The present invention relates to the field of lamps, and more specifically to a lamp comprising a burner fixed to a lamp base. In particular, the present invention relates to lamps for use in a vehicle headlight, where the burner comprises a discharge vessel to generate light from an electrical arc discharge generated between electrodes.
In electrical lamps, particularly in high intensity discharge (HID) lamps, reliable connection of housing parts to electrical mass or ground is desirable, both for security reasons and for reduction of electromagnetic interference (EMI). This especially applies for discharge lamps, where the lamp base comprises at least a part of the operating electronics, i.e. a driver circuit for operation of the burner and/or starting apparatus for igniting the arc discharge.
US 2006/0119282 A1 describes a high-pressure discharge lamp having a lamp base with an integrated starting apparatus. An electromagnetic shield is provided, which is connected to the ground reference potential of an operating device. The electromagnetic shield is provided as a metal housing which surrounds the lamp base, and has an aperture for a discharge vessel and for electrical connection of the lamp. The metal housing is made from aluminum or from an aluminum/magnesium alloy, or from a galvanized steel sheet. Inside, a lead frame is provided with electrical components of the starting apparatus, which comprises metallic webs embedded in electrically insulating plastic. A metallic tongue protrudes from the lead frame and out of the interior of the lamp base. In the mounted state, the metallic tongue of the metal web is in electrical and mechanical contact with a wall part of the metal housing. The metallic web, in a similar manner to a leaf spring, bears against the metal housing with a clamping fit.
It is an object of the present invention to provide a lamp with a reliable ground connection to a housing part, which is simple to manufacture.
This object is solved by a lamp according to claim 1. Dependent claims refer to preferred embodiments of the invention.
The lamp according to the invention comprises a burner, preferably a HID burner, fixed to a lamp base. The lamp base comprises at least a metal housing part. Preferably, the lamp base comprises a metal housing at least partly surrounding the lamp base to the sides. Further preferred, the lamp base is fully enclosed in a metal housing, except for an opening to the burner and for an electrical plug/socket connection.
Within the base, electrical contacts are provided, which may be part of operating circuitry or the burner. One of the electrical contacts is an electrical ground contact.
According to the invention, the electrical ground contact is electrically connected to the metal housing part by a contact spring. However, the metal housing part comprises a contact sheet element made out of a different metal material, and the contact spring is arranged to press against the contact sheet to provide an electrical ground connection to the metal housing part.
Thus, the electrical connection of the electrical ground contact within the housing to the metal housing part is established via the contact spring and the contact sheet element.
This construction according to the invention allows to choose the different parts of the metal housing part and of the contact sheet element differently according to their purpose, e.g. with respect to the metal material and thickness thereof. The contact sheet element may be chosen in order to achieve high contact reliability and low contact resistance. Suitable materials include e.g. steel, copper or other metal materials with good contact properties. Preferably the contact sheet may be a thin (e. g. 0.1-0.4 mm thickness) sheet of steel.
The metal housing part, on the other hand serves for stability and for heat conduction and/or radiation. For example, an aluminum material may be preferred. Oxidation on an aluminum material, which may lead to adverse contact properties, is not a problem, because the electrical contact is established via the contact sheet element.
By virtue of the present invention, it is possible to provide a metal housing suitable for the lamp base, while at the same time electrical contact is reliably provided through the contact sheet element.
According to preferred embodiments of the invention, the contact sheet element and the metal housing part are provided as flat metal materials with their surfaces on top of each other. This allows a close connection of the contact sheet element and the metal housing part, ensuring reliable contact. Preferably, the metal housing part has a greater thickness than the contact sheet element.
It is preferred to connect the contact sheet element and the metal housing part by a deformation of both elements, thereby mechanically locking the contact sheet and the metal housing part. For example, the two elements may be connected by a crimping or riveting connection. This type of connection may easily be made during manufacturing, ensuring a both mechanically and electrically reliable connection.
According to a further preferred embodiment of the invention, a holding element for the burner is provided on a top surface of the lamp base. The metal housing part is provided at least at the top surface of the base, oriented towards the burner. The burner holding element, preferably a burner holding ring, may serve to mechanically hold the burner and/or to mechanically fix the lamp to a reflector, e.g. via a bayonet connection. The burner holding element is preferably fixed to the top surface by a deformation of the metal housing part and of the contact sheet element. Thus, by one and the same deformation, which may be e.g. crimping, riveting, bending, etc, the purposes of fixing the burner holding element and of connecting the contact sheet element to the metal housing part are served.
