WO2011153797A1 - 一种陶瓷投影灯 - Google Patents

一种陶瓷投影灯 Download PDF

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Publication number
WO2011153797A1
WO2011153797A1 PCT/CN2010/079376 CN2010079376W WO2011153797A1 WO 2011153797 A1 WO2011153797 A1 WO 2011153797A1 CN 2010079376 W CN2010079376 W CN 2010079376W WO 2011153797 A1 WO2011153797 A1 WO 2011153797A1
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Prior art keywords
projection lamp
electrode
discharge chamber
solder
ceramic
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PCT/CN2010/079376
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English (en)
French (fr)
Inventor
张万镇
谢灿生
高鞠
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潮州市灿源电光源有限公司
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Publication of WO2011153797A1 publication Critical patent/WO2011153797A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J61/00—Gas-discharge or vapour-discharge lamps
    • H01J61/84—Lamps with discharge constricted by high pressure
    • H01J61/86—Lamps with discharge constricted by high pressure with discharge additionally constricted by close spacing of electrodes, e.g. for optical projection
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01J—ELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J61/00—Gas-discharge or vapour-discharge lamps
    • H01J61/02—Details
    • H01J61/36—Seals between parts of vessels; Seals for leading-in conductors; Leading-in conductors
    • H01J61/366—Seals for leading-in conductors

