first conductor passing through the eyelet; and a periphery of the first conductor. A part of the eyelet that is integrally and cylindrically protruded from the eyelet so as to cover the eyelet and has a welded portion formed into a convex shape on the eyelet and a shell electrically connected to the second conductive wire. And a base attached to the lamp body.

[0010] According to the lamp device of the first aspect, the first conductor penetrating the eyelet and a part of the eyelet integrally and cylindrically protruding from the eyelet so as to cover the periphery of the first conductor. Since the welding portion of the convex shape was formed on the eyelet by melting, the volume of the welding portion can be increased by enlarging the convex portion, and the eyelet and the first conductive wire can be connected mechanically and firmly. it can.

According to the lamp device of the second aspect, the lamp body for leading the first and second conductors; the eyelet, the first conductor penetrating the eyelet, and the periphery of the first conductor. A welded portion formed into a convex shape on the eyelet by melting a part of the eyelet integrally and cylindrically protruding from the eyelet, a shell electrically connected to the second conductive wire, and the eyelet from the shell to each other. And a base to be attached to the lamp body, the insulating member being electrically insulated and supported.

According to the lamp device of the second aspect, the first aspect of the present invention is the first aspect.
In addition to the effect of (1), an insulating member that insulates the eyelet and the shell can be formed at a position distant from the welded portion, and heat generated during welding is less likely to be transmitted to the insulating member. It is possible to prevent cracks and peeling of the eyelet from the insulating member.

According to a third aspect of the present invention, the first and second lamp devices are provided.
A lamp main body for leading out a conductive wire; an eyelet having a substantially flat surface and a concave portion formed substantially in the center of the flat portion; a portion of the eyelet formed in the concave portion of the eyelet; Is welded to form a convex shape on the eyelet by melting of the conductive wire and the material of each other, a circle surrounding the welded portion with a substantially V-shaped cross section by the peripheral surface of the welded portion and the inner surface of the concave portion. And a base attached to the lamp body, the shell having the annular peripheral groove and the second conductive wire electrically connected to each other.

According to a fourth aspect of the present invention, in the lamp device according to the third aspect, the welded portion has a height substantially equal to an opening surface of the concave portion of the eyelet.

According to a fifth aspect of the present invention, in the lamp device according to the third aspect, the welded portion projects from the opening surface of the concave portion of the eyelet at a height of about 1.5 mm or less.

The projected height of the welded portion is preferably 1.5 mm or less, but may be 1.5 mm.

According to a sixth aspect of the present invention, in the lamp device according to any one of the first to fifth aspects, the surface of the convex welded portion is formed of a curved surface.

In the lamp device of the present invention, since the welded portion is formed in the concave portion, it is possible to prevent the welded portion from excessively protruding from the eyelet even if the volume of the welded portion is increased. In addition, it is possible to obtain a desired strength of the welded portion, and it is possible to prevent a problem from occurring at the time of electrical connection with a lamp socket or the like.

According to a seventh aspect of the present invention, in the lamp device according to any one of the first to sixth aspects, the lamp main body is housed in the cylindrical base and the base and the first and second conductive wires are led out. It is characterized by comprising a circuit, a holder for holding the lighting circuit, and a fluorescent lamp mounted on the holder.

[0020] According to a eighth aspect of the present invention, there is provided an eyelet having a flat portion, a substantially central portion of the flat portion, a through hole penetrating the flat portion, and a cylindrical portion protruding from the flat portion. The first lead wire is electrically connected to the eyelet, the second lead wire is electrically connected to the shell, and the base is attached to the lamp body with respect to the base having a cylindrical shell on the other side. And a step of fusing and welding the cylindrical portion and the conductive wire to each other with the tip of the first conductive wire inserted into the through hole of the eyelet.

According to a ninth aspect of the present invention, in the lamp manufacturing method according to the eighth aspect, the connection between the eyelet and the first conductor is performed by connecting the eyelet with the first conductor through the cylinder. It is characterized by being welded after crushing from the side and fixing the conductor.

According to a tenth aspect of the invention, there is provided a lamp manufacturing method.
Or the lamp manufacturing method according to 9, wherein the eyelet has a concave portion formed substantially at the center of the flat portion, the cylindrical portion is formed in the concave portion, and the cross section is substantially V-shaped by the peripheral surface of the cylindrical portion and the inner surface of the concave portion. , Forming an annular circumferential groove surrounding the cylinder.

According to the method of manufacturing a lamp device of the present invention, the insertion of the conductor is made very easy by making the inner diameter of the through hole larger than the outer diameter of the conductor. By crushing, it is possible to reliably electrically connect the cylindrical portion and the conducting wire. Therefore, when welding is performed, both the cylindrical portion and the conductive wire can be melted, and the strength of the welded portion can be increased.

