JPH10188916A - Lamp and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a discharge lamp of high quality, in which lifetime and characteristic are improved and the dispersion of impurities of a bonding part inside an envelope main body is inhibited, by sealing a part, which includes a bonding part of a shoulder part of the envelope main body and a narrow diameter tube, and unifying the bonding part with a sealing part so as to prevent the exposure of the bonding part inside the envelope main body. SOLUTION: After concluding the positioning of a mount M inserted into an envelope 1, inert gas is blown into the envelope 1 from an upper side narrow diameter tube 30. A part from a lower side narrow diameter tube 30, which coincides with a sealing foil 10 of the blowing side of the mount M, to a shoulder part 1G, which includes a bonding part 11, is heated for softening, and the whole of the sealing foil 10 is embedded for sealing in the sealing part 13. Air inside of the envelope 1 is exhausted to nearly vacuum condition through an upper side narrow diameter tube 30, which is not sealed, and the envelope 1 is filled with the xenon gas or the like. Nearly whole of the envelope 1 is cooled by liquid nitrogen, while a part from the upper side narrow diameter tube 30, which is not sealed, to a shoulder part 1G, which includes a bonding part 11, is heated for softening, and sealing is thereby performed. The bonding part 11 is unified so as to form a part of the sealing part 13.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a halogen lamp which is used for various purposes including general household use and is particularly excellent in pressure resistance and production cost, and a method for producing the same.

[0002]

2. Description of the Related Art Incandescent lamps, for example, eggplant-shaped incandescent lamps called GLS, reflector-type incandescent lamps on which aluminum is deposited, shield beam-type incandescent lamps, incandescent lamps used in chandeliers, and silicon inside a glass bulb Various incandescent bulbs such as silica spheres coated with
Since Edison's invention, it has been widely used around the world.
In light of the future energy situation, the United States passed the Energy Saving Bill promptly in the United States. It is a prescribed fact that the percentage increase is statutory. On the other hand, in response to this trend, metal halide lamps are rapidly entering the field of general lighting recently, and accordingly, halogen lamps are required to have higher luminous efficiency and longer life. It has come to be. When comparing the halogen lamp and the metal halide lamp, the halogen lamp is very compact, has excellent light quality and color rendering properties, and does not change in brightness until the disconnection (that is, the luminous flux maintenance rate is 100%). It is generally said that the luminous efficiency and the life are inferior, though it is characteristic in that the luminous efficiency and the cost are low.

[0003] As a method that can meet the demand for such high efficiency and long life, there are a method of filling an inert gas having a molecular weight larger than that of Ar gas, N ₂ gas, and Kr gas, for example, a Xe gas, and a method of filling a charged gas. To suppress the volatilization of the filament during lighting. In addition, there is a method of coating the outer surface of the envelope with an infrared reflective multilayer film.

[0004] In the method of suppressing the volatilization during lighting of the filament by increasing the pressure of the filling gas, a distortion remains in the envelope or a part of the envelope having a low withstand voltage may be used. Otherwise, a rupture accident may occur. This applies to discharge lamps such as Xe lamps.

FIGS. 1 (a) (b), 2 (a), (b) or (c)
It shows a general manufacturing procedure of a double-end type envelope (1) in which both ends are narrowed to a small diameter, and heats and shrinks both ends of a large-diameter tube (31) cut to a predetermined size. Discharge lamps for halogen lamps, metal halide lamps, etc., in which the heated and softened ends of small-diameter small-diameter tubes (30) are joined to the contracted ends (32), respectively, and the small-diameter tubes (30) are connected to both ends. End type envelope (1) is formed.

