JP3678538B2

JP3678538B2 - Noble gas discharge lamp

Info

Publication number: JP3678538B2
Application number: JP12094997A
Authority: JP
Inventors: 真一堀田; 進高橋
Original assignee: Ushio Denki KK; NEC Lighting Ltd
Current assignee: Ushio Denki KK; Hotalux Ltd
Priority date: 1997-05-12
Filing date: 1997-05-12
Publication date: 2005-08-03
Anticipated expiration: 2017-05-12
Also published as: JPH10312776A

Description

【０００１】
【発明の属する技術分野】
この発明は希ガス放電灯に関し、特にガラスバルブの外周面に一対の帯状の外部電極を配置すると共に、外部電極に対し電気的な接続関係を有する端子にワイヤハ−ネスを接続してなる希ガス放電灯において、ハ−ネスの端子への接続構造の改良に関する。
【０００２】
【従来の技術】
本出願人は、先に、例えば図１１〜図１４に示す希ガス放電灯を提案した。同図において、１は例えばガラスバルブなどにて密閉状に構成された直管状の外囲器であって、その内面には希土類蛍光体，ハロリン酸塩蛍光体などの蛍光体よりなる発光層２が形成されている。特に、この発光層２には所定の開口角を有する発光層２を形成しないアパ−チャ部２ａがほぼ全長に亘って形成されている。そして、外囲器１の封着構造はガラスバルブの端部にディスク状の封着ガラス板を封着して構成されているが、例えば単にガラスバルブを加熱しながら縮径加工し溶断して構成することもできる。尚、この外囲器１の密閉空間には水銀などの金属蒸気を含まないキセノン（Ｘｅ），クリプトン（Ｋｒ），ネオン（Ｎｅ），ヘリウム（Ｈｅ）などの希ガスが単一又は混合して所定量封入されている。
【０００３】
この外囲器１の外周面にはシ−ト構体３が密着するように巻回されている。このシ−ト構体３は、例えば外囲器１の全長とほぼ同程度の長さを有し、かつ厚さが２０〜１００μｍの範囲に設定された絶縁性の透光性シ−ト４と、この透光性シ−ト４の一方の面に互いに所定の間隔だけ離隔配置して接着された不透光性の金属部材よりなる帯状の一対の外部電極５，６と、一端５１ａ，６１ａが外部電極５，６の端部に導電性接着剤５２，６２にて電気的に接続されると共に、他端５１ｂ，６１ｂが透光性シ−ト４の端縁部分より突出するように導出された端子５１，６１と、透光性シ−ト４の一方の面に付与された粘着ないし接着機能を有する接着層９とから構成されている。尚、シ−ト構体３において、外部電極５，６の外囲器１に当接する側の面には、予め、接着層９ａが形成されている。又、透光性シ−ト４としては、例えばポリエチレンテレフタレ−ト（ＰＥＴ）樹脂が好適するが、ポリエステル樹脂など他の樹脂も利用可能である。
【０００４】
上述のシ−ト構体３は外囲器１の外周面に、外部電極５，６が外囲器１と透光性シ−ト４との間に位置するように装着（巻回）されている。このシ−ト構体３の外囲器１への装着は、例えば展開状態のシ−ト構体３における透光性シ−ト４の一端４ａに外囲器１を配置した上で、外囲器１又はシ−ト構体３を相対的に移動（転動）させることにより行われる。尚、シ−ト構体３において、外部電極５，６はその表面に形成された接着層９ａを利用して外囲器１の外周面に接着されており、透光性シ−ト４はそれの一方の面に形成された接着層９を利用して巻回時に外囲器１の外周面に接着されると共に、それぞれの端部４ａ，４ｂは後述の第２の開口部（８）で重ね合わせられて接着されている。特に、シ−ト構体３の外囲器１への装着状態において、外部電極５，６の一端５ａ，６ａ間には第１の開口部７が、外部電極５，６の他端５ｂ，６ｂの間には第２の開口部８がそれぞれ形成されており、発光層２からの光は主としてアパ−チャ部２ａを介して第１の開口部７から外部に放出される。尚、第１，第２の開口部７，８の開口角 θ₁，θ₂ は θ₁ ≧θ₂ に設定されているが、用途などによっては逆の関係に設定することもできる。
【０００５】
さらに、外囲器１の端面（１ａ）には絶縁性（耐圧），難燃性に優れた絶縁部材にて成形された絶縁キャップ１０が装着されている。この絶縁キャップ１０は例えばポリカ−ボネイト樹脂にて成形されており、例えばブロック状のキャップ本体１１と、キャップ本体１１の周縁部分に一体的に形成された一対のＬ形状の支持片１２，１２とから構成されている。特に、キャップ本体１１の中央部分には外面側から内面側（外囲器１の端面側）に貫通する孔１１ａが、外周部分には平坦状の側面部１１ｂ，１１ｂがそれぞれ形成されている。そして、この絶縁キャップ１０は外囲器１の端部に、キャップ本体１１が外囲器１の端面側に位置し、かつ支持片１２，１２が外囲器１の端部外周面を支持するように配置され、孔１１ａ及びキャップ本体１１と外囲器１の端面（１ａ）との間には絶縁性に優れた接着剤１３が充実され固化されている。これによって、絶縁キャップ１０は外囲器１に固定（支持）される。その上、この絶縁キャップ１０の側面部１１ｂ，１１ｂには外部電極５，６から導出された端子５１，６１の他端５１ｂ，６１ｂがほぼ密接するように配置されている。尚、側面部１１ｂ，１１ｂに位置する端子部分５１ｂ，６１ｂには、外部回路との接続用ハ−ネス（リ−ド線）１４が半田などにより接続されている。
【０００６】
この希ガス放電灯は、端子５１，６１を介して外部電極５，６に高周波高電圧（例えば３０ＫＨｚで２５００Ｖｏ−ｐ）を印加することにより希ガスの放電が生じ、希ガスの励起線によって発光層２が励起されて発光するものであり、光はアパ−チャ部２ａを介して第１の開口部７から外部に放出される。特に、この希ガス放電灯には水銀が用いられていないために、点灯後における光量の立ち上がりが急峻であり、点灯と同時に光量がほぼ１００％近くにまで達するという特徴を有している。このために、ファクシミリ，イメ−ジスキャナ，複写機などのＯＡ機器の原稿読取用の光源として好適するものである。
【０００７】
【発明が解決しようとする課題】
ところで、この希ガス放電灯は、例えば図１５〜図１７に示すように製造される。まず、図１５（ａ）に示すように、例えば長尺状のセパレ−タ３Ｓの離型機能を有する一方の面に、例えばセパレ−タ３Ｓより幅が狭く、一方の面に接着層９ａを有する長尺状の金属部材よりなる導電性シ−トを順に重ね合わせて接着した後、導電性シ−トを図示しないカッタ−によって帯状に切断し、不要な部分をセパレ−タ３Ｓから剥離して除去することにより、外部電極５，６が所定の間隔で順に配列・形成される。この外部電極５，６の端部に、例えばニッケル粉末を含むエポキシ系の導電性接着剤５２，６２を被着する。次に、同図（ｂ）に示すように、端子５１，６１を外部電極５，６の端部に、一端５１ａ，６１ａが導電性接着剤５２，６２に載置されるように配置する。この状態で、炉内温度が例えば１００°Ｃに設定された処理炉にて５時間程度加熱処理する。これにより、導電性接着剤５２，６２が硬化し、端子５１，６１は外部電極５，６の端部に電気的機械的に接続される。次に、外部電極５，６の上を透光性シ−ト４にて覆い、透光性シ−ト４に外部電極５，６を接着させた後、透光性シ−ト４を所定の長さに切断し、セパレ−タ３Ｓより剥離することにより、図１６に示すようにシ−ト構体３が形成される。
【０００８】
