JP4873373B2 - Disc for lamp with reflector, lamp with reflector and method of manufacturing lamp with reflector - Google Patents

Description

  The present invention relates to a disk used for a lamp with a reflector, a lamp with a reflector using the disk, and a method for manufacturing the lamp with a reflector.

In recent years, so-called integrated lamps in which a screw base cap is attached to a cover that holds a light source inside have become widespread. In the manufacture of this integrated lamp, a process of attaching the screw base cap to the cover is always required.
For example, according to the light bulb-type fluorescent lamp of Patent Document 1, a spiral screw groove that matches the internal screw shape of the screw base cap to be mounted is cut in the cap mounting portion of the cover, and the screw base cap is attached to the tip of the cover. The process of fixing both by screwing in is shown as a prior art. And in the same document, as a technical subject that precision is required for the formation of the screw groove, instead of providing a screw groove at the tip of the cover, the screw base cap is directly put on the tip of the cover by punching (caulking). A fixing process is disclosed.

Incidentally, in recent years, unlike the bulb-type fluorescent lamp disclosed in Patent Document 1, a PAR lamp as shown in FIG. 6B in which a ceramic metal halide lamp as shown in FIG. (Hereinafter referred to as “lamp with reflector”) has been developed.
Also in such a lamp with a reflector, a process of caulking the screw base base to a cover (reflector) is usually used. Here, the fixing effect obtained by caulking is different between the case of a bulb-type fluorescent lamp whose cover is made of plastic and the case of a lamp with a reflector made of glass etc., so the caulking structure and process of both are compared in the same row However, at least in a lamp with a reflecting mirror, it is common to fix the base and the reflecting mirror not only by caulking but also by bonding in order to secure the fixing strength.

FIG. 7 shows a manufacturing method of a conventional lamp with a reflector described in, for example, Japanese Patent Application No. 2006-039414.
As shown in FIG. 7A, first, the disk 20 is fixed to the reflecting mirror 1 by adhesion. As shown in FIG. 8, the disk 20 includes a lower portion 20a and a flange portion 20b, and a hole 20c into which the sealing portion 3a of the light source 3 can be inserted passes through the lower portion 20a and the flange portion 20b. And while the lower part 20a is inserted in the base attachment part 1a of the reflective mirror 1, the collar part 20b is contact | abutted to the upper end surface of the base attachment part 1a, and the outer surface of the disk lower part 20a and the inner surface of the base attachment part 1a are Glued.

Next, as shown in FIG. 7B, the sealing portion 3a is inserted into the hole 20c. At this time, the light source 3 is aligned with the reflecting mirror 1 in the optical axis direction, and the sealing portion 3a is bonded and fixed to the disk 20 after alignment.
Then, as shown in FIG. 7 (b), an adhesive 50 is applied to the base attaching portion 1a, and the screw base base 4 is put on and adhered thereto, and at the caulking position 1b (caulking portion 4c), the screw base is attached. The base 4 is crimped to the reflecting mirror 1. At this time, the lead wire 3 d connected to one external lead pin 3 b of the light source 3 is drawn out from the eyelet portion 4 a of the screw base cap 4, and the lead wire 3 e connected to the other external lead pin 3 c is connected to the screw base cap 4. It is pulled out from the skirt part 4b and welded (by electric welding or soldering) to the eyelet part 4a and the skirt part 4b, respectively. Thereby, the lamp with a reflecting mirror as shown in FIG. 6B is completed.
Japanese Patent Laid-Open No. 10-275555

However, the above-described adhesion between the reflecting mirror 1 and the screw base 4 has a problem in manufacturing and a problem in reliability of a finished product.
First, as a manufacturing problem, not only the process of applying the adhesive 50 but also the process of drying the adhesive 50 after attaching the screw base die 4 is required. There is a problem that improvement cannot be achieved.

  Moreover, about a finished product, there exists a problem that an adhesive agent will deteriorate by the heat cycle by lighting / light extinction by the heat from the light source 3 during lighting. Moreover, since an external force is applied due to the attaching / detaching operation of the lamp with the reflector, it is difficult to maintain the initial adhesive performance of the adhesive 50 during the lamp life of several thousand to 10,000 hours.

The present invention has been made to solve the above problems.
A first aspect of the present invention is a substantially cylindrical disk for fixing a light source in a reflector mounting portion of a reflecting mirror in a lamp with a reflecting mirror, and includes one bottom surface and an outer diameter larger than an inner diameter of the mouthpiece mounting portion. The first and second portions for inserting a part of the light source are composed of a small first portion (lower portion) and a second portion (a collar portion) including the other bottom surface and having an outer diameter larger than the inner diameter of the base mounting portion. In the disc having a hole penetrating through the portion, the outer surface of the second portion is a disc having a fitting shape portion that fits into the internal screw shape of the screw base die attached to the die attachment portion of the reflecting mirror.

