The present invention relates generally to arc chambers for discharge lamps such as ceramic metal halide lamps and, in particular, the invention concerns the construction, shape and configuration of the ends of ceramic arc chambers where the electrodes for the chambers are introduced into the chambers.
Discharge lamps, such as ceramic metal halide lamps, produce light by the ionization of a filler material, such as a mixture of metal halide additives and mercury, that is vaporized when the lamp is turned on. The ionization takes place in a transparent or translucent discharge chamber that is formed of a ceramic material such as polycrystalline alumina for example. The discharge chamber, often referred to as an arc tube or arc chamber, contains electrodes that are adapted to be connected to an electric circuit. When the electric circuit is energized, an electric arc is established between the electrodes and the filler material is thereby vaporized and ionized and light generated.
The ceramic arc tube or chamber can be of a variety of shapes such as cylindrical, spherical or oblate for example. In the case of a cylindrically-shaped arc tube, the arc tube can comprise a continuous outer wall that can be somewhat elongated. The opposed ends of the arc tube can be closed off with ceramic end pieces. In that case, a respective ceramic leg is attached to each end piece and a respective electrode is inserted through an opening in the leg and a complementary opening in the end piece so that the tip of the electrode will be positioned within the space surrounded by the continuous outer wall of the arc tube. As a result, the tips of the electrodes will be facing one another and will be appropriately positioned to establish an arc between each other when the electrodes are energized.
When in use, the arc chamber may be arranged so that the electrodes assume a vertical orientation, with one end of the arc chamber and an accompanying electrode and end piece situated below the other end of the chamber and an accompanying electrode and end piece. The lower end of the arc chamber in such an orientation typically comprises the coolest region of the arc chamber so that it is the region where the metal halide additives tend to collect.
The metal halide additives that are used in the filler material often comprise rare earth halides. It is the case that the metal halide additives, and particularly the rare earth halide additives, are corrosive to ceramic materials such as polycrystalline alumina and the corrosion caused by the additives can result in premature failure of the ceramic arc tube. This circumstance is exacerbated where the temperature gradients that are created at the end piece at the bottom of the arc tube are such as to cause the metal halide additives to collect on the bottom end piece and against the outer wall of the arc tube where the outer wall of the arc tube is joined to the bottom end piece. Alumina from the inside surface of the outer wall is dissolved by the additives thereby causing the arc tube to fail. Increasing the thickness of the outer wall is not a satisfactory solution because doing so decreases the lumen output of the lamp.
Other difficulties associated with ceramic arc chambers, whether they are vertically or horizontally oriented, involve bowing of the arc chambers and cracking of the arc chambers. It would be of benefit to have available ceramic arc chambers that avoided these problems.
According to one aspect, the invention concerns a ceramic arc chamber for a discharge lamp comprising a body portion having a continuous outer wall that includes an outer surface and an inner surface and that surrounds a space adapted to contain electrodes and metal halide additives. The continuous outer wall includes a first end and a second end that are spaced longitudinally from one another and define the longitudinal extent of the continuous outer wall. At least the first end of the continuous outer wall has an opening into the space that is surrounded by the continuous outer wall. An end piece is located in the opening in the first end of the continuous outer wall and is joined to the inner surface of the continuous outer wall. The end piece has a closure wall that is arranged generally axially of the longitudinal extent of the continuous outer wall and an outer surface and an inner surface that faces the space surrounded by the continuous outer wall. The inner surface of the continuous outer wall of the body portion and the inner surface of the closure wall of the end piece are configured so as to merge in a manner such that their line of merger and the inner surface of the closure wall otherwise do not provide any sharp edges at the ends of the ceramic arc chamber adjacent the first end of the continuous outer wall.
According to a further aspect, the invention concerns a ceramic arc chamber for a discharge lamp comprising a body portion and at least one particularly configured end piece. The body portion has a continuous outer wall that includes an outer surface and an inner surface and that surrounds a space adapted to contain electrodes and metal halide additives. The continuous outer wall includes a first end and a second end that are spaced longitudinally from one another and that define the longitudinal extent of the continuous outer wall. The body portion is adapted to be arranged when in use so that the longitudinal extent of the continuous outer wall is positioned in a manner that the first end of the continuous outer wall is located below the second end of the continuous outer wall. At least the first end of the continuous outer wall has an opening into the space that is surrounded by the continuous outer wall. An end piece is located in the opening in the first end of the continuous outer wall and is joined to the inner surface of the continuous outer wall. The end piece has a closure wall that is arranged generally axially of the longitudinal extent of the continuous outer wall and has a thickness greater than the thickness of the continuous outer wall. The end piece has an outer surface and an inner surface that faces the space surrounded by the continuous outer wall. The inner surface of the continuous outer wall of the body portion and the inner surface of the closure wall of the end piece are configured such that they merge together in a manner so that the metal halide additives will accumulate substantially only on the inner surface of the closure wall and the significant deleterious accumulation of the metal halide additives against the inner surface of the outer wall of the body portion of the ceramic arc chamber is prevented.
According to a particular aspect, the configuration of the inner surface of the closure wall is such as to establish a thermal profile between the first end and the second end of the arc tube that causes the metal halide additives to be deposited substantially uniformly over the inner surface of the closure wall of the end piece.
