CN107799385B

CN107799385B - Sealing structure for discharge lamp, and discharge lamp provided with same

Info

Publication number: CN107799385B
Application number: CN201710556145.3A
Authority: CN
Inventors: 高桥浩; 乡田哲也; 山田敬重
Original assignee: Phoenix Electric Co Ltd
Current assignee: Phoenix Electric Co Ltd
Priority date: 2016-09-01
Filing date: 2017-07-10
Publication date: 2021-02-26
Anticipated expiration: 2037-07-10
Also published as: JP6727650B2; CN107799385A; JP2018037320A

Abstract

A discharge lamp and a sealing structure thereof are provided, which are composed of a light emitting tube (12), an electrode supporting rod (38), an electrode side distribution board (18), an external lead bar (20), an outer side distribution board (22), a glass member (24) welded to the inner surface of a sealing part (34), and a current conducting member (26) for electrically connecting the electrode side distribution board (18) and the outer side distribution board (22). The current-carrying member (26) is composed of at least a second current-carrying member (63) and a first current-carrying member (62) disposed on the center side of the sealing portion (34) with respect to the second current-carrying member (63) and disposed between the electrode-side power distribution board (18) and the outer-side power distribution board (22) so as not to directly contact the second current-carrying member (63). The glass member (24) is composed of at least a second glass material (49) disposed between the first and second current-carrying materials (62, 63) and a first glass material (48) disposed closer to the center of the seal (34) than the first current-carrying material (62).

Description

Sealing structure for discharge lamp, and discharge lamp provided with same

Technical Field

The present invention relates to a sealing structure of a discharge lamp through which a large lighting current can flow, and a discharge lamp provided with the same.

Background

In a general discharge lamp, a sealing portion is provided at an end portion of a glass arc tube, and an internal space is formed in the arc tube. On the other hand, each of the pair of electrodes is composed of an electrode rod, a metal foil electrically connected to an end of the electrode rod, and an external lead bar electrically connected to the metal foil, and is embedded in the sealing portion around a portion of the metal foil, thereby sealing the inside space of the arc tube from the outside.

For example, in the discharge lamp disclosed in patent document 1, conductive disk members are provided on an electrode rod (electrode support rod) and an external lead rod, respectively, in a sealing portion, and a metal foil is provided between these conductive disk members. Thus, the current supplied from the outside to the discharge lamp is supplied from the external lead bar to the electrode bar via the metal foil, and flows to the external lead bar on the opposite side through the electrode.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2012-209168

Disclosure of Invention

Problems to be solved by the invention

However, in the field of semiconductor or liquid crystal manufacturing, the discharge lamp is being increased in power to improve the production efficiency. Since the voltage applied to the discharge lamp is determined by factors such as the distance between electrodes, the discharge lamp is mainly increased in power by increasing the lighting current of the discharge lamp.

Therefore, a sealing structure of a discharge lamp that can pass a larger lighting current than the discharge lamp disclosed in patent document 1 is required.

The present invention has been developed in view of such problems of the prior art. Accordingly, a main object of the present invention is to provide a sealing structure of a discharge lamp that can pass a larger lighting current than a conventional discharge lamp, and a discharge lamp provided with the same.

Means for solving the problems

(1)

According to one aspect of the present invention, there is provided a sealing structure for a discharge lamp, comprising:

a light emitting tube having a light emitting tube portion and a sealing portion, the light emitting tube portion having an internal space;

an electrode support rod supporting the electrode disposed in the internal space;

an electrode-side distribution board electrically connected to the electrode support rod;

an external lead bar;

an outer distribution board electrically connected to the external lead bar;

a glass member disposed in the sealing portion and welded to an inner surface of the sealing portion; and

a current-carrying member disposed in the sealing portion and electrically connecting the electrode-side power distribution board and the outer power distribution board,

the conductive member has at least a first conductive material and a second conductive material,

the first conductive member is disposed closer to the center of the sealing portion than the second conductive member,

the first and second conductive members are arranged such that one end is electrically connected to the electrode-side distribution board and the other end is electrically connected to the outer-side distribution board, and the electrode-side distribution board and the outer-side distribution board are not in direct electrical contact with each other,

the glass member has at least a first glass material disposed closer to a center of the sealing portion than the first conductive material, and a second glass material disposed between the first conductive material and the second conductive material.

(2)

Preferably, the electrode-side distribution board has at least a first distribution material and a second distribution material,

the first energized material is connected to the first distribution material,

the second electrically conductive material is connected to the second electrical distribution material.

(3)

Preferably, the outer distribution board has at least an outer first distribution material and an outer second distribution material,

the first energized material is connected to the outer first distribution material,

the second electrically conductive material is connected to the outer second electrical distribution material.

(4)

According to another aspect of the present invention, there is provided a discharge lamp provided with the above-described sealing structure.

Effects of the invention

According to the present invention, the current-carrying member for electrically connecting the electrode-side power distribution board and the outer power distribution board includes at least the second current-carrying material and the first current-carrying material located closer to the center of the sealing portion than the second current-carrying material and not in direct electrical contact with the second current-carrying material between the electrode-side power distribution board and the outer power distribution board. That is, a plurality of current flow paths are prepared in the discharge lamp of the present invention. Thus, a sealing structure of a discharge lamp capable of flowing a larger lighting current than a conventional discharge lamp, and a discharge lamp provided with the same can be provided.

