JPH0729552A - Manufacture of small electric lamp - Google Patents

Abstract

PURPOSE:To reduce manufacturing cost significantly by attaining full automation of a manufacturing process. CONSTITUTION:An exhaust tube 4, the outer lead parts 1a of welds 1, a stem tube 2 and cane glass 3 are combined with each other, and are formed as a stem, and an anchor wire is implanted in the tip of the cane glass 3, and a filament is installed between welds tips, and is formed as a mount. The outer lead parts 1a are run along the exhaust tube 4, and the curved parts are formed, and the mount is installed internally in a glass globe, and the stem tube 2 and the glass globe are heated and sealed, and the outer lead parts 1a derived from the mount part are opened right and left, and are bent to the glass globe side, and after the inside of the glass globe is evacuated, the exhaust tube 4 is welded and sealed in the vicinity of the sealing part, and is derived from the sealing part of the glass globe, and the outer lead parts 1a bent to the glass globe side are shaped so that the tip parts can run along an axis extending line of the glass globe. A base is fitted to the sealing part of the glass globe, and the outer lead parts 1a are fixed to the base, and the outer lead parts 1a are connected to the base by soldering.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a small light bulb, and more particularly to an improvement in a method for manufacturing a small light bulb with a base.

[0002]

2. Description of the Related Art Small-sized light bulbs with a base such as night bulbs used in general households and decorative bulbs have been used for a long time.
11 (a) to 11 (j), as schematically shown in the embodiment of the manufacturing process, the manufacturing process is performed through stem manufacturing, mount manufacturing, sealing, exhausting, mouthpiece attaching, and soldering. .

First, in the stem manufacturing process shown in FIG. 11 (a), a pair of wells (introducing wires) 1 consisting of an outer lead portion 1a, a dumet wire 1b and an inner lead portion 1c,
The stem tube 2, the cane glass 3 and the exhaust tube 4 are integrally combined and heated and welded to manufacture a stem.

Next, in the mount manufacturing process,
As shown in FIG. 11 (b), while the anchor wire 5 is implanted at the tip of the cane glass 3 of the manufactured stem, the wells 1
The filament coil 6 is suspended between the tips of the inner lead portions 1c, and a mount having a structure in which an intermediate portion thereof is suspended and supported by the anchor wire 5 is manufactured.

In the next sealing step, as shown in FIG. 11 (c), the prefabricated mount is inserted and supplied into the support hole of the mount rod 7 of the sealing mechanism, and the glass ball 8 is placed on the upper portion. To supply the mount to the interior state. Then, as shown in FIG. 11 (d), the stem tube 2 and the glass bulb 8 are heat-sealed to manufacture a sealed lamp. In addition, in this sealing step, the exhaust pipe 4 of the mount is inserted into the support hole of the mount rod 7 of the sealing mechanism. At this time, in order to avoid burning by a sealing gas burner (not shown), the outer lead The portion 1a is randomly arranged along the outer circumference of the exhaust pipe 4, and is inserted into the support hole of the mount rod 7 together with the exhaust pipe 4.

Further, in the next exhaust step, as shown in FIG.
As shown in (e), the inside of the glass bulb 8 is evacuated through the exhaust pipe 4, and then the exhaust pipe 4 is several mm from the sealing portion with the stem pipe 2 as shown in FIG. 11 (f). Exhaust lamps are manufactured by welding and sealing at remote locations. In this evacuation step, the outer lead portions 1a are randomly folded back to the glass bulb 8 side in order to avoid burning by a gas burner for sealing (not shown).

Next, in the base attachment process, FIG. 11 (g)
As shown in Fig. 4, after separating the outer lead portion 1a led out to the sealed end side of the exhaust lamp and folded back to the glass bulb 8 side by stretching it by hand or the like, these outer lead portions 1a are Base with adhesive applied to the wall 9
The base 9 is fitted into the sealing portion of the exhaust lamp while being inserted or arranged at a predetermined position by manual work (see FIG. 11).
(g) to (i)). Then, by supplying to a die baking mechanism (not shown) and heating and baking to cure the adhesive,
The base 9 is fixed to the exhaust lamp.