In this case, the joint (1I) of the envelope (1) occurs at the joint between the shoulder (1G) of the envelope body (1H) and the small-diameter tube (30). Yes, with the conventional sealing method, small diameter tube (30)
Only the sealing portion was sealed, so this joint portion (1I) was not included in the sealing portion (13) at the time of sealing, and remained as it was on the shoulder portion of the envelope body (1H) even after sealing. . (See FIG. 10) Conventional halogen lamp (B). This joint portion (1I) is formed by heating the burner flame with impurities (for example, propane-
Carbon in the case of oxygen flame, OH in the case of hydrogen-oxygen flame
The base becomes an impurity) adheres to the surface forming the joint (1I) between the shoulder (1G) and the small-diameter tube (30), and this gets caught in the glass at the time of joining, and the joint (1I) Constitutes an internal defect. In addition, when the two (1G) and (30) are joined, the strength and strength of the joints are generated due to the degree of melting and the temperature of the various parts of the glass, and at the same time, the thermal distortion and the thickness variation due to the softening and joining are generated. I do. Furthermore, internal distortion due to uneven material distribution is applied to the joint (1I), and the joint (1I) is cracked while turning on and off repeatedly, and often a filament (not shown) is formed. Arc discharge at the time of disconnection (although the possibility of double-end type is less than that of single-ended type halogen lamps is small), the pressure inside the envelope (1) increases rapidly, and internal defects are included. The joint (1I) or the surrounding area sometimes burst. Therefore, sufficient pressure could not be applied to extend the life of the envelope (1) due to structural defects.

In addition, low power consumption type halogen lamps and small and high performance metal halide lamps, which are used especially at a commercial voltage, which are becoming popular in recent years, require extremely strict production conditions because of their small size. In particular, impurities and impurity gases generated from raw materials constituting the lamp greatly affect the performance. How to remove impurities and impurity gases is a major issue in improving the performance of the lamp, and it is necessary to avoid carbon and OH groups at the time of joining as much as possible. Since the joint (1I) between the shoulder (1G) of the envelope body (1H) and the small-diameter tube (30) contains impurities and impurity gases as described above, the envelope body (1H) in the joint
If (1I) is exposed, the joint
Impurities and impurity gases were diffused into the enclosure body (1H) from (1I), which had a significant effect on the characteristics and life of low-power-consumption halogen lamps and compact high-performance metal halide lamps.

[0008]

The problem to be solved by the present invention is as follows.
By sealing including the joint between the shoulder of the envelope body and the small-diameter tube, the joint is mixed and integrated into the sealed part to prevent internal distortion and internal defects in this part as in the past. At the same time, the joints that occlude impurities are mixed and integrated into the sealed part so that they are not exposed in the envelope body, so that low power consumption halogen lamps and small, high-performance metal halide lamps And so on, so as not to greatly affect the characteristics of the discharge lamp and the shortening of the service life.

[0009]

A lamp according to claim 1.
(A) is formed by connecting a small-diameter tube (30) to a shoulder (1G) formed on at least one of the envelope body (1H) that houses the filament (6) or the electrode (6a). A mount (M) having a filament (6) or a mount (Ma) having a discharge electrode (6a) is provided in the envelope (1), and then the end of the envelope (1) is sealed. In the stopped lamp, the sealing portion (13) includes the small-diameter tube (30), and at most includes a part of the linear portion (1L) of the envelope body (1H) ''. Claim 2 is a method for manufacturing the lamp (A), wherein the method comprises the steps of `` from a shoulder (1G) formed on at least one of the envelope body (1H) containing the filament (6) or the electrode (6a). An envelope (1) having an extended small-diameter tube (30)
Is provided with a mount (M) having a filament (6) or a mount (Ma) having a discharge electrode (6a).
In the method of manufacturing a lamp for sealing the end of (1), the method includes a small-diameter tube (30), and seals up to a portion of the linear portion (1L) of the envelope body (1H) at the maximum. '' It is characterized by things.

According to this, the straight portion of the envelope body (1H)
The joint (1I) formed in any part from the part of (1L) to the small diameter tube (30) is mixed together in the sealing part (13), and the weak part of this part is Even if the gas is dissipated and the high-pressure gas is sealed in the envelope (1), this joint (1
I) does not become a weak point and rupture occurs, and the junction body (1I) absorbing impurities is integrated into the sealing part (13), so that the envelope body (1H) Since it is not exposed to the inside, the characteristics and life of the discharge lamp such as a low power consumption type halogen lamp and a compact high performance metal halide lamp are not significantly affected. As shown in FIG. 2 (a), the joint portion (1I) is formed by connecting the narrowed open end of the shoulder (1G) and the end of the small-diameter tube (30). Or
As shown in FIG. 5A, the enlarged end of the small diameter tube (30) (in this case, this portion becomes the shoulder (1G)). Further, depending on the shape of the enlarged diameter end, the enlarged diameter end may be linear. > And a straight tube-shaped envelope main body (1H) cut at a predetermined length.
The lamp (A) includes discharge lamps such as double-ended and single-ended halogen lamps and metal halide lamps throughout the specification. Further, the sealing method includes not only a pinch seal but also various methods such as a method using heat shrinkage.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First, a method of manufacturing an envelope (1) for a general double-ended lamp (A) which is used in the present invention will be described with reference to FIGS. As the material of the glass used for the envelope (1), for example, quartz glass, hard glass, or another material suitable for the intended use is used. The envelope (1)
The inner diameter of the large diameter glass straight tube (31) used for
0 mm, and the wall thickness is 0.8 to 1.5 mm.