In addition, in a configuration in which the current-carrying member is 1-fold as in the conventional discharge lamp, when the current flowing through the current-carrying member increases, the width of a member (e.g., metal foil) constituting the current-carrying member increases, and the number of the members increases. Accordingly, the gap between the members constituting the current-carrying member becomes narrower, and therefore, the area where the glass member and the arc tube are in close contact with each other is reduced. As a result, the compressive strength of the light-emitting tube portion is reduced. However, according to the sealing structure of the present invention, by increasing the current-carrying material constituting the current-carrying member in accordance with the magnitude of the current, it is not necessary to increase the width or the number of pieces of the member (for example, metal foil) constituting each current-carrying material. This prevents the reduction in the pressure-resistant strength of the light-emitting tube portion because the gaps between the members constituting the conductive members, that is, the areas of close contact between the glass members and the light-emitting tube, are not reduced.

Drawings

Fig. 1 is a diagram showing an example of a discharge lamp 10 to which the present invention is applied.

Fig. 2 is an enlarged view showing an example of a sealing structure of a discharge lamp 10 to which the present invention is applied.

Fig. 3 is an enlarged cross-sectional view showing an example of a sealing structure of a discharge lamp 10 to which the present invention is applied.

Fig. 4 is an exploded perspective view showing an example of the electrode-side distribution board 18.

Fig. 5 is a cross-sectional view showing an example of the electrode-side distribution board 18.

Fig. 6 is an exploded perspective view showing an example of the outer distribution board 22.

Fig. 7 is a cross-sectional view showing an example of the outer distribution board 22.

Fig. 8 is an exploded perspective view showing an example of the glass member 24.

Fig. 9 is a cross-sectional view showing an example of the glass member 24.

Fig. 10 is an exploded perspective view showing an example of the energizing member 26.

Fig. 11 is a perspective view showing an example of the ring-shaped glass member 28.

Fig. 12 is a front view for explaining a manufacturing step of the sealing structure of the embodiment.

Fig. 13 is a sectional view for explaining a manufacturing step of the seal structure of the embodiment.

Fig. 14 is a sectional view for explaining a manufacturing step of the seal structure of the embodiment.

Fig. 15 is a sectional view for explaining a manufacturing step of the seal structure of the embodiment.

Fig. 16 is a sectional view for explaining a manufacturing step of the seal structure of the embodiment.

Fig. 17 is a sectional view for explaining a manufacturing step of the seal structure of the embodiment.

Fig. 18 is a sectional view for explaining a manufacturing step of the seal structure of the embodiment.

Fig. 19 is a sectional view for explaining a manufacturing step of the seal structure of the embodiment.

Fig. 20 is a sectional view for explaining a manufacturing step of the seal structure of the embodiment.

Fig. 21 is a sectional view for explaining a manufacturing step of the seal structure of the embodiment.

Fig. 22 is a sectional view for explaining a manufacturing step of the seal structure of the embodiment.

Fig. 23 is a sectional view showing a seal structure of a discharge lamp 10 according to a modification.

Fig. 24 is an exploded perspective view showing an electrode-side distribution board 18 according to a modification.

Fig. 25 is an exploded perspective view showing an outer distribution board 22 according to a modification.

Fig. 26 is a sectional view for explaining a manufacturing process of a seal structure according to a modification.

Fig. 27 is a sectional view for explaining a manufacturing process of a seal structure according to a modification.

Fig. 28 is a sectional view for explaining a manufacturing process of a seal structure according to a modification.

Fig. 29 is a perspective view showing the first current-carrying member 62 constituting the current-carrying member 26 according to another modification.

Fig. 30 is a perspective view showing a first current-carrying member 62 constituting a current-carrying member 26 according to still another modification.

Detailed Description

(sealing Structure of the present invention)

Next, a discharge lamp 10 to which the sealing structure of the present invention is applied will be described. As shown in fig. 1 to 3, the discharge lamp 10 is roughly provided with an arc tube 12, an electrode 14, an electrode support rod 16, an electrode-side distribution board 18, an external lead rod 20, an outer distribution board 22, a glass member 24, an energizing member 26, and an annular glass member 28. The rated power of the discharge lamp 10 of the present example is assumed to be 1kW or more and 40kW or less.

The arc tube 12 is formed of quartz glass, and has an arc tube portion 32 having an inner space 30 at a central portion thereof, and a pair of sealing portions 34 extending from the arc tube portion 32. Further, the outer diameter of the light emitting tube portion 32 is assumed to be 40mm to 300mm, and the outer diameter of the sealing portion 34 is assumed to be 25mm to 50 mm. The length of the light-emitting tube portion 32 in the longitudinal direction is appropriately adjusted according to the size of the electrode 14 and the like. The length of the seal portion 34 in the longitudinal direction is appropriately adjusted according to the length of the current-carrying member 26 and the like. In many discharge lamps 10, a cap (not shown) is connected to the tip of the outer lead bar 20, and the cap and the end of the sealing portion 34 are fixed with an adhesive.

Mercury necessary for light emission and an inert gas such as xenon or argon is mainly sealed in the internal space 30. Further, it is assumed that the enclosed amount of mercury is 1mg/cm³Above 24mg/cm³The following. The pressure of the internal space 30 at the time of lighting, which is assumed to be within the range of the mercury sealed amount, is assumed to be 2atm or more and 20atm or less. Further, emission of mercury produces a bright line spectrum of 365nm or the like. Note that the seal structures of both the seal portions 34 are the same as each other, and therefore, in the following description, basically one seal structure (of the left seal portion 34 in fig. 1) will be described, and this description will be referred to for the other seal structure.

