JP3893719B2

JP3893719B2 - Noble gas discharge lamp

Info

Publication number: JP3893719B2
Application number: JP03754198A
Authority: JP
Inventors: 真一堀田
Original assignee: Ushio Denki KK
Current assignee: Ushio Denki KK
Priority date: 1998-02-19
Filing date: 1998-02-19
Publication date: 2007-03-14
Anticipated expiration: 2018-02-19
Also published as: JPH11233070A

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、特にガラスバルブよりなる外囲器の外周面に一対の帯状の外部電極を配置すると共に、外囲器の端部から外部電極に対して電気的な接続関係を有するハ−ネスを導出してなる希ガス放電灯において、ハ−ネスの導出部分の保護構造の改良に関する。
【０００２】
【従来の技術】
従来のこの種の希ガス放電灯は、例えば図１３〜図１４に示すように、ランプ主体ＤＬの端部に絶縁性のキャップＨ，Ｈを装着して構成されている。即ち、ランプ主体ＤＬにおいて、Ａ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Ｂが形成されている。この発光層Ｂには所定の開口角を有する発光層Ｂを形成しないアパ−チャ部Ｂａがほぼ全長に亘って形成されている。そして、外囲器Ａ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Ａ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。この外囲器Ａの外周面には不透光性の金属部材よりなる帯状の一対の外部電極Ｃ，Ｄが互いに所定の間隔だけ離隔して配置（接着）されており、さらに、それらの外周面は、例えば熱収縮性樹脂よりなる保護チュ−ブＥにて被覆されている。又、外部電極Ｃ，Ｄの端部には予め端子Ｆ，Ｆが接続されており、その導出端には外部回路との接続用ハ−ネスＧ，Ｇが接続されている。一方、ランプ主体ＤＬの端部には絶縁性のキャップＨ，Ｈが、アパ−チャ部ＢａとキャップＨ，Ｈの取付耳Ｈｂ，Ｈｂとが所定の位置関係となるように装着されている。そして、キャップＨ，Ｈの内部空間Ｈａ，Ｈａにはエポキシ樹脂などの熱硬化性樹脂Ｊが注入・硬化されており、これによりランプ主体ＤＬとキャップＨとが固定される。
【０００３】
この希ガス放電灯は、ハ−ネスＧを介して外部電極Ｃ，Ｄに高周波高電圧（例えば２５ＫＨｚ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Ｂが励起されて発光するものであり、光はアパ−チャ部Ｂａから外部電極Ｃ，Ｄの端部間の開口部を経て外部に放出される。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。
【０００４】
【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、例えば次のように製造される。まず、外部電極Ｃ，Ｄの端部に端子Ｆ，Ｆを、導電性接着剤を用いて接続した後に、この外部電極Ｃ，Ｄを外囲器Ａの外周面に、互いに所定の間隔だけ離隔して配置し接着する。さらに、外囲器Ａの外周面に熱収縮性樹脂よりなる保護チュ−ブＥを、外部電極Ｃ，Ｄが被覆されるように装着し加熱処理することにより、保護チュ−ブＥは外囲器Ａ及び外部電極Ｃ，Ｄに密着されてランプ主体ＤＬが完成する。次に、ランプ主体ＤＬの端子Ｆ，Ｆにハ−ネスＧの一端を半田付けなどにより電気的に接続する。次に、ランプ主体ＤＬの端部にキャップＨを、内部空間Ｈａに外囲器Ａの端部及び端子Ｆとハ−ネスＧとの接続部が内包されるように配置する。次に、キャップＨの内部空間Ｈａにエポキシ樹脂Ｊを注入し、ランプ主体ＤＬの端部とキャップＨとの空間部を充実させる。然る後、この仮組立体を、温度が１２０°Ｃ程度にコントロ−ルされた加熱炉に５分間放置すると共に、その後、さらに６０〜８０°Ｃで２時間放置する。これにより、エポキシ樹脂Ｊは熱硬化され、ランプ主体ＤＬの端部とキャップＨとは強固に結合される。
【０００５】
しかしながら、キャップＨの内部空間Ｈａへのエポキシ樹脂Ｊの注入工程では、ハ−ネスＧが外囲器Ａの端部からキャップＨの外壁部分の一部に形成したハ−ネス挿通孔を介して外部に導出されているために、ハ−ネスＧとハ−ネス挿通孔との間には比較的に大きな隙間が形成されており、この隙間からエポキシ樹脂Ｊが漏れ、キャップＨの内部に部分的に空洞部が形成されることがある。特に、空洞部が大きい場合には充電部間（例えば端子間）で絶縁破壊が生ずる恐れがあるのみならず、ハ−ネスＧに作用する引張力が大きくなると、ハ−ネスＧと端子Ｆとの接続部に接続はずれが生じたり、外囲器Ａとの接続強度が低下したりするという問題が惹起され易くなる。
【０００６】
それ故に、本発明の目的は、外囲器の端部からのハ−ネスの導出部分を簡易的に保護できる上、ハ−ネスに外力が作用しても電気的な接続部分への影響を軽減できる希ガス放電灯を提供することにある。
【０００７】
【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互いに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、外部電極と電気的な接続関係を有し、かつそれの端部から導出した端子と、端子の導出部分と透光性シートの延長部との重ね合わせ部分と、端子と電気的な接続関係を有するハ−ネスと、重ね合わせ部分とハーネスのリード部を圧着を利用して電気的機械的に接続する接続手段と、ハ−ネスの導出側の外囲器の端部に、ハ−ネスと端子との接続部分が内部に位置するように配置した絶縁性を有する筒状部材と、筒状部材の内部空間に、ハ−ネスと端子との接続部分が埋没するように充実した絶縁性に優れた保護部材とを具備したことを特徴とする。
【０００８】
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、外囲器の外周面に、それのほぼ全長に亘って互いに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、外部電極と電気的な接続関係を有し、かつそれの端部から導出した端子と、端子の導出部分を折り返して接着した折返部と、端子と電気的な接続関係を有するハ−ネスと、折返し部とハーネスのリード部を圧着を利用して電気的機械的に接続する接続手段と、ハ−ネスの導出側の外囲器の端部に、ハ−ネスと端子との接続部分が内部に位置するように配置した絶縁性を有する筒状部材と、筒状部材の内部空間に、ハ−ネスと端子との接続部分が埋没するように充実した絶縁性に優れた保護部材とを具備したことを特徴とする。
【００１１】