次に、図１７に示すように、ステ−ジ１５にシ−ト構体３を載置した後、外囲器１をシ−ト構体３における透光性シ−ト４の一端４ａに、それの長手方向が外部電極５，６の長手方向に沿うように（平行となるように）位置させると共に、従動的に回転し、かつ上下動可能な一対のロ−ラ１６，１６を外囲器１の上部に弾力的に押し付けるように位置させる。この状態において、ステ−ジ１５を矢印方向Ｍに若干移動させる。すると、外囲器１はロ−ラ１６，１６に押さえ付けられた状態で反時計方向に回転すると共に、ロ−ラ１６，１６も外囲器１の回転に応じて従動回転する。これによって、外囲器１の外周面の一部には透光性シ−ト４の一端４ａが密着状態で接着される。その後、ステ−ジ１５を矢印方向Ｎに移動させると、外囲器１はロ−ラ１６，１６に弾力的に押さえ付けられた状態で時計方向に回転すると共に、ロ−ラ１６，１６も外囲器１の回転に応じて従動回転する。この際に、シ−ト構体３の透光性シ−ト４は、既に外囲器１に接着された一端４ａを起点として、外囲器１の回転に応じて外周面に巻回され始める。そして、外囲器１が例えば３９０°程度回転（ほぼ１回転）すると、外囲器１の外周面には、図１１に示すように、透光性シ−ト４が巻回される上、一端４ａに他端４ｂが重ね合わされ、接着層９によって接着される。
【０００９】
しかしながら、この提案による希ガス放電灯の製造過程において、端子５１，６１の外部電極５，６への接続は、外部電極５，６の端部に被着・塗布されたペ−スト状の導電性接着剤５２，６２に端子５１，６１の一端５１ａ，６１ａを押し付けることによって行われているのであるが、導電性接着剤５２，６２はそれが硬化するまでに何時間もかかるために、製造時間が長くなり、生産性が損なわれるという問題がある。
【００１０】
しかも、導電性接着剤５２，６２に端子５１，６１を若干押し付けた状態の仮接続状態では、一寸とした外力の付与により端子５１，６１の外部電極５，６に対する位置関係がずれてしまうために、導電性接着剤５２，６２が完全に硬化して端子５１，６１と外部電極５，６とが電気的機械的に確実に接続されるまでは端子５１，６１に外力が作用しないように配慮しなければならない。従って、作業が煩雑となるために、多大の工数が必要となり、製造コストが高くなる。
【００１１】
特に、シ−ト構体３を巻回した状態で、導電性接着剤５２，６２の硬化促進のための加熱処理を行う場合には、細心の注意を払っても端子５１，６１に外部電極５，６に対する位置ずれが発生するために、外囲器１の端部への絶縁キャップ１０の装着が困難になったり、絶縁キャップ１０の側面部１１ｂ，１１ｂにおける所定部分に端子５１，６１の他端５１ｂ，６１ｂが位置しなくなってハ−ネス１４の半田付けが困難になったりする。従って、製造歩留まりが低下するという問題もある。
【００１２】
それ故に、本発明の目的は、簡単な構成によってハ−ネスと外部電極との電気的な接続性を改善できる上、製造コストをも低減することのできる希ガス放電灯を提供することにある。
【００１３】
【課題を解決するための手段】
従って、本発明は、上述の目的を達成するために、内面に発光層を有する直管状の外囲器と、外囲器の外周面に、それのほぼ全長に亘って離隔して配置した金属部材よりなる帯状の一対の外部電極と、それぞれの外部電極の端部から外部電極部分を長手方向の外方に向けて導出して形成した端子と、外囲器の外周面に、外部電極が被覆されるように装着した、透光性シートにて構成した絶縁部材とを具備し、それぞれの端子に、前記透光性シートの一部を延長して重ね合わせるとともに、ハーネスを圧着を利用した接続手段によって電気的機械的に接続したことを特徴とする。
【００１４】
又、本発明の第２の発明は、内面に発光層を有する直管状の外囲器と、外囲器の全長とほぼ同程度の長さを有する透光性シートの一方の面に金属部材よりなる帯状の一対の外部電極を互いに離隔して配置し、かつそれぞれの外部電極の端部から外部電極部分を外方に向けて導出して端子を形成し、それぞれの端子に前記透光性シートの一部を延長して重ね合わせてなるシート構体とを具備し、前記外囲器の外周面にシート構体を、外囲器と透光性シートとの間に外部電極が位置するように巻回すると共に、シート構体のそれぞれの端子にハーネスを、圧着を利用した接続手段によって電気的機械的に接続したことを特徴とする。
【００１７】
【発明の実施の形態】
次に、本発明にかかる希ガス放電灯の第１の実施例について図１〜図４を参照して説明する。尚、図１１〜図１７に示す先行技術と同一部分には同一参照符号を付し、その詳細な説明は省略する。この実施例の特徴部分は外部電極５，６の端部部分をほぼ長手方向の外方に向けて延在させて形成した端子５Ａ，６Ａにハ−ネス２０，２０のリ−ド部２０ａ，２０ａを、圧着を利用した接続手段２１，２１によって電気的機械的に接続したことである。
【００１８】
具体的には、外囲器１の全長とほぼ同程度の長さを有する透光性シ−ト４の一方の面に金属部材よりなる帯状の一対の外部電極５，６を互いに離隔して配置し、かつ外部電極５，６の端部から外部電極部分を外方に向けて延在して端子５Ａ，６Ａを形成してなるシ−ト構体３を外囲器の外周面に、外囲器１と透光性シ−ト４との間に外部電極５，６が位置するように巻回すると共に、シ−ト構体３の端子５Ａ，６Ａにハ−ネス２０，２０のリ−ド部２０ａ，２０ａを、圧着を利用した接続手段２１，２１によって電気的機械的に接続したことである。
【００１９】
上述の外部電極５，６及び端子５Ａ，６Ａは同一部材、例えばアルミニウム箔にて構成されており、その肉厚はほぼ１０〜１００μｍの範囲に設定されている。例えばアルミニウム箔が硬質の場合には、その肉厚は１０〜５０μｍの範囲に、軟質の場合には、その肉厚は３０〜１００μｍの範囲にそれぞれ設定することが推奨される。ここで、アルミニウム箔並びにその硬質及び軟質は、一般的に次のように説明されている。即ち、アルミニウム箔は、日本では、ＪＩＳ−Ｈ−４１６０に基づき、６〜２００μｍの厚み範囲をアルミニウム箔と規定されている。又、アルミニウム箔の硬質及び軟質は熱処理の有無により区分されており、圧延上がりの状態のままのものが硬質箔、圧延後に焼鈍したものが軟質箔と呼称されている。
【００２０】
特に、端子５Ａ，６Ａの導出部分の幅は、外部電極５，６の幅より狭く構成されており、この導出部分にはハ−ネス２０，２０のリ−ド部２０ａ，２０ａが有端を含むほぼリング状の接続手段２１，２１を用いて圧着により接続されている。この接続手段２１，２１は、例えば黄銅，ニッケル，ステンレスなどの金属部材よりなるリング状の圧着端子にて構成されており、リング部分に端子５Ａ（又は６Ａ）及びハ−ネス２０のリ−ド部２０ａを重ね合わせて位置させた状態で、周知の圧着工具によって電気的機械的に接続される。尚、接続手段（圧着端子）２１のリング部分は無端状のリングの他、若干の隙間を有する有端状のリングであってもよい。
【００２１】
上述の端子５Ａ，６Ａとハ−ネス２０，２０との接続部分は、例えば次のように外装されている。即ち、外囲器１の端部には例えば樹脂材，ゴム材，セラミック材などのように絶縁性を有する筒状の外装チュ−ブ２２が、端子５Ａ，６Ａとハ−ネス２０，２０との接続部分を囲繞するように装着されており、その内部にはエポキシ樹脂，シリコ−ン樹脂などの封止部材２３が充填されている。尚、外装チュ−ブ２２としては、若干の柔軟性ないし弾力性を有する樹脂材にて構成することが望ましい。
【００２２】
