JPH0762999B2 - Far infrared heater lamp manufacturing method - Google Patents

Description

The present invention relates to a method for manufacturing a far infrared heater lamp.

[Background of the Invention]

The far-infrared heater lamp is used, for example, in heating appliances such as a stove and kotatsu, a dryer, a medical device, etc., and the main far-infrared ray emitted is usually 3 μm or more in wavelength.

The far-infrared heater lamp usually employs an incandescent bulb type configuration in which a filament is arranged inside a sealed body, and quartz glass is used as the sealed body.

Thus, from the viewpoint of increasing the radiation efficiency of far infrared rays, conventionally, a ceramic far-infrared radiation coating is provided on the outer surface of a quartz glass envelope.

Examples of materials for forming the far infrared radiation coating include zircon oxide-titanium oxide (ZrO ₂ —TiO ₂ ) based materials, lithium oxide-aluminum oxide-silicon dioxide (Li ₂ O—Al ₂ O ₃ —S
iO ₂ ) based materials, transition element oxides, alkali metal oxides,
Ceramic materials such as alkaline earth metal oxides are known.

By providing a ceramic far-infrared radiation coating as described above on the outer surface of the envelope, radiated light obtained by heating the filament is converted into a distribution of far-infrared rays when passing through the far-infrared radiation coating. , The radiation efficiency of far infrared rays is improved.

In recent years, a ceramic material containing phosphorous oxide has recently attracted attention as a material capable of obtaining a ceramic far-infrared radiation coating having high adhesion to quartz glass and excellent durability. .

[Problems to be solved by the invention]

However, when forming the far-infrared radiation coating with a ceramic material containing phosphorous oxide, as shown in FIG. 2, when fingerprints, dust, or the like adhere to the far-infrared radiation coating 80, the adhered portion 81 is removed. It turned out that there was a problem that it turned black, the quality of the appearance was inferior, and the commercial value decreased.

The present inventor has made extensive studies on the cause of the above-mentioned blackening, and during the lighting of the far-infrared heater lamp, the coating film 80 has a high temperature of, for example, about 350 to 600 ° C., and is included in fingerprints, dust, etc. attached to the coating film 80. It was found that the carbon atoms contained therein are liberated by the catalytic action of phosphoric acid generated due to the phosphorus oxides present in the coating film 80 to form a carbide.

On the other hand, an attempt was made to suppress the occurrence of the blackening phenomenon due to phosphorous oxide by using an oxidant together as a material for forming the coating film 80, but such a means sufficiently suppresses the blackening phenomenon. Turned out to be impossible.

[Object of the Invention]

The present invention has been made based on the above circumstances, and its object is to provide a far-infrared radiation coating having a large durability and a high far-infrared radiation efficiency with a simple structure, and further having a far-infrared radiation efficiency. It is an object of the present invention to provide a method of manufacturing a far infrared heater lamp capable of sufficiently preventing the occurrence of a blackening phenomenon in a coating film.

[Means for solving problems]

The present invention is an incandescent light bulb comprising a quartz glass envelope,
In the method for producing a far-infrared heater lamp having a coating for far-infrared radiation provided on the outer surface of the quartz glass envelope of the incandescent lamp, the outer surface of the quartz glass envelope of the incandescent bulb is phosphorylated. A far infrared radiation coating is formed by forming a far infrared radiation coating forming thin film with a ceramic material containing a substance, and treating the surface of this far infrared radiation coating forming thin film with an aqueous solution of an alkaline earth metal compound. Is formed.

[Advantageous effects of the invention]

In the far-infrared heater lamp manufactured by the method of the present invention, since the material for the incandescent lamp enclosure is quartz glass, and the far-infrared radiation coating is formed of a ceramic material containing phosphorous oxide, The adhesion strength of the coating to the quartz glass is extremely large, and the durability of the coating is remarkably high, and damage such as peeling of the coating is unlikely to occur, and the surface of the coating forming thin film for forming the coating is treated with a specific aqueous solution. As a result, the phosphorus oxide in the film for forming a film is converted into a substance that does not act as a catalyst, and as a result, even when fingerprints, dust, etc. adhere to the resulting film for emitting far infrared rays, the adhered part The occurrence of blackening phenomenon is sufficiently suppressed, the appearance quality is maintained stable for a long time, and the commercial value is improved.