The pair of electrodes 14 are members for generating arc discharge by a high voltage applied to the discharge lamp 10, and are formed of a high-melting metal containing tungsten as a main component, such as pure tungsten or thoriated tungsten. In the case of the discharge lamp 10 for dc, as shown in fig. 1, the right electrode 14 (anode) is formed to be larger than the left electrode 14 (cathode). Although not shown in the drawings, in the case of an alternating current discharge lamp, both electrodes 14 are formed to have the same size. The size of the electrode 14 is appropriately selected according to the rated power of the discharge lamp 10. Further, it is assumed that the distance between the pair of electrodes 14 is 2mm to 40 mm. Further, a sealed space (not shown) may be provided in the anode 14, and a heat conductor may be sealed in the sealed space. As the heat transfer body, a metal having a melting point lower than that of tungsten is selected.

The electrode support rod 16 is a rod-shaped member made of a high-melting metal such as tungsten or molybdenum, and has an electrode 14 attached to one end thereof. In the present embodiment, the electrode 14 and the electrode support rod 16 are formed as separate members, but the present invention is not limited thereto, and the electrode 14 and the electrode support rod 16 may be integrally formed of, for example, tungsten.

The electrode-side distribution plate 18 is a substantially disk-shaped member made of a high-melting-point metal such as tungsten or molybdenum, and functions to electrically connect the electrode support rod 16 and the current-carrying member 26 to each other. As shown in fig. 4 and 5, the electrode-side distribution board 18 of the present embodiment is made of a first distribution member 102, a second distribution member 104, and a third distribution member 106.

The first power distribution material 102 is a ring-shaped flat plate member whose outer diameter is formed slightly smaller than the inner diameter of the second power distribution material 104. Further, an electrode support rod mounting hole 38 into which the other end of the electrode support rod 16 is inserted is formed inside the first power distribution member 102. The outer diameter of the first electrical distribution member 102 is formed such that the bottom surface 102b side is larger than the top surface 102a (the surface into which the electrode support rod 16 is inserted when the electrode-side electrical distribution plate 18 is formed). That is, the cross section of the first distribution material 102 is formed in a tapered shape having an outer diameter gradually increasing from the top surface 102a toward the bottom surface 102 b. Of course, the size of the outer diameter on the top surface 102a side and the size of the outer diameter on the bottom surface 102b side may be made to coincide with each other.

The second dielectric member 104 is also a ring-shaped flat plate member having an outer diameter slightly smaller than the inner diameter of the third dielectric member 106, similarly to the first dielectric member 102, and the inner diameter is slightly larger than the outer diameter of the first dielectric member 102 as described above. The second power distribution member 104 is also formed to have a larger outer diameter and an inner diameter on the bottom surface 104b side than on the top surface 104a side (the surface into which the electrode support rod 16 is inserted when the electrode-side power distribution plate 18 is formed). That is, the cross section of the second dielectric member 104 has a tapered shape in which the outer diameter and the inner diameter gradually increase from the top surface 104a to the bottom surface 104 b. In addition, the taper angle of the inner diameter of the second distribution material 104 substantially coincides with the taper angle of the outer diameter of the first distribution material 102. Of course, the dimensions of the outer diameter and the inner diameter on the top surface 104a side and the dimensions of the outer diameter and the inner diameter on the bottom surface 104b side may be made to coincide with each other.

The third distribution material 106 is also a ring-shaped flat plate member whose inner diameter is formed slightly larger than the outer diameter of the second distribution material 104 as described above. The third power distribution member 106 is also formed to have a larger outer diameter and an inner diameter on the bottom surface 106b side than on the top surface 106a side (the surface into which the electrode support rod 16 is inserted when the electrode-side power distribution plate 18 is formed). That is, the cross section of the third dielectric member 106 has a tapered shape in which the outer diameter and the inner diameter gradually increase from the top surface 106a to the bottom surface 106 b. The taper angles of the inner and outer diameters of the third dielectric material 106 substantially match the taper angles of the outer diameter of the second dielectric material 104. Of course, the dimensions of the outer diameter and the inner diameter on the top surface 106a side and the dimensions of the outer diameter and the inner diameter on the bottom surface 106b side may be made to coincide with each other.

That is, the first distribution material 102, the second distribution material 104, and the third distribution material 106 may be combined to form 1 disk (i.e., the electrode-side distribution board 18). Further, 1/2, which is the difference between the outer diameter of the first dielectric material 102 and the outer diameter of the second dielectric material 104, corresponds to the thickness of the second glass material 49 (described later), and 1/2, which is the difference between the outer diameter of the second dielectric material 104 and the outer diameter of the third dielectric material 106, corresponds to the thickness of the third glass material 50 (described later). The outer diameter and thickness of each of the

current distribution members

102, 104, and 106 are set to an appropriate size according to the rated input current of the discharge lamp 10.

Returning to fig. 1 to 3, the external lead bar 20 is a rod-shaped member made of molybdenum for attaching a lead (not shown) connected to a power supply (not shown) and applying a high voltage from the power supply to the discharge lamp 10. One end of the external lead bar 20 is disposed to protrude outward from the sealing portion 34 of the light-emitting tube 12. The other end of the external lead bar 20 is connected to the outer distribution board 22 in the sealing portion 34.

The outer distribution board 22 is also a substantially disk-shaped member made of a high-melting metal such as tungsten or molybdenum, similarly to the electrode-side distribution board 18 described above, and functions to electrically connect the external lead bar 20 and the current-carrying member 26 to each other. As shown in fig. 6 and 7, the outer distribution board 22 of the present embodiment is composed of an outer first distribution member 110, an outer second distribution member 112, and an outer third distribution member 114.