In the subsequent soldering step, as shown in FIG. 11 (j), each outer lead portion is attached to the soldering portion 9a of the base 9.
Solder and connect 1a. Furthermore, after this, the manufacturing of the small light bulb is completed through the final stage lighting inspection process (not shown).

[0009]

The manufacturing method of the small-sized light bulb is mass-produced and can be satisfied for the time being, but it has the following problems. That is, after the mount manufacturing process, in order to avoid or prevent the outer lead portion 1a from being burnt out by the sealing gas burner in the sealing step, the outer lead portion 1a is randomly contacted with the outer peripheral surface of the exhaust pipe 4, The outer lead part 1a is randomly placed on the glass ball 8 side in order to insert and load it into the support hole of the mount rod 7 together with the exhaust pipe 4 and to avoid burning by the gas burner for closing the exhaust pipe even at the exhaust stage. Is turning back. Then, due to the insertion / loading of the mount rod 7 into the support hole at the sealing stage, the folding back at the exhaust stage, and the like, the pair of outer lead portions 1a are
Entanglement and entanglement occur with each other. Therefore, it is difficult to automatically perform the work of extending the outer lead portion 1a, separating and shaping the outer lead portion 1a, and the like, which are indispensable in the base attachment process, by mechanical means. That is, there is a problem that it is difficult to achieve full automation in the manufacturing process of the small light bulb, and it is difficult to reduce the manufacturing cost.

The present invention has been made in consideration of the above circumstances, and an object of the present invention is to achieve the full automation of the manufacturing process in the manufacture of a compact light bulb and to significantly reduce the manufacturing cost accordingly.

[0011]

According to the method for manufacturing a compact electric bulb of the present invention, a pair of wells outer lead portions are shaped and arranged in a gate shape with respect to an exhaust pipe, and a stem tube and a cane glass are combined and heated.・ Stem manufacturing process for manufacturing a stem integrally by welding and mounting process for manufacturing a mount by implanting an anchor wire at the tip of the cane glass of the manufactured stem and mounting a filament between the wells tips. And shaping the first outer lead portion in which the outer lead portion of the manufactured mount is arranged along the exhaust pipe and a curved portion is formed in the outer lead portion so that a partial gap is provided between the outer lead portion and the exhaust pipe. Step, and a sealing process for internally mounting the mount in which the first outer lead portion has been shaped into a glass ball while heat-sealing the stem tube of the mount and the glass ball. And a step of shaping the second outer lead portion that opens the outer lead portion that is led out from the sealed mount portion to the left and right and bends to the glass bulb side, and glass that has been shaped for the second outer lead portion. After the inside of the bulb is evacuated, the exhaust pipe is welded / closed in the vicinity of the sealing portion, and the exhaust / seal process is performed, and the exhaust / sealed glass bulb is led out and bent to the glass bulb side. A step of shaping a third outer lead portion, in which the outer lead portion is shaped so that its tip portion is along the extension line of the glass bulb axis, and a sealing of the glass bulb in which the third outer lead portion is shaped. The method further comprises: a base fitting step of fitting the base to the stopper and fixing the outer lead portion to a predetermined position of the base; and a soldering step of connecting the outer lead portion to the fixed base by soldering. .

[0012]

According to the method of manufacturing a small light bulb of the present invention, when manufacturing a small light bulb through the steps of stem making, mount making, sealing, exhausting, capping, and soldering, a pair of small bulbs are produced at appropriate stages. The outline is that each of the outer lead parts of the above is added with each of the shaping operations of forming a bent portion, forming a curved portion, opening and bending the leg, and stretching and pushing down the outer lead portion. The shaping can be done automatically by mechanical means. And
By appropriately shaping the outer lead portion as described above in the manufacturing process, not only the outer lead portion is easily and reliably prevented from being burnt out by the gas burner in the sealing step and the exhaust step, but also the outer lead portion is avoided. Entanglement and entanglement of the parts are prevented, and shaping operations such as stretching in the mouthpiece attaching process can be automatically performed by mechanical means. In other words, automation of the entire manufacturing process is achieved,
Moreover, this full automation can significantly reduce the manufacturing cost.

