TWI585819B - A production process of electrodeless lamp and a production process of electrodeless bulb - Google Patents

Description

Production process of electrodeless lamp and electrodeless bulb

The invention relates to a filament-free, electrodeless and endless lamp manufacturing process, and more particularly to a lamp manufacturing process for a gas discharge generating light source.

The electrodeless light source, also known as the electrodeless lamp, is a green illumination source that emits light according to the principle of electromagnetic induction and gas discharge. Compared with the conventional fluorescent lamp or white woven bulb, the electrodeless lamp does not have the electrode, the end point and the filament which limit the life of the light source. The components, therefore, do not produce electrical resistance or heating effects, and operate their free gas only in a vacuum or in an inert gas, so their service life is as long as hundreds of thousands of hours. Furthermore, the electrodeless lamp has many advantages such as high illuminance, high color rendering, no stroboscopic, low glare, low energy consumption, etc., so the electrodeless lamp is also called the fourth generation light source.

Although the electrodeless lamp has many advantages as described above, the lamp manufacturing process of the electrodeless lamp is cumbersome, and it is not easy to control the color temperature and the color rendering property of each lamp during the production process, so how to effectively control the lamp manufacturing process of the electrodeless lamp To avoid problems such as poor quality of the lamp and reduce the defective rate of the lamp, it is a problem that the industry is currently solving.

In order to solve the foregoing problems, the present invention provides a process for manufacturing an electrodeless lamp, which utilizes the process to improve lamp yield, reduce hidden risk, and ensure that the quality and stability of the produced lamp are not problematic.

The manufacturing process of the electrodeless lamp tube according to the first embodiment of the present invention comprises at least the following steps: (a) selecting a material step, selecting a material of the lamp tube; (b) shaping step, softening the lamp tube with a high heat temperature, and then molding The shape of the tube; (c) the first annealing step, the shaped tube is heated and annealed to eliminate residual stress in the tube; (d) the cutting step, the excess of the annealed tube The part is cut; (e) the washing step, the lamp is immersed in the first liquid to be cleaned, and then the tube is taken out and then dried; (f) the mixing step, the fluorescent powder and the second liquid Mixing and mixing into a fluorescent powder; (g) coating the powder, pouring the prepared fluorescent powder into the lamp tube after the dryness, so that the fluorescent powder adheres to the inner wall of the tube; (h) baking Drying step, drying the fluorescent powder on the inner wall of the lamp tube, so that the organic matter in the phosphor powder can be emitted; (i) docking step, using two high-temperature temperatures to dock two paired lamps into one a tube, and a side of the tube will extend with a vent; (j) a second annealing step that will be completed after docking Annealing the tube is heated to remove the residual stress within the tube; (k) placing step, placing an interface body capable of releasing electrons to a steady state and a spring indium mesh into the interior of the exhaust nozzle; (1) an exhausting step of extracting air and impurities inside the lamp tube from the exhaust nozzle , the inside of the lamp tube is in a vacuum state, and at the same time, an inert gas is injected; (m) a sealing step, and the exhaust nozzle is sealed by a high heat temperature.

The manufacturing process of the electrodeless lamp tube according to the second embodiment of the present invention comprises at least the following steps: (a) selecting a material step, selecting a material of the bulb; (b) shaping step, softening the bulb with a high heat temperature, and then shaping the bulb a shape; (c) a first annealing step of thermally annealing the shaped bulb to eliminate residual stress in the bulb; (d) a cutting step of cutting the excess portion of the annealed bulb; e) washing the step, soaking the bulb in the first liquid to be cleaned, and then removing the bulb and then drying it; (f) mixing step, mixing the phosphor with the second liquid to prepare a fluorescent powder; g) the powder coating step, pour the prepared fluorescent powder into the bulb after the dryness, so that the fluorescent powder adheres to the inner wall of the bulb; (h) the drying step, the fluorescent powder on the inner wall of the bulb The liquid is dried to allow the organic matter in the fluorescent powder liquid to be emitted; (i) the docking step, using the high heat temperature to dock the paired bulb and the exhaust nozzle into a complete bulb; (j) the second annealing step, heating and annealing the butted complete bulb to eliminate the lamp Residual stress in the tube; (k) placing step, placing an interface body capable of electron free steady state and a spring indium mesh into the inside of the exhaust nozzle; (1) exhausting step, air and impurities inside the bulb The exhaust nozzle is pulled out to bring the inside of the bulb into a vacuum state, and at the same time, an inert gas (m) sealing step is injected to seal the exhaust nozzle with a high heat temperature.

In order to make the above-described processes and steps disclosed in the present invention more comprehensible, the following is a specific example of the flow of the embodiments of the present invention.