The outer first interconnector 110 is a ring-shaped flat plate member, and the outer diameter thereof is formed to be slightly smaller than the inner diameter of the outer second interconnector 112. Further, an outer lead bar mounting hole 44 into which the other end of the outer lead bar 20 is inserted is formed inside the outer first power distribution member 110. The outer diameter of the outer first electrical distribution member 110 is formed such that the bottom surface 110b side is larger than the top surface 110a (the surface into which the external lead bar 20 is inserted when the outer electrical distribution board 22 is configured). That is, the cross section of the outer first distribution member 110 has a tapered shape in which the outer diameter gradually increases from the top surface 110a toward the bottom surface 110 b. Of course, the size of the outer diameter on the top surface 110a side and the size of the outer diameter on the bottom surface 110b side may be matched with each other.

The outer second interconnector 112 is also a ring-shaped flat plate member, similar to the outer first interconnector 110, and has an outer diameter slightly smaller than the inner diameter of the outer third interconnector 114, and has an inner diameter slightly larger than the outer diameter of the outer first interconnector 110 as described above. The outer diameter and the inner diameter of the outer second electrical distribution member 112 are also formed so that the bottom surface 112b side is larger than the top surface 112a side (the surface into which the external lead bar 20 is inserted when the outer electrical distribution board 22 is configured). That is, the cross section of the outer second electrical distribution member 112 has a tapered shape in which the outer diameter and the inner diameter gradually increase from the top surface 112a toward the bottom surface 112 b. In addition, the taper angle of the inner diameter of the outer second dielectric material 112 substantially coincides with the taper angle of the outer diameter of the outer first dielectric material 110. Of course, the dimensions of the outer diameter and the inner diameter on the top surface 112a side and the dimensions of the outer diameter and the inner diameter on the bottom surface 112b side may be made to coincide with each other.

The outer third power distribution material 114 is also a ring-shaped flat plate member whose inner diameter is formed slightly larger than the outer diameter of the outer second power distribution material 112 as described above. The outer diameter and the inner diameter of the outer third electrical distribution member 114 are also formed so that the bottom surface 114b side is larger than the top surface 114a side (the surface into which the external lead bar 20 is inserted when the outer electrical distribution board 22 is configured). That is, the cross section of the outer third dielectric member 114 has a tapered shape in which the outer diameter and the inner diameter gradually increase from the top surface 114a to the bottom surface 114 b. The taper angles of the inner and outer diameters of the outer third dielectric material 114 substantially coincide with the taper angle of the outer diameter of the outer second dielectric material 112. Of course, the outer diameter and inner diameter of the top surface 114a may be formed to have the same size as the outer diameter and inner diameter of the bottom surface 114 b.

That is, the outer first distribution material 110, the outer second distribution material 112, and the outer third distribution material 114 may be combined to form 1 disk (i.e., the outer distribution board 22). In addition, the difference between the outer diameter of the outer first power distribution material 110 and the outer diameter of the outer second power distribution material 112 coincides with the thickness of the second glass material 49, and the difference between the outer diameter of the outer second power distribution material 112 and the outer diameter of the outer third power distribution material 114 coincides with the thickness of the third glass material 50. The outer diameter or thickness of each of the

current distribution members

110, 112, and 114 is set to an appropriate size according to the rated input current of the discharge lamp 10.

The glass member 24 is a member made of quartz glass, which is disposed in the sealing portion 34, is welded to the inner surface of the sealing portion 34, and hermetically seals the internal space 30 of the light emitting tube portion 32, and in the present embodiment, is composed of a first glass material 48, a second glass material 49, and a third glass material 50, as shown in fig. 8 and 9.

The first glass material 48 is a substantially columnar member, and the outer diameter thereof is formed to be slightly smaller than the diameter of the first through hole 52 of the second glass material 49. The outer diameter of the first glass material 48 is formed to be substantially the same as the outer diameter of the first power distribution member 102 constituting the electrode-side power distribution plate 18 and the outer diameter of the outer first power distribution member 110 constituting the outer power distribution plate 22.

The second glass material 49 is a substantially cylindrical member having a larger diameter than the first glass material 48, and the diameter of the first through hole 52 formed in the second glass material 49 is formed to be slightly larger than the outer diameter of the first glass material 48. Thereby, the second glass material 49 can accommodate the first glass material 48 in the first through hole 52 thereof. The outer diameter of the second glass material 49 is substantially the same as the outer diameter of the second power distribution member 104 constituting the electrode-side power distribution plate 18 and the outer diameter of the outer second power distribution member 112 constituting the outer power distribution plate 22.

The third glass material 50 is a substantially cylindrical member, and the diameter of the second through hole 53 formed in the third glass material 50 is formed to be slightly larger than the outer diameter of the second glass material 49. Thereby, the third glass material 50 can receive the second glass material 49 in the second through hole 53 thereof. The outer diameter of the third glass material 50 is substantially the same as the outer diameter of the third power distribution member 106 constituting the electrode-side power distribution plate 18 and the outer diameter of the outer third power distribution member 114 constituting the outer power distribution plate 22.

The first glass material 48, the second glass material 49, and the third glass material 50 are formed to have the same length in the longitudinal direction.

The current-carrying member 26 is a member made of molybdenum having a function of electrically connecting the electrode-side power distribution plate 18 and the outer power distribution plate 22 to each other, and is composed of a first current-carrying material 62, a second current-carrying material 63, and a third current-carrying material 64 in the present embodiment, as shown in fig. 10. These current-carrying

members

62, 63, 64 are disposed separately from each other so as not to be in direct electrical contact with each other between the electrode-side distribution board 18 and the outer-side distribution board 22. In other words, the

conductive members

62, 63, and 64 are preferably electrically connected only via the electrode side distribution board 18 and the outer side distribution board 22.