【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。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。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１ａ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。
【００１２】
この外囲器１の外周面にはシ−ト構体３が装着（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を形成して構成されている。外囲器１の外周面にシ−ト構体３が装着された状態において、外部電極５，６の一方の端部間には第１の開口部７が、他方の端部間には第２の開口部８が形成されており、発光層２からの光は主としてアパ−チャ部２ａから第１の開口部７を介して外部に放出される。尚、シ−ト構体３において、透光性シ−ト４及び外部電極５，６の一方の面には接着層９及び接着層９ａが形成されており、外部電極５，６は透光性シ−ト４に接着層９を利用して接着されている。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、外部電極５，６としては例えばアルミニウム箔が好適するが、他の部材を適用することもできる。
【００１３】
又、外部電極５，６の端部から延在して形成された端子５Ａ，６Ａにはハ−ネス１０のリ−ド部１０ａが接続手段１１，１１によって電気的機械的に接続されている。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１０，１０のリ−ド部１０ａ，１０ａを、圧着を利用した接続手段１１，１１によって電気的機械的に接続されている。
【００１４】
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、ＪＩＳＨ４１６０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。
【００１５】
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１０，１０のリ−ド部１０ａ，１０ａが有端を含むほぼリング状の接続手段１１，１１を用いて圧着により接続されている。この接続手段１１，１１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１０のリ−ド部１０ａを重ね合わせた状態で、周知の圧着工具によってリング部分を押し潰すことにより外部電極５，６の端子５Ａ，６Ａとハ−ネス１０のリ−ド部１０ａとが圧着端子１１を介して電気的機械的に接続される。尚、接続手段（圧着端子）１１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。
【００１６】
上述の端子５Ａ，６Ａとハ−ネス１０，１０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部材（外装チュ−ブ）１２が、端子５Ａ，６Ａとハ−ネス１０，１０との接続部分を囲繞するように装着されており、その内部にはシリコ−ン樹脂などの熱硬化性樹脂，ゴム系部材などのように絶縁性に優れた保護部材１３が充填されている。この保護部材１３としては、硬化後の状態において、ＪＩＳＫ７５１５−１９８６「プラスチックのデュロメ−タ硬さ試験方法」に準拠するデュロメ−タＤ硬さが８０以下、好ましくは８０〜３０の範囲に設定されたものが推奨される。尚、外装チュ−ブ１２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く、例えばポリカ−ボネイト樹脂が推奨される。
【００１７】
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、図４（ａ），（ｂ）に示すように、例えば一方の面に接着層９を有する透光性シ−ト４に一方の面に接着層９ａを有する長尺状の金属部材よりなる外部電極５，６を、外部電極５，６に一体的に形成された端子５Ａ，６Ａが透光性シ−ト４の端部から突出するように重ね合わせて接着することによりシ−ト構体３を製造する。次に、外囲器１をシ−ト構体３における透光性シ−ト４の一端４ａに配置し、他端４ｂに向けて相対的に転動させることにより、外囲器１の外周面にはシ−ト構体３が、透光性シ−ト４によって外部電極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巻回されると共に、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（図３を参照）。
【００１８】
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１１及びハ−ネス１０を配置する。そして、圧着端子１１のリング部分に端子５Ａを挿入すると共に、ハ−ネス１０のリ−ド部１０ａ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１１を圧着することにより、端子５Ａとハ−ネス１０のリ−ド部１０ａ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１２を、内部に端子５Ａとハ−ネス１０のリ−ド部１０ａとの接続部分が位置するように装着し、内部に保護部材１３を充填・硬化させることにより、希ガス放電灯が完成する。
【００１９】
この実施例によれば、外囲器１の端部には外装チュ−ブ１２が、その一端が外囲器１に嵌合するような状態で装着されている関係で、ハ−ネス１０が導出される側の開口部以外には隙間などは形成されない。このために、開口部から充填された保護部材１３の外装チュ−ブ１２からの漏出を皆無にできる上、充填された保護部材１３の内部に空洞部が形成されることも防止できる。従って、保護部材１３と外囲器１の端面部分との結合強度を改善できる上、空洞部に起因する端子間での絶縁破壊の発生を抑制できる。
【００２０】
その上、保護部材１３の内部には空洞部が形成されにくいことから、保護部材１３に埋没されるように位置するハ−ネス１０と端子５Ａ，６Ａとの接続部分の周辺は保護部材１３によってほぼ緻密に充実される。従って、仮にハ−ネス１０に外力（例えば引張力）が作用しても、ハ−ネス１０と端子５Ａ，６Ａとの接続部分は保護部材１３によって確実に支持される結果、接続はずれ，端子切れなどを抑制できる。
【００２１】
又、外囲器１の端部に装着された外装チュ−ブ１２の他方の端部には開口部のみが存在しており、この開口部からはハ−ネス１０が導出されていることから、外装チュ−ブ１２の内部空間への保護部材１３の充填は外囲器１を、外装チュ−ブ１２の他端の開口部が上側となるようにほぼ直立に支持した状態で行うことができる。従って、保護部材１３の外装チュ−ブ１２への充填作業を単純化できるのみならず、保護部材１３の外装チュ−ブ１２への充填によってハ−ネス１０と端子５Ａ，６Ａとの接続部分の支持や絶縁保護を同時に行うことができ、作業能率を改善できる。
【００２２】