[Specific configuration of the invention]

Hereinafter, the manufacturing method of the present invention will be specifically described with reference to the drawings. FIG. 1 is an explanatory sectional view showing a far infrared heater lamp manufactured by the method of the present invention. In the figure, 10 is an incandescent lamp, and 20 is a coating for emitting far infrared rays.

In the incandescent light bulb 10, 11 is a long straight tubular quartz glass envelope, 12 is a long filament made of, for example, tungsten, 13 is a metal foil for airtight sealing made of molybdenum, 14
Is an external lead, and 15 is, for example, a ring-shaped supporter.
The incandescent light bulb 10 in the illustrated example is a double-end sealed type in which sealed portions are formed at both ends.

Both ends of the filament 12 are connected and fixed to the metal foils 13 and 13 so as to extend along the tube axis of the envelope 11, and are held in place by a plurality of supporters 15. The metal foils 13, 13 are airtightly embedded and fixed in the end sealing portions, and external leads 14, 14 are connected and fixed to the outer end sides thereof.

The far-infrared radiation coating 20 is a thin film for film formation (hereinafter also simply referred to as a “thin film”) formed on the outer surface of the quartz glass envelope 11 by a ceramic material containing phosphorous oxide. It is formed by a method of treating with an aqueous solution of a metal compound.

Examples of the phosphorus oxide contained in the ceramic material forming the far infrared radiation coating 20 include phosphorus pentoxide (P ₂ O ₅ ), aluminum phosphate (AlPO ₄ ), and the like. The amount of such phosphorus oxide used is preferably about 5 to 15% by weight of the ceramic material. When the amount of phosphorus oxide used is too small, the adhesion strength of the far infrared radiation coating 20 decreases, while when it is too large, the far infrared radiation efficiency decreases. When aluminum oxide (Al ₂ O ₃ ) is used as the ceramic material, the amount of phosphorus oxide used is such that when the phosphorus oxide is converted into phosphorus pentoxide (P ₂ O ₅ ), ₂ O ₃ ) 3 ~
The range is preferably about 5 times.

Examples of the ceramic material forming the far-infrared radiation coating 20 include silicon dioxide (SiO ₂ ), aluminum oxide (Al ₂ O ₃ ) titanium oxide (TiO ₂ ), zinc oxide (ZnO),
Zirconium oxide (ZrO ₂ ), magnesium oxide (Mg
O), lead oxide (PbO) and the like.

Among these materials, silicon dioxide (SiO ₂ ) and aluminum oxide (Al ₂ O ₃ ) are particularly effective components for efficiently emitting far infrared rays. In particular, the amount of silicon dioxide (SiO ₂ ) used is preferably 70% by weight or more of the ceramic material.

When forming the far-infrared radiation coating 20, first, a quartz glass envelope 11 made of a ceramic material containing phosphorus oxide is used.
A thin film is formed on the outer surface of the thin film. This thin film is formed as follows, for example.

That is, a fine powder made of phosphorus oxide and a ceramic material having far-infrared radiation characteristics is dispersed in water, for example,
A coating solution of about 20 to 50% by weight is prepared, and this coating solution is uniformly applied to the outer surface of the quartz glass envelope 11 using, for example, a spray gun to form a coating film. The thickness of this coating is
About 10 to 300 um, especially about 50 to 200 um is preferable. When the thickness is too small, film peeling is likely to occur, while when the thickness is too large, far infrared radiation efficiency is likely to decrease.

Next, the above coating film is applied at a temperature of, for example, about 150 ° C.
The coating film is dried for about one minute to remove water in the coating film. Furthermore, the coating film after drying is heat-treated at a temperature of, for example, about 260 to 350 ° C. for about 15 minutes to decompose and evaporate water of crystallization in the coating film to thermally cure the coating film, and thus the phosphorus oxide. A thin film of a ceramic material containing is formed.

Examples of the alkaline earth metal compound that can be used in the aqueous solution of the alkaline earth metal compound for treating the surface of the thin film include calcium acetate, calcium hydroxide, calcium nitrate and the like. The concentration of the alkaline earth metal compound aqueous solution is, for example, 20 to 30% by weight.
A degree is preferable.

In one example of the treatment method, an incandescent light bulb 10 having an envelope 11 in which a thin film is formed in an aqueous solution of an alkaline earth metal compound.
The whole is immersed for about several seconds, then the incandescent light bulb 10 is taken out and dried, and the washing and drying treatments are repeated an appropriate number of times to remove the unreacted alkaline earth metal compound.