The first current carrying member 62 is formed using a plurality of (4 in this embodiment) metal foils 66 made of molybdenum formed in a substantially long shape. The metal foil 66 constituting the first current carrying member 62 is disposed along the longitudinal direction of the first glass member 48 on the outer side surface of the first glass member 48 constituting the glass member 24. The length of the metal foil 66 constituting the first current-carrying member 62 is set to be slightly longer than the length of the first glass member 48 in the longitudinal direction, and the metal foil 66 slightly protrudes from the upper end and the lower end of the first glass member 48.

The second current carrying member 63 is also configured by using a plurality of (4 in the present embodiment) metal foils 66 made of molybdenum, which are formed in a substantially long shape, as in the first current carrying member 62. The metal foil 66 constituting the second conductive member 63 is disposed on the outer surface of the second glass member 49 constituting the glass member 24 along the longitudinal direction of the second glass member 49. The length of the metal foil 66 constituting the second conductive member 63 is set to be slightly longer than the length of the second glass member 49 in the longitudinal direction, and the metal foil 66 slightly protrudes from the upper end and the lower end of the second glass member 49.

Similarly, the third charging member 64 is formed using a plurality of (4 in the present embodiment) metal foils 66 made of molybdenum formed in a substantially elongated shape. The metal foil 66 constituting the third electrifying member 64 is disposed along the longitudinal direction of the third glass member 50 on the outer side surface of the third glass member 50 constituting the glass member 24. The length of the metal foil 66 constituting the third electric connection member 64 is set to be slightly longer than the length of the third glass member 50 in the longitudinal direction, and the metal foil 66 slightly protrudes from the upper end and the lower end of the third glass member 50.

Each of the metal foils 66 constituting the current-carrying member 26 is assumed to have a 1-piece size of 1.5mm to 20mm in width, 40mm to 150mm in length, and 10 μm to 40 μm in thickness.

The ring-shaped glass member 28 is a member provided as needed, and is disposed on at least one of the side of the electrode-side distribution board 18 closer to the internal space 30 of the light-emitting tube 32 and the side of the outer distribution board 22 than the sealing portion 34. As shown in fig. 11, the ring-shaped glass member 28 includes a substantially columnar body portion 70 made of quartz glass, and a through hole 72 formed in a substantially central portion of the body portion 70. The through hole 72 is a hole through which the electrode support bar 16 or the external lead bar 20 is inserted. That is, when the annular glass member 28 is disposed on the side closer to the internal space 30 of the light-emitting tube portion 32 than the electrode-side distribution board 18, the electrode support rod 16 is inserted into the through hole 72, and when the annular glass member 28 is disposed on the outer side than the outer distribution board 22, the external lead rod 20 is inserted into the through hole 72. In the present embodiment, the annular glass members 28 are provided on both sides of the electrode-side distribution board 18 closer to the internal space 30 of the light-emitting tube 32 and further to the outside than the outer distribution board 22.

(manufacturing step of seal Structure of the embodiment)

Next, the manufacturing steps of the sealing structure of the present embodiment will be described. The electrode 14 is connected to one end of the electrode support rod 16, and the other end of the electrode support rod 16 is inserted into the electrode support rod mounting hole 38 of the first power distribution member 102 constituting the electrode-side power distribution board 18, and then the electrode support rod 16 and the first power distribution member 102 are connected to each other by welding or the like. After the other end of the external lead bar 20 is inserted into the external lead bar mounting hole 44 of the external first electrical distribution member 110 constituting the external electrical distribution board 22, the external lead bar 20 and the external first electrical distribution member 110 are connected to each other by welding or the like. The first power distribution member 102 constituting the electrode-side power distribution board 18 and the electrode support rod 16 may be welded and connected to each other, and after the bracket 154 (described later) is finally assembled, the electrode support rod 16 may be inserted through the body portion 70 of the ring-shaped glass member 28, and then the electrode 14 may be connected to one end of the electrode support rod 16.

Next, as shown in fig. 12, the bottom surface 102b of the first wiring member 102 is brought into contact with the top surface 48a of the first glass member 48, and the bottom surface 110b of the outer first wiring member 110 is brought into contact with the bottom surface 48b of the first glass member 48. At this time, the side surface of the first glass material 48, the outer peripheral surface of the first power distribution member 102, and the outer peripheral surface of the outer first power distribution member 110 are flush with each other. Although not shown in the drawings, a thin metal disk (not shown) serving as a buffer material may be interposed between the top surface 48a of the first glass material 48 and the bottom surface 102b of the first power distribution member 102, or between the bottom surface 48b of the first glass material 48 and the bottom surface 110b of the outer first power distribution member 110. The metal thin circular plate is 1 element constituting the electrode side distribution plate 18 or the outer side distribution plate 22. The thin circular plate of metal is formed to have a diameter substantially the same as or slightly smaller than the diameter of the top surface 48a or the bottom surface 48b of the first glass material 48. The metal thin circular plate and the first conductive member 62 may or may not be electrically connected to each other.

Next, as shown in fig. 13, a plurality of metal foils 66 constituting the first conductive material 62 are arranged along the longitudinal direction of the side surface of the first glass material 48. As described above, since the metal foil 66 is set to be slightly longer than the length of the first glass material 48 in the longitudinal direction, one end of the metal foil 66 constituting the first current carrying material 62 reaches the outer peripheral surface of the first power distribution member 102, and the other end reaches the outer peripheral surface of the outer first power distribution member 110. Then, one end of each metal foil 66 and the first power distribution material 102 are electrically connected by welding or the like, and the other end of each metal foil 66 and the outer first power distribution material 110 are electrically connected by welding or the like (the electrical connection may be made only by sandwiching the metal foil 66 between the first power distribution material 102 and the second power distribution material 104. Thus, the 1 st bracket 150 is configured by the electrode support bar 16, the external lead bar 20, the first electrical distribution material 102, the outer first electrical distribution material 110, the first glass material 48, and the first conductive material 62.