[0013]

Embodiments of the present invention will be described below with reference to FIGS.

1 (a) to 1 (f) show respective steps of a stem manufacturing process in the embodiment of the method for manufacturing a compact light bulb according to the present invention, and FIGS. 2 (a) to 1 (l) show the steps after manufacturing a mount. Each process
It is the figure which showed each typically.

First, as shown in FIGS. 1 (a) to 1 (f), in this step, a pair of wells (consisting of an outer lead portion 1a, a Dumet wire 1b, and an inner lead portion 1c) is attached to an exhaust pipe 4. The outer lead part 1a is shaped and arranged in a gate shape,
The stem tube 2 and the cane glass 3 are combined and integrated by heating and welding to manufacture a stem.

The manufacturing process of this stem can be easily achieved by the following mechanism and means. FIG. 3 is a perspective view showing an example of a stem manufacturing mechanism, which has a structure in which a plurality of stem heads are arranged at equal intervals along the outer peripheral side of a turntable (not shown) that rotates intermittently. There is. Here, the stem head has a plurality of vertical holes for accommodating and supporting the inner lead portions 1c of the pair of wells 1 and the cane glass 3, respectively, and a wells holding means 10 arranged vertically, and above it. Opening / closing type stem tube holding means 11 and opening / closing type outer lead part holding means supported together with the stem tube holding means 11 and operating simultaneously
The exhaust pipe holding means 12 and the exhaust pipe holding means 13 are supported and arranged in a plurality of hollow columns 14 by a plurality of support shafts 15 penetratingly arranged therein. Then, corresponding to each stop position of the stem head due to the intermittent rotation of the turntable, the former stage is a supply means (not shown) for each member such as the pair of wells 1, stem tube 2, cane glass 3 and exhaust tube 4. ), An opening / closing cylinder 16 such as an air cylinder for opening / closing the opening / closing type holding means 11, 12, and a pair of open leg claws 17 and a pair of stop claws 18 forming the shaping means of the outer lead portion 1a, respectively. Deployed in close proximity. Also,
The latter part is a heating welding means (not shown) composed of a plurality of gas burners and a stem take-out means (not shown).
However, they are arranged close to each other.

In the stem manufacturing process, while the turntable is intermittently rotated, the above-described stem manufacturing mechanism is used to supply and heat-weld each member, and the outer member, as shown in FIGS. 1 (a) to 1 (f). The lead portion 1a is shaped.
That is, first, both the stem tube holding means 11 and the outer lead portion holding means 12 are opened, the cane glass 3 is supplied (FIG. 1 (a)), and then the stem tube 2 is supplied and the stem tube holding means 11 is supplied. Hold (Fig. 1 (b)).
After supplying a pair of wells 1 (Fig. 1 (c)),
The outer lead portion 1a of the wells 1 is shaped into a substantially gate shape (Fig. 1 (d)). Then, the exhaust pipe 4 was supplied (Fig. 1 (e).
After that, the above-mentioned members are heat-welded (FIG. 1 (f)).

Outer lead part in the stem manufacturing mechanism
The shaping of 1a will be described in detail with reference to FIGS. 4 (a) to 4 (d). 4 (b) to (c), the wells holding means
10 and the stem tube holding means 11, the wells holding means 10 are omitted in FIG. 4 (d).

First, as shown in FIG. 4 (a), the cane glass 3 is supplied to be inserted and supported in the vertical hole provided in the wells holding means 10, and then the stem tube 2 is supplied to hold the stem tube. After being held by the means 11, a pair of wells 1 is further supplied and supported by the vertical holes. In this state, the pair of open leg claws 17 (which constitutes the outer lead shaping means) that move forward and backward are arranged in front of the stem head.
A pair of stop claws 18 that advance and retreat with respect to each other are arranged above the left and right so as to face each other in the left and right directions. Then, as shown in FIG. 4 (b), the outer lead shaping moves forward with the open leg claw 17 closed to enter between the pair of outer lead portions 1a, and the stop claws 18 advance from the left and right with respect to each other. And stop at a predetermined position. At this time, the cane glass 3 and the wells 1 are held by the wells holding means 10, while the stem tube holding means 11 is opened, so that the stem tube 2 is supported by the wells 1.