特に、保護部材１３のデュロメ−タＤ硬さを８０以下、好ましくは８０〜３０の範囲に設定すれば、製造時及び使用時において、仮に外囲器１を構成するガラスバルブと保護部材１３との接触界面に不所望な応力が作用したとしても、かなりの部分が保護部材１３に吸収される。従って、保護部材１３としてシリコ−ン樹脂などの熱硬化性樹脂を用いた場合、それの熱硬化時に外囲器端面との接触界面に不所望な応力が作用したとしても、その応力が保護部材１３に吸収されるし、又、使用時に大きな温度差の生ずるようなモ−ドで作動させた場合などに不所望な応力が作用したとしても、保護部材１３に吸収されることから、外囲器端面に生ずるクラック破損を抑制でき、品位の高い製品を得ることができる。
【００２３】
しかも、保護部材１３のデュロメ−タＤ硬さを上述の範囲に設定すれば、ハ−ネス１０を介して端子５Ａ，６Ａとハ−ネス１０との接続部分に外力が作用しても、端子５Ａ，６Ａの切断を一層に軽減することができる。
【００２４】
さらには、外部電極５，６から延在して形成された端子５Ａ，６Ａとハ−ネス１０との接続は圧着端子よりなる接続手段１１のリング部分に端子５Ａ，６Ａとハ−ネス１０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、接続作業性を大幅に改善できる上、コストをも低減できる。
【００２５】
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１０のリ−ド部１０ａを接続手段１１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。
【００２６】
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１１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１０と端子５Ａとの接続の信頼性を一層高めることができる。
【００２７】
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とほぼ同程度の幅で延長されている。そして、接続手段１１のリング部分に延長部４Ａと端子５Ａとの重ね合わせ部分を挿入すると共に、ハ−ネス１０のリ−ド部１０ａを端子５Ａ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１０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。
【００２８】
この実施例によれば、圧着接続部分の端子５Ａ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１１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の肉厚を例えば厚い領域に設定すれば、端子５Ａに対する補強効果が向上し、充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。
【００２９】
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１０のリ−ド部１０ａを接続手段１１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１１のリング部分に延長部４Ａと端子５Ａの折返部５Ａａとの重ね合わせ部分を挿入すると共に、ハ−ネス１０のリ−ド部１０ａ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。
【００３０】
この実施例によれば、かしめ圧着部分の厚みが、端子５Ａ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。従って、信頼性の高い接続構体が得られるのみならず、保護部材のデュロメ−タＤ硬さが小さい領域でも、ハ−ネス１０に不所望に大きな外力が作用しても端子５Ａの切断を一層に低減できる。
【００３１】
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。
【００３２】
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。
【００３３】
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。
【００３４】
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。
【００３５】
図１１〜図１２は本発明の第７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、保護部材１３を囲繞する外装チュ−ブ１２を省略したことである。具体的には、次のように製造される。まず、図１２に示すように、外囲器１を直立状態に支持すると共に、外囲器１の上端部分に半円筒状の成形型２０，２０を、外囲器１の透光性シ−ト４を挟持するように装着する。この状態において、成形型２０，２０の閉成によって外囲器１の端面部分に形成されたキャビティ部２１に保護部材１３を充填し、硬化させる。然る後、成形型２０，２０を外囲器端部から取り外すことによって図１１の希ガス放電灯が完成する。
【００３６】
この実施例によれば、成形型２０，２０を多連式に構成することによって量産性を高めることができるし、外装チュ−ブの省略によりコストを低減できる。この実施例に、第２〜第６の実施例の構成を適用することもできる。
【００３７】
尚、本発明は、何ら上記実施例にのみ制約されることなく、例えばハ−ネスと外部電極との電気的な接続は圧着端子などの圧着を利用した接続手段による他、導電性接着剤，溶着，半田付けなどの接続手段を適用することもできる。又、外部電極と電気的な接続関係を有する端子は保護部材の内部において屈曲状態で位置させる他、外部電極のほぼ延長上に位置するように配置することもできる。又、保護部材に埋没されるハ−ネス部分に凹部ないし突部を形成すれば、端子部分などに作用する外力を緩和できる。特に、外部電極の形態において、「帯状」とは全体としての形態が帯状であることを意味し、外部電極の端部に三角状，半円状，矩形状などの異形部を有するものは勿論のこと、端部でない部分に孔などが存在したり、編目状になっているものなども含まれるものとする。
【００３８】
【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、肉厚が３００μｍで長さが１１ｍｍのポリカ−ボネイト樹脂よりなる外装チュ−ブを外囲器の端部に、内部に接続部分が配置されるように装着すると共に、外囲器をほぼ直立に支持した状態で、内部にシリコ−ン樹脂（保護部材）を充填してから１２０°Ｃに５分間加熱し硬化させる。尚、シリコ−ン樹脂のデュロメ−タ硬さＤは５０であった。
【００３９】
この希ガス放電灯を、−４０°Ｃの状態で３０分間放置してから８０°Ｃに急激に上昇させて３０分間放置し、次いで、８０°Ｃから−４０°Ｃにまで急激に下降させて３０分間放置する熱衝撃試験を１０サイクル繰り返した後に、シリコ−ン樹脂と外囲器端面との接触界面でのクラックの発生の有無を観察したところ、皆無であった。又、シリコ−ン樹脂より導出されたハ−ネスに１０Ｋｇの引っ張り力を作用させてアルミ端子部分での切断の有無を観察したところ、切断は全く認められなかった。
