JP4153759B2 - Manufacturing method of high-pressure discharge lamp - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a high-pressure discharge lamp.
[0002]
[Prior art]
As high-pressure discharge lamps, for example, metal halide lamps, those described in JP-A-6-196131 and JP-A-10-294085 are known.
A conventional metal halide lamp will be described with reference to FIG.
[0003]
As shown in FIG. 4, the metal halide lamp has an arc tube 130 in which a pair of electrodes (not shown) are arranged to face each other in an internal discharge space, and an explosion-proof sleeve 150 surrounding the arc tube 130. The arc tube 130 is supported between a pair of support members 140 and 145 provided to support the sleeve 150. The support members 140 and 145 are both metal thin plates.
[0004]
The arc tube 130 includes power feeders 134 and 135 extending from the upper and lower narrow tube portions 132 and 133, respectively, and the stem wires 121 and 122 are connected to the outside of the support members 140 and 145, respectively. It is like that.
Further, on the surface of the arc tube 130, a starting lead wire 161 for assisting the starting of the lamp is arranged close to or in contact with the lamp. The upper end of the starting lead wire 161 is welded to the power feeder 134 via the resistance element 162 in the upper space of the upper support member 140. The starting conductor 161 and the resistance element 162 constitute a starting conductor 160. The starting conducting wire 161 is installed on the arc tube 130 by being wound approximately 1/2 turn around the upper and lower narrow tube portions. The lower end of the start-up conducting wire 161 is stopped in the form of a free end while being wound around the lower narrow tube portion, and is not electrically connected to anything.
As described above, the metal halide lamp is configured such that the arc tube 130, the support members 140 and 145, and the other components are housed in the outer tube 110 having the base 120 attached to the lower end portion.
[0005]
In the metal halide lamp shown in FIG. 4, the starting conductor 160 is provided to assist the starting of the lamp. A method for forming the starting conductor 160 will be described with reference to FIG.
First, a straight metal wire 1611 is prepared, and a lower end portion thereof is bent in a direction perpendicular to the longitudinal direction of the metal wire, and processed with a number of turns of 1/2 to 3/4 turns. The inner diameter of the winding at this time is the same as or slightly larger than the outer diameter of the narrow tube portion 133 (see FIG. 5B) of the arc tube 130. By this processing, the engaging portion 161b is formed at the lower end as shown in FIG.
[0006]
Next, the engaging portion 161 b is engaged with the narrow tube portion 133 in the arc tube 130, and the metal wire 1611 is attached to the arc tube 130. Then, the attached metal wire 1611 is bent along the outer periphery of the main body 131 of the arc tube 130 (FIG. 5B). Finally, the metal wire 1611 is wound (1/2 to 3/4 turn) along the outer surface of the upper thin tube portion 132 in the arc tube 130. By this winding process, the engaging portions 161a and 161b are engaged with the thin tube portions 132 and 133 at both ends of the arc tube 130, and the starting conductor 161 is constructed with the body portion 131 formed with the portion 161 along the outer surface thereof. Is completed (FIG. 5C).
[0007]
[Problems to be solved by the invention]
However, when the above-described method for laying the starting lead wire 161 is used, the starting lead wire 161 can be erected only after the arc tube 130 is manufactured, and the working efficiency is very poor. That is, the manufacturing process of the arc tube 130 and the erection process of the starting lead wire 161 can be performed only in a serial process relationship.
[0008]
The present invention has been made to solve such a problem, and it is possible to construct a starter conductor with respect to the arc tube with good working efficiency and to reduce the manufacturing cost. An object is to provide a method for manufacturing a lamp.
[0009]
[Patent Document 1]
JP-A-6-196131 [0010]
[Patent Document 2]
Japanese Patent Laid-Open No. 10-294085
[Means for Solving the Problems]
In order to achieve the above object, a method for manufacturing a high-pressure discharge lamp according to the present invention is a method for manufacturing a high-pressure discharge lamp in which a starting conducting wire for assisting starting is arranged close to or in contact with the surface of an arc tube. The wire for forming the starting conducting wire is subjected to a bending process corresponding to the outer surface shape of the arc tube, and at least a part of the bent wire is subjected to the outer surface of the arc tube. And a step of erection in a state along the line .
