WO2013170431A1

WO2013170431A1 - Method for manufacturing flat fluorescent lamp

Info

Publication number: WO2013170431A1
Application number: PCT/CN2012/075482
Authority: WO
Inventors: 赖勇清
Original assignee: 福建永德吉灯业股份有限公司
Priority date: 2012-05-15
Filing date: 2012-05-15
Publication date: 2013-11-21

Abstract

A method for manufacturing a flat fluorescent lamp comprises the steps of: providing two glass plates (11, 12), wherein a plurality of separable fluorescent lamp discharge channels (21) and electrodes (22) are arranged between the two glass plates (11, 12); arranging a ring of sealant (42) on at least one glass plate corresponding to the periphery (23) of each fluorescent lamp (20); bonding the peripheries of the two glass plates (11, 12) to form a cavity by sealing; vacuumizing the cavity to form a vacuum environment; injecting gas discharge medium into the vacuum environment; in the vacuum environment, heating and fusing the sealant (42) on the periphery of each fluorescent lamp; cutting and separating each fluorescent lamp (20) on the glass plates (11, 12), thereby obtaining a plurality of flat fluorescent lamps. By using such method, a number of fluorescent lamps can be produced at a time, the cost is reduced, materials are saved and the production efficiency is greatly improved.

Description

Method for manufacturing flat fluorescent lamp

Technical field

The present invention relates to a fluorescent lamp and a method of manufacturing the same, and more particularly to a method of manufacturing a flat fluorescent lamp.

Background technique

The structure of the flat fluorescent lamp is made up of two glass plates. A discharge channel is arranged between the two glass plates, and a phosphor luminescent material is arranged on the wall of the discharge channel. The discharge channel is filled with a discharge gas medium and mercury, and both ends of the discharge channel Set with electrodes. A typical flat fluorescent lamp is an external electrode flat fluorescent lamp (hereinafter referred to as EEFL), which is developed for backlighting of liquid crystal devices. As a general lighting product research and development is in the experimental stage, the technical difference between backlight and general lighting is: general lighting requires higher light efficiency and high luminous intensity per unit area. The external electrode flat fluorescent lamp has a lifespan of more than 30,000 hours compared with ordinary fluorescent lamps, and the general fluorescent lamp has a typical life of 10,000 hours; high efficiency and linear dimming can be realized, and the actual power of the dimming lighting process can be lowered to 1-2W, and the ordinary fluorescent lamp is adjusted. Poor light effect, low dimming efficiency, dimming lighting process seriously affects the life of the lamp, the darker the brightness, the shorter the life of the lamp; the number of switches can be realized countless times, the number of tests is up to 5000000 times and the electrode has no loss, ordinary fluorescent lamps are generally The number of switching is 10,000 times; the system lighting efficiency is high. Therefore, it has all the properties of LEDs, and the color of light is better than LEDs. Flat fluorescent lamps can generally be made as single-sided illumination and double-sided illumination sources.

The process for manufacturing a flat fluorescent lamp is the same as that of an ordinary fluorescent lamp. The difference is that the formation of the discharge channel is different. The ordinary fluorescent lamp forms a discharge channel by a tubular structure, and the discharge channel of the flat fluorescent lamp is disposed between two fluorescent glass plates.

At present, in the manufacturing process of flat fluorescent lamps, before forming a vacuum environment, the main methods are as follows: 1. Forming a discharge channel of a fluorescent lamp on a glass plate of two glass plates, a vacuum exhaust passage required for the process, an exhaust pipe connection passage, and a connection. The gas injection port (or the suction port) of the discharge channel and the exhaust channel is first bonded and sealed around the fluorescent glass plate except the gas injection port (or the suction port) communicating with the exhaust channel, and then exhausted through the exhaust pipe and exhaust The channel and the gas injection port (or the suction port) pump the vacuum discharge channel of the fluorescent lamp, charge and discharge the gas medium and mercury, and finally bind and seal the fluorescent lamp gas injection port (or the suction port) to form a fluorescent lamp; 2. The discharge channel is directly connected to the exhaust gas. The tube is first bonded to seal the periphery of the fluorescent glass plate, and then the vacuum discharge channel is evacuated, the gas medium and the mercury are charged and discharged, and finally the exhaust pipe is sealed to form a fluorescent lamp. The defects of the method 1 are as follows: a. The periphery of the fluorescent lamp is sealed before the vacuum treatment except for the air suction port, and the natural gap between the glass plates is deformed under the pressure generated by the vacuum processing, causing the cracking of the fluorescent lamp during the production process and the use process. , affecting product quality and cost, b, the size of the gas injection port set on the glass plate is small, the pumping efficiency is low, affecting production efficiency.

