JPS62278725A - Manufacture of compact type fluorescent lamp - Google Patents

Abstract

PURPOSE:To make the generation rate of a stem sealing failure reducible as well as to aim at the promotion of inexpensiveness in cost, by peripheral edges of each stem and opening ends of a double U-shaped bulb are heated and deposited by four burners set up shiftably, and sealing the stem. CONSTITUTION:Four mount stems 38 are set up just under four opening ends n1-n4 of a double U-shaped bulb 31, and each is independently erected in pin supporters 39 at the same height usually. Stems 35a and 35a with electrode are fed to each upper end of two pins in a horizontal line of these four mount pins 38 and other stems 35b and 35b with no electrode to the remaining two pieces, respectively. These four mount pins 38 are connected to the pin supporter 39 as possible to move up and down. Four burners 41 are tightly attached to a position of the specified height from each tip of these mount pins 38, and these burners 41 blow up flames 46 and 46 from plural nozzles 45 formed on the top, performing the neaxt stem sealing. With this constitution, the generation rate of a stem sealing failure is reducibel, and such an inexpensive fluorescent lamp that os favorable for mass production is securable.

Description

Detailed Description of the Invention 3. Detailed Description of the Invention The present invention relates to a method for manufacturing a compact fluorescent lamp having a double U-shaped discharge path. The present invention relates to a stem enclosing method for enclosing four stems in four open ends of a double U-shaped valve formed by connecting one end of each U-shaped valve.

A compact fluorescent lamp with a meandering double U-shaped discharge path on one side consumes significantly less power than an incandescent bulb of the same brightness, has a long lifespan, and has the same brightness as an incandescent bulb. Because they are easy to use, they have recently become popular in various lighting fields as an alternative to incandescent light bulbs. This compact fluorescent lamp generally has two U-shaped bulbs connected to form a double U-shaped discharge path, and the conventional structure and manufacturing method are shown in Figures 7 to 13. This will be explained with reference to FIGS. 14 to 23.

The compact fluorescent lamps (1) shown in Figures 7 to 9 are manufactured using four straight tube bulbs with enclosed stems, and (2a), (2b)... are of the same length. 4 straight pipe type valves, (3) (3)... each half (2a
) (2b) Fluorescent film formed on the inner surface of..., (4a)
(4b)- is each valve (2a) (2b)...
Four stems enclosed in one end of (5) (5)...
・ indicates the exhaust pipe extending from each stem (4a) (4b)..., (6) (6)... indicates the stem (4a) with two electrodes.
) These are two lead wires derived from (4a). (7) is a cap-shaped base made of +IW resin or the like which is fixed to the stem-side end of each valve (2a), (2b), etc. via an adhesive (8).

This compact fluorescent lamp (1) is manufactured through the steps shown in FIGS. 10 to 13. First, as shown in FIG. 10, a large number of straight tube bulbs (2a), (2b), etc., each having a fluorescent film (3) formed on its inner peripheral surface, are prepared. next,
As shown in Figure 11, each straight pipe type valve (2a) (2
b) Enclose the electrode-equipped stem (4a) with lead wires (6) (6) at the open end of... and the electrode-less stem (4b) with only the exhaust pipe (5) using a butt seal method or the like. , the non-stem end of each straight pipe valve (2a) (2b) is sealed.

Next, as shown in Fig. 12, one straight pipe valve (2a) having a stem with electrodes (4a) and one straight pipe valve (2b) having a stem without electrodes (4b) are connected. Align the ends on the stem side to the same height, make them face each other in parallel with a spacing 11 about the size of a crane, and connect the opposing surfaces of the non-stem side ends of both valves (2a) and (2b) between these opposing surfaces. An inserted sheet burner (not shown) heats the area locally to soften it, while
A valve connecting part (2a) (2b) in which high pressure gas such as nitrogen gas is supplied into both valves (2a) (2b) to swell the locally heated parts of both valves (2a) (2b) and weld them into a tubular shape. 9) and one U-shaped valve (10
). A large number of such U-shaped valves (10) are prepared, and then, as shown in FIG. Interval l! with both U-shaped valves (10) facing each other in parallel.
(10) Straight pipe valve without electrode (2b) (2b
) between the opposing surfaces of the stem-side end of the valve connecting part ( ).
A tubular valve connection part (11) is formed in the same manner as in 9) to obtain one double U-shaped valve (12).