In the present invention, terms are defined as follows unless otherwise specified.

The lamp body includes an incandescent lamp, a discharge lamp,
It means a device provided with a light-emitting body such as an LED, an EL element, and a cathode ray tube. In particular, a device such as a discharge lamp which does not emit light even when directly connected to a commercial power supply has a configuration including a lighting circuit.

The discharge lamp is filled with a discharge medium. In the case of a fluorescent lamp, mercury, argon gas, or the like is filled at a predetermined pressure, but the present invention is not limited to this.
That is, the discharge lamp may be a high-pressure discharge lamp such as an HID lamp or a rare gas discharge lamp such as a xenon lamp, and is not particularly limited.

The bulb of the discharge lamp is provided with a pair of electrodes. The pair of electrodes may be sealed at both ends of the bulb, may be sealed adjacent to one end, or may be provided on the outer surface of the bulb. Further, they may be arranged in other positional relations.

The material and form of the electrodes are not particularly limited as long as they can generate a discharge in the bulb of the discharge lamp by applying a required voltage between the pair of electrodes.

The first and second conductors are connected to a pair of outer wells connected to both ends of a filament when the lamp body is an incandescent lamp, and to a power supply terminal of a lighting circuit when the lamp body is a discharge lamp or the like. Things. But,
The present invention is not limited to this, and it is only necessary that the light emitter of the lamp body is electrically connected so as to emit light.

The base is not limited to other forms as long as it has an eyelet and a shell. Generally, JI
It means E type or Swan type type standardized by S. Therefore, the form of the eyelet or the shell is almost specified, but in the invention, the eyelet contacts the contact piece on the inner part of the lamp socket, and the shell can be joined to the contact piece on the inner surface of the lamp socket, such as by screwing. Any form is acceptable.

The "eyelet" of the present invention may be used as a "tip base" or the "shell" of the present invention.
May be referred to as a “joining base”.

In the present invention, the eyelet and the conducting wire are required to be welded through a process of melting each other, but the amounts of both melted do not need to be equal, and if the original shape is not retained. , Melted. In other words, if it contributes to the improvement of the welding strength between the eyelet and the conductor, if there is a part where both the eyelet and the conductor are melted and mixed, even if a little, they are welded through the process of melting each other. Shall be.

Further, the material of the eyelet and the conductor need not be mixed in the entire welded portion. In other words, if it contributes to the improvement of the welding strength between the eyelet and the conductor, the material of the eyelet and the conductor is mixed if there is a portion where both the eyelet and the conductor are melted and mixed, even if a little. Welded part.

The welded portion may be made of the same material as the eyelet and the conductor, or may be made of different materials. In short, any material can be used as long as the material of both the eyelet and the conductive wire can be melted by welding to form a weld. Generally, brass is often used as the material of the eyelet, but it may be formed of copper instead. When the eyelet is made of copper as described above, zinc gas generated during brass welding is not generated even when arc welding is performed in the welding step of the eyelet with the conductor. Further, since the zinc gas adheres to the surface of the welded portion after welding, the electrical contact with the lamp socket is not hindered, and the appearance is not significantly impaired. Since copper is easily melted, when a large amount is melted, the whole is easily melted sufficiently.

Further, the welded portion does not need to have a convex shape as a whole. Conversely, part of the convex portion of the eyelet may be a welded portion.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the lamp device according to the present invention will be described below with reference to the drawings.

FIG. 1 is a partially perspective view of an exploded state showing an embodiment of the lamp device of the present invention, FIG. 2 is a side view of the same exploded state, and FIG. FIG. 4 is a cross-sectional view, and FIG. 4 is a top view showing the base in a welding step of the first conductive wire. The lamp device of the present embodiment is a bulb-type fluorescent lamp.

In these figures, 10 is a lamp device,
The lamp device 10 includes a lamp body 13 and a base 12. The lamp body 13 includes the base 11, the lighting circuit 1,
6 and a fluorescent lamp 15. Hereinafter, the description will be made with the base 12 side being positioned on the upper side.

