Lamp with internally attached eyelet lead, and method therefor

Information

  • Patent Grant
  • 6653770
  • Patent Number
    6,653,770
  • Date Filed
    Wednesday, July 19, 2000
    23 years ago
  • Date Issued
    Tuesday, November 25, 2003
    20 years ago
Abstract
Without applying soldering or plasma arc welding, a lead wire is brought into connection with an eyelet easily and reliably so that lighting failure due to incomplete contact is prevented and cost saving is achieved. A base (7) has a screw form shell (8) and an eyelet (9). An end portion of the shell (8) is provided with the eyelet (9) via an insulator. A lead wire (11a) supplying power is brought into connection with a portion of the eyelet (9) at other than an outer surface of the eyelet.
Description




FIELD OF THE INVENTION




The present invention relates to bulb-form lamps.




BACKGROUND OF THE INVENTION




In a conventional lamp such as a bulb-form fluorescent lamp, as shown in

FIG. 6

, a fluorescent tube


4


, a lighting circuit


5


to light this fluorescent tube


4


, and two lead wires


11




a


and


11




b


brought into connection with this lighting circuit


5


and supplying power thereto are housed in an envelope


19


comprising a globe


1


and a case


18


.




At one end of the case


18


, a base


20


is screwed in. This base


20


has a screw-form shell


20




a


and an eyelet


20




c


provided at one end of this shell


20




a


via glass-made insulator


20




b


. Portions respectively of the shell


20




a


and the eyelet


20




c


are embedded into the insulator


20




b


, and thereby the shell


20




a


, the insulator


20




b


, and the eyelet


20




c


are integrated.




One lead wire


11




a


is brought into connection with the base


20


on the outside, that is, onto the outer surface of the eyelet


20




c


by soldering.




Also, the lead wire


11




a


and the eyelet


20




c


are brought into connection by plasma arc welding from the environmental view point.




The manufacturing method of such a conventional lamp is as follows.




After an envelope


19


, a fluorescent tube


4


, and a lighting circuit


5


with which lead wires


11




a


and


11




b


are brought into connection are assembled by means of a normal method, the base


20


is screwed into one end portion of the case


18


and undergoes caulking to be fixed into the case


18


. In that occasion, one lead wire


11




a


is arranged to be led out from a through hole


20




d


formed in the eyelet


20




c


. In addition, the portion led out from this lead wire


11




a


is brought into connection with the outer surface of the eyelet


20




c


by means of soldering or plasma arc welding.




However, in such a conventional lamp, in the case where the lead wire


11




a


is brought into connection with the eyelet


20




c


, flux (resin, etc.) used for soldering is formed as a film on the surface of soldering, and therefore, such a base


20


installed in a socket (not shown) of an illumination equipment causes the contact between the eyelet


20




c


and the socket to be incomplete. In addition, the eyelet


20




c


is corroded by this flux so that the eyelet


20




c


suffers from incomplete contact with the socket. There was a problem that due to such incomplete contact, lamps fail to be lighted.




In addition, there was a problem that the case where the lead wire


11




a


is brought into connection with the eyelet


20




c


by means of plasma arc welding gives rise to total costs since the plasma arc welding apparatus is expensive, requires a large installation space, and needs a lot of maintenance work.




The present invention has been achieved to solve these problems, and provides a low cost bulb-form lamp and a manufacturing method therefor, in which a lead wire is brought into connection with an eyelet easily and reliably without applying soldering or plasma arc welding, thereby preventing lighting failure due to incomplete contact is prevented.




DISCLOSURE OF THE INVENTION




A bulb-form lamp of the present invention includes a base having a screw form shell and an eyelet provided at an end portion of this shell via an insulator, and is configured so that a lead wire supplying power is brought into connection with a portion of the eyelet at other than the outer surface of the eyelet.




In addition, a first manufacturing method of a bulb-form lamp of the present invention is a method for manufacturing a bulb-form lamp including a base having a screw form shell and an eyelet provided in an end portion of this shell via an insulator, wherein a lead wire supplying power is brought into connection with a portion of the eyelet at other than the outer surface of the above described eyelet, comprising the steps of: leading out the lead wire from an eyelet receiving section formed in the insulator; bringing an end portion of the led out lead wire into connection with the eyelet; and fitting the eyelet into the eyelet receiving section.




The above described lamp and the manufacturing method therefor can bring the lead wire into connection with the eyelet easily and reliably without applying soldering or plasma arc welding and therefore, the failure of lighting due to incomplete contact can be prevented and cost saving can be achieved.