According to a preferred embodiment of the invention, there is a non-conductive holder element disposed within the housing, and the contact spring is fixed to the holder element. Preferably, the electrically insulating holder element is made out of plastic material and disposed within a metal housing. The holder element preferably serves to hold components of the operating circuit for the burner, such as e.g. contact leads of a leadframe and components of a driver circuit and/or ignitor. It is further preferred that the holder element forms an enclosure of a plug/socket connection accessible from the outside to provide an electrical connection of the lamp to an external power supply, such as the onboard electrical supply of a motor vehicle.
Preferably, the non-conductive holder element comprises an opening, and the contact spring extends through the opening to contact the metal housing part via the contact sheet element. This allows to easily fix contact leads and/or electrical components to the holder at an insulation distance from the metal housing.
It is preferred that the lamp base comprises an electrical plug/socket connector with multiple electrical contacts, one of which is an electrical ground/mass contact, electrically connected to the contact spring. The connector further preferably comprises a supply voltage contact and may include a further contact for transmission of control signals.
The contact spring is preferably made from a flat spring material, such as e.g. brass material with nickel plating, or steel. It preferably comprises at least one spring tongue pressing against the contact sheet. Further preferred is to provide multiple elements, such as at least two spring tongues, to improve electrical contact also under adverse mechanical conditions.
These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments hereinafter.
In the drawings,
As visible in particular from the cross-sectional view of
The burner 14 is mechanically held relative to the lamp cap housing 12 by a holding ring structure 32 provided around the burner 14, fixed to a collar of the burner 14 by spot-welded spring tongues.
The lamp base 12 comprises a metal outer housing 40, an inner housing holder element 30, and a bottom plate 44. All of the outer housing wall elements 40, 44 are made out of aluminum as a metal material of good heat conduction properties. The inner holder element 30 is made out of a plastic material.
Within the lamp base 12, electrical components of a lamp operating circuit 50 are arranged. The lamp operating circuit 50 is supplied with electrical power from an electrical plug/socket connector 52 opening to the side of the lamp base 12. For use in a motor vehicle headlamp, the lamp 10 is electrically connected to onboard electrical power and to ground via the connector 52. The lamp operating circuit 50 integrated within the lamp base 12 provides all circuitry required to adapt the voltage supplied at connector 52 to the type of electrical driving voltage and current required for the operation of the burner 14 during ignition, following run-up and steady-state operation. The lamp operating circuit 50 comprises on a printed circuit board 58 and connected thereto circuitry and electrical components for ignition and operation of the lamp 10 as well as a microcontroller for controlling operation of to the burner 14.
As visible from the exploded view shown in
As visible in particular from the cross-sectional view of
As the burner 14 is thus installed to protrude into the lamp cap housing 12, the electrical contact leads from the burner 14, namely the central contact lead 22 and return contact lead 24, also extend into the lamp cap housing 12. In operation of the lamp 10, and in particular during ignition, insulation needs to be provided to prevent flashover between the electrical contact leads 22, 24 as well as from any of the contact leads 22, 24 to components or contact leads of the lamp operating circuit 50 or parts of the lamp cap housing 12. In order to provide this insulation, a plastic cap 60 is provided, covering the central contact lead 22 and the return contact lead 24 axially. The cap 60 serves to provide electrical insulation, in particular between the central contact lead 22 and return contact lead 24, but also between the contact leads 22, 24 and the metal bottom plate 44.
Components of the lamp operating circuit 50 are arranged on a printed circuit board 58 provided within the lamp base 12, holding and electrically interconnecting the electrical circuit components provided thereon. The printed circuit board (PCB) 58 with electrical components mounted on a top surface is arranged directly on the bottom plate 44. Thus, there is close thermal contact between the lamp operating circuit 50 and the bottom plate 44, so that the bottom plate 44 serves as heat sink.
