JP2010177092A - Electrode assembly manufacturing method of metal vapor discharge lamp - Google Patents

Electrode assembly manufacturing method of metal vapor discharge lamp Download PDF

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JP2010177092A
JP2010177092A JP2009019577A JP2009019577A JP2010177092A JP 2010177092 A JP2010177092 A JP 2010177092A JP 2009019577 A JP2009019577 A JP 2009019577A JP 2009019577 A JP2009019577 A JP 2009019577A JP 2010177092 A JP2010177092 A JP 2010177092A
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halogen
intermediate material
molybdenum
resistant intermediate
conductive cermet
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Fumihide Uehara
原 文 秀 植
Seiji Yamada
田 誠 司 山
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Iwasaki Denki KK
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Iwasaki Denki KK
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Abstract

<P>PROBLEM TO BE SOLVED: To hardly generate thermal deformation, regardless of the crystal structure specific to a molybdenum wire, thermal history or processing history, when a halogen-proof intermediate material formed by tightly winding a molybdenum wire around a molybdenum rod and a conductive cermet are carried out at butt welding. <P>SOLUTION: Before carrying out butt welding of a halogen-proof intermediate material (5) and a conductive cermet (6), a molybdenum rod (5a) and a molybdenum wire (5b) are melted by a piece end part (5d) of the halogen-proof intermediate material (5). After the molybdenum rod (5a) and the molybdenum wire (5b) are hardened with their tip formed into a round shape and are integrated with one another by the surface tension force of the melt, the piece end part (5d) of the halogen-proof intermediate material (5) and the conductive cermet (6) are abutted against at butt welding. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

本発明は、セラミックメタルハライドランプなどの金属蒸気放電灯などに用いられる電極アセンブリの製造方法に関する。   The present invention relates to a method for manufacturing an electrode assembly used in a metal vapor discharge lamp such as a ceramic metal halide lamp.

近年のメタルハライドランプは、石英製発光管に代えて、石英よりも耐熱性、耐食性に優れた透光性アルミナで成るセラミック製発光管を用いたセラミックメタルハライドランプが数多く商品化されている。この種のランプは、透光性セラミックで成る発光管の両端にアルミナセラミック等の細管で成る一対のキャピラリを焼きばめて取り付けるシリンドリカル型が一般的であったが、最近は、焼嵌め加工の面倒を解消するため、発光管とその両端に設けるキャピラリとを透光性セラミックで一体成形したワンピース型が普及しつつある（特許文献１参照）。   In recent years, many metal halide lamps using ceramic arc tubes made of translucent alumina made of translucent alumina, which are superior in heat resistance and corrosion resistance to quartz, have been commercialized instead of quartz arc tubes. This type of lamp is generally a cylindrical type in which a pair of capillaries made of alumina ceramic or other thin tubes are attached to both ends of a light emitting tube made of translucent ceramic. In order to eliminate troublesomeness, a one-piece type in which an arc tube and capillaries provided at both ends thereof are integrally formed of translucent ceramic is becoming widespread (see Patent Document 1).

このようなワンピース型のメタルハライドランプを、例えば図３を参照して説明すると、ランプ本体を構成する発光管２とキャピラリ３Ｒ、３Ｌが、夫々の境界部分に角隅部を生じない丸みを帯びた滑らかな曲面形状に設計されて、透光性アルミナの粉末圧縮体で一体成形されている。   Such a one-piece type metal halide lamp will be described with reference to FIG. 3, for example. The arc tube 2 and capillaries 3R, 3L constituting the lamp body are rounded so as not to form corners at the respective boundary portions. Designed to have a smooth curved surface, it is integrally formed with a powder compact of translucent alumina.

そして、発光管２の両端に形成されたキャピラリ３Ｒ、３Ｌ内には、一対の電極アセンブリ２１が挿通されて、そのキャピラリ３Ｒ、３Ｌの両端が、電気絶縁性を有するフリットガラス１０などのシール材によって気密にシールされると同時に、各電極アセンブリ２１がキャピラリ３Ｒ、３Ｌ内の定位置に固定されており、発光管２の内部には金属ハロゲン化物、水銀、始動用ガス等が封入されている。   A pair of electrode assemblies 21 are inserted into the capillaries 3R and 3L formed at both ends of the arc tube 2, and both ends of the capillaries 3R and 3L have a sealing material such as frit glass 10 having electrical insulation. At the same time, each electrode assembly 21 is fixed at a fixed position in the capillaries 3R and 3L, and the inside of the arc tube 2 is filled with metal halide, mercury, starting gas, and the like. .

電極アセンブリ２１は、夫々タングステンロッドで成る電極棒４ａの先端側にタングステン線４ｂを密巻きして放熱用のコイル部が形成された電極４と、モリブデンロッド５ａの外周部にモリブデン線５ｂを密巻きしてコイル部が形成された耐ハロゲン性中間材５と、アルミナ粉末とモリブデン粉末とを混合燒結して成る導電性サーメット６とが直列的に突合せ溶接された構成となっており、キャピラリ３Ｒ、３Ｌ内に挿通された各電極アセンブリ１の外表面とキャピラリ３Ｒ、３Ｌの内表面との間には、発光管２の内部へ通ずる空隙７が形成されている。   The electrode assembly 21 includes an electrode 4 in which a tungsten wire 4b is closely wound around the tip side of an electrode rod 4a made of a tungsten rod, and a heat radiating coil portion is formed. The halogen-resistant intermediate material 5 wound to form a coil portion and a conductive cermet 6 formed by mixing and sintering alumina powder and molybdenum powder are serially butt welded, and the capillary 3R A gap 7 is formed between the outer surface of each electrode assembly 1 inserted into 3L and the inner surface of capillaries 3R, 3L.

そして、各電極アセンブリ２１は、導電性サーメット６の端部にモリブデン線で成る電力供給リード８が突合せ溶接されて、その溶接部に補強用リング９が外嵌され、該リング９内から各キャピラリ２Ｒ、２Ｌ内にかけて、耐ハロゲン性中間材５と導電性サーメット６の接合部Ｗを覆うようにフリットガラス１０が充填されている。   In each electrode assembly 21, a power supply lead 8 made of molybdenum wire is butt welded to the end of the conductive cermet 6, and a reinforcing ring 9 is externally fitted to the welded portion. The frit glass 10 is filled so as to cover the joint portion W between the halogen-resistant intermediate material 5 and the conductive cermet 6 over 2R and 2L.

