WO2012171144A1

WO2012171144A1 - Hid arc tube, manufacturing method thereof, illumination device and illumination system

Info

Publication number: WO2012171144A1
Application number: PCT/CN2011/001009
Authority: WO
Inventors: 陈宗烈; 龚仕宏
Original assignee: 盐城豪迈照明科技有限公司
Priority date: 2011-06-17
Filing date: 2011-06-17
Publication date: 2012-12-20
Also published as: CN103534782B; CN103534782A

Abstract

An HID arc tube, a manufacture method thereof, an illumination device and an illumination system are provided. The manufacture method for HID arc tube includes: forming a bulb shell which includes a discharge cavity (5) and outer shells (1) extending from two ends of the discharge cavity (5) respectively, wherein forming a conical hollow location part (11) neighboring the discharge cavity (5) in the outer shell (1). The outer diameter and the inner diameter of the hollow location part (11) decrease synchronously and gradually along the direction to the discharge cavity (5), and the thickness of the tube wall does not change. An electrode location part (9) with a shape of trapezoid and cone is formed, and the electrode location part has a conical surface which can tightly combine with the hollow location part (11), and the electrode location part can be used to fix the electrode (8) and make the electrode (8) enter into the discharge cavity (5) with a predetermined length (L) when the electrode location part (9) is tightly combined with the hollow location part (11). The electrode location part, on which the electrode (8) is fixed, enters into the hollow location part (11), and tight combination between the electrode location part (9) and the hollow location part (11) is realized. The method can make the arc tube have accurate electrode space, improve the vacuum and cold junction temperature, and improve the luminous efficiency, lifetime, and consistency of the product.

Description

HID arc tube and manufacturing method thereof, lighting device and lighting system

The invention relates to the field of illumination, in particular to an HID arc tube, a manufacturing method thereof, a lighting device and a lighting system. Background technique

As shown in Fig. 1, in the existing HID arc tube, whether it is a traditional quartz glass tube or a PCA ceramic arc tube developed in recent years, the manufacturing process usually includes a bulb forming, and the formed bulb includes a discharge chamber 5 And the outlet tube 1 at both ends of the discharge chamber; assembling the first electrode 4 and sealing; injecting mercury, metal halide pellets and inert gas 3, etc.; assembling the second electrode 6, exhausting and sealing, and the like. Most of the above processes are carried out in a glove box. The computer screen in the glove box shows that the manual electrode positioning is to make a circle of the guide wire tail 2, relying on the friction between the ring 2 and the inner wall of the outlet tube 1 to position the electrode. The HID arc tube exhaust process is not only to remove the impurity gas from the material in the arc tube, but also to incorporate mercury, metal halide and inert gas into the arc tube. The most important thing is to precisely adjust the distance between the two electrodes. This is because HID The distance between the two electrodes of the arc tube determines the important indexes such as the tube pressure, tube flow, photoelectric parameters and even the metal halide cycle and life of the HID arc tube. These processes are currently performed manually, and most types of arc tubes require gloves on the glove box, making it difficult to ensure the pole spacing and concentricity of the two electrodes in the HID arc tube. Moreover, the conventional process of manufacturing the HID arc tube is the second electrode sealing after the completion of the key exhaust (referred to as two seals), and the high temperature at the time of sealing necessarily causes the material to release the impurity gas and remains in the arc tube, affecting the arc tube. Light efficiency and longevity. Moreover, the inaccurate positioning of the electrodes also seriously affects the light distribution of the arc tube and the reflector cup, affecting the light output, the beam angle, and the light-emitting efficiency and characteristics of the lamp.

The manufacturing method of the above HID arc tube can be referred to as a sealing method. In the Chinese patent application (Application No. 200810097227.7) of the inventor's composite HID arc tube (referred to as composite arc tube), a two-sealing method is adopted for the composite arc tube, wherein the composite HID arc tube is used. The discharge chamber is coated with a polycrystalline alumina layer and both ends of the outer lead tube adjacent to the discharge chamber are also partially coated with a polycrystalline alumina layer. This method can be changed The above-mentioned composite HID arc tube inner layer PCA ceramics have insufficient pressure and air tightness caused by sealing with a glass material, which improves the sealing reliability and the yield of the finished product. Specifically, the two sealing methods include sealing the first and second sections of the outlet tube at the two ends of the discharge chamber of the HID arc tube, and sealing the first section of the arc chamber with a glass solder. The second section is non-matching sealing with molybdenum foil. Through the two-stage sealing method, it is also inevitable that a sealing method in the prior art generates a problem that impurity gas enters the discharge chamber at a high temperature in two seals. In particular, the difficulty of the sealing method is that the solder is fed into the lead-out tube for a certain distance during the first sealing, and the molybdenum foil and the outer lead wire are blocked, which is inconvenient to operate. In addition, in the fabrication of the composite HID arc tube, the positioning of the two electrodes needs to be manually performed by the cooperation of the camera and the monitor. Therefore, it is also difficult to ensure the pole pitch and coaxiality of the two electrodes in the HID arc tube. Summary of the invention

The technical problem to be solved by the present invention is to provide a plug sealing method for manufacturing a HID arc tube, which can accurately locate the distance between two electrodes in a HID arc tube and prevent high temperature when the HID arc tube is sealed in two places. The impurity gas that may be released by the heating material enters the arc tube discharge chamber. The invention also provides a HID arc tube prepared by the method, a lighting device with a precise light distribution curve formed by the HID arc tube of the invention and the multi-diagonal parabolic reflector lamp cup of the vapor deposition medium film layer, and the illumination device comprising the same The lighting system of the device.

To this end, the present invention provides a method of making an HID arc tube comprising the following steps:

Forming a bulb, the bulb comprising a discharge chamber and an outer lead tube respectively extending from both ends of the discharge chamber, wherein a position of the outer lead tube adjacent to the discharge chamber forms a tapered hollow positioning member, the hollow positioning member facing the discharge chamber In the direction, the outer diameter and the inner diameter gradually decrease, and the wall thickness does not change;

An electrode positioning member forming a trapezoidal cone shape having a tapered surface capable of achieving a tight fit with the hollow positioning member for fixing the electrode and extending the electrode into the discharge chamber by a predetermined length when the electrode positioning member is tightly engaged with the hollow positioning member ; as well as

The electrode positioning component with the electrode fixed is inserted into the hollow positioning component to realize the electrode setting A tight fit between the bit member and the hollow positioning member.