For example, the invention patent of the Chinese Patent Application No. 200610038965.5 discloses a flat-type external electrode fluorescent lamp and a manufacturing method thereof, in which a phosphor layer is formed on one of two flat glass plates, and another layer is perforated. A glass exhaust pipe is connected at the opening position, a spacer is formed between the two glass plates to form a discharge channel, and a glass sealing medium is coated around the glass plate to seal the two pieces of glass together (forming a discharge vessel). The discharge vessel space between the two glass plates is baked, exhausted, filled with inert gas, and mercury is injected through the exhaust pipe to form a discharge gas, the exhaust pipe is sealed, and the exhaust system is separated to become a discharge plate (ie, Become a fluorescent light).

The invention patent of Chinese Patent Application No. 200510058824.5 discloses a method for manufacturing a fluorescent lamp, which comprises: forming at least one injection port connected to a discharge channel in a horizontal direction of a fluorescent lamp to communicate while forming a discharge space a discharge passage; a sealing agent is disposed in the gas injection port to seal the gas injection port; a mercury pellet containing mercury is disposed on one side of the sealant, and a discharge space of the fluorescent lamp is evacuated; an inert gas is diffused into the discharge space; The mercury vapor evaporated by the mercury pellet is dispersed to the discharge space. Then, the sealant is melted and the connection between the gas injection port and the discharge channel is sealed.

The invention patent of Chinese Patent Application No. 200610065968.8 discloses a method for manufacturing a flat fluorescent lamp, which comprises: discharging air from a discharge passage through an exhaust pipe, diffusing mercury vapor in the discharge passage, blocking a gas inlet and an outermost passage. The passage between the gas and the removal of the gas inlet and exhaust pipe.

The above flat fluorescent lamps are prepared by forming a fluorescent lamp or a fluorescent lamp product including a plurality of inseparable discharge channels in the glass plate. There is only one fluorescent lamp product finally formed. Not only is the efficiency low, but the manufacturing process has defects in that it is vacuumed by a suction port or a gas injection port, and then vacuum-treated and then sealed to seal the suction port or the gas injection port. In the first sealing except the suction port, the flatness of the glass plate material, the unevenness of the process of coating the phosphor, etc., cause a gap between the fluorescent glass plates, and this gap is in the vacuum processing of the subsequent channel. Since the periphery of the fluorescent glass plate is bonded and fixed, the internal and external pressure generated by the vacuum causes some gaps of the fluorescent glass plate to be eliminated to form deformation stress, which is likely to cause cracking of the fluorescent lamp product, and some gaps that cannot be eliminated cause leakage gaps, resulting in leakage gaps. Short circuit of the discharge channel, seriously affecting product quality.

Chinese Utility Model Patent No. 201020225298.3 discloses a structure of a flat fluorescent lamp which is mainly used for illumination, but the utility model patent does not disclose its manufacturing method.

Korean Patent KR10-0827602 discloses a method for simultaneously manufacturing two or more flat fluorescent lamps on one mother board, the main feature of which is a method for manufacturing a flat fluorescent lamp having a plurality of discharge spaces, the main process including: in a mother board a sub-board having the discharge channel is disposed thereon, and a discharge channel injection port is formed on the same plane as the discharge channel, and an exhaust pipe connected to the gas injection port and communicating with the sub-plate is formed, and the above several structures are first a substrate attachment; a second substrate attachment is bonded to a plane corresponding to the first substrate attachment; an air body is extracted from the discharge space; an inert gas and a mercury gas are injected into the discharge space; and the passage is completely sealed by the sealing material; The board is cut into multiple unit daughter boards.