As shown in fig. 14, after the holder 150 is inserted into the glass tube X1 time, the glass tube X is shrunk (shrink) by a method such as heating the glass tube X from the outside, and the first current carrying member 62 is held between the glass tube X and the first glass member 48 by bringing the side surface of the first glass member 48 into close contact with the portion where the first current carrying member 62 does not exist. Then, the glass tube X is cut at the boundary between the first glass material 48 and the first wiring material 102 and the boundary between the first glass material 48 and the outer first wiring material 110. As shown in fig. 15, a part of the glass tube X remaining after cutting and in close contact with the side surface of the first glass material 48 becomes a second glass material 49.

Next, as shown in fig. 16, the second interconnector 104 is disposed on the outer periphery of the first interconnector 102, and the outer second interconnector 112 is disposed on the outer periphery of the outer first interconnector 110. At this time, the metal foil 66 constituting the first conductive member 62 is sandwiched between the outer peripheral surface of the first power distribution member 102 and the inner peripheral surface of the second power distribution member 104, and between the outer peripheral surface of the outer first power distribution member 110 and the inner peripheral surface of the outer second power distribution member 112. Although not shown in the drawings, a ring-shaped metal thin disk (not shown) as a buffer material may be interposed between the top surface 49a of the second glass member 49 and the bottom surface 104b of the second power distribution member 104, and between the bottom surface 49b of the second glass member 49 and the bottom surface 112b of the outer second power distribution member 112. The metal thin circular plate is 1 element constituting the electrode side distribution plate 18 or the outer side distribution plate 22. The metal thin circular plate is formed to have an outer diameter substantially the same as or slightly smaller than the outer diameter of the top surface 49a or the bottom surface 49b of the second glass material 49. The inner diameter of the metal thin circular plate is slightly larger than the outer diameter of the top surface 48a or the bottom surface 48b of the first glass material 48. The metal disk and the second conductive member 63 may or may not be electrically connected to each other.

Next, as shown in fig. 17, a plurality of metal foils 66 constituting the second conductive member 63 are arranged along the longitudinal direction on the side surface of the second glass member 49. As described above, since the metal foil 66 is set to be slightly longer than the length of the second glass material 49 in the longitudinal direction, one end of the metal foil 66 constituting the second current carrying member 63 reaches the outer peripheral surface of the second current carrying member 104, and the other end reaches the outer peripheral surface of the outer second current carrying member 112. Then, one end of each metal foil 66 and the second power distribution material 104 are electrically connected by welding or the like, and the other end of each metal foil 66 and the outer second power distribution material 112 are electrically connected by welding or the like. Thus, the electrode support bar 16, the external lead bar 20, the first current distribution material 102, the outer first current distribution material 110, the first glass material 48, the first current carrying material 62, the second current distribution material 104, the outer second current distribution material 112, the second glass material 49, and the second current carrying material 63 constitute the secondary holder 152.

As shown in fig. 18, after the holder 152 is inserted into the glass tube Y2 times, the glass tube Y is shrunk (shrink) by a method such as heating the glass tube Y from the outside, and the side surface of the second glass material 49 is brought into close contact with a portion where the second current-carrying member 63 does not exist. Then, the glass tube Y is cut at the boundary between the second glass material 49 and the second power distribution material 104 and the boundary between the second glass material 49 and the outer second power distribution material 112. As shown in fig. 19, a part of the glass tube Y remaining after cutting and in close contact with the side surface of the second glass material 49 becomes a third glass material 50.

Next, as shown in fig. 20, the third interconnector 106 is disposed on the outer periphery of the second interconnector 104, and the outer third interconnector 114 is disposed on the outer periphery of the outer second interconnector 112. At this time, the metal foil 66 constituting the second conductive member 63 is sandwiched between the outer peripheral surface of the second conductive member 104 and the inner peripheral surface of the third conductive member 106, and between the outer peripheral surface of the outer second conductive member 112 and the inner peripheral surface of the outer third conductive member 114. Although not shown in the drawings, a ring-shaped metal thin disk (not shown) as a buffer material may be interposed between the top surface 50a of the third glass material 50 and the bottom surface 106b of the third power distribution member 106, and between the bottom surface 50b of the third glass material 50 and the bottom surface 114b of the outer third power distribution member 114. The metal thin circular plate is 1 element constituting the electrode side distribution plate 18 or the outer side distribution plate 22. The metal thin circular plate is formed to have an outer diameter substantially the same as or slightly smaller than the outer diameter of the top surface 50a or the bottom surface 50b of the third glass material 50. The inner diameter of the metal thin circular plate is formed slightly larger than the outer diameter of the top surface 49a or the bottom surface 49b of the second glass material 49. The metal thin circular plate and the third electrifying member 64 may or may not be electrically connected to each other.

Next, as shown in fig. 21, a plurality of metal foils 66 constituting the third electrifying member 64 are arranged along the longitudinal direction on the side surface of the third glass member 50. As described above, since the metal foil 66 is set to be slightly longer than the length of the third glass material 50 in the longitudinal direction, one end of the metal foil 66 constituting the third current passing material 64 reaches the outer peripheral surface of the third current distributing material 106, and the other end reaches the outer peripheral surface of the outer third current distributing material 114. Then, one end of each metal foil 66 and the third power distribution material 106 are electrically connected by welding or the like, and the other end of each metal foil 66 and the outer third power distribution material 114 are electrically connected by welding or the like. Thus, the final carrier 154 is composed of the electrode support rod 16, the external lead rod 20, the first current distribution material 102, the outer first current distribution material 110, the first glass material 48, the first current carrying material 62, the second current distribution material 104, the outer second current distribution material 112, the second glass material 49, the second current carrying material 63, the third current distribution material 106, the outer third current distribution material 114, the third glass material 50, and the third current carrying material 64.