Preferably, after the step of forming the bulb, the method further comprises coating a polycrystalline alumina layer on the inner wall of the discharge chamber and the hollow positioning member.

Preferably, the electrode positioning member is prepared by adding a rare earth material of high purity alumina, silica, zirconia, magnesia or boron oxide.

Preferably, the electrode positioning member includes a tapered through hole provided on a central axis thereof for accommodating a tungsten rod, the inner diameter of the tapered through hole toward the first end of the discharge chamber being smaller than the hole at the second end The inner diameter of the mouth is large; the tungsten rod is provided with a prefabricated end, the aperture of the second end of the tapered through hole and the opening of the first end are respectively tightly matched with the tungsten rod and the prefabricated end, and then the tungsten is fixed at the small hole of the through hole The rod is flattened; and the electrode is attached to the preformed end of the tungsten rod to extend into one end of the discharge chamber.

Preferably, the metal halide pellet is built into the discharge chamber before the electrode positioning member to which the electrode is fixed is inserted into the hollow positioning member, and then the exhaust gas is evacuated and then high purity mercury and inert gas are placed.

Preferably, the manufacturing method of the present invention further comprises sealing the molybdenum foil (for the quartz arc tube and the composite arc tube) or the glass solder (for the ceramic arc tube) after the electrode positioning member is tightly fitted with the tapered port.

The invention also provides an arc tube comprising:

a bulb comprising a discharge chamber and an outer lead tube respectively extending from both ends of the discharge chamber, wherein a position of the outer lead tube adjacent to the discharge chamber is formed with a tapered hollow positioning member facing the discharge chamber In the direction, the outer diameter and the inner diameter gradually decrease, and the wall thickness does not change;

An electrode positioning member having a trapezoidal cone shape, the electrode positioning member extending into the hollow positioning member and being in a tight fitting state with the hollow positioning member; wherein the electrode positioning member is fixed with an electrode, and the electrode is inserted into the discharge The predetermined length within the cavity.

Preferably, the inner wall of the discharge chamber and the inner wall of the hollow positioning member are coated with a polycrystalline alumina layer.

Preferably, a tungsten rod is further mounted on the electrode positioning component.

Preferably, the electrode positioning member includes a tapered through hole provided on a central axis thereof for accommodating a tungsten rod, and the inner diameter of the tapered through hole toward the first end of the discharge chamber is larger than The inner diameter of the two-end orifice is large; the tungsten rod is provided with a pre-formed end, and the second end of the tapered through-hole and the first end of the orifice are respectively tightly matched with the tungsten rod and the pre-formed end, and then small in the through-hole The tungsten rod at the hole is flattened; and the electrode is attached to the preformed end of the tungsten rod to extend into one end of the discharge chamber.

Since the present invention is provided with a conical hollow positioning position as a part of the positioning device on the outer tube of the HID arc tube and the discharge chamber, the hollow positioning member is referred to, and the outer diameter of the hollow positioning member in the direction toward the discharge chamber Simultaneously with the inner diameter, the thickness of the outer tube wall is constant; the trapezoidal cone-shaped electrode positioning member on the inner guide wire tungsten rod abutting the electrode is completely concave and convex; then two seals are performed, that is, Plug seal, plug first seal; such two high temperature transient heating arc tube filled with argon and mercury vapor and the impurity gas released by the material is expanded and pressurized to nearly one atmosphere, violently to the outlet tube only about ten times this pressure The impact of the two ends is such that the convex head that is in close contact with the concave is subjected to a large impact pressure, and the concave and convex parts are more closely matched, and the heated gas cannot smoothly enter the arc tube cavity, and must be folded back to the other end of the extraction tube; After the completion of the second arc tube, the permanent airtight sealing was completely realized, and the tail pipe was sawed, and the impurity gas was naturally released.

The HID arc tube is made of the theoretical impurity gas <<lppm, that is, one millionth; but according to the HID traditional process, the impurity gas introduced by the second process is far less than >1ppm. The HID arc tube prepared by the method of the present invention has an impurity content of <<1 ppm.

The present invention also provides a lighting device comprising an HID arc tube, an outer arc tube protection tube, a reflector lamp cup, a lamp cover, and the like, which are fabricated according to the above-described plug sealing method.

Preferably, the lamp cup is made of hard glass, and the inner surface for reflecting light is provided with a reflecting surface constituting a parabola.

Preferably, the rhombohedral surface of the vapor deposition medium film layer is evenly distributed on the reflecting surface of the lamp cup. The present invention also provides an illumination system including a plurality of the above illumination devices.

Preferably, the plurality of illumination devices are arranged along a line, and the optical axes of the reflected light beams of the plurality of lamp cups respectively adapted to each of the illumination devices and the optical axis angle formed by the one-word arrangement direction are along the edge The direction in which the in-line arrangement is sequentially decreased, while the beam angles of the reflected beams of the plurality of lamp cups are sequentially decreased. Preferably, the optical axis angle is between 90 ° and 30 ° and the beam angle is between 60 ° and 8. between.

In the present invention, a pair of tapered hollow positioning members are formed on the outer lead tube at the junction with the discharge chamber as a positioning reference for the electrodes, and a trapezoidal cone which is structurally adapted to the tapered hollow positioning member and which can achieve a tight fit The shaped electrode positioning member determines the length of the electrode extending into the discharge chamber, and uses the sealing and fixing of the tapered hollow positioning member and the electrode positioning member to accurately position the distance between the two electrodes in the HID arc tube and achieve sealing Air tightness. That is to say, in the prior art, the pole pitch and the coaxiality of the two electrodes of the arc tube are determined by the combination of a magnifying glass or a monitor and a camera to be converted into a sealing and fixing by the tapered hollow positioning member and the electrode positioning member, thereby not only The ability to accurately position the distance between the two electrodes greatly improves the yield and consistency of the product. Moreover, the tight fit of the tapered hollow positioning member and the electrode positioning member can avoid or greatly reduce the two-way quartz arc tube and The molybdenum foil sealing of the composite arc tube is also the high-temperature heating material of the ceramic arc tube when the high-temperature heating material may release the impurity gas into the arc tube discharge cavity, thereby ensuring and improving the luminous efficiency and lumen maintenance of the arc tube. It also reduces the labor intensity of labor and improves the labor productivity of arc tube sealing and exhausting processes.

