1. Field of the Invention
The present invention relates to a ceramic metal halide lamp.
2. Description of Related Art
A high-pressure mercury lamp, a high-pressure sodium lamp, a metal halide lamp and a ceramic metal halide lamp, for example, are known as a high-intensity discharge lamp (HID lamp). The HID lamp is adapted to produce light by effectively utilizing discharge between electrodes provided therein. Therefore, as compared with an incandescent lamp, the high-intensity discharge lamp has distinguishing characteristics such as large luminous flux, being suitable for use in illumination of a large-scale space and having high energy efficiency.
In the HID lamps, a metal halide lamp that uses metal halides as a luminous material has merits such as excellent color rendering property to produce light close to white light (natural light) as compared with a mercury lamp to produce rays of bluish-white light. Moreover, this metal halide lamp has a merit of high luminous efficiency.
It has been customary to use a quartz luminous tube as a luminous tube for use with a metal halide lamp. In recent years, a translucent ceramic luminous tube is used instead of the quartz luminous tube. A metal halide lamp using a ceramic luminous tube is called, especially, a “ceramic metal halide lamp”.
A ceramic metal halide lamp has a tendency to change its electrical characteristics in the early stage in which the lamp begins to glow after it was completed as a product and this metal halide lamp also tends to change its optical characteristics in accordance with the change of the electrical characteristics. In particular, electrical characteristics and optical characteristics of the ceramic metal halide lamp are changed with violence during 10 hours passed after the ceramic metal halide lamp had begun to glow. After 100 hours, electrical characteristics and optical characteristics of the ceramic metal halide lamp become stable. The change of the electrical characteristics may emerge as a lowering of a lamp voltage and the change of the optical characteristics may emerge as a change of color.
If a ceramic metal halide lamp is designed under the specifications to raise an initial lamp voltage in order to compensate a lowering of a lamp voltage, there then arise problems known as the extinguishment of lamp and the like.
Accordingly, it is an object of the present invention to provide a ceramic metal halide lamp which can decrease electrical characteristics and optical characteristics changed at the first time when a lamp begins to glow.
Further, it is an object of the present invention to provide a manufacturing method of a ceramic metal halide lamp which can decrease electrical characteristics and optical characteristics changed at the first time when a lamp begins to glow.
In one or more embodimets of the present invention, a manufacturing method of a ceramic metal halide lamp, silver iodide (AgI) being sealed into a luminous tube of said ceramic metal halide lamp together with a predetermined quantity of mercury, metal halides and an inert gas, comprising the steps of: measuring a change of luminous flux by changing AgI/total amount of metal halide (weight ratio) and determining an upper limit amount of silver iodide (AgI) by specifying an upper limit value of said AgI/total amount of metal halide based on an allowable lowering rate of luminous flux; measuring a change of a lamp voltage by changing said AgI/total amount of metal halide and determining a lower limit amount of said silver iodide (AgI) by specifying a lower limit value of said AgI/total amount of metal halide based on an allowable lowering rate of a lamp voltage; sealing silver iodide (AgI) of an amount which falls within an upper limit amount and a lower limit amount of said silver iodide (AgI) into a luminous tube together with other sealed materials to thereby complete a luminous tube; and manufacturing a lamp by using said luminous tube.
Further, in one or more embodimets of the present invention, a ceramic metal halide lamp manufactured by the above manufacturing method.
Further, in one or more embodimets of the present invention, a manufacturing method of a ceramic metal halide lamp, silver iodide (AgI) being sealed into a luminous tube of said ceramic metal halide lamp together with a predetermined quantity of mercury, metal halides and an inert gas, comprising the steps of: measuring a change of a lamp voltage by changing AgI/total amount of metal halide (weight ratio) and determining a lower limit amount of silver iodide (AgI) by specifying a lower limit value of said AgI/total amount of metal halide based on an allowable lowering rate of a lamp voltage; measuring a change of luminous flux by changing said AgI/total amount of metal halide (weight ratio) and determining an upper limit amount of said silver iodide AgI by specifying an upper limit value of said AgI/total amount of metal halide based on an allowable lowering rate of luminous flux; sealing silver iodide (AgI) of an amount which falls within an upper limit amount and a lower limit amount of said silver iodide (AgI) into a luminous tube together with other sealed materials to thereby complete a luminous tube; and manufacturing a lamp by using said luminous tube.
Further, in one or more embodimets of the present invention, a ceramic metal halide lamp manufactured by the above manufacturing method.
Further, in one or more embodimets of the present invention, a ceramic metal halide lamp using a luminous tube into which there are sealed silver iodide specified by the following equations.
0.1≦AgI/total amount of metal halide (weight ratio)≦0.35
Further, in the above ceramic metal halide lamp, said ceramic metal halide lamp may use a luminous tube in which a gap (total gap of upper and lower gaps) between an electrode mount and a thin tube portion falls within a range of 0.1±0.05 mm.