次に、この希ガス放電灯の製造方法について図４〜図５を参照して説明する。まず、例えば図１５（ａ）に示すような長尺状のセパレ−タ（３Ｓ）の離型機能を有する一方の面に、例えばセパレ−タより幅が狭く、一方の面に接着層９ａを有する長尺状の金属部材よりなる導電性シ−トを順に重ね合わせて接着した後、導電性シ−トを図示しないカッタ−によって、図４（ａ）に示すような形状に切断し、不要な部分をセパレ−タから剥離して除去することにより、外部電極５，６及び端子５Ａ，６Ａが一体となって所定の間隔で順に配列・形成される。次に、長尺状のセパレ−タに接着層９を有する長尺状の透光性シ−ト（４）を、外部電極５，６が被覆され、かつ端子５Ａ，６Ａの導出部分が露呈されるように重ね合わせて接着する。然る後、透光性シ−ト（４）を所定の長さに切断し、セパレ−タより剥離することにより、図４（ａ）に示すシ−ト構体３が得られる。以下、例えば図１７に示す方法に基づいて外囲器１の外周面にはシ−ト構体３が、図３に示すように巻回され、透光性シ−ト４の一端４ａに他端４ｂが重ね合わされて接着層９によって接着される。
【００２３】
次に、図５に示すように、
長尺状のセパレ−タに接着層９を有する長尺状の透光性シ−ト（４）を、外部電極５，６が被覆され、かつ端子５Ａ，６Ａの導出部分が露呈されるように重ね合わせて接着する。然る後、透光性シ−ト（４）を所定の長さに切断し、セパレ−タより剥離することにより、図４（ａ）に示すシ−ト構体３が得られる。以下、例えば図１７に示す方法に基づいて外囲器１の外周面にはシ−ト構体３が、図３に示すように巻回され、透光性シ−ト４の一端４ａに他端４ｂが重ね合わされて接着層９によって接着される。
【００２４】
次に、図５に示すように、外囲器１の端面側に延在されている端子５Ａ（６Ａ）の先端部分に接続手段たる圧着端子２１及びハ−ネス２０を配置する。そして、圧着端子２１のリング部分に端子５Ａを挿入すると共に、ハ−ネス２０のリ−ド部２０ａを端子５Ａに重ね合わせるようにリング部分に挿入する。この状態において、周知の圧着工具（図示せず）を用いて圧着端子２１を圧着することにより、端子５Ａとハ−ネス２０のリ−ド部２０ａとが圧着・接続され、図１に示す接続状態が得られる。次に、外囲器１の端部に外装チュ−ブ２２を、内部に端子５Ａとハ−ネス２０のリ−ド部２０ａとの接続部分が位置するように装着し、内部に封止部材２３を充填・硬化させることにより、希ガス放電灯が完成する。
【００２５】
この実施例によれば、端子５Ａ，６Ａは外部電極５，６と同一部材にて構成され、かつ外部電極５，６の端部から延在させて形成されているために、端子の形成が容易となり、生産性を改善できる上、製造コストを低減できる。特に、導電性シ−トからカッタ−によって所定形状に切断する場合には、端子５Ａ，６Ａの外部電極５，６に対する位置ずれが全く発生しないために、ハ−ネス２０との接続手段２１による接続を能率よく遂行できる。即ち、上述の先行技術のように、外部電極５，６の端部に端子５１，６１を導電性接着剤５２，６２を用いて接続する必要がなく、かつ硬化のための長い加熱処理作業もないために、生産性を著しく改善できる。
【００２６】
又、端子５Ａ，６Ａとハ−ネス２０との接続は圧着端子よりなる接続手段２１のリング部分に端子５Ａ，６Ａとハ−ネス２０とを重ね合わせるように挿入した状態で圧着操作することにより、接続できるために、接続に要する作業時間を上述の先行技術に比較して大幅に短縮できる。従って、かかる接続に要する工数を最小限に止めることができ、生産性の改善は勿論のこと、コストをも低減できる。
【００２７】
さらには、端子５Ａ，６Ａとハ−ネス２０との接続部分は外装チュ−ブ２２に充填された封止部材２３によって囲繞され、支持されているために、ハ−ネス２０を介して端子５Ａ，６Ａに引っ張り力が作用しても、端子５Ａ，６Ａの切断を軽減ないし抑制することができる。
【００２８】
図６は本発明の第２の実施例を示すものであって、上述の第１の実施例と基本的な構成は同一である。異なる点は、端子５Ａ（６Ａ）の導出部分を、接着層９ａが内側となるように折り返して接着した折返部５Ａａ（６Ａａ）を形成し、この部分にハ−ネス２０のリ−ド部２０ａを接続手段２１を用いて圧着・接続したことである。尚、この折返部５Ａａは、同図（ｂ）に示すように、導出部分５Ａを図示矢印の方向に折り返すことによって構成される。
【００２９】
この実施例によれば、かしめ圧着部分の端子５Ａの厚みが２倍に増加されるために、接続手段２１による圧着時に、端子５Ａの折返部５Ａａからの切断を有効に防止できる。逆説的には、折返部５Ａａの形成によって導出部分の強度が向上する分、圧着強度を高めることができるために、圧着によるハ−ネス２０と端子５Ａとの接続の信頼性を一層高めることができる。
【００３０】
図７は本発明の第３の実施例を示すものであって、第１の実施例と基本的な構成は同一である。異なる点は、端子５Ａ（６Ａ）の導出部分に透光性シ−ト４の延長部４Ａを重ね合わせたことである。この延長部４Ａは透光性シ−ト４の端部から外方に向けて端子５Ａ（６Ａ）とほぼ同程度の幅で延長されている。そして、接続手段２１のリング部分に延長部４Ａと端子５Ａ（６Ａ）との重ね合わせ部分を挿入すると共に、ハ−ネス２０のリ−ド部２０ａを端子５Ａ（６Ａ）に重ね合わされるようにリング部分に挿入した上で、圧着工具を用いて圧着・接続される。尚、圧着に先立って、ハ−ネス２０が当接される端子部分の接着層９ａは、電気的接続の信頼性を高める上で、予め、除去しておくことが望ましい。
【００３１】
この実施例によれば、圧着接続部分の端子５Ａ（６Ａ）の厚みは、例えば１０〜１００μｍと薄いものの、その外面側に透光性シ−ト４の延長部４Ａが重ね合わされているために、それの強度が補強され、接続手段２１による圧着時に、端子５Ａからの切断を有効に防止できる。特に、透光性シ−ト４の肉厚を、例えば２０〜１００μｍの範囲でも厚い領域に設定すれば、端子５Ａ（６Ａ）に対する補強効果が向上し、十分な圧着力での圧着が可能となり、接続の信頼性も高めることができる。
【００３２】
図８は本発明の第４の実施例を示すものであって、第３の実施例と基本的な構成は同一である。異なる点は、端子５Ａ（６Ａ）の導出部分を、接着層９ａが内側となるように折り返して接着した折返部５Ａａを形成し、この部分にハ−ネス２０のリ−ド部２０ａを接続手段２１を用いて圧着・接続したことである。尚、この折返部５Ａａは、図６（ｂ）に示すように、導出部分５Ａを図示矢印の方向に折り返すことによって構成される。そして、接続手段２１のリング部分に延長部４Ａと端子５Ａ（６Ａ）の折返部５Ａａ（６Ａａ）との重ね合わせ部分を挿入すると共に、ハ−ネス２０のリ−ド部２０ａを折返部５Ａａに重ね合わされるようにリング部分に挿入した上で、圧着工具を用いて圧着・接続される。
【００３３】
この実施例によれば、かしめ圧着部分の厚みが、端子５Ａ（６Ａ）の折返部５Ａａと透光性シ−ト４の延長部４Ａとによって上述の各実施例に比較して格段に厚くなり、同部分の強度が一層に補強される。このために、信頼性の高い接続構体が得られる。
【００３４】
図９は本発明の第５の実施例を示すものであって、第１の実施例と基本的な構成は同一である。異なる点は、同図（ｂ）に示すように構成された外部電極５，６を外囲器１の外周面に図示しない接着層を利用して貼着した後に、外囲器１の外周面に一方の面に接着層を有するＰＥＴ樹脂などの透光性シ−ト４０を、外部電極５，６が被覆されるように巻回して接着したことである。
【００３５】
この実施例によれば、上述の各実施例に比較すると、機械化，作業能率の点で劣るものの、ハ−ネスと外部電極５，６との電気的な接続性については同等の改善効果が期待できる。特に、透光性シ−ト４０の巻回に先立って、外囲器１の外周面にシリコ−ンワニスなどの透光性の絶縁被膜を形成しておけば、外部電極間の絶縁耐力を改善できる。尚、この実施例に、第２〜第４の実施例に示す圧着接続構造を適用することもできる。
【００３６】