Further, the joint between the HID arc tube discharge chamber and the outer lead tube is a cold end position, which is often caused by poor temperature of the tungsten halogen circulation, affecting the light output and life; in the present invention, the outer lead tube and the discharge chamber The joint forms a tapered hollow positioning member as part of the positioning device, the hollow positioning member gradually decreasing in diameter in a direction toward the discharge chamber, that is, an outer diameter dimension of the joint between the discharge chamber and the outer lead tube is relative to the entire outer lead tube The diameter is the most slender place; this is very beneficial to the increase of the cold end temperature, enhance the gold halide cycle of the arc tube, and improve the light efficiency to extend the life.

Further, the HID arc tube manufactured by the above-described plug sealing method is combined with an arc tube outer protection tube, a reflector lamp cup, and a lamp cover to form an illumination device. Since the position of the electrodes at both ends is accurate and the distance between the electrodes is accurate, and then matching with the parabolic reflecting surface of the molded one-time molded hard lamp cup, as long as the designing of the light distribution curve is calculated according to the reflection angle of the lamp cup itself (or actual After the adjustment, the arc tube is inserted into the vertical center line of the reflecting surface of the lamp cup, that is, the height of the arc tube illuminating center is concentrated at the axis of the reflecting surface of the lamp cup, so that the maximum light intensity and the projection angle can be obtained accurately. Uniform beam angle; batch In the production of mass, it is not necessary to look at the light spot every time. Therefore, it is suitable for mass production. The reflective surface of the lamp cup is composed of multi-diamond surface, which is conducive to the formation of a uniform spot, without dark areas, and improves the uniformity of illumination; The dielectric film layer formed by alternating high-purity silicon monoxide and zinc sulfide in a high vacuum atmosphere has 19 to 21 layers, which greatly enhances the interference to photons, and compares other types of reflectors in arc tubes. In the case of the same light, the output of the maximum light intensity can be obtained.

Moreover, the design of the interaction with the hard light cup also facilitates the flexibility of the production planning: for example, the arc tube is vacuumed with an outer protective tube, and the cup is made of mud fluorosilicate + alumina + water glass. The material bonding is very reliable; if the protective tube is not added, the tail of the lamp cup can be designed to directly match the molybdenum rod of the arc tube lead, and the lamp cup and the lamp cover are also fire-sealed and then vacuumed, thereby eliminating a protective tube seal. Connect, and you can get the same effect.

Although the above technique is merely an example of MH (metal halide lamp) arc regulation in HID (High Pressure Gas Discharge Lamp), it is easy for those skilled in the art to understand and extend the technology to the improvement of the design and fabrication process of the entire HID arc tube. Such as high pressure sodium lamp, ultra high pressure mercury lamp, etc. DRAWINGS

The invention will be more readily understood and its accompanying advantages and features will become more <RTIgt;

1 is a schematic view showing a method of fabricating a HID arc tube in the prior art; FIG. 2 is a schematic view showing a bubble structure of a HID arc tube formed according to an embodiment of the present invention;

Figure 3 shows a schematic view of a mold for forming a bulb of an HID arc tube in accordance with an embodiment of the present invention;

4 is a schematic structural view of an electrode positioning member according to an embodiment of the present invention; FIG. 5 is a schematic view showing positioning of a first electrode by a tight fit of an electrode positioning member and a hollow positioning member according to an embodiment of the present invention;

6 is a schematic view showing positioning of two electrodes by a tight fit of an electrode positioning member and a hollow positioning member according to an embodiment of the present invention;

Figure 7 shows a plug sealing joint for making a HID arc tube in accordance with an embodiment of the present invention. Flow chart of the law;

Fig. 8a is a schematic view showing the structure and concentrating reflection of the var6 type reflector lamp cup; Fig. 8b is a schematic view showing the structure of three different types of reflector lamp cups; Fig. 8c is a view showing the prior art for ceramic metal halide Schematic diagram of the reflector lamp cup of the lamp;

Figure 9 is a schematic view showing a lighting device constructed by a composite arc tube and a reflector lamp cup according to an embodiment of the present invention;

Figures 10a and 10b respectively show two combinations of low power series metal halide lamp cups made for a composite arc tube fabricated in accordance with an embodiment of the present invention;

Figure 10c is a schematic illustration of the combination of the low power series metal halide lamp cup shown in Figure 10a and the illumination system constructed in accordance with an embodiment of the present invention.

The drawings are not to scale and the corresponding elements in the drawings are detailed description

In order to make the content of the present invention clearer and easier to understand, the specific embodiments of the present invention are described in detail below with reference to the accompanying drawings.

1 shows a method of sealing a HID arc tube by a so-called one sealing method used in the prior art, in which the exhausting process is additionally connected in the middle of the arc tube in addition to the high-power HID made of quartz glass. Exhaust pipe exhaust on an exhaust pipe (this method has been proved to destroy the geometry of the discharge cavity, which is not conducive to the metal halide cycle, affecting light output, life and light color stability). Moreover, the glove on the glove box is carried out in the glove box, so it is difficult to ensure the pole spacing and coaxiality of the two electrodes in the HID arc tube, so that the yield and consistency of the product cannot be guaranteed. In addition, the process of manufacturing the HID arc tube is the second step after the completion of the critical exhaust, and the high temperature at the time of sealing inevitably causes the material to release the impurity gas, which remains in the arc tube and affects the quality of the arc tube.

The present invention has been improved over the prior art. The key to the present invention is the introduction of a positioning device for positioning the electrodes during the fabrication of the HID arc tube to ensure that the distance between the two electrodes within the HID arc tube is a predetermined distance. That is, the present invention prior art The determination of the electrode spacing is determined by operation in an artificial glove box to determine the electrode spacing by means of a positioning device as a precision preform. In the present invention, since the electrode pitch is determined by the positioning means, the uncertainty and inconsistency of the manual operation can be avoided, and the product yield and consistency are improved. In addition, the positioning device introduced in the HID arc tube manufacturing process can also seal the discharge chamber after the electrode is fixed, that is, the arc chamber can be sealed while the electrode position is fixed, thereby It can effectively prevent the high temperature during the two sealings from causing the impurity gas released by the material to enter the discharge chamber, further ensuring the quality of the HID discharge tube.