ところで、耐ハロゲン性中間材５の外径と導電性サーメット６の外径が大きく異なって両者の接合部Ｗに段差が生ずると、ランプの点滅による温度変化により、フリットガラス１０が接合部Ｗのひずみの影響を受け、その段差部分で応力集中を起こしてクラックが入りやすいという問題があるため、従来より、耐ハロゲン性中間材５及び導電性サーメット６は同径のものが用いられている。
また、モリブデンで成る耐ハロゲン性中間材５よりもアルミナ粉末とモリブデン粉末とを混合焼結した導電性サーメット６の方が融点が低く、これらを突合せ溶接する際に導電性サーメット６の溶融物が流れ出るため、耐ハロゲン性中間材５の片端部に溶融物を流し込む流入部を予め形成して溶接する方法も提案されている（特許文献２参照）。 By the way, if the outer diameter of the halogen-resistant intermediate material 5 and the outer diameter of the conductive cermet 6 are greatly different and a step is formed between the two, the frit glass 10 is attached to the joint W due to a temperature change caused by blinking of the lamp. Since there is a problem that stress concentration is caused at the stepped portion due to the strain and cracks easily occur, conventionally, the halogen-resistant intermediate material 5 and the conductive cermet 6 have the same diameter.
Further, the conductive cermet 6 in which the alumina powder and the molybdenum powder are mixed and sintered has a lower melting point than the halogen-resistant intermediate material 5 made of molybdenum, and the melt of the conductive cermet 6 is generated when these are butt welded. In order to flow out, a method is also proposed in which an inflow portion into which a melt is poured into one end portion of the halogen-resistant intermediate material 5 is formed in advance and welded (see Patent Document 2).

図５はこのような電極アセンブリ２１の製造方法を示し、まず、例えば直径０.４〜０.５ｍｍのモリブデンロッド５ａの外周部に、直径０.１５〜０.２ｍｍのモリブデン線５ｂを密巻きしていく（図５（ａ）参照）。
これを所定長さに切断することにより耐ハロゲン性中間材５を形成すると共に、その片端部にモリブデン線５ｂが巻かれずにモリブデンロッド５ａが露出された流入部２２を形成しておく（図５（ｂ））。 FIG. 5 shows a method of manufacturing such an electrode assembly 21. First, for example, a molybdenum wire 5b having a diameter of 0.15 to 0.2 mm is closely wound around the outer periphery of a molybdenum rod 5a having a diameter of 0.4 to 0.5 mm. (See FIG. 5A).
By cutting this into a predetermined length, the halogen-resistant intermediate material 5 is formed, and an inflow portion 22 where the molybdenum rod 5a is exposed without winding the molybdenum wire 5b is formed at one end thereof (FIG. 5 (b)).

次いで、耐ハロゲン性中間材５と導電性サーメット６を突合せ溶接する。
突合せ溶接は抵抗溶接の一種であり、耐ハロゲン性中間材５の流入部２２を下向きにして、導電性サーメット６の上端に突合せた状態で加圧し瞬間的に大電流を流すことにより接合部Ｗにジュール熱を発生させる（図５（ｃ））。
これにより接合部Ｗが加熱され、所定の温度に達したところでモリブデンでなる耐ハロゲン性中間材５より融点の低い導電性サーメット６からアルミナ成分が溶出して耐ハロゲン性中間材５の流入部２２に流入するため、これが冷却して溶接が完了したときに接合部Ｗの外周が膨らむこともない（図５（ｄ））。 Next, the halogen-resistant intermediate material 5 and the conductive cermet 6 are butt welded.
Butt welding is a type of resistance welding, in which the inflow portion 22 of the halogen-resistant intermediate material 5 faces downward and is pressed against the upper end of the conductive cermet 6 so that a large current is instantaneously supplied to the joint W. Joule heat is generated (FIG. 5C).
As a result, the joining portion W is heated, and when a predetermined temperature is reached, the alumina component is eluted from the conductive cermet 6 having a melting point lower than that of the halogen-resistant intermediate material 5 made of molybdenum, and the inflow portion 22 of the halogen-resistant intermediate material 5 Therefore, when this is cooled and welding is completed, the outer periphery of the joint W does not swell (FIG. 5D).

そして最後に、耐ハロゲン性中間材５とタングステン電極４を突合せ溶接する。
ここでは、耐ハロゲン性中間材５の先端側に、電極４のタングステンロッド４ａを突き合わせた状態で瞬間的に大電流を流すことにより接合部にジュール熱を発生させ、これにより接合部が加熱され、所定の温度に達したところでタングステン電極４より融点の低い耐ハロゲン性中間材５のモリブデンロッド５ａが溶融し、電極４が突合せ溶接されて電極アセンブリ２１が完成する（図５（ｅ））。 Finally, the halogen resistant intermediate material 5 and the tungsten electrode 4 are butt welded.
Here, Joule heat is generated in the joint by instantaneously supplying a large current to the front end side of the halogen-resistant intermediate material 5 in a state where the tungsten rod 4a of the electrode 4 is abutted, and this heats the joint. When the temperature reaches a predetermined temperature, the molybdenum rod 5a of the halogen-resistant intermediate material 5 having a melting point lower than that of the tungsten electrode 4 is melted, and the electrode 4 is butt welded to complete the electrode assembly 21 (FIG. 5E).

このような電極アセンブリ２１において、耐ハロゲン性中間材５と導電性サーメット６を突合せ溶接する場合に、流れ出した溶融物で流入部２２を完全に塞ぐことができれば、接合部Ｗは外周面に凹凸のない直径が略一定の棒状体となるが、実際には、溶融物で外径が膨らまないように流入部２２を大きめに形成せざるを得ないので、図５（ｄ）に示すように、接合部Ｗに凹部２３が残ることが多い。   In such an electrode assembly 21, when the halogen-resistant intermediate material 5 and the conductive cermet 6 are butt welded, if the inflow portion 22 can be completely blocked by the melt that has flowed out, the joint portion W is uneven on the outer peripheral surface. Although the diameter of the inflow portion 22 becomes a rod-like body having a substantially constant diameter, in practice, the inflow portion 22 must be formed so as to prevent the outer diameter of the melt from expanding, as shown in FIG. In many cases, the recess 23 remains in the joint W.