【００４０】
【発明の効果】
以上のように本発明によれば、外囲器の端部には絶縁性に優れた保護部材が、内部に空洞部が形成されないように配置されているために、保護部材と外囲器との結合強度を改善できる。
【００４１】
しかも、ハ−ネスと端子との接続部分は保護部材に埋没されるように配置されているために、接続部分の絶縁処理を簡単に行うことができる上、ハ−ネスを保護部材にて確実に支持できる。従って、仮にハ−ネスに外力（例えば引張力）が作用しても、ハ−ネスと端子との接続部分は保護部材によって確実に支持される結果、接続はずれ，端子切れなどを抑制できる。
【００４２】
特に、外囲器の端部に筒状部材を装着すれば、ハ−ネスが導出される側の開口部以外には隙間などは形成されない。このために、開口部から充填された保護部材の筒状部材からの漏出を皆無にできる上、充填された保護部材の内部に空洞部が形成されることも防止できる。従って、保護部材と外囲器の端面部分との結合強度を一層に改善できる。
【００４３】
その上、外囲器の端部に筒状部材を装着すれば、筒状部材の自由端側には開口部のみが存在していることから、筒状部材の内部空間への保護部材の充填は外囲器を、筒状部材の開口部が上側となるようにほぼ直立に支持した状態で行うことができる。従って、保護部材の筒状部材への充填作業を単純化できるのみならず、保護部材の筒状部材への充填によってハ−ネスと端子との接続部分の支持や絶縁保護を同時に行うことができ、作業能率を改善できる。
【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】本発明にかかる希ガス放電灯の第７の実施例を示す側断面図。
【図１２】図１１に示す保護部材の成形方法を説明するための側断面図。
【図１３】従来の希ガス放電灯の一部破断側面図。
【図１４】図１３のＸ−Ｘ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
１０ハ−ネス
１０ａリ−ド部
１１接続手段
１２筒状部材（外装チュ−ブ）
１３保護部材
２０成形型
２１キャビディ部
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 pair of belt-like external electrodes are arranged on the outer peripheral surface of an envelope made of a glass bulb, and the electrical connection relationship from the end of the envelope to the external electrode is established. The present invention relates to an improvement in a protective structure of a portion for deriving a harness in a rare gas discharge lamp obtained by deriving a possessed harness.
[0002]
[Prior art]
A conventional rare gas discharge lamp of this type is configured by attaching insulating caps H and H to the end of the lamp main body DL as shown in FIGS. That is, in the lamp main body DL, A is a straight tubular envelope that is hermetically sealed with, for example, a glass bulb, and its inner surface is made of a phosphor such as a rare earth phosphor or a halophosphate phosphor. A light emitting layer B is formed. In this light emitting layer B, an aperture portion Ba that does not form the light emitting layer B having a predetermined opening angle is formed over almost the entire length. The sealing structure of the envelope A is configured 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) or the like that does not contain metal vapor such as mercury is mixed in the sealed space of the envelope A. A predetermined amount is enclosed. On the outer peripheral surface of the envelope A, a pair of strip-like external electrodes C and D made of a light-impermeable metal member are disposed (adhered) at a predetermined distance from each other. The surface is covered with a protective tube E made of, for example, a heat-shrinkable resin. Further, terminals F and F are connected in advance to the ends of the external electrodes C and D, and harnesses G and G for connection to an external circuit are connected to the lead-out ends. On the other hand, insulating caps H and H are attached to the end of the lamp main body DL so that the aperture portion Ba and the mounting ears Hb and Hb of the caps H and H are in a predetermined positional relationship. A thermosetting resin J such as an epoxy resin is injected and cured in the internal spaces Ha and Ha of the caps H and H, whereby the lamp main body DL and the cap H are fixed.
