A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
This application claims priority to Japanese National Application 2009-015951, filed Jan. 27, 2009, the content of which is fully incorporated herein.
The present invention relates to an electronic ballast for lighting an gas discharge lamp. More particularly the present invention relates to an electronic ballast for a discharge-type lamp having a grounding spacer and an insulating filler.
Electronic ballasts for discharge-type lamps are known in the art. Such ballasts generally include one or more substrates, or circuit boards, upon which circuit components are mounted. Circuit boards for electronic ballasts are typically positioned inside the ballast housing. It is often desirable in the art to minimize the size of ballast housings to minimize the device profile and to reduce production costs. Thus, it is generally desirable to position ballast circuit boards near the interior ballast housing wall to save space.
A circuit board with electrical components mounted on both sides of a circuit board positioned near a ballast housing interior wall places electrical components in close proximity to the housing wall. When circuit components positioned near the ballast housing wall become charged, a charge potential may develop between the charged component and the housing wall. In some instances, the charge potential may induce an electric discharge between the component and the wall. A charge potential between a charged component and an electrical terminal of a nearby circuit component mounted on the same or an adjacent circuit board may also develop, causing a similar electric discharge. Such an event can cause damage to circuit components, often resulting in device malfunction or failure.
Others in the art have attempted to address these potential problems by positioning one or more spacers between the circuit board and the housing wall to create a gap between the circuit board and the electrical components extending from the side of the circuit board facing the housing wall. By separating charged components from the interior housing wall by a sufficient distance, the likelihood of an electric discharge between a component and the housing wall can be reduced. However, increasing the distance between the circuit board and the ballast housing wall undesirably increases the overall device profile.
Others have attempted to prevent electric discharge between charged circuit components and ballast housing walls by forming holes in the circuit board and pouring an electrically insulating liquid filler material through the holes to fill the gap between the prior art circuit board and the wall. The insulating filler forms a shield between the circuit board and the wall, thereby preventing undesirable electric discharge and allowing a reduction of the gap distance between the circuit board and the housing wall for achieving reduced device profile. However, pouring insulating filler into the gap between the prior art circuit board and the housing wall can result in the formation of gaseous bubbles in the filler. A bubble trapped between a charged component and either the ballast housing wall or an adjacent component or component terminal provides a path for component-damaging electric discharge.
Additionally, a circuit board positioned near a housing wall can shift relative to the wall, causing variation in the gap between circuit components and the wall. Gap variations can increase the potential for electric discharge. Others have attempted to use spacers in combination with an insulating filler to prevent circuit board shifting. This prior art approach includes pouring a liquid insulating filler between the circuit board and the housing wall to a depth greater than the height of the circuit board. The filler encapsulates the circuit board in a hardened medium and adheres the circuit board to the housing wall. However, the insulating filler may become weak or deteriorate over time, causing a reduction in the adhesiveness between the filler and the circuit board or the filler and the wall, resulting in detrimental movement of the circuit board relative to the housing.
Still others have attempted to address the problem of electric discharge by positioning a layer of insulating paper between the interior surface of the ballast housing and the insulating filler. The insulating paper aims to prevent discharge between the charged part and the housing wall. However, the layer of insulating paper decreases the thermal conductivity of the ballast housing and reduces heat dissipation through the housing wall, thereby raising the internal ballast housing temperature to an undesirable level, potentially damaging circuit components or causing fire.
Additionally, in one type of discharge lamp, a high voltage is necessary to initially light, or start, the lamp. The high voltage can become unstable, causing fluctuations in circuit performance and causing component or device failure. Others have attempted to stabilize a starting high voltage by mechanically and electrically connecting an earth electrode, or ground connector, on the circuit board to the ballast housing wall using an electrically conductive wire and a screw connector. However, the use of a wire conductor can adversely affect performance of the ballast due to, among other things, inconsistencies between individual wires including differences in the ways individual wires are drawn.
What is needed then is an electronic ballast for a lighting device having a circuit board electrically insulated from the ballast housing wall by an insulating filler and electrically grounded to the housing wall through a spacer having an internal electrical terminal.
The present invention provides a discharge lamp lighting device, or electronic ballast, including a ballast housing defining an interior cavity and having a first interior surface substantially facing the interior cavity. The ballast includes a circuit board positioned in the interior cavity oriented substantially parallel to the first interior surface and including an outer edge defining a circuit board perimeter having substantially the same outer shape as the first interior surface. The circuit board is substantially flat and includes a first side facing substantially toward the first interior surface and a second side facing substantially away from the first interior surface. A ground electrode is positioned on one side of the circuit board.