Definitions

  • the invention belongs to the field of ceramic light sources, and in particular relates to a ceramic projection lamp.
  • the projector needs high intensity and needs to be close to the 'point source' source.
  • the development of microchip technologies such as DLP and LCD has promoted the development of projector digitization and miniaturization, and has also promoted the requirements for high-efficiency projection lamps.
  • ultra-high pressure quartz mercury lamps are commonly used.
  • the emission line of mercury under normal conditions is mainly in the ultraviolet portion, but under the ultra-high pressure conditions of 100-300 atmospheres, the spectral line of mercury atoms is more widened due to the broadening.
  • the visible light has a luminous efficacy of up to 60 lumens per watt.
  • the brightness of the projector is not ideal. Compared with flat panel displays such as LCD and PDP, the projector often needs to be used under relatively dark background light.
  • the main reason is that the current ultra-high pressure mercury lamp has a luminous efficiency of about 60 lumens per watt, which needs to be improved; the current ultra-high pressure mercury lamp has a bluedish spectrum and a relatively small red component. Since the projection effect needs to meet certain color index requirements, the unbalanced spectrum can only achieve the required color coordinates by filtering out the blue color, so that the color utilization rate is lowered.
  • the life of the lamp is relatively short, about 2-3 thousand hours, the use and popularity of the projector affected by short life.
  • the short-lived causes mainly include: the quartz arc tube used is softened at high temperatures and then deformed or burst at high pressure.
  • Quartz is devitrified by the induction of impurities at high temperatures, that is, the microcrystallization process, which causes the arc tube to become opaque locally or entirely.
  • the pole distance of the electrode of the projection lamp is relatively short, the working current is relatively high, so that the operating temperature of the electrode tip is high, the evaporation of the electrode material causes the arc tube to blacken, and the distance between the electrodes is changed, resulting in a change in the electrical and optical properties of the light source.
  • an object of the present invention is to provide a ceramic projection lamp having high luminous efficiency and good sealing effect.
  • the technical solution of the present invention is: a ceramic projection lamp comprising a discharge chamber and an electrode tube disposed at two ends of the discharge chamber and an electrode assembly extending into the discharge chamber through the electrode tube, wherein the discharge chamber and the electrode tube are Made of a transparent ceramic material, the electrode assembly is hermetically sealed by solder and an electrode tube filled with mercury, and further, it may be filled with a small amount of metal or rare earth halide.
  • the invention Compared with the quartz projection lamp, the invention has higher mechanical strength and higher temperature resistance, and can improve the working temperature and air pressure of the light source, so as to improve the light efficiency, color and life of the light source.
  • the stress of the integral ceramic projection lamp can be eliminated during the forming and sintering process.
  • the temperature at the time of sealing has little effect on the ceramic, and the sealing portion is the lowest operating temperature, so that the stress problem can be lowered to a very low level.
  • the junction of the quartz projection lamp at the junction of the inner tube and the cavity coincides with the maximum thermal stress, which is a major reason for the scrapping of the quartz projection lamp.
  • the mercury gas pressure of the invention is higher, resulting in a higher voltage, and at the same power, the current is smaller, so that the electrode heat is reduced.
  • high mercury gas pressure can also directly inhibit the evaporation of tungsten, and the present invention does not cause blackening of the arc tube.
  • the electrode tube comprises a connected inner tube section and a welding groove, the inner tube section is close to the discharge cavity, the welding groove is located at the end surface, and the inner diameter of the welding groove is larger than the inner pipe section, and the welding groove realizes the hermetic sealing of the discharge cavity by filling the solder.
  • the advantage of the scheme in the end face welding compared to the welding in the electrode tube is that the solder is kept away from the high temperature arc to the maximum extent, which is beneficial to improve the performance and life of the solder.
  • the solder bath can more reliably ensure the quantity and quality of the solder to ensure the airtightness of the lamp under high pressure conditions.
  • the solder can be melted in situ in the solder bath without the solder flowing through the capillary to a certain depth before soldering. In-situ soldering of the solder in the solder bath simplifies the sealing process and reduces sealing time.
  • solder can be reduced in length from the arc high temperature region compared to the prior art soldering process, which contributes to some applications where the arc tube scale is required to be shorter.
  • the cold end position of this scheme can effectively control the front, and because it is closer to the heat source part, the cold end temperature is increased and the working pressure of the light source is ensured.
  • the electrode assembly comprises a tungsten core rod, a cermet rod and a lead wire which are sequentially connected, and the tungsten core rod extends into the discharge chamber, the cermet rod is located in the inner tube section, and the outer diameter of the cermet rod and the inner tube section The inner diameter is equivalent and the lead is connected to the end of the cermet rod and extends out of the electrode tube through the solder in the solder bath.
  • the electrode tube and the electrode assembly can reduce the gap as much as possible to block the loss of mercury and halide into the gap of the electrode tube.
  • the cermet rod portion is mainly in the inner tube section, its function is to carry current and effectively block the conduction of heat. A lead is added for connection to an external circuit.
  • the expansion coefficient of the cermet rod is very close to that of the electrode tube, and the electrode tube can be effectively prevented from being broken or gap due to the inconsistent expansion coefficient of the electrode tube or the cermet rod.
  • the smaller gap effectively prevents the loss of luminescent substances caused by luminescent substances such as halides and mercury entering the gap, and the resulting reduction in efficacy and color change of light.
  • the end of the cermet rod is provided with a boss structure that is matched with the welding groove.
  • the electrode assembly is inserted into the electrode tube. Due to the structure of the boss, the electrode assembly can be well positioned at the preset position, and after filling, the filler is filled into the solder tank. In this solution, The solder is not filled in the gap between the electrode assembly and the electrode tube, and the complexity of the sealing process can be effectively reduced.
  • the top of the boss structure is formed with a plurality of tapered surfaces to make it easier for the solder to wet the solder bath and the electrodes.
  • the soldering groove has an outwardly constricted structure, and the shrinking structure applies an axial pressure to the overall structure of the solder, which can effectively prevent the solder from falling off.
  • the welding groove may have a truncated cone structure or a truncated cone or a spherical structure.
  • a plurality of concave/convex groove structures may be disposed on the side of the welding groove, and the groove/groove structure has a gripping force on the whole solder, which can effectively prevent the solder from falling off after the aging of the solder.
  • the weld groove has an inner diameter of 2 to 5 mm and a depth of 2 to 5 mm; the inner tube has an inner diameter of 0.4 to 1.5 mm and a length of 10 to 40 mm.
  • connection between the outer curved surface of the discharge chamber and the electrode tube is a smooth transition structure, avoiding acute angle curvature, so as to reduce the stress of the ceramic projection lamp.
  • Figure 1 is a cross-sectional view of a ceramic projection lamp of the present invention.
  • the present invention discloses a ceramic projection lamp comprising a discharge chamber 1 and an electrode tube 2 disposed at two ends of the discharge chamber 1 and an electrode assembly 3 extending through the electrode tube 2 into the discharge chamber 1.
  • the cavity 1 and the electrode tube 2 are made of a transparent ceramic material, and the electrode assembly 3 is hermetically sealed by the solder 4 and the electrode tube 2, which is filled with mercury and a small amount of metal or rare earth halide.
  • the discharge chamber 1 is filled with a metal halide of a proper ratio as a luminescent substance to increase the light efficiency and further improve the color of the light.
  • Metal halides include Na (sodium), K (potassium), Cs, Ce, In Halides, or some rare earth halides, or a combination thereof.
  • the mercury gas pressure of ceramic projection lamps is generally above 300 atmospheres.
  • the electrode tube 2 includes a connecting inner tube section 21 and a welding groove 22, the inner tube section 21 is close to the discharge chamber 1, the welding groove 22 is located at the end surface, and the inner diameter of the welding groove 22 is larger than the inner tube section 21, and the welding groove 22 is filled with solder. 4 A hermetic seal of the discharge chamber 1 is achieved.
  • the welding of this invention is different from the sealing of a quartz arc tube.
  • the quartz arc tube sealing is formed by shrinking the high temperature melting quartz under the condition of pressure difference and sealing with the electrode assembly.
  • the electrode assembly of the quartz projection lamp comprises a metal electrode and a molybdenum sheet, and the metal electrode is welded with the molybdenum sheet. Since the weld is very close to the high temperature zone of the arc and the weld is small, this weld is also one of the reasons for the scrapping or life reduction of the quartz projection lamp.
  • the invention can provide the solder portion in a safe position away from the high temperature region of the arc as needed, i.e., in the solder bath.
  • the electrode assembly 3 includes a tungsten core rod 31, a cermet rod 32 and a lead 33 connected in series, the tungsten core rod 31 extending into the discharge chamber 1, the cermet rod 32 being located in the inner tube section 21, and the cermet rod 32
  • the outer diameter is equivalent to the inner diameter of the inner tube section 21, and the lead is connected to the end of the cermet rod 32 and passes through the solder 4 in the soldering groove 22 to protrude outside the electrode tube 2.
  • the inner surface of the electrode tube 2 is polished to a high precision, and is matched with the high-precision outer surface of the electrode assembly 3 to achieve a gap of less than 30 ⁇ m between the inner surface of the electrode tube 2 and the outer surface of the electrode assembly 3, and can be processed through high precision. It reaches below 5 microns. This unique ultra-fine gap reduces the pressure of the mercury gas-sealed solder and the entry of mercury species into the gap between the electrode tubes.
  • the precision of the pitch of the tungsten core rod 31 is relatively high, and the distance between the tungsten core rods 31 is between 0.5 and 2 mm, and the precision can be less than 0.05 mm.
  • the pitch accuracy is ensured by precise positioning on the electrode assembly, and the precise positioning of the electrode assembly is achieved by the above-described sealing structure and the polished structure of the inner surface of the electrode tube and the outer surface of the electrode assembly.
  • the accuracy of the coaxiality of the electrode assembly of the ceramic projection lamp is relatively high, and the coaxiality accuracy is less than 0.5° from the off-axis angle, and even less than 0.05°.
  • the accuracy of the coaxiality is achieved by the inner wall of the electrode tube and the surface precision of the electrode assembly.
  • the ceramic projector lamp Due to the high air pressure, the ceramic projector lamp has a higher airtight requirement, and the welding groove is deeper than 1.5 mm.
  • the inner wall of the arc tube and the surface of the electrode assembly are highly finished, generally below 5 microns, and some are below 2 microns.
  • the discharge end of the tungsten core rod 31 is processed into a conical head or a round head to ensure sufficient heating of the discharge end, and to increase the electron emission capability and the accuracy of the emission position of the tungsten core rod.
  • the end of the cermet rod 32 is provided with a boss structure which is matched with the welding groove 22; the top of the boss structure is formed with a plurality of tapered surfaces.
  • the welding groove 22 has an outwardly constricted structure, such as a truncated cone structure or a truncated cone or a spherical structure.
  • a plurality of concave/convex groove structures may be disposed on the side of the welding groove 22.
  • the weld groove 22 has an inner diameter of 2 to 5 mm and a depth of 2 to 5 mm; the inner tube 21 has an inner diameter of 0.4 to 1.5 mm and a length of 10 to 40 mm.
  • connection between the outer curved surface of the discharge chamber 1 and the electrode tube 2 is a smooth transition structure.

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  • Vessels And Coating Films For Discharge Lamps (AREA)

Description

一种陶瓷投影灯
技术领域
本发明属于陶瓷光源领域，尤其涉及一种陶瓷投影灯。
背景技术
投影机需要高强度，需接近'点光源'的光源。微芯片技术如DLP、LCD的发展推动了投影机数字化和小型化的发展，也推动了对高效投影灯的要求。
目前普遍采用的是超高压石英汞灯，汞在正常条件的发射谱线主要在紫外线部分，但是在100-300个大气压的超高气压条件下，汞原子发光谱线的由于展宽而产生更多的可见光，其光效可达60流明每瓦。
目前投影机的亮度还不够理想，比起LCD、PDP等平板显示器，投影机往往还需要在比较暗的背景光线下使用。其中原因主要是：目前的超高压汞灯的光效在60流明每瓦左右，还有待提高；目前的超高压汞灯的光谱偏蓝，红的成分相对小。由于投影效果需要达到一定的色指标要求，不平衡的光谱只有通过过滤掉蓝色来达到要求的色坐标，这样颜色利用率降低。
目前投影灯寿命都比较短，大约2-3千小时，短寿命影响的投影机的使用和普及。短寿命的原因主要包括：使用的石英电弧管在高温下变软然后在高气压下发生形变或炸裂。
石英在高温下经由杂质的诱导会发生析晶，即微晶化过程，而导致电弧管局部或整体变得不透明。
由于投影灯电极极距比较短，因此工作电流比较高，致使电极头工作温度较高使电极材料蒸发导致电弧管发黑，并且改变电极之间的距离，导致光源的电和光性质发生变化。
发明内容
针对现有技术的缺点，本发明的目的是提供一种发光效率高、密封效果好的陶瓷投影灯。
为实现上述目的，本发明的技术方案为：一种陶瓷投影灯，包括放电腔及设于放电腔两端的电极管及通过电极管伸入放电腔内的电极组件，该放电腔及电极管由透明陶瓷材料制得，该电极组件通过焊料与电极管实现气密密封，该放电腔内填充有汞，进一步地，其还可以填充少量金属或稀土卤化物。
本发明相比石英投影灯具有更高的机械强度，更高的耐温性，可以提高光源的工作温度和气压，以致于提高光源的光效，颜色和寿命。
整体陶瓷投影灯的应力可以在成型和烧结过程中排除。在封接时的温度对于陶瓷基本无影响，而且封接部位是工作温度最低的，这样应力问题可以降到很低。而石英投影灯封接部位在内管和腔体的交接处，恰恰与热应力最大处吻合，这便是石英投影灯报废的一大原因。
本发明汞气压较高，导致电压较高，在同样的功率下，电流较小，使电极发热减小。另外，高汞气压也可以直接抑制钨的蒸发，本发明不会导致电弧管发黑。
该电极管包括相连接的内管段及焊接槽，该内管段靠近放电腔，焊接槽位于端面处，且焊接槽的内径较内管段大，焊接槽通过填充焊料实现放电腔的气密密封。
本方案在端面焊接比起在电极管内焊接的优点是使焊料最大限度的远离高温电弧，有利提高焊料的使用性能和寿命。同时，焊料槽可以更可靠地保证焊料的数量和质量，以确保投影灯在高压条件下的气密性。焊料可以在焊料槽原地融化焊接，而不要焊料在毛细管里流动，到达一定深度，然后再完成焊接。焊料在焊料槽里原地焊接简化了封接过程和减少了封接时间。
另外，焊料比起在现有现有技术焊接的工艺更远离电弧高温区，电极管的长度可以相应减小，有助于一些对电弧管尺度要求短小一点的应用。此方案的冷端位置能有效控制靠前，由于更接近热源部分，提高了冷端温度，保证光源的工作压力。
进一步地，该电极组件包括依次相连接的钨芯棒、金属陶瓷杆及引线，该钨芯棒伸入放电腔内，该金属陶瓷杆位于内管段，且金属陶瓷杆的外径与内管段的内径相当，引线与金属陶瓷杆末端连接并穿过焊接槽中的焊料伸出电极管外。
由于电极管内壁没有焊接的功能，电极管和电极组件可以尽可能的减小间隙，以阻拦汞和卤化物进入电极管间隙而带来的流失。由于金属陶瓷杆部分主要在内管段内，其功能为输送电流并且有效地阻拦热量的传导。外加一条引线，用于与外电路相接。该金属陶瓷杆的膨胀系数与电极管很接近，能有效避免由于电极管或金属陶瓷杆的膨胀系数不一致，而导致的电极管破裂或存在间隙。较小的间隙有效地防止了发光物质如卤化物和汞进入间隙而带来的发光物质的流失和由此引起的光效减低和光的颜色的变化。