A second manufacturing method of the present invention is a method for manufacturing a bulb-form lamp including a base having a screw form shell and an eyelet provided at an end portion of this shell via an insulator, wherein a lead wire supplying power is brought into connection with a portion of the eyelet at other than the outer surface of the eyelet, comprising the steps of: leading out the lead wire from an eyelet receiving section formed in the insulator; disposing the led out lead wire along a side surface of the eyelet receiving section; fitting the eyelet into the eyelet receiving section; and sandwiching the lead wire between the eyelet and the insulator.




According to the above described manufacturing method, the lead wire can be brought into connection with the eyelet easily and reliably without applying soldering or plasma arc welding and therefore, the failure of lighting due to incomplete contact can be prevented and cost saving can be achieved. Also, without applying caulking or resistance welding, the lead wire can be brought into connection with the eyelet, and thus the manufacturing process can be simplified and production efficiency can be improved.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a partially cut away front view of a bulb-form fluorescent lamp according to a first embodiment of the present invention;





FIG. 2

is an enlarged sectional view of an essential part of the bulb-form fluorescent lamp;





FIG. 3

is an enlarged sectional view of an essential part of a bulb-form fluorescent lamp according to a second embodiment of the present invention;





FIG. 4

is an enlarged sectional view of an essential part of a bulb-form fluorescent lamp according to a third embodiment of the present invention;





FIG. 5

is a front section of an eyelet for use in the bulb-form fluorescent lamp; and





FIG. 6

is a partially cut away front view of a conventional bulb-form fluorescent lamp.











PREFERRED EMBODIMENTS




Preferred embodiments of the present invention will be described as follows with reference to accompanying drawings.




A bulb-form fluorescent lamp of the rated power of 13W according to a first embodiment of the present invention is sized with total length of 120 mm and with maximum outer diameter of 60 mm. As shown in

FIG. 1

, a fluorescent tube


4


with outer diameter of 11 mm with three U-form tubes


4




a


being brought into bridge connection forming one discharge route, a lighting circuit


5


to light this fluorescent tube


4


, and a holder


6


holding an end portion of the fluorescent tube


4


and holding a lighting circuit


5


on the opposite end against the fluorescent tube


4


are housed inside an envelope


3


consisting of a transparent globe


1


and a case


2


made of resin. In addition, a cylindrical portion


2




a


formed in one end portion of the case


2


is provided with a base


7


.




The both end portions of the fluorescent tube


4


are provided with electrodes (not shown). In addition, inside the fluorescent tube


4


, predetermined quantities of respective mercury and rare gas are sealed in.




The base


7


consists of a screw-shaped shell


8


and a thrust-pin-shaped eyelet


9


.




A portion of the case


2


is interposed between the shell


8


and the eyelet


9


, and this portion of the case


2


functions as an insulator to insulate the shell


8


from the eyelet


9


.




The shell


8


is fixed at a cylindrical section


2




a


of the case


2


.




As shown in

FIG. 2

, the eyelet


9


comprises a cylinder-shaped barrel section


9




a


with 7 mm length and 3 mm maximum outer diameter and a circular convex head portion


9




b


with 10 mm outer diameter at its outer periphery.




In addition, this eyelet


9


is fitted into the eyelet receiving section


10


formed at the tip of the cylinder section


2




a


of the case


2


.




Moreover, a protruding engaging section


9




c


is provided on the side surface of the barrel section


9




a


of the eyelet


9


. In addition, this engaging section


9




c


is engaged with a to-be-engaged portion


10




a


provided on the inner surface of the eyelet receiving section


10


. Consequently, after the eyelet


9


is fitted into the eyelet receiving section


10


, the eyelet


9


can be prevented from being removed from the eyelet receiving section


10


.




The lighting circuit


5


is brought into connection with two lead wires


11




a


and


11




b


each having a conductor portion with 0.5 mm diameter. One lead wire


11




a


is inserted in a lead wire insertion section


9




d


formed inside the barrel section


9




a


of the eyelet


9


and in caulked so as to be brought into connection with the eyelet


9


. Insertion section


9




d


formed inside the barrel section


9




a


is a blind hole, i.e., a hole having a closed end and a single open end that opens into the interior of the cylinder section


2




a


of the lamp. That is, the lead wire


11




a


is brought into connection with the eyelet


9


at a portion other than the outer surface. Here, the outer surface of the eyelet


9


refers to a surface facing a terminal of the socket contacting the eyelet


9


at the time when the base


7


is attached to the socket (not shown) of the illumination equipment.




