Information
-
Patent Grant
-
6642668
-
Patent Number
6,642,668
-
Date Filed
Tuesday, August 27, 200222 years ago
-
Date Issued
Tuesday, November 4, 200321 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Nguyen; Hoang
- Tran; Thuy Vinh
Agents
-
CPC
-
US Classifications
Field of Search
US
- 315 77
- 315 82
- 315 85
- 315 224
- 315 225
- 315 209 T
- 315 276
- 315 277
- 315 291
- 315 307
- 315 DIG 2
- 315 DIG 5
- 315 DIG 7
- 307 101
- 307 106
- 307 108
- 323 901
- 361 679
- 361 816
- 361 818
- 363 132
-
International Classifications
-
Abstract
Providing a discharge lamp device to reduce noise radiation and to reduce a surge pulse current resulting from a shield sheath involves providing a ballast, including a DC/DC conversion circuit for boosting a direct current voltage from a battery, an inverter circuit for converting the voltage boosted by the DC/DC conversion circuit into an alternating current voltage, a starting circuit having a second transformer for boosting to such a voltage that causes a breakdown between electrodes of a lamp in starting up the lamp, and a metal case for accommodating the DC/DC conversion circuit, the inverter circuit, and the starting circuit. A secondary winding of the second transformer of the starting circuit is connected between the lamp and the inverter circuit connected to the lamp. An electrode member is interposed between the second transformer and the metal case.
Description
CROSS REFERENCE TO RELATED APPLICATION
This application is based upon, claims the benefit of priority of, and incorporates by reference the contents of prior Japanese Patent Application No. 2001-256772 filed Aug. 27, 2001.
BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The invention relates to a discharge lamp device for lighting a high voltage discharge lamp. Specifically, the device is applicable to an automotive headlight device employing a discharge lamp.
2. Description of Related Art
In general, among the discharge lamp devices is a vehicle-mounted discharge lamp device which comprises a DC/DC converter for boosting a voltage supplied from an external power source, an inverter circuit for converting the boosted voltage into an alternating current voltage, and a starting circuit for producing high voltage to begin lighting a discharge lamp.
This starting circuit is provided with a high voltage transformer for causing a spark discharge so that a breakdown occurs between the electrodes of the discharge lamp. The high voltage transformer is composed of a primary winding and a secondary winding, and the secondary winding is connected between the discharge lamp and the inverter circuit.
In addition, wiring extending from the high voltage transformer to the discharge lamp is covered with a shield sheath in order to prevent noise radiation resulting from restriking noises that occur when the current flowing through the discharge lamp alternates in direction. The shield sheath also prevents noise radiation resulting from the alternating current flowing through the wiring that leads to the discharge lamp, upon alternating-current driving of the discharge light by the inverter circuit. Additionally, for the prevention of noise radiation, the high voltage transformer and the electronic circuits connected to the high voltage transformer, such as the inverter circuit, are typically accommodated in an electronic circuit case made of metal and are grounded along with the shield sheath.
In the conventional configuration, the shield sheath structure causes ground stray capacitances not only of the wiring between the discharge lamp and the high voltage transformer but also of the high voltage transformer. Consequently, when the high voltage transformer produces a high voltage at the start of lighting, the voltage to be applied to the discharge lamp charges these ground stray capacitances while being boosted. Subsequently, when the voltage reaches a high voltage and is applied to the discharge lamp for breakdown, the electric charges of the ground stray capacitance, having been charged up, then flow as a surge pulse current. In some cases, semiconductor switching devices, and the like, in the inverter circuit for converting a direct current voltage into an alternating current voltage may be broken.
SUMMARY OF THE INVENTION
The present invention has been achieved in view of the foregoing, and it is thus an object thereof to provide a discharge lamp device which can reduce noise radiation and reduce the surge pulse current resulting from the shield sheath.
According to a first aspect of the present invention, a lighting control circuit is provided including: a DC/DC conversion circuit having a first transformer for boosting a direct current voltage from a direct current power source; an inverter circuit having a semiconductor switching device for converting the voltage boosted by the DC/DC conversion circuit into an alternating current voltage; a starting circuit having a second transformer for boosting to such a voltage so as to cause a breakdown between electrodes of a discharge lamp in starting up the discharge lamp; and an electronic circuit case for accommodating the DC/DC conversion circuit, the inverter circuit, and the starting circuit. A secondary winding of the second transformer of the starting circuit is connected between the discharge lamp and the inverter circuit connected to the discharge lamp. An electrode member is interposed between the second transformer and the electronic circuit case.