According to another aspect, the inner surface of closure wall of the end piece includes an inclined portion and a portion that is arranged inwardly of the inclined portion, in relation to the space that is surrounded by the continuous outer wall, and below the inclined portion when the ceramic arc chamber is arranged for use. The inclined portion essentially joins the inner surface of the continuous outer wall to the portion of the inner surface of the closure wall that is arranged inwardly of the inclined portion and below the inclined portion.
According to a further aspect, the inner surface of the closure wall of the end piece is curvilinear in profile. The curvilinear profile of the inner surface of the closure wall extends inwardly from the inner surface of the continuous outer wall, in relation to the space surrounded by the outer wall of the body portion, and downwardly when the ceramic arc chamber is arranged for use.
According to still another aspect, the inner surface of the closure wall of the end piece has a spherical configuration that extends inwardly from the inner surface of the continuous outer wall, in relation to the space surrounded by the continuous outer wall, and downwardly when the ceramic arc chamber is arranged for use. In a particular embodiment, the outer surface of the closure wall of the end piece has a substantially conical configuration.
In yet a further aspect, the outer surface and the inner surface of the continuous outer wall are substantially cylindrical.
In yet another aspect, the first end of the continuous outer wall includes a terminal portion that forms a support for the end piece. The end piece includes a flange portion that extends axially outwardly of the longitudinal extent of the continuous outer wall and rests on the terminal portion of the continuous outer wall.
In still a further aspect, the end piece comprises an injection molding end piece.
In yet a further aspect, each of the first end and the second end of the continuous outer wall has an opening into the space that is surrounded by the continuous outer wall and similar respective end pieces are located in the openings so that either the first end or the second end of the continuous outer wall can be located below the other when the ceramic arc chamber is arranged for use.
The continuous outer wall 14 includes a first end 22 and a second end 24 that are spaced longitudinally from one another and that define the longitudinal extent of the continuous outer wall. When in use, the arc chamber 10 is placed in the manner illustrated in
At least the first end 22 of the continuous outer wall 14 has an opening 26 into the space 20 that is surrounded by the continuous outer wall. In the embodiment of the invention shown in
Giving attention to the first end 22 of the continuous outer wall 14 and the opening 26 located thereat, it can be seen that the opening 26 is adapted to receive an end piece, indicated generally at 28, which in the exploded view of
The end piece 28 has a closure wall 30 that is arranged generally axially of the longitudinal extent of the continuous outer wall 14. The closure wall has a thickness greater than the thickness of the continuous outer wall 14, as can be seen in
The first end 22 of the continuous outer wall 14 includes a terminal portion 36 that forms a support for the end piece 28, and the end piece includes a flange portion 38 that extends axially outwardly of the longitudinal extent of the continuous outer wall 14 and rests on the terminal portion 36 of the continuous outer wall. In the embodiment of
The end pieces 28 also include ceramic legs 40 that are fixed to the closure wall 30. As shown in
As noted above, each of the first end 22 and the second end 24 of the continuous outer wall 14 has an opening into the space 14 that is surrounded by the continuous outer wall. And in the embodiment illustrated in
The ends of the electrodes opposite the electrode tips extend beyond the ends of the legs 40 and are connected to an electric circuit that can be connected to a source of electric power for the purpose of energizing the electrodes. As indicated above, when the electrodes are energized, an electric arc is established between the electrode tips. The electric arc vaporizes and ionizes the filler material in the arc chamber, including the metal halides, such as rare earth halides that form a part of the filler material, and light is thereby generated. The filler material, including the metal halides, will condense and fall to the first end 22 of the arc chamber 10.
As previously noted, the metal halides are corrosive and can cause the arc tube to fail. This is particularly the case if the metal halides are permitted to accumulate in a way that they contact the inside surface 18 of the outer wall 14 which typically is relatively thin. Accordingly, the invention provides for lessening the opportunity for the metal halides to accumulate in a manner to cause the arc tube to readily fail. Generally speaking, to accomplish this result, the inner surface 18 of the continuous outer wall 14 of the body portion 12 and the inner surface 34 of the closure wall 30 of the end piece 28 are configured such that they merge together in a manner so that the metal halide additives will accumulate substantially only on the inner surface 34 of the closure wall 30 and be spread over a large area in a thin layer, and the significant deleterious accumulation of the metal halide additives against the inner surface 18 of the continuous outer wall 14 of the body portion 12 of the ceramic arc chamber 10 is prevented.
The foregoing result is accomplished in the embodiment of
The second embodiment of the invention shown in
A difference between the embodiment of
The third embodiment of the invention shown in
A difference between the embodiment of
The feature of the embodiments of
The feature of the embodiments of
The deposition of the metal halides as has been described above, particularly with reference to
In each of the embodiments of the invention shown in
The embodiments described above, particularly the embodiments illustrated in
Although the invention has been described with respect to certain embodiments thereof, it will be recognized by those skilled in the art that the invention can be practiced with modifications that are within the spirit and the scope of the claims that follow. For example, the ceramic arc chamber is not limited to a three-piece construction but can be constructed of two, five or any number of pieces as will be understood by those skilled in the art.