[0003]
In this rare gas discharge lamp, a high-frequency high voltage (for example, 2500 Vo-p at 25 KHz) is applied to the external electrodes C and D through the harness G to cause discharge of the rare gas, and light is emitted by the excitation line of the rare gas. The layer B is excited to emit light, and light is emitted to the outside from the aperture portion Ba through the opening between the end portions of the external electrodes C and D. 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.
[0004]
[Problems to be solved by the invention]
By the way, this rare gas discharge lamp is manufactured as follows, for example. First, after connecting the terminals F and F to the end portions of the external electrodes C and D using a conductive adhesive, the external electrodes C and D are separated from each other on the outer peripheral surface of the envelope A by a predetermined distance. Then place and glue. Further, by attaching a protective tube E made of heat-shrinkable resin to the outer peripheral surface of the envelope A so that the external electrodes C and D are covered and heat-treating, the protective tube E is surrounded by The lamp main body DL is completed by being in close contact with the vessel A and the external electrodes C and D. Next, one end of the harness G is electrically connected to the terminals F and F of the lamp main body DL by soldering or the like. Next, the cap H is disposed at the end of the lamp main body DL, and the end of the envelope A and the connection between the terminal F and the harness G are included in the internal space Ha. Next, the epoxy resin J is injected into the internal space Ha of the cap H, and the space between the end of the lamp main body DL and the cap H is enriched. Thereafter, the temporary assembly is left in a heating furnace controlled at a temperature of about 120 ° C. for 5 minutes, and then further left at 60 to 80 ° C. for 2 hours. Thereby, the epoxy resin J is thermally cured, and the end portion of the lamp main body DL and the cap H are firmly bonded.
[0005]
However, in the step of injecting the epoxy resin J into the inner space Ha of the cap H, the harness G passes through the harness insertion hole formed in the outer wall portion of the cap H from the end of the envelope A. Since it is led out to the outside, a relatively large gap is formed between the harness G and the harness insertion hole, and the epoxy resin J leaks from this gap, and a part inside the cap H In some cases, a hollow portion may be formed. In particular, when the cavity is large, not only there is a risk of dielectric breakdown between charged parts (for example, between terminals), but if the tensile force acting on the harness G increases, the harness G and the terminal F The problem is that the connection is disconnected at the connection part or the connection strength with the envelope A is lowered.
[0006]
Therefore, the object of the present invention is to easily protect the harness lead-out portion from the end of the envelope, and to prevent the influence on the electrical connection portion even if an external force acts on the harness. It is to provide a rare gas discharge lamp that can be reduced.
[0007]
[Means for Solving the Problems]
Therefore, in order to achieve the above-mentioned object, the present invention arranges a straight tubular envelope having a light emitting layer on the inner surface and an outer peripheral surface of the envelope so as to be separated from each other over almost the entire length thereof. A pair of strip-shaped external electrodes made of a metal member; A terminal having an electrical connection relationship with the external electrode and led out from an end thereof, an overlapping part of the lead-out part of the terminal and the extension part of the translucent sheet, and a terminal A harness having an electrical connection with A connection means for electrically and mechanically connecting the overlapped portion and the lead portion of the harness using crimping, and a connection portion between the harness and the terminal are provided at the end of the envelope on the harness output side. An insulative tubular member arranged so as to be located inside, and the internal space of the tubular member is enhanced so that the connection portion between the harness and the terminal is buried. And a protective member having excellent insulating properties.
[0008]
According to a second aspect of the present invention, there is provided a straight tubular envelope having a light emitting layer on the inner surface, and a metal member disposed on the outer peripheral surface of the envelope so as to be separated from each other over substantially the entire length thereof. A pair of strip-shaped external electrodes; A terminal that has an electrical connection relationship with the external electrode and that is led out from an end thereof, a folded portion that is folded and bonded to the lead-out portion of the terminal, and a terminal A harness having an electrical connection with A connection means for electrically and mechanically connecting the folded portion and the lead portion of the harness using crimping; An insulating cylindrical member disposed at the end of the envelope on the harness outlet side so that the connection portion of the harness and the terminal is located inside, and an internal space of the cylindrical member Harness The connection between the terminal and the terminal is buried And a protective member with excellent insulation properties as described above.
[0011]
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. 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. 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 configured by sealing a disc-shaped sealing glass plate 1a 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.
[0012]
A sheet structure 3 is mounted (wound) on the outer peripheral surface of the envelope 1. The sheet structure 3 has a pair of strip-like external electrodes 5 and 6 made of a metal member on one surface of a translucent sheet 4 having a length substantially the same as the entire length of the envelope 1, for example. The terminals 5 A and 6 A are formed so as to be spaced apart from each other and extend outward from the end portions of the external electrodes 5 and 6 toward the outside. In a state where the sheet structure 3 is mounted on the outer peripheral surface of the envelope 1, the first opening 7 is provided between one end portions of the external electrodes 5 and 6, and the second opening is provided between the other end portions. The opening 8 is formed, and the light from the light emitting layer 2 is mainly emitted from the aperture 2a to the outside through the first opening 7. In the sheet structure 3, an adhesive layer 9 and an adhesive layer 9a are formed on one surface of the translucent sheet 4 and the external electrodes 5 and 6, and the external electrodes 5 and 6 are translucent. The sheet 4 is bonded using an adhesive layer 9. Further, for example, polyethylene terephthalate (PET) resin is suitable as the translucent sheet 4, and aluminum foil is suitable as the external electrodes 5 and 6, for example, but other members can also be applied.