[0012]
In the high pressure discharge lamp manufacturing method according to the present invention, the wire is bent according to the outer surface shape of the arc tube, and the bent wire is installed on the arc tube. In parallel with the production, the wire can be bent. Therefore, compared with the conventional manufacturing method in which a part of the wire is attached to the outer surface of the arc tube, and the wire is bent and installed along the outer surface of the arc tube in that state, the manufacturing according to the present invention is performed. In the method, work efficiency can be improved.
[0013]
In addition, the arc tube targeted by the manufacturing method according to the present invention has a main body portion and two thin tube portions extending from both ends of the main body portion, and in the step of bending, the wire rod is marked. It is also characterized in that processing is performed in a state having an engaging portion that is engaged with each of the two thin tube portions from one thin tube portion to the other thin tube portion in the arc tube . Here, each of the engaging portions of the wire rod has a structure in which it is engaged with the thin tube portion with a number of turns of less than one turn.
[0014]
Moreover, in the manufacturing method of the high-pressure discharge lamp according to the present invention, the configuration is such that the central axes related to the windings of the two engaging portions are shifted from each other in a state before the wire is installed on the arc tube. It is also characterized by adopting. As a result, after the wire rod is installed on the arc tube, a force is applied to the two engaging portions so that the central axis for winding returns to the state before the installation. Therefore, adopting such a configuration is effective from the viewpoints of both the ease of laying the wire rod on the arc tube and the difficulty of detaching the wire rod after erection .
The wire in the manufacturing method can be made of various materials, but contains at least one element selected from molybdenum (Mo), tungsten (W), niobium (Nb), and iron (Fe). It is particularly desirable to use those to be used from the viewpoints of heat resistance, electrical resistance, and the like.
[0015]
In a high-pressure discharge lamp, a starting lead wire constituting the starting conductor may be installed near or in contact with the arc tube to assist the starting of the lamp. The starting lead wire can be installed on the arc tube with high work efficiency.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
The structure of the high-pressure discharge lamp targeted by the manufacturing method according to the embodiment of the present invention will be described with reference to FIG. 1 using a metal halide lamp as an example. FIG. 1 is a side view (partially sectional view) showing a configuration of a metal halide lamp.
As shown in FIG. 1, in the metal halide lamp 1, an arc tube 30 is supported in a space between a pair of support members 40 and 45 arranged opposite to each other by using stem wires 21 and 22 to be described later. It is stored in 10 internal spaces. The pair of support members 40 and 45 are configured not to be rattled in the outer tube 10 by the bent portions formed at the edges thereof.
[0017]
A cylindrical sleeve 50 made of quartz glass is provided outside the arc tube 30 between the pair of support members 40 and 45. The sleeve 50 is provided for explosion protection.
The outer tube 10 has an E-shaped base 20 attached to the lower end thereof, and can be attached to an external socket through this.
[0018]
The arc tube 30 is composed of a main body 31 whose envelope is cylindrical and narrow tube portions 32 and 33 extending from both sides. The dimensions of the thin tube portions 32 and 33 are, for example, an outer diameter of 2 to 5 mm and a thickness of 0.5 to 2.0 mm. The main body portion 31 and the thin tube portions 32 and 33 are made of a ceramic material made of alumina.
In the internal space (discharge space) of the main body 31, two electrodes (not shown) arranged opposite to each other with a space therebetween are housed, and a rare gas such as argon gas and a metal halide as a luminescent metal. Is enclosed.
[0019]
Feeders 34 and 35 are led out from the ends of the thin tube portions 32 and 33, respectively. The power feeding bodies 34 and 35 are electrically connected to a pair of electrodes (not shown in FIG. 1) that are opposed to each other with a space inside the main body 31. And the part which the electric power feeding bodies 34 and 35 derive | lead-out in the thin tube parts 32 and 33 is sealed with the glass frit. However, the glass frit is sealed only in the end portion on the opposite side to the main body portion 31 inside the narrow tube portions 32 and 33. Therefore, a gap of about 0.05 mm exists between the inner surface of the thin tube portions 32 and 33 on the main body portion 31 side and the respective power feeders 34 and 35 or the electrodes.