Next, as shown in FIG. 4 (c), the open leg claw 17 is opened to push the outer lead portion 1a left and right. At this time, the vicinity of the tip of the pushed outer lead portion 1a hits the corresponding stopper claw 18, and as a result, the outer lead portion 1a
1a is shaped like a portal with its legs open. Then, Fig. 4 (d)
As shown in, the stem tube holding means 11 is closed again and the outer lead holding means 12 is closed to temporarily fix and hold the portal-shaped outer lead portion 1a. And
In this state, the exhaust pipe 4 is supplied, sandwiched and held by the exhaust pipe holding means 13, and then the respective members are heated and welded by the heat welding means, whereby the stem fabrication is completed.

Next, the manufacturing process of the small bulb after the stem manufacturing process will be described with reference to FIGS. 2 (a) to (l).

2 (a) to 2 (c) show an embodiment of the mount manufacturing process. First, the stem tube 2 portion of the manufactured stem is clamped and held by a clamp holding means (not shown). , The inner lead portions 1c are shaped so as to widen toward the tip so that the distance becomes wider, and the tip of the cane glass 3 is heated and softened to implant the required number of anchor wires 5 (Fig. 2 (a)). ). Next, as shown in FIG. 2 (b), the filament coil 6 is suspended at the tip of each inner lead portion 1c, and the intermediate portion thereof is fixed to the anchor wire 5
Suspend and support with. Subsequently, as shown in FIG. 2C, a curved portion 1d is formed on the outer lead portion 1a. Details of the outer lead shaping will be described with reference to FIGS. 5 and 6.

That is, as shown in FIG. 5 (a), with the stem tube 2 portion sandwiched and held, the opening / closing is performed from the side thereof, that is, from the direction in which the outer lead portions 1a and the exhaust pipe 4 are aligned. The paired lead guides 19 are moved forward to a predetermined position in an open state. Next, FIG. 5 (b) and FIG. 5 (b)
6, when viewed from the direction A, the lead guide 19 is closed, and the pair of outer lead portions 1a are sandwiched in a floating state so as not to shift back and forth, and then the lead guide 19 of the outer lead portion 1a. The upper side of the sandwiching portion is clamped together with the exhaust pipe 4 from the left and right by a pair of sandwiching and shaping claws 20 each having a laterally concave sandwiching surface. As a result, each outer lead portion 1a has a curved portion (a generally doglegged loose portion) 1d.
Are formed (shaping of the first outer lead portion). In this way, a mount having a partial gap between the outer lead portion 1a and the outer peripheral surface of the exhaust pipe 4 is completed. Therefore, the mount is transferred while being clamped by the clamping and shaping claw 20, and as shown in FIG. ) Insert and supply into the support hole of the mount rod 7 as shown in FIG.

FIG. 2 (d) shows an embodiment of the former stage of the sealing process which is the next process. At this stage, as described above, the outer lead portion 1a is inserted into the support hole of the mount rod 7 together with the exhaust pipe 4. After that, the glass bulb 8 is supplied and a predetermined portion is heated and sealed by a gas burner (not shown) for heating and sealing to complete a sealed lamp (small tube). In this sealing step, the curved portion 1d formed on the outer lead portion 1a elastically abuts on the inner peripheral surface of the support hole in a state where each outer lead portion 1a is inserted into the support hole, whereby Rotation of the mount due to vibration during operation of the sealing mechanism is prevented. In addition, even in the take-out stage after the completion of sealing, the outer lead portion 1a shaped in this way can be taken out from the support hole of the mount rod 7 in the same way as when inserting and supplying, so that it is automatically performed in the next step. The shaping means can be easily implemented.