また、凹部２３が残るだけでなく、稀ではあるが、抵抗溶接する際に、モリブデン線５ｂが熱変形する場合があることが判明した。
一般に、モリブデン線５ｂの曲げ加工を行う場合は、一次加工で線引きされたモリブデン線５ｂを１２００〜１５００℃で予め熱処理することにより柔軟性の大きな一次再結晶状態にしておく。
このように熱処理されたモリブデン線５ｂを用いると、その柔軟性が大きいため、二次加工としてコイルのような小径の曲げ加工も可能となる。 Further, it has been found that the molybdenum wire 5b may be thermally deformed during resistance welding as well as the recess 23 remains.
In general, when bending the molybdenum wire 5b, the molybdenum wire 5b drawn by the primary processing is preheated at 1200 to 1500 [deg.] C. to obtain a highly flexible primary recrystallized state.
When the heat-treated molybdenum wire 5b is used, the flexibility thereof is large, so that a small-diameter bending process such as a coil can be performed as a secondary process.

しかしながら、そのような曲げ加工を行うと二次加工での歪みが大きいためモリブデン線５ｂに内部応力が残り、耐ハロゲン性中間材５と導電性サーメット６を突合せ溶接するときに、図６に示すように、モリブデンロッド５ａに巻き付けたモリブデン線５ｂの端部がほどけて緩むように熱変形することが判明した。   However, when such a bending process is performed, distortion in the secondary process is large, so that internal stress remains in the molybdenum wire 5b, and when the halogen-resistant intermediate material 5 and the conductive cermet 6 are butt welded, as shown in FIG. Thus, it has been found that the end of the molybdenum wire 5b wound around the molybdenum rod 5a is thermally deformed so that it is loosened and loosened.

すなわち、図６に示すように、耐ハロゲン性中間材５のモリブデンロッド５ａの端面と導電性サーメット６の端面同士を突合せた状態で大電流を流すと、導電性サーメット６の先端が溶融されるが、このときモリブデンロッド５ａは約１８００〜２０００℃に達しており、その熱が接合部Ｗの近傍に巻かれているモリブデン線５ｂに伝わることにより、図示するほど極端ではないが、モリブデン線５ｂの端部がほどけて緩むように熱変形し、密巻きされている他の部分に比して外径の大きい大径部５ｃが形成されることが判明した。   That is, as shown in FIG. 6, when a large current is passed with the end faces of the molybdenum rod 5a of the halogen-resistant intermediate material 5 and the end faces of the conductive cermet 6 facing each other, the tip of the conductive cermet 6 is melted. However, at this time, the molybdenum rod 5a has reached about 1800 to 2000 ° C., and the heat is transferred to the molybdenum wire 5b wound in the vicinity of the joint W. It was found that a large-diameter portion 5c having a large outer diameter was formed as compared with other portions that were tightly wound.

この種のメタルハライドランプにおいては、耐ハロゲン性中間材５とキャピラリ３Ｒ、３Ｌの直径差は１００μｍ程度しかないので、大径部の直径がそれより大きくなると電極アセンブリ２１をキャピラリ３Ｒ、３Ｌに挿通することができなくなり、それより変形量が小さくてもモリブデン線５ｂが緩んで外径が大きくなった大径部５ｃはキャピラリ３Ｒ、３Ｌとの隙間が小さくなるので、そこにフリットガラス１０を充填したときに、隙間の違いによりクラックが発生する原因となりやすい。
なお、突合せ溶接した場合にモリブデン線５ｂが変形することは稀であることから、熱変形はモリブデン線５ｂの結晶構造、熱履歴、加工履歴、溶接条件など悪条件が重なったときに出現するものと思われるが、その原因を特定することはできなかった。 In this type of metal halide lamp, the difference in diameter between the halogen-resistant intermediate material 5 and the capillaries 3R, 3L is only about 100 μm, so that the electrode assembly 21 is inserted into the capillaries 3R, 3L when the diameter of the large diameter portion becomes larger. Even if the deformation amount is smaller than that, the large-diameter portion 5c in which the molybdenum wire 5b is loosened and the outer diameter is increased has a small gap with the capillaries 3R and 3L, and thus the frit glass 10 is filled therewith. Sometimes cracks are likely to occur due to gap differences.
Since the molybdenum wire 5b rarely deforms when butt welding is performed, thermal deformation appears when adverse conditions such as the crystal structure, thermal history, processing history, and welding conditions of the molybdenum wire 5b overlap. It seems that the cause could not be identified.

さらに、耐ハロゲン性中間材５と導電性サーメット６が理想的に突合せ溶接された場合は、図５（ｄ）に示すように、モリブデンロッド５ａが導電性サーメット６内に埋め込まれるように接合される。
しかしながら、突合せ溶接の際に、モリブデンロッド５ａの上に密巻きされたモリブデン線５ｂの上から耐ハロゲン性中間材５をクランプして下向きに加圧し、その先端を導電性サーメット６に強く押し当てているため、その押圧力によりモリブデン線５ｂがモリブデンロッド５ａ上でずれ落ち、相対的にモリブデンロッド５ａが引っ込むことがある。
この場合、突合せ溶接の際の押圧力が不足してモリブデンロッド５ａが導電性サーメット６内に十分埋め込まれず、その埋込量が浅くなるため接合部Ｗにおける強度が不足し、電極アセンブリ２１が折れやすくなるという問題が判明した。 Further, when the halogen-resistant intermediate material 5 and the conductive cermet 6 are ideally butt welded, the molybdenum rod 5a is joined so as to be embedded in the conductive cermet 6 as shown in FIG. The
However, at the time of butt welding, the halogen-resistant intermediate material 5 is clamped and pressed downward from the molybdenum wire 5b tightly wound on the molybdenum rod 5a, and the tip is strongly pressed against the conductive cermet 6. Therefore, the molybdenum wire 5b may be displaced on the molybdenum rod 5a due to the pressing force, and the molybdenum rod 5a may be relatively retracted.
In this case, the pressing force at the time of butt welding is insufficient and the molybdenum rod 5a is not sufficiently embedded in the conductive cermet 6, and the embedded amount becomes shallow, so that the strength at the joint W is insufficient and the electrode assembly 21 is broken. The problem of becoming easier was found.