Consequently, the interposition of the electrode member between the second transformer and the electronic circuit case allows suppression of a stray capacitance lower than the ground stray capacitance in the conventional configuration where the second transformer and the electronic circuit case are grounded therebetween.
It is therefore possible to reduce the stray capacitance to be charged when the second transformer produces a high voltage during startup. Thus, after a breakdown occurs between the electrodes of the discharge lamp, the amount of discharge of the electric charges, having been accumulated in the stray capacitances up to then, can be reduced with a reduction in surge pulse current.
In another aspect of the present invention, the electrode member is connected to a low-voltage side of the secondary winding of the second transformer. Consequently, even if such a high voltage, so as to cause a breakdown between the electrodes of the discharge lamp, is produced by the second transformer during startup, the connection of the electrode member to the low-voltage side of the secondary winding of the second transformer can surely reduce the stray capacitance that occurs in the second transformer.
In another aspect of the present invention, the electrode member is interposed at least between the secondary winding of the second transformer and the electronic circuit case. That is, to reduce the stray capacitance that occurs in the second transformer, the electrode member only has to be interposed between the second winding, which produces a high voltage, and the electronic circuit case. This will decrease waste of the electrode member used to reduce the stray capacitance.
In another aspect of the present invention, the electrode member is formed by evaporating a metal layer onto an insulating film. Consequently, the electrode member to be interposed between the second transformer and the electronic circuit case can be fabricated at a low cost without increasing the complexity or number of parts of the discharge lamp device, in particular, around the electronic circuit case.
In another aspect of the present invention, the electrode member is folded in two to cover both sides of the second transformer accommodated in the electronic circuit case. Since the second transformer accommodated in the electronic circuit case is covered at both sides with the folded electrode member, the ground stray capacitance of the second transformer can be eliminated.
According to another aspect of the present invention, the lighting control circuit is connected directly to the discharge lamp. This eliminates the need for the wiring from the second transformer of the starting circuit, constituting the lighting control circuit, to the discharge lamp, i.e., the shield sheath. It is therefore possible to reduce the surge pulse current resulting from the shield sheath while simplifying the discharge lamp device.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1
is a block diagram showing the circuit configuration of a discharge lamp device according to a first embodiment of the present invention;
FIG. 2
is a partial, exploded perspective view showing the configuration of the lighting control circuit of
FIG. 1
;
FIG. 3
is a cross-sectional view as seen from III—III in
FIG. 2
;
FIG. 4A
is a cross-sectional view of the discharge lamp device according to a second embodiment of the present invention;
FIG. 4B
is a partial cross-sectional view of the lighting control circuit of
FIG. 4A
; and
FIG. 5
is a block diagram showing the circuit configuration of the discharge lamp device according to the second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
With reference to
FIGS. 1
to
3
, description will be given of a first embodiment of the present invention in which the discharge lamp device is applied to an automotive discharge lamp device.
FIG. 1
is a block diagram showing the circuit configuration of the discharge lamp device according to a first embodiment.
FIG. 2
is a partial, exploded perspective view showing the configuration of the lighting control circuit shown in FIG.
1
.
FIG. 3
is a cross-sectional view as seen from III—III of FIG.
2
.
As shown in
FIG. 1
, the discharge lamp device comprises a direct current power source or battery
10
, a lighting switch
20
, and a lighting control circuit (hereinafter, referred to as a ballast)
100
which lights a lamp
30
with an alternating current based on a boosted voltage of the direct current voltage from the battery
10
when the lighting switch
20
is ON.
This ballast
100
includes a DC/DC conversion circuit
120
, an inverter circuit
130
, a starting circuit
140
, a control circuit
160
, and an electronic circuit case
170
. Incidentally, in this instance, the lamp
30
is a discharge lamp such as a metal halide lamp which is an automotive headlight. During startup, the starting circuit
140
applies a high voltage that causes a breakdown between electrodes of the lamp
30
. After a breakdown, the unstable glow discharge transforms into arc discharge for a stable lighting state.