図１０は本発明の第６の実施例を示すものであって、第５の実施例と基本的な構成は同一である。異なる点は、図９（ｂ）に示すように構成された外部電極５，６を外囲器１の外周面に図示しない接着層を利用して貼着した後に、外囲器１の外周面にＰＥＴ樹脂などの熱収縮性樹脂よりなる保護チュ−ブ５０を、外部電極５，６が被覆されるように装着し、熱収縮したことである。尚、この保護チュ−ブ５０は外囲器１に装着した後、例えば１５０〜２００°Ｃ程度に加熱し、収縮させることにより外囲器１の外周面に密着される。
【００３７】
この実施例によれば、第５の実施例に比較すると、機械化，作業能率の点で若干劣るものの、ハ−ネスと外部電極５，６との電気的な接続性については同等の改善効果が期待できる。特に、透光性シ−ト４０の巻回に先立って、外囲器１の外周面にシリコ−ンワニスなどの透光性の絶縁被膜を形成しておけば、外部電極間の絶縁耐力を改善できる。尚、この実施例に、第１〜第４の実施例に示す圧着接続構造を適用することもできる。
【００３８】
尚、本発明は、何ら上記実施例にのみ制約されることなく、例えば端子は外部電極の幅と同一幅で延在させ、延在部分を延在方向に対して直角方向に２つ折りないし３つ折りにして重ね合わせて構成することもできる。又、ほぼリング状の接続手段は金属部材にて構成することが望ましいが、金属以外の部材にて構成することもできる。さらには、外囲器の端部の外装チュ−ブは省略することも可能である。
【００３９】
【実施例】
次に、実験例について説明する。外径が８ｍｍ，長さが３００ｍｍの鉛ガラスよりなる外囲器に図４に示すシ−ト構体を巻回・密着させる。このシ−ト構体において、透光性シ−トには肉厚が５０μｍのＰＥＴ樹脂を用い、かつそれの外囲器に当接する側の面全体には厚さが２５μｍのシリコ−ン系樹脂接着剤が被着・形成されており、外部電極には肉厚が５０μｍの軟質のアルミニウム箔を用いて長さが２９０ｍｍ，巾が８ｍｍの帯状に形成されており、しかもそれの端部には幅が２．５ｍｍ，突出長さ（延在長さ）が４ｍｍの端子を一体的に形成されている。尚、外部電極の外囲器に当接する側の面全体には厚さが２０μｍのアクリル系樹脂接着剤が形成されている。次に、幅が２ｍｍ，内径が３ｍｍのリング状の圧着端子（接続手段）のリング部分に、シ−ト構体の端子及びハ−ネスのリ−ド部を重ね合わせるように挿入する。尚、この圧着端子は黄銅よりなり、その表面には１〜２μｍの銅下地メッキが形成されており、さらに、その上に３〜５μｍの半田メッキが形成されている。次に、周知の圧着工具を利用して圧着端子を圧着する。これにより、ハ−ネスと端子とは電気的機械的に接続される。然る後、外囲器の端部にポリカ−ボネイト樹脂よりなる外装チュ−ブを、内部に接続部分が配置されるように装着し、内部にエポキシ樹脂を充填し硬化させて希ガス放電灯を製作した。
【００４０】
この希ガス放電灯を、外部電極間にハ−ネスを介して３０ＫＨｚ，２５００Ｖｏ−ｐの高周波高電圧を印加して点灯させた状態において、ハ−ネスに１０Ｋｇの引っ張り力を作用させても点灯状態に何らの変化は認められなかった。又、この希ガス放電灯を周囲温度が６０°Ｃ，相対湿度が９０％の雰囲気に配置し、それぞれの外部電極間に３０ＫＨｚ，２５００Ｖｏ−ｐの高周波高電圧を印加する加速試験を行なったところ、１０００時間を経過するも圧着端子による接続部分には変色など何らの変化も認められなかった。
【００４１】
【発明の効果】
以上のように本発明によれば、端子は外部電極と同一部材にて構成され、かつ外部電極の端部から延在させて形成されているために、端子の形成が容易となり、生産性を改善できる上、製造コストを低減できる。従って、先行技術のように、外部電極の端部に端子を導電性接着剤を用いて接続する必要がなく、かつ硬化のための長い加熱処理作業もないために、生産性を著しく改善できる。
【００４２】
特に、外部電極及び端子を、導電性シ−トからカッタ−によって所定形状に切断して構成すれば、端子を能率的に形成できるのみならず、端子の外部電極に対する位置ずれが発生しないために、ハ−ネスとの接続手段による接続を能率よく遂行できる。
【００４３】
又、端子とハ−ネスとの接続は接続手段のリング部分に端子とハ−ネスとを重ね合わせるように挿入した状態で圧着操作することにより行われるために、接続に要する作業時間を上述の先行技術に比較して大幅に短縮できる。従って、かかる接続に要する工数を最小限に止めることができ、生産性の改善は勿論のこと、コストをも低減できる。
【図面の簡単な説明】
【図１】本発明にかかる希ガス放電灯の第１の実施例を示す側断面図。
【図２】図１の横断面図。
【図３】図１のＵ−Ｕ断面図。
【図４】本発明にかかるシ−ト構体を示す図であって、同図（ａ）は展開状態を示す図、同図（ｂ）は同図（ａ）のＶ−Ｖ断面図。
【図５】本発明にかかる端子とハ−ネスとの接続手段による接続前の分解状態を示す横断面図。
【図６】本発明にかかる希ガス放電灯の第２の実施例を示す図であって、同図（ａ）は端子とハ−ネスとの接続手段による接続状態を示す要部側断面図、同図（ｂ）は接続前の状態を示す側断面図。
【図７】本発明にかかる希ガス放電灯の第３の実施例を示す図であって、同図（ａ）は端子とハ−ネスとの接続手段による接続状態を示す要部側断面図、同図（ｂ）は同図（ａ）の平面図。
【図８】本発明にかかる希ガス放電灯の第４の実施例を示す図であり、端子とハ−ネスとの接続手段による接続状態を示す要部側断面図。
【図９】本発明にかかる希ガス放電灯の第５の実施例を示す図であって、同図（ａ）は縦断面図、同図（ｂ）は同図（ａ）に示す外部電極の平面図。
【図１０】本発明にかかる希ガス放電灯の第６の実施例を示す縦断面図。
【図１１】先行技術にかかる希ガス放電灯の縦断面図。
【図１２】図１１の側面図であって、同図（ａ）は一部破断状態のＷ−Ｗ矢視図、同図（ｂ）は端子の斜視図。
【図１３】図１１のＸ−Ｘ断面図。
【図１４】図１２に示す絶縁キャップの斜視図。
【図１５】先行技術にかかるシ−ト構体の製造方法を説明するための図であって、同図（ａ）はセパレ−タに配置された外部電極に導電性接着剤を被着した状態を示す平面図、同図（ｂ）は導電性接着剤に端子を仮接続した状態を示す平面図。
【図１６】組立状態のシ−ト構体を示す平面図。
【図１７】先行技術にかかるシ−ト構体の外囲器への巻回方法を説明するための縦断面図。
【符号の説明】
１外囲器
２発光層
２ａアパ−チャ部
３シ−ト構体
４，４０透光性シ−ト
４Ａ延長部
５，６外部電極
５Ａ，６Ａ端子
５Ａａ折返部
７第１の開口部
８第２の開口部
９，９ａ接着層
２０ハ−ネス
２０ａリ−ド部
２１接続手段
２２外装チュ−ブ
２３封止部材
５０保護チュ−ブ[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a rare gas discharge lamp, and in particular, a rare gas formed by arranging a pair of strip-shaped external electrodes on the outer peripheral surface of a glass bulb and connecting a wire harness to a terminal having an electrical connection relationship with the external electrodes. The present invention relates to an improvement of a connection structure to a harness terminal in a discharge lamp.