First, as shown in FIG. 1A, at least one end of the large-diameter tube 31 for forming an envelope cut to a required size is rotated while heating. ) To form a shoulder (1G) without gradually reducing the opening diameter.
In the case of FIG. 1, both ends are heated, but of course only one may be used. The shoulder (1G) may be formed so that its cross section draws an arc as shown in FIG. 2 (a), or may be formed in a tapered shape as shown in FIG. 3 (a). Alternatively, as shown in FIG.
May be heated to increase the diameter by a jig (9), and this may be connected to a straight tubular envelope body (1H). In this case, when one end of the small-diameter tube (30) is heated and expanded with the jig (9) as described above, the expanded end may become linear following the tapered portion. Simultaneously with or before or after heating the end of the large diameter tube (31), heat the end of the small diameter tube (30),
When the two members (30) and (31) are sufficiently heated and can be softened and bonded, they are joined to form the envelope (1). Where the joint
The formation portion of (1I) is formed by connecting the narrowed open end of the shoulder (1G) and the end of the small-diameter tube (30) as shown in FIG. As shown in FIG. 5A, the enlarged end of the small diameter tube (30) (in this case, this portion becomes the shoulder (1G)). Further, depending on the shape of the enlarged diameter end, the enlarged diameter end may be linear. > And a straight tube-shaped envelope body (1
A typical example is a case where the end of H) is formed by being connected. FIGS. 2 (a), 3 (a) and 5 (a) are front sectional views of the envelope (1) in which the small diameter pipe (30) is connected to both ends. As shown by a two-dot chain line, the end of one of the small diameter tubes (30) may be a closed end.

FIGS. 2 (b) (c), 3 (b) (c) and 5 (b) show examples of the state of the joint (1I). In the case of FIG. 2 (b), the small diameter tube (30) is penetrated into the shoulder (1G) and joined, and in the case of FIG. 2 (c), the small diameter tube (30) is This is the case where it is joined to the open end of the shoulder (1G). FIG. 3 (b) shows a case where the small-diameter tube (30) penetrates and joins into the tapered shoulder (1G), and FIG. This is the case where it is joined to the open end of the shoulder (1G) formed in a tapered shape. FIG. 5B shows a case where the enlarged end of the small-diameter tube (30) is joined to the open end of the straight tubular envelope body (1H). In addition to this, the bonding state is infinite, but in any case, as described above, carbon and OH groups at the time of heating become impurities and adhere to the surface forming the bonding portion (1I), which is the glass at the time of bonding. It is caught inside and constitutes an internal defect at the joint (1I). Also, when the two (1G) and (30) are joined, the strength and strength of the joints occur due to the degree of melting and the temperature of the glass at various places, and at the same time, thermal distortion and thickness variation due to the softening and joining conditions also occur. doing.

Next, the procedure for manufacturing the double-ended halogen lamp (A) will be described with reference to FIG. Both ends are open, the envelope body (1H) is thick, and a small-diameter tube (30) is connected to both ends of a normal envelope (1) `` Of course, it is not limited to this, only one And insert the mount (M) from one open end (1a) into the envelope (1),
At (3), the envelope (1) and the mount (M) are held at an optimal position in the axial direction and the radial direction of the mount (M) with respect to the envelope (1). "Of course, instead of the suspension method, both ends of the mount (M) may be chucked in a conventional manner."

The filament (6) of the mount (M) is a double coil (or single coil) made of tungsten.
In the case of the present embodiment, a lead portion (21) in which a protection coil is covered on a single coil portion at both ends is formed, the lead portion (21) is welded to a sealing foil (10), and further the sealing is performed. For foil
(10) with external lead rod (8) welded, without sealing foil, lead part directly welded to lead rod (not shown), etc. (1) is for quartz glass, and the latter is for hard glass. Further, the shape of the lead portion (21) is not limited to the above shape, and a single coil portion of the filament (6) may be directly welded to the end of the sealing foil (10), or a rod-shaped inner portion may be formed. It may be connected to the sealing foil (10) via a lead rod (not shown).