In addition, the other end of the lead wire


11




b


is brought into connection with an end section of the shell


8


by soldering or the like on the side opposite from the eyelet


9


via a through hole


2




b


provided in the case


2


.




Incidentally, the lead wire


11




a


, which is inserted into the lead wire insertion section


9




d


, is brought into connection with the eyelet


9


by caulking, or otherwise may be brought into connection by resistance welding instead of caulking.




Next a manufacturing method of such a bulb-form fluorescent lamp will be described as follows.




Following a normal method without any change, the case


2


and the globe


1


are attached and integrated with the fluorescent tube


4


and the lighting circuit


5


held by the holder


6


. At the same time, the lead wire


11




a


is led out from the eyelet receiving section


10


.




In addition, the led out lead wire


11




a


is inserted into the lead wire insertion section


9




d


of the eyelet


9


and they are caulked together for connection. Thereafter, the eyelet


9


connected with the lead wire


11




a


is fitted into the eyelet receiving section


10


. Thus, the bulb-form fluorescent lamp is manufactured.




Incidentally, following a normal method without any change, the lead wire


11




b


is brought into connection with the shell


8


.




According to the above described configuration of the present invention, the lead wire


11




a


can be brought into connection with the eyelet


9


easily and reliably without applying soldering or plasma arc welding and therefore, the lighting failure due to incomplete contact can be prevented and cost saving can be achieved.




In addition, the head


9




b


of the eyelet


9


is convexly shaped so that contact between the eyelet


9


and the socket of lighting equipment can be made in a further ensured manner.




Next, a bulb-form fluorescent lamp according to a second embodiment of the present invention is configured the same as the bulb-form fluorescent lamp of the rated power 13 W according to the first embodiment of the present invention as shown in

FIG. 3

, with an exception that the lead wire


11




a


is sandwiched between the thrust-pin-shaped eyelet


12


and the case


13


that is in the eyelet receiving section


14


.




The portion of the lead wire


11




a


being sandwiched is brought into an L-bent state.




The eyelet


12


has a cylinder-shaped barrel section


12




a


with 7 mm length and 3 to 6 mm outer diameter and a circular convex head portion


12




b


with 10 mm diameter at its outer periphery. Inside this barrel section


12




a


, no lead wire insertion section


9




d


as in the above described embodiment is provided.




A protruding engaging section


12




c


is provided on the side surface of the barrel section


12




a


of the eyelet


12


. In addition, this engaging section


12




c


is engaged with the inner surface of the cylinder section


13




a


formed at an end section of the case


13


. Thus, with the engaging section


12




c


being provided in the eyelet


12


, after the eyelet


12


is fitted into the eyelet receiving section


14


, the eyelet


12


can be prevented from being removed from the eyelet receiving section


14


.




The manufacturing method of this bulb-form fluorescent lamp is as follows.




Following a normal method without any change, the case


13


and the globe


1


are attached and integrated with the fluorescent tube


4


and the lighting circuit


5


being held by the holder


6


. Before the eyelet


12


is fitted into the eyelet receiving section


14


, the lead wire


11




a


is disposed along the inner surface of the eyelet receiving section


14


in advance and then the eyelet


12


is fitted into the eyelet receiving section


14


. Thereby, the lead wire


11




a


is sandwiched between the eyelet


12


and the case


13


that is in the eyelet receiving section


14


, and brought into connection with the eyelet


12


. Thus, the bulb-form fluorescent lamp is manufactured.




According to the above described configuration of the present invention, the lead wire


11




a


can be brought into connection with the eyelet


12


easily and reliably without applying soldering or plasma arc welding and therefore, the failure of lighting due to incomplete contact can be prevented and cost saving can be achieved. Also, without applying caulking or resistance welding, the lead wire


11




a


can be brought into connection with the eyelet


12


, and thus the manufacturing can be simplified and production efficiency can be improved.




In addition, the lead wire


11




a


is sandwiched in an L-bent state so that the lead wire


11




a


is less liable to be removed from the location between the eyelet


12


and the eyelet receiving section


14


or the tip end of the case


13


.




Next, a bulb-form fluorescent lamp according to a third embodiment of the present invention is configured the same as the bulb-form fluorescent lamp of the rated power 13 W according to the first embodiment of the present invention as shown in FIG.