该金属陶瓷杆末端设有与焊接槽配合定位的凸台结构。封接时，将电极组件插进电极管中，由于凸台结构的作用，电极组件能很好地定位在预设位置，插装后，再将填料填充到焊料槽上，此方案中，由于焊料不是填充在电极组件与电极管的间隙中，能有效减少密封工艺的复杂性。
该凸台结构顶部形成有若干锥面，使焊料更容易润湿焊接槽和电极。
进一步地，为防止焊料老化后由焊料槽脱落，该焊接槽呈一向外缩口结构，缩口结构给焊料的整体结构施加一轴向的压力，能有效防止其脱落。
进一步地，该焊接槽可呈圆台结构或圆锥台或球形结构。
同样地，该焊接槽侧面上也可设有若干凹/凸槽结构，凹槽/凸槽结构对焊料整体具有抓紧力，能有效防止焊料老化后由焊料槽脱落。
该焊接槽的内径尺寸为2-5毫米范围内，深度在2-5毫米；内管段内径在0.4-1.5毫米范围内，长度在10-40毫米范围内。
该放电腔的外曲面与电极管的连接处为光滑过渡结构，避免锐角曲率，以减小陶瓷投影灯的应力。
附图说明
图1 为本发明陶瓷投影灯的剖面图。
具体实施方式
以下结合实施例及附图对本发明进行详细的描述。
如图1所示，本发明公开了一种陶瓷投影灯，其包括放电腔1及设于放电腔1两端的电极管2及通过电极管2伸入放电腔1内的电极组件3，该放电腔1及电极管2由透明陶瓷材料制得，该电极组件3通过焊料4与电极管2实现气密密封，该放电腔1内填充有汞与少量金属或稀土卤化物。该放电腔1充入适当比例的金属卤化物作为发光物质以增加光效和进一步改善光的颜色。金属卤化物包括Na（钠），K(钾)，Cs,Ce,In 的卤化物，或一些稀土卤化物，或者他们的组合。陶瓷投影灯的汞气压一般在300个大气压以上。
该电极管2包括相连接的内管段21及焊接槽22，该内管段21靠近放电腔1，焊接槽22位于端面处，且焊接槽22的内径较内管段21大，焊接槽22通过填充焊料4实现放电腔1的气密密封。
此发明的焊接不同于石英电弧管的封接。石英电弧管封接是通过高温融化石英在压力差的条件下收缩而与电极组件结合封接而成。石英投影灯的电极组件包括金属电极和钼片，金属电极与钼片焊接而成。由于焊接处与电弧高温区很接近，而且焊接点很小，此焊接点也是导致石英投影灯报废或寿命减小的原因之一。此发明可以根据需要将焊料部分设于远离电弧高温区的安全位置，即为该焊接槽中。
该电极组件3包括依次相连接的钨芯棒31、金属陶瓷杆32及引线33，该钨芯棒31伸入放电腔1内，该金属陶瓷杆32位于内管段21，且金属陶瓷杆32的外径与内管段21的内径相当，引线与金属陶瓷杆32末端连接并穿过焊接槽22中的焊料4伸出电极管2外。
电极管2内表面经抛光达到高精度，并配合电极组件3的高精度外表面抛光，以达到电极管2内表面和电极组件3外表面之间间隙小于30微米，经过高精度的加工甚至可以达到5微米之下。这样特有的超微小间隙减小了汞气压密封焊料的压力和汞物质进入电极管间隙内。
钨芯棒31间距的精度要求较高，钨芯棒31间距在0.5到2毫米之间，精度可以达到0.05毫米以下。间距精度通过在电极组件上精确定位而保证，而电极组件的精确定位由上述的密封结构及电极管内表面与电极组件外表面的抛光结构来综合实现。
陶瓷投影灯的电极组件的同轴度精度要求较高，同轴度精度做到离轴角度小于0.5°，甚至做到小于0.05°。同轴度精度由电极管内壁和电极组件表面加工精度实现。
由于高气压，陶瓷投影灯的气密要求更高，其焊接槽较深，为1.5毫米以上。电弧管内壁和电极组件表面精加工要求较高，一般在5微米以下，有些灯在2微米以下。
另外，钨芯棒31的放电端加工成锥形头或圆形头，保证放电端充分加热，增加钨芯棒的电子发射能力和发射位置的准确性。
该金属陶瓷杆32末端设有与焊接槽22配合定位的凸台结构；该凸台结构顶部形成有若干锥面。
该焊接槽22呈一向外缩口结构，如呈圆台结构或圆锥台或球形结构。当然，该焊接槽22侧面上还可以设有若干凹/凸槽结构。
该焊接槽22的内径尺寸为2到5毫米范围内，深度在2-5毫米；内管段21内径在0.4-1.5毫米范围内，长度在10-40毫米范围内。
为了避免锐角曲率，以减小陶瓷投影灯的应力，该放电腔1的外曲面与电极管2的连接处为光滑过渡结构。