[0002]
[Prior art]
The present applicant has previously proposed, for example, the rare gas discharge lamp shown in FIGS. In FIG. 1, reference numeral 1 denotes a straight tubular envelope that is hermetically sealed by a glass bulb or the like, and has a light emitting layer 2 made of a phosphor such as a rare earth phosphor or a halophosphate phosphor on its inner surface. Is formed. In particular, the light emitting layer 2 is formed with an aperture 2a that does not form the light emitting layer 2 having a predetermined opening angle over almost the entire length. The sealing structure of the envelope 1 is formed by sealing a disc-shaped sealing glass plate at the end of the glass bulb. For example, the glass bulb is simply heated while the glass bulb is heated and melted. It can also be configured. In addition, a rare gas such as xenon (Xe), krypton (Kr), neon (Ne), helium (He), which does not contain a metal vapor such as mercury, is contained in the sealed space of the envelope 1 singly or mixedly. A predetermined amount is enclosed.
[0003]
The sheet structure 3 is wound around the outer peripheral surface of the envelope 1 so as to be in close contact therewith. The sheet structure 3 has, for example, an insulating translucent sheet 4 having a length substantially equal to the entire length of the envelope 1 and a thickness set in a range of 20 to 100 μm. A pair of translucent metal electrodes 5 and 6 made of a translucent metal member adhered to one surface of the translucent sheet 4 at a predetermined distance from each other, and one ends 51a and 61a. Are electrically connected to the end portions of the external electrodes 5 and 6 by the conductive adhesives 52 and 62, and the other ends 51 b and 61 b are led out from the end edge portions of the translucent sheet 4. Terminals 51 and 61, and an adhesive layer 9 having an adhesive or adhesive function applied to one surface of the translucent sheet 4. In the sheet structure 3, an adhesive layer 9 a is formed in advance on the surface of the external electrodes 5, 6 on the side in contact with the envelope 1. The translucent sheet 4 is preferably, for example, a polyethylene terephthalate (PET) resin, but other resins such as a polyester resin can also be used.
[0004]
The above-described sheet structure 3 is mounted (wound) on the outer peripheral surface of the envelope 1 so that the external electrodes 5 and 6 are positioned between the envelope 1 and the translucent sheet 4. Yes. The sheet structure 3 is attached to the envelope 1 by placing the envelope 1 at one end 4a of the light-transmitting sheet 4 in the unfolded sheet structure 3, for example. This is done by relatively moving (rolling) 1 or the sheet structure 3. In the sheet structure 3, the external electrodes 5 and 6 are bonded to the outer peripheral surface of the envelope 1 using an adhesive layer 9a formed on the surface thereof, and the translucent sheet 4 is Adhering to the outer peripheral surface of the envelope 1 at the time of winding using the adhesive layer 9 formed on one surface of each of the first and second ends 4a and 4b is a second opening (8) described later. Overlaid and bonded. In particular, when the sheet structure 3 is attached to the envelope 1, the first opening 7 is provided between the one ends 5 a and 6 a of the external electrodes 5 and 6, and the other ends 5 b and 6 b of the external electrodes 5 and 6. A second opening 8 is formed between each of them, and light from the light emitting layer 2 is emitted to the outside mainly from the first opening 7 through the aperture 2a. The opening angle θ of the first and second openings 7 and 8 ₁ , Θ ₂ Is θ ₁ ≧ θ ₂ However, depending on the application, the reverse relationship can be set.
[0005]
Furthermore, the end face (1a) of the envelope 1 is provided with an insulating cap 10 formed of an insulating member having excellent insulation (pressure resistance) and flame retardancy. The insulating cap 10 is formed of, for example, polycarbonate resin. For example, a block-shaped cap main body 11 and a pair of L-shaped support pieces 12 and 12 integrally formed on a peripheral portion of the cap main body 11. It is composed of In particular, a hole 11a penetrating from the outer surface side to the inner surface side (end surface side of the envelope 1) is formed in the central portion of the cap body 11, and flat side portions 11b and 11b are formed in the outer peripheral portion. The insulating cap 10 is positioned at the end of the envelope 1, the cap body 11 is positioned on the end face side of the envelope 1, and the support pieces 12 and 12 support the outer peripheral surface of the end of the envelope 1. Between the hole 11a and the cap body 11 and the end surface (1a) of the envelope 1, an adhesive 13 excellent in insulation is enriched and solidified. As a result, the insulating cap 10 is fixed (supported) to the envelope 1. In addition, the other end portions 51 b and 61 b of the terminals 51 and 61 led out from the external electrodes 5 and 6 are disposed on the side surface portions 11 b and 11 b of the insulating cap 10 so as to be in close contact with each other. A connection harness (lead wire) 14 for connection to an external circuit is connected to the terminal portions 51b and 61b located on the side surface portions 11b and 11b by soldering or the like.
[0006]
In this rare gas discharge lamp, a high-frequency high voltage (for example, 2500 Vo-p at 30 KHz) is applied to the external electrodes 5 and 6 through terminals 51 and 61 to cause discharge of the rare gas, and light is emitted by the excitation lines of the rare gas. The layer 2 is excited to emit light, and the light is emitted to the outside from the first opening 7 through the aperture 2a. In particular, since no mercury is used in this rare gas discharge lamp, the amount of light rising after lighting is steep, and the amount of light reaches almost 100% simultaneously with lighting. For this reason, it is suitable as a light source for reading originals in office automation equipment such as a facsimile, an image scanner, and a copying machine.
[0007]
[Problems to be solved by the invention]
By the way, this rare gas discharge lamp is manufactured, for example, as shown in FIGS. First, as shown in FIG. 15 (a), for example, the width of the separator 3S having a release function is narrower than that of the separator 3S, for example, and the adhesive layer 9a is provided on the one surface. After the conductive sheets made of long metal members are sequentially stacked and bonded, the conductive sheets are cut into strips by a cutter (not shown), and unnecessary portions are peeled off from the separator 3S. Thus, the external electrodes 5 and 6 are sequentially arranged and formed at a predetermined interval. Epoxy conductive adhesives 52 and 62 containing, for example, nickel powder are attached to the ends of the external electrodes 5 and 6. Next, as shown in FIG. 2B, the terminals 51 and 61 are arranged at the ends of the external electrodes 5 and 6 so that the ends 51a and 61a are placed on the conductive adhesives 52 and 62, respectively. In this state, heat treatment is performed for about 5 hours in a processing furnace in which the furnace temperature is set to 100 ° C., for example. As a result, the conductive adhesives 52 and 62 are cured, and the terminals 51 and 61 are electrically and mechanically connected to the ends of the external electrodes 5 and 6. Next, the outer electrodes 5 and 6 are covered with the translucent sheet 4, the external electrodes 5 and 6 are bonded to the translucent sheet 4, and then the translucent sheet 4 is fixed to the predetermined sheet. The sheet structure 3 is formed as shown in FIG. 16 by cutting to a length of 2 mm and peeling from the separator 3S.
[0008]
Next, as shown in FIG. 17, after the sheet structure 3 is placed on the stage 15, the envelope 1 is placed on one end 4a of the light-transmitting sheet 4 in the sheet structure 3. A pair of rollers 16 and 16 which are positioned so that the longitudinal direction of the external electrodes 5 and 6 is parallel to the longitudinal direction of the external electrodes 5 and 6 and which can be rotated and moved vertically are enveloped. Position it so that it is elastically pressed against the top of 1. In this state, the stage 15 is slightly moved in the arrow direction M. Then, the envelope 1 rotates counterclockwise while being pressed against the rollers 16 and 16, and the rollers 16 and 16 are also rotated in accordance with the rotation of the envelope 1. Thus, one end 4a of the translucent sheet 4 is adhered to a part of the outer peripheral surface of the envelope 1 in a close contact state. Thereafter, when the stage 15 is moved in the arrow direction N, the envelope 1 rotates clockwise while being elastically pressed against the rollers 16 and 16, and the rollers 16 and 16 are also rotated. It rotates following the rotation of the envelope 1. At this time, the translucent sheet 4 of the sheet structure 3 starts to be wound around the outer peripheral surface in accordance with the rotation of the envelope 1, starting from the one end 4a already bonded to the envelope 1. . Then, when the envelope 1 rotates, for example, about 390 ° (approximately one rotation), a translucent sheet 4 is wound around the outer peripheral surface of the envelope 1 as shown in FIG. The other end 4 b is overlapped with the one end 4 a and bonded by the adhesive layer 9.
