JP3462458B2 - High pressure discharge lamp and manufacturing method thereof - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a high pressure discharge lamp using a ceramic discharge tube and a method for manufacturing the same.

[0002]

2. Description of the Related Art In such a high-pressure discharge lamp, a plugging material (usually called a ceramic plug) is inserted inside both ends of a ceramic discharge tube to close each end and to close each end. A through hole is provided in the material, and a metal current conductor having a predetermined electrode system fixed thereto is inserted into the through hole. An ionized luminescent material is enclosed in the internal space of the ceramic discharge tube. As such a high-pressure discharge lamp, a high-pressure sodium light emitting lamp and a metal halide lamp are known, and in particular, the metal halide lamp has a good color rendering property. By using ceramic as the material of the discharge tube, it became possible to use it at high temperature.

FIG. 1 is a sectional view showing a preferred example of the structure of the end portion of such a ceramic discharge tube. The main body 11 of the ceramic discharge tube has a tubular or barrel shape with both ends narrowed, and a cylindrical end 12 is provided at both ends of the main body 11. The main body 11 and the end portion 12 are made of, for example, an alumina sintered body. The inner surface 11a of the main body 11 has a curved shape, and the inner surface 12a of the end portion 12 is straight when viewed in the axial direction of the main body, so that a corner portion 36 is formed between the main body 11 and the end portion 12. There is. A closing member 41 is inserted and held inside the end portion 12, and a through hole 41 a is formed so as to extend in the axial direction of the closing member 41. The elongated current conductor 5 is inserted into the through hole 41a,
It is fixed. In this example, the current conductor 5 has a cylindrical shape, and the ionized luminescent material is introduced into the internal space 13 of the main body 11 through the inside surface 5 a of the current conductor 5. The outer end of the current conductor 5 is provided with a sealing portion 5b that seals the starting gas and the luminescent material and then seals the electrode shaft 7 to the outer peripheral surface of the current conductor 5. .

It is necessary to seal between the plug 41 and the end 12 of the ceramic discharge tube and between the plug 41 and the current conductor 5, but in a preferred example, a calcined body of the plug 41 is used. The current conductor 5 is inserted into the through hole of the above, and the closing member 41 is inserted into the end portion 12 to manufacture an assembly, and the assembly is integrally sintered. At this time, the end portion 1 is formed by integral sintering.
2 and the blocking member 41, and the blocking member 41 and the current conductor 5 are sealed.

In the above-mentioned sealing method, the end portion 12 is not inserted into the calcined body of the end portion 12 without the calcined body of the closing member 41 being inserted.
When the calcined body is fired, the inner diameter of the end portion 12 is designed to be smaller than the outer diameter of the closing member 41. Therefore, the occluding member 41 is firmly tightened and held in the end portion 12. The same applies to the blocking member 41 and the current conductor 5. As the material of the current conductor, molybdenum, tungsten, rhenium or alloys thereof are advantageous from the viewpoint of corrosion resistance, and as the material of the ceramic discharge tube, alumina ceramics is generally used. Also,
If alumina ceramics is used as the material of the plugging material, the difference in thermal expansion between the plugging material and the current conductor becomes large. Therefore, as the material of the plugging material, a composite material of alumina ceramics and the above metal or another cermet is used. Known to be used.

[0006]

However, as a result of further studies on this manufacturing method, the present inventor has found the following problems. That is, in the above-mentioned stage of integral firing, the calcined body of the end portion 12 and the calcined body of the sealing material 41 are certainly shrunk in the lateral direction (circumferential direction of the ceramic discharge tube) in FIG. Due to the contraction, the blocking member 41 and the current conductor 5 are firmly held and sealed. However, at the stage of this integral firing, at the same time,
Both the calcined body of the end portion 12 and the calcined body of the sealing material 41 are fired and shrunk also in the direction of arrow E (direction of the central axis of the ceramic discharge tube). As a result, a large thermal stress is generated and remains between the closing member 41 and the end portion 12 and between the closing member 41 and the current conductor 5 when viewed in the direction E of the central axis of the ceramic discharge tube.

In particular, when the high pressure discharge lamp exhibits excellent color rendering properties and its coldest point is 700 ° C. or higher, lighting is performed.
When the light-off cycle is repeated, the effect of the above-mentioned residual stress is expanded by this heat cycle, and there is a possibility that destruction or leakage of the ionized light-emitting substance may occur.

Further, in the end sealing structure as shown in FIG. 1, basically, the pressure between the blocking member 41 and the current conductor 5 seals the both, but it is still lighted. Since the extinguishing cycle is repeated many times, it is necessary to further improve the reliability of this sealed portion in view of the difference in thermal expansion coefficient between the two. Therefore, it is necessary to develop a seal structure having high corrosion resistance and reliability especially for metal halides.

An object of the present invention is to damage or destroy each member at the end due to this heat cycle and to leak an ionized light-emitting substance in the sealed structure of the end of the ceramic discharge tube even if lighting and extinguishing are repeated many times. Is not to occur.

[0010]

A high pressure discharge lamp according to the present invention is a ceramic discharge tube having an internal space filled with an ionized luminescent material; at least a part of which is fixed inside the end of the ceramic discharge tube. A plugging member, which is provided with a through hole; a current conductor with an electrode system which is inserted into the through hole of the plugging member; and other than the through hole,
It is characterized in that it comprises an encapsulant layer formed so as to bond to the obstruction material and the current conductor with the electrode system.

Furthermore, the method for manufacturing a high-pressure discharge lamp according to the present invention manufactures a fired body of a plugging material, in which the current of the plugging material is not intervened in the through hole of the fired body of the plugging material. A conductor is inserted, a sintered body of the ceramic discharge tube is manufactured, and at least a part of the sealing material is fixed inside the end of the sintered body of the ceramic discharge tube, and a sealing material containing a component of the sealing material is fixed. A stop material component layer is formed so as to be in contact with the plugging material and the current conductors other than through holes, and the plugged material of the plugging material, the fired body of the ceramic discharge tube and the sealing material component layer are sintered. Characterize.

The inventor of the present invention, as described above, regarding the destruction between the end of the ceramic discharge tube and the plug, the plug between the plug and the current conductor, and the leakage of the ionized luminescent material,
We have studied it in detail, but in this process, there is no sealant between the through hole of the blocker and the current conductor, and there is a body to be burned (calcined body, molded It has been conceived that the encapsulant and the current conductor are sealed by bonding the encapsulant layer to both the encapsulant and the current conductor without causing a large compressive stress due to firing shrinkage of the body or the degreased body). As a result, a large residual stress does not occur in the direction of the central axis of the ceramic discharge tube due to firing shrinkage of the material to be fired of the occluding material, so that a breakage between the occluding material and the current conductor, and the generation of the ionized luminescent material from here. A leak can be prevented.

Moreover, when the metallization layer is used as a sealing material layer for sealing the end portion of the ceramic discharge tube,
The inventors have found that the corrosion resistance to ionized luminescent materials, especially metal halides, in the ceramic discharge tube is extremely high, which significantly increases the life of the ceramic discharge tube, and completed the present invention.

As the current conductor, it is possible to use a current conductor made of various high melting point metals or high melting point conductive ceramics. However, a high melting point metal is preferable from the viewpoint of electrical conductivity, and as such a high melting point metal, one or more metals selected from the group consisting of molybdenum, tungsten, rhenium, niobium, tantalum and alloys thereof are more preferable. Of these, the coefficient of thermal expansion of niobium and tantalum is almost in balance with the coefficient of thermal expansion of ceramics, particularly alumina ceramics, which constitutes the ceramic discharge tube, but it is known that these metals are easily corroded by metal halides.

Therefore, in order to prolong the life of the current conductor, it is preferable that the current conductor is made of molybdenum, tungsten, rhenium or an alloy thereof.
However, these metals generally have a small coefficient of thermal expansion.
For example, the coefficient of thermal expansion of alumina ceramics is 8 × 10.
^-6 K ^-1 , and the coefficient of thermal expansion of molybdenum is 6 x 10 ^-6 K
^-1 , and the coefficient of thermal expansion of tungsten and rhenium is 6 ×
It is 10 ^-6 K ^-1 or less.

When molybdenum is used as the material of the current conductor, the molybdenum further contains La ₂ O ₃ and C.
At least one of eO ₂ and 0.1% by weight in total
It is particularly preferable that the content is 2.0% by weight.

The encapsulating material layer may be a glass layer, but is preferably a metallized layer. Here, the metallized layer is formed by forming a sealing material component layer containing a metal component at a predetermined position on the end portion of the ceramic discharge tube, and firing the sealing material component layer to form a plugging material and a current conductor. It can be formed so as to be bonded to both.

Here, as the metal component constituting the metallized layer, one or more metals selected from the group consisting of molybdenum, tungsten, rhenium, niobium, tantalum and alloys thereof are preferable, and particularly, the metallized layer has a corrosion resistance to halogen. From the viewpoint of properties, one or more metals selected from the group consisting of molybdenum, tungsten, rhenium and alloys thereof are preferable.

Ceramics are contained in the metallized layer.
Ingredients can also be included, but this ceramic composition
As a component, a ceramic that is corrosion resistant to ionized luminescent materials
Is preferable, and specifically, Al₂ O₃ , SiO
₂ , Y₂ O₃ , Dy ₂ O₃ And B₂ O₃ A group of
One or more selected ceramics are preferred. Especially
Ceramics of the same type as the material of the Lamic discharge tube are preferred.
In particular, alumina ceramics is particularly preferable. This metalla
Inclusion of metal and ceramic components in the Izu layer
The ratio should be 30/70% by volume to 70/30% by volume.
And are preferred. The thickness of the metallized layer is 5-10.
It is preferably 0 μm.

It is preferable to add a binder having excellent thermal decomposability to the metallized paste for forming the metallized layer.
Examples include ethyl cellulose and acrylic binders.

As the material of the plugging material, the same kind of material as the ceramic discharge tube can be used, or different kinds of materials can also be used. However, it is preferable to use the same kind of material as the ceramic discharge tube for the portion inserted inside the end. This is because, as a result, residual stress in the central axis direction of the ceramic discharge tube is hardly generated between the ceramic discharge tube and the blocking member. However, the same kind of material here means that the base ceramics are common, and the added components may be different.

In the present invention, the closure may be divided into two or more parts, an inner part fixed in the end of the ceramic discharge vessel and an outer part integrated with this inner part. May be equipped with. At this time, it is preferable that there is substantially no compressive stress from the inner portion to the current conductor. For this purpose, it is preferable that the diameter of the through hole in the inner portion is equal to or larger than the diameter of the current conductor. The encapsulant layer is formed so as to be joined to the outer portion and the current conductor.

The outer portion and the current conductor can be brought into close contact with each other, and a compressive stress can be applied from the outer portion toward the current conductor.

By thus closely contacting the outer portion and the current conductor, it is possible to seal the two, and at this time, the inner portion is not crimped to the current conductor. Moreover, since the outer part is outside the ceramic discharge tube and the stress from the end is small, the pressure between the outer part and the current conductor becomes excessive, causing damage and leakage of the ionized luminescent material. The risk of doing so is small.

However, when a large compressive stress is applied from the outer portion toward the current conductor, cracks may occur during repeated operation, so that a substantially large amount of stress is generated between the outer portion and the current conductor. It is preferable that no compressive stress is generated.

However, when the sealing material layer is a glass layer, there are the following restrictions. That is, in the case of performing sealing with a glass layer, first, the above-mentioned occluding material is fired, then a glass frit is installed on the end face of the outer portion of this occluding material, and the glass frit is melted to melt the glass layer. To form. However, in this process, if there is a gap between the outer portion and the current conductor or there is substantially no compressive stress, it is difficult to position and fix the blocker and the glass frit, and the melting The glass frit will flow into the arc tube. Therefore, when the sealing material layer is a glass layer, the outer portion and the current conductor,
It is preferable that they are in close contact with each other so that they do not move easily.

On the other hand, when the encapsulating material layer is a metallized layer, the metallizing paste is applied to the molded body or the calcined material before firing the plugging material, and then the plugging material and the metallizing paste are integrally fired. Therefore, it is not necessary that the outer portion and the current conductor are in close contact with each other both before and after firing. Therefore, as described above, it is preferable that substantially no compressive stress is generated between the outer portion and the current conductor.

When the blocking member is a joined body of the inner portion and the outer portion, the material of the inner portion is preferably the same kind of material as the ceramic discharge tube. As a result, the inner portion and the end of the ceramic discharge tube are integrated after firing.

