JP4482721B2 - Manufacturing method of lamp with reflector and the lamp - Google Patents

Description

The present invention relates to a lamp with a small reflector used mainly in combination with a reflector in the field of video equipment and optical equipment, and a method of manufacturing the same.

Conventionally, light source devices related to lamps with small reflectors are mainly used in projectors, projection TVs, projectors, etc., and are compact and lightweight with high resolution, high definition, improved brightness, uniformity of irradiated screen, low cost, etc. There is a continuous demand for the system.
Further, in order to meet such a demand for small size and light weight, the lamp with a reflector, which is a central device, is required to be further downsized and output.

Further, with the miniaturization of the mirror, the wiring for supplying power to the lamp is also simplified.
For example, as shown in FIG. 1 of Patent Document 1, the power supply terminal is directly attached to the power supply terminal mounting hole provided on the outer surface of the reflector by eyelet or the like, and a lamp seal is attached to the power supply wire crimping portion of the power supply terminal. Wiring for supplying power to the lamp is performed by collectively crimping and connecting a power supply line connecting the stop portion to the crimp terminal and an external power supply line connecting the external device such as a lamp power source to the crimp terminal. Similar wiring attachment examples are shown in FIG. 1 of Patent Documents 2 to 4 and FIG. 2 of Patent Document 5. However, in any case, the external power supply line is omitted.

JP 09-063337 A Japanese Patent Laid-Open No. 08-069777 Japanese Patent Laid-Open No. 11-204085 JP 2004-335363 A Japanese Patent Laid-Open No. 08-069775

Although the power supply method as in Patent Document 1 can surely reduce the size around the reflecting mirror, manufacturing the lamp with the reflecting mirror requires the following work procedure. Hereinafter, a description will be given with reference to FIG.
(1) In FIG. 2A, the power supply terminal 8 is attached to the power supply terminal mounting hole 14 provided on the reflecting surface of the reflecting mirror 4 by using eyelets. The power supply terminal 8 includes an attachment portion 12 provided with a hole for attaching to the reflecting mirror, and a cylindrical power supply wire crimping portion 13 for inserting and fixing the power supply wire 10 by crimping.
(2) In FIG. 2B, the arc tube 1 is inserted into the reflecting mirror 4, the arc tube 1 is temporarily turned on, and the arc tube 1 is aligned. At this time, the feeding line 10 is passed from the reflecting surface side of the reflecting mirror 4 through the feeding terminal mounting hole 14 to the outside, and the end of the feeding line 10 is connected to a power supply for temporary lighting. It does not pass through the hole provided in the feeder line crimping part 13, so that an excessive force is not applied to the arc tube 1 when the arc tube 1 moves when the position of the arc tube 1 is adjusted.
(3) In FIG. 2C, with the position of the arc tube 1 determined, an adhesive is poured between the reflecting mirror 4 and the arc tube 1 to fix them.
(4) In FIG.2 (d), a part of feeder 10 is cut | disconnected. This is because the length of the feeder line 10 is set to a length necessary for adjusting the position of the arc tube up to the previous section. However, if it is left as it is, it is too long to pass through the hole provided in the feeder line crimping portion 13. Because.
(5) In FIG. 2 (e), the tip of the power supply line 10 protruding to the outside of the reflecting mirror 4 is bent so as to enter the hole provided in the power supply line crimping portion 13.
(6) In FIG. 2 (f), using radio pliers or the like, all the part of the feeder line 10 protruding outside the reflector 4 is passed through the hole provided in the feeder line crimping part 13 of the feeder terminal 8.
(7) In FIG. 2 (g), the feed wire crimping portion 13 can be used with crimping pliers while the feed wire 10 is deformed so as to be substantially parallel to the central axis of the hole provided in the feed wire crimping portion 13. Then, the excess power supply line 10 coming out from the power supply line crimping portion 13 of the power supply terminal 8 is cut.
(8) The external power supply line and the power supply line 10 are connected by passing an external power supply line (not shown) through the hole provided in the power supply line crimping part 13 and pressing the power supply line 10 together.