This double U-shaped valve (12) heats and seals the exhaust pipe (5) that is not used as an exhaust pipe in the exhaust process, and then sends it to the exhaust process to exhaust impurity gas inside the valve, activate the electrode, and deactivate the gas. After exhaust treatment such as filling with gas or mercury is performed, the exhaust pipe (5) is sealed off. Thereafter, the base (7) is fixed to the stem side end of the double U-shaped valve (12). The base (7) has four base pins (13) (13), as shown by chain lines in FIGS. 7 and 8, for example.
A cap (14) having ... is attached, and a cap bottle (1
3) Connect the lead wire (6) to (13)...
is connected.

Compact fluorescent lamps (15
) is a double U-shaped bulb made from two U-shaped bulbs, and then four stems are simultaneously enclosed in the double U-shaped bulb using the base, as shown in Figures 17 to 23. Manufactured in a process.

First, a large number of U-shaped valves (16) as shown in FIG. 17 are prepared. This U-shaped valve (16) is made by heating and softening the central part of a straight pipe valve (not shown) and bending it into a U-shape. The interval 12 between the straight pipe valves (16a) and (16b) is about 111.Next, the curved pipe portion (16c) of the U-shaped valve (16) is reheated and softened, and this curved pipe portion (
16c) with a two-part structure (1) as shown in Figure 18.
7) Fit it into (17) and fill the valve with high pressure gas,
Mold the softened bent pipe part (16c) (17) (17)
A tubular valve connection part (18
) to form. A U-shaped valve molded in this way (
Prepare a large number of copies of 19).

Next, as shown in Figure 19, two U-shaped valves (1
9) Align the opening ends of (19) to the same height, and connect each straight pipe type valve (16a), (16a), (16b)
and (16b) are opposed in parallel with an interval of 12, and the opposing portions of the open ends of each of the straight pipe valves (16b) and (16b) are locally heated from the inside with a burner (not shown), and a burner flame is generated. The tube is expanded and welded to form a tubular valve connection part (20), thereby obtaining one double U-shaped valve (21). Next, as shown in FIG. 20, a fluorescent suspension suspension is applied to the inner surface of the double U-shaped bulb (21) and fired to produce Fluorescent II! 1:22) is formed, and then the fluorescent light 19 (22) on the inner peripheral surfaces of the four open ends m1 to m4 of the double U-shaped bulb (21) is removed with a brush or the like.

Next, the four open ends m of the double U-shaped valve (21)
4 stems from 1 to m4 (23a) (23b)
Enclose... This stem enclosure is located at the four open ends of the double U-shaped valve (21) m! ~m4 (7) The interval 12 is as narrow as tflg, so the four open ends m1~
Since it is difficult to uniformly heat m4 over the entire circumference with a burner (not shown), the following ceramic base (24) is used.
and frit glass (25), from Figure 21 to 2.
This is done as shown in Figure 3. That is, the base (24) is a dish-shaped thing that closes the four open ends of the double U-shaped valve (21), and has exhaust pipe insertion holes (26) (2
6)..., a frit glass (25) is coated on the bottom surface of this base (24), and two stems with electrodes (23a) (23a) and two stems without electrodes (23b) are placed on top of the frit glass (25). ) (23b ”) is connected to each exhaust pipe (27) (27)... and the lead wire (28) (
28)... through the corresponding insertion hole (26) (26).
It is inserted into and held upright. 4 on base (24)
Right above the four stems (23a) (23b)..., the four corresponding open ends m1~ of the double U-shaped valve (21)
m4 facing each other, as shown in Figure 23, each stem (
23a) (23b)... in the corresponding open ends m1 to m4, press the base (24) against the open end of the double U-shaped valve (21), and insert the whole into the heating path. The frit glass (25) is heated and melted through the glass. Then, the molten frit glass (25)
are the four open ends m 1 of the double U-shaped valve (21)
”' m 4 and 4 stems (23a) (23b)
Four stems (23
a) (23b)... are simultaneously included.

After that, the exhaust pipe (27) (2) protrudes from the base (24).
7)... is used to exhaust the double U-shaped valve (21), and the exhaust pipes (27) (27)... are sealed off.

The sun is about to rise. Compact fluorescent lamp (1) shown in Figures 7 to 9 above
are four independent straight pipe valves (2a) (2b)
After forming a fluorescent film and enclosing a stem, two straight tube bulbs (2a) and (2b) are connected to form a U-shaped bulb (10). shaped valve (10
) (10) and double U-shaped valve (12)
In order to form the
As a result, there was a problem in that the manufacturing cost increased.