As shown in fig. 22, the annular glass members 28 are attached to the electrode support rods 16 and the external lead rods 20 on the final holder 154, respectively, and are inserted into the end portions (portions to be the sealing portions 34) of the light-emitting tube 12, and then the end portions of the light-emitting tube 12 are shrunk (shrink) by heating the end portions of the light-emitting tube 12 from the outside, whereby the third glass material 50, the two annular glass members 28, and the end portions of the light-emitting tube 12 are brought into close contact with each other. Thereby, the seal portion 34 is formed, and the seal structure is completed (see fig. 3).

(feature of sealing Structure of the present embodiment)

According to the sealing structure of the present embodiment, the current-carrying member 26 electrically connecting the electrode-side distribution board 18 and the outer distribution board 22 is composed of the three current-carrying

members

62, 63, 64, and there are 3 current paths for the current flowing through the discharge lamp 10, so that a larger lighting current than that of the conventional discharge lamp can be passed.

In addition, in a configuration in which the current-carrying member is 1-fold as in the conventional discharge lamp, when the current flowing through the current-carrying member increases, the width of the foil constituting the current-carrying member increases, and the number of foils increases. Accordingly, the gap between the foils becomes narrower, and thus the area where the glass member and the arc tube are in close contact with each other is reduced. As a result, the compressive strength of the light-emitting tube portion is reduced. However, according to the sealing structure of the present embodiment, by increasing the current-carrying

members

62, 63, 64 constituting the current-carrying members 26 in accordance with the magnitude of the current, it is not necessary to increase the width or the number of pieces of the metal foil 66 constituting each of the current-carrying

members

62, 63, 64. Thus, the gaps between the metal foils 66, that is, the areas of contact between the

glass materials

48, 49, and 50 and between the third glass material 50 and the arc tube 12 are not reduced, and therefore, a decrease in the pressure resistance of the arc tube portion 32 can be avoided.

(modification 1)

Instead of the electrode side distribution board 18 and the outer side distribution board 22 of the above-described embodiment, the electrode side distribution board 18 and the outer side distribution board 22 having the shapes shown in fig. 23 to 25 may be used. The electrode-side distribution board 18 and the outer-side distribution board 22 of modification 1 are made of first to

third distribution members

102, 104, and 106, and outer first to

third distribution members

110, 112, and 114, respectively.

The first to third

power distribution members

102, 104, and 106 of modification 1 are each formed in a substantially annular shape, and have an electrode support rod insertion hole 120 formed in the center thereof to allow the electrode support rod 16 to be inserted therethrough. In addition, the outer diameter of the second power distribution material 104 is formed to be larger than the outer diameter of the first power distribution material 102, and the outer diameter of the third power distribution material 106 is formed to be larger than the outer diameter of the second power distribution material 104. In addition, 1/2 for the difference between the outer diameter of the first electrical distribution material 102 and the outer diameter of the second electrical distribution material 104 is consistent with the thickness of the second glass material 49, and 1/2 for the difference between the outer diameter of the second electrical distribution material 104 and the outer diameter of the third electrical distribution material 106 is consistent with the thickness of the third glass material 50.

Similarly, the outer first to third

power distribution members

110, 112, and 114 of modification 1 are each formed in a substantially annular shape, and an outer lead bar insertion hole 122 is formed in the center thereof to such an extent that the outer lead bar 20 can be inserted therethrough. In addition, the outer diameter of the outer second power distribution material 112 is formed to be larger than the outer diameter of the outer first power distribution material 110, and the outer diameter of the outer third power distribution material 114 is formed to be larger than the outer diameter of the outer second power distribution material 112. In addition, 1/2, which is the difference between the outer diameter of the outer first electrical distribution material 110 and the outer diameter of the outer second electrical distribution material 112, is consistent with the thickness of the second glass material 49, and 1/2, which is the difference between the outer diameter of the outer second electrical distribution material 112 and the outer diameter of the outer third electrical distribution material 114, is consistent with the thickness of the third glass material 50.

Next, a description will be given of a procedure for manufacturing a seal structure using the electrode side distribution board 18 and the outer side distribution board 22 of modification 1. In the manufacturing process of the seal structure of modification 1, the above steps are referred to as the same contents as those of the manufacturing process of the seal structure, and only different contents in the manufacturing process will be described.

As shown in fig. 26, the holder 150 is inserted into the glass tube X1 time, and the glass tube X shrunk by heating is cut in the vicinity of the edge on the top surface 102a side of the outer peripheral surface of the first power distribution member 102 and in the vicinity of the edge on the top surface 110a side of the outer peripheral surface of the first power distribution member 110. A part of the glass tube X remaining after cutting and in close contact with the side surface of the first glass material 48, the outer peripheral surface of the first electrical distribution member 102, and the outer peripheral surface of the outer first electrical distribution member 110 becomes the second glass material 49.

Then, as shown in fig. 27, the electrode support bar 16 is inserted through the electrode support bar insertion hole 120 formed in the second electrical distribution member 104, and the bottom surface 104b of the second electrical distribution member 104 is brought into contact with the top surface 102a of the first electrical distribution member 102, and thereafter, the first electrical distribution member 102 and the second electrical distribution member 104 are electrically connected by welding or the like. In this state, the side surface of the second glass material 49 is flush with the outer peripheral surface of the second power distribution material 104.