The feeder 10 is usually made of Ni wire or Ni—Mo alloy wire. If the wire diameter is 0.2 mm or less, the above operation can be easily performed. However, in a commercially available lamp with a reflector, the feeder wire 10 is a normal wire. Since the diameter is 0.3 to 0.6 mm and the bending rigidity of the power supply line 10 is large, the efficiency of the operation of passing through the crimping hole of the power supply terminal 8 described in (6) is very poor.
Further, in the description of FIG. 2G of (7) above, the work for raising the feeder crimping portion 13 to approximately 90 degrees with respect to the outer surface of the reflecting mirror requires bending the feeder wire 10 inserted in the feeder crimping portion 13 together. Therefore, a larger force is required than bending the power supply terminal 8 alone.
In addition, in the description of FIG. 2F of (6), when the feeder 10 is passed through the hole provided in the feeder crimping portion 13, an excessive force is applied to the arc tube 1 connected to the feeder 10. In some cases, the end of the arc tube 1 fixed to the reflecting mirror 4 may be broken.
Further, in the description of FIG. 2E of (5) above, after the feeder line crimping portion 13 of the feeder terminal 8 is raised to approximately 90 degrees with respect to the mounting portion on the outer surface of the reflecting mirror 4, the feeder wire 10 is crimped to the feeder line. Although there is also a method of passing through the section 13, this is further inferior in workability.
In the above description of the operation, the feeder 10 is cut twice. However, at the time of the first cut, since the size of the portion finally protruding from the feeder crimping portion 13 is not known, the cut with a sufficient length is made. This is because it is necessary to cut the length to the correct length after actually bending the feeder line crimping portion 13 and the feeder line 10.

The present invention provides a reflector for facilitating workability even in a miniaturized light source device when a feeder line connected to the outside from an end of an arc tube sealing portion of a lamp with a reflector is fixed on the outer surface of the reflector. An object of the present invention is to provide a manufacturing method of a lamp with a mirror and a lamp structure with a reflecting mirror using the component.

In order to achieve the above object, the manufacturing method of the present invention includes a double-end type high-pressure discharge lamp having two sealing portions extending from both ends of an arc tube in which a luminescent material is sealed. In a method for manufacturing a lamp with a reflector, in which the electrode axis of the discharge lamp and the optical axis of a reflector having a reflecting surface such as a parabolic ellipsoid are arranged substantially in parallel; Fixing a power supply terminal having a structure in which a power supply line can be inserted from a gap or opening provided along a direction to the outside of the reflecting mirror; and feeding the power supply line from the reflecting surface side of the reflecting mirror to the outside A step of pulling out; a step of positioning the arc tube by temporarily lighting the arc tube; and an inorganic heat resistance between the reflector and the arc tube with the position of the arc tube being determined. Pour the adhesive and fix both Process and that; step the put in through the gap or opening of the power supply terminals without cutting the power feed line drawn to reflector outside of the feeding wire bonding portion, and then cut the excess power supply line And a step of crimping and fixing the power supply line to the power supply terminal together with the external power supply line.

A lamp manufactured by applying the manufacturing method of the present invention is a double-end type high-pressure discharge lamp having two sealing portions extending from both ends of an arc tube in which a luminescent material is sealed. In a lamp with a reflecting mirror in which the electrode axis of a high-pressure discharge lamp and the optical axis of a reflecting mirror having a reflecting surface such as a parabolic ellipsoid are arranged substantially parallel to each other; a power feeding terminal outside the reflecting mirror; The portion of the power supply terminal that crimps and holds the power supply line is bent at both ends of the flat plate at the time before the power supply wire is crimped, and the power supply line is formed by the flat plate and the side surface serving as the bottom surface. A groove portion for insertion is formed, and an interval between both plates forming both wall surfaces of the groove portion is crimped and fixed to the power supply terminal on the end side which is an opening portion on the side facing the bottom surface. Is it sufficiently larger than the diameter of the power supply line The has a shape having an opening which is shaped to be smaller than the spacing in the vicinity of the bottom face of the groove portion, the feed line from the Ni lines or Ni-Mo alloy wire having a diameter 0.3~0.6mm This is a lamp with a reflector.

As described above, by applying the manufacturing method of the present invention, it becomes easy to attach the power supply line to the power supply terminal, the work process is improved as follows, and workability is improved.

That is, since the feeder line is inserted through a gap or opening provided along the longitudinal direction of the feeder line crimping portion, the operation becomes much easier than the operation of pushing the wire from the cylindrical end face. Further, it can be inserted into the feeder crimping portion of the feeder terminal without being cut before the insertion.