1‧‧‧Light tube production process

101‧‧‧Selection steps

102‧‧‧Shaping steps

103‧‧‧First annealing step

104‧‧‧ cutting steps

105‧‧‧Washing steps

106‧‧‧Matching steps

107‧‧‧Powdering step

108‧‧‧Drying steps

109‧‧‧Docking steps

110‧‧‧Second annealing step

111‧‧‧Placement steps

112‧‧‧Exhaust step

113‧‧‧ Sealing steps

2‧‧‧Light tube

21‧‧‧ inner wall

211‧‧‧Fluorescent powder layer

22‧‧‧Exhaust nozzle

221‧‧‧ openings

3‧‧‧Complete lamp

4‧‧‧Solid alloy

5‧‧‧Spring Indium Net

51‧‧‧Indium mesh

52‧‧‧ Spring

6‧‧‧ Seal

7‧‧‧Light bulb

8‧‧‧Complete bulb

Fig. 1 is a schematic view showing the production process of the present invention.

Fig. 2A is a perspective view showing the first stage of the manufacturing process of the first embodiment of the present invention.

Fig. 2A-1 is a perspective view showing the first stage of the manufacturing process of the first embodiment of the present invention.

Fig. 2B is a perspective view showing the second stage of the production flow of the first embodiment of the present invention.

Fig. 2C is a perspective view showing the third stage of the production flow of the first embodiment of the present invention.

2C-1 is a partially enlarged perspective schematic view of the third stage of the first embodiment of the present invention.

2C-2 is a partially enlarged cross-sectional perspective view showing another embodiment of the third stage of the first embodiment of the present invention.

Fig. 2D is a perspective view showing the fourth stage of the production flow of the first embodiment of the present invention.

2D-1 is a partially enlarged perspective schematic view of the fourth stage of the first embodiment of the present invention.

Fig. 3A is a perspective view showing a second embodiment of the present invention.

Figure 3B is a perspective perspective view of a second embodiment of the present invention.

Fig. 3C is a schematic enlarged cross-sectional view showing the exhaust nozzle of the second embodiment of the present invention.

The following description is a preferred embodiment of the present invention, which is intended to describe the basic spirit of the invention, but is not intended to limit the invention. The actual inventive content must be referenced to the scope of the following claims.

It must be understood that the terms "comprising", "comprising" and "the" are used in the <RTI ID=0.0> </RTI> <RTIgt; </ RTI> to indicate the existence of specific technical features, numerical values, method steps, work processes, components and/or components, but do not exclude Add more technical features, values, method steps, job processing, components, components, or any combination of the above.

Please refer to FIG. 1 , which is a schematic diagram of the production process of the present invention. An electrodeless lamp manufacturing process 1 includes at least a material selection step 101, a shaping step 102, a first annealing step 103, a cutting step 104, a washing step 105, a compounding step 106, a powder coating step 107, and baking. The dry step 108, the docking step 109, the second annealing step 110, the placing step 111, the venting step 112, and the sealing step 113 are described in detail with the following first embodiment and second embodiment. . First, please refer to the 2A-2D drawings at the same time, which is the first embodiment of the present invention.

In the material selection step 101, a suitable material is used as the lamp tube 2. The embodiment of this step is made of glass material, but it is not limited thereto. Ceramic materials or other materials that do not absorb microwaves may also be used.

The shaping step 102 is used to shape the shape required for the tube 2. The specific method of this step is to soften the glass by using a high heat temperature, and then shape the shape of the tube 2, such as a straight tube shape, a semicircular shape, a U shape, a spiral shape or a spherical shape, and the present embodiment is made of a semicircular shape. Description, as shown in Figure 2, but not limited to this. The high heat temperature varies depending on the softening melting point of various glass materials. For example, the softening melting point of quartz glass is above 1100 degrees Celsius, and the softening melting point of hard glass is above 600 degrees Celsius, so the high heat temperature of this step must be high. Softening melting point of various glass materials.

The first annealing step 103 aligns the temperature inside and outside the molded lamp tube 2 to avoid bursting. The specific method of this step is to heat-anneal the molded lamp tube 2 to eliminate the residual stress in the lamp tube 2. The temperature of the heat annealing is 500 degrees Celsius or more.

In the cutting step 104, the excess portion of the lamp tube 2 is cut. The specific method of this step is to cut the excess portion of the annealed lamp tube 2 by using a lamp cutting machine.