しかも、この種の不具合は、接合部Ｗの外周を導電性サーメット６から溶出したアルミナ成分が被覆しているため、容易に判別することができず、厳密に製品検査しようとすれば、突合せ溶接前に全ての耐ハロゲン性中間材５及び導電性サーメット６の長さを予め測定しておき、突合せ溶接後にその全長を測定することにより、これらの値から埋込量を測定するしかない。
しかし、このような検査には手間がかかるため、製造コストが嵩み、生産効率が低下するという問題がある。 In addition, this type of defect cannot be easily identified because the outer periphery of the joint W is covered with the alumina component eluted from the conductive cermet 6, and if strict product inspection is attempted, butt welding is performed. The length of all the halogen-resistant intermediate materials 5 and the conductive cermet 6 is measured in advance, and the total length is measured after butt welding, so that the amount of burying can be measured from these values.
However, since such an inspection takes time, there is a problem that the manufacturing cost increases and the production efficiency decreases.

特開２００５−３０２６２４号公報JP 2005-302624 A 特開２００７− ７３３４０号公報JP 2007-73340 A

そこで本発明は、耐ハロゲン性中間材を構成するモリブデン線ごとに異なる固有の結晶構造、熱履歴、加工履歴などにかかわらず、導電性サーメットとの突合せ溶接時に熱変形を生じたり、埋込量が浅くなることによる強度不足を生じないようにすることを技術的課題としている。   Therefore, the present invention may cause thermal deformation during butt welding with a conductive cermet regardless of the unique crystal structure, thermal history, processing history, etc. that are different for each molybdenum wire constituting the halogen-resistant intermediate material. It is a technical problem to prevent a lack of strength due to the shallowness of the steel.

この課題を解決するため、本発明は、金属蒸気放電灯の発光管の両端に形成されたキャピラリに挿入されて気密封止される電極アセンブリの製造方法において、前記電極アセンブリは、発光管内に対向配設される電極と、モリブデンロッドにモリブデン線を密巻きして成る耐ハロゲン性中間材と、当該耐ハロゲン性中間材と同径でこれより融点の低い導電性サーメットを突合せ溶接して形成され、前記耐ハロゲン性中間材と導電性サーメットとを突合せ溶接する前に、前記耐ハロゲン性中間材の片端部でモリブデンロッドとモリブデン線とを溶融させ、その溶融物の表面張力によりモリブデンロッドとモリブデン線とを先丸状に硬化させて一体化させた後、当該耐ハロゲン性中間材の先丸状の片端部と導電性サーメットとを突き合わせ溶接することを特徴としている。   In order to solve this problem, the present invention provides a method of manufacturing an electrode assembly that is inserted into capillaries formed at both ends of an arc tube of a metal vapor discharge lamp and hermetically sealed, wherein the electrode assembly is opposed to the arc tube. It is formed by butt welding an electrode to be disposed, a halogen-resistant intermediate material formed by closely winding a molybdenum wire around a molybdenum rod, and a conductive cermet having the same diameter and lower melting point as the halogen-resistant intermediate material. Before butt welding the halogen resistant intermediate material and the conductive cermet, the molybdenum rod and the molybdenum wire are melted at one end of the halogen resistant intermediate material, and the molybdenum rod and the molybdenum wire are melted by the surface tension of the melt. After the wire is cured in a rounded shape and integrated, the rounded end of the halogen-resistant intermediate material and the conductive cermet are butt welded It is characterized in that.

本発明方法によれば、モリブデンロッドにモリブデン線を密巻きして成る耐ハロゲン性中間材のモリブデンロッドとモリブデン線とを予め溶融一体化させたので、耐ハロゲン性中間材と導電性サーメットを突合せ溶接する際にその接合部がモリブデン線の内部応力を解放させる温度に加熱されても、モリブデン線はモリブデンロッドに一体化されているため、これがほどけて緩むように熱変形することがない。
なお、耐ハロゲン性中間材のモリブデンロッドとモリブデン線とを溶接する際には、耐ハロゲン性中間材と導電性サーメットを突合せ溶接するときのように、モリブデン線がほどけて緩むように変形することはなかった。
これは、耐ハロゲン性中間材と導電性サーメットを突合せ溶接する場合と、モリブデンを溶かす場合とでは、その溶接条件が異なるためと思われる。
あくまでも仮説ではあるが、耐ハロゲン性中間材と導電性サーメットを突合せ溶接する場合はその温度がモリブデンの溶融温度までは達しないように溶接条件が設定されているところから、その温度が、二次加工での歪みが大きい場合にモリブデン線の内部応力を解放させコイル形状を変化させる温度条件に適合するためと思われる。
一方、モリブデンロッドとモリブデン線とをレーザ溶接する場合はモリブデンの溶融温度まで瞬時に加熱されるように溶接条件が設定されるため、モリブデン線が変形する前に溶融されると考えられる。 According to the method of the present invention, since the molybdenum rod and the molybdenum wire of the halogen resistant intermediate material formed by closely winding the molybdenum wire around the molybdenum rod are fused and integrated in advance, the halogen resistant intermediate material and the conductive cermet are butt-matched. Even when the joint is heated to a temperature at which the internal stress of the molybdenum wire is released during welding, the molybdenum wire is integrated with the molybdenum rod, so that it does not thermally deform so that it can be loosened and loosened.
When welding a molybdenum rod of a halogen-resistant intermediate material and a molybdenum wire, it is not possible to deform so that the molybdenum wire is unscrewed and loosened like when butt welding the halogen-resistant intermediate material and the conductive cermet. There wasn't.
This seems to be because the welding conditions differ between the case where the halogen-resistant intermediate material and the conductive cermet are butt-welded and the case where molybdenum is melted.
Although it is a hypothesis to the last, when butt welding a halogen-resistant intermediate material and conductive cermet, the welding conditions are set so that the temperature does not reach the melting temperature of molybdenum. It seems to meet the temperature condition that releases the internal stress of the molybdenum wire and changes the coil shape when the strain in processing is large.
On the other hand, when laser welding a molybdenum rod and a molybdenum wire, the welding conditions are set so that the molybdenum wire is instantaneously heated to the melting temperature of molybdenum, so it is considered that the molybdenum wire is melted before it is deformed.