Next, a leg opening means (not shown) is inserted into the curved portion 1d formed on the outer lead portion 1a of the sealed lamp (FIG. 2 (e)) and opened left and right (FIG. 2 (f)). ) Then, while being kept away from the exhaust pipe 4 by a bending means, as the shaping of the second outer lead, the shaping is performed by bending the glass bulb 8 side upward (FIG. 2 (g)). Details of the leg opening and bending of the outer lead portion 1a will be described with reference to FIGS. 7 (a) to 7 (d). First, as shown in FIG. 7 (a), while holding the exhaust pipe 4 by the exhaust pipe holding means 21 of the sealed lamp,
After moving the pair of open / close type lead opening means 22 forward and inserting the ends thereof into the gaps between the curved portion 1d of the outer lead portion 1a and the exhaust pipe 4, as shown in FIG. 7 (b), the lead opening means 22 is opened. The outer lead portion 1a opens in a fan shape and is separated from the exhaust pipe 4 by moving the leg means 22 in a circular arc upward while opening the leg means 22 to the left and right. Then, as shown in FIG. 7 (c), the pair of lead bending means 23 provided with two pins at their tips are advanced to pass the outer lead portion 1a between the two pins, and this state By rotating the lead bending means 23 by a predetermined angle (about 90 degrees), the outer lead portions 1a are respectively bent toward the glass ball 8 side (upward) as shown in FIG. 7 (d).

Next, in the evacuation process, the glass ball 8
The inside is evacuated and the exhaust pipe 4 is closed (heated and welded). The obtained exhaust lamp is shown in Fig. 2 (h). In this exhaust step, a gas burner is used to close the exhaust pipe 4, but in the previous step, each outer lead portion 1a is bent to the glass ball 8 side (upward), so it is sealed. Burnout due to an abatement gas burner is avoided.

Next, as shown in FIGS. 2 (i) to 2 (k), the base 9 is attached to the exhaust lamp. Before the base attaching step, the outer lead portion 1a is shaped by stretching or the like. . Details of the shaping will be described with reference to FIGS. 8 and 9. That is, first, as shown in FIG. 8 (a), the head portion of the glass ball 8 is held by the vacuum type holding means 24, and the outer lead portion 1a is moved by a pair of open / close and sandwich type lead stretching means 25 that move in an arc. Insert it and, as shown in Fig. 8 (b), stretch the curved part while handling it and correct it almost straightly. Then, as shown in FIG. 9 (a), the lead pressing means 26 arranged above is lowered to press down one of the outer lead portions 1a and fold it downward, and as shown in FIG. 9 (b). , Sandwiched by the lead receiving means 27 arranged below,
Shape the tip so that it extends along the extension of the lamp axis.
Outer lead shaping ... (Fig. 9 (c)). Next, in the middle stage of the base attachment process, as shown in FIGS. 10 (a) to (c),
Using the mouthpiece supply means 28 that performs an arc motion and a vertical motion,
The base 9 having the inner wall surface coated with the adhesive is fitted to the exhaust lamp, and the outer lead portions 1a are inserted and arranged at predetermined positions of the base 9. Further, in the subsequent stage, as shown in FIG. 10D, the adhesive is heated and cured by a die baking mechanism (not shown), and the die 9 is fixed to the exhaust lamp.

Further, in the soldering process, the base 9
Each outer lead portion 1a is soldered and connected to the soldering portion 9a. FIG. 2 (i) shows the state after the soldering is completed.
After that, through the usual lighting, inspection process, etc.,
Manufacture of small light bulbs completed.

[0029]

According to the method of manufacturing a small light bulb according to the present invention, the outer lead portions are shaped into the best shape separated from each other in all the steps from the stem manufacturing to the base attachment and the soldering. Therefore, the burnout by the gas burner is avoided, and the phenomenon that each outer lead part is entangled or entangled is eliminated. Therefore, when attaching the base, extend and separate the outer leads.
The shaping can be done automatically by mechanical means, eliminating the need for manual shaping. Therefore, it is possible to achieve full automation of the process in manufacturing the small light bulb, and it is possible to significantly reduce the manufacturing cost.

[Brief description of drawings]

FIG. 1A to FIG. 1F are schematic diagrams sequentially showing each step of a stem manufacturing process in an embodiment of a method for manufacturing a small light bulb according to the present invention.