When the axial alignment and the radial alignment of the mount (M) with respect to the envelope (1) are completed, nitrogen or nitrogen is introduced into the envelope (1) from the upper small-diameter tube (30) in the drawing. An inert gas such as an argon gas is blown, and blown out from a lower opening end in the figure to keep the inside of the envelope (1) and a blowing portion at the blowing end at an inert atmosphere.

Subsequently, the lower small-diameter tube (30) corresponding to the sealing foil (10) on the blow-out side of the mount (M) is connected to the joint (1).
Heating and softening up to the shoulder portion (1G) including I) is performed, and the entire sealing foil (10) is embedded in the sealing portion (13) for sealing, generally by pinching. A portion surrounded by a virtual line in the lower virtual line in FIG. 6 is the pinching area (P) at this time.

When the sealing is completed, the air in the envelope (1) is evacuated to a substantially vacuum state through the unsealed upper small-diameter tube (30) in the drawing, and further operations such as washing are performed. Finally, a required gas such as Xe gas is filled, and while almost the entire envelope (1) is cooled with liquid nitrogen, the unsealed upper small-diameter tube (30) is joined to the joining portion in the same manner as described above. Heat and soften up to the shoulder (1G) containing (1I) and seal. The portion surrounded by a rectangle by the virtual line on the upper side in FIG. 6 is the pinching area (P) at this time. As a result, the connection part (1I) is mixed in
It becomes part of (13), and the weak points will be dissipated.
The gas filling pressure of the lamp (A) thus formed reaches, for example, 15 to 20 atm at room temperature. FIG. 7 is a cross-sectional view of an example of a halogen lamp (A) sealed by using an envelope (1) in which a shoulder (1G) is formed in a tapered shape, and FIG. 7 is a cross-sectional view of an example of a discharge lamp (A). The figure is shown in FIG. Traces of the connecting portion (1I) are symbolically shown by broken lines, but in reality there are almost no traces integrated.

The phantom line in FIG. 6 shows the lower small-diameter tube.
In the case where (30) is the closed end, in this case, insert the mount (M) from one open end into the envelope (1),
As described above, it is hung by the support member (3). When the axial and radial alignment of the mount (M) with respect to the envelope (1) is completed, the air in the envelope (1) is evacuated to a substantially vacuum state through the upper small-diameter tube (30), Subsequently, a washing operation is performed to keep the inside of the envelope (1) in a reduced-pressure inert atmosphere. Subsequently, a portion from the closed small-diameter tube (30) to the shoulder portion (1G) is heated and softened, and the portion including the joint portion (1I) is sealed as described above.

When the sealing of the lower closed-side small-diameter tube (30) is completed, the air in the envelope (1) is evacuated to a substantially vacuum state through the upper small-diameter tube (30). Work, and finally fill with necessary gas such as Xe gas
While cooling almost all of (1) with liquid nitrogen, the portion from the small-diameter tube (30) to the shoulder portion (1G) including the joint portion (1I) is heated and softened and sealed as described above. Finally, cut off the closed end and lead the rod.
Expose (8). As described above, the gas pressure of the lamp (A) is, for example, 15 to 20 atm at room temperature.

FIG. 8 shows a discharge lamp (A) formed by the method of the present invention.
FIG. In the figure, (Ma) is the mount and its (6)
a) is an electrode and a sealing foil (10) embedded in the sealing portion (13).
The rear end is welded. Needless to say, the sealing method includes not only a method using a pinch seal but also a method using heat shrinkage. Of course, a type that does not use the sealing foil (10) can be manufactured, and a single-ended type can also be manufactured.
In any case, the common point is that sealing is performed including the connection portion (1I).

Next, the double-end type halogen lamp
The case where (A) is mounted on the outer valve (2) for use will be briefly described. The outer bulb (2) in FIG. 9 is of an eggplant type, and a neck (7) is protruded from the base thereof. The neck (7) of the outer bulb (2) is the same as a conventional eggplant type general incandescent lamp. A screw cylinder part (5) of the same size is mounted and fixed with an adhesive. The stem (4) is integrated with the stem (4) at the opening of the neck (7), and a part of the stem-side lead rod (14) is embedded in the stem (4).
One end of the stem-side lead rod (14) protrudes from the tip of (4).