The outer lead bar 20 is inserted into the outer lead bar insertion hole 122 formed in the outer second interconnector 112, and the bottom surface 112b of the outer second interconnector 112 is brought into contact with the top surface 110a of the outer first interconnector 110, and then the outer first interconnector 110 and the outer second interconnector 112 are electrically connected by welding or the like. In this state, the side surface of the second glass material 49 is flush with the outer peripheral surface of the outer second power distribution material 112.

Further, after the second current-carrying member 63 is disposed to form the holder 152 for 2 times, as shown in fig. 28, the holder 152 for 2 times is inserted into the glass tube Y, and the glass tube Y shrunk by heating is cut in the vicinity of the edge on the top surface 104a side of the outer peripheral surface of the second current-carrying member 104 and in the vicinity of the edge on the top surface 112a side of the outer peripheral surface of the outer second current-carrying member 112. A part of the glass tube Y remaining after cutting and in close contact with the side surface of the second glass material 49, the outer peripheral surface of the second electrical distribution member 104, and the outer peripheral surface of the outer second electrical distribution member 112 becomes the third glass material 50.

Thereafter, the third current distributing member 106, the outer third current distributing member 114, and the third current conducting member 64 are arranged to form a final mount 154, and the final mount 154 and the annular glass member 28 are inserted into the end portion of the arc tube 12, and the end portion is shrunk (shrink) to form the sealing portion 34, thereby completing the sealing structure (see fig. 23).

(modification 2)

In the above-described embodiment, the electrode side distribution board 18 and the outer side distribution board 22 are each formed of 3 members, but the electrode side distribution board 18 and the outer side distribution board 22 may be formed of 2 members, or 4 or more members.

(modification 3)

In the above-described embodiment, the energizing member 26 is constituted by 3 members, but the energizing member 26 may be constituted by 2 energizing members, or 4 or more energizing members. It is preferable that the number of components constituting the electrode side distribution board 18 and the outer side distribution board 22, the number of components constituting the current-carrying member 26, and the number of components constituting the glass member 24 be equal to each other.

(modification 4)

In the above-described embodiment, the electrode support rod 16 and the first power distribution member 102 constituting the electrode-side power distribution board 18 are formed separately, but they may be formed integrally. Similarly, the outer lead bar 20 and the outer first power distribution member 110 constituting the outer power distribution board 22 may be formed integrally without being separated from each other.

(modification 5)

In the above-described embodiment, each of the current-carrying

members

62, 63, 64 constituting the current-carrying member 26 is formed of the plurality of metal foils 66 formed in a substantially long shape, but instead, as shown in fig. 29 or 30, a shape may be adopted in which several cut-out portions 130 are provided on the surface of a cylinder formed of a metal foil (in fig. 29 or 30, the first current-carrying member 62 is shown as an example, but the second current-carrying member 63 or the third current-carrying member 64 is also the same shape). The glass material located inside the cylinder and the glass material located outside the cylinder are welded to each other through these notches 130, thereby improving airtightness. Therefore, it is preferable to optimize the ratio of the area of the cutout portion 130 to the area of the metal foil portion in accordance with the pressure resistance of the internal space 30 of the light-emitting tube portion 32 required for the discharge lamp 10. In other words, it is not necessary that the

energization members

62, 63, and 64 constituting the energization member 26 all have the same shape, and for example, the first energization member 62 may have a shape in which several cutout portions 130 are provided on the surface of a metal foil cylinder, and the third energization member 64 may have a plurality of metal foils formed in a substantially elongated shape.

It should be understood that the embodiments disclosed herein are illustrative in all respects, and not restrictive. The scope of the present invention is defined not by the above description but by the claims, and is intended to include meanings equivalent to the claims and all modifications within the scope of the claims.

Description of the symbols

10 … discharge lamp, 12 … luminous tube, 14 … electrode, 16 … electrode support rod, 18 … electrode side distribution board, 20 … external lead bar, 22 … external distribution board, 24 … glass component, 26 … energizing component, 28 … annular glass component, 30 … internal space, 32 … luminous tube portion, 34 … sealing portion, 38 … electrode support rod mounting hole, 44 … external lead bar mounting hole, 48 … first glass material, 49 … second glass material, 50 … third glass material, 52 … first through hole, 53 … second through hole, 62 … first energizing material, 63 … second energizing material, 64 … third energizing material, 66 … metal foil, 70 … (of annular glass component 28) main body portion, 72 … through hole, 102 … (of electrode side distribution board 18) first energizing material, 104 … (of electrode side distribution board 18) second energizing material, and third electrode side distribution board energizing material (…) of electrode side distribution board 18) third electrode distribution board, 110 … (of the outer panelboard 22) outer first electrical distribution material, 112 … (of the outer panelboard 22) outer second electrical distribution material, 114 … (of the outer panelboard 22) outer third electrical distribution material, 120 … electrode support bar insert through holes, 122 … outer lead bar insert through holes, 130 … cut-outs, 150 … 1 sub-mounts, 152 … 2 sub-mounts, 154 … final mounts, X … glass tubes, Y … glass tubes.

Claims

1. A sealing structure for a discharge lamp, comprising:

an external lead bar;

an outer distribution board electrically connected to the external lead bar;

2. The sealing structure of claim 1,

the electrode-side distribution board has at least a first distribution material and a second distribution material,

the first energized material is connected to the first distribution material,

3. The sealing structure according to claim 1 or 2,

the outer distribution board has at least an outer first distribution material and an outer second distribution material,

4. A discharge lamp having the sealing structure according to any one of claims 1 to 3.