Patent Application
20090146571
The present invention relates to a discharge lamp with high lamp lumen maintenance. It finds particular application in connection with a ceramic metal halide (CMH) lamp with a source of available halogen in the fill and will be described with particular reference thereto.
High Intensity Discharge (HID) lamps are high-efficiency lamps that can generate large amounts of light from a relatively small source. These lamps are widely used in many applications, including highway and road lighting, lighting of large venues such as sports stadiums, floodlighting of buildings, shops, industrial buildings, and projectors, to name but a few. The term “HID lamp” is used to denote different kinds of lamps. These include mercury vapor lamps, metal halide lamps, and sodium lamps. Metal halide lamps, in particular, are widely used in areas that require a high level of brightness at relatively low cost. HID lamps differ from other lamps because their functioning environment requires operation at high temperature and high pressure over a prolonged period of time. Also, due to their usage and cost, it is desirable that these HID lamps have relatively long useful lives and produce a consistent level of brightness and color of light. Although in principle, HID lamps can operate with either an alternating current (AC) supply or a direct-current (DC) supply, in practice, the lamps are usually driven via an AC supply.
Discharge lamps produce light by ionizing a vapor fill material, such as a mixture of rare gases, metal halides and mercury with an electric arc passing between two electrodes. The electrodes and the fill material are sealed within a translucent or transparent discharge vessel that maintains the pressure of the energized fill material and allows the emitted light to pass through it. The fill material, also known as a “dose,” emits a desired spectral energy distribution in response to being excited by the electric arc. For example, halides provide spectral energy distributions that offer a broad choice of light properties, e.g. color temperatures, color renderings, and luminous efficacies.
Such lamps often have a light output that diminishes over time due to blackening of the discharge vessel walls. The blackening is due to tungsten transported from the electrode to the wall. It has been proposed to incorporate a calcium oxide or tungsten oxide oxygen dispenser in the discharge vessel, as disclosed, for example in WO 99/53522 and WO 99/53523 to Koninklijke Philips Electronics N.V.
The exemplary embodiment provides a new and improved metal halide lamp with improved lumen maintenance.
In one aspect of the exemplary embodiment, a lamp includes a discharge vessel. Tungsten electrodes extend into the discharge vessel. An ionizable fill is sealed within the vessel. The fill includes a buffer gas, optionally free mercury, a halide component that includes a rare earth halide selected from the group consisting of lanthanum halides, praseodymium halides, neodymium halides, samarium halides, cerium halides, and combinations thereof, and a source of available halogen. Optionally, a source of available oxygen is present in the discharge vessel. The source of available halogen and optional source of available oxygen are present in an amount such that a solubility of tungsten species in a vapor phase in the ionized fill during lamp operation is lower adjacent to at least a portion of one of the electrodes than at a wall of the discharge vessel, such that tungsten from the electrode that would otherwise be deposited on the wall during lamp operation is transported back to the electrode.
In another aspect, a lamp includes a discharge vessel. Tungsten electrodes extend into the discharge vessel. An ionizable fill is sealed within the vessel. The fill includes a buffer gas, optionally free mercury, a halide component comprising a rare earth halide selected from the group consisting of lanthanum halides, praseodymium halides, neodymium halides, samarium halides, cerium halides, and combinations thereof, and at least one of the group consisting of a) an alkali metal halide, b) an alkaline earth metal halide, and c) a halide of an element selected from indium and thallium. The fill further includes mercury halide at a concentration of at least 0.4 μmol/cm3.
In another aspect, a method of forming a lamp includes providing a discharge vessel, providing tungsten electrodes which extend into the discharge vessel, and sealing an ionizable fill within the vessel. The fill includes a buffer gas, optionally free mercury, a halide component comprising a rare earth halide selected from the group consisting of lanthanum halides, praseodymium halides, neodymium halides, samarium halides, cerium halides, and combinations thereof, and a source of available halogen. Optionally, a source of available oxygen is present in the discharge vessel. The source of available halogen and optional source of available oxygen are present in an amount such that the solubility of tungsten species in a vapor phase of the ionized fill during lamp operation is lower adjacent to at least a portion of an electrode than at a wall of the discharge vessel, such that tungsten from the electrode that would otherwise be deposited on the wall during lamp operation is transported back to the electrode.
One advantage of at least one embodiment is the provision of a ceramic arc tube fill with improved performance and lumen maintenance.
Another advantage of at least one embodiment resides in reduced wall blackening.
Another advantage is that a tungsten regeneration cycle is maintained between a wall of a discharge vessel and a portion of an electrode that is operating at a higher temperature than the wall.
Still further advantages will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiments.
Aspects of the exemplary embodiment relate to a fill for a lamp which is formulated to promote a tungsten regeneration cycle by enabling a higher solubility of tungsten species adjacent the wall of the lamp, where deposition would otherwise occur, than at the electrode, even though the electrode operates at a substantially higher temperature than the wall.
With reference to
The electrodes become heated during lamp operation and tungsten tends to vaporize from the tips 28, 30. Some of the vaporized tungsten may deposit on an interior surface 32 of wall 16. Absent a regeneration cycle, the deposited tungsten may lead to wall blackening and a reduction in the transmission of the visible light.
While the electrodes 20, 22 may be formed from pure tungsten, e.g., greater than 99% pure tungsten, it is also contemplated that the electrodes may have a lower tungsten content, e.g., may comprise at least 50% or at least 95% tungsten.
The exemplary arc tube 12 is surrounded by an outer bulb 36, which is provided with a lamp cap 38 at one end through which the lamp is connected with a source of power (not shown), such as mains voltage. The bulb 36 may be formed of glass or other suitable material. The lighting assembly 10 also includes a ballast (not shown), which acts as a starter when the lamp is switched on. The ballast is located in a circuit that includes the lamp and the power source. The space between the arc tube and outer bulb may be evacuated. Optionally a shroud (not shown) formed from quartz or other suitable material, surrounds or partially surrounds the arc tube to contain possible arc tube fragments in the event of an arc tube rupture.
The interior space 14 has a volume commensurate with the operating voltage of the lamp and sustainable wall loading. For example, for a 70 W lamp, the volume may be about 0.15 cm3 to about 0.3 cm3, e.g., about 0.2 cm3, and for a 250 W lamp, the volume may be about 0.5 cm3 to about 2.0 cm3, e.g., about 1.35 cm3.
The ionizable fill 18 includes a buffer gas, optionally free mercury (Hg), a halide component, a source of available halogen, and optionally a source of available oxygen. The components of the fill 18 and their respective amounts are selected to provide the available halogen at the wall surface 32 for reaction with any tungsten deposited there. The halide component includes a rare earth halide and may further include one or more of an alkali metal halide, an alkaline earth metal halide, and a Group IIIA halide (indium and/or thallium halide). In operation, the electrodes 20, 22 produce an arc between tips 28, 30 of the electrodes that ionizes the fill to produce a plasma in the discharge space. The emission characteristics of the light produced are dependent, primarily, upon the constituents of the fill material, the voltage across the electrodes, the temperature distribution of the chamber, the pressure in the chamber, and the geometry of the chamber. In the following description of the fill, the amounts of the components refer to the amounts initially sealed in the discharge vessel, i.e., before operation of the lamp, unless otherwise noted.
The buffer gas may be an inert gas, such as argon, xenon, krypton, or combination thereof, and may be present in the fill at from about 5-20 micromoles per cubic centimeter (μmol/cm3) of the interior chamber 14. The buffer gas may also function as a starting gas for generating light during the early stages of lamp operation.
In one embodiment, suited to CMH lamps, the lamp is backfilled with Ar. In another embodiment, Xe or Ar with a small addition of Kr85 is used. The radioactive Kr85 provides ionization that assists in starting the lamp. The cold fill pressure may be about 60-300 Torr, although higher cold fill pressures are not excluded. In one embodiment, a cold fill pressure of at least about 120 Torr is used. In another embodiment, the cold fill pressure is up to about 240 Torr. Too high a pressure may compromise starting. Too low a pressure can lead to increased lumen depreciation over life. During lamp operation, the pressure of the buffer gas may be at least about 1 atm.
The mercury dose may be present at from about 3 to 35 mg/cm3 of the arc tube volume. In one embodiment, the mercury dose is about 20 mg/cm3. The mercury weight is adjusted to provide the desired arc tube operating voltage (Vop) for drawing power from the selected ballast. In an alternative embodiment, the lamp fill is mercury-free.
The halide component may be present at from about 20 to about 80 mg/cm3 of arc tube volume, e.g., about 30-60 mg/cm3. A ratio of halide dose to mercury can be, for example, from about 1:3 to about 15:1, expressed by weight. The halide(s) in the halide component can each be selected from chlorides, bromides, iodides and combinations thereof. In one embodiment, the halides are all iodides. Iodides tend to provide longer lamp life, as corrosion of the arc tube and/or electrodes is lower with iodide components in the fill than with otherwise similar chloride or bromide components. The halide compounds usually will represent stoichiometric relationships.
The rare earth halide of the halide component is one that is selected in type and concentration such that it does not form a stable oxide by reactions with the optional source of oxygen, i.e., forms an unstable oxide. By this it is meant that it permits available oxygen to exist in the fill during lamp operation. Exemplary rare earth halides which form unstable oxides include halides of lanthanum (La), praseodymium (Pr), neodymium (Nd), samarium (Sm), cerium (Ce), and combinations thereof. The rare earth halide(s) of the fill can have the general form REX3, where RE is selected from La, Pr, Nd, Sm, and Ce, and X is selected from Cl, Br, and I, and combinations thereof. The rare earth halide may be present in the fill at a total concentration of, for example, from about 3 to about 13 μmol/cm3. An exemplary rare earth halide from this group is cerium halide, which may be present at a molar concentration of at least 2% of the halides in the fill, e.g., at least about 8 mol % of the halides in the fill. In one embodiment, only rare earth halides from this limited group of rare earth halides are present in the fill. The lamp fill thus is free of other rare earth halides, by which it is meant that all other rare earth halides are present in a total amount of no more than about 0.1 μmol/cm3. In particular the fill is free of halides of the following rare earth elements: terbium, dysprosium, holmium, thulium, erbium, ytterbium, lutetium, and yttrium. Other halides which form stable oxides are also not present in the fill, such as scandium halides and magnesium halides.
The alkali metal halide, where present, may be selected from sodium (Na), potassium (K), and cesium (Cs) halides, and combinations thereof. In one specific embodiment, the alkali metal halide includes sodium halide. The alkali metal halide(s) of the fill can have the general form AX, where A is selected from Na, K, and Cs, and X is as defined above, and combinations thereof. The alkali metal halide may be present in the fill at a total concentration of, for example, from about 20 to about 300 μmol/cm3.
The alkaline earth metal halide, where present, may be selected from calcium (Ca), barium (Ba), and strontium (Sr) halides, and combinations thereof. The alkaline earth metal halide(s) of the fill can have the general form MX2, where M is selected from Ca, Ba, and Sr, and X is as defined above, and combinations thereof. In one specific embodiment, the alkaline earth metal halide includes calcium halide. The alkaline earth metal halide may be present in the fill at a total concentration of, for example, from about 10 to about 100 μmol/cm3. In another embodiment, the fill is free of calcium halide.
The group IIIa halide, where present, may be selected from thallium (Tl) and indium (In) halides. In one specific embodiment, the group IIIa halide includes thallium halide. The group IIIa halide(s) of the fill may have the general form LX or LX3, where L is selected from Tl and In, and X is as defined above. The group IIIa halide may be present in the fill at a total concentration of, for example, from about 1 to 10 μmol/cm3.
The source of available halogen is generally an unstable halide or other halogen containing compound that is capable of increasing the concentration of vapor phase WO2X2, through one or more reactions occurring during lamp operation, where X is as defined above. The source of free halogen may be a compound capable of reacting directly or indirectly with tungsten metal, tungsten-containing species, or a compound of tungsten to form WO2X2. The source of available halogen may be a halide selected from mercury halides, such as HgI2, HgBr2, HgCl2, and combinations thereof.
In general, the source of free halogen is not a rare earth halide or a halide of indium, thallium, sodium, magnesium, potassium, cesium, calcium, barium, or strontium or any halide that binds the halogen more tightly than tungsten, making it unavailable for reaction. In the case of iodide, the source of available halogen may be present in the fill at a total concentration, expressed in terms of its I2 content of, for example, at least about 0.4 moles/cm3, e.g., from 0.4-7 micromoles/cm3 and in one embodiment, from about 1-3 micromoles/cm3. In the case of HgBr2 and HgCl2, the WO2Br2 or WO2Cl2 complex formed during lamp operation is more stable than for the corresponding WOI2 compound, and thus lower amounts of HgBr2 or HgCl2 can be used than for HgI2. The source of available halogen may be present in sufficient quantity to provide an available halogen (e.g., I2 or other reactive halogen species) concentration in the fill, during lamp operation, of at least about 0.4 μmol/cm3.
The source of available oxygen is one which, under the lamp operating conditions, makes oxygen available for reaction with other fill components to form WO2X2. The source of available oxygen gas may be an oxide which is unstable under lamp operating temperatures, such as an oxide of tungsten, free oxygen gas (O2), water, molybdenum oxide, mercury oxide, or combination thereof. The oxide of tungsten may have the general formula WOnXm, where n is at least 1, m can be 0, and X is as defined above. Exemplary tungsten oxides include WO3, WO2, and tungsten oxyhalides, such as WO2I2. The source of available oxygen may be present in the fill expressed in terms of its O2 content at, for example, from about 0.1 μmol/cm3, e.g., from 0.2-3 μmol/cm3 and in one embodiment, from 0.2-2.0 μmol/cm3. As will be appreciated, certain oxides do not decompose readily to form available oxygen under lamp operating conditions, such as cerium oxide and calcium oxide, and thus do not tend to act effectively as sources of oxygen. In general, most oxides of rare earth elements are not suitable sources of available oxygen as they are stable at lamp operating temperatures.
In one embodiment, the tungsten electrode is partially oxidized to form tungsten oxide, e.g., a spot on its surface is thermally oxidized prior to insertion into the lamp, to provide the source of available oxygen. In other embodiments, comminuted tungsten oxide, such as tungsten oxide chips, may be introduced in the fill.
Where both tungsten oxide and mercury halide are present in the fill, one or both of them may be present at lower amounts than those indicated above. For example tungsten oxide and mercury halide are present in the fill in sufficient amount for the following equation to be satisfied:
0.2≦(A+2B)≦12
where A is the amount of mercury halide in μmol/cm3, and B is the amount of tungsten oxide, expressed in terms of μmol O2/cm3.
In one embodiment:
0.4≦(A+2B)≦6
In general the mercury halide and WO3 are present in sufficient amount to allow at least 1×10−9 μmol/cm3 of WO2I2 (as vapor) to be present in the fill during lamp operation (i.e., once tungsten has formed on the wall).
In various embodiments, the lamp fill, when the lamp is formed, i.e. before operation, consists essentially of a buffer gas, optionally free mercury, optionally tungsten oxide, and a halide component consisting essentially of mercury halide, a rare earth halide selected from the group consisting of lanthanum halides, praseodymium halides, neodymium halides, samarium halides, cerium halides, and combinations thereof, and at least one of an alkali metal halide, an alkaline earth metal halide and a halide of an element selected from In and Tl.
Exemplary fill compositions for 70 W and 250 W lamps may be formulated as shown in Table 1, where one or both of HgI2 and WO3 may be present.
The fill is formulated to provide conditions which favor regeneration, i.e., favor the solubility of tungsten in the fill 18 at the wall 32 while favoring the redeposition of the solubilized tungsten at the electrode(s) 20, 22. The electrode temperature during lamp operation may be about 2500-3200K at the electrode tip 28, 30, and in one embodiment, is maintained at a temperature of less than about 2700K. Regeneration can be achieved by selecting the lamp fill to provide a higher solubility of tungsten species adjacent the wall than at the electrode tip.
The regeneration is achieved even though the wall 32 of the discharge vessel, where significant tungsten deposition would otherwise occur, is at a lower temperature than the electrode tip 28 or 30 (or other portion of the electrode on which the tungsten is redeposited). For example, the wall may be at a temperature that is at least 200K lower than the portion of the electrode on which redeposition occurs, and in general, is at least 500K lower.
Where SPWTe is the SPW at the temperature of the electrodes 20, 22 (2600K) and SPWTs is the SPW at the temperature of the wall surface 32. This means is that if the value is <0, the SPW established by vapor/W equilibrium at the arctube wall, i.e., by vapor in contact with W deposited on the wall, is larger than the SPW for at least one point on the electrode surface, thus there is a driving force for W deposition from the vapor phase to the electrode for at least that one point—and perhaps over wider regions if the value is <0 over a range of electrode temperatures. In general, lower supersaturation values are more favorable, although if the supersaturation value becomes too negative, it may be undesirable. Values within the range shown in
Knowing the temperature of the arc tube wall 32 in the region where blackening due to tungsten deposition is most likely to occur and the temperature of the electrode tip 28, 30, in lamp operation, a suitable amount of HgI2 or WO3 can be determined which favors regeneration while minimizing the effect on other lamp properties. While the plots consider HgI2 and WO3 independently, it will be appreciated that similar plots could be created for combinations of HgI2 and WO3 and appropriate amounts of the two compounds selected.
Without being bound by any particular theory, it is believed that HgI2 and WO3 both lead to an increase in concentrations of WO2I2 and HgI2 in the vapor and thus are capable of decreasing W supersaturation and increasing wall cleaning. It is believed that HgI2 reacts with Al11CeO18 (formed by reaction of alumina in the arc tube wall with CeI3 in the fill) and with the deposited W to form WO2I2. In the case of WO3, this reacts with CeI3 (and Hg) to form WO2I2 and HgI2.
By way of example,
Because WO3 tends to reduce the amount of CeI3 present in the fill, the concentration of WO3 in the fill, in general, should not be so high that it impacts the color rendering of the lamp significantly. Additionally, in vertically operating lamps where a temperature gradient exists between the electrodes, it is desirable to avoid high concentrations of tungsten oxide to avoid excessive transport of tungsten between the two electrodes 20, 22.
In various aspects, the ballast is selected to provide the lamp, during operation, with a wall loading of at least about 30 W/cm2. The wall loading may be at least about 50 W/cm2, and in some embodiments, about 70 W/cm2, or higher. Below about 25-30 W/cm2, the arc tube walls tend to be too cool for efficient maintenance of the active tungsten halogen cycle. As defined herein, the arc tube wall loading (WL)=W/A where W is the total arc tube power in watts and A is the area in cm2 of the arc tube wall which is located between the electrode tips 28, 30. The arc tube power is the total arc tube power including electrode power. In general the dose and wall loading are sufficient to maintain a wall temperature of at least about 1000K, e.g., 1000-1400K.
The ceramic metal halide arc tube 12 can be of a three part construction, and may be formed, for example, as described, for example, in any one of U.S. Pat. Nos. 5,866,982; 6,346,495; 7,215,081; and U.S. Pub. No. 2006/0164017. It will be appreciated that the arc tube 12 can be constructed from fewer or greater number of components, such as one or five components. The parts are formed as green ceramic and bonded in a gas tight manner by sintering or other suitable method. An exemplary arc tube can be constructed by die pressing, injection molding, or extruding a mixture of a ceramic powder and a binder into a solid cylinder. The ceramic powder may comprise high purity alumina (Al2O3), optionally doped with magnesia. Other ceramic materials which may be used include non reactive refractory oxides and oxynitrides such as yttrium oxide, lutetium oxide, and hafnium oxide and their solid solutions and compounds with alumina such as yttrium-aluminum-garnet and aluminum oxynitride. Binders which may be used individually or in combination include organic polymers such as polyols, polyvinyl alcohol, vinyl acetates, acrylates, cellulosics and polyesters. Subsequent to die pressing/extrusion, the binder is removed from the green part, typically by thermal pyrolysis, e.g., at about 900-1100° C., to form a bisque-fired part. The sintering step may be carried out by heating the bisque-fired parts in hydrogen at about 1850-1880° C. The resulting ceramic material comprises a densely sintered polycrystalline alumina.
In other embodiments, the arc tube is formed of quartz glass and can be formed of one piece.
The exemplary lamp finds use in a variety of applications, including highway and road lighting, lighting of large venues such as sports stadiums, floodlighting of buildings, shops, industrial buildings, and in projectors.
Without intending to limit the scope of the present invention, the following example demonstrates the formation of lamps with improved lumen maintenance.
Arc tubes 12 were formed according to the shape shown in
The lamps were run in a standard burning cycle (11 hrs. on followed by 1 hour off) for extended periods in a horizontal orientation (i.e., at 90 degrees to that illustrated in
Table 3 shows the results obtained after 100 hrs. V is the burning voltage. Lumens is the lumen output of the lamp. X color and Y color are the chromaticity X and Y, respectively, on a standard CIE (Commission Internationale de l'Eclairage) chromaticity diagram in which the chromaticity coordinates X and Y represent relative strengths of two of the three primary colors. CRI is the color rendering index, and is a measure of the ability of the human eye to distinguish colors by the light of the lamp, higher values being favored. CCT is the correlated color temperature of the lamp, which is the color temperature of a black body which most closely matches the lamp's perceived color. dCCy is the difference in chromaticity of the color point, on the Y axis (Y color), from that of the standard black body curve. The results are the mean of about 5 lamps. As can be seen from Table 3, the exemplary lamps B, C, D, and F have good characteristics, as compared with the control lamps.
The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations.