The halogen lamp (A) is connected to a lead rod (14) (14) derived from a stem (4) attached to a neck (7) by an external lead rod (8) ( 8) is attached integrally. In the present embodiment, one external lead rod (8) and the lead rod (14) on the stem side are connected via a relay lead rod (14a). The connection between the lead rods is generally performed by welding.

A center contact (17) disposed at the center of the screw cylinder (5) via an insulator (16) and one stem-side lead rod (14).
However, the other stem-side lead rod (14) in the screw cylinder (5)
However, they are generally connected via a Dumet wire.
As a result, it can be used by being directly attached to a conventional eggplant-type incandescent lamp socket.

[0025]

According to the present invention, the joint formed in the envelope is mixed and unified into the sealing portion, so that the internal distortion of this portion is eliminated. As a result, the joint portion is not exposed to the envelope main body side, so that the pressure resistance of the envelope can be greatly improved. There is no possibility that the joint between the portion and the small-diameter tube becomes a weak point and rupture occurs. And therefore, the internal pressure of the envelope can be increased more than before,
The life and characteristics of discharge lamps such as halogen lamps and metal halide lamps can be greatly improved. Further, since impurities and impurity gases at the joint portion are not diffused into the envelope body, a person who realizes a lamp with higher performance and higher quality can be realized.

[Brief description of the drawings]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1A is a front sectional view showing a heated state of a large-diameter tube for forming an envelope in the method of the present invention. FIG. Cross section just before joining

FIG. 2 (a): Front sectional view of an envelope in which a large-diameter pipe and a small-diameter pipe whose shoulders are arc-shaped are joined. (B): Connection of the small-diameter pipe and the large-diameter pipe. (C)… Other partial enlarged cross-sectional view showing the joined state of the small-diameter pipe and the large-diameter pipe.

FIG. 3 (a): Front sectional view of an envelope in which a large-diameter pipe and a small-diameter pipe having a tapered shoulder are joined together (b): A joined state of the small-diameter pipe and the large-diameter pipe (C)… Other partial enlarged cross-sectional view showing the joined state of the small-diameter pipe and the large-diameter pipe.

4A is a front sectional view showing a state in which one end of a small-diameter tube is expanded. FIG. 4B is a partially enlarged view showing a joined state between a large-diameter end of the small-diameter tube and a straight-tube large-diameter tube. Front view

5A is a front sectional view of an envelope having a tapered shoulder portion. FIG. 5B is a partially enlarged front sectional view of the shoulder portion of FIG. 5A.

FIG. 6 is a front sectional view showing a heating state in a sealing step according to the method of the present invention.

FIG. 7 is a front sectional view of the double-ended envelope of the present invention formed in FIG. 6;

FIG. 8 is a front sectional view of the double-ended metal halide lamp of the present invention formed by the method of the present invention.

FIG. 9 is a partially cutaway front view when the double-ended lamp of the present invention is mounted on an eggplant-shaped outer bulb.

FIG. 10 is a front sectional view of a double-ended halogen lamp formed by a conventional method.

[Explanation of symbols]

(A) Lamp (1) Envelope (1H) Envelope body (1G) Shoulder (1I) Joint (1L)
… Linear part (2)… Outer valve (3)… Locking member (4)… Stem (5)… Screw tube part (6)… Filament (7)… Neck part (10)… Sealing foil (13)… Sealing Stop

Claims (2)

[Claims] 1. A mount having a filament or a mount having a discharge electrode in an envelope formed by connecting a small-diameter tube to a shoulder formed on at least one of an envelope main body accommodating a filament or an electrode. In the lamp in which the end of the envelope is sealed, the sealed portion includes a small-diameter tube and at most a part of the straight portion of the envelope body. The lamp characterized by the above. 2. A mount having a filament or a mount having a discharge electrode in an envelope formed by connecting a small-diameter tube to a shoulder formed on at least one of an envelope main body accommodating a filament or an electrode. Then, in the method of manufacturing a lamp for sealing the end of the envelope, it is necessary to include a small-diameter tube and seal up to a part of the straight portion of the envelope body at the maximum. A method for producing a lamp, comprising: