WO2010118245A1

WO2010118245A1 - Silicone covered light bulbs

Info

Publication number: WO2010118245A1
Application number: PCT/US2010/030415
Authority: WO
Inventors: Thomas James Irvine; Yun Ping Liu
Original assignee: Thomas James Irvine; Yun Ping Liu
Priority date: 2009-04-08
Filing date: 2010-04-08
Publication date: 2010-10-14

Abstract

A sealed silicone coated compact fluorescent lamp ("CFL") which will contain the mercury and other dangerous debris within the silicone sheath if the CFL should break.

Description

SILICONE COVERED LIGHT BULBS

The present invention is directed to light bulbs sheathed in silicone which protects the bulb from damage and contains the debris, including the toxic mercury, if the bulb should break.

Background of the invention

Compact fluorescent lamps ("CFLs") have become increasingly popular. They generate less heat, draw less electrical current, and are more energy efficient than standard incandescent bulbs. According to recent government statistics, if every American home replaced just one light bulb with an Energy Star approved CFL, the United States would save enough energy to light more than 2.5 million homes for a year and prevent greenhouse gases equivalent to the emissions of nearly 800,000 cars.

CFLs, however, contain small amounts of mercury. This is problematic if the CFL breaks since mercury is highly toxic. The present invention is directed to correcting this problem by providing a CFL sealed in a silicone sheath. If the CFL breaks, the mercury as well as the glass and other debris from the bulb, is safely contained within the sheath.

Brief summary of the invention

The object of this invention is to provide a light bulb, such as a CFL, that is sealed by a protective silicone sheath. The silicone sheath is fitted over a glass bulb which is then sealed with epoxy to the ballast base of the CFL. In the alternative, the lamp burner can be dipped into a silicone-glue slurry or the slurry can be poured over the burner, and then epoxied onto the back of the plastic base. The resulting sealed construction will contain the mercury vapor and other dangerous debris within the silicone sheath if the CFL should break.

The silicone-covered CFL is shatter-resistant and may be used with a higher degree of safety than regular non-protected bulbs in sensitive areas such as commercial kitchens, hospitals, laboratories, schools, and nurseries.

In addition to the safe and effective mercury containment system, the silicone- covered CFL of the present invention, by virtue of the epoxy sealant, is water-resistant. This improves the useful life of the bulb in humid conditions. The silicone covering also expedites heat transfer which results in a lower bulb temperature and longer bulb life.

The silicone sheath or coating may be made in any of a myriad of colors and may be used over clear or frosted glass.

The present invention may be adapted for use with fluorescent tubes, by attaching the silicone at the ends of the tube, as well as for cold cathode fluorescent lamp and induction lighting, which would be attached in a manner similar to that used for CFLs.

Brief description of the drawings

Fig. 1 is a view of the silicone sheath of the present invention. Fig. 2 is a view of the silicone sheath being fit over a glass globe. Fig. 3 is a view of the CFL tubing connected to the ballast base. Fig. 4 is a view of the assembled sheathed CFL. Fig. 5 is a cross-sectional view of Fig. 4 taken at line 5 - - 5. Fig. 6 is a view of a shattered CFL of the present invention. Detailed description of the invention

Fig. 1 shows a preferred embodiment of the silicone sheath 10 of the present invention. The sheath is manufactured from standard silicone film compositions. The thickness of sheath 10 is preferably between about 5 to 7 mils which provides the necessary strength and flexibility required by this application. The sheath has a closed rounded top portion 11 and an open end 12.

Fig. 2 shows sheath 10 as it is partially fitted over glass globe 20 which encases the CFL burner 30, shown in Fig. 3. Sheath 10 is then pulled fully over globe 20 such that open end 12 is aligned with the open edge (not shown) of globe 20. Fig. 5 shows a cross-sectional view of globe 20 covered by sheath 10. An epoxy glue bead is applied to the globe edge and sheath open end 12. The globe edge is then fit into cavity 32 of ballast base 31 of the CFL. The assembled product is shown in Fig. 4.