A plurality of electronic circuit components are mounted on the circuit board, and one of the plurality of electronic circuit components has a distal end extending away from the first side of the circuit board toward the first interior surface. The distal end defines a maximum component distance from the first side of the circuit board. An insulating filler is disposed between the circuit board and the ballast housing. In one embodiment, the insulating filler extends from the first interior surface to the distal end of the electronic circuit component. An electrically conductive spacer includes a first end connected to the first interior surface of the housing and includes a second end contacting the first side of the circuit board. The second end of the spacer defines a fastener hole therein. The circuit board defines a clearance hole extending from the first side to the second side, and the clearance hole overlaps the fastener hole. An electrically conductive fastener is inserted through the clearance hole into the fastener hole so that the fastener contacts both the ground electrode and the spacer.
Another embodiment of the present invention provides a lighting fixture apparatus for providing illumination. The lighting fixture includes a lamp housing shaped for receiving the lamp and an electronic ballast electrically connected to the lamp housing. The electronic ballast includes a ballast housing defining an internal cavity and having a first interior surface. The electronic ballast also includes a circuit board having first and second sides positioned in the internal cavity. The first side of the circuit board faces substantially toward the first interior surface and the circuit board defines at least one clearance hole extending from the first side to the second side and includes a ground electrode at least partially surrounding the clearance hole. The electronic ballast also includes an electrically conductive spacer having a first end connected to the ballast housing and having a second end abutting the first side of the circuit board, the second end defining a fastener engagement hole overlapping the clearance hole. The electronic ballast also includes a metal fastener extending through the clearance hole into the fastener engagement hole. The metal fastener comprises an electrically conductive material and engages in electrical contact with both the ground electrode and the spacer.
Referring to
A substrate, or circuit board, 2 is housed in the ballast housing 1. In one embodiment, the circuit board 2 is substantially planar, substantially rectangular, and is oriented substantially parallel to the first interior surface 44 of the ballast housing 1. The circuit board 2 may have the same shape as the first interior surface 44. The circuit board 2 includes a first side 24 facing substantially toward the first interior surface 44 and a second side 25 substantially facing away from the first interior surface 44. In one embodiment, an earth, or ground, pattern 2c forms an earth, or ground, electrode 2a on the circuit board 2, as seen in
A plurality of electronic circuit components 3 are mounted on the circuit board 2. The circuit components can be mounted on either the first side 24 or second side 25 of the circuit board 2. In one embodiment, the electronic circuit components 3 may be electrically interconnected on the circuit board 2 for powering or regulating a gas-discharge lamp.
Referring now to
Further, as shown in
In one embodiment, an insulating filler 5 is positioned in the ballast housing 1 at least partially between the circuit board 2 and the first interior surface 44. As shown in
Referring now to
Therefore, by sandwiching the circuit board 2 between the spacer 4 and the fastener 9, it is possible to mechanically secure the circuit board 2 without relying on the adhesive nature of the insulating filler. Also, by electrically connecting the ground pattern 2c to the ballast housing 1 through the spacer 4 and fastener 9, it is possible to stabilize the circuit so that a variation in ballast performance (including EMI noise) can be prevented.
Referring now to
The insulating filler 5 may include a minimum insulation performance dimension above which insulation performance and fluidity of the insulation material are guaranteed. In one embodiment, the insulation performance dimension of the insulating filler 5 is 1 mm. By setting the first spatial distance L1 as greater than or equal to 1 mm, the insulating filler 5 is filled up without leaving a gap between the first side 24 of the circuit board 2 and the first interior surface 44 of the ballast housing 1 without its fluidity being inhibited.
Referring again to
In one embodiment, the plurality of electronic components 3 include both insertion terminal components and surface mount components. In one embodiment, only surface mount components are mounted on the first side 24 of the circuit board 2, and only insertion terminal components are mounted on the second side 25 of the circuit board 2. In this one of several embodiments in accordance with the present invention, flow soldering of the first side 24 of the circuit board 2 may be used to simultaneously secure the surface mount and insertion terminal components to the circuit board 2. Referring now to
Referring now to
Referring now to
Referring now to
The notched recess 12a extends a length L3 into the edge of the circuit board 2. In one embodiment, the distance L3 is chosen to be equal to or greater than the insulation performance dimension to ensure fluidity and insulation performance of the insulating filler 5. In one embodiment, the dimension L3 is greater than 1 mm.
Referring now to
Referring now to
The illumination fixture 25 generally includes a ballast A and a lamp housing 15 shaped for receiving a lamp 14. In one embodiment, the fixture 25 is a adapted for receiving a gas-discharge lamp. In one embodiment a cable 13 electrically connects the electronic ballast A to the lamp housing 15, as seen in FIGS. 11A and 11B. Alternately, the lamp housing 15 may be directly connected to the electronic ballast A.
Thus, although there have been described particular embodiments of the present invention of a new and useful Electronic Ballast with Grounding Spacer and Insulating Filler, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.
Number | Date | Country | Kind |
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2009-015951 | Jan 2009 | JP | national |