[0020]
The power feeding body 34 is inserted into the upper space through the upper support member 40, and is connected to the stem wire 21 extending from the stem 80 in the led portion. The power feeding body 34 is welded to the support member 40 at its intersection. In addition to the stem wire 21, one lead of a resistance element 62 that is a component of the starting conductor 60 is connected to the power feeding body 34. The resistance element 62 has a starting lead 61 connected to the other lead.
[0021]
The starting conducting wire 61 passes through an insulator 75 fitted in a hole provided in the support member 40 and is led out to a lower space of the support member 40. The starting lead wire 61 led out to the lower space of the support member 40 is engaged with the outer periphery of the end portion on the main body portion 31 side of the thin tube portions 32 and 33 of the arc tube 30, and is installed on the arc tube 30. Here, the portion of the starting lead wire 61 close to the main body 31 of the arc tube 30 is slightly inclined from the axial direction of the arc tube 30.
[0022]
On the other hand, the power feeding body 35 extending from the lower narrow tube portion 33 passes through the insulator 70 fitted in the hole in the lower support member 45 and is led out to the lower space of the support member 45. That is, unlike the power supply body 34, the power supply body 35 is electrically insulated from the support member 45 to be inserted. This is to prevent the power feeding body 35 and the stem wire 21 from causing a discharge through the support member 45 when the lamp is lit. The other stem wire 22 extending from the stem 80 is connected to the power supply body 35 drawn out to the lower space of the support member 45.
[0023]
Of the members constituting the metal halide lamp 1, the starting conductor 60 is provided for starting at a low pulse voltage at the time of starting the lamp, and is superimposed on the AC voltage of the sine wave at the time of starting. The applied pulse voltage can assist in starting by causing a slight discharge between the starting conducting wire 61 and the electrode in the narrow tube portion 33 or the power feeding body 35 in the vicinity thereof. The resistance element 62 in the starting conductor 60 causes unwanted discharge between the electrode and the starting lead 61 even when the arc tube 30 is damaged and the electrode disposed therein is exposed outside the arc tube 30. It is inserted so as not to occur.
[0024]
Below, the manufacturing method of the starting lead wire 61 to the arc_tube | light_emitting_tube 30 among the manufacturing methods which concern on embodiment of this invention is demonstrated using FIG.
As shown in FIG. 2A, in the manufacturing method according to the present embodiment, before the starting lead wire 61 is installed on the arc tube 30, the shape of the starting lead wire 61 is matched to the external shape of the arc tube 30. It should be bent.
[0025]
Specifically, a 0.2 mm diameter wire made of molybdenum (Mo) is bent at an angle of approximately 90 ° with respect to the longitudinal direction. The bent wire is wound at a certain distance (a distance determined by the external shape of the arc tube 30 to be installed) and wound at about 1/2 turn (about 180 ° bending). A landing part 61a is formed. The winding inner diameter of the engaging portion 61a is the same as or slightly larger than the outer diameter of the thin tube portion 32 in the arc tube 30.
[0026]
The front portion of the engaging portion 61a in the wire is bent again by about 90 ° and directed downward in FIG. Thereafter, the wire is bent into a substantially U-shape. Of the portions processed into a substantially U-shape, a portion 61 c that is linear in the vertical direction becomes a portion along the outer side wall of the main body 31 when it is installed on the arc tube 30.
After the substantially U-shaped bending process, it is directed again downward in FIG.
[0027]
After being bent by about 90 °, the end of the wire is wound at a winding number of about 1/2 turn (about 180 ° bending) to form the engaging portion 61b, and the starting conducting wire 61 is completed.
The winding center axis of the engaging portion 61a and the winding center axis of the engaging portion 61b are set to have a constant interval in the z direction in the coordinate system shown at the lower right in the drawing. This will be described later.