The washing step 105 is for removing the dirt of the lamp tube 2, so that the inner wall 21 of the tube 2 is easily powdered. The specific method of this step is: immersing the lamp tube 21 in the first liquid material for cleaning, and then taking out the lamp tube 21 and then drying it. Wherein the first liquid system is an acidic water washing liquid or alkali A water wash, deionized water or a mixture of acid wash and deionized water.

In the mixing step 106, the required phosphor powder is prepared according to different color temperatures. The specific method of this step is: mixing the phosphor powder with the second liquid substance to prepare a fluorescent powder liquid. The phosphor powder may be a trichromatic phosphor powder for achieving different color temperature effects after generating a light source, such as ultraviolet, infrared, long and short wavelengths in visible light, etc., and the second liquid substance may be an acidic liquid. , alkaline liquid, reverse osmosis water, deionized water, ultrapure water or distilled water.

The powder coating step 107 is applied with a phosphor layer 211 on the surface of the inner wall 21 of the tube 2. The specific method of this step is: pouring the prepared fluorescent powder into the lamp tube 2 after the dryness, so that the fluorescent powder adheres to the inner wall 21 of the tube 2, thereby forming the phosphor layer 211.

The baking step 108 is for emitting organic matter in the phosphor layer 211. The specific method of this step is to dry the phosphor layer 211 of the inner wall 21 of the bulb 2 to allow the organic matter in the phosphor layer 211 to be emitted. The drying temperature is above 70 degrees Celsius.

In the docking step 109, the two lamps 2 are butted into one complete tube 3. The specific procedure of this step is to butt the two paired lamps 2 into a complete tube 3 by using a high heat temperature, and the side wall of the complete tube 3 extends at least one exhaust nozzle 22. An opening 221 is defined in one side of the exhaust nozzle 22. The high heat temperature varies depending on the softening melting point of various glass materials, and the high heat temperature must be higher than the softening melting point of various glass materials.

The second annealing step 110 is to converge the temperature inside and outside the completed tube 3 to avoid bursting. The specific method of this step is to heat-anneal the buttted complete tube 3 to eliminate the residual stress in the tube. The temperature of the heat annealing is 500 degrees Celsius or more.

The placing step 111 is to use a medium that can make the electrons free of steady state and a bomb The reed indium mesh 5 is placed inside the exhaust nozzle 22, wherein the interface body can be a solid alloy 4. The specific method of this step is: placing the solid alloy 4 and the spring indium mesh 5 from the opening 221 into the interior of the exhaust nozzle 22, and the solid alloy 4 and the spring indium mesh 5 can be adjacent to each other or connected to each other, such as 2C-1. Figure and Figure 2C-2. . The spring indium mesh 5 is formed by interconnecting an indium mesh 51 and a spring 52, and the indium mesh 51 is placed inside the bulb 2, and the spring 52 is fixedly disposed inside the exhaust nozzle 22.

The venting step 112 brings the interior of the completed tube 3 into a vacuum state. The specific method of this step is: extracting the air and impurities inside the complete bulb 3 from the opening 221 of the exhaust nozzle 22, causing the interior of the complete bulb 3 to be in a vacuum state, and simultaneously injecting an inert gas such as helium or neon. Gas, helium, neon or other steady-state gases make it possible to stabilize the free gas in the lamp.

In the sealing step 113, the opening 221 of the exhaust nozzle 22 is sealed. The specific procedure of this step is to weld the opening 221 of the exhaust nozzle 22 to the sealing member 6 by a high heat temperature, as shown in Fig. 2D-1. The high heat temperature varies depending on the softening melting point of various glass materials, and the high heat temperature must be higher than the softening melting point of various glass materials.

3A to 3C show a second embodiment of the present invention, which is described by a spherical bulb. The manufacturing process of the second embodiment of the present invention is substantially the same as the manufacturing process of the first embodiment. The main difference is that the docking step 109 and the placing step 111 have such a difference. The detailed description is as follows: the material selecting step 101 is performed by selecting an appropriate material. Used as a light bulb 7. The embodiment of this step is made of glass material, but it is not limited thereto. Ceramic materials or other materials that do not absorb microwaves may also be used.

The shaping step 102 is used to shape the shape required for the bulb 7. The specific method of this step is to soften the glass with high heat temperature and shape the shape of the bulb 7. The high heat temperature will vary depending on the softening melting point of various glass materials, such as the softening of quartz glass. The melting point is above 1100 degrees Celsius, and the softening melting point of hard glass is above 600 degrees Celsius, so the high heat temperature of this step must be higher than the softening melting point of various glass materials.

The first annealing step 103 aligns the temperature inside and outside the molded bulb 7 to avoid bursting. The specific procedure of this step is to heat-anneal the shaped bulb 7 to eliminate the residual stress in the bulb 7. The temperature of the heat annealing is 500 degrees Celsius or more.