The DC/DC conversion circuit
120
is also provided with a first transformer (not shown) having a primary winding (not shown) arranged on the side of the battery
10
and a secondary winding (not shown) arranged on the side of the lamp
30
. Semiconductor switching devices (not shown), such as MOS transistors, connected to the primary winding are turned ON/OFF by the control circuit
160
so that the direct current voltage from the battery
10
is boosted for a high voltage output.
The inverter circuit
130
has MOS transistors
131
-
134
which form semiconductor switching devices arranged in an H bridge. Drive circuits
130
a
alternately turn ON/OFF the MOS transistors
131
-
134
of diagonal relationships so that the lamp
30
is driven to light with an alternating current.
The starting circuit
140
connects to a point between the inverter circuit
130
and the lamp
30
, comprises a second transformer
141
having a primary winding
141
a
and a secondary winding
141
b
, a capacitor (not shown), and a thyristor (not shown) as a unidirectional semiconductor device, and starts the lamp
30
to light it. That is, when the lighting switch
20
is turned ON, the capacitor is charged. Subsequently, when the thyristor is turned ON, the capacitor discharges to apply a high voltage (for example, 25 kV) to the lamp
30
through the second transformer
141
. As a result, the lamp
30
causes a breakdown between its electrodes for spark ignition.
In the ballast
100
having the foregoing configuration, when the lighting switch
20
is turned ON, the DC/DC conversion circuit
120
, having the first transformer, outputs a boosted voltage of the battery voltage. The high voltage output from this DC/DC conversion circuit
120
(around 300-500V in a preparatory stage of lighting, around 100 V after the start of lighting) is boosted by the second transformer
141
of the starting circuit
140
via the inverter circuit
130
to a higher voltage (for example, 25 kV) and applied to the lamp
30
so that a breakdown occurs. As a result, the lamp
30
begins to light.
With continuing reference to
FIG. 1
, the electrode member
180
is isolated from the electric circuit case
170
. The electrode member
180
is electrically connected to the low voltage side terminal
141
c
of the secondary coil
141
b
as shown in
FIG. 1
, and conducts with the low voltage side terminal
141
c
. The electrode member
180
covers the transformer
141
and defines stray capacitance with the secondary coil
141
b
since the electrode member
180
is electrically connected to the low voltage side terminal
141
c
. The stray capacitance may be illustrated as a capacitor cf
3
connected in parallel with the secondary coil
141
b.
Now, the mounting structure of the ballast
100
will be described below with reference to
FIGS. 2 and 3
. As shown in
FIG. 2
, the ballast
100
has a metallic electronic circuit case (hereinafter, referred to as metal case)
170
in which the individual circuits, such as the starting circuit
140
, are accommodated. The outer periphery of this metal case
170
is electrically connected to a shield sheath
50
, which covers a high voltage cord
40
for connecting the lamp
30
and the transformer
141
of the starting circuit
140
, and is grounded. Consequently, it is possible to avoid noise radiation resulting from restriking noises that occur when the current flowing through the lamp
30
alternates in direction and to eliminate noise radiation resulting from the alternating current flowing through the wiring (more specifically, the high voltage cord
40
) that leads to the lamp
30
, upon the alternating-current driving of the lamp
30
by the inverter circuit
130
.
This metal case
170
also contains a resin case
171
. Terminals
171
a
are insert-molded in the resin case
171
. Consequently, the parts that can be formed as semiconductor devices, such as the control circuit
160
and the MOS transistors, are integrated into an IC, or hybrid IC, and electrically connected to the transformer
141
through the terminals
171
a.
Moreover, since the second transformer
141
of the starting circuit
140
, or the secondary winding
141
a
in particular, outputs a high voltage (for example, 25 kV), the second transformer
141
is surrounded by the resin case
171
and a resin cover
172
as shown in
FIG. 2
so that the high voltage is insulated. Here, in the discharge lamp device having the foregoing configuration, the shield sheath structure forms ground stray capacitances Cf
1
and Cf
2
not only from the high voltage cord
40
but also from the starting circuit
140
(more specifically, the second transformer
141
) which is connected to the high voltage cord
40
(FIG.