A second preferred embodiment is to coat burner 30 of Fig. 3 with a silicone glue solution, wherein the main component is silicone dioxide, mSiO₂nH₂O, an odorless and non-toxic solution. Because the particle size is 10-20 nm, it is transparent and does not affect the color of the object that is coated. Colored pigments, however, may be added to the silicone solution if desired, in which case the coating will not be transparent but will be colored. Burner 30 is dipped into the silicone glue solution and slowly rotated continuously at 25°C for 20 minutes or until the thickness of the coating has a thickness of approximately 0.2 mm to 0.4 mm, and preferably 0.3 mm. Maintaining the slow rotation, the silicone coated burner is then heated in an oven for 30 minutes at 150⁰C to vaporize the water. Once dried, the ends 33 of burner 30 are inserted into the base 31 through holes 34. A bead of epoxy is applied to around ends 33 so that they are sealed to base 31.

An alternative method of coating the CFL of Fig. 3 is to pour the silicone glue solution over a slowly continuously rotating burner 30 at 25°C for 20 minutes or until the thickness of the coating has a thickness of approximately 0.2 mm to 0.4 mm, and preferably 0.3 mm. Maintaining the slow rotation, the silicone coated burner is then heated in an oven for 30 minutes at 150⁰C to vaporize the water. Once dried, the ends 33 of burner 30 are inserted into the base 31 through holes 34. A bead of epoxy is applied to around ends 33 so that they are sealed to base 31.

If the globe and the fluorescent tubing of the CFL of the present invention is broken or cracked, the silicone sheath contains the debris, including the mercury, in a sealed sack 60, e.g., as shown in Fig. 6.

Claims

Claim

1. A compact fluorescent lamp comprising a silicone sheath having a closed top portion and an open end portion; a glass globe having an open edge portion; a fluorescent tubing burner fit into a ballast base wherein the ballast base has a cavity within a circumference; wherein the sheath is fit over the glass globe such that the open end of the sheath is aligned with the open edge of the globe, an epoxy glue bead is applied to the aligned sheath and globe portions, which portions are inserted into the cavity in the ballast base such that the globe encases the fluorescent tubing.

2. A compact fluorescent lamp according to claim 1 wherein the sheath has thickness between 5 and 7 mils.

3. A compact fluorescent lamp according to claim 1 wherein the sheath is colorless.

4. A compact fluorescent lamp according to claim 1 wherein the sheath is colored.

5. A compact fluorescent lamp comprised of: a. a ballast base having two holes thereon, b. a fluorescent tubing burner having two ends, c. wherein the burner has been dipped into a silicone dioxide solution, rotated continuously until a coating is formed thereon, then dried in an oven, and d. wherein an epoxy bead is applied to the ends of the burner and the ends are inserted into the holes in the ballast base such that the epoxy bead seals the ends within the ballast base.

6. A compact fluorescent lamp of claim 5 wherein the burner has been dipped in the silicone dioxide solution for 20 minutes at 25°C and has been dried in the oven for 30 minutes at 25°C.

7. A compact fluorescent lamp according to claim 5 wherein the coating has a thickness between 0.2 and 0.4 mm.

8. A compact fluorescent lamp according to claim 5 wherein the coating is colorless.

9. A compact fluorescent lamp according to claim 5 wherein the coating is colored.

10. A compact fluorescent lamp comprised of: a. a ballast base having two holes thereon, b. a fluorescent tubing burner having two ends, c. wherein a silicone dioxide solution has been poured over the burner while it has been rotated continuously until a coating is formed thereon, and dried in an oven, while being rotated continuously, and d. wherein an epoxy bead is applied to the ends of the burner and then ends are inserted into the holes in the ballast base such that the epoxy bead seals the ends within the ballast base.

11. A compact fluorescent lamp of claim 10 wherein the burner has been dipped in the silicone dioxide solution for 20 minutes at 25°C and has been dried in the oven for 30 minutes at 25°C.

12. A compact fluorescent lamp according to claim 10 wherein the coating has a thickness between 0.2 and 0.4 mm.

13. A compact fluorescent lamp according to claim 10 wherein the coating is colorless.

14. A compact fluorescent lamp according to claim 10 wherein the coating is colored.