4


and

FIG. 5

, with an exception that the eyelet


15


formed with a plate member concavely press-molded is fitted into the eyelet receiving section


17


of the case


16


.




The eyelet


15


has a thickness of 0.3 mm to 1.0 mm.




As shown in

FIG. 4

, an lead wire insertion section


15




b


is provided on part of an outer periphery


15




a


of an eyelet


15


. The lead wire


11




a


is, for example, inserted into this lead wire insertion section


15




b


and caulked so as to be brought into connection with the eyelet


15


.




In addition, a plate form engaging section


15




c


is provided on the outer periphery of the eyelet


15


. This engaging section


15




c


is bent inward a little after being inserted into a through hole


17




b


to be described later. Thus bent engaging section


15




c


can serve to prevent removal of the eyelet receiving section


17


from the eyelet


15


.




This eyelet receiving section


17


is provided with a dent


17




a


into which the outer periphery section


15




a


is fitted, a through hole section


17




b


into which the lead wire insertion section


15




b


is thrust, and a through hole section (not shown) into which the engaging section


15




c


is thrust.




The manufacturing method of this bulb-form fluorescent lamp is the same as for the bulb-form fluorescent lamp according to the first embodiment of the present invention.




According to the above described configuration, the lead wire


11




a


can be brought into connection with the eyelet


15


easily and reliably without applying soldering or plasma arc welding and therefore, the failure of lighting due to incomplete contact can be prevented. Also, since the eyelet


15


can be easily formed, cost saving can be achieved.




Although the case where the lead wire


11




a


is inserted into the lead wire insertion section


15




b


and undergoes caulking has been described in the foregoing third embodiment, in other cases, for example, where the lead wire


11




a


is sandwiched between the eyelet


15


and the case


16


or where the lead wire


11




a


undergoes resistance welding to be connected to the eyelet


15


, the same effect as described above can be afforded.




The bulb-form fluorescent lamp has been described in the foregoing first to third embodiments, but without limiting to this, all types of lamps using a base, such as incandescent lamps, reflector lamps or high-pressure discharge lamps, can also afford the same effect as described above.



Claims
  • 1. A bulb-form lamp comprising a base having a screw-form shell and an eyelet provided at an end portion of the shell via an insulator wherein:a lead wire insertion section of the eyelet has an attached lead wire for supplying power, and the base comprises a through hole, the hole having located therein the lead wire insertion section and attached lead wire, wherein the attached lead wire extends from an eyelet portion other than the outer surface of the eyelet into the interior of the lamp.
  • 2. The lamp according to claim 1, further comprising caulking applied to the attached lead wire, thereby connecting the lead wire with the eyelet.
  • 3. The lamp according to claim 1, wherein the lead wire and the eyelet are brought into connection by applying resistance welding.
  • 4. The lamp according to claim 1, wherein the eyelet comprises an engaging section for engagement with the insulator.
  • 5. The lamp according to claim 1, wherein the eyelet is formed by concavely press-molding a plate member.
  • 6. The lamp according to claim 1, wherein the eyelet has a convex shaped head.
  • 7. The lamp according to claim 1, further including a lighting circuit to light a fluorescent tube, and a case housing the lighting circuit, wherein the lead wire is brought into connection with the lighting circuit and the insulator is a part of the case.
  • 8. The lamp according to claim 1, wherein said eyelet comprises an engaging section for locking engagement in a hole located in the insulator.
  • 9. A manufacturing method of a bulb-form lamp including a base having a screw form shell and an eyelet located at an end portion of the shell via an insulator, comprising:leading out a lead wire from an eyelet receiving section formed in the insulator; attaching an end portion of the led out lead wire to the eyelet at a portion of the eyelet other than the outer surface of the eyelet; and fitting the eyelet into the eyelet receiving section.
  • 10. The manufacturing method according to claim 9, further comprising connecting the lead wire to the eyelet by resistance welding.
  • 11. The manufacturing method according to claim 9, further comprising forming an eyelet by concavely press-molding a plate member.
Priority Claims (1)
Number Date Country Kind
11-213293 Jul 1999 JP
US Referenced Citations (2)
Number Name Date Kind
2336529 Cartun Dec 1943 A
5568009 Gandhi Oct 1996 A
Foreign Referenced Citations (2)
Number Date Country
59121757 Jul 1984 JP
4-94003 Mar 1992 JP