The positioning device of the present invention comprises two parts, a part of which is a tapered hollow positioning member formed on the outer lead tube adjacent to the position of the discharge chamber, which functions as a positioning reference, and the tapered hollow positioning member is formed adjacent to the outer lead tube. The other part is an electrode positioning member, which is in the shape of a trapezoidal cone, and can be tightly fitted with the hollow positioning member to achieve sealing and fixing of the hollow positioning member and the electrode positioning member, wherein the electrode positioning member For fixing the electrode, when the electrode positioning member and the hollow positioning member formed on the outer lead tube are tightly fitted, the electrode can be ensured to extend into the discharge chamber by a predetermined length, and the electrode spacing is determined in this manner.

DETAILED DESCRIPTION OF THE INVENTION Hereinafter, specific embodiments of the present invention will be described with reference to the drawings.

First, a bulb as shown in Fig. 2 is formed. The bulb of the HID arc tube according to the present invention comprises a discharge chamber 5 and an outer lead tube 1. Among them, the difference from the prior art is that the present invention forms a tapered hollow positioning member 1 1 at the junction of the outer lead tube 1 and the discharge chamber 5.

Generally speaking, the quartz arc tube forming process uses a quartz glass tube having the same outer diameter and inner diameter as the lead-out tube to be rotated on the arc tube forming machine at both ends, and the heating head is continuously heated to the middle position of the glass tube, and the two ends of the clamp are simultaneously fed to the middle. Extrusion, when the design of the extrusion process is completed, the outer shell of the bulb is closed, and the wind blower is blown into the arc tube while the outer mold is closed.

In order to form the bulb shown in FIG. 2 according to the present invention, as shown in FIG. 3, the present invention provides a pair of tapered inner molds 7' and a squeezing device 6 in the original air duct of the quartz glass tube. The shape of the inner mold 7' size (only the composite arc tube increases the design thickness of the reserved ceramic coating) is identical to the electrode positioning member of the present invention. The squeezing device 6 connecting the tapered inner mold 7' in the outer end of the outer tube 1 before the opening of the outer shell of the blister after the blowing of the air is completed simultaneously After the above operation is completed, the outer mold 7" is opened, and the extrusion device 6 connected to the tapered inner mold 7 is withdrawn, and the outer mold 7" is opened, and the tapered inner mold 7 is connected. The instantaneous state of the 'squeezing device 6 has not exited. In this way, the quartz arc tube (the composite arc tube needs to be coated with the ceramic slurry and sintered (not shown) to form a pair of hollows on the outer lead tube 1 adjacent to the discharge chamber 5 Positioning component 1 1. The existing ceramic arc tube molding has both an outer mold and an inner mold. As long as the mold is designed and adjusted according to the invention, the requirements of the plug sealing technology can be met, and the ceramic slurry is not required to be coated. Convenient and convenient.

As shown in Fig. 2, the bulb of the HID arc tube formed in accordance with the present invention includes a discharge chamber 5 and an outer lead tube 1 at both ends of the discharge chamber. The length of the discharge chamber shown in Figure 2 is H. In the prior art, the operation in the artificial glove box is used to position the electrodes and determine the spacing between the two electrodes, which makes it difficult to ensure product consistency. The present invention employs a positioning device as a precision preform to position the electrodes and determine the electrode spacing to improve product consistency. To this end, the present invention first forms a pair of hollow positioning members 1 1 which can serve as a positioning reference on the outer lead pipe 1, and the hollow positioning member 1 1 is a part of the positioning means for positioning electrodes.

As shown in FIG. 2, in the present invention, a conical hollow positioning member 1 1 is formed at the joint of the outer lead tube 1 and the discharge chamber 5, and the hollow positioning member 1 1 is a part of the outer lead tube 1 in the orientation The outer diameter and the inner diameter of the discharge chamber are gradually reduced in synchronization, and the thickness of the outer wall of the outer lead tube 1 is constant; the smallest diameter is joined to the discharge chamber 5.

In the present invention, after the HID arc tube bulb is formed, a pair of "conical mouths with precise geometrical dimensions, small internal and external dimensions, and like a grinding bottle are formed on the outer tube of the outer tube and the arc tube discharge chamber. "The hollow positioning member, which is part of the positioning device of the present invention, functions as a positioning reference. If the internal mold formation used in this method is not sufficiently precise, it can be compensated by methods known to those skilled in the art, such as precision grinding after ceramic arc tube pre-firing. For a composite arc tube, a tapered hollow positioning member as part of the positioning device of the present invention can be formed by sintering a ceramic slurry after forming a hollow positioning member similar to a "conical opening".

Next, an electrode positioning member 9 as another portion of the positioning device according to an embodiment of the present invention will be described with reference to FIG.

As shown in FIG. 4, the electrode positioning member 9 has a trapezoidal cone shape and can be oxidized by high purity. Aluminum, zirconia, boron oxide, or silicon oxide is added to prepare rare earth, and the ratio of various ingredients is appropriately adjusted to suit the expansion coefficient of the main material used for the arc tube, and the preparation process is mature and easy to operate. The central axis of the electrode positioning member 9 is provided with a slightly tapered through hole 9-1. The taper of the through hole 9-1 is when the electrode positioning member 9 is mounted on the HID arc tube blister. One end of the tube and the small hole face one end of the discharge chamber. The through hole 9-1 is for receiving the tungsten rod 12, and the outer diameter of the tungsten rod 12 can be completely and closely matched with the maximum and minimum diameters of the through hole. The tungsten rod is provided with a prefabricated end 12-1 which is pre-finished for precise fastening (such as welding) to the electrode, and the electrode is connected to the pre-formed end 12-1 of the tungsten rod so as to extend into one end of the discharge chamber. . The tungsten rod 12 is inserted into the through hole 9-1 to be tightly fitted, and then flattened at the small hole of the through hole 9-1, and Fig. 4 shows the flattening fixed portion 12-2. After the tungsten rod 12 is inserted into the through hole 9-1, the glass material can be filled into the slit of the flat fixing portion and then heated to perform hermetic sealing.