The material of the outer portion is preferably a composite material having a coefficient of thermal expansion between the coefficient of thermal expansion of the material of the ceramic discharge tube and the coefficient of thermal expansion of the material of the current conductor. As a result, the difference in thermal expansion between the outer portion and the current conductor after the integral firing can be reduced.

More specifically, this composite material is preferably a composite material of a first component having a relatively high thermal expansion coefficient and a second component having a relatively low thermal expansion coefficient, Here, the first component of the composite material is preferably a ceramic of the same kind as the material of the inner portion and the material of the ceramic discharge tube. As a result, the ceramic component diffuses at the interface between the inner part and the outer part after the integral firing,
This is because the two are firmly joined. It is particularly preferable that both the ceramic discharge tube and the first component of the composite material forming the outer portion are alumina ceramics. This is because alumina has high corrosion resistance, and when an alumina component is contained in the composite material,
Usually, at about 1600 ° C. or higher, the solid diffusion reaction at the time of sintering causes the disappearance of the seam between the outer portion and the inner portion, and the joint portion forms a substantially integral structure.

The second component of the composite material is a refractory metal such as tungsten, molybdenum, or rhenium, which has corrosion resistance to metal halides, aluminum nitride, silicon nitride, titanium carbide, silicon carbide, zirconium carbide, titanium diboride. , Zirconium diboride, etc. are preferably selected from ceramics having a low coefficient of thermal expansion. As a result, high corrosion resistance to metal halide can be imparted to the outer portion.

In this case, the ratio of alumina as the main component is 60 to 90% by weight, and the ratio of the second component is 10%.
It is desirable to set the content to ˜40% by weight. Further, it is preferable that the encapsulating material layer is sandwiched between the occluding material and the thermal expansion reducing material provided on the opposite side of the occluding material, and the encapsulating material layer is bonded to the thermal expansion easing material. . When the occluding material having the inner part and the outer part as described above is used as the occluding material, the outer part and the thermal expansion reducing material are opposed to each other.

That is, when the encapsulating material layer is formed on the surface of the encapsulating material, due to the heat cycle of turning on and off as described above, the thermal expansion difference is caused between the encapsulating material and the encapsulating material layer. Cracks may occur. However, if the sealing material layer is sandwiched between the blocking material and the thermal expansion relaxation material,
As a result of the thermal stress being applied line-symmetrically to both sides of the encapsulant layer, the thermal stress concentrated in the vicinity of the interface between the encapsulant layer and the occluding material is relaxed by the heat cycle described above, and microcracks and the like are generated. Less likely to occur.

The material of the thermal expansion relaxation material is preferably a material having a thermal expansion coefficient similar to or equal to the thermal expansion coefficient of the portion of the occluding material that is in contact with the sealing material layer. When the occluding material has the outer portion and the inner portion, the material for the thermal expansion relaxation material is preferably a material having a thermal expansion coefficient close to or equal to the thermal expansion coefficient of the outer portion. Therefore, in this latter case, it is preferable to use the above-mentioned composite material as the material of the thermal expansion relaxation material, especially the material of the outer portion and the composite material in which the first component and the second component are common. preferable.

Further, when the blocking member has an outer portion and an inner portion, it is slightly larger than the outer diameter of the current conductor made of a high melting point metal between the outer portion and the thermal expansion relaxation material. It is possible to insert an annular member having an outer diameter, form a sealing material layer between the annular member and the outer portion, and form an encapsulating material layer between the annular member and the thermal expansion relaxation material. . In this way, by inserting the annular member between the sealing material layers, it becomes easy to join the current conductor with the sealing material.

Further, an annular protruding portion is formed on the outer peripheral surface of the current conductor, the annular protruding portion is inserted between the closing member and the thermal expansion relaxation member, and the sealing material is interposed between the annular protruding portion and the closing member. A layer can be formed and a sealing material layer can also be formed between the annular protrusion and the thermal expansion relaxation material. In this case, in addition to the effect of the annular member described above, the following effect is further obtained. In each of the above-mentioned sealing methods, it is necessary to prevent the ionized luminescent substance from leaking by joining both the blocking material and the current conductor with the sealing material layer.

However, since the annular protrusion is on the outer peripheral surface of the current conductor, there is no possibility that the ionized luminescent material leaks from between the annular protrusion and the current conductor. Therefore, in this aspect, when the sealing material layer is formed between the annular protruding portion and the occluding material, the contact surface (sealing surface) between the sealing material layer and the annular protruding portion.
Can be completely sealed only by forming it on a surface vertical to the central axis direction of the ceramic discharge tube, so that the life of this sealed portion is further increased.

Further, when the occluding member has an inner portion and an outer portion, an annular protrusion is inserted between the outer portion of the occluding member and the thermal expansion relaxation material. Further, in this aspect, the following sealing method is more preferable. That is, in each of the above-mentioned sealing methods, the sealing material layer is formed on the outer end surface of the occluding material, and the thermal expansion relaxation material is further provided outside the sealing material layer. However, if these sealing methods are adopted, a slight gap remains between the inner surface of the through hole of the blocker and the current conductor, and both are not firmly adhered. Also, since the ionized luminescent material flows in, the efficiency of light emission decreases accordingly.

However, the first plugging material is fixed to the inner space side of the end portion of the ceramic discharge tube, and the second plugging material is fixed to the end face side of the end portion of the ceramic discharge tube. The annular protrusion may be inserted between the second closing member and the second closing member. In this case, a sealing material layer is formed between the first closing material and the annular protruding portion, and a sealing material layer is also formed between the second closing material and the annular protruding portion. These encapsulant layers are
It is formed so as to extend in a plane perpendicular to the central axis direction of the ceramic discharge tube.

With this configuration, the ionized luminescent material flows into the gap between the first plugging member and the current conductor at the end of the ceramic discharge tube, but does not flow into the gap. Therefore, the deterioration of the luminous efficiency can be improved.

The above-described sealing method can be adopted at both ends of the ceramic discharge tube, but at one of these ends, it is necessary to inject the ionized luminescent material through the inside of the current conductor. , The current conductor must be tubular. At the other end, various types of current conductors such as a rod shape and a tubular shape can be adopted.

Here, it has been found that when the current conductor is provided with the annular protrusion, a problem occurs in the step of inserting the current conductor into the through hole of the firing target body of the blocker.
That is, when the current conductor is linear, after the electrode system is attached to the tip of the current conductor by welding and then inserted from the opposite end of the electrode system into the through hole, the blockage occurs. The assembly can be manufactured by easily attaching the current conductor with the electrode system in the through hole of the material to be fired. Alternatively, only the current conductor may be metallized with the plugging material and the electrodes may be welded before the final firing.

However, in the case where the welded electrode system is provided with the ring-shaped protrusion, if the ring-shaped protrusion is tried to be inserted into the through hole of the body to be fired from the opposite side of the electrode system in order, the ring-shaped protrusion of the body to be fired is formed. This assembly is impossible because it hits the end face. Of course, if the diameter of the annular protrusion is made smaller so that it can be inserted into the through hole, assembly is possible, but if the diameter of the annular protrusion is made smaller, the aforementioned sealing portion also becomes smaller, The sealing performance by this sealing material layer will fall. Therefore, the diameter of the annular protrusion is
It is preferable to make it larger than the inner diameter of the through hole.

As a result, it was necessary to insert the current conductor into the through hole of the body to be fired of the plugging material from the side where the electrode system was attached, that is, the tip side. However, at this time, in the conventional assembly method, the electrode system was fixed to the outer peripheral surface of the current conductor by welding, but as a result, the electrode system could not be inserted into the through hole of the body to be fired, and It turned out to hit the end face. Further, the electrode shaft of the electrode system is attached to the current conductor, and a welding method is used as this attachment method. However, since this welding material bulges from the outer peripheral surface of the current conductor, the bulging welding material may also hit the end surface of the body to be fired.

Of course, if the diameter of the current conductor is made sufficiently smaller than the inner diameter of the through hole of the body to be fired before firing, such a problem is less likely to occur. This method cannot be adopted because it will not be stably held inside.

Therefore, the present inventor has conceived that when the current conductor has a tubular shape, the electrode system is attached to the inner surface of the current conductor on the internal space side of the ceramic discharge tube. As a result, in particular, the raised portion of the welding material is raised toward the inner peripheral surface side of the current conductor, so that the raised portion does not collide with the end surface of the fired body of the plugging material. Of course, at the same time, this welding method can also bring the position of the electrode closer to the center side in the radial direction of the arc tube, thereby improving the lighting stability.

It has also been conceived that an electrode system is attached to the inner space side of the ceramic discharge tube of the current conductor, and the tip side of this electrode system is bent toward the central axis of the ceramic discharge tube. As a result, the electrode portion at the tip of the electrode system can be easily accommodated in the through hole of the body to be fired.

However, when the electrode shaft of the electrode system is attached to the inner peripheral surface of the current conductor, the welding material rises around the attachment portion. This bump can also occur when brazing material is used. The larger size of the ridge may hinder the flow of the ionized luminescent material during injection of the ionized luminescent material through the tubular current conductor.

Therefore, the present inventor prevents the injection of the ionized luminescent material from being obstructed by the ridge by providing an emission port for the ionized luminescent material in the current conductor in front of the raised portion or the mounting portion. Such an emission port may be continuous with the emission port at the tip of the current conductor, or may be formed separately.

INDUSTRIAL APPLICABILITY The present invention can be suitably applied to a high pressure discharge lamp in which various ionized luminescent substances are encapsulated, but is particularly useful for a metal halide lamp in which a highly corrosive metal halide is encapsulated. It is even more suitable when the ceramic discharge tube is made of alumina ceramics.

Further, in the present invention, when at least the end portion of the ceramic discharge tube of the occluding material is made of the same kind of material as the ceramic discharge tube, the pressure occluding material is provided outside the occluding material, A current conductor is inserted into each through-hole of the crimp blocker, and a space between the blocker and the crimp blocker and a space between the crimp blocker and the current conductor are sealed by a sealant layer, and the crimp blocker and the current A crimping force can be applied to the sealing material layer between the conductors in the circumferential direction from the crimping and closing material.

In this case, the occluding material is, as described above,
The ceramic discharge tube may be an integral blocker made of the same material as the ceramic discharge tube, or may be a joined body of the inner portion and the outer portion made of this material.
Here, the same type of material means that the base ceramics are common, and includes, for example, cermet containing alumina as a main component, and the added components may be different.

A through hole is formed in the crimping blocker, and a current conductor is passed through the through hole. The preferable material of the crimp blocker is the same as the material of the outer portion described above, and specifically, the coefficient of thermal expansion between the coefficient of thermal expansion of the material of the ceramic discharge tube and the coefficient of thermal expansion of the material of the current conductor. The above-mentioned composite material having As described above, this composite material is preferably a composite material of the first component having a relatively high coefficient of thermal expansion and the second component having a relatively low coefficient of thermal expansion.

A metallized paste layer is provided between each of the pressure-bonded plugging material to be fired and the plugging material to be baked, and between the pressure-bonding plugging material to be fired and the current conductor. And the metallizing paste layer is integrally fired. At this time, each of the objects to be fired shrinks by firing, but the current conductor does not shrink. Therefore, if the inner diameter of the pressure-bonding blocker after firing, which is obtained when the current conductor is not inserted into the through-hole of the body to be fired of the pressure-bonding blocker, is smaller than the outer diameter of the current conductor (preferably 5 to 5). (If reduced by about 10%), compressive stress is applied from the pressure-bonding blocker toward the metallized layer and the current conductor after the integral firing. It has been found that the pores in the metallized layer become smaller and become closed pores due to the compressive stress, and the denseness of the metallized layer is further improved.

In this aspect, it is preferable that the above-mentioned thermal expansion relaxation material is further arranged outside the pressure-bonding closing material, and a metallization layer is provided between the thermal expansion relaxation material and the pressure-bonding closing material. That is, also in this aspect, as described above,
Along with the heat cycle of turning on and off, cracks may also occur between the pressure-bonding blocker and the metallized layer due to the difference in thermal expansion. However, when the metallization layer is sandwiched between the pressure-bonding blocker and the thermal expansion relaxation material, thermal stress is applied to both sides of the metallization line symmetrically. The thermal stress concentrated near the interface with the material is relaxed, and microcracks are less likely to occur.