The base 11 is also called a cover or a base. As shown in FIGS. 1 and 2, the base 11 is integrally formed in a substantially cylindrical shape with a heat-resistant synthetic resin such as polybutylene terephthalate (PBT). ing. The base body 11 is formed with a base body portion 21 that expands downward and a base mounting portion 22 that extends in a substantially cylindrical shape from above the base body portion 21. Then, the base body 21
In the vicinity of the opening at the lower end of the connector, engagement portions 24 are provided in a claw-like shape and protruded inward from a plurality of locations. A base fitting portion 25 which is a large-diameter large-diameter portion which is vertically raised is formed in an annular shape at the lower end portion of the base mounting portion 22. The upper end portion is formed with a lead wire insertion portion 26, which is a notch portion for a lead wire, and a guide notch portion 27, which are open to the upper end surface 25a as one end portion. The wire insertion portion 26 has a wire guide portion 26a that opens in an expanded shape on the upper end surface 25a.
And a conductive wire groove 26b extending downward from the lower end of the conductive wire guide 26a, that is, toward the base fitting portion 25. The lower end portion, that is, the distal end portion of the conductive wire groove portion 26b is formed to be separated from the base fitting portion 25 by a predetermined dimension. Further, the guide notch 27
Is formed in a shape in which a part of the upper end portion of the base mounting portion 22 is cut out linearly or radially. In the present embodiment, a pair of vertical first guide contact portions 27a located on the same plane with each other are formed. , And a second guide contact portion 27b that is parallel to or horizontal to the upper end surface 25a. The guide contact portions 27a and 27b are formed in a smooth plane.

The base 12 constitutes an Edison type base such as an E26 type, and has an insulating portion 31, a conductive eyelet 32 fixed to the center of the upper end of the insulating portion 31, and an insulating portion 31. And a conductive shell 33 fixed to the outer periphery of the base 31 and screwed into the socket.
Inside the base 12, a storage recess opening downward is formed.

The holding member 14 is also called a partition member or the like. The holding member 14 is made of a heat-resistant synthetic resin such as polybutylene terephthalate and has a substantially disc-shaped partition plate portion 41 and an outer peripheral portion of the partition plate portion 41. And a substantially cylindrical tubular portion 42 extending upward from above is integrally formed. Partition plate part 4
1, a mounting hole 43 is formed at a vertex of a regular hexagon. Note that, of the six mounting holes 43, two pairs of mounting holes 43 adjacent to each other are formed continuously with each other. A base fitting portion 44 is formed in the cylindrical portion 42 at a substantially central portion in the height direction to fit into an opening at the lower end of the base body 21 of the base 11, and at the upper end thereof. The plurality of notch portions 42a for the conductor and the board fitting portion 45
Are formed. An annular step 44a, which is located on the outer periphery and fits the lower end of the base body 21, is fitted to the base fitting portion 44.
And a plurality of engagement receiving portions 44b with which the engaging portions 24 of the base body 21 are engaged, and an engaging portion guide portion 44c for guiding the engaging portions 24 to the engagement receiving portions 44b.

The substrate fitting portion 45 is formed with a pair of chucking grooves 46 which open at the upper end at a predetermined interval in the circumferential direction. The space between these pairs of chucking grooves 46 is an elastically deformable arm 47, and an engaging portion 48 protrudes inwardly from the distal end of each arm 47. Further, inside the substrate fitting portion 45, ridges 49 are formed at four locations along the axial direction, which are located on the sides of the chuck grooves 46, and the upper ends of the ridges 49 are in contact with each other. Part 49a
It has become. Of the four ridges 49, a positioning engagement part 49b projects further upward from the contact part 49a of one ridge 49. The upper end of the positioning engaging portion 49b is formed substantially flush with the upper end of the board fitting portion 45, whereas the lower surface of the engaging portion 48 is formed at the upper end of the board fitting portion 45. It is located slightly above, and the upper surface of the contact portion 49 a is located slightly below the upper end of the board fitting portion 45.

In the fluorescent lamp 15, three lamp bulbs 51, that is, three arc bulbs whose middle portions are smoothly curved, that is, arc tubes are arranged at predetermined positions, and are sequentially connected by communication tubes (not shown). A discharge path is formed. Each lamp bulb 51 has a phosphor film formed on the inner surface and a rare gas such as argon and mercury sealed inside. Filaments or electrodes are sealed at bulb ends located at both ends of the discharge path. The lighting circuit 16 includes a disk-shaped substrate 60 which is a so-called circuit substrate. The substrate 60 has a straight edge 62 formed by linearly cutting four sides of a disk fitted inside the substrate fitting portion 45, and further,
A positioning engagement receiving portion 63 is formed by cutting out a part of the outer peripheral portion. A plurality of electric components are mounted on one surface, or one surface and the other surface, which is the upper surface of the substrate 60, and an inverter circuit that performs high-frequency lighting, that is, a high-frequency lighting circuit is configured. As the electric components, there are provided an electrolytic capacitor 65, a rod-shaped wrapping pin 66, and other components 67 such as a transistor, a chip-shaped rectifying element, and a resistor arranged in the center. On the lower surface of the substrate 60, components having relatively high heat resistance and small thickness are mounted. Further, from the board 60, first and second conductive wires W1 and W2 connected to the high-frequency lighting circuit are led out toward the base 12 side.

First, each base end of the lamp bulb 51 of the fluorescent lamp 15 is inserted into the mounting hole 43 of the holder 14 from below, and an adhesive such as silicone is filled from above. And fix it.

Next, the three or four wires Wf connected to the electrodes of the fluorescent lamp 15 are passed through the inside of the holder 14 and led out to the outer peripheral side through the notch 42a for the wire. The board 60 is inserted into the board fitting portion 45 from the opening on the upper side of 14, and fitted and fixed. That is, both sides of the two linear edges 62 of the substrate 60 are gripped by the chucks that constitute the manufacturing apparatus, and each chuck is held by the chuck groove 46.
The substrate 60 is pressed into the substrate fitting portion 45 while holding the substrate 60 with the chuck, and each chuck is retracted to the side. Then, the disc-shaped outer peripheral portion of the substrate 60 is fitted to the inner peripheral surface of the substrate fitting portion 45,
The lower surface of the substrate 60 comes into contact with the contact portion 49a of the ridge 49, and the upper surface of the straight green portion 62 of the substrate 60 is engaged with the engaging portion 48 to be retained and retained. In this state, the ridges 49
Is engaged with the positioning engagement receiving portion 63 of the substrate 60, and is positioned in the circumferential direction and is stopped and held. Further, in this state, the upper surface, which is one surface of the substrate 60, is held so as to be flush with one end 45a, which is the upper end of the substrate fitting portion 45, or to protrude above the one end 45a.

Next, one end of a lead wire Wf led out to the outer peripheral side is wound around three or four wrapping pins 66 mounted on one surface of the substrate 60 by a winding device constituting a manufacturing apparatus, and mechanically and electrically Connect to

Further, with the first and second conductive wires W1 and W2, which are wires, that is, wires mounted on the substrate 60 with solder or the like at one end thereof, are passed through the inside of the base 11, an adhesive is applied as necessary. After the application, the holding body 14 to which the fluorescent lamp 15 and the substrate 60 are attached is press-fitted from the opening of the base body 11 to engage the engaging portion 24 of the base body 11 with the engagement receiving portion 44b of the holding body 14, The base 11 and the holder 14 are fixed.

The other end of the first conductive wire W1 is electrically and mechanically connected to the eyelet 32 of the base 12 by welding. The other end of the second conductive wire W2 is led out of the base mounting portion 22 through the conductive wire insertion portion 26, and is folded back to be disposed on the base fitting portion 25. Then, in this state, the housing recess of the base 12 is moved in one direction to cover the base mounting portion 22, and from the outer peripheral side of the base fitting portion 25, a plurality of positions, that is, 6 directions or more and 10 directions or less, for example, 8 directions The conductor W2 is sandwiched between the base fitting portion 25 and the shell 33 to be electrically connected to the shell 33 by pressing in opposition to each other, that is, by punching and caulking at eight places. ,
The base 12 is fixed to the base 11, and the lamp device 10 is assembled.

Here, a convex welded portion having a gentle slope is formed on the eyelet 32 to which the conductive wire W1 is welded. The connection process between the conductor W1 and the eyelet 32 will be described with reference to FIG. 3A to 3D are views showing a part of the base connecting step of the lamp manufacturing method of the present invention. 3A to 3D show a cross section of a part of the base. FIG. 4 is a side sectional view showing a part of the die in one step of conducting wire welding.

First, the eyelet 32 will be described with reference to FIG. Reference numeral 32a is a cylindrical portion formed so as to protrude from a substantially central portion of the flat portion of the eyelet 32. The eyelets 32 are formed of copper. Therefore, the cylindrical portion 32a is formed integrally with copper and other portions of the eyelet 32 such as a flat portion. The cylindrical portion 32a is hollow and forms a through hole vertically penetrating the flat portion of the eyelet 32 by the hollow portion. Eyelet 32
Has a concave portion 32c substantially at the center of the flat portion 32b,
2a is formed in this recess. Thereby, the cross section is substantially V by the peripheral surface of the cylindrical portion 32a and the inner surface of the concave portion 32c.
A letter-shaped peripheral groove 32d is formed. Circumferential groove 32d
Is formed in an annular shape surrounding the cylindrical portion 32a. The eyelet 32 is attached to a glass insulating portion 31 for ensuring electrical insulation from the shell 33. Circumferential groove 32
The insulating part 31 does not exist under the part d and the cylindrical part 32a. In addition, when the insulating portion 31 is not provided below the circumferential groove portion 32d, heat at the time of welding becomes difficult to be transmitted to the insulating portion 31, and cracks in the insulating portion 31 can be suppressed. However, if the problem of cracks does not occur in the insulating portion 31, the insulating portion 31 may be provided below the peripheral groove portion 32d.

FIG. 3A shows a state in which the conductive wire W1 is attached to the eyelet 32 so as to be connected thereto. As shown in the drawing, the conductor W1 and the base 12 are held by separate devices (not shown), and are held in a state where the tip of the conductor W1 is at the same position as the tip of the cylindrical portion 32a.

FIG. 3B shows the eyelet 32 in the state shown in FIG. 3A in which the cylindrical portion 32a is crushed from the side to fix the conductive wire W1. In the figure, reference numeral 101 denotes a punch, which is disposed on the side of the cylindrical portion 32a at a regular interval (90 ° interval) in the circumferential direction of the cylindrical portion 32a.
The outer surfaces of the cylindrical portion 32a are squashed to a predetermined depth by swinging the punches 101 facing each other so as to approach each other. At this time, the four punches 101 are simultaneously swung toward the center of the cylindrical portion 32a.
As shown in FIG. 5, 2a receives forces from four directions at the same time, so that it is possible to prevent the cylinder portion 32a from tilting.
Avoiding such inclination of the cylindrical portion 32a can be achieved by using three or more punches. If the tip of the conductor W1 is protruded from the cylindrical portion 32a in this state, the shape can be easily modified, and the first conductor W1 can be easily adjusted.
It is possible to visually check whether or not 1 has been inserted and crushed.

The base end of the cylindrical portion 32a forms a part of the circumferential groove 32d having a substantially V-shaped cross section as described above. For this reason, when the cylindrical portion 32a is deformed in the crushing step using the punch 101, a reaction force is generated, and the reaction force is likely to affect other portions of the eyelet 32. Most of the reaction force is applied to the peripheral groove portion 32d. And the other part of the eyelet 32 is not deformed.

In this embodiment, the inner diameter of the through-hole 32f of the cylindrical portion 32a is about 1.5 mm, while the conductor W1
Has an outer diameter of about 0.5 mm, and according to this dimensional difference, insertion of the conductive wire W1 into the through-hole 32f becomes very easy. Therefore, in a state where the conductor W1 is inserted through the through-hole 32f, the cylindrical portion 32a and the conductor W1 are not in a state of being securely connected electrically, but by the process shown in FIG. Thus, both the cylindrical portion 32a and the conductive wire W1 can be melted by plasma arc welding in a step shown in FIG. 3C described later. Thus, the outer shape of the conductor W1 and the through hole 3
When the difference in the inner diameter of 2f is large, it is necessary to largely deform the cylindrical portion 32a in order to fix the conductive wire W1 to the cylindrical portion 32a, but as described above, the cylindrical portion 32a of the eyelet 32 accompanying the crushing process by the circumferential groove portion 32d. Other deformations can be prevented. Note that the eyelet 32 in the present embodiment is
Is about 0.3 mm. Therefore, if the eyelet 32 is formed of a material having a material thickness smaller than this, it can be said that the same deformation preventing action can be obtained.

In the crushing step, the cylindrical portion 32a
5 is crushed by the punch 101 in FIG. FIG. 5 is a top view of the base. Thus, the cylindrical portion 32
The cross section a is formed in a cross shape. FIG. 6 is a side sectional view of the same.

FIG. 3C shows a state in which the lamp device in which the eyelet 32 is processed in the state of FIG. 3B is attached to a welding machine. In the figure, reference numeral 102 denotes a welding machine, which is schematically shown in drawing. 102a is a plasma torch. 102
b is a power supply connected to the plasma torch 102a.
Reference numeral 102c denotes a base-side terminal which contacts the eyelet 32 to make it electrically conductive and is connected to the AC power supply 102b. A switch 102d turns on and off the power supply to the plasma torch 102a. Note that in FIG.
Has been described as a DC power supply, but when the shell 33 is made of aluminum or the like, the power supply may be an AC power supply.

In this state, when the switch is closed, a plasma arc is generated between the plasma torch 102a and the cylindrical portion 32a or the end of the conductive wire W1. Due to the energy of this plasma arc, the conductor W1 and the cylindrical portion 3
2a melts and they are welded. At this time, the voltage applied to the plasma torch 102a and the welding time are adjusted to control so that only the conductive wire W1 and the cylindrical portion 32a are melted, and the other part of the eyelet 32 is not melted.

FIG. 3D shows the eyelet 32 after the plasma welding has been performed. As shown in the figure, the conductive wire W1 and the cylindrical portion 32a are welded and integrated, and the resulting welded portion has a convex shape with a curved surface. The welding portion 32e is formed in a circular shape with the through hole of the eyelet 32 as the center. Further, the welded portion 32e remains at the center of the recess 32c, and the tip of the welded portion 32e has a height substantially equal to the opening of the recess 32c. Since the welded portion 32e remains at the center of the recess 32c, the welded portion 32e does not reach the portion of the eyelet 32 that is in contact with the insulating portion 31, as is apparent from the drawing. This is because the welding portion 32e is formed so as to form an annular circumferential groove 32g having a substantially V-shaped cross section and surrounding the welding portion by the peripheral surface of the welding portion 32e and the inner surface of the concave portion 32c. Is formed from the molten glass, the molten glass is hard to be formed at the center of the concave portion 32c beyond the peripheral groove 32g. This suppresses the insulating portion 31 from approaching the welded portion 32e and prevents the insulating portion 31 from being heated more than necessary, thereby preventing cracks in the insulating portion 31 and peeling of the eyelet 32. Further, since the distal end portion of the welded portion 32e has the same height as the opening of the concave portion 32c, the mechanical strength of the welded portion 32e can be kept at an appropriate level. Note that the protrusion height of the welded portion 32e is
It is preferable that the thickness is about 1.5 mm or less from the opening c in view of mechanical strength and electrical connection by contact with the socket terminal.

Next, another operation obtained by each configuration of this embodiment will be described. According to the present embodiment, the substrate 60 of the lighting circuit 16 relates to the shape and the manufacturing method of the bulb-type fluorescent lamp.
The first conductive wire W1 of the first and second conductive wires W1 and W2 connected to the base wire passes through the inside of the cylindrical base mounting portion 22 and is connected to the eyelet 32 of the base 12. The second conductive wire W2 is led out of the base fitting portion 22 through the conductive wire insertion portion 26, and is folded back and disposed on the base fitting portion 25, so that the second base wire W2 is electrically fixed to the shell 33 at the same time as the base 12 is mechanically fixed. Can be connected to The base mounting part 22 is provided with a base fitting part 25 that fits on the inner peripheral side of the base 12, and the lead insertion part 26 is formed at a position separated from the base fitting part 25, that is, the lead insertion part 26 notch length for base 12
Of the shell 33 does not reach the position of the open end of the shell 33. Therefore, the notch in the lead wire insertion portion is inserted into the shell 33 of the base 12.
As compared with the configuration provided up to the position of the opening end, the waterproofness can be easily improved with a simple structure, and the manufacturing cost can be reduced.

A pair of first guide contact portions 27a located on the same vertical plane are formed in the base mounting portion 22. Therefore, by abutting the rails, which are guide members, on these guide abutting portions 27a, the direction of the base 11 can be easily and accurately captured in the transport process of transporting in the horizontal direction. Therefore, the operation of passing the conductor W2 through the conductor insertion portion 26 is facilitated, and the automation of the assembly operation is facilitated.
Manufacturing costs can be reduced. Further, since the second guide contact portion 27b, which is orthogonal to the first guide contact portion 27a and has a horizontal bottom surface, is provided, the first guide contact portion 27a provided at the upper end portion of the base mounting portion 22 is provided. The second guide contact portion 27b and the second guide contact portion 27b can simultaneously regulate the position in two different directions, the horizontal direction and the vertical direction. Also, the second guide contact portion 2
By making the 7b a horizontal plane, the base 11 can be hardly tilted even when it comes into contact with the guide for the first guide contact portion 27a.

Further, the base 12 is moved in one direction and caulked and fixed to the base fitting portion 22, so that, for example, the base 12 is only allowed to be loosely inserted into the base body 11 in the process before caulking. As compared with a configuration in which the base 12 is fixed by screwing the base 12 into the base 11, automation of the assembling operation is facilitated and the manufacturing cost can be reduced. In addition, by caulking from six directions or more, the strength can be secured, and temporary fixing (auxiliary fixing) by screwing or the like can be unnecessary. On the other hand, by caulking from 10 directions or less, the manufacturing equipment can be simplified and the manufacturing cost can be reduced. Then, the bases 12 are hardly inclined and can be fixed at an accurate position by setting the swaging points to face each other and making the gaps equal to each other. For example, by caulking eight points, the effect of preventing inclination can be further improved. 4 for an 8-point punch
Using a machine that can simultaneously punch eight points at 5 ° intervals, it can be firmly fixed with relatively simple equipment. Furthermore, since the conductor W2 is arranged between the mouthpiece fitting part 25 of the mouthpiece mounting part 22 of the base 11 and the mouthpiece 12, the conductor W2 is caulked.
At the position where is disposed, the base 12 is in close contact with the conductive wire W2 and is deformed in a convex shape, so that the electrical connection and the mechanical connection between the conductive wire W2 and the base 12 can be easily and reliably confirmed visually. By caulking at six or more points, the punch position and the position of the conductor W1 approach each other, and the position of the conductor W2 can be reliably deformed into a convex shape.

It should be noted that, in addition to the configuration of the above embodiment, the base 1
By providing a seal member such as an O-ring between the base mounting portion 22 and the end of the shell 33 of the base 12, the waterproof function can be further improved.

In the above embodiment, the configuration in which the fluorescent lamp 15 is exposed has been described. However, gloves of various shapes as light control bodies may be provided. In addition, the configuration and method of the lead wire to the base are similar to those of H having the same type of base.
It can be widely applied to other lamp devices such as ID lamps.

According to the lamp device 10 of the present invention, the eyelet 32 and the conductor W1 are welded through a process of melting each other, and the eyelet 32 and the conductor W formed by this are welded.
Since the welded portion 32e in which the material 1 and the material 1 are mixed has a convex shape, the convex portion is enlarged to increase the welded portion 32e.
By increasing the volume of e, the eyelet 32 and the conducting wire W1 are mechanically and strongly connected.

Therefore, it is possible to prevent the melted portion of the eyelet 32 from reaching the flat portion 32b so as to prevent the eyelet 32 from melting and forming a hole. Sufficient welding strength can be obtained even if the melting amount of is reduced. Accordingly, the amount of the conductive wire W1 to be melted can be reduced, and the conductive material hardened after welding is less likely to spread in a range deviated from the through-hole 32f of the eyelet 32, and the mechanical strength of welding can be secured.

Further, since the welded portion 32e is formed in the concave portion 32c of the eyelet 32, the material of the welded portion 32e that has been melted does not overflow from the concave portion 32c during welding, or the material below the eyelet 32 is not welded. Insulating part 31
The influence of heat on the eyelet 32 can be suppressed, and problems such as peeling of the eyelet 32 can be prevented.

Further, the tip of the welded portion 32e is
Since it has a height substantially equal to that of the opening 2c, the mechanical strength of the welded portion 32e can be kept at an appropriate level.

According to the lamp device 10 of the present invention, even when mechanical contact with the terminal of the lamp socket is made only at the tip end of the welded portion 32e, the terminal of the lamp socket and the welded portion 32e can be securely connected. Contact can be made and poor contact hardly occurs.

According to the lamp device 10 of the present invention, the conductor W
The welding of No. 1 can be performed at a position distant from the insulating portion 31 which insulates the eyelet 32 and the shell 33. Therefore, the heat generated during welding is less likely to be transmitted to the insulating portion 31, and it is possible to prevent the insulating portion from being cracked and the eyelet from peeling off from the insulating portion.

According to the method of manufacturing the lamp device of the present invention, the insertion of the conductor W1 becomes very easy by making the inner diameter of the through hole 32f larger than the outer diameter of the conductor. By crushing the tubular portion 32a, the tubular portion 32a and the conductor W1 can be reliably electrically connected. Therefore, when performing welding, the cylindrical portion 32a
And the conductor W1 can be melted.

Further, by the crushing step, the conducting wire W1 is
2a, the cylindrical portion 3
The shape of the portion to be welded in which the conductor 2a and the conductor W1 are combined is adjusted, and the size and shape of the convex welded portion 32e obtained by welding the cylindrical portion 32a and the conductor W1 can also be made required. The shape of the weld 32e can be made to have high mechanical strength. Further, in a state where the conductive wire W1 is fixed to the cylindrical portion 32a by the crushing step, by checking the shape of the crushed portion to be welded, it is predicted whether or not a required shape having high mechanical strength can be obtained by the subsequent welding. And quality control is easy.

According to the present invention, the eyelet 32 further has an annular peripheral groove 32d having a substantially V-shaped cross section and surrounding the cylinder by the peripheral surface of the cylindrical portion 32a and the inner surface of the concave portion 32c. In the step of crushing the cylindrical portion 32a, the cylindrical portion 32a
The reaction force of the deformation caused by the crushing of the eyelet 32 can be absorbed by the circumferential groove, and the deformation of the cylindrical portion 32a of the eyelet 32 and the flat portion 32b other than the circumferential groove can be prevented.

In the above embodiment, the lamp main body 10 has been described as including the base 11, the holder 14 for holding the lighting circuit 16, and the fluorescent lamp 15. However, the lamp body 10 may be only a lamp bulb having a built-in filament. A base is attached to the lamp body 10 to form an incandescent lamp. When the lamp body 10 is an incandescent light bulb, the second conductor W2 may be welded to a desired portion of the shell 33 to make an electrical connection.

According to the lamp device of the present invention, the first lead wire penetrating the eyelet and a part of the eyelet integrally and cylindrically protruding from the eyelet so as to cover the periphery of the first lead wire. Melted to form a convex welded portion on the eyelet, so that the convex portion can be enlarged to increase the volume of the welded portion, and that the eyelet and the first conductive wire be mechanically and strongly connected. Can be.