[0028]
Further, the number of windings of the engaging portion 61a and the engaging portion 61b may be less than one turn since the spring property of the wire can be used. However, in order to prevent the starting wire 61 once attached to the arc tube 30 from being easily removed, the engaging portions 61a and 61b are formed with the number of turns of 1/2 turn or more as described above. It is desirable to keep it. As shown in FIG. 2B, the bent starting lead wire 61 is installed in a state of traversing the outer periphery of the arc tube 30.
[0029]
The installation of the starting lead wire 61 to the arc tube 30 does not require bending at this point, and the engaging portion 61b is attached to the narrow tube portion 33 below the arc tube 30, and the engaging portion 61a is attached. This can be done simply by attaching to the upper narrow tube portion 32.
As described above, the starting conducting wire 61 installed on the arc tube 30 is formed by shifting the winding central axes of the engaging portion 61a and the engaging portion 61b during bending, so that the engaging wire 61 is attached at the time of installation. The portion 61a and the engaging portion 61b are not easily detached from the arc tube 30 due to the spring property of returning to the original (free) state. The state in which this spring property is acting is that the starting conductor 61 is installed on the arc tube 30 so that the straight portion 61 c of the starting conductor 61 has an angle with respect to the axial direction of the arc tube 30. I can hear from you.
[0030]
The shape of the starting lead wire 61 after bending will be described with reference to FIG. FIG. 3 is a side view showing the starting conducting wire 61 after bending and a top view of the starting lead wire 61 as viewed from above.
As shown in the side view of FIG. 3, the starting conducting wire 61 is formed into a shape suitable for the external shape of the arc tube 30 to be installed by bending. However, as described above, the engaging portion 61a to be engaged with the thin tube 32 and the engaging portion 61b to be engaged with the thin tube 33 are, as shown in the top view, in a state where the starting conductor 61 is free and only the distance d. It is designed to be eccentric. In other words, the eccentric distance d has a spring property when the starting lead wire 61 is installed on the arc tube 30 so that the starting lead wire 61 is not easily detached from the arc tube 30. Function.
[0031]
The distance d is preferably set to 3 mm which is substantially equivalent to the winding inner diameter of the engaging portions 61a and 61b of 3 mm. However, this numerical value needs to be set to an optimal numerical value depending on the wire diameter and mechanical characteristic value of the wire used for the starting conducting wire 61.
Further, as shown in FIG. 3, a straight portion (a portion to be brought close to the main body portion 31 of the arc tube 30) 61c in the starting conducting wire 61 in a bent state is maintained in the vertical direction. The straight portion 61c is elastically deformed until the distance between the winding center axes becomes substantially 0 when the starting conducting wire 61 is installed on the arc tube 30, and is shown in FIG. 2 (b). Thus, it has an angle with the axial direction of the arc tube 30.
[0032]
As described above, before erection to the arc tube 30, the wire is bent in advance so as to conform to the external shape of the arc tube 30, and the bent starting lead wire 61 is attached to the arc tube 30. If installed so as to be fitted, the working efficiency can be improved and the manufacturing cost can be reduced as compared with the conventional manufacturing method in which the wire rod is wound around the arc tube 30 or bent. .
[0033]
Further, since the starting lead wire 61 is formed such that the engaging portion 61a and the engaging portion 61b are eccentric by a distance d, the engaging portions 61a and 61b are eccentric due to the eccentricity of the engaging portions 61a and 61b. Due to the spring property of the starting lead 61, the starting lead 61 is not easily detached from the arc tube 30.
(Other matters)
In the embodiment of the invention described above, the metal halide lamp has been described as an example. However, the present invention can be similarly applied to a high-pressure discharge lamp having a starting conductor disposed in the vicinity of the arc tube. For example, the technique of the present invention can be applied to a mercury lamp or a high-pressure sodium lamp, and the same effects as in the above embodiment can be obtained.
[0034]
In the above-described embodiment, the resistance element 62 is provided together with the starting conductor 61 as a constituent member of the starting conductor 60. However, the resistance element 62 is not necessarily essential.