In the present invention, when the thermal expansion relaxation material is provided, it is preferable to further form a sealing material layer in the gap between the thermal expansion relaxation material and the current conductor. As a result, a stronger sealing material layer can be obtained.

In order to manufacture the above high pressure discharge lamp,
In the manufacturing method of the present invention, the encapsulant component layer containing the component of the encapsulant is formed so as to contact the fired body of the encapsulant and the current conductors other than through holes, and The fired body, the body to be fired of the ceramic discharge tube, and the encapsulant component layer are sintered. At this time, regarding the ceramic discharge tube,
Ceramics, for example, extruded alumina powder,
A cylindrical product is obtained, or air is blown into the molded product to perform blow molding to form a cylindrical molded product having a bulged central portion, and the molded product is dried and degreased.
On the other hand, the material of the occluding material is weighed, water, alcohol, an organic binder and the like are added, and the mixture is granulated using a spray dryer or the like to produce a granular powder for molding. This is press-molded to produce a molded body of the occluding material having a through hole.

Then, the current conductor is inserted into the through hole of the molded body, and the assembly is calcined to scatter the molding aid and the like to obtain a calcined body. Alternatively, the molded body can be calcined to scatter a molding aid or the like to produce a calcined body, and the current conductor can be inserted into the through hole of the calcined body. In these calcination steps, if a part of the occluding material is formed by cermet, such as the outer part of the occluding material, the occluding material is heated in a reducing atmosphere at 130%.
When heated at 0 ° C to 1600 ° C, the tungsten oxide, molybdenum oxide, etc. mixed as the second component of the occluding material are reduced.

Next, the calcined body of the plugging material is inserted inside the end portion of the calcined body of the ceramic discharge tube, and the ceramic discharge tube and the plugging material are integrally fired. As a result, the ceramic discharge tube and the blocking member are integrally joined. On this occasion,
When the current conductor is firmly held by the outer part of the plug, the diameter of the through hole after firing when the current conductor is not inserted into the through hole of the calcined body of the outer part is the current before insertion. It is preferable to make the diameter 1 to 10% smaller than the diameter of the conductor. Further, when the calcined body of the plugging material is not inserted into the end portion of the calcined body of the ceramic discharge tube, the inner diameter of the end portion after firing is 1 to more than the outer diameter of the plugging material after firing.
It is preferably 10% smaller.

This final firing is also preferably performed in a reducing atmosphere, and the temperature is preferably 1700 ° C. to 1900 ° C. As described above, when the reducing atmosphere is used at the stage of calcination or firing, reduction of the second component in the plugging material, for example, tungsten can be promoted and oxidation can be prevented.

The encapsulant component layer is formed at a predetermined location as described above, and if necessary, a calcined body of the thermal expansion relaxation material is arranged to dispose of the calcined body of the plugging material and the ceramic discharge tube. The fired body and the sealing material component layer are integrally fired.

At this time, when the annular protrusion is formed on the outer peripheral surface of the current conductor, the annular protrusion and the body to be fired of the plugging member are opposed to each other when viewed in the central axis direction of the ceramic discharge tube. An encapsulant component layer can be formed between the part and the body to be fired of the occluding material.

Further, in this aspect, when the current conductor is further tubular, the electrode system is attached to the inner surface of the current conductor on the inner space side of the ceramic discharge tube,
Next, this current conductor is inserted into the through hole of the sintered body of the plugging material from the electrode system side, and the current conductor is fixed in this through hole. Alternatively, the electrode system is attached to the inner space side of the ceramic discharge tube of the current conductor, the tip side of the electrode system is bent toward the central axis of the ceramic discharge tube, and then this current conductor is covered with the plugging material. The current conductor can be fixed in the through hole of the fired body by inserting it from the electrode system side.

The shape of the ceramic discharge tube can be generally tubular, cylindrical, drum-shaped, or the like. When the current conductor is tubular and the ionized luminescent material is sealed inside the discharge tube through the current conductor, the current conductor is closed by laser welding or electron beam welding after the sealing.

In addition, a storage recess for storing the liquid phase ionized luminescent material is formed in advance on the surface of the occluding material itself on the inner space side, and a liquid metal halide or the like is introduced into the storage recess of the occluding material. Can be flowed in. That is, when the high-pressure discharge lamp is repeatedly turned on and off, most of the metal halide is in the vapor phase at the time of lighting and is distributed in the internal space of the ceramic discharge tube. However, as shown in FIG. 1, a part of the remaining liquid phase flows toward the side of the end 12 where the temperature is relatively low, as indicated by arrow D. The metal halide that flows in this liquid state is corrosive to the ceramic discharge tube,
In particular, it is corrosive to the alumina sintered body. For this reason, when a high-pressure discharge lamp is used for a long period of time and an experiment in which lighting and extinction are repeated is performed, the periphery of the corner 36 is corroded,
Sometimes a corroded surface was formed. Then, since the liquid-phase metal halide is easily stored along the corroded surface, the corrosion is further facilitated along the corroded surface. When such corrosion easily occurs, the life of the high pressure discharge lamp is shortened.

However, according to the above method, the liquid-phase metal halide or the like preferentially flows toward the storage recess of the plugging material, and is hard to store in the region between the main body and the end of the ceramic discharge tube. It was confirmed that the corrosion of this part was significantly reduced. However, although corrosion progresses in the vicinity of the recess for storing the clogging material, even if the clogging material itself corrodes, since the thickness of the clogging material is large, it does not adversely affect the life of the high pressure discharge lamp.

In this aspect, it is preferable to provide the storage recess with an inclination, and specifically, the thickness of the plugging material as viewed in the direction of the central axis of the ceramic discharge tube (the thickness as viewed in the direction E through which the through hole extends). It is preferable to form the storage recess so that the height decreases from the corner toward the through hole. As a result, the width of the storage recess increases from the corner toward the through hole, that is, from the peripheral edge of the ceramic discharge tube toward the center.

Furthermore, it is preferable that the inner surface of the main body of the ceramic discharge tube and the storage recess be smoothly continuous without a step. That is, it is preferable that the corners do not appear as steps on the inner surface of the ceramic discharge tube. By adopting such a combination of shapes, it is possible to prevent the liquid-phase ionized light-emitting substance flowing along the inner peripheral surface of the main body from staying around the step.

Further, the high-pressure discharge lamp according to the present invention is a ceramic discharge tube whose internal space is filled with an ionized luminescent material; and a closing member at least a part of which is fixed inside the end of the ceramic discharge tube. A plug having a through hole; a current conductor with an electrode system inserted through the through hole of the plug; and a sealing member formed so as to be in close contact with the plug and the current conductor. It is characterized by having a metallized layer of.

The present inventor has found that the sealing of the end portion of the ceramic discharge tube by the metallization layer as described above is extremely effective against the corrosion of metal halides, sodium and the like, particularly the corrosion by metal halides. I found it. The specific material of the metallized layer and various modes in which the metallized layer is used as the sealing material have already been described.

However, the specific mode of using the metallized layer for sealing or hermetically sealing the end of the ceramic discharge tube is not limited to the above.

That is, in addition to the aspects described above, a metallization layer is further formed on the surface of the occluding material facing the inner space side of the ceramic discharge tube, and at least the occluding material and the current conductor are formed by this metallizing layer. It is possible to coat the gap so as not to communicate with the discharge tube.

In addition, a metallization layer may be provided between the through hole of the plug and the current conductor in the end of the ceramic discharge tube.

In this aspect, the first plugging member is fixed to the inner space side of the end of the ceramic discharge tube, and the second plugging member is fixed to the end face side of the end of the ceramic discharge tube. A crimp closure material can be inserted between the closure material and the second closure material. In this case, a sealing material layer may be formed between the first closing material and the pressure-bonding closing material, and a sealing material layer may be formed between the second closing material and the pressure-bonding closing material. it can.
These sealing material layers are formed so as to extend in a direction perpendicular to the central axis direction of the ceramic discharge tube. According to this aspect, the space between the crimp blocker and the current conductor is sealed by the metallized layer, and the crimping force is applied to the metallized layer between the crimp blocker and the current conductor in the circumferential direction.

Further, in this way, at the end of the ceramic discharge tube, the ionized luminescent material flows into the gap between the first plugging member and the current conductor, but does not flow to the end. Therefore, the luminous efficiency can be improved. As described above, when the pressure is applied from the pressure-bonding blocker to the metallized layer during firing, the sealing property is particularly improved. This is because when the metallized layer is baked as it is, pores are easily generated, but when the metallized paste is baked while applying pressure to the metallized layer between the pressure-bonding blocker and the current conductor, the pores in the metallized layer are reduced. Because.

In this aspect, the first plugging material and the second plugging material are preferably made of the same material as the ceramic discharge tube, as described above.

The preferable material of the pressure-bonding closing material is as described above. Specifically, it is the aforementioned composite material having a coefficient of thermal expansion between the coefficient of thermal expansion of the material of the ceramic discharge tube and the coefficient of thermal expansion of the material of the current conductor.

When the metallization layer is formed between the current conductor and the through-hole, the metallizing paste is applied to the through-hole of the firing target of the plugging material, and the through-hole to which the metallizing paste of the plugging material is applied is predetermined. The current conductor is fixed in the through hole by inserting the current conductor into the position and baking the metallizing paste, and then the plugging material is inserted at a predetermined position on the inner surface of the end of the sintered body of the ceramic discharge tube, It can be fired together.

In this case, the metallizing paste is
Of the two main surfaces of the occluding material that are orthogonal to the through holes of the occluding material,
When the plugging material is fixed to the inner surface of the end portion of the ceramic discharge tube, it can be applied also to the outer main surface of the ceramic discharge tube. In particular, it is preferable that glass is permeated into the open pores of the metallized layer provided on the main surface of the plugging material after the integral firing, because the denseness of the metallized layer is further improved.

In this aspect, by providing and fixing the metallization layer between the through hole of the plugging material and the current conductor, generation and residual of large thermal stress seen in the direction of the central axis of the ceramic discharge tube is eliminated. It is possible to obtain a highly reliable high-pressure discharge lamp that does not cause damage or destruction of each member at the end portion due to a heat cycle that is generated by repeating lighting and extinguishing and leakage of an ionized luminescent material. The metallized layer has a high corrosion resistance to the ionized luminescent material in the ceramic discharge tube, particularly metal halide, and thus serves to prolong the life of the ceramic discharge tube. At this time, pressure due to firing shrinkage of the plugging material is applied to the metallized layer, so that the airtightness of the metallized layer is improved.

Further, by providing the first thermal expansion relaxation material and the second thermal expansion relaxation material on the outer side and the inner side of the blocker, the stress generated by the difference in thermal expansion between the blocker and the metallized layer is relaxed. be able to. In this case, in particular, the second thermal expansion relaxation material provided inside the blocking material protects the metallized layer exposed in the ceramic discharge tube, and also serves to reduce back arc to the metallized layer.

It is to be noted that a glass layer is provided on the metallized layer in contact with the outside air of the occluding material, and the glass is allowed to penetrate into the open pores of the metallized structure, the occluding material, the first thermal expansion relaxation material, and the second thermal expansion relaxation material. Providing chamfered portions such as C chamfers and R chamfers at the corners of the material that are in contact with the ceramic discharge tube can be said to be preferable modes because the reliability of the sealing portion can be further improved.

As is clear from the above description, according to the present invention, a ceramic discharge tube having an internal space filled with an ionized luminescent material, a plugging material for sealing an end portion of the ceramic discharge tube, and a plugging material. In a high-pressure discharge lamp equipped with a current conductor with an electrode system that is layered through the through-hole, even if a large number of lighting-extinguishing operations are repeated, damage and destruction of each end member due to this heat cycle It is possible to obtain a highly reliable end structure in which leakage is unlikely to occur.

Hereinafter, the present invention will be described in more detail with reference to the drawings. FIG. 2 is a schematic diagram showing a metal halide high pressure discharge lamp. The ceramic discharge tube 10 is housed in the outer tube 2 made of quartz glass or hard glass, and the central axis of the outer tube 2 and the central axis of the ceramic discharge tube 10 coincide with each other. Both ends of the outer tube 2 are hermetically closed by the bases 3. The ceramic discharge tube 10 includes a barrel-shaped main body 11 having a bulged central portion, and end portions 12 at both ends of the main body 11. The ceramic discharge tube 10 is held by the outer tube 2 with two lead wires 1 interposed therebetween,
Each lead wire 1 is connected to the base 3 via a foil 4, respectively. The upper lead wire 1 is welded to the tubular or rod-shaped current conductor 6, and the lower lead wire 1 is welded to the tubular current conductor 5.