On the other hand, the compact fluorescent lamp (15) shown in Figs. 14 to 16 has a double U-shaped bulb (21) in which two molded U-shaped bulbs (19) are connected. Straight tube type bulbs (16a) (16b)... Since the fluorescent film can be formed all at once and the stem can be sealed inside, it has the advantage of requiring fewer manufacturing steps and excelling in mass production. However, this fluorescent lamp In (15), four stems (
The ceramic base (24) used as a means for simultaneously enclosing 23a) (23b)... is expensive, and the fluorescent lamp (15) is expensive because of this base (24).
The problem was that it was expensive.

The following can be considered as a solution to such problems. For example, the double U-shaped valve (2
1) is supported vertically with the open ends m1 to m4 facing down, and one stem (23a
) (23b)... is inserted and held in place, and while rotating the entire double U-shaped valve (21) around its center line, insert the double U-shaped valve (21) on the side of each opening end m1 to m4. Heat and melt the open ends m1 to m4 and the stem periphery with a burner flame from the side to form the four stems (23a) (23b).
. . . are simultaneously sealed in each open end m1 to m4. Encapsulation of the stem by such a drop seal method makes it possible to reduce the cost of a compact fluorescent lamp by eliminating the need for a ceramic base. 12, so if each open end m1 to m4 is heated with a burner flame from the side, the burner flame cannot be sufficiently applied to the inside of each open end m1 to m4, and There are many places where the stem is defective.

In addition, the double U-shaped valve (21) is connected to the open end m1 to m
4 vertically below, position and insert the stems (23a), (23b)... into each of the open ends m1 to m4, and expose the open ends m1 to m4 and the peripheral edge of the stem to the burner flame from below. It is possible to encapsulate the stem using the butt seal method, which involves heating and welding. In this case, since the open ends m1-m4 of the double U-shaped valve (21) are heated from below with a burner flame,
It is possible to heat the opening ends m1 to m4 more uniformly over the entire circumference, which is advantageous compared to the drop seal method.

However, the lengths of the four straight pulp pipes (16a) (16b) of the double U-shaped valve (21) vary in dimensional accuracy due to several rounds of heat treatment during pulp production. When the stem is enclosed, the heights of the four open ends m1 to m4 vary, and the spacing between the four open ends m1 to m4 and the bar varies, resulting in the height of the four open ends m
It is difficult to encapsulate a stem under the same heating conditions in a 1-m 4 area, and insufficient or excessive heating temperature may result in defective stem encapsulation.

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to solve the problem of stem encapsulation by the bar/ ) seal method and to provide an inexpensive compact fluorescent lamp.

The present invention achieves the above object by installing four stems in the four open ends of a double U-shaped valve, which is formed by connecting two U-shaped valves with openings at both ends. A portion that is held in place so as to contact the open end of the U-shaped valve, and separates the peripheral edge of each stem and the open end of the double U-shaped valve from each open end of the double U-shaped valve. This is accomplished by a manufacturing method that includes a stem-encapsulating step in which the stem is heated and welded using four independent burners that are movably arranged and facing each open end at a predetermined interval.

By independently movably arranging four burners using the butt seal method that heat the four open ends of the Sakuri double U-shaped valve and the peripheral edge of the stem inserted into the open ends, Even if the double U-shaped valve has dimensional variations, the distances between its four open ends and the four burners can always be maintained at normal values.

A specific example of an apparatus for implementing the method of the present invention is shown in FIGS. 1 to 6. To explain this, in the same figure, (30)
(30) is two U-shaped valves with openings at both ends, (31) is a double U-shaped valve with two U-shaped valves (30) (30) connected at one point, and (32) is a double U-shaped valve. , a fluorescent film formed on the inner surface of the double U-shaped bulb (31), (33)
(33) is a pair of chucks that vertically support the double U-shaped valve (31) with its four open ends n1 to n4 facing down, and (34) is supported by chucks (33) (33). A total of four stems (35a) (3), one each at the four open ends n1 to n4 of the double U-shaped valve (31).
This is a stem encapsulating machine that simultaneously encapsulates 5b'')...