Further, in one or more embodimets of the present invention, a ceramic metal halide lamp using a luminous tube into which there are sealed silver bromide specified by the following equations.
0.1≦AgBr/total amount of metal halide (weight ratio)≦0.35
Further, in the above ceramic metal halide lamp, wherein said ceramic metal halide lamp may use a luminous tube in which a gap (total gap of upper and lower gaps) between an electrode mount and a thin tube portion falls within a range of 0.1±0.05 mm.
According to the above embodimets of the present invention, it is possible to provide a ceramic metal halide lamp which can decrease electrical characteristics and optical characteristics changed at the first time when a lamp begins to glow.
Furthermore, according to the above embodimets of the present invention, it is possible to provide a manufacturing method of a ceramic metal halide lamp which can decrease electrical characteristics and optical characteristics changed at the first time when a lamp begins to glow.
A ceramic metal halide lamp according to one or more embodiments of the present invention will be described below with reference to the accompaning drawings. It should be noted that, in the drawings, identical elements are denoted by the identical reference numerals and overlapping description will be omitted.
Those elements will be explained in brief, respectively.
The luminous tube 4 will be explained later on in relation to
The mount 8 comprises mainly a stem tube 14 with a pair of lead-in wires hermetically sealed therein and a support 16 formed of a wire material such as a nickel-plated iron wire and a round-bar material molded as a nearly rectangular-shaped frame.
The inner tube 18 is disposed to surround the periphery of the luminous tube 4 in order to protect the outer bulb from influences exerted on the luminous tube when the luminous tube 4 is exploded and is formed of a transparent quartz glass tube. The inner tube 18 may be formed of either an open-type inner tube or a closed-type inner tube.
The outer bulb 2 is made of a translucent hard glass such as a borosilicate glass, for example. The outer bulb may be formed of either a transparent-type outer bulb or diffusing-type (opaque) outer bulb. The outer bulb 2 is of a BT-type outer bulb including a central portion 2a with a maximum diameter, a closed top portion 2c in the left side as seen from the sheet of drawing and a neck portion 2b in the right side as seen from the sheet of drawing. The neck portion 2b includes a sealed portion into which a flare portion of the stem tube 14 is sealed. After the flare portion of the stem tube was sealed into the sealed portion, the outer bulb 2 is evacuated through an exhaust pipe (not shown) disposed at the neck portion, whereafter an inert gas such as an argon (Ar) gas and a nitrogen (N2) gas is sealed into the outer bulb or the outer bulb is evacuated in the airtight atmosphere.
The screw-in base 6 is joined to the outer bulb so as to cover this sealed portion by using a heat-resistant adhesive or the base 6 is screwed to a molded thread groove and thereby attached to the outer bulb.
The lamp 10 shown in
A ceramic metal halide lamp has a tendency to lower a lamp voltage at the first time when it beings to glow after it was completed as a product and tends to change color in accordance with the lowering of the lamp voltage.
Having investigated and analyzed a luminous tube of which lamp voltage was lowered, the inventor of the present application found one of such causes to lower a lamp voltage such that a material sealed into the thick tube portion 4a of the luminous tube 4 penetrates a gap between the electrode mount and the thin tube portion with the result that a sealed material within the thick tube portion 4a is decreased.
A phenomenon in which the material sealed into the thick tube portion 4a penetrates the gap between the electrode mount and the thin tube portion will be explained with reference to
A metal halide of a sealed material 48 is sealed into the thick tube portion 4a in the solid state (powder, pellet, etc.) when the luminous tube is manufactured. This metal halide is placed in a mixed state of a liquid and a gas during the ceramic metal halide lamp is glowing. A very small quantity of metal halide permeates into the tip end of the thin tube portion through the gap between the thin tube portion 4c and the molybdenum coil rod 45 and erodes the polycrystalline alumina. As a result, the quantity of the sealed material within the thick tube portion 4a of the luminous tube decreases to cause a lamp voltage to be lowered and color of light to be changed. By adding an upper gap and a lower gap, it is to be noted that the size of the gap between the thin tube portion 4c and the molybdenum coil rod 45 should fall within a range of 0.1±0.05 mm. Such ceramic luminous tube was developed by ROYAL PHILIPS ELECTRONICS and the fundamental structure thereof was not varied later on.
Therefore, in the beginning, the inventor of the present application has taken the following two steps as countermeasures to cope with the phenomenon in which the sealed material permeates into the gap between the electrode mount and the thin tube portion.
Countermeasure 1: By increasing a quantity of a sealed material sealed into the thick tube portion 4a, it is possible to maintain a necessary quantity of a sealed material in the thick portion 4a even when the sealed material permeates into the gap to decrease the quantity of the sealed material.