According to the manufacturing method of the present invention, when the feeder line connected to the outside from the end of the arc tube sealing portion of the lamp with the reflecting mirror is fixed on the outer surface of the reflecting mirror, the operability can be achieved even in the downsized light source device. It is possible to provide a method of manufacturing a reflector-equipped lamp that makes it much easier. In addition, the number of parts is the same as before, which can be implemented with almost no additional material cost. The workability and manufacturing yield of fixing through the feeder line are dramatically improved, and the lamp manufacturing cost is drastically reduced. Since an excessive force is not applied to the power supply line, there is an advantage that there is no risk of damaging the arc tube.
In addition, by adopting the above manufacturing method, it is possible to provide a lamp with a reflector whose manufacturing cost is drastically reduced compared with the conventional product.

In order to carry out the manufacturing method of the present invention, the power supply terminal provided with a gap or opening having a width through which the power supply line passes along the longitudinal direction of the power supply line crimping part is reflected before the power supply line is crimped. Attached to the outside of the mirror, bend the feeder crimping part before inserting the feeder, insert the feeder into the feeder crimping part from the gap or opening, and plug the feeder once before inserting the external feeder After cutting, the external power supply line and the power supply line may be crimped and fixed together.
In addition, in order to manufacture the lamp with a reflector according to the present invention, the feeder line is connected at the time before the feeder line is crimped along the longitudinal direction of the feeder line crimp portion of the feeder terminal attached to the outside of the reflector. A power feeding terminal provided with a gap or opening having a width to pass through may be used. In addition, about the other components which comprise a lamp with a reflecting mirror, the completely same components as before can be used.
Specific shapes will be described in the following examples.

FIG. 1 is a view in which a part of an embodiment of a lamp with a reflector according to the present invention is omitted. In FIG. 1, reference numeral 1 denotes an arc tube, which is usually made of quartz glass. Electrodes 2a and 2b are embedded and fixed in sealing portions at both ends of the arc tube 1. The distance between the electrodes 2a and 2b and the arc length are 1.0 mm.

In the arc tube 1 formed in this way, halogen gas, Hg, and starting argon are enclosed as an enclosure. 3a and 3b are molybdenum foils connected to the electrodes 2a and 2b, are connected to the lead wire 7 and the rear lead wire 9, and are connected to a ballast via an external power supply line (not shown). Here, the lead wire 7 on the reflecting surface side is connected to the feeder line 10, and the feeder line 10 protrudes from the feeder line mounting hole 14 provided in the reflector 4 to the outside of the reflector 4, and is fed to the feeder terminal 8. It is passed through the crimping part and crimped together with an external power supply line (not shown) and connected to a lighting power supply (not shown). On the other hand, the rear lead wire 9 on the side of the base 5 is connected to the other external power supply line (not shown) by a rear crimping sleeve 11.

The arc tube 1 is fixed to the bottom of the reflector 4 with an inorganic heat-resistant adhesive 6 mainly composed of alumina and silica via a base 5 to constitute a lamp with a reflector. The reflecting mirror 4 has an outer size of 50 mm × 50 mm and a focal length F of 7 mm.

In the lamp with a reflecting mirror, the feeding terminal 8 is fixed to the feeding terminal mounting hole 14 provided on the outer surface of the reflecting mirror 4 by a method such as eyelet before the feeding line 10 and the external feeding line are crimped and fixed.
Thus, when the power supply terminal 8 is crimped and fixed with the eyelet, since the eyelet is hollow, a hole penetrating the reflecting mirror at the center of the eyelet even after the power supply terminal 8 is fixed to the reflecting mirror 4, a so-called power supply line through hole is provided. The power supply terminal 10 can be pulled out from the reflective surface side of the reflecting mirror 4 by using the power supply terminal mounting hole 14. In addition to the eyelets, if the fixing method is such that a hole penetrating the reflecting mirror 4 remains after the feeding terminal 8 is fixed, a hole to be opened in the reflecting mirror 4 is provided for the feeding line through hole and the feeding terminal mounting hole. Can be common.
When a fixing method using a copper rivet or the like without a hollow portion is used, it is necessary to provide a small hole for passing the power supply line 10 in the vicinity of the attachment hole 14 for fixing the power supply terminal.
As shown in FIG. 3A, the feeder line crimping portion 13 is provided with a gap or an opening 15 along its longitudinal direction. A cross section perpendicular to the longitudinal direction of the feeder crimping portion 13 has a shape shown in FIG. Further, in FIG. 4A-1, the gap 15 has substantially the same width, but the gap may be wide on the outer side or outer peripheral side and narrow on the inner side or inner peripheral side. An example is shown in FIG.
In order to make this shape, for example, a commercially available round terminal-type crimp terminal is used as a material, and a substantially cylindrical portion is formed by a processing machine such as a slitter along the longitudinal direction of the substantially cylindrical portion which is the feeder crimp portion 13. A notch from the one end surface to the other end surface is provided. The gap may be formed by evaporating the relevant part by laser irradiation or the like.