Furthermore, although the wire used for the starting conducting wire 61 is made of molybdenum (Mo) having a wire diameter of 0.2 mm in the above, the wire used is not limited to this. For example, as the wire, one containing at least one element selected from molybdenum (Mo), tungsten (W), niobium (Nb), and iron (Fe) (including an alloy) can be used. The diameter may be set to a value suitable for the material from the viewpoints of electrical resistance and mechanical and temperature strength.
[0035]
【The invention's effect】
As described above, the method for manufacturing a high-pressure discharge lamp according to the present invention is a method for manufacturing a high-pressure discharge lamp in which a starting conducting wire for assisting starting is arranged close to or in contact with the surface of an arc tube. The wire for forming the starting conducting wire is subjected to a bending process corresponding to the outer surface shape of the arc tube, and at least a part of the bent wire is applied to the outer surface of the arc tube. And a step of erection in a state along. Therefore, the manufacturing method of the high-pressure discharge lamp according to the present invention can manufacture the high-pressure discharge lamp with high work efficiency compared to the conventional method of erection the arc tube while bending the wire. Can be done.
[0036]
Moreover, in the manufacturing method of the high-pressure discharge lamp according to the present invention, the wire extends from one thin tube portion to the other thin tube portion of the arc tube with respect to the wire, and has an engaging portion that is engaged with each of the two thin tube portions. It is also characterized by adopting a configuration in which the state is processed, and the two anchoring portions are shifted from each other in the central axes related to the winding in a state before the wire is installed on the arc tube. Each of the engaging portions in the wire rod has a structure in which it is engaged with the thin tube portion with a number of turns of less than one turn.
In the manufacturing method of the high-pressure discharge lamp according to the present invention, after the above-described configuration is adopted, after the wire rod is installed on the arc tube, the central shaft for winding is not installed on the two engaging portions. A force to return to the state is applied. Therefore, adopting such a configuration is effective from the viewpoints of both the ease of laying the wire rod on the arc tube and the difficulty of detaching the wire rod after erection.
Therefore, in the method for manufacturing a high-pressure discharge lamp according to the present invention, the starting conductor can be installed on the arc tube with good working efficiency, which is advantageous in terms of cost.
[Brief description of the drawings]
1 is a side view of a metal halide lamp manufactured by the method according to an embodiment of the invention (partial sectional view).
FIG. 2 is a process diagram showing a process of attaching a starting lead wire 61 to the arc tube 30 in a process for manufacturing a metal halide lamp according to an embodiment of the invention.
FIGS. 3A and 3B are a side view and a top view showing the starting conducting wire 61 in a state before being installed on the arc tube 30. FIGS.
FIG. 4 is a side view (partially sectional view) of a conventional metal halide lamp.
FIG. 5 is a process diagram showing a process of laying a starting lead wire 161 to the arc tube 130 by a conventional manufacturing method.
[Explanation of symbols]
1. Metal halide lamp10. Outer tube 20. Base 30. Arc tube 31. Main body 32, 33. Capillary tube 60. Starting conductor 61. Lead wire for starting

Claims (2)

A method for manufacturing a high-pressure discharge lamp in which a starting lead wire for assisting starting is disposed in close proximity to or in contact with the surface of an arc tube,
A step of bending the wire for forming the starting lead wire in accordance with the outer surface shape of the arc tube;
Laying the wire material subjected to the bending process in a state where at least a part thereof is along the outer surface of the arc tube ,
The arc tube has a main body portion and two narrow tube portions extending from both ends of the main body portion,
In the step of performing the bending process, the wire has an engaging part for engaging with each of the two thin tube parts from the thin tube part to the other thin tube part of the arc tube. Is processed,
Each of the engaging portions in the wire rod is wound into a state of being engaged with the thin tube portion of the arc tube with a winding number of less than one turn,
The two anchoring portions corresponding to each of the two narrow tube portions in the arc tube are characterized in that the central axes of the windings are shifted from each other in a state before the wire is installed on the arc tube. A method for manufacturing a high-pressure discharge lamp. The method for manufacturing a high-pressure discharge lamp according to claim 1, wherein the wire contains at least one element selected from molybdenum, tungsten, niobium, and iron.

Images