In the cutting step 104, the excess portion of the bulb 7 is cut. The specific procedure of this step is to cut the excess portion of the annealed bulb 7 by using a tube cutter.

The washing step 105 is for removing the dirt of the bulb 7, so that the inner wall 21 of the bulb 7 is easily powdered. The specific method of this step is: immersing the bulb 7 into the first liquid material for cleaning, and then taking out the bulb 7 and then drying it. The first liquid material may be an acidic water washing solution, an alkaline water washing liquid, deionized water or a mixture of an acid washing liquid and deionized water.

In the mixing step 106, the required phosphor powder is prepared according to different color temperatures. The specific method of this step is: mixing the phosphor powder with the second liquid substance to prepare a fluorescent powder liquid. The phosphor powder may be a trichromatic phosphor powder for achieving different color temperature effects after generating a light source, such as ultraviolet, infrared, long and short wavelengths in visible light, etc., and the second liquid substance may be an acidic liquid. , alkaline liquid, reverse osmosis water, deionized water, ultrapure water or distilled water.

The powder coating step 107 applies a phosphor layer 211 to the surface of the inner wall 21 of the bulb 7. The specific method of this step is: pouring the prepared fluorescent powder into the bulb 7 after the dryness, so that the fluorescent powder adheres to the inner wall 21 of the bulb 7, thereby forming the phosphor layer 211.

The baking step 108 is for emitting organic matter in the phosphor layer 211. The specific method of this step is: drying the phosphor layer 211 of the inner wall 21 of the bulb 7 to make the phosphor layer The organic matter in 211 is emitted. The drying temperature is above 70 degrees Celsius.

Docking step 109, the bulb 7 is docked into a complete bulb 8. The specific method of the step is to use the high heat temperature to butt the paired bulb 7 and the exhaust nozzle 22 into a complete bulb 8, wherein the exhaust nozzle 22 has an opening on one side (not shown), but The opening is the opening 221 of the exhaust nozzle of the first embodiment, as shown in Fig. 2C-1.

The second annealing step 110 tends to align the temperature inside and outside the completed bulb 8 to avoid bursting. The specific method of this step is to heat-anneal the butted complete bulb 8 to eliminate the residual stress in the bulb. The temperature of the heat annealing is 500 degrees Celsius or more.

The placing step 111 places an interface body capable of releasing electrons with a steady state and a spring indium mesh 5 into the interior of the exhaust nozzle 22, wherein the interface body can be a solid alloy 4. This step is specifically carried out by placing the solid alloy 4 and the spring indium mesh 5 from the opening into the interior of the exhaust nozzle 22, and the solid alloy 4 and the spring indium mesh 5 can be adjacent to each other or connected to each other. The spring indium mesh 5 is formed by interconnecting an indium mesh 51 and a spring 52.

The venting step 112 presents the interior of the completed bulb 8 in a vacuum state. The specific method of this step is: extracting the air and impurities inside the complete bulb 8 from the opening of the exhaust nozzle 22, causing the interior of the complete bulb 8 to be in a vacuum state, and simultaneously injecting an inert gas such as helium, neon, or xenon. Gas, helium or other steady-state gases that stabilize the free gas in the bulb.

In the sealing step 113, the opening of the exhaust nozzle 22 is sealed 6 . The specific procedure of this step is to weld the opening of the exhaust nozzle 22 to the sealing joint 6 by using a high heat temperature, as shown in FIG. 3C.

Although the flowchart of FIG. 1 is executed in a specified order, without being in violation of the spirit of the present invention, those skilled in the art can achieve the same effect. The order between these steps can be modified, for example, the order of the washing step 11 and the compounding step 12 can be reversed, or the processing or the like can be performed at the same time, so the present invention is not limited to using only the order as described above. In addition, those skilled in the art may also integrate several steps into one step, or perform more steps in sequence or in parallel in addition to these steps, and thus the present invention is not limited thereby.

Although the present invention has been described using the above embodiments, it should be noted that these descriptions are not intended to limit the invention. Rather, the invention encompasses modifications and similar fabrication processes that are apparent to those skilled in the art. Therefore, the scope of the claims of the present application should be interpreted in the broadest form to include all obvious modifications and similar processes.