After the tungsten rod 12 is accommodated in the through hole 9-1 at the intermediate shaft, it is necessary to assemble the electrode 8, the molybdenum foil 10, and the molybdenum rod 13 for the composite arc tube; and for the ceramic arc tube, the electrode 8 and the molybdenum are assembled. Lead wire, outer lead wire (not shown). Specifically, the electrode 8 is precisely fastened (e.g., welded) to the pre-finished end 12-1 of the tungsten rod 12 shown in Fig. 4, in such a manner that not only the distance over which the electrode 8 protrudes can be easily determined, Moreover, the electrode 8 after the precise fastening connection (e.g., splicing) is simultaneously on the central axis of the outer lead tube 1. In this process, it is necessary to ensure that the total length of the tungsten rod and the electrode 8 projecting from the upper portion of the trapezoidal cone of the electrode positioning member 9 is a predetermined length! ^. The predetermined length L is determined by the distance between the two electrodes in the final HID arc tube product to be formed. That is, in the present invention, the length of the electrode 8 extending into the discharge chamber is determined by the predetermined length L. The predetermined length L is directly related to the distance between the two electrodes in the final HID arc tube product, and changing the predetermined length L changes the distance between the two electrodes in the final HID arc tube. In the present invention, the distance between the two electrodes in the discharge chamber 2 and the coaxiality are ensured by the electrode positioning member 9. As shown in Fig. 4, the tungsten rod 12 is additionally provided with a molybdenum foil 10 and a molybdenum rod 13.

In the present invention, the electrode positioning member 9 shown in Fig. 4 is structurally adapted to fit the hollow positioning member 11 shown in Fig. 3, that is, it should be combined with the tapered hollow positioning member 1 on the outer lead tube 1. It can be precisely fitted to achieve precise positioning of the two electrodes in the HID arc tube. In this embodiment, the electrode positioning member 9 and the inner portion used in the preparation of the arc tube bulb The molds are identical in size. However, the present invention is not limited thereto, as long as the electrode positioning member and the hollow positioning member can achieve a close fit.

In a preferred embodiment, a composite HID arc tube can be fabricated using a plug sealing method for making a HID arc tube in accordance with the present invention, the fabrication of which is substantially the same as described above for the preparation of a conventional HID arc tube. However, it should be noted that during the formation of the composite HID arc tube, the polycrystalline alumina layer needs to be partially coated in the discharge chamber and in the outer lead tube adjacent to both ends of the discharge chamber after molding. Therefore, both the inner film and the electrode positioning member for the bulb forming used in the preparation of the composite HID arc tube by the plug sealing method of the present invention are not completely uniform in outer dimensions. Since the polycrystalline alumina layer is partially coated on both ends of the composite arc tube outside the adjacent discharge chamber, the inner mold and the electrode positioning member for forming the bulb having the hollow positioning member are not completely identical in outer dimensions. Instead, a polycrystalline alumina layer should be distinguished.

Referring to Figures 5 and 6, the electrode positioning member is closely fitted to the hollow positioning member to fix the pitch of the two electrodes.

Fig. 5 shows a schematic view of positioning an electrode 8 by the electrode positioning member 9 in close fitting with the hollow positioning member 1 according to an embodiment of the present invention. In Fig. 5, an electrode positioning member 9 equipped with an electrode 8, a molybdenum foil 10, and a molybdenum rod 13 extends into the outer lead tube 1 and is hermetically connected to the hollow positioning member 1 1 on the outer lead tube 1, at which time the electrode is positioned. The total length of the tungsten rod and electrode 8 projecting from the trapezoidal cone of the component 9 is fixed to the desired predetermined length L. At this time, similar to the grinding cap "cap" inserted into the "mouth" of the grinding mouth, the trapezoidal cone-shaped electrode positioning member 9 is "snapped" into the tapered hollow positioning member 1 1 and further tightly fitted thereto. Once the electrode positioning member 9 is tightly engaged with the hollow positioning member 1, the precise positioning of the electrode 8 in the discharge chamber 5 can be achieved.

After accurately positioning an electrode 8 (for a sealing), a metal halide pellet is built into the discharge chamber 5 (after degassing), and then the exhaust gas is evacuated and then high-purity mercury and inert gas are placed, and then the graph is used. The same step shown in Figure 5 locates the other electrode, as shown in Figure 6.

The tight fit of the above-described electrode positioning member 9 and the hollow positioning member 11 can not only accurately position the electrodes, but also achieve a seal therebetween. That is to say, the sealing and fixing are achieved by the tight fitting of the electrode positioning member 9 and the hollow positioning member 1 1 , the electrode is accurately positioned and a barrier is provided between the discharge chamber and the external space, thereby ensuring the outside of the second sealing time. The gas does not smoothly enter the discharge chamber and destroys the quality of the HID arc tube. For the ceramic metal halide lamp arc tube which has been developed in recent years and which is produced by a two-time synchronous sealing and sealing production, the plugging technology of the invention is more convenient for operation, improves labor productivity and ensures accurate positioning of the electrode. The impurity gas is <1 ppm after the arc tube is made.

In the present invention, the positioning device for positioning the electrode includes a hollow positioning member 1 1 and an electrode positioning member 9 , wherein the hollow positioning member 1 1 is formed on the outer lead tube adjacent to the discharge chamber, and functions as a positioning reference. The electrode positioning member 9 is for fixing the length of the electrode into the discharge chamber. The present invention achieves precise positioning between the two electrodes within the HID arc tube by a close fitting of the two components (i.e., plug sealing).