The operating circuit 50 arranged within the base 12 comprises all necessary circuitry, such that the lamp 10 for all modes of operation requires only connection to the onboard voltage of a motor vehicle, which may be supplied at the plug/socket connector 52. The operating circuit 50 includes an ignitor for supplying a high voltage to the burner 14 for igniting an arc discharge within the discharge vessel 18. The operating circuit further comprises a driver circuit for generating an alternating current for operation of the burner 14 in a run-up period after ignition and in subsequent steady-state operation. The operating circuit 50 comprises a micro-controller for control of the operation of the components of operating circuit 50 and of the burner 14.
As shown in
The contact path elements 70 are flat, elongate metal strips or webs. Corresponding to the three contacts 62 of the plug/socket connector 52, there are three contact path elements 70 arranged in parallel within the base 12, extending from the connector 52 to the PCB 58. The contact path elements 70 are bent roughly L-shaped, as shown in
As visible from
The contact path elements 70 are bent at an angle of about 90° to continue as a second section 70b towards the PCB 58, i. e. substantially in parallel to the longitudinal axis X of the lamp 10. The second section 70b of the contact path elements 70 is held and guided by the holder 30, but not fixed thereto. The holder 30 provides an elongate opening, through which the second section 70b of the contact path elements 70a protrudes, such that each of the metal webs is surrounded by the plastic material of the holder 30 in traverse directions. Thus, the second section 70b of the contact path elements 70 is slidably received within the opening of the holder 30, such that it is movable in longitudinal direction while being guided in traverse direction by the enclosing plastic material.
During assembly of the lamp 10, the assembled PCB 58 is connected to the holder 30 as shown in the exploded view of
In order to be able to establish a reliable solder connection, the holder 30 and the contact path elements 70 are pre-assembled with the length of the second section 70b designed for an interference fit, i. e. longer than necessary for an exact 90° bend between the first section 70a and second section 70b of the contact path elements 70. Thus, before assembly, the contact flaps 71b extend out of the holder 30 to protrude a small distance below. As the PCB 58 is fitted, a force acts longitudinally on the second section 70b of a contact path element 70, such that this section of the contact path elements 70 slides longitudinal within the guiding fit of the holder 30. Within the base 12, the holder 30 leaves a spring space 74 free, into which a third section 70c of the contact path elements is received as it is deflected by the force exerted on the second section 70b of the contact path elements 70.
By providing the mentioned oversize, slidable reception and spring space 74, a clamping fit of the contact flaps 71b on the contact surfaces 72 of the PCB 58 is achieved, where a spring force of the deflected third section 70c of the contact path elements 70 achieves a pressing force, pressing the contact flaps 71b onto the contact surfaces 72. Subsequently, the solder connection is made.
The holder 30 comprises an opening 45 which allows access to the contact flaps 71b and contact surfaces 72 for soldering.
As already mentioned, one of the contacts 62 provided at the connector 52 is an electrical ground contact, connected to electrical ground of the motor vehicle. As shown in
The holder 30 includes an opening 78 provided within the top wall 38. The contact spring 76 is fixed to the holder 30 and extends through the opening 78 up to the metal housing 40.
As shown in the partial views of
The burner holding ring 32 includes a flange 33 extending downwardly up to the top surface 80. The burner holding ring 32 is fixed to the base 12 by means of a crimping connection of the top surface 80 of the metal housing 40 with the flange 33. As shown in
As shown in
As already explained, the operating circuit 50 comprises an ignitor for igniting an electrical arc discharge within the discharge vessel 18. The ignitor includes an ignition transformer 54 as shown in
The insulation compound 43 is a silicone insulation compound, which is filled into the insulation chamber 42 in upside-down orientation, as e.g. shown in
During filling of the insulation chamber 42 in the upside-down orientation as shown in
The central opening 28 in the top wall 38 of the holder 30, through which the burner 14 protrudes, is connected with a further opening in the top wall 38, through which the return contact 24 enters the base 12. The retention wall 46 is arranged to surround both openings. Further, the top wall 38 of the holder 30 includes, as already explained, an opening 78 for the ground contact spring 76. The opening 78, as shown in
As shown in the figures, in particular
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments.
Variations of the disclosed embodiment can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure and the appended claims. In the claims, the word “comprising” or “including” does not exclude other elements, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.
Filing Document | Filing Date | Country | Kind |
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PCT/IB2013/052974 | 4/15/2013 | WO | 00 |
Number | Date | Country | |
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61638582 | Apr 2012 | US |