また、耐ハロゲン性中間材のモリブデンロッドとモリブデン線は、溶融モリブデンの表面張力によりモリブデンロッドとモリブデン線が先丸状に硬化されて一体化される。
したがって、導電性サーメットと突合せ溶接する際にモリブデン線をクランプして加圧しても、モリブデン線がモリブデンロッドからずれ落ちることがないので、その埋込量が一定に維持され、強度不足を生じることがない。
しかも、その先端面は凸曲面状に膨出されるので、突合せ溶接する際にその中央部が最初に触れることとなり、導電性サーメットの中央部からアルミナが溶出することによって溶融しないモリブデン粒が移動し、耐ハロゲン中間材の先丸状部分が導電性サーメット先端面に食い込んでいくため高い溶接強度を得ることができる。また、溶出したアルミナは導電性サーメット外径より小径となる空間に溜まるので、その空間の周囲には溶融物が溢れ出にくくなり、同径の耐ハロゲン性中間材と導電性サーメットを接合部で外径変化させることなく均一な太さで突合せ溶接することができる。 Further, the molybdenum rod and the molybdenum wire of the halogen-resistant intermediate material are integrated by hardening the molybdenum rod and the molybdenum wire into a rounded shape by the surface tension of the molten molybdenum.
Therefore, even if the molybdenum wire is clamped and pressed when butt welding with the conductive cermet, the molybdenum wire does not slip off from the molybdenum rod, so that the amount of embedding is maintained constant, resulting in insufficient strength. There is no.
In addition, since the tip surface bulges into a convex curved surface, the center portion of the butt weld is first touched during butt welding, and the molybdenum particles that do not melt move due to the dissolution of alumina from the center portion of the conductive cermet. Since the rounded portion of the halogen-resistant intermediate material bites into the tip surface of the conductive cermet, high welding strength can be obtained. In addition, since the eluted alumina accumulates in a space that is smaller than the outer diameter of the conductive cermet, it is difficult for the melt to overflow around the space, and the halogen-resistant intermediate material of the same diameter and the conductive cermet are joined at the joint. Butt welding can be performed with a uniform thickness without changing the outer diameter.

本発明に係る電極アセンブリの製造方法の一例を示す説明図である。It is explanatory drawing which shows an example of the manufacturing method of the electrode assembly which concerns on this invention. 接合部の各大図である。It is each big figure of a junction part. セラミックメタルハライドランプの全体構成図である。It is a whole block diagram of a ceramic metal halide lamp. 耐ハロゲン性中間材の先端形状と歩留まりの関係を示すグラフである。It is a graph which shows the relationship between the front-end | tip shape of a halogen-resistant intermediate material, and a yield. 従来の電極アセンブリの製造方法を示す説明図である。It is explanatory drawing which shows the manufacturing method of the conventional electrode assembly. 従来の電極アセンブリの熱変形を示す説明図である。It is explanatory drawing which shows the thermal deformation of the conventional electrode assembly.

本発明は、耐ハロゲン性中間材を構成するモリブデン線ごとに異なる固有の結晶構造、熱履歴、加工履歴などにかかわらず、耐ハロゲン性中間材と導電性サーメットとを突き合わせ溶接する際に、モリブデン線が熱変形を生じないようにするという目的を達成するために、耐ハロゲン性中間材の片端部でモリブデンロッドとモリブデン線とを溶融させ、その溶融物の表面張力によりモリブデンロッドとモリブデン線とを先丸状に硬化させて一体化させた後、先丸状の片端部と導電性サーメットとを突き合わせ溶接することとした。   In the present invention, when butt welding a halogen-resistant intermediate material and a conductive cermet regardless of the specific crystal structure, thermal history, processing history, etc., which is different for each molybdenum wire constituting the halogen-resistant intermediate material, In order to achieve the purpose of preventing the wire from undergoing thermal deformation, the molybdenum rod and the molybdenum wire are melted at one end of the halogen-resistant intermediate material, and the molybdenum rod and the molybdenum wire are bonded by the surface tension of the melt. After being hardened and integrated into a rounded shape, one end of the rounded shape and the conductive cermet were butt welded.

以下、本発明を図面に示す実施例に基づいて説明する。
なお、図３と共通する部分は同一符号を付して詳細説明は省略する。
金属蒸気放電灯の発光管２の両端に形成されたキャピラリ３Ｒ、３Ｌに気密封止される電極アセンブリ１は、タングステンロッドで成る電極棒４ａの先端側にタングステン線４ｂを密巻きして放熱用のコイル部が形成された電極４と、モリブデンロッド５ａの外周部にモリブデン線５ｂを密巻きしてコイル部が形成された耐ハロゲン性中間材５と、アルミナ粉末とモリブデン粉末とを混合燒結して成る導電性サーメット６とが直列的に突合せ溶接された構成となっている。 Hereinafter, the present invention will be described based on embodiments shown in the drawings.
In addition, the same code | symbol is attached | subjected to the part which is common in FIG. 3, and detailed description is abbreviate | omitted.
An electrode assembly 1 hermetically sealed in capillaries 3R and 3L formed at both ends of an arc tube 2 of a metal vapor discharge lamp has a tungsten wire 4b tightly wound around the tip side of an electrode rod 4a made of a tungsten rod for heat dissipation. The electrode 4 in which the coil part is formed, the halogen-resistant intermediate material 5 in which the coil part is formed by closely winding the molybdenum wire 5b around the outer periphery of the molybdenum rod 5a, and alumina powder and molybdenum powder are mixed and sintered. The conductive cermet 6 is butt welded in series.