According to an embodiment of the present invention, in the process of fabricating the HID arc tube, a precise preform (i.e., a positioning device including the electrode positioning member and the hollow positioning member) is preliminarily formed before positioning the electrode, and then the precision preform is used. In the prior art, the high temperature sealing of the glass solder has become a "plug" of tight fit. This "plug" undoubtedly provides a very effective "salting" of the impurity gas that may be released at a high temperature when the second process of the outer tube of the molybdenum foil or the glass solder is sealed. For the quartz foil tube and the composite arc tube two-way sealed molybdenum foil seal, when the quartz outer tube is softened and melted into the melting point, the gas of the outlet tube is "caught" when the two sealing jaws are completely squeezed into place. It has to be clean and has the effect of "one time and for all". For the two-way sealing of the ceramic arc tube or a two-sealed ceramic metal halide lamp arc tube, the position of the glass material from the plug sealing joint to the outlet tube is longer. A distance, and a small space slightly lower than the pressure of the arc tube discharge chamber (the mercury vapor pressure at room temperature is about 0.5Pa), it is inevitable that there is impurity gas. However, in the first time after the arc tube is made, the ignition point is aging, and the sealing end of the electrode near the end of the electrode is the natural cold end of the arc tube, and the source is continuously circulated to the high pressure of the metal halide substance in the discharge chamber. The next place will be tightly sealed in the place where only a little leak can be made here. This is because the discharge chamber of the arc tube works at a high temperature, the air pressure is much higher than the pressure of the outlet tube, and the arc is cooled in the vacuum tube. Slowly in the protective state, so that the pressure of the discharge chamber is still higher than the outer lead tube; after the complete cooling, the mercury vapor pressure is close to 0.5Pa at room temperature because of the mercury content in the discharge chamber, then theoretically the discharge chamber The pressure is always higher than the outer tube; even if it is completely balanced, the gas exchange is extremely slow and difficult in the two "chamber" blockage, as if there is a sealed door in the middle of the two chambers. It is a truth to not be able to convect smoothly. When the lamp is turned on twice, the gold halide material that is continuously circulated to the source again starts the second "sealing" and "plugging".

Next, a method of fabricating an HID arc tube according to an embodiment of the present invention will be described in detail with reference to FIG. First, in step S71, a bulb is formed, wherein a position of the outer tube adjacent to the discharge chamber forms a tapered hollow positioning member as a part of the positioning device, and the hollow positioning member is gradually reduced in outer diameter and inner diameter in a direction toward the discharge chamber. Small, the wall thickness is constant. In step S72, an electrode positioning member 9, which is another part of the positioning means, is formed, and the electrode 8 is fixed to the electrode positioning member 9 and projected from the electrode positioning member 9 by a predetermined length. In step S73, the electrode positioning member 9 as the positioning device is tightly engaged with the hollow positioning member 1 1 to perform plugging and sealing of the first electrode, and then the entire arc tube is deaerated at a high temperature, and then the metal halide pellet is placed. The metal halide pellet in the discharge chamber is degassed at a low temperature and exhausted to a high vacuum, and then mercury and an inert gas are placed. In step S74, the electrode positioning member 9 as two parts of the positioning device is tightly fitted with the hollow positioning member 1 to realize the sealing between the two and the precise positioning of the electrodes, thereby realizing precise positioning of the second electrode. In step S75, two sealings are performed.

The distance between the two electrodes in the HID arc tube determines the important indexes such as tube pressure, tube flow, photoelectric parameters and even the metal halide cycle and life of the HID arc tube. In the prior art, manual positioning with a magnifying glass makes it difficult to ensure accuracy, especially product consistency. The present invention has been improved in the prior art by using a precision preform as a positioning device for positioning the electrodes. The prefabricated parts can be formed by pressing by a mechanized precision mold, and can also be formed by precision grinding after pre-sintering, which can ensure accurate positioning size and geometric precision, thereby ensuring the high quality of the HID arc tube and design. consistency. In addition, in the present invention, in the process of positioning the electrode by using a precise preform, the impurity gas which may be released by the high-temperature heating material in the second sealing of the HID arc tube is effectively prevented from entering the arc tube discharge chamber, thereby ensuring Improve the quality of the arc tube. The labor intensity is reduced, and the labor productivity of the arc tube sealing and exhausting process is improved.

The HID arc tube prepared by the above method of the invention can accurately position the electrode to an error of plus or minus 0.01 mm, and the impurity gas remaining in the arc tube after the sealing of the two molybdenum foils is <1 ppm. In this way, the lamp power of the lamp formed by the HID arc tube can be subdivided to form a series of illuminations with more power and less difference in power. Figure 8a shows a Murl6 lamp cup made of high borosilicate hard glass stamped with a parabolic multi-retroreflective surface on its inner surface; it is alternately vapor-deposited with 19 to 21 dielectric layers under a high vacuum atmosphere. Therefore, the beam angle of such a lamp cup is very accurate, such as from 8° and 12° of a narrow beam to 24° of a medium beam, 36° to a wide beam of 60°, etc. Secondly, in the above 19-21 In the design of the layer dielectric film, each layer acts on the photons, which add up to the maximum reflection and refraction interference of the photons, that is, the maximum light extraction in the case where the light source of the light source is the same; again, The multi-diamond reflecting surface adjusts the projection angle after light refraction to make the spot uniform. In addition, this film has a long time of high temperature solid film, and it is suitable for indoor and outdoor use because it is immersed in water for a long time. Reflective lamp cups with such excellent characteristics as shown in Fig. 8b are also available in various specifications such as PAR20, PAR30, and PAR38.

The above lamp cup is usually matched with a halogen lamp made of a quartz bulb, and the halogen lamp can be made from 20W to 250W in a small volume, and the illuminant can provide an arbitrary value of 50001m or less at a point, that is, a so-called point source. Guangtong. Currently, halogen lamps are listed as obsolete products in the general lighting field. For this reason, there are a variety of alternatives to halogen lamps: fluorescent lamps, which are only feasible at low light beams with a wide beam (near 180 °); LEDs, although small enough to be close to a point, have low luminous flux, and The halogen lamp and HID of the point source are a surface light source in terms of volumetric light transmittance. The larger the required light flux, the larger the light-emitting surface, and the small wattage is concentrated by a collecting lens. The metal halide lamp in the HID which is the same as the light-emitting principle of the present invention is generally called a metal halide lamp, and the quartz arc tube series in the metal halide lamp is extruded. When the foaming shell is formed, there is no inner mold in the outer mold, and the discharge chamber is irregular. This causes the deflection angle of the lamp to change at different ignition angles. For example, a lamp rotates 360° and the color temperature changes 1000K. Obviously, the quartz arc tube The series of metal halide lamps are not suitable for making projection lamps with reflector lamps; as shown in Figure 8c, ceramic metal halide lamps are more suitable for the above lamp cups, but because of the key shape of the bulbs, exhaust sealing and other key The process is too difficult, the operation is difficult, the cost is high, it is difficult to popularize, and the electrode positioning is inaccurate, the optical center is offset, etc., and the difficulty of popularizing the cost reduction is increased. Especially worth mentioning is because the single layer Insufficient pressure on ceramic forming and accurate positioning of electrodes are extremely difficult. At present, the minimum power of low-power ceramic metal halide lamps is only 20W, and the luminous flux has reached 12001m. Compared with the most popular VL 6/50W halogen lamp cup, the maximum light Passing only about 6001m, so when The front pole needs a new light source that can replace this halogen lamp cup.