The respective current conductors 5 and 6 are inserted and fixed in the through holes of the respective block members. An electrode shaft 7 is hermetically connected to each of the current conductors 5 and 6 in the main body 11 by welding. A coil 9 is attached to the electrode shaft 7.
Is wrapped around. The electrode system is not particularly limited, and for example, the electrode shaft 7
It is also possible to form a spherical end portion of the and use this spherical portion as an electrode. The structure of the occluding material will be described later.

In the case of a metal halide high pressure discharge lamp,
The internal space 13 of the ceramic discharge tube 10 is filled with an inert gas such as argon and a metal halide, and further filled with mercury if necessary.

FIG. 3 is an enlarged cross-sectional view showing the periphery of the end portion of the ceramic discharge tube shown in FIG. The inner surface 11 a of the main body 11 has a curved shape, and the inner surface 12 a of the end portion 12 is
A is straight when viewed in the direction of the central axis of the ceramic discharge tube, and a corner portion 36 is formed between the main body 11 and the end portion 12. A blocking member 50A is inserted inside the end portion 12. The occluding member 50A includes an inner portion 14 that is mostly accommodated in the end portion 12 and an outer portion 15 that is not accommodated in the end portion 12. The inner portion 14 and the outer portion 15 are integrated, and the through holes 14a, 15
The central axes of a are also substantially the same. Inner part 14 and end 1
2 is formed of the same kind of ceramics, preferably alumina ceramics, and the interface between the two is almost eliminated in the firing step.

In the through hole 14a and the through hole 15a,
An elongated tubular current conductor 5 is inserted. Current conductor 5
A sealing portion 5b that seals the starting gas and the ionized luminescent material after enclosing the starting gas and the ionized luminescent material is provided at the outer end of the. A crimping surface 40 is formed between the current conductor 5 and the outer portion 15. A ring-shaped thermal expansion relaxation material 17 is provided further outside the end surface 15b of the outer portion 15, and the end surface 15b of the outer portion and the end surface 17b of the thermal expansion relaxation material 17 face each other. The current conductor 5 is also inserted into the through hole 17a at the center of the thermal expansion relaxation material 17. The encapsulating material layer 16A is sandwiched between the outer portion 15 and the thermal expansion relaxation material 17, and the encapsulating material layer 16A includes the end surfaces 15b and 17b and the current conductor 5.
Covers a part of the surface. As a result, a sealing surface 20 in the central axis direction of the ceramic discharge tube and a sealing surface 19 in the vertical direction are formed. As the sealing material layer, a metallized layer is preferable, but a glass layer can also be used. A glass layer 42 is formed around the protruding portion of the current conductor 5 from the thermal expansion relaxation material 17.

In this embodiment, the current conductor 5 with the electrode system is inserted into the through hole of the molded body or the calcined body of the blocking material 50A, and the molded body or the calcined body of the blocking material is molded into a ceramic discharge tube. An assembly is manufactured by inserting it into an end of a body or a calcined body, and the assembly is integrally sintered. At this time, the outer portion 15 is made of the material of the ceramic discharge tube 10, preferably alumina, and the above-mentioned second component,
It is made of composite material or cermet.

When the encapsulating material layer 16A is the metallization described above, the paste that constitutes the encapsulating material layer 16A is applied so as to form an application layer having a shape shown in FIG.
The firing is performed integrally with the firing target of the plugging material and the firing target of the ceramic discharge tube. When the sealing material layer 16A is a glass layer, a glass material (preferably a glass frit) is provided between the sealing material 50A and the thermal expansion relaxation material 17 after the sealing material 50A and the ceramic discharge tube 11 are integrally fired. Installed
The glass material is melted to form a glass layer.

FIG. 4 is a sectional view showing a structure of an end portion of a ceramic discharge tube according to another embodiment of the present invention. The end structure shown in FIG. 4 is substantially the same as the end structure shown in FIG. 3, so the same members are designated by the same reference numerals and the description thereof is omitted.

In the present embodiment, the blocking member 56 is made of an integrally fired body of the inner portion 14 fixed inside the end portion 12 of the ceramic discharge tube 11 and the outer portion 57 exposed from the end portion. There is. The material of the outer portion is the same as the material of the outer portion 15 in FIG. The current conductor 5 is inserted into the through hole 57a of the outer portion 57. In this embodiment, a slight clearance is provided between the surface of the through hole 57a of the outer portion 57 and the current conductor 5, so that no compressive stress is applied to the current conductor 5. However, in FIG. 4, the clearance is exaggerated to some extent.

The thermal expansion relaxation material 17 is installed so as to face the end surface 57b of the outer portion 57. In this embodiment, the ring-shaped portion 58a of the sealing material layer 58 hermetically seals between the end surface 57b of the outer portion 57 and the end surface 17b of the thermal expansion relaxation material 17. The sealing material is also filled between the through hole 17a of the thermal expansion relaxation material 17 and the outer peripheral surface of the current conductor 5 to form the sealing material layer 58b.

FIGS. 5, 6, and 7 are sectional views showing, in an enlarged manner, the periphery of the end portion of a ceramic discharge tube according to another embodiment of the present invention. However, in each embodiment, the same reference numerals are assigned to the members already shown in FIGS. 3 and 4, and the description thereof may be omitted.

In the embodiment shown in FIG. 5, the current conductor 5 is inserted into the through hole of the annular member 18, and the annular member 18 is interposed between the outer portion 15 and the thermal expansion relaxation material 17. Then, a sealing material layer 16C was formed between the end surface 15b of the outer portion and the annular member 18, and a sealing material layer 16B was formed between the end surface 17b of the thermal expansion relaxation material and the annular member 18. Thereby, the sealing surface 19 extending in the direction perpendicular to the central axis direction of the ceramic discharge tube was formed. In addition, the annular member 1
8 and the current conductor 5 have a slight gap, the sealing material layers 16B and 16C are joined to the current conductor, and the sealing surface 20 is also formed on this contact portion.

In the embodiment shown in FIG.
The occluding material 56 shown in was used. The current conductor 5 was inserted into the through hole of the annular member 18, and the annular member 18 was interposed between the outer portion 57 and the thermal expansion relaxation material 17. The sealing material layer 59A is provided between the end surface 57b of the outer portion and the annular member 18.
Then, a sealing material layer 59B was formed between the end surface 17b of the thermal expansion relaxation material and the annular member 18. Thereby, the sealing surface 19 extending in the direction perpendicular to the central axis direction of the ceramic discharge tube was formed. Further, there is a slight gap between the annular member 18 and the current conductor 5, and the sealing material layers 59A, 59
B is joined to the current conductor, and the sealing surface 20 is also formed on this contact portion.

As described above, the compressive stress is not applied between the through hole 57a of the outer portion 57 and the current conductor 5. Further, the sealing material is also filled between the through hole 17a of the thermal expansion relaxation material 17 and the outer peripheral surface of the current conductor 5 to form the sealing material layer 59C.

In the embodiment shown in FIG. 7, the closure 5
OB is constituted by the inner portion 14 and the outer portion 21. The material of the outer portion 21 is the same as that described above, but in this embodiment, the current conductor 5 inserted into the through hole 21a and the outer portion 21 are not firmly adhered. An annular protrusion 22 is formed on the outer peripheral surface of the current conductor 5, and the annular protrusion 22 extends in a direction perpendicular to the central axis of the ceramic discharge tube. This annular protrusion 22 is provided between the outer portion 21 and the thermal expansion relaxation material 17.
Has been inserted. A sealing material layer 16D is formed between the end surface 21b of the outer portion 21 and the annular protruding portion 22, and the sealing surface 19 is formed in this portion. Annular protrusion 2
2 and the end surface 17b of the thermal expansion relaxation material also between the sealing material layer 16
E is formed.

To manufacture such an end structure, the following method is preferable. FIG. 8 is a cross-sectional view for explaining this manufacturing method, and shows a state before the current conductor 23 and the body to be fired are assembled. Both ends of the current conductor 23 are open. On the outer peripheral surface of the current conductor 23, the above-mentioned annular protruding portion or flange portion 22 is formed. At the assembly stage, it is necessary to insert the current conductor 23 into the through hole 54 of the fired body 51 of the occluding material. Here, the body 51 to be fired of the occluding material is the body 5 to be fired of the inner portion.
2 and the outer part to be fired 53. However, since the outer diameter of the annular protruding portion 22 is larger than the diameter of the through hole 54, first, as shown by an arrow A, the tip of the current conductor 23 is inserted into the through hole 54, and this tip portion is baked 51. Project from. Next, the electrode shaft 7 is welded to the tip portion of the current conductor 23 protruding from the through hole 54 as indicated by arrow B.

After the assembly thus obtained is integrally fired, the ionized luminescent material is injected into the ceramic discharge tube through the internal space 23a of the current conductor 23, and then the tip portion of the current conductor 23 is sealed with a laser beam or the like. Then, the current conductor 5 is obtained. This makes it possible to create the end structure shown in FIG.

However, in this manufacturing method, the current conductor 2
After completely inserting 3 into the through hole of the fired body of the occluding material, the electrode system will be welded to the current conductor. However, it is difficult to perform the above assembly after welding the electrode system to the current conductor for the reasons mentioned above.

In this case, it is preferable to use a combination of the current conductor and the electrode system as shown in FIG. 9 (a). That is, the electrode system 27 includes the linear portion 27.
a, a bent portion 27b and a linear portion 27c are provided,
The electrode 9 is provided on the linear portion 27c. When the electrode system is attached to the current conductor 24, the linear portion 27 is attached to the inner peripheral surface 24b of the tip portion of the current conductor 24.
Attach a. At this time, a raised portion 26 is formed, which may hinder the flow of the ionized luminescent material flowing into the internal space 24a, so that the emission port 25 is formed in front of the raised portion 26. The linear portion 27c is located substantially at the center axis of the ceramic discharge tube in this embodiment. This assembly is inserted into the through hole 54 as indicated by arrow C.
After the encapsulation of the ionized luminescent material is completed, the discharge port 2
5 is sealed. Further, as shown in FIG. 9B, the linear portion 27a is welded to the inner peripheral surface of the end portion of the current conductor 28, and the emission port 29 is formed in an oblique direction from the end portion, so that the protrusion 26 is formed. The ionized luminescent material can be released from the front side. Then, the ionized luminescent material is sealed from the inner space 28a of the current conductor, and then the emission port 29 is sealed to form an end structure as shown in FIG.

The members shown in FIG. 10 are almost the same as the members shown in FIG. 7, but only the current conductors and the electrode system shown in FIG. 9B are used.
The outer end of the current conductor 28 is sealed by the sealing portion 30. The linear portion 27a of the electrode system 27 is fixed to the inner peripheral surface of the current conductor 28.

In the embodiment shown in FIG. 11, the current conductor 24 and the electrode system 27 shown in FIG. 9A were used as the current conductor and the electrode system. End 12
Among them, the first closing member 33 is fixed to the inner space 13 side, and the second closing member 32 is fixed to the end face side. The first closing member 33 and the second closing member 32 are separated from each other, and the annular protrusion 22 is inserted between them. The current conductors 24 are respectively inserted into the through holes 33a of the blocking member 33 and the through holes 32a of the blocking member 32, but the current conductors 24 are not firmly held by these blocking members in these portions.

The annular protrusion 22 and the end surface 33 of the blocking member 33.
A sealing material layer 16F is formed between the sealing surface 19 and b, and a sealing surface 19 is formed in the contact portion between them so as to extend in a direction perpendicular to the central axis direction of the ceramic discharge tube. A sealing material layer 16G is formed between the annular projecting portion 22 and the end surface 32b of the occluding material 32, and the sealing surface 19 is formed so as to extend in a direction perpendicular to the central axis direction of the ceramic discharge tube at the contact portion thereof. Are formed. The outer end of the current conductor 24 is sealed by the sealing portion 30. According to such an end structure, in addition to the above-described effect, the sealing surface 19 is further formed at a position closer to the internal space 13, so that the end has a very small gap for accommodating the ionized luminescent material.