2 (a) to (l) are schematic views sequentially showing each step after the mount is manufactured in the embodiment of the method for manufacturing a compact electric bulb according to the present invention.

FIG. 3 is a perspective view showing a structural example of a stem manufacturing mechanism used in the implementation of the method for manufacturing a small light bulb according to the present invention.

4 (a) to (d) are schematic views showing a step of shaping the outer lead portion in the stem manufacturing step in the embodiment of the method for manufacturing a small light bulb according to the present invention.

5 (a) to 5 (c) are schematic views showing a step of shaping the outer lead portion immediately after the mount is manufactured in the embodiment of the method for manufacturing a compact light bulb according to the present invention.

6 is an arrow view from the direction A in FIG. 5 (b).

7 (a) to 7 (d) are schematic views showing a step of opening the outer lead portion of the sealed lamp and then bending and shaping the outer lead portion in the embodiment of the method for manufacturing a small light bulb according to the present invention.

8 (a) and 8 (b) are schematic views showing a step of stretching the outer lead portion in the preceding stage of the base attaching step in the embodiment of the method for manufacturing a small light bulb according to the present invention.

9 (a) to 9 (c) are schematic views showing a step of pressing down and shaping the outer lead portion in the base attachment step in the embodiment of the method for manufacturing a small light bulb according to the present invention.

10 (a) to 10 (d) are schematic views showing a process of fitting and fixing a base to an exhaust lamp in the embodiment of the method for manufacturing a compact electric bulb according to the present invention.

11 (a) to 11 (j) are schematic views showing a main part of an embodiment of a conventional method for manufacturing a compact light bulb in process order.

[Explanation of symbols]

1 ... Wells 1a ... Outer lead part 1b ... Dumet wire 1c ... Inner lead part 1d ... Curved part 2
… Stem tube 3… Cane glass 4… Exhaust tube 5
… Anchor wire 6… Filament coil 7… Mount rod 8… Glass ball 9… Base 9a… Soldering part 10…
Wells holding means 11 ... Stem tube holding means 12 ... Outer lead holding means 13 ... Exhaust tube holding means 14 ... Hollow column 15 ... Support shaft 16 ... Open / close cylinder
17… Opening claw 18… Stopping claw 19… Lead guide 20
… Clamping and shaping claws 21… Exhaust pipe holding means for sealed lamps 22
... Lead opening means 23 ... Lead bending means 24 ... Vacuum type holding means 25 ... Lead stretching means 26 ... Lead pushing means 27
… Lead receiving means 28… Clasp supply means

Claims (1)

[Claims] 1. A stem manufacturing process in which an outer lead portion of a pair of wells is shaped and arranged in a gate shape with respect to an exhaust pipe, and a stem pipe and a cane glass are combined and integrated by heating and welding to form a stem. While mounting an anchor wire at the tip of the cane glass of the manufactured stem, a mount manufacturing step of manufacturing a mount by mounting a filament between the wells tips, and an outer lead part of the manufactured mount as an exhaust pipe. A first outer lead portion shaping step of forming a curved portion in the outer lead portion so that a partial gap is provided between the first outer lead portion and the exhaust pipe; and shaping of the first outer lead portion. While mounting the mount inside the glass bulb, the stem tube of the mount and the glass bulb are sealed by heating, and the mount is led out from the sealed mount portion. A step of shaping the second outer lead portion in which the outer lead portion is opened to the left and right and bent toward the glass bulb, and after the glass bulb in which the second outer lead portion has been shaped is evacuated, the exhaust pipe is sealed. Exhaust / sealing process of welding / sealing in the vicinity of the part, and the outer lead part bent out toward the glass sphere and led out from the sealing part of the exhausted / sealed glass sphere, the tip of which is a glass sphere. A third outer lead portion shaping step of shaping along the extension line of the shaft, and a mouthpiece fitted to the sealing portion of the glass bulb on which the third outer lead portion has been shaped to fit the outer lead portion. A method of manufacturing a small light bulb, comprising: a base attachment step of fixing the base to a predetermined position, and a soldering step of connecting an outer lead portion to the fixed base by soldering.