In the method for manufacturing the reflector-equipped lamp configured as described above, improvement in workability will be described.
FIG. 3 is an explanatory diagram illustrating the method of manufacturing a lamp with a reflector using the present invention, as necessary, with an overall view of the reflector or a partially enlarged view.
When the manufacturing method according to the present invention is applied, the crimping part processing procedure is simplified as follows.

(1) In FIG. 3A, the power supply terminal 8 is attached to the power supply terminal mounting hole 14 provided on the reflecting surface of the reflecting mirror 4 using eyelets. At this time, if the power supply line crimping portion 13 of the power supply terminal 8 is bent at an angle at which the crimping operation can be performed before being attached to the reflecting mirror 4, and approximately 90 degrees with respect to the outer surface of the reflecting mirror 4, the subsequent workability is further facilitated. . Of course, the feed wire crimping portion 13 may be bent after the feed terminal 8 is fixed to the reflecting mirror 4.
(2) In FIG. 3B, the arc tube 1 is inserted into the reflecting mirror 4, the arc tube 1 is temporarily turned on, and the arc tube 1 is aligned. At this time, the feeder 10 is passed from the reflecting surface side of the reflector 4 through the feeder terminal mounting hole 14 to the outside, and the end thereof is temporarily connected to a power supply for temporary lighting. When the arc tube 1 is moved when adjusting the position of the arc tube 1 without passing through the wire crimping portion 13, it is ensured that no excessive force is applied to the arc tube 1.
(3) In FIG. 3C, the inorganic heat resistant adhesive 6 is poured between the reflecting mirror 4 and the arc tube 1 in a state where the position of the arc tube 1 is fixed, and both are fixed.
(4) In FIG. 3 (d), the feeder 10 for feeding power to the electrode sealed on the lamp reflecting surface side is passed through the hole of the feeding terminal 8 attached to the reflecting mirror 4 from the reflecting surface side of the reflecting mirror 4. Pass outside. Next, when the front end portion of the power supply line 10 protruding to the outside of the reflecting mirror 4 is tilted toward the power supply line crimping portion 13, the power supply line extends from the gap or opening 15 provided along the longitudinal direction of the power supply line crimping portion 13. 10 can be put in the feeder line crimping part 13.
(5) In FIG.3 (e), the said feeder 10 is completely pushed in to the feeder crimping part 13, and the excess feeder 10 is cut. Next, the external power supply line and the power supply line 10 are connected by passing an external power supply line (not shown) through the power supply line crimping part 13 and crimping it together with the power supply line 10.

In FIG. 3 (d), since the gap 15 is open on the substantially cylindrical side surface that is the feeder line crimping portion 13 of the feeder terminal 8, the feeder wire 10 is inserted into the feeder line crimping portion 13 from there. It has a shape that can be inserted, and even if the feeder 10 is long, workability is not affected. Therefore, it is not necessary to cut the power supply line twice during the process of crimping and fixing the power supply line 10 to the power supply terminal 8 as in the conventional example, and the power supply is performed in the process immediately before the external power supply line is inserted into the power supply line crimping part 13. What is necessary is just to cut the electric wire 10 once.
Further, in FIG. 3A, the power supply line 10 is inserted into the power supply line crimping part 13 even if the power supply line 10 is bent at an angle that allows a crimping operation before the power supply line 10 is inserted into the power supply line crimping part 13 of the power supply terminal 8. There is no effect on the workability of the process.
Thus, according to the manufacturing method of the present invention, almost all problems in the conventional work process can be solved.