Countermeasure 2: The gap between the electrode mount of the thin tube portion and the thin tube portion should be narrowed as much as possible. However, under the present circumstances, when the gap between the electrode mount of the thin tube portion and the thin tube portion is narrowed more, size tolerance of the parts should be determined strictly in order to positively insert the electrode mount into the thin tube portion, which gives rise to a lowering of yield and hence a ceramic metal halide lamp becomes costly. Moreover, it became clear that the above-described work to insert the electrode mount into the thin tube portion becomes difficult so that working efficiency is caused to be lowered. Thus, the above countermeasures are not yet adopted.
[Increase of Material Sealed into Thick Tube Portion]
However, when the quantity of the metal halide serving as the sealed material 48 within the thick tube portion 2a was increased with the same ratio as that of the present state, there was caused a problem of increasing a tendency in which the metal halide erodes the polycrystalline alumina in the thin tube portion 4c. In particular, if the sealed material 48 contains rare earth metal halides such as Dy, Ho and Tm, then an extent in which the sealed material erodes the polycrystalline alumina is increased remarkably.
Accordingly, the quantity of the metal halide was not increased but silver iodide (AgI) was added to the sealed material. The reason that the silver iodide is used is that the silver iodide is fundamentally unable to present a high peak level in the visible light region so that it does not affect the optical characteristics of the lamp considerably. Furthermore, since the silver iodide hardly reacts with the polycrystalline alumina that forms the thin tube portion, there is then no risk that the silver iodide will erode the polycrystalline alumina.
However, experiments had revealed that an excessive increase of a quantity of silver iodide exerts a delicate influence upon a luminous flux value of the lamp. Accordingly, experiments were carried out to determine a quantity of silver iodide relative to metal halides.
As a first stage, an upper limit value of a quantity of silver iodide was determined in a range such that the silver iodide may not affect a luminous flux value considerably. Inasmuch as a change of a luminous flux value falls within a range of ±5%, light with such change of luminous flux value is not incongruous with human eyes and it does not bring about a trouble in an actual use.
If on the other hand the quantity of silver iodide is small relative to the quantity of metal halide, then the metal halide permeates into a gap so that a lamp voltage cannot be suppressed from being lowered. Accordingly, as a second stage, a lower limit value of a quantity of silver iodide was specified in a range such that a lamp voltage may not be lowered considerably. Inasmuch as a change of a lamp voltage value falls within a range of ±5%, there arises no problem in an actual use.
Based on the above-mentioned experiments, since it has been found that the addition of AgI is effective for decreasing the change of electrical characteristics and the change of optical characteristics, it is to be noted that a scope of the AgI/total amount should be determined next.
As a first stage, an upper limit value of the AgI/total amount is specified based on an allowable lowering rate of luminous flux. Thus, since the total amount of the material sealed into the lamp (i.e. total amount of metal halides) is clear, it is possible to determine the upper limit amount of AgI.
As a second stage, a lower limit value of silver iodide is specified based on an allowable lowered value of a lamp voltage. Since the total amount of a material sealed into the lamp (i.e. total amount of metal halides) is clear, it is possible to determine the lower limit amount of the silver iodide (AgI).
As set forth above, the scope of the AgI/total amount is specified so as to satisfy 0.1≦AgI/total amount≦0.35.
At a step 51, an upper limit value of AgI/total amount is determined. To be concrete, as shown in
At a step S2, a lower limit value of AgI/total amount is determined. To be concrete, as shown in
At a step S3, the AgI/total amount is specified within a range of the above-described lower limit value to the upper limit value. An absolute amount of silver iodide (AgI) that should be sealed into the luminous tube is decided and the silver iodide of the above absolute amount is sealed into the luminous tube together with other sealed materials thereby completing the luminous tube.
At a step S4, this luminous tube is used to manufacture a lamp.
The silver iodide (AgI) is used in the above-described embodiment. However, other silver halides, especially, a silver bromide (AgBr) have similar characteristics. Accordingly, it can be expected that the silver bromide (AgBr) can be used instead of the silver iodide (AgI).
Further, other metal iodides (copper iodide and gold iodide) also have characteristics substantially the same as those of the silver iodide and the silver bromide (AgBr). Accordingly, it can be expected that these other metal iodides are used instead of the silver iodide and the silver bromide.
While the ceramic metal halide lamp with the outer bulb protective structure according to the embodiment of the present invention has been described so far, these descriptions are made by way of example and may not limit the scope of the present invention. Addition, cancellation, change, improvement and the like easily made on the embodiment by those skilled in the art may fall within the scope of the present invention. A technical scope of the present invention may be determined by the description of the attached claims.
Number | Date | Country | Kind |
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2011-239087 | Oct 2011 | JP | national |