The U-shaped valve (30) is obtained, for example, by molding the curved pipe portion of a conventional U-shaped valve that has been bent as shown in FIGS. 17 and 18. valve(
30), two opposing straight pipe valves (30a) (30)
The interval 13 in b) is set to 2 to 9 mm in order to facilitate the stem enclosing operation described below. The opening ends n1"f14 of the two U-shaped valves (30) (30) are aligned, and the straight pipe-shaped pulps (30a), (30a), (30b) of the two U-shaped valves (30) (30) are aligned.
) and < (30b) are opposed in parallel with a gap of 13, and one straight pipe type valve (30b) (
30b) open end n2. The opposite part of fi3 is the first
Similar to the conventional method shown in Fig. 9, the tubular valve connection part (3
6) to obtain a double U-shaped valve (31). Thereafter, a fluorescent film (32) is formed on the inner surface of the double U-shaped bulb (31), and only the fluorescent film (32) on the inner surface of each open end n1 to n4 is removed.

A pair of chucks (33) (33) connect the non-opening end of the double U-shaped valve (31) to, for example, a molded valve connection part of two U-shaped valves (30) (30). (37) (37) is clamped from the axial direction, so that the double U-shaped valve (31) has opening ends n1 to n4.
Stem enclosure 1 placed in a fixed position with the stem facing straight down.
It is held in a fixed position directly above (34).

The stem enclosing machine (34) inserts corresponding four stems (
35a) (35b)... are positioned and inserted, heated and sealed using the butt seal method. To explain its specific structure, (38) (38)... are four vertical cylindrical pieces. Mount pin, (39) is each mount pin (38)
(3B) Spring (40) (
(41) (41)... is a vertically movable pin support supported via each mount pin (38).
) (38) It is a ring-shaped burner fixed at an approximately intermediate position. 4 mount pins (38) (
38)... are arranged directly below the four open ends n1 to n4 of the double U-shaped valve (31), and each is attached to the pin support (39) independently at the same height in normal times. It will be erected. Stems with electrodes (35a) (35a) are attached to the upper ends of two horizontal rows of each mount pin (38) (38)...
) is attached to the upper end of the remaining two electrode heat rest stems (35b) (
35b) is supplied. In addition, each stem (35a)
(42) in (35b)... (42)...
* is an exhaust pipe, (43) (43)... is a beam wire, and these are inserted into the mount pin (38) (38).... In addition, each stem (35a) (35b)...
The outside diameter of the flared portion (44) (44)... is approximately the same as the valve outside diameter of the double U-shaped valve (31).

The pin support (39) reciprocates up and down with a constant stroke.

Four mounting pins (38) are attached to this pin support (39).
(38) ... is each independent spring (40)
(40) are connected to each other so as to be movable up and down. Four ring-shaped burners (41) (41) are placed at a certain height from the tip of each mount pin (38) (38)...
... is fixed, and each burner (41) (41)
... is a plurality of nozzles (45) formed on the top surface (45
)... blows up the flame (46) (46)... to complete the next stem inclusion.

A double U-shaped valve (
31) is carried in, the pin support (39) moves up by a certain stroke, and as shown in FIG.
38) (38)... Upper stem (35a) (35
b)- are inserted into the four corresponding open ends n1-n4 of the double U-shaped valve (31). Here, double U
Four straight pipe valves (30a) with a shape valve (31)
(30b)... There are variations in length, and there are variations in the height of each opening end n1 to n4, and as shown in FIG. ) has the highest open end, and one adjacent straight pipe valve (30
b) is at the lowest position, and if the difference in height between the two is d, then the pin support (39) is located at the lowest position of the stem (35) corresponding to the open end of the straight pipe valve (30b).
After the peripheral edge of the flare part (44) of b) comes into contact with d
The four open ends n1 rise to a slightly higher fixed position.
~ Stem (35a) (35b) for all n4
... are inserted all at once. The pin support at this time (39
) and each mount pin (38) (38)... The springs (40) (40) are compressed by an amount corresponding to the height of the open ends 01 to n4, and each mount pin (38)
(38) ... upper stem 7177 part (44) (
44)... is brought into elastic contact with the opening end surfaces of the opening end portions n1 to n4. In addition, the height of each mount pin (38) (38)... on the pin support (39) changes depending on the height of the corresponding open end n1 to n4, and each mount pin (38) (38) Burner integrated with (41)
(41)..., and the intervals between the corresponding opening ends n1 to n4 are constant. Therefore, each burner (41) (41
)... nozzle (45) (45)... flame (
46) When (46)... is blown up with the prescribed firepower, the stem flare part (44) (44)... is directly above it.
The peripheral edge of ・ and the corresponding opening end portions n1 to n are heated under the same heating conditions and welded as shown in FIG.
Two stems (35a) (35b'')... are simultaneously enclosed in each of the opening ends n1 to n4.In addition, when such stems are enclosed, as shown by the line tIi in FIG. 6, a double U-shape is formed. Batting plates (47) (47)... are arranged on the sides of each open end n1 to n4 of the shaped valve (31), and the batting plates (47) (47)...
7)... at the stem flare part (44) (44)...
・It may be pressed against the lower peripheral edge several times at appropriate timing.