[0013]
A lead portion 10a of the harness 10 is electrically and mechanically connected to the terminals 5A and 6A formed extending from the end portions of the external electrodes 5 and 6 by connecting means 11 and 11, respectively. . 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. It is wound so that the external electrodes 5 and 6 are positioned between the envelope 1 and the translucent sheet 4, and the harnesses 10 and 10 are wound around the terminals 5A and 6A of the sheet structure 3. The gate portions 10a and 10a are electrically and mechanically connected by connecting means 11 and 11 using crimping.
[0014]
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. When the aluminum foil is soft, the thickness is recommended to be set within 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. Moreover, 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.
[0015]
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 10a and 10a of the harnesses 10 and 10 have ends in the lead-out portions. It is connected by crimping using the substantially ring-shaped connecting means 11, 11. The connection means 11, 11 is composed of, for example, a ring-shaped crimp terminal made of a metal member such as brass, nickel, or stainless steel, and the terminal 5A (or 6A) and the lead 10 of the harness 10 are connected to the ring portion. With the portion 10a overlapped, the ring portion is crushed by a known crimping tool, whereby the terminals 5A and 6A of the external electrodes 5 and 6 and the lead portion 10a of the harness 10 are connected via the crimping terminal 11. Electrically and mechanically connected. The ring portion of the connecting means (crimp terminal) 11 may be an endless ring having a slight gap in addition to the endless ring.
[0016]
The connecting portion between the terminals 5A and 6A and the harnesses 10 and 10 is packaged as follows, for example. That is, at the end of the envelope 1, a cylindrical member (exterior tube) 12 having an insulating property such as a resin material, a rubber material, a ceramic material, etc. is connected to the terminals 5A, 6A and the harness 10, 10 is attached so as to surround the connecting portion, and the inside thereof is filled with a protective member 13 having excellent insulating properties such as a thermosetting resin such as a silicone resin and a rubber-based member. . The protective member 13 has a durometer D hardness of 80 or less, preferably in the range of 80 to 30 in accordance with JIS K 7515-1986 “Durometer Hardness Test Method for Plastics” in a state after curing. The set one is recommended. The exterior tube 12 is preferably made of a resin material having some flexibility or elasticity, and for example, polycarbonate resin is recommended.
[0017]
Next, a method for manufacturing the rare gas discharge lamp will be described with reference to FIGS. First, as shown in FIGS. 4 (a) and 4 (b), for example, a translucent sheet 4 having an adhesive layer 9 on one surface and a long metal member having an adhesive layer 9a on one surface. The external electrodes 5 and 6 are stacked and bonded so that the terminals 5A and 6A formed integrally with the external electrodes 5 and 6 protrude from the end of the translucent sheet 4. The structure 3 is manufactured. Next, the envelope 1 is disposed at one end 4a of the translucent sheet 4 in the sheet structure 3, and is relatively rolled toward the other end 4b, whereby the outer peripheral surface of the envelope 1 is placed. The sheet structure 3 is wound so that the outer electrodes 5 and 6 are covered with the translucent sheet 4 and the lead-out portions of the terminals 5A and 6A are exposed, and the translucent sheet is provided. The other end 4b is superimposed on one end 4a of the G 4 and bonded by the adhesive layer 9 (see FIG. 3).
[0018]
Next, as shown in FIG. 5, the crimp terminal 11 and the harness 10 which are connection means are arranged at the tip of the terminal 5 A (6 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 11, and the lead portion 10a of the harness 10 is inserted into the ring portion so as to overlap the terminal 5A. In this state, by crimping the crimp terminal 11 using a known crimp tool (not shown), the terminal 5A and the lead portion 10a of the harness 10 are crimped and connected, and the connection shown in FIG. A state is obtained. Next, the outer tube 12 is attached to the end portion of the envelope 1 so that the connecting portion between the terminal 5A and the lead portion 10a of the harness 10 is located inside, and the protective member 13 is placed inside. By filling and curing, a rare gas discharge lamp is completed.
[0019]
According to this embodiment, the outer tube 12 is attached to the end of the envelope 1 so that one end of the outer tube 12 is fitted to the envelope 1. No gap or the like is formed except for the opening on the side to be led out. For this reason, leakage from the outer tube 12 of the protective member 13 filled from the opening can be eliminated, and formation of a cavity in the filled protective member 13 can be prevented. Therefore, the coupling strength between the protective member 13 and the end surface portion of the envelope 1 can be improved, and the occurrence of dielectric breakdown between the terminals due to the cavity can be suppressed.
[0020]
In addition, since it is difficult to form a hollow portion inside the protective member 13, the protective member 13 surrounds the connection portion between the harness 10 and the terminals 5 A and 6 A that are positioned so as to be buried in the protective member 13. It will be fulfilled almost precisely. Therefore, even if an external force (for example, a tensile force) is applied to the harness 10, the connection portion between the harness 10 and the terminals 5A and 6A is reliably supported by the protective member 13. Etc. can be suppressed.
[0021]
Further, only the opening exists at the other end of the outer tube 12 attached to the end of the envelope 1, and the harness 10 is led out from this opening. The filling of the protective member 13 into the inner space of the outer tube 12 can be performed in a state where the envelope 1 is supported substantially upright so that the opening at the other end of the outer tube 12 is on the upper side. it can. Therefore, not only can the work of filling the outer tube 12 with the protective member 13 be simplified, but also the connection between the harness 10 and the terminals 5A and 6A is achieved by filling the outer tube 12 with the protective member 13. Support and insulation protection can be performed simultaneously, and work efficiency can be improved.
[0022]
In particular, if the durometer D hardness of the protective member 13 is set to 80 or less, and preferably in the range of 80 to 30, the glass bulb and the protective member 13 that constitute the envelope 1 temporarily during manufacture and use. Even if an undesired stress is applied to the contact interface, a considerable portion is absorbed by the protective member 13. Therefore, when a thermosetting resin such as a silicone resin is used as the protective member 13, even if an undesired stress acts on the contact interface with the envelope end surface during the thermosetting, the stress is protected. 13 and even if an undesired stress is applied when operating in a mode in which a large temperature difference occurs during use, the protective member 13 absorbs it. Crack breakage occurring on the end face of the vessel can be suppressed, and a high quality product can be obtained.
[0023]
In addition, if the durometer D hardness of the protective member 13 is set within the above range, even if an external force acts on the connection portion between the terminals 5A, 6A and the harness 10 via the harness 10, the terminal The cutting of 5A and 6A can be further reduced.
[0024]
Furthermore, the terminals 5A and 6A formed extending from the external electrodes 5 and 6 and the harness 10 are connected to the ring portion of the connecting means 11 made of a crimp terminal, and the terminals 5A and 6A and the harness 10 are connected. Can be connected by crimping in a state where they are inserted so as to overlap each other, so that the connection workability can be greatly improved and the cost can be reduced.
[0025]
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 10a of the harness 10 is formed in this portion. Is crimped and connected using the connecting means 11. The folded portion 5Aa is configured by folding the lead-out portion 5A in the direction of the arrow as shown in FIG.
[0026]
According to this embodiment, since the thickness of the terminal 5A of the crimping crimping portion is doubled, it is possible to effectively prevent the terminal 5A from being cut off from the folded portion 5Aa when the connecting means 11 is crimped. 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 10 and the terminal 5A by the crimping can be further enhanced. it can.
[0027]
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 extension 4A is extended from the end of the translucent sheet 4 to the outside with a width approximately equal to that of the terminal 5A. Then, an overlapping portion of the extension portion 4A and the terminal 5A is inserted into the ring portion of the connecting means 11, and the lead portion 10a of the harness 10 is inserted into the ring portion so as to overlap the terminal 5A. Then, 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 10 is in contact in advance in order to improve the reliability of electrical connection.
[0028]
According to this embodiment, although the thickness of the terminal 5A of 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 thereof. Strength is reinforced and cutting from the terminal 5A can be effectively prevented during crimping by the connecting means 11. In particular, if the thickness of the translucent sheet 4 is set to a thick region, for example, the reinforcing effect on the terminal 5A is improved, crimping with a sufficient crimping force is possible, and connection reliability can be improved. .
[0029]
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 inside, and the lead portion 10a of the harness 10 is connected to this portion. 11 was 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, the overlapping portion of the extension portion 4A and the folded portion 5Aa of the terminal 5A is inserted into the ring portion of the connecting means 11, and the ring portion 10a of the harness 10 is overlapped with the folded portion 5Aa. After inserting into the part, it is crimped and connected using a crimping tool.
[0030]
According to this embodiment, the thickness of the crimped crimping portion becomes much thicker than the above-described embodiments due to the folded portion 5Aa of the terminal 5A and the extension portion 4A of the translucent sheet 4, and the same portion. Is further reinforced. Accordingly, not only a highly reliable connection structure can be obtained, but also in the region where the durometer D hardness of the protective member is small, the terminal 5A is further cut even if an undesirably large external force acts on the harness 10. Can be reduced.
[0031]
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.
[0032]
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.
[0033]
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.
[0034]
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.
[0035]
FIGS. 11 to 12 show a seventh embodiment of the present invention, and the basic configuration is the same as that of the first embodiment. The difference is that the outer tube 12 surrounding the protective member 13 is omitted. Specifically, it is manufactured as follows. First, as shown in FIG. 12, the envelope 1 is supported in an upright state, and the semi-cylindrical molds 20, 20 are placed on the upper end portion of the envelope 1. Attached so as to hold the G4. In this state, the protective member 13 is filled in the cavity portion 21 formed in the end surface portion of the envelope 1 by closing the molds 20 and 20 and cured. After that, the rare gas discharge lamp of FIG. 11 is completed by removing the molds 20 and 20 from the end of the envelope.
[0036]
According to this embodiment, it is possible to increase the mass productivity by configuring the molds 20 and 20 in a multi-line system, and it is possible to reduce the cost by omitting the outer tube. The configurations of the second to sixth embodiments can also be applied to this embodiment.