[0009]
However, in the manufacturing process of the noble gas discharge lamp according to this proposal, the connection of the terminals 51 and 61 to the external electrodes 5 and 6 is made of paste-like conductive material applied and applied to the end portions of the external electrodes 5 and 6. The conductive adhesives 52 and 62 are manufactured by pressing the ends 51a and 61a of the terminals 51 and 61 against the conductive adhesives 52 and 62, but the conductive adhesives 52 and 62 are manufactured because they take many hours to cure. There is a problem that time is increased and productivity is impaired.
[0010]
In addition, in the temporary connection state in which the terminals 51 and 61 are slightly pressed against the conductive adhesives 52 and 62, the positional relationship of the terminals 51 and 61 with respect to the external electrodes 5 and 6 is shifted due to the application of a single external force. In addition, external force does not act on the terminals 51 and 61 until the conductive adhesives 52 and 62 are completely cured and the terminals 51 and 61 and the external electrodes 5 and 6 are securely and electrically connected. You must consider it. Therefore, since the work becomes complicated, a great number of man-hours are required, and the manufacturing cost increases.
[0011]
In particular, when a heat treatment for accelerating the curing of the conductive adhesives 52 and 62 is performed in a state where the sheet structure 3 is wound, the external electrodes 5 are connected to the terminals 51 and 61 even if extreme care is taken. 6, it becomes difficult to attach the insulating cap 10 to the end of the envelope 1, and other than the terminals 51 and 61 at predetermined portions of the side surfaces 11 b and 11 b of the insulating cap 10. The ends 51b and 61b are no longer positioned, making it difficult to solder the harness 14. Therefore, there is a problem that the manufacturing yield is lowered.
[0012]
SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a rare gas discharge lamp that can improve the electrical connectivity between the harness and the external electrode with a simple configuration and can also reduce the manufacturing cost. .
[0013]
[Means for Solving the Problems]
Therefore, in order to achieve the above-mentioned object, the present invention provides a straight tubular envelope having a light emitting layer on the inner surface, and a metal disposed on the outer peripheral surface of the envelope so as to be spaced substantially over the entire length thereof. A pair of strip-shaped external electrodes made of a member; each From the end of the external electrode External electrode part Derived from the outside in the longitudinal direction Formed The terminal and the outer peripheral surface of the envelope were mounted so that the external electrode was covered , Composed of translucent sheet An insulating member, A part of the translucent sheet was extended and superimposed on each terminal, and the harness was electrically and mechanically connected by a connecting means using crimping. It is characterized by that.
[0014]
According to a second aspect of the present invention, there is provided a metal member on one surface of a straight tubular envelope having a light emitting layer on the inner surface and a translucent sheet having substantially the same length as the entire length of the envelope. A pair of strip-shaped external electrodes formed separately from each other, and each Deriving the external electrode part outward from the end of the external electrode to form a terminal, A part of the translucent sheet is extended and superposed on each terminal. A sheet structure is wound around the outer peripheral surface of the envelope so that an external electrode is positioned between the envelope and the translucent sheet, and each terminal of the sheet structure is wound. The harness is electrically and mechanically connected by connection means using crimping.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
Next, a first embodiment of a rare gas discharge lamp according to the present invention will be described with reference to FIGS. The same parts as those of the prior art shown in FIGS. 11 to 17 are denoted by the same reference numerals, and detailed description thereof is omitted. The characteristic part of this embodiment is that the lead portions 20a of the harnesses 20 and 20 are formed on the terminals 5A and 6A formed by extending the end portions of the external electrodes 5 and 6 substantially outward in the longitudinal direction. 20a is electrically and mechanically connected by connecting means 21 and 21 using crimping.
[0018]
Specifically, a pair of strip-like external electrodes 5 and 6 made of a metal member are separated from each other on one surface of a translucent sheet 4 having a length substantially the same as the entire length of the envelope 1. The sheet structure 3 is disposed on the outer peripheral surface of the envelope, and the sheet structure 3 formed by extending the external electrode portion outwardly from the ends of the external electrodes 5 and 6 to form the terminals 5A and 6A. The outer electrodes 5 and 6 are wound between the envelope 1 and the translucent sheet 4 and the harnesses 20 and 20 are wound around the terminals 5A and 6A of the sheet structure 3. That is, the connecting portions 20a and 20a are electrically and mechanically connected by connecting means 21 and 21 using crimping.
[0019]
The external electrodes 5 and 6 and the terminals 5A and 6A described above are made of the same member, for example, an aluminum foil, and the thickness thereof is set in a range of approximately 10 to 100 μm. For example, when the aluminum foil is hard, the thickness is recommended to be set in the range of 10 to 50 μm, and when the aluminum foil is soft, the thickness is recommended to be set in the range of 30 to 100 μm. Here, the aluminum foil and its hard and soft are generally described as follows. That is, in Japan, the aluminum foil defines a thickness range of 6 to 200 μm as an aluminum foil based on JIS-H-4160. Further, the hardness and softness of the aluminum foil are classified according to the presence or absence of heat treatment, and those that remain in the rolled state are called hard foils and those that are annealed after rolling are called soft foils.
[0020]
In particular, the widths of the lead-out portions of the terminals 5A and 6A are narrower than the widths of the external electrodes 5 and 6, and the lead portions 20a and 20a of the harnesses 20 and 20 have ends in the lead-out portions. It is connected by crimping using the substantially ring-shaped connecting means 21, 21 including. The connecting means 21 and 21 are configured by ring-shaped crimp terminals made of a metal member such as brass, nickel, and stainless steel, and the terminals 5A (or 6A) and the leads 20 of the harness 20 are provided in the ring portion. In a state where the portions 20a are overlapped and positioned, they are electrically and mechanically connected by a known crimping tool. The ring portion of the connecting means (crimp terminal) 21 may be an endless ring having a slight gap in addition to the endless ring.
[0021]
The connecting portions between the terminals 5A and 6A and the harnesses 20 and 20 are packaged as follows, for example. That is, at the end of the envelope 1, a cylindrical outer tube 22 having an insulating property such as a resin material, a rubber material, a ceramic material, etc. is connected to the terminals 5A and 6A and the harnesses 20 and 20, respectively. Is attached so as to surround the connecting portion, and the inside thereof is filled with a sealing member 23 such as an epoxy resin or a silicone resin. The outer tube 22 is preferably made of a resin material having a slight flexibility or elasticity.
[0022]
Next, a method for manufacturing the rare gas discharge lamp will be described with reference to FIGS. First, for example, the width of the long separator (3S) as shown in FIG. 15 (a) having a releasing function is narrower than that of the separator, for example, and the adhesive layer 9a is provided on the one surface. After the conductive sheets made of long metal members are stacked and bonded in order, the conductive sheets are cut into a shape as shown in FIG. By stripping and removing these parts from the separator, the external electrodes 5 and 6 and the terminals 5A and 6A are integrally arranged and formed in order at a predetermined interval. Next, the long light-transmitting sheet (4) having the adhesive layer 9 on the long separator is covered with the external electrodes 5 and 6, and the lead-out portions of the terminals 5A and 6A are exposed. Overlap and bond as shown. Thereafter, the light-transmitting sheet (4) is cut to a predetermined length and peeled off from the separator to obtain the sheet structure 3 shown in FIG. 4 (a). For example, based on the method shown in FIG. 17, the sheet structure 3 is wound around the outer peripheral surface of the envelope 1 as shown in FIG. 3, and the other end is connected to one end 4 a of the translucent sheet 4. 4 b are superposed and bonded by the adhesive layer 9.