Here, the fitting shape portion may be configured by at least one protrusion provided on the outer surface of the second portion. Then, it is preferable that the protrusion has a shape having a predetermined length in the outer peripheral direction of the second portion so that the inclination of the protrusion with respect to the bottom surface of the disk matches the screw angle of the screw base die.
In addition, the fitting shape portion is composed of at least one projection row composed of two or more projections provided in the second portion, and in each projection row, the inclination between the projections with respect to the bottom surface of the disk is a screw base die. It may be made to correspond to the screw angle.

  According to a second aspect of the present invention, there is provided a lamp with a reflecting mirror comprising a reflecting mirror having a light source fixed via the disk of the first side face and a screw base, and the screw base is screwed into the second part. In addition, a part of the screw base cap is a reflector-equipped lamp in which a portion of the screw base is crimped to a cap mounting portion of the reflector.

  According to a third aspect of the present invention, there is provided a method of manufacturing a lamp with a reflecting mirror, the step of fixing the light source inside the base mounting portion of the reflecting mirror through the disk on the first side, and a screw in the second portion. It is a manufacturing method including a step of screwing a base base and a step of crimping a part of the screw base base to a base mounting portion of a reflecting mirror.

In the manufacture of the lamp with a reflecting mirror, no adhesive is used for fixing the reflecting mirror and the screw base, so that it is possible to omit the application step and the drying step of the adhesive, thereby improving the production efficiency.
In addition, since the adhesive is not used in a portion where stress due to heat and external force is applied, the reliability of the product can be improved.

FIG. 1 is a view showing a disk of the present invention. In the present invention, members other than the disk 2 (the reflecting mirror 1, the light source 3, and the screw base 4) may be the same as those used in the prior art. In this embodiment, an E26 base is assumed for the screw base base 4.
The disk 2 includes a lower portion 2a, a flange portion 2b, a hole 2c, and a protrusion 2d. The difference from the conventional disk 20 is that the thickness of the flange 2b is thicker than that of the conventional flange 20b, and the protrusion 2d is provided there. The outer diameter of the lower part 2a is smaller than the inner diameter of the base attaching part 1a as in the lower part 20a of the prior art, and the outer diameter of the flange part 2b is smaller than the inner diameter of the base attaching part 1a as in the prior art flange part 20b. large.

FIG. 2 is a diagram for explaining a method of manufacturing a reflector-equipped lamp using the disk 2, and FIG. 3 is a flowchart of the manufacturing method.
Steps S101 to S103 are the same as those in the conventional example described with reference to FIG. Specifically, in step S101, the disk 2 is bonded to the base attaching portion 1a, and in step S102, the sealing portion 3a of the light source 3 is inserted into the hole 2c and the light source 3 is aligned in the optical axis direction. Then, the sealing portion 3 a is bonded to the disk 2.

  Next, in step S111, the screw base die 4 is screwed in the projection 2d (in the direction of the arrow in FIG. 2). Here, in the screwing process of step S111, in order to make the screwing work easier, a lubricant such as grease may be applied to the protrusion 2d to improve the sliding of the screw base. In step S111, it is necessary to pull out the lead wires 3d and 3e from the eyelet portion 4a and the skirt portion 4b, respectively, for the subsequent step S121.

In step S112, the screw base die 4 is caulked and fixed to the reflecting mirror 1 at the caulking position 1b. As a result, in the screw base die 4, 4 c becomes a crimped portion.
Finally, in step S121, the lead wires 3d and 3e are welded to the eyelet part 4a and the skirt part 4b of the screw base die 4 (by electric welding, soldering, etc.), respectively, as in the prior art, and the manufacturing is completed.

  By using the disk 2 provided with the projection 2d described above, the screw base cap 4 is securely fixed to the reflecting mirror 1 by the fitting effect of the projection 2d and the screw base cap 4 and the caulking effect.

  As for the details of the disk 2, as shown in FIG. 4 (a), when the protrusion 2d is formed with a certain length, the inclination with respect to the horizontal is the same as the screw angle (θ) of the screw base die 4 ( 1), and the width of the protrusion 2d needs to be accommodated in the screw groove.

  Further, as shown in FIG. 4 (b), the projection 2d may not have an angle in the oblique direction, for example, the cross section may be circular, polygonal, or the like. In this case, it is sufficient to consider only the size of the protrusion 2d, and the manufacture is easy.