1‧‧‧Light tube production process

101‧‧‧Selection steps

102‧‧‧Shaping steps

103‧‧‧First annealing step

104‧‧‧ cutting steps

105‧‧‧Washing steps

106‧‧‧Matching steps

107‧‧‧Powdering step

108‧‧‧Drying steps

109‧‧‧Docking steps

110‧‧‧Second annealing step

111‧‧‧Placement steps

112‧‧‧Exhaust step

113‧‧‧ Sealing steps

Claims (12)

The manufacturing process of the electrodeless lamp comprises at least the following steps: (a) selecting a material step, selecting a material of the lamp tube; (b) shaping step, softening the lamp tube with a high heat temperature, and then shaping the shape of the lamp tube; c) a first annealing step of heating and annealing the shaped lamp tube to eliminate residual stress in the lamp tube; (d) cutting step of cutting the excess portion of the annealed lamp tube; e) washing the tube step, soaking the lamp tube in the first liquid material for cleaning, and then taking out the lamp tube and then drying it; (f) mixing step, mixing the phosphor powder with the second liquid substance to prepare the fluorescent powder liquid (g) the powder coating step, pour the prepared fluorescent powder into the lamp tube after the dry, so that the fluorescent powder adheres to the inner wall of the tube; (h) the drying step, the inside of the tube The phosphor powder of the wall is dried to allow the organic matter in the phosphor powder to be emitted; (i) the docking step, the two matched lamps are docked into a complete tube by using a high heat temperature, and the lamp is a sidewall is extended on the side wall of the tube; (j) a second annealing step to heat-anneal the completed completed tube To eliminate the residual stress within the tube; (K) placing step, the steady-state free of a way for an electronic interface and a spring member placed inside the exhaust gas indium net mouth; (1) an exhausting step of extracting air and impurities inside the lamp tube from the exhaust nozzle, causing the inside of the lamp tube to be in a vacuum state and simultaneously injecting an inert gas; (m) sealing step, using a high heat temperature to discharge the exhaust nozzle Sealed. The process for manufacturing an electrodeless lamp according to claim 1, wherein the step of the washing step and the step of the compounding step can be reversed or performed simultaneously. The process for producing an electrodeless lamp according to claim 1, wherein the high heat temperature in the shaping step must be higher than the softening melting point of the glass material. The process for manufacturing an electrodeless lamp according to claim 1, wherein the first liquid material is an acidic water washing solution, an alkaline water washing liquid, a deionized water or an acid pickling liquid and deionized water. Mixture. The process for producing an electrodeless lamp according to claim 1, wherein the second liquid is an acidic liquid, an alkaline liquid, a reverse osmosis water, a deionized water, an ultrapure water or a distilled water. The process for producing an electrodeless lamp according to claim 1, wherein the phosphor powder is a trichromatic phosphor powder. The process for producing an electrodeless lamp according to claim 1, wherein the high heat temperature in the docking step must be higher than the softening melting point of the glass material. The process for producing an electrodeless lamp according to claim 1, wherein the inert gas system is helium, neon, xenon, xenon or other steady state gas. The process for manufacturing an electrodeless lamp according to claim 1, wherein the spring indium mesh is formed by interconnecting an indium mesh and a spring, and the indium mesh is placed inside the lamp tube, and the spring is placed Inside the exhaust nozzle. The process for producing an electrodeless lamp according to claim 1, wherein the high heat temperature in the shaping step must be higher than the softening melting point of the glass material. An electrodeless bulb manufacturing process comprises at least the following steps: (a) selecting a material, selecting a material of the bulb; (b) shaping step, softening the bulb with a high heat temperature, and then shaping the shape of the bulb; (c) first a sub-annealing step of thermally annealing the shaped bulb to eliminate residual stress of the bulb; (d) cutting step to cut excess portion of the annealed bulb; (e) washing step, bulb Soaking into the first liquid material for cleaning, and then taking out the bulb and then drying it; (f) mixing step, mixing the phosphor powder with the second liquid substance to prepare a fluorescent powder liquid; (g) coating step, mixing Pour the good fluorescent powder into the bulb after the dryness, so that the fluorescent powder adheres to the inner wall of the bulb; (h) the drying step, drying the fluorescent powder on the inner wall of the bulb to make the fluorescent The organic matter in the powder can be emitted; (i) the docking step, using the high heat temperature to dock the paired bulb with a nozzle to form a complete bulb; (j) the second annealing step, the completed bulb after docking Heat annealing to eliminate residual stress in the bulb (k) a placing step of placing an interface body capable of releasing electrons in a steady state and a spring indium mesh into the interior of the exhaust nozzle; (1) an exhausting step of extracting air and impurities inside the bulb from the exhaust nozzle, The inside of the bulb is brought into a vacuum state, and an inert gas is simultaneously injected; (m) a sealing step of sealing the exhaust nozzle with a high heat temperature. The manufacturing process of the electrodeless bulb according to claim 11, wherein the step of the washing step and the step of the compounding step can be reversed or performed simultaneously.