[0023]
Next, as shown in FIG.
The long translucent sheet (4) having the adhesive layer 9 on the long separator is covered with the external electrodes 5 and 6 and the lead-out portions of the terminals 5A and 6A are exposed. Glue to each other. Thereafter, the light-transmitting sheet (4) is cut to a predetermined length and peeled off from the separator to obtain the sheet structure 3 shown in FIG. 4 (a). For example, based on the method shown in FIG. 17, the sheet structure 3 is wound around the outer peripheral surface of the envelope 1 as shown in FIG. 3, and the other end is connected to one end 4 a of the translucent sheet 4. 4 b are superposed and bonded by the adhesive layer 9.
[0024]
Next, as shown in FIG. 5, the crimp terminal 21 and the harness 20 which are connecting means are arranged at the tip of the terminal 5 </ b> A (6 </ b> A) extending to the end face side of the envelope 1. Then, the terminal 5A is inserted into the ring portion of the crimp terminal 21, and the lead portion 20a of the harness 20 is inserted into the ring portion so as to overlap the terminal 5A. In this state, by crimping the crimp terminal 21 using a known crimp tool (not shown), the terminal 5A and the lead portion 20a of the harness 20 are crimped and connected, and the connection shown in FIG. A state is obtained. Next, the outer tube 22 is attached to the end of the envelope 1 so that the connecting portion between the terminal 5A and the lead portion 20a of the harness 20 is located inside, and the sealing member is provided inside. By filling and curing 23, a rare gas discharge lamp is completed.
[0025]
According to this embodiment, since the terminals 5A and 6A are made of the same member as the external electrodes 5 and 6 and are formed to extend from the ends of the external electrodes 5 and 6, the terminals are not formed. It becomes easy and productivity can be improved and manufacturing cost can be reduced. In particular, when the conductive sheet is cut into a predetermined shape by a cutter, the terminals 5A and 6A are not displaced at all with respect to the external electrodes 5 and 6, so that the connection means 21 to the harness 20 is used. Connection can be carried out efficiently. That is, unlike the prior art described above, it is not necessary to connect the terminals 51 and 61 to the ends of the external electrodes 5 and 6 using the conductive adhesives 52 and 62, and a long heat treatment operation for curing is also required. Therefore, productivity can be significantly improved.
[0026]
Further, the connection between the terminals 5A, 6A and the harness 20 is performed by crimping the terminals 5A, 6A and the harness 20 in a state where the terminals 5A, 6A and the harness 20 are overlapped with each other in the ring portion of the connecting means 21 made of a crimp terminal. Since the connection is possible, the work time required for the connection can be greatly reduced as compared with the above-described prior art. Therefore, the number of man-hours required for such connection can be minimized, and the cost can be reduced as well as improving the productivity.
[0027]
Furthermore, since the connection portion between the terminals 5A, 6A and the harness 20 is surrounded and supported by the sealing member 23 filled in the outer tube 22, the terminal 5A is interposed via the harness 20. , 6A, even if a pulling force is applied, the cutting of the terminals 5A, 6A can be reduced or suppressed.
[0028]
FIG. 6 shows a second embodiment of the present invention, and the basic configuration is the same as that of the first embodiment. The difference is that the lead-out portion 5Aa (6Aa) is formed by folding the lead-out portion of the terminal 5A (6A) so that the adhesive layer 9a is inside, and the lead portion 20a of the harness 20 is formed in this portion. Is crimped and connected using the connecting means 21. The folded portion 5Aa is configured by folding the lead-out portion 5A in the direction of the arrow as shown in FIG.
[0029]
According to this embodiment, since the thickness of the terminal 5A of the crimped crimping portion is doubled, it is possible to effectively prevent the terminal 5A from being cut off from the folded portion 5Aa when crimping by the connecting means 21. Paradoxically, since the strength of the lead-out portion is improved by the formation of the folded portion 5Aa, the crimping strength can be increased, so that the reliability of the connection between the harness 20 and the terminal 5A by the crimping can be further increased. it can.
[0030]
FIG. 7 shows a third embodiment of the present invention, and the basic configuration is the same as that of the first embodiment. The difference is that the extended portion 4A of the translucent sheet 4 is superimposed on the lead-out portion of the terminal 5A (6A). The extending portion 4A extends outward from the end of the light-transmitting sheet 4 with a width substantially equal to that of the terminal 5A (6A). Then, an overlapping portion of the extension portion 4A and the terminal 5A (6A) is inserted into the ring portion of the connecting means 21, and the lead portion 20a of the harness 20 is overlapped with the terminal 5A (6A). After inserting into the ring part, it is crimped and connected using a crimping tool. Prior to crimping, it is desirable to remove the adhesive layer 9a at the terminal portion with which the harness 20 is in contact in advance in order to improve the reliability of electrical connection.
[0031]
According to this embodiment, although the thickness of the terminal 5A (6A) at the crimping connection portion is as thin as 10 to 100 μm, for example, the extension portion 4A of the translucent sheet 4 is superimposed on the outer surface side. The strength thereof is reinforced, and the disconnection from the terminal 5A can be effectively prevented when the connecting means 21 is crimped. In particular, if the thickness of the translucent sheet 4 is set to a thick region even in the range of 20 to 100 μm, for example, the reinforcing effect on the terminal 5A (6A) is improved, and crimping with sufficient crimping force becomes possible. In addition, the reliability of the connection can be improved.
[0032]
FIG. 8 shows a fourth embodiment of the present invention, and the basic configuration is the same as that of the third embodiment. The difference is that the lead-out portion 5Aa is formed by folding the lead-out portion of the terminal 5A (6A) so that the adhesive layer 9a is on the inside, and the lead portion 20a of the harness 20 is connected to this portion. 21 is crimped and connected. In addition, this folding | returning part 5Aa is comprised by folding the derivation | leading-out part 5A in the direction of the arrow shown in figure as shown in FIG.6 (b). Then, an overlapping portion of the extended portion 4A and the folded portion 5Aa (6Aa) of the terminal 5A (6A) is inserted into the ring portion of the connecting means 21, and the lead portion 20a of the harness 20 is inserted into the folded portion 5Aa. After being inserted into the ring portion so as to be overlapped, they are crimped and connected using a crimping tool.
[0033]
According to this embodiment, the thickness of the crimped crimping portion is much thicker than the above-described embodiments due to the folded portion 5Aa of the terminal 5A (6A) and the extension portion 4A of the translucent sheet 4. The strength of the same part is further reinforced. For this reason, a highly reliable connection structure is obtained.
[0034]
FIG. 9 shows a fifth embodiment of the present invention, and the basic configuration is the same as that of the first embodiment. The difference is that after the external electrodes 5 and 6 configured as shown in FIG. 5B are attached to the outer peripheral surface of the envelope 1 using an adhesive layer (not shown), the outer peripheral surface of the envelope 1 In other words, a translucent sheet 40 such as a PET resin having an adhesive layer on one surface is wound and adhered so that the external electrodes 5 and 6 are covered.
[0035]
According to this embodiment, compared with the above-described embodiments, although it is inferior in mechanization and work efficiency, the same improvement effect is expected with respect to the electrical connectivity between the harness and the external electrodes 5 and 6. it can. In particular, if a translucent insulating film such as a silicone varnish is formed on the outer peripheral surface of the envelope 1 prior to winding the translucent sheet 40, the dielectric strength between the external electrodes is improved. it can. The crimp connection structure shown in the second to fourth embodiments can also be applied to this embodiment.
[0036]
FIG. 10 shows a sixth embodiment of the present invention, and the basic configuration is the same as that of the fifth embodiment. The difference is that the outer electrodes 5 and 6 configured as shown in FIG. 9B are attached to the outer peripheral surface of the envelope 1 using an adhesive layer (not shown), and then the outer peripheral surface of the envelope 1. And a protective tube 50 made of a heat-shrinkable resin such as PET resin was attached so that the external electrodes 5 and 6 were covered, and heat-shrinked. After the protective tube 50 is mounted on the envelope 1, it is brought into close contact with the outer peripheral surface of the envelope 1 by being heated to, for example, about 150 to 200 ° C. and contracted.