この電極アセンブリ３を製造する際は、図１（ａ）に示すように、例えば直径０.４〜０.５ｍｍのモリブデンロッド５ａの外周部に、直径０.１５〜０.２ｍｍのモリブデン線５ｂを密巻きし、所定長さに切断された直径０.７０〜０.９０ｍｍ程度の耐ハロゲン性中間材５を直立させた状態で、その先端を溶融する。
本例では、その上方から、モリブデンロッド５ｂと同軸的にレーザ光Ｌを照射して、モリブデンロッド５ａとモリブデン線５ｂとを溶融している。 When the electrode assembly 3 is manufactured, as shown in FIG. 1A, for example, a molybdenum wire 5b having a diameter of 0.15 to 0.2 mm is formed on the outer periphery of a molybdenum rod 5a having a diameter of 0.4 to 0.5 mm. The tip is melted in a state in which the halogen-resistant intermediate material 5 having a diameter of about 0.70 to 0.90 mm cut into a predetermined length is kept upright.
In this example, the laser beam L is irradiated coaxially with the molybdenum rod 5b from above to melt the molybdenum rod 5a and the molybdenum wire 5b.

ここで、レーザ光Ｌを照射してモリブデンロッド５ａとモリブデン線５ｂとを溶融させた後、所定時間経過すると、図１（ｂ）及び（ｃ）に示すように、その先端部分が溶融物（液滴）の表面張力により先丸状となり、これが冷えると硬化して一体化される。
このとき、先丸状に硬化される片端部５ｄの外径が耐ハロゲン性中間材５の外径に等しくなるように溶融量がコントロールされる。
溶融量は、例えば、レーザ溶接の溶接条件によりコントロールされ、本例では、出力１５０ＷのＹＡＧレーザを用い、レーザ光の照射時間を実験により１０ｍｓとした。 Here, after irradiating the laser beam L and melting the molybdenum rod 5a and the molybdenum wire 5b, when a predetermined time elapses, as shown in FIGS. It becomes a rounded tip due to the surface tension of the droplets, and when it cools, it hardens and integrates.
At this time, the amount of melting is controlled so that the outer diameter of the one end portion 5 d that is hardened in a rounded shape is equal to the outer diameter of the halogen-resistant intermediate material 5.
The amount of melting is controlled by, for example, laser welding conditions. In this example, a YAG laser with an output of 150 W was used, and the irradiation time of laser light was experimentally set to 10 ms.

この条件で先丸状に加工された片端部５ｄの先端面の曲率半径Ｒを測定したところ、耐ハロゲン性中間材５の直径Ｄに対して、０.５７Ｄ≦Ｒ≦０.５８Ｄであった。この曲率半径は、先端面頂点近傍における値であり、先端面が完全な部分球面に形成されていることを意味するものではない。
また、溶接条件を変えて、片端部５ｄを種々の曲率半径Ｒに形成した耐ハロゲン性中間材５を用いて形成した電極アセンブリ１について実験を行ったところ、歩留り９９％以上となる曲率半径Ｒの範囲は、０.５５Ｄ≦Ｒ≦０.８０Ｄであった（図４参照）。
なおこのとき、Ｒ＜０.５５Ｄとすると、導電性サーメット６を突き合わせ溶接するときに、耐ハロゲン性中間材５の片端部５ｄが導電性サーメット６の先端面に食い込みすぎてモリブデン・リッチ層が径方向に膨らんでしまい、食込量を減らすと接合部Ｗに段差が形成されて溶出したアルミナでその段差を覆いきれない。このため、ランプ完成後にフリットガラスにクラックが生じ易くなり、いずれの場合も電極アセンブリとしては不良品となる。
また、Ｒ＞０.８０Ｄとすると、耐ハロゲン性中間材５の端面がほぼ平面に近くなるので、導電性サーメット６を突き合わせ溶接するときに導電性サーメット６の外径より小径となる空間（図２参照）がほとんどなくなり、溶出したアルミナが接合部に付着すると導電性サーメット６の外径より膨らんでしまうため、やはり、電極アセンブリとしては不良品となる。 When the radius of curvature R of the front end surface of the one end portion 5d processed into a rounded shape was measured under these conditions, it was 0.57D ≦ R ≦ 0.58D with respect to the diameter D of the halogen-resistant intermediate material 5. . This radius of curvature is a value in the vicinity of the apex of the tip surface, and does not mean that the tip surface is formed into a complete partial spherical surface.
Further, when an experiment was conducted on the electrode assembly 1 formed by using the halogen-resistant intermediate material 5 in which the one end portion 5d was formed with various curvature radii R under different welding conditions, the curvature radius R yielding 99% or more was obtained. The range was 0.55D ≦ R ≦ 0.80D (see FIG. 4).
At this time, if R <0.55D, when the conductive cermet 6 is butt welded, one end portion 5d of the halogen-resistant intermediate material 5 bites into the front end surface of the conductive cermet 6 and the molybdenum-rich layer is formed. If the amount of encroachment is reduced due to swelling in the radial direction, a step is formed at the joint W, and the step cannot be covered with the eluted alumina. For this reason, cracks are likely to occur in the frit glass after completion of the lamp, and in any case, the electrode assembly is a defective product.
Further, when R> 0.80D, the end surface of the halogen-resistant intermediate material 5 is almost flat, so that when the conductive cermet 6 is butt welded, the space becomes smaller than the outer diameter of the conductive cermet 6 (see FIG. 2) is almost eliminated, and when the eluted alumina adheres to the joint portion, it swells from the outer diameter of the conductive cermet 6, so that it becomes a defective product as an electrode assembly.

上述の説明では、レーザ光で加熱溶融する場合について説明したが、本発明はこれに限らず、プラズマ溶接、ＴＩＧ溶接など任意の方法を用いることができ、要するに、直径１ｍｍにも満たない耐ハロゲン性中間材５の片端部５ｄのみをモリブデン線５ｂが熱変形する前に溶融する程度に短時間で融点まで局部加熱することができれば、加熱方法は任意である。   In the above description, the case of heating and melting with laser light has been described. However, the present invention is not limited to this, and any method such as plasma welding or TIG welding can be used. In short, the halogen resistance is less than 1 mm in diameter. The heating method is arbitrary as long as only one end portion 5d of the conductive intermediate material 5 can be locally heated to the melting point in a short time to the extent that the molybdenum wire 5b is melted before being thermally deformed.