Figure 9 shows a low power 5W~150W series lamp cup made for a composite arc tube made in accordance with the method of the present invention. From 5W to 35W, each interval is 5W, which is 5W, 10W, 15W—up to 35W; from 10W, every interval is 10W—one to 75W; from 75W, every interval is 25W—to specifications up to 150W. Covering the whole series of traditional low-power metal halide lamps, it has increased from 14 traditional specifications of only 20W, 35W, 50W, 75W, 100W and 150W to 14; especially the only 2 additions from 5W to 35W. It is seven. This can divide the lamp power into such a small size, mainly because the plug sealing method of the present invention can accurately position the electrode in the arc tube to an error of plus or minus 0.01 mm and the residual of the arc tube after sealing the two molybdenum foils. The impurity gas is really < ^ 111. Compared with the prior art ceramic metal halide lamp 12001m/20W, the luminous flux has increased by 50% to 18001m, and the life expectancy has increased by 1.5 times, from 6000h to 15000h. In particular, the 5W, 10W, and 15W specifications directly replace the halogen lamp cups 20W, 35W, and 50W, which are the three most commonly used varieties. They can be directly used as ordinary lighting products when matched with electronic ballasts.

Figure 10a and Figure 10b show two representative lighting devices consisting of a combination of low-power 5W~150W series metal halide lamp cups made of composite arc tube. Figure 10c shows the product shown in Figure 10a for high-grade roads. , such as the lighting effect diagram of the highway.

With the development of expressways and the rapid advancement of urbanization, the demand for road lighting is getting larger and larger, and people's control requirements are getting larger and larger, resulting in a rapid increase in electricity consumption every year. The low-power 5W~150W series metal halide lamp cups made by the composite arc tube shown in Fig. 10a can be arranged as a street lamp with reasonable arrangement of lighting devices, which can meet any pole height, pole distance and illumination requirements, and more importantly, The watts are equivalent to two watts of illumination of any previous source, and the uniformity of illumination is increased by more than 50%. A single-side three-lane, rod spacing 30m, pole height 12m original 400W high-pressure sodium lamp as a reference system; the alternative of the present invention is a small-power 20W metal halide lamp cup made of composite arc tube 5 sets of X 2 group One group is responsible for one side of the rod; the reflection angle of each group of 5 cups is 8 °, 12 °, 24 °, 36 °, 60 ° from the farthest point to the bottom of the rod, respectively. 3m from the center of a section of the road; such a reasonable arrangement, as shown in Figure 10c, the spots in the center of the road one after another, forming a linear light strip with very uniform illumination. This uses multiple lights as well as with each light The plurality of lamp cups are arranged, and the plurality of lamps are arranged in a line, and the angle of the beam reflected by the lamp cups corresponding to each of the lamps is gradually decreased in one direction in a direction, thereby realizing a "band"illumination; By simply adjusting the power of each lamp and the beam angle reflected by the lamp cup to increase the uniformity of the intensity distribution in the strip illumination, reducing glare; due to the use of multiple lamps and the lamp cups fitted to each lamp In the case of meeting the required illuminance, a low-power lamp can be used to reduce the consumption of electric energy; in road lighting applications, the amount and power of the lamp can be adjusted by the road illumination and the uniformity of the light intensity, and The beam angle reflected by the lamp cup adapted to the lamp is realized, so that the height of the lamp post can be reduced, thereby not only simplifying the maintenance and maintenance of the road lighting device, but also further increasing the road surface illumination by reducing the height of the lamp post. . Actual comparison measurement illuminance data is shown in Table 1:

Table 1

Among them, the data of 15 meters from the distance bar was not tested because it intersected the adjacent rod.

Contrast result: The illuminance is increased by more than 20% on average, the illuminance uniformity is increased by more than 30%; 20W/support X 10 is = 200W, saving 200W than the original 400W, saving 50%; The color rendering index is increased from Ra20 to Ra80 (Sunshine) The lower window is Ra l OO ), which is increased by 4 times; the driver does not feel dazzling when driving from a distance, only feels that this piece is brighter and the object is more clear.

FIG. 10b is a schematic diagram of a lighting device composed of a combination of a low power 150W metal halide lamp PAR38 lamp cup fabricated by a composite arc tube. Different arrangements and combinations are suitable for different large-area projection lighting applications. For example, Chenghuang Square cylindrical high-beam projection lighting can be arranged in a circle form (as shown in the simple diagram of Figure 10b), wall washing and large billboard projection can be Two or two, three or three... or one by one. The principle is that the total power of the original design can be used in a half-half installation to achieve satisfactory illumination or surface brightness. In short, the HID arc tube manufactured by the above-described plug sealing method is combined with an arc tube outer protection tube, a reflector lamp cup, and a lamp cover to form an illumination device. Since the position of the electrodes at both ends is accurate and the distance between the electrodes is accurate, it is matched with the parabolic dielectric film reflecting surface of the molded one-time formed hard lamp cup, as long as the reflection angle of the design of the lamp cup itself is calculated when designing the light distribution curve ( Or the actual measurement and measurement) The depth dimension of the arc tube inserted into the vertical center line of the reflecting surface of the lamp cup, that is, the height of the arc tube illuminating center at the axis of the reflecting surface of the lamp cup, the maximum light intensity and the projection angle can be obtained. Accurate and consistent beam angle; In the mass production, it is not necessary to look at the light spot every time. Therefore, it is suitable for mass production. The reflective surface of the lamp cup is composed of multi-diamond surface, which is conducive to the formation of a uniform spot, no dark area, and improved. Uniformity of illuminance; Furthermore, the dielectric film layer formed by alternating high-purity silicon monoxide and zinc sulfide in a high vacuum atmosphere has 19 to 21 layers, which greatly enhances the interference to photons, and compares other types. The reflector can obtain the maximum illuminance when the arc tube is connected to the light, or reduce the power of the lamp by half when the original illuminance is maintained. Electricity around 50%.