FIG. 12 is a sectional view showing an end structure of a ceramic discharge tube according to another embodiment. In this embodiment, the plugging material 60 is made of the same material as that of the ceramic discharge tube 11, and the pressure-bonding plugging material 61 is installed outside the plugging material 60. The current conductor 5 is inserted into each of the through holes 60 a and 61 a of the closing member 60 and the pressure-bonding closing member 61. The space between the end surface 60b of the closing material 60 and the end surface 61b of the pressure-bonding closing material 61 is hermetically sealed by the sealing material layer 62A. The sealing material layer 62A forms the sealing surface 19 extending in the direction perpendicular to the axial direction.

Further, there is a slight gap between the through hole 61a of the crimp blocker 61 and the outer peripheral surface of the current conductor 5, and this gap is filled with the sealant, forming the sealant layer 62B. is doing. A crimping force is applied in the circumferential direction from the crimping blocker 61 to the sealing material layer 62B between the crimping blocker 61 and the current conductor 5. As a result, a seal surface 20 extending in the axial direction of the ceramic discharge tube is formed between the inner peripheral surface of the pressure-bonding blocker 61 and the outer peripheral surface of the current conductor 5.

A thermal expansion relaxation material 17 is further installed outside the crimp blocker 61, and the current conductor 5 is inserted into the through hole 17 a of the thermal expansion relaxation material 17. The gap between the end surface 17b of the thermal expansion relaxation material 17 and the end surface 61c of the pressure-bonding closing material 61 is also hermetically sealed by the sealing material layer 62C.

A preferable material for the pressure-bonding blocker 61 is the same as the material for the outer portion of the blocker described above. When manufacturing this end structure, in a preferred embodiment, metallization is used as a sealing material, and a metallizing paste layer is provided between the body to be fired of the pressure-bonding blocker 61 and the body to be fired of the blocker 60. A metallization paste layer is provided between the body to be fired of the pressure-bonding blocker 61 and the current conductor 5, and a metallizing paste layer is provided between the pressure-bonding blocker 61 and the thermal expansion relaxation material 17, The metallizing paste layer is integrally fired. At the time of this integral firing, each body to be fired shrinks by firing, but the current conductor 5 does not shrink. Therefore, if the inner diameter of the pressure-bonding blocker 61 after firing, which is obtained when the current conductor 5 is not inserted into the through-hole of the body of the pressure-bonding blocker 61, is made smaller than the outer diameter of the current conductor 5, After firing, compressive stress is applied from the pressure-bonding blocker 61 toward the metallized layer 62B and the current conductor 5. Then, the pores in the metallized layer 62B become smaller due to the compressive stress and become closed pores.
It has been found that the compactness of is further improved.

FIG. 13 is a sectional view showing an end structure of a ceramic discharge tube according to still another embodiment. Blocking material 63
Is formed of the same material as the ceramic discharge tube 11, and the pressure-bonding closing material 64 is installed outside the closing material 63. The current conductor 5 is inserted into each of the through holes 63a and 64a of the closing member 63 and the pressure-bonding closing member 64. The space between the end surface 63b of the closing material 63 and the end surface 64b of the pressure-bonding closing material 64 is hermetically sealed by the sealing material layer 66A.
Here, the end surface 63a of the closing member 63 is slightly inclined when viewed from the direction perpendicular to the central axis F of the ceramic discharge tube, and the end surface 64b of the pressure-bonding closing member 64 is substantially parallel to the end surface 63b. Therefore, by the sealing material layer 66A,
The sealing surface 70 is formed so as to extend in a direction slightly inclined with respect to the direction perpendicular to the central axis F.

There is a slight gap between the through hole 64a of the pressure-bonding blocker 64 and the outer peripheral surface of the current conductor 5, and this gap is filled with the sealant to form the sealant layer 66B. There is. Sealing material layer 66 between the crimp closure 64 and the current conductor 5
A crimping force is applied to B from the crimping blocker 64 in the circumferential direction. As a result, a sealing surface 20 extending in the central axis F direction of the ceramic discharge tube is formed between the inner peripheral surface of the pressure-bonding blocker 64 and the outer peripheral surface of the current conductor 5.

A thermal expansion relaxation material 65 is further installed outside the crimp blocker 64, and the current conductor 5 is inserted into the through hole 65 a of the thermal expansion relaxation material 65. The gap between the end surface 65b of the thermal expansion relaxation material 65 and the end surface 64c of the pressure-bonding closing material 64 is also hermetically sealed by the sealing material layer 66C.

Here, the end surface 64c of the crimp closure member 64
Is slightly inclined when viewed from the direction perpendicular to the central axis F of the ceramic discharge tube, and the end surface 65b of the thermal expansion relaxation material 65 is
Are substantially parallel to the end surface 64c. Therefore, the sealing material layer 66C forms a sealing surface so as to extend in a direction slightly inclined with respect to the direction perpendicular to the central axis F.
The pressure-bonding blocker 64 is formed so that the thickness linearly increases from the outer peripheral side toward the inner peripheral side.

The preferable material of the pressure-bonding blocker 64 is the same as the material of the pressure-bonding blocker 61 described above, and the preferable manufacturing method of the end structure of FIG. 13 is also the preferable manufacturing method of the end structure of FIG. Is the same as. However, as shown in FIG. 13, when the end surface of the pressure-bonding blocker 64 is inclined with respect to the direction perpendicular to the central axis F of the ceramic discharge tube, the blocker 63 is formed.
Between the body to be fired, the body to be pressure-bonded with the pressure-blocking material 64, and the body to be fired with the thermal expansion relaxation material 65.
The paste layers of B and 66C are formed to produce an integrated assembly. Also in the process, this inclination can reduce the thermal stress in the axial direction and the radial direction of the electrode. Furthermore, since the position of the central axis of this assembly becomes easy to understand, this assembly can be performed easily.

12 and 13, the encapsulating material layer may be a metallized layer, and the material of the metallized layer may be a composite material of alumina and molybdenum, tungsten, rhenium, or an alloy thereof. In this case, regarding the metallized layer 62B or 66B and each inner peripheral side of the ring-shaped metallized layer 62A or 66A closer to the current conductor 5, the metallized layer contains molybdenum, tungsten, rhenium or an alloy thereof. By increasing the ratio, the content ratio of alumina in the metallized layers 62A, 66A can be increased on the outer peripheral side of the metallized layers 62A, 66A. By adopting such a graded composition in the metallized layers 62A and 62B or in the metallized layers 66A and 66B, the stress applied to each part of the metallized layer by the thermal cycle can be further relaxed.

Further, the metallization layer for sealing may be formed on the surface of the occluding material on the inner space 13 side.
In this case, since the sealing surface formed by the metallized layer is formed at a position extremely close to the internal space 13, the gap for accommodating the ionized luminescent material is extremely small at the end. FIG. 14 is a sectional view showing such an embodiment.

The occluding member 50C is composed of the inner portion 34 and the outer portion 15. There is almost no compressive stress between the inner portion 34 and the current conductor 5, but the current conductor 5 is retained by the outer portion 15. The outer portion 15 lies outside the end 12. Current conductor 5
Through the through hole 34a of the inner portion 34 and the through hole 15a of the outer portion 15, the end surface 15 of the outer portion 15
The glass layer 42 is formed on b.

A curved surface 37 is formed on the surface of the inner portion 34 on the internal space 13 side, and the edge of the curved surface 37 is in contact with the corner portion 36, and the curved surface 37 is against the inner surface 11 a of the main body 11. And is smoothly continuous, and the corner portion 36 does not appear as a step between the main body 11 and the curved surface 37.

The curved surface 37 has an inclination angle substantially the same as that of the inner surface 11a at the edge in contact with the corner portion 36, and as it approaches the through hole 34a, the inclination angle gradually approaches the horizontal direction. There is. As a result, a storage recess 38 is formed on the inner portion 34 or the inner space 13 side of the blocking member 50C itself. Inner surface 11a of main body 11
The liquid-phase ionized luminescent material flowing toward the end 12 as indicated by arrow D immediately flows into the storage recess 38.

In each of the embodiments described above, the sealing material for gas sealing is provided in the portion other than between the through hole of the plugging material and the current conductor in the end portion of the body of the ceramic discharge tube. Layers have been formed. However, as mentioned above, a metallization layer may be formed between the through hole of the plug and the current conductor in the end of the body of the ceramic discharge tube.

For example, in the embodiment shown in FIG. 15, on the inner space side of the end 12 of the ceramic discharge tube 11,
The first blocking member 33 is fixed, and the second blocking member 32 is fixed to the end face side of the end portion 12. The first closing member 33 and the second closing member 32 are separated from each other, and the crimping closing member 67 is inserted between the first closing member 33 and the second closing member 32. Through-hole 67 of crimp closure 67
The current conductor 5 is inserted in a.

First block 33 and second block 3
2 is made of the same material as that of the ceramic discharge tube 11 like the one shown in FIG.
The airtightness of the contact surface between the end portion 12 and the end 12 is completely maintained. A metallization layer 68C is formed between the end surface 33b of the first closing member 33 and the end surface 67b of the pressure-bonding closing member 67. The metallized layer 68A is also formed between the end surface 32b of the second closing member 32 and the end surface 67c of the pressure-bonding closing member 67. These metallized layers 68A and 68C are formed in the radial direction of the ceramic discharge tube 11, and the sealing surface 19 is formed so as to extend in this direction.

A metallized layer 68 B is also formed between the pressure-bonding blocker 67 and the current conductor 5. Crimp closure 67
For the metallization layer 68B between the current conductor 5 and
Due to the shrinkage of the pressure-bonding blockage material in the circumferential direction during firing, a pressure-bonding force is applied from the pressure-bonding blockage material 67 in the circumferential direction.

In the embodiment shown in FIG. 16, the first blocking member 72 is fixed to the inner space side of the end portion 12 of the ceramic discharge tube 11, and the second blocking member is attached to the end face side of the end portion 12. The material 71 is fixed. The first closing member 72 and the second closing member 71 are separated from each other, and the crimping closing member 73 is inserted between these closing members. Closure material 71
The current conductor 5 is inserted into the through hole 71a, the through hole 72a of the closing member 72, and the through hole 73a of the crimping closing member 73.

First occluding member 72 and second occluding member 7
1 is made of the same material as that of the ceramic discharge tube 11, and therefore the airtightness of the contact surface between the respective closing members 71, 72 and the end 12 is completely maintained. End surface 72 of the closure member 72
b is slightly inclined when viewed from the direction perpendicular to the central axis F of the ceramic discharge tube, and the end surface 73b of the pressure-bonding blocking material 73 is formed.
Is substantially parallel to the end surface 72b. Sealing material layer 74
A sealing surface 70 is formed by C so as to extend in a direction slightly inclined with respect to the direction perpendicular to the central axis F.

The end surface 71b of the closing material 71 is also slightly inclined when viewed from the direction perpendicular to the central axis F of the ceramic discharge tube, and the end surface 73c of the pressure-bonding closing material 73 is substantially parallel to the end surface 71b. The encapsulating material layer 74A extends in a direction slightly inclined from the direction perpendicular to the central axis F,
A sealing surface 70 is formed.

The metallization paste is also filled between the pressure-bonding blocking material 73 and the current conductor 5, and the metallization layer 74B is formed by this baking. A pressure-bonding force is applied to the metallized layer 74B between the pressure-bonding blocking material 73 and the current conductor 5 in the circumferential direction from the pressure-bonding blocking material 73.

17 to 19 are cross-sectional views showing the structure of still another example of the sealing structure at the end of the ceramic discharge tube shown in FIG.

In the end structure shown in FIG. 17, for example, a disk-shaped occluding member 81 made of the above-mentioned composite material (cermet) is preferably provided inside the end 12 of the ceramic discharge tube 10 made of Al ₂ O ₃ . Is fixed. A through hole 82 having a circular cross section is formed in the center of the blocking member 81. A tubular current conductor 6 made of, for example, molybdenum is housed in the through hole 82, and the current conductor 6 is fixed via the metallized layer 83. An electrode 9 such as a coil is provided at the end of the current conductor 6 inside the ceramic discharge tube 10. In this example, the main surface 81a on the outer side of the occluding member 81
A metallized layer 84 continuous with the metallized layer 83 is formed thereon. Then, a glass layer 85 is formed on the metallized layer 84.

In the example shown in FIG. 17, the metallization layer 83 fixes the gap 81 and the current conductor 6 to each other, and
And the end 12 of the ceramic discharge tube 10 are fixed by a compressive force from the end 12 of the ceramic discharge tube 10 to the plug 81 due to a difference in thermal expansion during firing. The presence of the metallized layer 83 can reduce the generation and residual of stress in the direction of the through hole 82.