1
).
Additionally, this ground stray capacitance Cf
1
is formed between the high voltage cord
40
and the shield sheath
50
, and the ground stray capacitance Cf
2
is formed between the second winding
141
b
of the second transformer
141
and the metal case
170
. That is, when the second transformer
141
produces a high voltage at the start of lighting, the voltage to be applied to the lamp
30
charges these ground stray capacitances Cf
1
and Cf
2
while being boosted. Subsequently, when the voltage reaches a high voltage and causes a breakdown between the electrodes of the lamp
30
while the diagonal MOS transistors
131
and
134
are ON, for example, the charges having been accumulated as the ground stray capacitances Cf
1
and Cf
2
up to then flow as a surge pulse current in the direction of the arrows shown in FIG.
1
.
In the worst case, this surge pulse current, when it flows, might flow through the H-bridged MOS transistors
131
-
134
of the inverter circuit
130
and break the MOS transistors
133
and
134
, in particular. For this reason, protective capacitors C
6
and C
7
for bypassing this surge pulse current are typically connected to a connecting point between the electrode of the lamp
30
and the MOS transistors
133
and
134
. For the same reason, protective capacitors C
1
-C
4
and C
5
are also arranged between the drains and sources of the respective transistors
131
-
134
.
Meanwhile, according to the embodiment of the present invention, an electrode member
180
shown in
FIG. 2
is interposed between the second transformer
141
and the metal case
170
. This electrode member
180
is a thin conductor, such as copper foil, laminated with insulating films. Incidentally, a metal layer
180
b
of such a conductor as copper may be evaporated onto one side of a laminate
180
a
. That is, for the second transformer
141
surrounded by the resin film
171
and the resin cover
172
, the electrode member
180
can be arranged between the resin cover
172
and the metal case
170
with its laminate portion toward the metal case
170
as shown in
FIG. 3
, so that the electrode member
180
secures insulation from the metal case while forming a stray capacitance Cf
3
between the second transformer
141
and the electrode member
180
(FIG.
1
).
Since the electrode member
180
is interposed between the second transformer
141
and the metal case
170
, the ground stray capacitance Cf
2
for situations where the second transformer
141
and the metal case
170
are grounded can thus be replaced with and suppressed to the stray capacitance Cf
3
which is smaller than the ground stray capacitance Cf
2
. Incidentally, as shown in
FIG. 1
, stray capacitance Cf
3
is desirably formed so that the metal layer
180
b
of the electrode member
180
is connected to the low-voltage side of the secondary winding
141
b
of the second transformer
141
through a connecting part
180
bc
and a terminal
171
a
. This can ensure a reduction in ground stray capacitance as compared to the conventional ground stray capacitance Cf
2
.
Consequently, adopting the configuration of the discharge lamp device of the present embodiment, or the ballast
100
in particular, allows a reduction in stray capacitance when the second transformer
141
produces a high voltage during startup. Thus, after a breakdown occurs between the electrodes of the lamp
30
, the amount of discharge of the electric charges having been accumulated in the stray capacitances up to then can be reduced with a reduction in surge pulse current.
Moreover, the reduced surge pulse current prevents the switching devices such as the MOS transistors
131
-
134
from becoming broken. This allows a reduction of the parts count of protective capacitors for bypassing a surge pulse current. For example, a reduction of the protective capacitor C
7
in
FIG. 1
, provided that the required capacities are secured by combinations of inexpensive capacitors.
In addition, if the second transformer
141
is surrounded by the resin cover
172
or the like for insulating the high voltage produced, the electrode member
180
is formed by evaporating the metal layer
180
b
onto the insulating film
180
a
. This allows inexpensive fabrication without increasing the constitution of the discharge lamp device, in particular, around the ballast
100
.
Modified First Embodiment
In such configuration that the electrode member
180
shall be arranged on top and bottom, on both sides of the second transformer
141
, the electrode member
180
is desirably folded in two and inserted above and below the second transformer
141
as shown in
FIG. 2
so that the second transformer
141
accommodated in the metal case
170
is covered on both sides (see FIGS.
