WO2002047102A2 - Electrodeless lamp - Google Patents

Electrodeless lamp Download PDF

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Publication number
WO2002047102A2
WO2002047102A2 PCT/US2001/046900 US0146900W WO0247102A2 WO 2002047102 A2 WO2002047102 A2 WO 2002047102A2 US 0146900 W US0146900 W US 0146900W WO 0247102 A2 WO0247102 A2 WO 0247102A2
Authority
WO
WIPO (PCT)
Prior art keywords
preform
aperture
electrodeless lamp
window
ceramic
Prior art date
Application number
PCT/US2001/046900
Other languages
French (fr)
Inventor
Floyd R. Pothoven
Terry A. Pothoven
Original Assignee
Itw, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Itw, Inc. filed Critical Itw, Inc.
Priority to AU2002227271A priority Critical patent/AU2002227271A1/en
Publication of WO2002047102A2 publication Critical patent/WO2002047102A2/en

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J9/00Apparatus or processes specially adapted for the manufacture, installation, removal, maintenance of electric discharge tubes, discharge lamps, or parts thereof; Recovery of material from discharge tubes or lamps
    • H01J9/24Manufacture or joining of vessels, leading-in conductors or bases
    • H01J9/245Manufacture or joining of vessels, leading-in conductors or bases specially adapted for gas discharge tubes or lamps
    • H01J9/247Manufacture or joining of vessels, leading-in conductors or bases specially adapted for gas discharge tubes or lamps specially adapted for gas-discharge lamps
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C04B35/111Fine ceramics
    • C04B35/115Translucent or transparent products
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/14Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/64Burning or sintering processes
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J61/00Gas-discharge or vapour-discharge lamps
    • H01J61/02Details
    • H01J61/30Vessels; Containers
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J61/00Gas-discharge or vapour-discharge lamps
    • H01J61/02Details
    • H01J61/30Vessels; Containers
    • H01J61/302Vessels; Containers characterised by the material of the vessel
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J61/00Gas-discharge or vapour-discharge lamps
    • H01J61/02Details
    • H01J61/36Seals between parts of vessels; Seals for leading-in conductors; Leading-in conductors
    • H01J61/361Seals between parts of vessel
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J65/00Lamps without any electrode inside the vessel; Lamps with at least one main electrode outside the vessel
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J65/00Lamps without any electrode inside the vessel; Lamps with at least one main electrode outside the vessel
    • H01J65/04Lamps in which a gas filling is excited to luminesce by an external electromagnetic field or by external corpuscular radiation, e.g. for indicating plasma display panels
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J65/00Lamps without any electrode inside the vessel; Lamps with at least one main electrode outside the vessel
    • H01J65/04Lamps in which a gas filling is excited to luminesce by an external electromagnetic field or by external corpuscular radiation, e.g. for indicating plasma display panels
    • H01J65/042Lamps in which a gas filling is excited to luminesce by an external electromagnetic field or by external corpuscular radiation, e.g. for indicating plasma display panels by an external electromagnetic field
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/94Products characterised by their shape
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02BCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B20/00Energy efficient lighting technologies, e.g. halogen lamps or gas discharge lamps