Further, in this example, the glass layer 85 is formed on the metallized layer 84, and the glass having high corrosion resistance is permeated into the metallized structure to improve the airtightness and the life. The metallized layer 84 and the glass layer 85 are not essential to the present invention. Figure 1
The structure shown in FIG. 7 can be particularly preferably used when the inner diameter of the end 12 of the discharge tube 10 is relatively small.

In the structure shown in FIG. 18, the cylindrical first blocking member 8 is provided on the inner surface of the end 12 of the ceramic discharge tube.
7 is fixed, the cylindrical second obstruction material 86 is accommodated in the inner space of the first obstruction material 87, and the current conductor 6 is accommodated in the inner space of the second obstruction material 86. . The metallization layer 83 is provided between the first plug 87 and the second plug 86, and between the second plug 86 and the current conductor 6.
A and 83B are formed. A metallization layer 84A continuous with the metallization layers 83A and 83B is formed on the main surface of the plugging members 86 and 87 facing the outside of the ceramic discharge tube, and a glass layer 85 is formed on the metallization layer 84A. . Inner space 13 of the closures 86 and 87
A metallized layer 84B that is continuous with the metallized layers 83A and 83B is formed on the main surface facing the.

Then, the coefficient of thermal expansion of the ceramics discharge tube 10 is set to Tc, and the coefficient of thermal expansion of the first closing member 87 is set to Tc.
1, the second expansion material 86 has a coefficient of thermal expansion T2, and the current conductor 6 has a coefficient of thermal expansion Tm, Tc ≧ T1>
It is necessary to select the material of each member so as to satisfy the relationship of T2 ≧ Tm.

In the example shown in FIG. 18, even if the inner diameter of the end portion 12 is large, the effect of the present invention can be achieved. Therefore, the inner diameter of the end portion 12 of the ceramic discharge tube 10 is relatively large. Can also be suitably applied to.

Note that, also in the example shown in FIG. 18, the metallized layer 84A and the glass layer 85 can be eliminated if necessary. Further, the occluding member is composed of the two first occluding members 87 and the second occluding member 86, but the number of radial divisions is two.
The division is not limited, and it is also possible to provide one or more thermal expansion relaxation materials between the first thermal expansion relaxation material and the second thermal expansion relaxation material. However, even in this case,
It is necessary to make the coefficient of thermal expansion of the outer thermal expansion relaxation material larger than the coefficient of thermal expansion of the inner thermal expansion relaxation material,
Moreover, it is necessary to satisfy the relationship of Tc ≧ T1> T2 ≧ Tm.

In the example shown in FIG. 19, the first thermal expansion relaxation material 89 is provided so as to face the main surface of the plug 81 facing the outside of the ceramic discharge tube 10.
The second thermal expansion reducing material 90 is provided on the side opposite to the first thermal expansion reducing material 89. Through holes 89a, 90a of the first thermal expansion relaxation material 89 and the second thermal expansion relaxation material 90
A current conductor 6 is housed therein. The inner diameter of the first thermal expansion relaxation material 89 and the inner diameter of the second thermal expansion relaxation material 90 are
It is designed to be larger than the inner diameter of the blocking member 81.

A metallized layer 84 A is provided and fixed between one main surface of the first thermal expansion relaxation material 89 and the blocking material 81, and at the same time, one main surface of the second thermal expansion relaxation material 90 is closed. A metallized layer 84B is also provided between and fixed to the material 81. Further, by utilizing the compressive stress due to the firing shrinkage of the end portion 12 of the ceramic tube 10, the metallization layer 83 is pressure-bonded to the current conductor 6 by the blocking member 81, and the current conductor 6 is held.

First thermal expansion relaxation material 89 in this example
Serves as a backup ring that relieves stress in the central axis direction of the end portion 12 of the ceramic discharge tube 10. In addition to the above-mentioned role of the backup ring, the second thermal expansion relaxation material 90 has the metallized layer 84B exposed in the ceramic discharge tube 10 in the ceramic discharge tube 10.
By protecting the metallized layer 84B from the gas in the inner space thereof, the occurrence of back arc on the metallized layer 84B is reduced.

The material of the first thermal expansion relaxation material 89 and the second thermal expansion relaxation material 90 is not particularly limited, but is preferably the same as that of the ceramic discharge tube 10, for example, Al ₂ O ₃ .

In the example shown in FIG. 19, a glass layer is provided on the metallized layer 84 A of the blocking material 81 and between the first thermal expansion relaxation material 89 and the current conductor 6 which are provided outside the blocking material 81. By providing 85, the glass is infiltrated into the exposed metallized structure.

Further, a corner portion of the first thermal expansion relaxation material 89 that contacts the end portion 12 of the ceramic discharge tube 10, a corner portion that contacts the end portion 12 of the second thermal expansion relaxation material 90, and the blocking member 81.
A chamfered portion 88 is formed at each of the corner portions that contact the end portion 12 of the. The chamfered portion 88 may have a shape such as an R chamfer in addition to the C chamfer shown in the drawing.
By providing such a chamfered portion 88, stress concentration between the corner portion of each member and the end portion 12 of the ceramic discharge tube 10 can be relaxed, and breakage at the corner portion can be eliminated. Also in this example, as shown in FIG.
Can be composed of a plurality of members.

In the above-mentioned embodiment, as the material of the blocking member 81, the same kind of material as the ceramic discharge tube 10 can be used, or different materials can be used. Here, the same type of material means that the base ceramics are common, and the added components may be different.

Next, the metallized layers 83, 83A, 83
As the material of B, 84, 84A, and 84B, the above-mentioned materials can be used, and the thickness can be set as described above.

As the material of the current conductor 6, the above-mentioned materials can be used.

Hereinafter, a preferred example of the method for manufacturing a high pressure discharge lamp according to the present invention will be described with reference to the flowcharts shown in FIGS. 20 and 21. The manufacturing method of the high pressure discharge lamp shown in FIG. 20 mainly relates to the manufacturing method of the high pressure discharge lamp having the end structure shown in FIG. 17, and the manufacturing method of the high pressure discharge lamp shown in FIG. The present invention relates to a method for manufacturing a high pressure discharge lamp.

First, in FIG. 20, a cermet ring molded body to be the blocking material 81 after firing is granulated with a spray dryer or the like to obtain powder of 2000 to 3000 Kgf /
Obtained by press molding at a pressure of cm ² . The obtained molded body is 6
The binder is removed by heating at a temperature of 00 to 800 ° C. Next, for the molded body for which the binder removal processing has been completed,
Deoxidation is performed in a hydrogen reducing atmosphere at a temperature of 1200 to 1400 ° C. to obtain a cermet ring. This deoxidizing treatment is intended to give the cermet ring a certain level of strength, prevent paste leveling failure due to solvent suction at the time of applying the paste below, and enhance the handling property of the cermet ring.

Next, through-hole printing is performed on the inner surface of the through-hole of the obtained cermet ring to print a metallizing paste composed of Mo: 60 vol%, Al ₂ O ₃ : 40 vol%, a small amount of binder and a solvent. . In this through-hole printing, the metallizing paste is applied around one side of the through hole, and the metallizing paste is drawn into the through hole by vacuuming from the other end of the through hole, and the metallizing paste is applied to the entire inner surface of the through hole. It is done by printing. The cermet ring after this through hole printing is dried at a temperature of about 120 ° C. Next, end face printing is performed by printing metallizing paste on one of the main surfaces of the cermet ring. This end face printing is performed twice. Dry the cermet ring after edge printing.

Then, a Mo pipe or rod as the electrode conductor 6 prepared in advance is inserted into the through hole of the obtained cermet ring and set at a predetermined position, and 1400 is set.
Pre-baking is performed in a reducing atmosphere having a dew point of 20 to 50 ° C at a temperature of to 1600 ° C. Next, a cermet ring preliminarily fired and fixed with a Mo pipe or rod was inserted into the end surface of the alumina tube obtained by previously removing the binder and calcination of the alumina formed body, and set at a predetermined position, 1600 to 1900.
The high-pressure discharge lamp of the present invention is obtained by carrying out main firing at a temperature of ° C in a reducing atmosphere having a dew point of -10 to 20 ° C. In addition, by infiltrating glass having corrosion resistance into the metallized structure after the main firing,
The structure shown in FIG. 17 and FIG. 18 is one example, in order to improve the airtightness and the life. Note that the preforming and the main firing are performed in different steps in order to prevent the binder in the metallizing paste from contaminating the alumina tube and to align the electrodes.

In the manufacturing method shown in FIG. 21, a cermet ring molded body to be the blocking member 81 is granulated with a spray dryer or the like to obtain powder of 2000 to 3000 Kgf / cm 2.
Obtained by press molding at a pressure of ² . The obtained molded body is 60
The binder is removed by heating at a temperature of 0 to 800 ° C. Next, for the molded body for which the binder removal processing has been completed,
Deoxidation is performed in a hydrogen reducing atmosphere at a temperature of 1200 to 1400 ° C. to obtain a cermet ring. This deoxidizing treatment is intended to give the cermet ring some strength, prevent paste leveling failure due to the blowing of a solvent at the time of applying the paste described below, and enhance the handling property of the cermet ring.

Next, through-hole printing is performed on the inner surface of the through-hole of the obtained cermet ring to print a metallizing paste composed of Mo: 60vol%, Al ₂ O ₃ : 40vol%, a small amount of binder and a solvent. . In this through-hole printing, the metallizing paste is applied around one side of the through hole, and the metallizing paste is drawn into the through hole by vacuuming from the other end of the through hole, and the metallizing paste is applied to the entire inner surface of the through hole. It is done by printing. The cermet ring after this through hole printing is dried at a temperature of about 120 ° C. Next, perform end face printing that also prints metallizing paste on both main surfaces of the cermet ring,
Dry the cermet ring after edge printing. The end surface printing on both main surfaces is performed by performing end surface printing on one main surface and then performing the same end surface printing on the other main surface, and by performing each end surface printing twice.

In parallel, two alumina rings to be the first thermal expansion relaxation material 89 and the second thermal expansion relaxation material 90 after firing are prepared. Alumina ring is 2000 ~ 3000Kgf /
The alumina ring molded body press-molded at a pressure of cm ² is heated at a temperature of 600 to 800 ° C. to remove the binder, and then calcined at a temperature of 1200 to 1500 ° C. in a hydrogen reducing atmosphere. I'm getting it. The obtained alumina ring is subjected to metallization printing only on both main surfaces. Thereafter, the alumina ring is not dried, but the alumina ring, the cermet ring prepared as described above, and the alumina ring are laminated in this order with a slight load applied and dried to obtain an assembly.

After that, a Mo pipe or rod as the electrode conductor 6 prepared in advance is inserted into the through hole of the obtained assembly and set at a predetermined position, and 1400 to 1600.
Pre-baking is performed in a reducing atmosphere having a dew point of 20 to 50 ° C at a temperature of ° C. Next, a cermet ring preliminarily fired and fixed with a Mo pipe or rod was inserted into the end surface of the alumina tube obtained by previously removing the binder and calcination of the alumina formed body, and set at a predetermined position, 1600 to 1900. The high-pressure discharge lamp of the present invention is obtained by carrying out main firing at a temperature of ° C in a reducing atmosphere having a dew point of -10 to 20 ° C. Note that glass having corrosion resistance may be permeated into the metallized structure after the main firing to improve airtightness and life, and the structure shown in FIG. 19 is one example.

It should be noted that, in the above-mentioned embodiment, the molding is performed by press molding, but it goes without saying that this molding is not limited to press molding. Further, although the metallizing paste is applied to the green compact, the application of the metallizing paste is not limited to the green compact.

Further, in the present invention, when at least the end of the ceramic discharge tube of the plug is made of the same material as the ceramic discharge tube, thermal expansion is performed so as to face the plug on the outside of the ceramic discharge tube. A relaxation material can be provided, and a space between the thermal expansion relaxation material and the closing material is sealed with a melt of the glass material, and a space between the thermal expansion relaxation material and the current conductor is sealed with a melt of the glass material. can do. 22 to 26 are sectional views showing the end structure of this embodiment.

In the end structure of FIG. 22, the end 12
An occluding member 91 is inserted inside the. This occluding material 91
An elongated tubular current conductor 5 is inserted into the through hole 91b. A crimping surface is formed between the current conductor 5 and the blocking member 91. A ring-shaped thermal expansion relaxation material 93 is provided at a position facing the outer main surface 91d of the closing material 91, and the main surface 91d of the closing material 91 and the end surface 93a of the thermal expansion relaxation material 93 face each other. is doing. Thermal expansion relaxation material 9
The current conductor 5 is also inserted into the through hole 93b at the center of 3.