In this method, when the first substrate attachment and the second substrate attachment are bonded, when the adhesive is applied, since the separation between the sub-plates is taken into consideration (see the 34th line of the specification for details), vacuuming is performed. Previously, an adhesive was applied between the sub-boards for bonding. Then, a vacuum pumping, a discharge medium, and the like are performed through an exhaust pipe, and the passage (gas injection port) is sealed by a sealing material, and finally the mother board is cut into a plurality of unit sub-boards.

The method still uses a gas injection port for vacuuming, and then vacuum sealing and then sealing the air suction port or the gas injection port. When the first substrate attachment and the second substrate attachment are bonded, the flatness of the glass plate material, the unevenness of the process of coating the phosphor, etc., cause a gap between the fluorescent glass plates, and the gap is in the back channel. In the vacuum processing, since the periphery of the fluorescent glass plate is bonded and fixed, the internal and external pressure generated by the vacuum causes some gaps of the fluorescent glass plate to be eliminated and deformed to form deformation stress, which is likely to cause cracking of the fluorescent lamp product, and some gaps that cannot be eliminated cause leakage. The gap creates a short circuit in the discharge channel, which seriously affects the quality of the product.

In view of this, the inventors have intensively studied the defects of the prior art, and have produced the present case.

Summary of the invention

The technical problem to be solved by the present invention is to provide a method for manufacturing a flat fluorescent lamp which is simple in preparation process and cost-effective.

The present invention solves the above technical problems by adopting the following technical solutions:

The manufacturing method of the flat fluorescent lamp comprises the following steps:

Step 1: provide two glass plates, a first glass plate and a second glass plate. There are a plurality of separable fluorescent lamp discharge channels and electrodes between the two glass plates; and the glass plates are further connected with the discharge channels of the fluorescent lamps. An exhaust passage; the glass plate is connected with an exhaust pipe; and the exhaust passage is in communication with the exhaust pipe;

Step 2: a ring of a first sealant is disposed at a periphery of at least one of the glass plates, and a second sealant is disposed on at least one of the glass plates at a position of each of the fluorescent lamps; the melting point of the first sealant is lower than Describe the melting point of the second sealant;

Step 3: attaching two pieces of glass plates together, melting the first sealant by heating, and sealing the two glass plates to form a cavity;

Step 4: vacuuming the discharge channel of the fluorescent lamp through the exhaust pipe and the exhaust passage;

Step 5: injecting a gas discharge medium into the discharge channel of the fluorescent lamp through the exhaust pipe and the exhaust passage;

Step 6: completing all the seals around the plurality of fluorescent lamps at one time by heating the second sealant;

Step 7: Cut and separate each fluorescent lamp on the glass plate to obtain a plurality of flat fluorescent lamps.

Further, in the first step, the discharge channels and the electrodes of the plurality of fluorescent lamps are directly formed by heating on at least one glass plate of the two glass plates.

Further, in the first step, a spacer is disposed between the two glass plates to form a discharge channel, an electrode, and an exhaust passage.

The invention has the advantages that: since the sealing around the discharge channel of the fluorescent lamp is completed in one time after the fluorescent lamp forms a vacuum environment, the two fluorescent glass plates are squeezed by a large pressure difference outside the glass plate before sealing, thereby eliminating the natural existence of the process or the material. The gap, so that after the fluorescent lamp is sealed and sealed, there is no deformation stress between the fluorescent glass plates, which solves the fatal defect of the flat fluorescent lamp production and the cracking process of the lighting process; at the same time, the gap between the discharge tubes is eliminated, and the discharge channel is increased. The resistance between the two solves the problem that the discharge channel of the fluorescent lamp cannot be completely illuminated due to the short circuit of the gap; since the periphery of the fluorescent lamp is not sealed in the vacuum processing, the entire fluorescent lamp is surrounded by a 'injection port', which greatly improves pumping. Gas efficiency, increasing the vacuum of fluorescent lamps.

DRAWINGS

The present invention will be further described below in conjunction with the embodiments with reference to the accompanying drawings.

Fig. 1A is a schematic exploded view of a first embodiment of the present invention.

Fig. 1B is a structural schematic view showing the bonding of two sheets of glass sheets according to the first embodiment of the present invention.

Fig. 1C is a schematic view of a fluorescent lamp after cutting according to a first embodiment of the present invention.

Fig. 2A is a schematic exploded view of a second embodiment of the present invention.