Using a general crimping terminal that has been die-molded in the shape of a flat wire crimping part as a material, the feeder crimping part 13 is bent and formed into a U-shaped opening as shown in FIG. 4B. Use things. By using such a power supply terminal 8, the power supply line 10 and the external power supply line can easily enter the power supply line crimping portion 13.

Using a general crimp terminal punched and molded in the shape of a flat wire crimp portion, the feeder crimp portion 13 is bent into a shape having an opening as shown in FIG. The gap or opening 15 is closed so that the portion opened from the U-shape is narrow, and has a shape similar to a horseshoe when viewed from the end face.
Although it is more difficult to insert the electric wire than in the second embodiment, the electric wire that has been once inserted is less likely to be pulled out, so that the electric wire does not protrude from the feeder crimping portion 13 in the crimping step.
As another embodiment, a prismatic shape may be used as a modified example of the substantially cylindrical power line crimping portion.

In the embodiment, the short arc type mercury lamp is used to explain the present invention. However, it is obvious that a metal halide lamp and a xenon lamp having the same structure have the same effect.

The present invention is used as a light source device mainly for projectors, projection TVs, projectors and the like used in combination with reflectors in the field of video equipment and optical equipment.

1 is an overall view of a lamp with a reflector according to the present invention. (A)-(g) is a manufacturing method explanatory drawing of the conventional lamp | ramp with a reflecting mirror. (A)-(e) is explanatory drawing of the manufacturing method of the lamp | ramp with a reflecting mirror of this invention. The enlarged view which looked at the electric power feeding terminal crimping part in Examples 1-3 of this invention from the end surface direction is (a)-(c).

Explanation of symbols

1 arc tube 2a, 2b electrode 3a, 3b molybdenum foil 4 reflector 5 base 6 inorganic heat resistant adhesive 7 lead wire 8 feed terminal 9 rear lead wire 10 feed wire 10
11 Rear crimping sleeve 12 Mounting portion 13 Feed line crimping portion 14 Feeding terminal mounting hole 15 Clearance or opening

Claims (2)

A double-ended high-pressure discharge lamp having two sealing portions extending from both ends of a light-emitting tube in which a light-emitting substance is sealed is provided with a reflection surface such as an electrode axis of the high-pressure discharge lamp and a parabolic elliptical surface. In a method for manufacturing a reflector-equipped lamp in which the optical axes of the reflectors provided on the inner side thereof are substantially parallel to each other; a feed line from a gap or an opening 15 provided along the longitudinal direction of the feed line crimping part 13 A step of fixing a power supply terminal having a structure capable of inserting the power supply terminal to the outside of the reflecting mirror; a step of pulling out the power supply line from the reflecting surface side of the reflecting mirror; and a step of temporarily lighting the arc tube A step of aligning the arc tube; a step of pouring an inorganic heat-resistant adhesive between the reflector and the arc tube in a state where the position of the arc tube is fixed, and fixing both; and the reflection Pulled out of the mirror The feed line to the power supply terminal with an external power supply line; the placed through the gap or opening of the power supply terminals without cutting the power supply line in said feed line crimping portion, then cutting the excess feed line to process and A method of manufacturing a lamp with a reflecting mirror, comprising: a step of crimping and fixing. A double-ended high-pressure discharge lamp having two sealing portions extending from both ends of a light-emitting tube in which a light-emitting substance is sealed is provided with a reflection surface such as an electrode axis of the high-pressure discharge lamp and a parabolic elliptical surface. In a lamp with a reflecting mirror that is combined with the optical axis of the reflecting mirror on the inside in a substantially parallel state; a feeding terminal is provided on the outside of the reflecting mirror; the feeding terminal is a part that crimps and holds the feeding line The both sides of the flat plate are bent to form side surfaces, and a groove portion is formed by the flat plate serving as the bottom surface and the side surface; the distance between both plates forming both wall surfaces of the groove portion is on the side facing the bottom surface At the end that becomes the opening, the power supply terminal that is formed to be sufficiently larger than the diameter of the power supply line to be crimped and fixed to the power supply terminal and smaller than the interval in the vicinity of the bottom surface of the groove portion is used . Feed line is wire Lamp with reflector for being Ni lines or Ni-Mo alloy wire 0.3 to 0.6 mm.

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