2
and
3
). Then, in the process of assembly to cover both sides of the second transformer
141
(more specifically, via the resin cover
172
which surrounds the second transformer
141
), the electrode member
180
can be easily mounted from one direction as shown in FIG.
2
.
Second Embodiment
In a second embodiment of the present invention, the configuration such that the ballast
100
and the lamp
30
are connected with the high voltage cord
40
, of the first embodiment, is replaced with the configuration that the ballast
100
is connected directly to the lamp
30
(see FIG.
4
A). Incidentally, in
FIG. 4A
, the automotive discharge lamp device is configured so that the lamp
30
and a reflector
6
that has a reflecting mirror on its surface side are accommodated in a lamp chamber which is composed of a transparent lens
3
and a housing
4
. In the present embodiment, this lamp chamber contains the ballast
100
so that the ballast
100
is located on the backside of the reflector
6
.
As in a block diagram of
FIG. 5
which shows the circuit configuration, the shield sheath
50
for covering the high voltage cord
40
can be omitted to eliminate the ground stray capacitance Cf
1
resulting from the shield sheath structure. Besides, as shown in
FIG. 4A
, non exposure of the high voltage cord
40
prevents noise radiation resulting from the high voltage cord
40
. Moreover, in the ballast
100
of the present embodiment, the electrode member
180
is interposed between the second transformer
141
and the metal case
170
as shown in FIG.
4
B. This allows a reduction in stray capacitance occurring in the second transformer
141
(more specifically, the stray capacitance Cf
3
).
Consequently, the elimination of the ground stray capacitance Cf
1
resulting from the shield sheath structure and the large reduction of stray capacitance in terms of the stray capacitance Cf
3
resulting from the interposition of the electrode member
180
allow a reduction of, for example, the protective capacitors C
1
-C
4
which have been arranged between the drains and sources of the respective MOS transistors
131
-
134
arranged in an H bridge.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
Claims
- 1. A discharge lamp device comprising:a lighting control circuit device including: a DC/DC conversion circuit having a first transformer for boosting a direct current voltage from a direct current power source; an inverter circuit having a semiconductor switching device for converting the voltage boosted by said DC/DC conversion circuit into an alternating current voltage; a starting circuit having a second transformer for boosting to a voltage which causes a breakdown between electrodes of a discharge lamp in starting up said discharge lamp; and an electronic circuit case for accommodating said DC/DC conversion circuit, said inverter circuit, and said starting circuit, the discharge lamp device further comprising: a secondary winding of said second transformer of said starting circuit that is connected between said discharge lamp and said inverter circuit connected to said discharge lamp, and an electrode member interposed between said second transformer and said electronic circuit case.
- 2. The discharge lamp device according to claim 1, wherein said electrode member is connected to a low-voltage side of said secondary winding of said second transformer.
- 3. The discharge lamp device according to claim 2, wherein said electrode member is an evaporated metal layer on an insulating film.
- 4. The discharge lamp device according to claim 2, wherein said electrode member is interposed at least between said secondary winding of said second transformer and said electronic circuit case.
- 5. The discharge lamp device according to claim 4, wherein said electrode member is an evaporated metal layer on an insulating film.
- 6. The discharge lamp device according to claim 5, wherein said electrode member is folded in two to cover both sides of said second transformer accommodated in said electronic circuit case.
- 7. The discharge lamp device according to claim 6, wherein said lighting control circuit is connected directly to said discharge lamp.
- 8. The discharge lamp device according to claim 1, wherein said electrode member is interposed at least between said secondary winding of said second transformer and said electronic circuit case.
- 9. The discharge lamp device according to claim 8, wherein said electrode member is an evaporated metal layer on an insulating film.
- 10. The discharge lamp device according to claim 1, wherein said electrode member is an evaporated metal layer on an insulating film.
- 11. The discharge lamp device according to claim 1, wherein said electrode member is folded in two to cover both sides of said second transformer accommodated in said electronic circuit case.
- 12. The discharge lamp device according to claim 1, wherein said lighting control circuit is connected directly to said discharge lamp.
- 13. The discharge lamp device according to claim 1 wherein the electrode member is isolated from the electronic circuit case.
Priority Claims (1)
Number |
Date |
Country |
Kind |
2001-256772 |
Aug 2001 |
JP |
|
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