[0037]
According to this embodiment, compared with the fifth embodiment, although it is slightly inferior in mechanization and work efficiency, the same improvement effect is obtained with respect to the electrical connectivity between the harness and the external electrodes 5 and 6. I can expect. In particular, if a translucent insulating film such as a silicone varnish is formed on the outer peripheral surface of the envelope 1 prior to winding the translucent sheet 40, the dielectric strength between the external electrodes is improved. it can. The crimp connection structure shown in the first to fourth embodiments can also be applied to this embodiment.
[0038]
The present invention is not limited to the above-described embodiment. For example, the terminal extends with the same width as that of the external electrode, and the extending portion is folded in a direction perpendicular to the extending direction. It is also possible to fold and superimpose. Further, it is desirable that the substantially ring-shaped connecting means is constituted by a metal member, but it can also be constituted by a member other than metal. Further, the outer tube at the end of the envelope can be omitted.
[0039]
【Example】
Next, experimental examples will be described. The sheet structure shown in FIG. 4 is wound and adhered to an envelope made of lead glass having an outer diameter of 8 mm and a length of 300 mm. In this sheet structure, a PET resin having a thickness of 50 .mu.m is used for the translucent sheet, and a silicone resin having a thickness of 25 .mu.m is formed on the entire surface in contact with the envelope. Adhesive is applied and formed, and the outer electrode is formed into a strip of 290 mm long and 8 mm wide using a soft aluminum foil with a thickness of 50 μm, and at the end of it A terminal having a width of 2.5 mm and a protruding length (extended length) of 4 mm is integrally formed. An acrylic resin adhesive having a thickness of 20 μm is formed on the entire surface of the external electrode on the side in contact with the envelope. Next, the terminal of the sheet structure and the lead portion of the harness are inserted so as to overlap with the ring portion of the ring-shaped crimp terminal (connecting means) having a width of 2 mm and an inner diameter of 3 mm. The crimp terminal is made of brass, and has a 1-2 μm copper base plating formed on the surface thereof, and further, a 3-5 μm solder plating is formed thereon. Next, the crimp terminal is crimped using a known crimping tool. Thereby, the harness and the terminal are electrically and mechanically connected. After that, an outer tube made of polycarbonate resin is attached to the end of the envelope so that the connecting portion is arranged inside, and the inside is filled with epoxy resin and cured, so that the rare gas discharge lamp Was made.
[0040]
This rare gas discharge lamp is lit even when a 10 Kg tensile force is applied to the harness in a state in which a high frequency high voltage of 30 KHz and 2500 Vo-p is applied between the external electrodes via the harness. No change in state was observed. This rare gas discharge lamp was placed in an atmosphere with an ambient temperature of 60 ° C. and a relative humidity of 90%, and an acceleration test was performed in which a high frequency high voltage of 30 KHz and 2500 Vo-p was applied between each external electrode. After 1000 hours, no change such as discoloration was observed in the connection portion by the crimp terminal.
[0041]
【The invention's effect】
As described above, according to the present invention, since the terminal is formed of the same member as the external electrode and is formed to extend from the end portion of the external electrode, it is easy to form the terminal and increase productivity. In addition to improvement, manufacturing costs can be reduced. Therefore, unlike the prior art, it is not necessary to connect the terminal to the end portion of the external electrode using a conductive adhesive, and there is no long heat treatment work for curing, so that productivity can be remarkably improved.
[0042]
In particular, if the external electrode and the terminal are cut into a predetermined shape from the conductive sheet with a cutter, not only can the terminal be formed efficiently, but also the positional displacement of the terminal with respect to the external electrode does not occur. The connection with the harness can be efficiently performed.
[0043]
In addition, since the connection between the terminal and the harness is performed by performing a crimping operation in a state where the terminal and the harness are inserted so as to overlap each other on the ring portion of the connection means, the work time required for the connection is reduced as described above. Compared to the prior art, it can be greatly shortened. Therefore, the number of man-hours required for such connection can be minimized, and the cost can be reduced as well as improving the productivity.
[Brief description of the drawings]
FIG. 1 is a side sectional view showing a first embodiment of a rare gas discharge lamp according to the present invention.
FIG. 2 is a cross-sectional view of FIG.
3 is a cross-sectional view taken along the line U-U in FIG.
4A and 4B are views showing a sheet structure according to the present invention, in which FIG. 4A is a diagram showing an unfolded state, and FIG. 4B is a cross-sectional view taken along line VV in FIG.
FIG. 5 is a cross-sectional view showing an exploded state before connection by the terminal and harness connection means according to the present invention.
FIG. 6 is a view showing a second embodiment of the rare gas discharge lamp according to the present invention, in which FIG. 6 (a) is a sectional side view of the main part showing the connection state between the terminal and the harness. FIG. 4B is a side sectional view showing a state before connection.
FIG. 7 is a view showing a third embodiment of the rare gas discharge lamp according to the present invention, in which FIG. 7 (a) is a cross-sectional side view of a main part showing a connection state between the terminal and the harness. FIG. 4B is a plan view of FIG.
FIG. 8 is a view showing a fourth embodiment of the rare gas discharge lamp according to the present invention, and is a cross-sectional side view of a main part showing a connection state between the terminal and the harness.
9A and 9B are diagrams showing a fifth embodiment of the rare gas discharge lamp according to the present invention, in which FIG. 9A is a longitudinal sectional view, and FIG. 9B is an external electrode shown in FIG. FIG.
FIG. 10 is a longitudinal sectional view showing a sixth embodiment of the rare gas discharge lamp according to the present invention.
FIG. 11 is a longitudinal sectional view of a rare gas discharge lamp according to the prior art.
12A and 11B are side views of FIG. 11, in which FIG. 11A is a partially broken WW arrow view, and FIG. 12B is a perspective view of a terminal.
13 is a sectional view taken along line XX in FIG.
14 is a perspective view of the insulating cap shown in FIG. 12. FIG.
FIG. 15 is a view for explaining a method for manufacturing a sheet structure according to the prior art, in which FIG. FIG. 2B is a plan view showing a state where a terminal is temporarily connected to a conductive adhesive.
FIG. 16 is a plan view showing the seat structure in an assembled state.
FIG. 17 is a longitudinal sectional view for explaining a method of winding a sheet structure around an envelope according to the prior art.
[Explanation of symbols]
1 Envelope
2 Light emitting layer
2a Aperture part
3 Sheet structure
4,40 Translucent sheet
4A extension
5,6 External electrode
5A, 6A terminals
5Aa Turnaround
7 First opening
8 Second opening
9, 9a Adhesive layer
20 Harness
20a lead part
21 Connection means
22 Exterior tube
23 Sealing member
50 Protective tube

Claims

A straight tubular envelope having a light emitting layer on its inner surface;
A pair of strip-shaped external electrodes made of a metal member arranged on the outer peripheral surface of the envelope so as to be spaced substantially over its entire length;
A terminal formed by leading the external electrode portion outward in the longitudinal direction from the end of each external electrode;
The outer peripheral surface of the envelope is equipped with an insulating member composed of a translucent sheet, mounted so that the external electrode is covered,
A rare gas discharge lamp , wherein a part of the translucent sheet is extended and superposed on each terminal, and a harness is electrically and mechanically connected by a connecting means using crimping .

A straight tubular envelope having a light emitting layer on its inner surface;
A pair of external electrodes of the strip made of a metal member spaced apart from one another and arranged on one surface of the light transmissive sheet having a total length substantially similar length of the envelope, and from the end of each external electrode The external electrode portion is led outward to form terminals, and a sheet structure formed by extending a part of the translucent sheet and overlapping each terminal is provided,
The sheet structure is wound around the outer peripheral surface of the envelope so that the external electrode is positioned between the envelope and the translucent sheet, and a harness is used for each terminal of the sheet structure, and crimping is used. A rare gas discharge lamp characterized by being electrically and mechanically connected by connecting means.