By treating the surface of the thin film with an aqueous solution of an alkaline earth metal compound, the phosphorus oxide in the thin film reacts with the alkaline earth metal compound and is converted into a substance having no carbonization catalyst action.

An example of such a reaction is shown below.

P ₂ O ₅ ＋ 2Ca (CH ₃ COO) ₂ ＋ 3H ₂ O → 2CaHPO ₄ ＋ 4CH ₃ COOH According to the far-infrared heater lamp manufactured by the above method, the material of the envelope 11 of the incandescent light bulb 10 is quartz glass. In addition, since the far-infrared radiation coating 20 is made of a ceramic material containing phosphorus oxide,
The adhesion strength of the 20 to the quartz glass is large and the durability of the coating 20 is remarkably large, and damage such as peeling of the coating 20 is unlikely to occur, and the surface of the coating forming thin film for forming the coating 20 has a specific surface. By being treated with the aqueous solution, the phosphorus oxide in the film for forming a film is converted into a substance having no catalytic action, and as a result, even when fingerprints, dust, etc. adhere to the film 20, blackening occurs in the adhered part. The occurrence of the phenomenon is sufficiently suppressed, the appearance quality is maintained stable for a long time,
Product value is improved.

[Experimental example]

(1) Experimental Example 1 (for the present invention) Silicon dioxide 89.7% by weight Aluminum oxide 1.9% by weight Phosphorus pentoxide 8.4% by weight A fine powder of the ceramic material having the above composition was dispersed in water to prepare a coating solution. The coating liquid was applied to the outer surface of the quartz glass envelope in an incandescent lamp (50V-230W) using a spray gun to form a coating film having a thickness of 80 to 130 um.
Then, the incandescent light bulb is kept at a temperature of 150 ° C for 5 minutes to dry the coating film, and then it is further kept at a temperature of 300 ° C for 15 minutes to heat-cure the coating film. A thin film of a ceramic material containing phosphorous oxide was formed and adhered to the outer surface of the body.

Next, change the incandescent lamp with the above thin film to a concentration of 30% by weight.
Dipped in an aqueous solution of calcium acetate for 5 seconds, taken out of the incandescent bulb, dried, washed with water and dried twice to remove unreacted calcium acetate. A far-infrared heater lamp (Lamp A) having a coating for far-infrared radiation processed by an aqueous solution was manufactured.

Next, an experiment was conducted in which saliva and dust were made to adhere to the surface of the far-infrared radiation coating of the lamp A, and then the lamp A was actually turned on for one hour to see if a blackening phenomenon occurred in the coating. I checked. The results are shown in Table 1 below.

(2) Experimental Example 2 (for comparison) In the above Experimental Example 1, the far infrared heater lamp (lamp) for comparison is similarly used except that the surface of the thin film made of the ceramic material containing phosphorus oxide is not treated with the calcium acetate aqueous solution. a) was produced.

Next, with respect to the comparative lamp a, the same lighting experiment as in Experimental Example 1 was conducted to examine whether or not the blackening phenomenon occurred. The results are shown in Table 1 below.

As can be understood from the above results, the far-infrared heater lamp manufactured by the method of the present invention can be lit for a long time without the occurrence of the blackening phenomenon, and the appearance quality is extremely excellent. It is a thing.

On the other hand, in the far-infrared heater lamp for comparison, since the coating is not treated with the aqueous solution of the alkaline earth metal compound, the blackening phenomenon is remarkable and the appearance quality is poor.

[Brief description of drawings]

FIG. 1 is an explanatory sectional view showing an example of a far infrared heater lamp manufactured by the method of the present invention, and FIG. 2 is an explanatory view of a blackening phenomenon. 10 …… Incandescent bulb, 11 …… Fused quartz glass enclosure 12 …… Filament, 13 …… Metal foil 14 …… External lead, 15 …… Supporter 20 …… Far infrared radiation coating 80 …… Far infrared radiation coating 81: Adhesion part

Claims (1)

[Claims] 1. A far-infrared heater lamp comprising an incandescent lamp having a quartz glass envelope and a far-infrared radiation coating provided on the outer surface of the quartz glass envelope of the incandescent bulb. In the method, on the outer surface of the quartz glass envelope of the incandescent bulb, a far infrared radiation coating film forming thin film is formed by a ceramic material containing phosphorus oxide, the surface of the far infrared radiation coating film forming thin film, A method for producing a far infrared heater lamp, which comprises forming a coating for far infrared radiation by treating with an aqueous solution of an alkaline earth metal compound.