次いで、耐ハロゲン性中間材５と導電性サーメット６を突合せ溶接する。
突合せ溶接は抵抗溶接の一種であり、図１（ｄ）に示すように、耐ハロゲン性中間材５の先丸状の片端部５ｄを下向きにして、導電性サーメット６の上端に突合せた状態で瞬間的に大電流（本例では、０.９Ｖ、９０Ａ）を流すことにより接合部Ｗにジュール熱を発生させて溶接させる。
片端部５ｄは先丸状に形成されているので、その先端中心部が導電性サーメット６の先端に点接触されており、アルミナ粉末とモリブデン粉末とを混合燒結して成る導電性サーメット６はその融点がモリブデンからなる耐ハロゲン性中間材５より低いので、大電流を流すことにより導電性サーメット６からアルミナが溶出する。 Next, the halogen-resistant intermediate material 5 and the conductive cermet 6 are butt welded.
Butt welding is a type of resistance welding, as shown in FIG. 1 (d), in a state in which the end portion 5 d of the halogen-resistant intermediate material 5 faces downward and is butted against the upper end of the conductive cermet 6. By instantaneously supplying a large current (0.9 V, 90 A in this example), Joule heat is generated at the joint W to be welded.
Since the one end portion 5d is formed in a rounded shape, the center of the tip is point-contacted with the tip of the conductive cermet 6, and the conductive cermet 6 formed by mixing and sintering alumina powder and molybdenum powder is Since the melting point is lower than that of the halogen-resistant intermediate material 5 made of molybdenum, alumina is eluted from the conductive cermet 6 by passing a large current.

導電性サーメット６が融点近傍まで加熱されると、図１（ｅ）に示すように、導電性サーメット６の中央部からアルミナが溶出することによって耐ハロゲン性中間材５の先丸状の片端部５ｄの形状に応じて凹曲面６ａが形成され、導電性サーメット６の先端近傍にはモリブデンの比率が高いモリブデン・リッチ層６ｂが形成される。導電性サーメット６から溶出したアルミナは導電性サーメット外径より小径となる空間Ｘ（図２参照）に溜まっていき、これが冷えると硬化して耐ハロゲン性中間材５と導電性サーメット６が一体化し、突合せ溶接が完了する。
なお、溶出したアルミナは導電性サーメット外径より小径となる空間Ｘに溜まるので、その空間Ｘの周囲には溢れ出にくくなり、同径の耐ハロゲン性中間材５と導電性サーメット６を接合部Ｗで外径が変化することなく均一な太さに突合せ溶接することができる。 When the conductive cermet 6 is heated to the vicinity of the melting point, as shown in FIG. 1 (e), the alumina elutes from the central portion of the conductive cermet 6 to cause one end of the round end of the halogen-resistant intermediate material 5 A concave curved surface 6a is formed in accordance with the shape of 5d, and a molybdenum rich layer 6b having a high molybdenum ratio is formed in the vicinity of the tip of the conductive cermet 6. The alumina eluted from the conductive cermet 6 accumulates in a space X (see FIG. 2) that is smaller than the outer diameter of the conductive cermet, and when it cools, it hardens and the halogen-resistant intermediate material 5 and the conductive cermet 6 are integrated. The butt welding is completed.
Since the eluted alumina is accumulated in the space X having a smaller diameter than the outer diameter of the conductive cermet, it is difficult to overflow around the space X, and the halogen-resistant intermediate material 5 and the conductive cermet 6 having the same diameter are joined to each other. W can be butt welded to a uniform thickness without changing the outer diameter.

そして最後に、耐ハロゲン性中間材５の上端部に電極４を突合せ溶接する。
この場合も、図１（ｅ）に示すように、耐ハロゲン性中間材５のモリブデンロッド５ａの端面に、電極のタングステンロッド４ａを突合わせた状態で瞬間的に大電流（本例では、１.０Ｖ、１００Ａ）を流すことにより溶接させる。
この場合、電極４を構成するタングステンロッド４ａよりも、耐ハロゲン性中間材５を構成するモリブデンロッド５ａの方が融点が低いので、モリブデンを溶融し得る程度の大電流が流され、これにより生じたジュール熱によりモリブデンロッド５ａの突合せ部分が溶融する温度に瞬時に加熱され、この熱により、モリブデン線５ｂも溶融される。
この結果、モリブデンロッド５ａにタングステンロッド４ａが埋め込まれると共に、モリブデン線５ｂも溶融されてモリブデンロッド５ａに一体化される。 Finally, the electrode 4 is butt welded to the upper end of the halogen-resistant intermediate material 5.
Also in this case, as shown in FIG. 1 (e), a large current (in this example, 1 in this example) is instantaneous in a state where the tungsten rod 4a of the electrode is abutted against the end face of the molybdenum rod 5a of the halogen-resistant intermediate material 5. Welding by flowing 0.0V, 100A).
In this case, since the melting point of the molybdenum rod 5a constituting the halogen-resistant intermediate material 5 is lower than that of the tungsten rod 4a constituting the electrode 4, a large current capable of melting molybdenum is caused to flow. The Joule heat instantaneously heats the butt portion of the molybdenum rod 5a to a melting temperature, and the molybdenum wire 5b is also melted by this heat.
As a result, the tungsten rod 4a is embedded in the molybdenum rod 5a, and the molybdenum wire 5b is also melted and integrated with the molybdenum rod 5a.