[0037]
The present invention is not limited to the above-described embodiment. For example, the electrical connection between the harness and the external electrode is not limited to a connection means using crimping such as a crimping terminal, a conductive adhesive, Connection means such as welding and soldering can also be applied. In addition, the terminal having an electrical connection relationship with the external electrode can be positioned in a bent state inside the protective member, and can also be disposed so as to be positioned substantially on the extension of the external electrode. Further, if a recess or protrusion is formed in the harness portion buried in the protective member, the external force acting on the terminal portion can be reduced. In particular, in the form of the external electrode, the “strip shape” means that the form as a whole is a strip shape, and of course, the end portion of the external electrode has a deformed portion such as a triangular shape, a semicircular shape, or a rectangular shape. In other words, a hole or the like in a portion that is not an end portion or a stitch shape is included.
[0038]
【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. Thereafter, an outer tube made of polycarbonate resin having a wall thickness of 300 μm and a length of 11 mm is attached to the end of the envelope so that the connecting portion is disposed inside, and the envelope In a state in which is supported substantially upright, the inside is filled with a silicone resin (protective member), and then heated to 120 ° C. for 5 minutes to be cured. The durometer hardness D of the silicone resin was 50.
[0039]
The rare gas discharge lamp is allowed to stand for 30 minutes at −40 ° C., then rapidly raised to 80 ° C. and left for 30 minutes, and then rapidly lowered from 80 ° C. to −40 ° C. After repeating the thermal shock test that was allowed to stand for 30 minutes for 10 cycles, the occurrence of cracks at the contact interface between the silicone resin and the envelope end face was observed, and there was no result. In addition, when a tensile force of 10 kg was applied to the harness derived from the silicone resin to observe the presence or absence of cutting at the aluminum terminal portion, no cutting was observed.
[0040]
【The invention's effect】
As described above, according to the present invention, since the protective member having excellent insulating properties is disposed at the end of the envelope so that the hollow portion is not formed therein, the protective member, the envelope, Can improve the bonding strength.
[0041]
In addition, since the connection portion between the harness and the terminal is disposed so as to be buried in the protective member, the insulation of the connection portion can be easily performed, and the harness can be reliably secured by the protective member. Can be supported. Therefore, even if an external force (for example, a tensile force) acts on the harness, the connection portion between the harness and the terminal is reliably supported by the protective member, so that disconnection, terminal disconnection, and the like can be suppressed.
[0042]
In particular, if a cylindrical member is attached to the end of the envelope, no gap or the like is formed except for the opening on the side from which the harness is derived. For this reason, it is possible to eliminate leakage of the protective member filled from the opening from the cylindrical member, and it is also possible to prevent the hollow portion from being formed inside the filled protective member. Therefore, the coupling strength between the protective member and the end surface portion of the envelope can be further improved.
[0043]
In addition, if a cylindrical member is attached to the end of the envelope, only the opening exists on the free end side of the cylindrical member, so that the internal space of the cylindrical member is filled with the protective member. Can be performed in a state where the envelope is supported substantially upright so that the opening of the cylindrical member is on the upper side. Accordingly, not only can the work of filling the cylindrical member with the protective member be simplified, but also the support of the connection between the harness and the terminal and the insulation protection can be performed simultaneously by filling the cylindrical member with the protective member. Can improve work efficiency.
[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 side sectional view showing a seventh embodiment of the rare gas discharge lamp according to the present invention.
12 is a side sectional view for explaining a method of forming the protective member shown in FIG.
FIG. 13 is a partially broken side view of a conventional rare gas discharge lamp.
14 is a sectional view taken along line XX in FIG.
[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
10 Harness
10a lead part
11 Connection means
12 Tubular member (exterior tube)
13 Protection member
20 Mold
21 Cavidy Club
50 Protective tube

Claims

A straight tubular envelope having a light emitting layer on the inner surface, a pair of strip-shaped external electrodes made of metal members arranged on the outer peripheral surface of the envelope and spaced apart from each other over substantially the entire length thereof, and an external electrode, A terminal having an electrical connection relationship, a terminal led out from the end thereof, a superposed portion of the lead-out portion of the terminal and the extension portion of the translucent sheet, and a terminal having an electrical connection relationship with the terminal ; A connection means for electrically and mechanically connecting the overlapping portion and the lead portion of the harness using crimping, and the harness and the terminal at the end of the envelope on the harness outlet side. Insulating cylindrical member arranged so that the connection part is located inside, and excellent insulation with excellent insulation so that the connection part between the harness and the terminal is buried in the internal space of the cylindrical member A rare gas discharge lamp comprising a member.

A straight tubular envelope having a light emitting layer on the inner surface, a pair of strip-shaped external electrodes made of metal members arranged on the outer peripheral surface of the envelope and spaced apart from each other over substantially the entire length thereof, and an external electrode, A terminal that has an electrical connection relationship and is led out from an end thereof, a folded portion that is folded and bonded to the terminal lead portion, a harness that has an electrical connection relationship with the terminal , and a folding portion; The connection portion between the harness and the terminal is located inside the connection means for electrically and mechanically connecting the lead portion of the harness using crimping and the end portion of the envelope on the harness output side. a cylindrical member having an arrangement the insulation as, the inner space of the tubular member, ha - the connection portion between the nested and terminal equipped with a protective member having excellent full insulating properties so that you buried A rare gas discharge lamp characterized by