When the stem enclosure is completed, the bottle support (39) is lowered to the lower limit position. Then mount pin (3B) (
3B)... is a spring (40) (40)...
With the same force, they are aligned at the same height on the pin support (39).

The specific implementation apparatus of the method of the present invention is not limited to the above example, but the following can also be used.

For example, the above four mount pins (38) (38)
Stem (35a) (35b) supported by...
It is also possible to lower the double U-shaped valve (31) toward .

The four mount pins (38) (38)... and the four ring-shaped burners (41) (41)... are separated, and each burner (41) (41)... can be raised and lowered independently. Move the burner (4) up and down when inserting the stem.
1) Maintain the distance between (41) and each opening of the double U-shaped valve (31) to a normal value.

Furthermore, the present invention can be similarly applied to the manufacture of compact fluorescent lamps in which a fluorescent film is formed on a double U-shaped bulb obtained by sequentially connecting four independent straight tube bulbs and a stem is enclosed. It is possible.

Furthermore, the double U-shaped valve and mounting pin can be arranged horizontally to perform the enclosing work.

According to the present invention, even if there are variations in length of the four straight pipe valves of the double U-shaped valve, a stem can be attached to each open end of the four straight pipe valves. It is possible to encapsulate them under the same heating conditions, which reduces the incidence of stem encapsulation defects.In addition, simultaneous encapsulation of four stems into a double U-shaped valve makes it possible to encapsulate special components such as ceramic bases. It is possible to provide a low-cost, compact fluorescent lamp that can be realized without the use of fluorescent lamps and has good mass productivity.

[Brief explanation of drawings]

1 to 6 are for explaining a specific example of an apparatus for carrying out the method of the present invention. Figure, 3rd
The figure is a cross-sectional view taken along line A-A in Figure 2, Figure 4 is an enlarged cross-sectional view taken along line B-B in Figure 2, and Figures 5 and 6 are when the stem of the device in Figure 1 is enclosed. FIG. 7 to 13 are for explaining a compact fluorescent lamp manufactured by a conventional manufacturing method, and FIGS. 7 and 8 are a front view and a side view including a partial cross section of the fluorescent lamp, Figure 9 is a plan cross-sectional view of the fluorescent lamp in Figure 7;
13 are perspective views of the bulb at each step showing the bulb manufacturing process of the fluorescent lamp of FIG. 7. Figures 14 to 23 are for explaining compact fluorescent lamps manufactured using other conventional manufacturing methods.
Figures 15 and 15 are a front view and side view including a partial cross section of the fluorescent lamp, Figure 16 is a plan view of the fluorescent lamp in Figure 14, and Figures 17 to 20 are the bulb of the fluorescent lamp in Figure m14. A perspective view of the bulb at each step showing the manufacturing process; FIG. 21 is an exploded perspective view of the fluorescent lamp in FIG. 14 before the stem is enclosed;
FIG. 22 is a partially enlarged side sectional view of FIG. 21, and FIG. 23 is a side sectional view of FIG. 22 after the stem is enclosed. (30) -U-shaped valve, (31)...Double U-shaped valve, (35a)
(35b)-=stem, (41)-burner, n1~
n4 --- Open end.

Claims (1)

[Claims] (1) Four stems are placed within the four open ends of a double U-shaped valve formed by connecting two U-shaped valves that are open at both ends, and their peripheral edges contact the open ends of the double U-shaped valve. Insert and hold the periphery of each stem and double U
The opening end of the double U-shaped valve is connected to the opening end of the double U-shaped valve by four independent burners facing each opening end at a predetermined interval and movably disposed at a portion separated from each opening end of the double U-shaped valve. A method for manufacturing a compact fluorescent lamp, comprising a step of enclosing a stem by heating and welding.