A sealing material layer 92A made of a molten glass material is provided between the main surface 91d of the occluding material 91 and the end surface 93a of the thermal expansion easing material 93.
A sealing material layer 92B made of a molten glass material is provided between the through hole 93b and the current conductor 5. By this, the sealing surface in the central axis direction of the ceramic discharge tube,
A sealing surface perpendicular to the central axis is formed.

It has been found that the use of such a melt of the glass material further improves the gas leak prevention performance.

As the composition of such glass, a known glass composition can be used, and specifically, Dy ₂
O ₃ -Al ₂ O ₃ -SiO ₂ based glass and Y ₂ O _3-
Al ₂ O ₃ -SiO ₂ -based glass (or more, JP-B No. 56 -
No. 44025, Japanese Patent Application Laid-Open No. 61-233962, and Japanese Patent Publication No. 61-37225). However, the above-mentioned _{Dy 2 O 3 -Al 2 O 3} -SiO 2
By further adding MoO ₃ to the Y-based glass and the Y ₂ O ₃ —Al ₂ O ₃ —SiO ₂ type glass,
The corrosion resistance of this glass and the wettability of the current conductor are further improved. Thus, in the structure of FIG. 22, the leakage rate 8.3 × 10 ^{- 11} (mbar · l · s
^{- 1)} was achieved following.

The main surface 91 of the closing member 91 on the inner space 13 side
An insulating layer 95 made of a material having a corrosion resistance to a halogen gas can be formed on c. Further, an electrode shaft receiving portion 91a is formed on the main surface 91c side.

In the end structure of FIG. 23, the same members as those shown in FIG. 22 are designated by the same reference numerals, and the description thereof will be omitted. This also applies to FIGS. 24 and below.

In FIG. 23, the blocking member 50A is inserted inside the end portion 12. Through hole 1 of the blocking member 50A
The current conductor 5 is inserted into 4a and 15a. A crimping surface is formed between the outer portion 15 and the current conductor, but no crimping is performed between the inner portion 14 and the current conductor 5. A ring-shaped thermal expansion relaxation material 93 is provided at a position facing the outer main surface 15b of the closure material 50A, and between the main surface 15b of the closure material 50A and the end surface 93a of the thermal expansion relaxation material 93. Further, a sealing material layer 92A made of a melted material of glass material is provided. Inner space 1 of the blocking member 50A
An insulating layer 95 made of a material having corrosion resistance to a halogen gas can be formed on the main surface 14c on the third side. Further, a receiving portion 14b for the electrode shaft is formed on the main surface 14c side.

In FIG. 24, the blocking member 56 is inserted inside the end portion 12. Through hole 14 of the blocking member 56
The current conductor 5 is inserted into a and 57a. Between the outer portion 57 and the current conductor 5, the inner portion 14 and the current conductor 5
No crimping is done between and. A ring-shaped thermal expansion relaxation material 93 is provided at a position facing the outer main surface 57b of the closure member 56, and the main surface 57b of the closure material 56, the end surface 93a of the thermal expansion relaxation material 93, and the current conductor 5 are provided. Between the end surface 93b, a sealing material layer 92A made of a melt of a glass material,
92B is provided. A metallization layer 96 is also formed between the outer portion 57 and the current conductor 5.

In FIG. 25, the closing member 97 is inserted inside the end portion 12. Through hole 97a of the closing member 97
The current conductor 106 is inserted therein. The current conductor 106 illustrated in this embodiment is rod-shaped, and gas cannot pass through the inside of the current conductor 106. Closure material 9
A ring-shaped thermal expansion mitigating material 93 is provided at a position facing the outer main surface 97d of 7, and between the main surface 97d of the closing material 97 and the end surface 93a of the thermal expansion mitigating material 93.
Between the current conductor 106 and the end surface 93b, sealing material layers 92A and 92B made of a melted glass material are provided.

A metallization layer 98 is formed between the inner surface of the blocking member 97 and the current conductor 106. When the metallized layer 98 is provided in this way, the compression stress applied to the metallized layer 98 by the firing shrinkage of the blocking material 97 promotes the densification of the metallized layer 98. According to this aspect, the risk of gas leakage is further reduced by the synergistic effect of the high corrosion resistance of the metallized layer 98 and the high airtightness of the glass layers 92A and 92B.

Further, it is preferable to form an insulating layer 95 made of a material having corrosion resistance against halogen gas and electrical insulation on the main surface 97c of the closing member 97 on the inner space 13 side, whereby the metallized layer is formed. A short circuit to 98 can be reliably prevented.

The electrode shaft receiving portion 9 is provided on the main surface 97c side.
7b is formed.

In FIG. 26, the receiving portion 12b protruding inside the end portion 12 is formed, and the closing member 97 shown in FIG. 25 is placed on the receiving portion 12b, and the closing member 97 and the surface 12 of the end portion 12A.
A sealing material layer 105 composed of a melt of a glass material
It is sealed by.

That is, in each of the end structures of the embodiments as shown in FIGS. 22 to 24, the pipe-shaped current conductor 5 is used, and the gas is passed into the inner space of the current conductor 5. As a result, a predetermined gas is supplied to the inside of the ceramic discharge tube 10. However, if the end structure as shown in FIG. 26 is used, and the space between the occluding material 97 and the inner side surface 12a of the end part 12A is sealed by the encapsulating material layer 105, the occluding material 97 can be sealed. Immediately before installation inside 12A, a predetermined gas is injected into the ceramic discharge tube 10, and then a closing member 97 is installed in this end 12A with a glass material interposed therebetween, The glass frit can then be melted. According to this method, a high pressure discharge lamp can be produced without injecting gas from the pipe-shaped current conductor 5.

When the encapsulating material layer is formed by the molten glass material as described above, as shown in FIG. 27A, the occluding material 91 (15, 57, 97, etc.) and the thermal expansion easing material 93 are used. It is preferable to form a curved surface 99 that is recessed inward at the end portion of the encapsulating material layer 92A between and. This is preferable because stress is less likely to concentrate at one point in the encapsulating material layer. Furthermore, as shown in FIG. 27B, the corners of the end portions of the blocking material 91 (15, 57, 97, etc.) on the sealing material layer side and the ends of the thermal expansion relaxation material 93 on the sealing material layer side. By forming the chamfered portion 101 at each of the corners of the portion,
It is even more difficult for such stress concentration to occur.

In order to manufacture the high pressure discharge lamp having the above-mentioned end structure, unlike the case of the metallized layer, the main body of the ceramic discharge tube to which the closing member is fixed and the thermal expansion relaxation material are After manufacturing separately by a firing method or the like, a glass material is installed between the plugging material and the thermal expansion relaxation material fixed to the ceramic discharge tube, and between the thermal expansion relaxation material and the current conductor. The encapsulant layer is formed by melting the material.

In a particularly preferred embodiment, the method as shown in the flow chart of FIG. 28 is used. That is, a molded body of the occluding material is prepared, the molded body is debindered, and calcined at, for example, 700 to 1200 ° C. to obtain a calcined body. This calcined body is reduced as described above. If necessary, a metallizing paste is applied to this calcined body, and the metallizing paste is dried. Such a metallized paste is, for example, as shown in FIG.
In each structure shown in FIG. 26, each metallized layer is formed.

On the other hand, a current conductor 5 or 6 with an electrode system was prepared, and this current conductor was inserted into the through hole of the occluding member to obtain an assembly.
Pre-baking is performed at 1700 ° C. in a hydrogen + nitrogen atmosphere. On the other hand, a ceramic discharge tube molded body made of alumina or the like is prepared, and the molded body is debindered, for example, 700 ° C.
A calcined body is obtained by calcining in air at ~ 1200 ° C.

A pre-fired body of the plugging material is inserted into the end portion of the calcined body of the ceramic discharge tube, and the temperature is, for example, 1600 ° C.
Main firing is performed at 2000 ° C. in a hydrogen + nitrogen atmosphere.

On the other hand, a molded body of the thermal expansion relaxation material is prepared,
The molded body is debindered and calcined to obtain a calcined body. The calcined body is, for example, 1600 ° C to 2000 ° C.
Main baking is performed in a hydrogen + nitrogen atmosphere at ℃.

[0175] The main surface of the occluding material and the end surface of the thermal expansion reducing material are opposed to each other, a predetermined glass frit is installed between them, and the glass frit is melted to form a sealing material layer. Of the two current conductors to be integrated with the ceramic discharge tube, one or both of them is a pipe-shaped current conductor 5. A predetermined halide gas is filled through this current conductor to seal the inlet of the current conductor 5.

However, when both the current conductors to be integrated with the ceramic discharge tube are rod-shaped current conductors, the halide gas cannot be enclosed through the current conductors. Therefore, on the end portion side shown in FIG. 26, the thermal expansion relaxation material 93 and the blocking material 97 are respectively fired and manufactured, and then the thermal expansion relaxation material 93, the blocking material 97, and the current conductor 106 are made of glass. Sealing material layer 92
Joined by A and 92B. On the other hand, the calcined body of the ceramic discharge tube is fired. Then, a halide gas is sealed in the ceramic discharge tube, the plug 97 is immediately inserted into the end 12A of the ceramic discharge tube, and a glass frit is installed between them to connect the plug 97 and the end 12A. The space is sealed with molten glass.

Although the present invention has been described in terms of certain preferred embodiments above, the specific details illustrated are exemplary only, and the invention resides in the true spirit and scope of the following claims. It should be understood that other methods can be implemented without departing from.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a structure around an end portion of a conventional ceramic discharge tube.

FIG. 2 is a schematic view schematically showing an example of the entire structure of a high pressure discharge lamp.

FIG. 3 is an enlarged cross-sectional view showing a structure around an end portion 12 of a ceramic discharge tube 11 of a high-pressure discharge lamp according to an embodiment of the present invention, showing a thermal expansion relaxation with an outer portion 15 of a plug 50A. An encapsulating material layer 16A is formed between the material 17 and the material 17.

FIG. 4 is an enlarged cross-sectional view showing a structure around an end portion 12 of a ceramic discharge tube 11 in a high pressure discharge lamp according to another embodiment of the present invention, showing a thermal expansion of an outer portion 57 of a plug 56. A sealing material layer 58 is formed between the relaxing material 17 and the relaxing material 17.

5 is an enlarged cross-sectional view showing a structure around an end portion 12 of a ceramic discharge tube 11 according to still another embodiment of the present invention, showing an outer portion 15 of a plug 50A and a thermal expansion relaxation material 17. FIG. The annular member 18 is inserted between the two, and the sealing material layers 16B and 16C are formed between them.

FIG. 6 is an enlarged cross-sectional view showing the structure around the end portion 12 of the ceramic discharge tube 11, and shows the outer portion 5 of the plug 56.
The ring-shaped member 18 is inserted between the thermal expansion relaxation material 17 and the thermal expansion relaxation material 17, and the sealing material layers 59A and 59B are formed between them.

FIG. 7 is an enlarged cross-sectional view showing a structure around an end portion 12 of a ceramic discharge tube 11 according to still another embodiment of the present invention, in which an annular protrusion 22 is formed on an outer peripheral surface of a current conductor 5. The sealing material layer 16 is provided between the outer portion 21 and the annular protrusion 22, and between the thermal expansion relaxation material 17 and the annular protrusion 22.
D and 16E are formed.

FIG. 8 is a cross-sectional view for explaining a method of manufacturing an assembly of the current conductor 23 and the firing target 51 of the plugging material in the high-pressure discharge lamp according to the embodiment of the present invention.

9A and 9B are views for explaining a method of manufacturing an assembly of current conductors 24 and 28 and a sintered body 51 of an occluding material in a high pressure discharge lamp according to an embodiment of the present invention. FIG.

FIG. 10 is an enlarged cross-sectional view showing a structure around an end portion 12 of a ceramic discharge tube 11 according to still another embodiment of the present invention, in which an annular protrusion 22 is formed on an outer peripheral surface of a current conductor. And the current conductor and electrode system shown in FIG. 9 (b) was used.

FIG. 11 is a cross-sectional view showing, in an enlarged scale, a structure around an end portion 12 of a ceramic discharge tube 11 according to still another embodiment of the present invention, in which an annular protrusion 22 is formed on an outer peripheral surface of a current conductor 5. The current conductor and electrode system shown in FIG. 9 (a) was used.