このように製造された電極アセンブリ１は、同径の耐ハロゲン性中間材５と導電性サーメット６とを突合せ溶接する場合に、モリブデン線４ｂがほどけて緩むように熱変形したり、加圧時にモリブデン線５ｂがずれ落ちたりすることがなく、また、接合部Ｗには径方向に凹部や凸部が形成されることもなく、一定の外径で連結される。
したがって、電極アセンブリ１をキャピラリ３Ｒ，３Ｌに挿通してその接合部Ｗまでフリットガラス１０を充填して封止したときに、フリットガラス１０が均一の厚さで充填されることとなるので、ランプの点灯に伴う熱膨張によりフリットガラス１０にクラックが入ることもない。 The electrode assembly 1 manufactured as described above is thermally deformed so that the molybdenum wire 4b is unscrewed and loosened when the halogen-resistant intermediate material 5 and the conductive cermet 6 having the same diameter are butt welded, The wire 5b does not slip off, and the joint W is connected with a constant outer diameter without forming a concave portion or a convex portion in the radial direction.
Therefore, when the electrode assembly 1 is inserted into the capillaries 3R and 3L and the frit glass 10 is filled and sealed up to the joint W, the frit glass 10 is filled with a uniform thickness. The frit glass 10 is not cracked by the thermal expansion associated with the lighting.

なお、本例では、耐ハロゲン性中間材５と導電性サーメット６とを突合せ溶接した後、電極４と耐ハロゲン性中間材５を突合せ溶接する場合について説明したが、本発明はこれに限らず、電極４と耐ハロゲン性中間材５を突合せ溶接した後、耐ハロゲン性中間材５と導電性サーメット６とを突合せ溶接する場合であってもよい。   In this example, the case where the halogen resistant intermediate material 5 and the conductive cermet 6 are butt welded and then the electrode 4 and the halogen resistant intermediate material 5 are butt welded is described. However, the present invention is not limited to this. Alternatively, the electrode 4 and the halogen resistant intermediate material 5 may be butt welded, and then the halogen resistant intermediate material 5 and the conductive cermet 6 may be butt welded.

以上述べたように、本発明は、発光管内に対向配設される電極と、モリブデンロッドにモリブデン線を密巻きして成る耐ハロゲン性中間材と、当該耐ハロゲン性中間材と同径でこれより融点の低い導電性サーメットを突合せ溶接して、金属蒸気放電灯の電極アセンブリを製造する用途に適用し得る。   As described above, the present invention includes an electrode disposed oppositely in the arc tube, a halogen-resistant intermediate material formed by closely winding a molybdenum wire around a molybdenum rod, and the same diameter as the halogen-resistant intermediate material. The present invention can be applied to an application for manufacturing an electrode assembly of a metal vapor discharge lamp by butt welding a conductive cermet having a lower melting point.

１ 電極アセンブリ
２ 発光管
３Ｒ，３Ｌ キャピラリ
４ａ タングステンロッド
４ｂ タングステン線
４ 電極
５ａ モリブデンロッド
５ｂ モリブデン線
５ 耐ハロゲン性中間材
６ 導電性サーメット
１０ フリットガラス
Ｗ 接合部

DESCRIPTION OF SYMBOLS 1 Electrode assembly 2 Arc tube 3R, 3L Capillary 4a Tungsten rod
4b Tungsten wire 4 Electrode 5a Molybdenum rod 5b Molybdenum wire 5 Halogen-resistant intermediate material 6 Conductive cermet 10 Frit glass W Joint

Claims (3)

金属蒸気放電灯の発光管の両端に形成されたキャピラリに挿入されて気密封止される電極アセンブリの製造方法において、
前記電極アセンブリは、発光管内に対向配設される電極と、モリブデンロッドにモリブデン線を密巻きして成る耐ハロゲン性中間材と、当該耐ハロゲン性中間材と同径でこれより融点の低い導電性サーメットを突合せ溶接して形成され、
前記耐ハロゲン性中間材と導電性サーメットとを突合せ溶接する前に、前記耐ハロゲン性中間材の片端部でモリブデンロッドとモリブデン線とを溶融させ、その溶融物の表面張力によりモリブデンロッドとモリブデン線とを先丸状に硬化させて一体化させた後、当該耐ハロゲン性中間材の先丸状の片端部と導電性サーメットとを突き合わせ溶接することを特徴とする電極アセンブリの製造方法。 In a method for manufacturing an electrode assembly that is inserted into capillaries formed at both ends of an arc tube of a metal vapor discharge lamp and hermetically sealed,
The electrode assembly includes an electrode disposed oppositely in the arc tube, a halogen-resistant intermediate material formed by closely winding a molybdenum wire around a molybdenum rod, and a conductive material having the same diameter as the halogen-resistant intermediate material and a lower melting point. Formed by butt welding sexual cermet,
Before butt welding the halogen resistant intermediate material and the conductive cermet, the molybdenum rod and the molybdenum wire are melted at one end of the halogen resistant intermediate material, and the molybdenum rod and the molybdenum wire are melted by the surface tension of the melt. Are cured in a rounded shape and integrated, and then the rounded end of the halogen-resistant intermediate material and the conductive cermet are butt welded to each other. 先丸状に硬化された前記片端部の外径が、耐ハロゲン性中間材の外径に等しくなるように溶融条件を決定した請求項１記載の電極アセンブリの製造方法。   The method for manufacturing an electrode assembly according to claim 1, wherein the melting condition is determined so that the outer diameter of the one end portion cured in a rounded shape is equal to the outer diameter of the halogen-resistant intermediate material. 前記耐ハロゲン性中間材の直径をＤとしたときに、先丸状に硬化された片端部の先端面の曲率半径Ｒが０.５５Ｄ≦Ｒ≦０.８０Ｄである請求項１記載の電極アセンブリの製造方法。

2. The electrode assembly according to claim 1, wherein a radius of curvature R of a front end surface of one end portion hardened in a rounded shape is 0.55D ≦ R ≦ 0.80D, where D is a diameter of the halogen-resistant intermediate material. Manufacturing method.

JP2009019577A 2009-01-30 2009-01-30 Electrode assembly manufacturing method of metal vapor discharge lamp Pending JP2010177092A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2458615A2 (en) 2010-11-30 2012-05-30 NGK Insulators, Ltd. Arc tube and method of manufacturing same

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2458615A2 (en) 2010-11-30 2012-05-30 NGK Insulators, Ltd. Arc tube and method of manufacturing same

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