It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the scope of the invention. It is to be understood by those skilled in the art that the present invention is not limited by the description of the invention, but the invention is not limited by the accompanying claims.

Claims

Rights request

A method of making an HID arc tube, comprising:

Forming a bulb, the bulb comprising a discharge chamber (5) and an outer lead tube (1) extending from both ends of the discharge chamber (5), wherein a position adjacent to the discharge chamber (5) is formed on the outer lead tube (1) a conical hollow positioning member (11), the outer diameter and the inner diameter of the hollow positioning member (11) gradually decrease in the direction toward the discharge chamber (5), and the wall thickness is constant;

An electrode positioning member (9) forming a trapezoidal cone shape having a tapered surface capable of achieving a tight fit with the hollow positioning member (11) for fixing the electrode (8) and the electrode positioning member (9) and the hollow positioning member (11) The predetermined length (L) of the electrode (8) into the discharge chamber (5) when tightly fitted;

The electrode positioning member (9) to which the electrode (8) is fixed is inserted into the hollow positioning member (11) to achieve a tight fit between the electrode positioning member (9) and the hollow positioning member (11).

2. The method according to claim 1, wherein after the step of forming the bulb, further comprising coating a polycrystalline alumina layer on the inner wall of the discharge chamber (5) and the hollow positioning member (11).

3. Method according to claim 1 or 2, wherein the electrode positioning member (9) is prepared from a high purity alumina, silica, zirconia, magnesia or boron oxide addition rare earth material.

The method according to claim 1 or 2, wherein the electrode positioning member (9) comprises a tapered through hole (9-1) provided on a central axis thereof for accommodating a tungsten rod (12), The inner diameter of the orifice of the tapered through hole (9-1) facing the first end of the discharge chamber (5) is larger than the inner diameter of the orifice of the second end;

The tungsten rod (12) is provided with a prefabricated end (12-1), the second end of the tapered through hole (9-1) and the first end of the opening respectively with the tungsten rod (12) and the prefabricated end (12) -1) A tight fit is achieved, then the tungsten rod (12) is flattened at the small hole of the through hole (9-1); and the electrode (8) is attached to the prefabricated end of the tungsten rod (12) (12-1) ) to extend into one end of the discharge chamber (5).

The manufacturing method according to claim 1 or 2, wherein the electrode positioning member (9) to which the electrode (8) is fixed is inserted into the hollow positioning member (11) and is fitted in the discharge chamber (5) before being tightly fitted thereto Into the gold halide pellets, then evacuate and then place high purity mercury and inert gas.

The manufacturing method according to claim 1 or 2, further comprising a molybdenum foil or a glass solder seal after the electrode positioning member (9) is tightly fitted to the hollow positioning member (11).

7 An HID arc tube comprising:

a bulb comprising a discharge chamber (5) and an outer lead tube (1) extending from both ends of the discharge chamber (5), wherein a position adjacent to the discharge chamber (5) on the outer lead tube (1) is formed a tapered hollow positioning member (11), the outer diameter and the inner diameter of the hollow positioning member (U) gradually decrease in the direction toward the discharge chamber (5), and the wall thickness of the tube is constant;

An electrode positioning member (9) having a trapezoidal cone shape, the electrode positioning member (9) extending into the hollow positioning member (11) and in a tightly fitted state with the hollow positioning member (11); wherein the electrode An electrode (8) is fixed to the positioning member (9), and the electrode (8) protrudes into the discharge chamber (5) by a predetermined length (L).

The HID arc tube according to claim 7, wherein the inner wall of the discharge chamber (5) and the inner wall of the hollow positioning member (11) are coated with a polycrystalline alumina layer.

The HID arc tube according to claim 7 or 8, wherein the electrode positioning member (9) is further provided with a tungsten rod (12).

The HID arc tube according to claim 7 or 8, wherein the electrode positioning member (9) comprises a tapered through hole provided on a central axis thereof for accommodating the tungsten rod (12)

(9-1), the inner diameter of the orifice of the tapered through hole (9-1) toward the first end of the discharge chamber (5) is larger than the inner diameter of the orifice of the second end;

The tungsten rod (12) is provided with a prefabricated end (12-1) and a tapered through hole (9-1) The two-end orifice and the first-end orifice are tightly fitted with the tungsten rod (12) and the preformed end (12-1), respectively, and then the tungsten rod (12) is placed at the small hole of the through hole (9-1). Flattening; and

The electrode (8) is connected to the pre-formed end (12-1) on the tungsten rod (12) to extend into the discharge chamber

One end of (5).

The HID arc tube according to claim 7 or 8, wherein the electrode positioning member (9) is prepared by adding a rare earth material of high purity alumina, silica, zirconia, magnesia or boron oxide.

12. A lighting device comprising:

HID arc tube according to one of claims 7 to 11;

An outer protective tube of the HID arc tube;

a reflector cup adapted to the HID arc tube;

Lamp cover

The lighting device according to claim 12, wherein the lamp cup is made of hard glass and the inner surface is provided with a reflecting surface that constitutes a parabola.

The illuminating device according to claim 13, wherein the reflecting surface is uniformly distributed with the rhombohedral surface of the vapor-deposited dielectric film layer.

15. A lighting system comprising:

A plurality of illumination devices according to any one of claims 12-13.

16. The illumination system of claim 15 wherein

The plurality of illumination devices are arranged in a line, and an optical axis angle of the reflected light beam of the plurality of light cups respectively adapted to each of the illumination devices and the alignment direction of the word arrangement is along the The direction of the in-line arrangement is sequentially decreased, and the beam angles of the reflected beams of the plurality of lamp cups are sequentially decreased.

17. The illumination system of claim 16 wherein

The optical axis angle is between 90° and 30°, and the beam angle is between 60° and 8

° between.