FIG. 12 shows an end portion 12 according to still another embodiment of the present invention.
It is sectional drawing which expands and shows the structure of the circumference | surroundings of FIG.
An encapsulating material layer is formed between and the pressure-bonding encapsulating material 61.

FIG. 13 shows an end portion 12 according to still another embodiment of the present invention.
It is sectional drawing which expands and shows the structure of the circumference | surroundings of FIG.
A sealing material layer is formed between the pressure-bonding sealing material 64 and
The thickness of the pressure sealing material 64 increases from the outer peripheral side toward the inner peripheral side.

FIG. 14 illustrates an end portion 12 according to still another embodiment of the present invention.
It is sectional drawing which expands and shows the structure of the circumference | surroundings of FIG.
A metallized layer 16H is formed on the surface of the inner portion 34 of C on the inner space 13 side.

FIG. 15 illustrates an end portion 12 according to still another embodiment of the present invention.
FIG. 6 is an enlarged cross-sectional view showing the structure of the periphery of FIG. 1, in which a crimp sealing material 67 is inserted between the first closing member 33 and the second closing member 32, and a sealing member is provided between these members. Stop material layer 68A,
68C is formed.

FIG. 16 illustrates an end portion 12 according to another embodiment of the present invention.
FIG. 7 is an enlarged cross-sectional view showing the structure around the device, in which a pressure-bonding sealing material 73 is inserted between a first closing member 72 and a second closing member 71, and a sealing member is provided between these members. Stop material layer 74A,
74C is formed.

FIG. 17 illustrates an end portion 12 according to still another embodiment of the present invention.
FIG. 8 is an enlarged cross-sectional view showing the structure of the periphery of the occluding member 81.
A metallization layer 83 is formed between the current conductor 6 and the current conductor 6.

FIG. 18 illustrates an end portion 12 according to another embodiment of the present invention.
FIG. 4 is an enlarged cross-sectional view showing the structure of the periphery of the second closing member 86, and the second closing member 86 is housed in the inner space of the first closing member 87.

FIG. 19 illustrates an end portion 12 according to still another embodiment of the present invention.
FIG. 8 is an enlarged cross-sectional view showing the structure of the periphery of the occluding member 81.
The first thermal expansion mitigating material 89 is fixed to the outside of the, and the second thermal expansion mitigating material 90 is fixed to the inside of the closing material 81.

FIG. 20 is a flowchart showing an example of steps of a manufacturing method according to the present invention.

FIG. 21 is a flowchart showing another example of the manufacturing process in the present invention.

FIG. 22 is a cross-sectional view showing the structure of the end portion of still another high-pressure discharge lamp, in which a thermal expansion mitigating material 93 is provided between the clogging material 91 and the thermal expansion mitigating material 93 facing the outside of the clogging material 91. Glass layers 92 </ b> A and 92 </ b> B are formed between the current conductors 5.

FIG. 23 is a cross-sectional view showing the structure of the end portion of still another high-pressure discharge lamp, showing the outer portion 15 and the outer portion 1 of the closing member 50A.
5 between the thermal expansion mitigating material 93 and the thermal expansion mitigating material 9
Glass layers 92A and 92B are formed between the electrode 3 and the current conductor 5.

FIG. 24 is a cross-sectional view showing the structure of the end portion of still another high-pressure discharge lamp, showing the outer portion 57 and the outer portion 57 of the closing member 56.
Between the thermal expansion mitigating material 93 facing the
The glass layers 92A and 92B are formed between and the current conductor 5.

FIG. 25 is a cross-sectional view showing the structure of the end portion of still another high-pressure discharge lamp, in which glass layers 92A and 92B are formed,
In addition, the metallized layer 98 is formed between the blocking member 97 and the current conductor 106.

26] The entire sealing structure shown in FIG. 25 is sealed to the end portion 12A of the main body 11 by a metallized layer 105.

27A and 27B show a glass layer 92, respectively.
It is sectional drawing which expanded and showed the periphery of the end surface of A. FIG.

FIG. 28 is a flow chart illustrating a process for manufacturing each form of the sealing structure as shown in FIGS. 22 to 27.

─────────────────────────────────────────────────── ─── Continuation of front page (31) Priority claim number Japanese Patent Application No. 7-191938 (32) Priority date July 27, 1995 (July 27, 1995) (33) Priority claim country Japan (JP) (56) References JP 2001-155682 (JP, A) JP 63-184258 (JP, A) JP 6-318435 (JP, A) JP 5-290810 (JP, A) Sho 61-184268 (JP, U) Patent 3229325 (JP, B2) International publication 96/021940 (WO, A1) (58) Fields investigated (Int.Cl. ⁷ , DB name) H01J 61/36 H01J 9/24

Claims (17)

(57) [Claims] 1. A ceramic discharge tube having an internal space filled with an ionized luminescent material and a starting gas; a plugging member, at least a part of which is fixed inside an end of the ceramic discharge tube, having a through hole. A blocking member; a current conductor with an electrode system inserted into the through hole of the blocking member; and a member other than the through hole, which is formed so as to be joined to the blocking member and the current conductor. A high pressure discharge lamp comprising a sealing material layer, wherein the sealing material layer comprises a metallized layer. 2. The sealing material layer is sandwiched between the plugging material and a thermal expansion relaxation material provided outside the ceramic discharge tube so as to face the plugging material, and The high pressure discharge lamp according to claim 1, wherein the high pressure discharge lamp is joined to a thermal expansion relaxation material. 3. An annular projecting portion is formed on an outer peripheral surface of the current conductor, and the annular projecting portion is inserted between the closing member and the thermal expansion reducing material. The high pressure discharge lamp according to claim 2, wherein the sealing material layer is formed between the sealing material and the annular protrusion and the thermal expansion reducing material. 4. A first plugging member is fixed to the inner space side of the end of the ceramic discharge tube, and a second plugging member is fixed to the end face side of the end of the ceramic discharge tube. ,
An annular protrusion is formed on the outer peripheral surface of the current conductor,
The annular protruding portion is inserted between the first closing member and the second closing member, between the first closing member and the annular protruding portion and the second closing member and the The high pressure discharge lamp according to claim 1, wherein the encapsulant layer is formed between the annular protrusion and the annular protrusion. 5. The current conductor has a tubular shape, and an electrode system is attached to an inner surface of the current conductor on the inner space side of the ceramic discharge tube.
The high pressure discharge lamp according to claim 3 or 4. 6. An electrode system is attached to an inner space side of the ceramic discharge tube of the current conductor, and a tip side of the electrode system is bent toward a central axis of the ceramic discharge tube. The high-pressure discharge lamp according to any one of claims 3 to 5, characterized in that. 7. The plugging material is made of the same kind of material as the ceramic discharge tube at least in the end portion of the ceramic discharge tube, and the thermal expansion is relaxed so as to face the plugging material outside the ceramic discharge tube. And a sealing material layer made of a melt of a glass material is provided between the thermal expansion relaxation material and the closing material and between the thermal expansion relaxation material and the current conductor. The high pressure discharge lamp according to claim 1, characterized in that: 8. A ceramic discharge tube having an internal space filled with an ionized luminescent material; a plugging member, at least a part of which is fixed inside an end of the ceramic discharge tube, having a through hole. A ceramic discharge tube, comprising: a blocker; a current conductor inserted through the through-hole of the blocker; and a sealing metallization layer formed so as to be bonded to the blocker and the current conductor. The metallization layer is provided between the through hole of the plug and the current conductor in the end portion of the first plug so as to face the main surface of the plug that faces the outside of the ceramic discharge tube. A thermal expansion relaxation material is provided, a second thermal expansion relaxation material is provided on the opposite side of the closure material from the first closure material, and the first thermal expansion relaxation material and the first expansion material Second thermal expansion relaxation material The current conductor is accommodated in the through hole, the inner diameter of the first thermal expansion relaxation material and the inner diameter of the second thermal expansion relaxation material is larger than the inner diameter of the closing material, the first thermal expansion A high-pressure discharge lamp, wherein a glass layer is formed between the through hole of the relaxation material and the current conductor so as to come into contact with the metallized layer. 9. A corner portion of glass, which penetrates into the open pores of the metallized layer and contacts the ceramic discharge lamp of the base material, a corner portion of the first thermal expansion relaxation material, which contacts the ceramic discharge tube, and 9. The high pressure discharge lamp according to claim 8, wherein a chamfered portion is provided at each corner of the second thermal expansion relaxation material that contacts the ceramic discharge tube. 10. A method of manufacturing a high-pressure discharge lamp according to claim 1, wherein a fired body of the plugging material is produced, and a sealing material is provided in a through hole of the fired body of the plugging material. The current conductor is inserted without interposing components, a sintered body of the ceramic discharge tube is manufactured, and at least a part of the occluding material is fixed inside the end of the sintered body of the ceramic discharge tube. A sealing material component layer containing a sealing material component is formed so as to contact the plugging material and the current conductors other than the through holes, and the plugging material of the plugging material and the target of the ceramic discharge tube are formed. A method for manufacturing a high-pressure discharge lamp, comprising sintering a fired body and the encapsulant component layer. 11. An annular projecting portion is formed on an outer peripheral surface of the current conductor, and the annular projecting portion and the body to be fired of the blocker are opposed to each other when viewed in a central axis direction of the ceramic discharge tube, and the annular body is formed. The method for manufacturing a high pressure discharge lamp according to claim 10, wherein the encapsulant component layer is formed between the protruding portion and the body to be fired of the closing material. 12. The method for manufacturing a high pressure discharge lamp according to claim 8, wherein a metallizing paste is applied to the through holes of the body to be fired of the plugging material, and the metallizing paste of the plugging material is applied to the through holes. The current conductor is inserted into a predetermined position and the metallizing paste is baked to fix the current conductor in the through hole, and then the plug is closed at a predetermined position on the inner surface of the end of the body to be fired of the ceramic discharge tube. A method for manufacturing a high pressure discharge lamp, comprising: inserting a body to be fired and then firing the body integrally. 13. The ceramic discharge tube when the metallizing paste is fixed to the inner surface of the end portion of the ceramic discharge tube of the two main surfaces of the plugging material which are orthogonal to the through holes of the plugging material. 13. The high pressure discharge lamp according to claim 12, wherein the glass is infiltrated into the outer main surface, and the glass permeates into the open pores of the metallized layer provided on the main surface of the plugging material after the integral firing. Manufacturing method. 14. The high pressure discharge lamp according to claim 12, wherein a chamfered portion is provided at a corner portion of the body to be fired of the plugging material, the corner being in contact with the ceramic discharge tube, and then the integral firing is performed. Production method. 15. A body to be fired of a cylindrical first thermal expansion relaxing material and a body of a fired body of a second cylindrical thermal expansion relaxing material are respectively molded, and at this time, the first body after integral baking is formed. The inner diameter of the thermal expansion relaxing material and the inner diameter of the second thermal expansion relaxing material are made larger than the inner diameter of the closing material, and at least the metallizing paste is applied to the through holes of the fired body of the closing material, and the closing is performed. Material to be fired, the first thermal expansion relaxation material to be fired body and the second thermal expansion relaxation material to be fired body through the through hole through the current conductor at a predetermined position, the metallized paste Baking, and then the first thermal expansion relaxation material, the second thermal expansion relaxation material, and the closing material in which the current conductors are fixed at a predetermined position on the inner surface of the end of the body to be fired of the ceramic discharge tube. After that, it is integrally fired, and the metallized paste layer is An object to be fired of the plugging material and the first object to be fired of the thermal expansion relaxation material, and a metallizing paste layer is provided between the object to be fired of the plugging material and the object to be fired of the second thermal expansion relaxation material. It is provided between and.
2. The method for manufacturing a high pressure discharge lamp according to 2. 16. The glass is melted between the through hole of the first thermal expansion relaxation material and the current conductor on the metallized layer of the plugging material after the integral firing.
The method for manufacturing a high pressure discharge lamp according to claim 15. 17. A chamfered portion is provided at a corner portion of the fired body of the plugging material that contacts the ceramic discharge tube, and a chamfered portion is formed at a corner portion of the fired body of the first thermal expansion relaxation material that contacts the ceramic discharge tube. 16. The unitary firing is performed after a portion is provided and a chamfered portion is provided at a corner portion of the body to be fired of the second thermal expansion relaxation material that is in contact with the ceramic discharge tube. High-pressure discharge lamp manufacturing method.