Further, according to the lamp device of the present invention, since the welded portion is formed in the concave portion, it is possible to prevent the welded portion from excessively protruding from the eyelet even if the volume of the welded portion is increased. In welding the conductive wire, an insulating portion that insulates the eyelet and the shell can be formed at a position away from the welded portion. Therefore, the heat generated during welding is less likely to be transmitted to the insulating portion, and it is possible to prevent the insulating portion from being cracked and the eyelet from separating from the insulating portion.

According to the method of manufacturing a lamp device of the present invention, the insertion of the conductor is very easy by making the inner diameter of the through hole larger than the outer diameter of the conductor. By crushing, it is possible to reliably electrically connect the cylindrical portion and the conducting wire. Therefore, when welding is performed, both the cylindrical portion and the conductive wire are melted, and the eyelet and the first conductive wire can be mechanically and firmly connected.

[Brief description of the drawings]

FIG. 1 is a partial perspective view showing an embodiment of a lamp device according to the present invention in an exploded state.

FIG. 2 is a side view showing the lamp device shown in FIG. 1 in an exploded state.

FIG. 3 is a partial cross-sectional view showing each step of welding a first conductive wire to a base.

FIG. 4 is a side sectional view showing a part of a base in one step of welding a first conductive wire.

FIG. 5 is a top view showing the base in another step of welding the first conductive wire.

FIG. 6 is a side sectional view showing the die in another step shown in FIG. 5;

[Explanation of symbols]

10 lamp apparatus, 12 base, 13 lamp body, 3
2: Eyelet, 32e: weld, 33: shell, W1
.., A first conductive wire, W2, a second conductive wire.

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Kenji Sakai 4-3-1 Higashishinagawa, Shinagawa-ku, Tokyo Toshiba Lighting & Technology Corporation (56) References JP-A-10-106488 (JP, A) JP-A Heisei 10-275602 (JP, A) JP-A-3-43950 (JP, A) JP-A-62-73552 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) H01J 5/50 F21S 2/00 H01J 9/36

Claims (10)

(57) [Claims] 1. A lamp body for leading first and second conductors; an eyelet; a first conductor passing through the eyelet ;
From the eyelet to cover the periphery of the first conductive wire of
And a part of the cylindrically projected eyelet is melted to have a welded portion formed into a convex shape on the eyelet and a shell electrically connected to the second conductive wire, and is mounted on the lamp body. A lamp device comprising: a base; 2. A lamp body for leading first and second conductors; an eyelet; a first conductor passing through the eyelet ;
From the eyelet to cover the periphery of the first conductive wire of
And a part of the cylindrically projecting eyelet is melted to form a welded portion formed into a convex shape on the eyelet.
Having an insulating member for electrically supporting the shell and the eyelet electrically connected to each other from the shell and supporting the electrically connected wires, and a base mounted on the lamp body. apparatus. (3)Lamp book for deriving first and second conductors
With the body; One surface is formed almost flat, and almost in the center of the flat part
An eyelet with a recess, inside the recess of this eyelet
And a part of the eyelet and the first conductor are connected to each other.
By melting, the materials mix and form an eyelet
Welds formed in a convex shape, the peripheral surface of this weld and the recess
The cross section is substantially V-shaped with the inner surface,
A shell in which the circumferential groove and the second conductor are electrically connected;
And a base attached to the lamp body; A lamp device comprising: 4. The lamp device according to claim 3 , wherein the welding portion has a height substantially equal to an opening surface of the concave portion of the eyelet. 5. The lamp device according to claim 3 , wherein the welded portion projects from the opening surface of the concave portion of the eyelet at a height of about 1.5 mm or less. Weld 6. convex shape surface lamp apparatus of claims 1 to 5 any one wherein it is a curved surface. 7. A lamp body is mounted on a cylindrical base, a lighting circuit housed in the base and leading out the first and second conductors, a holding body for holding the lighting circuit, and a holder. The lamp device according to any one of claims 1 to 6 , further comprising a fluorescent lamp. 8. An eyelet having a flat portion and having a through-hole at substantially the center of the flat portion and having a cylindrical portion protruding from the flat portion is formed on one side, and on the other side. Electrically connecting the first conductor to the eyelet, electrically connecting the second conductor to the shell, and attaching the base to the lamp body with respect to the base having a cylindrical shell; Melting the cylindrical portion and the conductive wire to each other and welding them in a state where the tip of the cylindrical portion is inserted through the through-hole of the eyelet. 9. The connection between the eyelet and the first conductor is made by the first
9. The method for manufacturing a lamp device according to claim 8, wherein, after the conductor is inserted through the cylinder, the cylinder is crushed from the side to fix the conductor, and then welded. The eyelet has a concave portion formed substantially at the center of the flat portion, and the cylindrical portion is formed in the concave portion. The cross section of the eyelet is substantially V-shaped by the peripheral surface of the cylindrical portion and the inner surface of the concave portion. The method according to claim 8, wherein an annular groove is formed.