Claims (10)

  1. 一种陶瓷投影灯，其特征在于，包括放电腔及设于放电腔两端的电极管及通过电极管伸入放电腔内的电极组件，该放电腔及电极管由透明陶瓷材料制得，该电极组件通过焊料与电极管实现气密密封，该放电腔内填充有汞。
  2. 根据权利要求1所述的陶瓷投影灯，其特征在于，该放电腔还填充有少量金属或稀土卤化物。
  3. 根据权利要求1所述的陶瓷投影灯，其特征在于，该电极管包括相连接的内管段及焊接槽，该内管段靠近放电腔，焊接槽位于端面处，且焊接槽的内径较内管段大，焊接槽通过填充焊料实现放电腔的气密密封。
  4. 根据权利要求3所述的陶瓷投影灯，其特征在于，该电极组件包括依次相连接的钨芯棒、金属陶瓷杆及引线，该钨芯棒伸入放电腔内，该金属陶瓷杆位于内管段，且金属陶瓷杆的外径与内管段的内径相当，引线与金属陶瓷杆末端连接并穿过焊接槽中的焊料伸出电极管外。
  5. 根据权利要求4所述的陶瓷投影灯，其特征在于，该金属陶瓷杆末端设有与焊接槽配合定位的凸台结构。
  6. 根据权利要求5所述的陶瓷投影灯，其特征在于，该凸台结构顶部形成有若干锥面。
  7. 根据权利要求1所述的陶瓷投影灯，其特征在于，该焊接槽呈一向外缩口结构。
  8. 根据权利要求7所述的陶瓷投影灯，其特征在于，该焊接槽呈圆台结构或圆锥台或球形结构，或侧面上设有若干凹/凸槽结构。
  9. 根据权利要求2所述的陶瓷投影灯，其特征在于，该焊接槽的内径尺寸为2-5毫米范围内，深度在2-5毫米；内管段内径在0.4-1.5毫米范围内，长度在10-40毫米范围内。
  10. 根据权利要求1至9任一项所述的陶瓷投影灯，其特征在于，该放电腔的外曲面与电极管的连接处为光滑过渡结构。
PCT/CN2010/079376 2010-06-07 2010-12-02 一种陶瓷投影灯 WO2011153797A1 (zh)

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CN106166792A (zh) * 2015-10-16 2016-11-30 圣戈本陶瓷及塑料股份有限公司 具有复杂几何形状的透明陶瓷和其制造方法

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