  Further, as shown in FIG. 4C, one protrusion row 2e may be constituted by a plurality of protrusions 2d, and the protrusions 2d may be arranged in an oblique direction in the protrusion row 2e. In this case, the inclination formed by the protrusion 2d needs to coincide with the screw angle (θ) of the screw base die 4 (see FIG. 1). A plurality of protrusion rows 2e may be provided.

Further, it is desirable that the protrusion 2d is provided at one to five locations on the outer periphery of the flange portion 2b (see FIG. 5 (a) or (b)). When the single protrusion 2d is configured, only the shape of the protrusion 2d needs to be considered, and the arrangement thereof is arbitrary. On the other hand, when the plurality of protrusions 2 d are configured, the position of each protrusion 2 d needs to be at a position corresponding to the screw pitch of the screw base cap 4. 5 (a) and 5 (b), the protrusions of the type of FIG. 4 (a) are shown, but the same arrangement can be made for the protrusions of the type of FIG. 4 (b) or (c). .
Furthermore, the disk 2 is made of ceramic or the like, and high-precision processing is easy. For this reason, the entire outer portion of the flange portion 2b may have a screw shape that fits with the internal shape of the screw base die 4.

  In summary, as long as the projection 2d has a shape that fits into the screw shape inside the screw base die 4, the shape, arrangement, and number of each can be selected as appropriate. In other words, the shape and arrangement of the protrusions 2d provided on the disc or the outer surface shape of the flange portion 2b can be appropriately selected according to the material of the disc 2 and the capability (processing accuracy) of the processing machine.

  Although the E26 base is assumed as the screw base base 4 in the above, the concept of the present invention can be similarly applied to screw bases of other sizes or other standards. That is, since members other than the disk 2 (the reflecting mirror 1, the light source 3 and the screw base cap 4) may be conventional members, the disk and the manufacturing method of the present invention are generally used for various lamps with a reflecting mirror. Can be applied.

With the above configuration, since the bonding step can be eliminated when the screw base die 4 is fixed to the reflecting mirror 1, the manufacturing time can be shortened and the production efficiency is greatly improved.
In the fitting structure, since deterioration with time due to thermal factors cannot occur, the fixed state is reliably maintained, and the reliability of the lamp with a reflecting mirror can be improved.

It is a figure of the disk of this invention. It is a figure explaining the manufacturing method of the lamp with a reflecting mirror of this invention. It is a flowchart which shows the manufacturing method of the lamp | ramp with a reflecting mirror of this invention. It is a figure explaining the disk of this invention. It is a figure explaining the disk of this invention. It is a figure of a common light source and a lamp with a reflecting mirror. It is a figure explaining the manufacturing method of the conventional lamp | ramp with a reflecting mirror. It is a figure of the conventional disc.

Explanation of symbols

1. Reflector 1a. Base attachment part 1b. 1. Caulking position Disc 2a. Lower part 2b. Buttocks 2c. Hole 2d. Protrusion 2e. Projection row 3. Light source 3a. Sealing portions 3b, 3c. External lead pins 3d, 3e. 3. Lead wire Screw base 4a. Eyelet part 4b. Skirt portion 4c. Caulking section

Claims (6)

A substantially cylindrical disk for fixing a light source in a reflector mounting portion of a reflector in a lamp with a reflecting mirror, the first portion including one bottom surface and having an outer diameter smaller than the inner diameter of the cap mounting portion; and In the disk including the second bottom surface and including a second portion having an outer diameter larger than the inner diameter of the base mounting portion and having a hole penetrating the first and second portions for inserting a part of the light source,
A disk having a fitting-shaped portion in which an outer surface of the second portion is fitted into an internal screw shape of a screw base die attached to a die attaching portion of the reflecting mirror.   The disk according to claim 1, wherein the fitting-shaped portion includes at least one protrusion provided on the second portion.   3. The disk according to claim 2, wherein the protrusion has a shape having a predetermined length in the outer peripheral direction of the second portion, and the inclination of the protrusion with respect to the bottom surface of the disk matches the screw angle of the screw base cap. disk.   The disk according to claim 1, wherein the fitting-shaped portion includes at least one protrusion row including two or more protrusions provided on an outer surface of the second portion. A disc in which the inclination between the protrusions with respect to the bottom surface matches the screw angle of the screw base die. A reflector with a light source fixed through the disk according to any one of claims 1 to 4, and a lamp with a reflector comprising a screw base cap,
A lamp with a reflector, wherein the screw base cap is screwed into the second portion, and a part of the screw base cap is crimped to a cap mounting portion of the reflector. A method of manufacturing a lamp with a reflector,
Fixing the light source to the inside of the base mounting portion of the reflecting mirror via the disk according to any one of claims 1 to 4;
A manufacturing method, comprising: screwing a screw base cap into the second portion; and caulking a part of the screw base cap to a cap mounting portion of the reflecting mirror.

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