Figure 2B is a side elevational view of the post-cut fluorescent lamp of the second embodiment of the present invention.

detailed description

First embodiment:

Step 1: As shown in FIG. 1A and FIG. 1B, two glass plates, a first glass plate 11 and an opposite second glass plate 12 are provided; wherein the first glass plate 11 is formed with discharge channels 21 of three fluorescent lamps 20 and external An electrode 22; an exhaust pipe 31 is disposed at an edge of the first glass plate 11, and an exhaust passage 32 is further disposed at a middle portion of the first glass plate 11, and the exhaust passage 32 communicates with the exhaust pipe 31 .

Step 2: a first sealant 41 is disposed around the first glass plate 11 or the second glass plate 12, and a second sealant 42 is disposed in the peripheral region 23 of the fluorescent lamp 20, wherein the first sealant 41 has a low melting point At the melting point of the second sealant 42.

Step 3: attaching two

glass plates

11, 12 together, melting the first sealant 41 by heating, and sealing the periphery of the two

glass plates

11, 12 to form a cavity;

Step 4: evacuating the cavity through the exhaust pipe 31;

Step 5: injecting mercury into the vacuum chamber through the exhaust pipe 31 and filling the inert gas;

Step 6: by heating the second sealant 42 to complete the entire sealing of the periphery of the fluorescent lamp 20 at one time;

Step 7: The fluorescent lamp 20 is cut and separated. FIG. 1C is a side view of the fluorescent lamp 20 after cutting.

Second embodiment:

Step 1: As shown in FIG. 2A, two glass plates, a first glass plate 11 and an opposite second glass plate 12 are provided; wherein the first glass plate 11 is formed with discharge channels 21 and outer electrodes 22 of three fluorescent lamps 20, A discharge channel 21 and an outer electrode 22 of three fluorescent lamps 20 are also formed on the second glass plate 12 at a position corresponding thereto; an exhaust pipe 31 is provided at an edge of the first glass plate 11 at the first glass plate 11 An exhaust passage 32 is also provided in the middle portion, and the exhaust passage 32 communicates with the exhaust pipe 31.

Step 3: attaching two

glass plates

11, 12 to form a cavity;

Step 4: evacuating the cavity through the exhaust pipe 31;

Step 7: The fluorescent lamp 20 is cut and separated. 2B is a side view of the fluorescent lamp 20 after cutting.

Third embodiment:

This embodiment is the same as the remaining steps of the first embodiment, except that a spacer is disposed between the two glass plates in the first step to form a discharge channel, an electrode, and an exhaust passage.

In the invention, since the sealing around the discharge channel of the fluorescent lamp is completed in one time after the fluorescent lamp forms a vacuum environment, the two fluorescent glass plates are pressed by the huge pressure inside and outside the glass plate before sealing, thereby eliminating the gap generated by the process or the material, so that the sealing is performed. After the agent is sealed and sealed, there is no deformation stress between the fluorescent glass plates, which solves the fatal defect of the cracking of the flat fluorescent lamp lighting process, and the gap between the discharge tubes is eliminated, the discharge resistance is increased, and the short circuit of the discharge channel is solved. Since the gap between the glass plates is eliminated, the problem of cracking is solved, and the size of the glass plate can be increased in the production process, and more fluorescent lamps can be produced at one time, thereby reducing production cost, saving materials, and greatly improving Production efficiency and reduced yield.

Claims

A method for manufacturing a flat fluorescent lamp, comprising the steps of:

Step 2: a ring of a first sealant is disposed at a periphery of at least one of the glass plates, and a second sealant is disposed on at least one of the glass plates corresponding to a position of each of the fluorescent lamps; the first sealant has a low melting point a melting point of the second sealant;

Step 3: attaching two pieces of glass plates correspondingly, and melting the first sealing agent by heating, so that the periphery of the two glass plates is sealed to form a cavity;

2. The method of manufacturing a flat fluorescent lamp according to claim 1, wherein in the first step, the discharge channels and the electrodes of the plurality of fluorescent lamps are directly formed by heating on at least one of the glass plates of the two glass sheets.

3. The method of manufacturing a flat fluorescent lamp according to claim 1, wherein in the first step:

A spacer is disposed between the two glass plates to form a discharge channel, an electrode, and an exhaust passage.