Definitions

  • the present invention relates to an electrodeless lamp, that is to say a hollow structure containing a material excitable by radio frequency energy to emit visible light.
  • the object of the invention is to provide an electrodeless lamp body having a translucent window.
  • a body for an electrodeless lamp comprising: • a body preform of sintered ceramic material, defining the shape of the body which is hollow; • an aperture in the preform for charging the excitable material into the hollow body; and
  • the preform has a stepped recess at one end for receiving the window, which is accommodated in the stepped recess.
  • the charging aperture may be sealed with a disc of sintered ceramic material fused to the body across the aperture.
  • the body may be formed at the aperture with a collapsible lip, which seals the aperture on fusing of the lip.
  • the ceramic material of the preform can be of alumina ceramic or quartz.
  • the window can be of alumina ceramic, particularly artificial sapphire, or quartz.
  • an electrodeless lamp having a body in accordance with the first aspect, with its charging aperture sealed and containing the excitable material.
  • an electrodeless lamp consisting in the steps of:
  • the excitable material is charged into the hollow body whilst the latter is still hot from the firing of the preform and the laser irradiation also is carried out whilst the hollow body is still hot.
  • the lamp body is flushed with inert gas to cool it from its firing temperature and flush oxygen from it prior to injection of excitable material.
  • the method preferably includes the evacuation of the lam body prior to injection of excitable material.
  • Figure 1 is a cross-sectional view o f a first lamp of the invention, with a disc seal;
  • Figure 2 is a similar view of a seco nd lamp, with a collapsible lip aperture prior to sealing;
  • Figure 3 is a similar view of the second lamp after sealing; and Figure 4 is a process flow diagram for forming another lamp of the invention.
  • the lamp 1 has a body 2 of sintered alumina ceramic material and an artificial sapphire window 3.
  • the body 2 is initially moulded in green state and the window is pressed into a front recess 4.
  • the combination is fired at a temperature of the order of 1500°C, to fuse the body into a coherent pressure-tight state with the window.
  • a pellet of excitable material is added through a rear, charging aperture 5.
  • a disc 6 of ceramic with frit 7 is placed over the aperture. The disc is irradiated by laser to fuse the frit and the disc to the body, thus sealing the excitable material into the lamp.
  • the lamp 11 has a body 12 and window 13 formed and sealed together in essentially the same manner as in the first embodiment.
  • the charging aperture 15 has a lip 21 around its orifice 22, the lip being defined by a groove 23. The lip is such that on charging of the excitable material into the body, and laser irradiation of the lip, the lip collapses into a fused closure 26 to close the aperture at its orifice entrapping the excitable material.
  • the choice of the inert gas and the excitable material will be within the abilities of the man skilled in the art, as will be the choice of ceramic material.
  • This can be of alumina ceramic or quartz.
  • the window can be of alumina for example artificial sapphire or of quartz.
  • the excitable material can be of indium bromide with argon or krypton or sulphur with krypton.
  • FIG. 4 there is shown a process flow diagram for forming another lamp of the invention. It will be described in accordance with the steps shown in the Figure.
  • a preform for the lamp body 102 is moulded from green ceramic material. It has a circular cylindrical side wall 1021, with an end wall 1022, having a central sealing lip 121 defining a charging aperture 115. Its other end has a rim 1023 surrounding a recess 104.
  • Step 2 An artificial sapphire window 103 is pressed into the lamp body 102 at the recess 104.
  • Step 3 The body and window are fired at 1500°C. This unifies the body and the window to it.
  • Step 4. The body and window are inverted and robotically placed centrally on a turntable T within an open topped dish D.
  • a laser L is arranged above the body and used to maintain the temperature of the body at 1500°C by irradiation.
  • Step 5 A krypton injection needle N is inserted through the aperture 115 far enough for its end to be close to the window.
  • the needle has a closed end with side ports.
  • the krypton flushes oxygen from the body and flows into the dish D, where it is retained, whereby oxygen is displaced from the body.
  • Step 6 Cooler krypton is now injected to cool the body to 400°C.
  • the krypton needle is withdrawn and an indium bromide injection needle H3N is inserted into the body in its stead.
  • the needle has a small, heated reservoir R of indium bromide with a piezoelectric crystal C in its side wall. Pulsing of the crystal forces a droplet of the molten indium bromide from the needle IBN into the body.
  • Step 7 Immediately after injection, the needle is withdrawn and a vacuum shroud S is dropped over the body 102 to seal with the dish.
  • the shroud is evacuated swiftly to remove any possible trace of oxygen.
  • the shroud is refilled with krypton and the lamp body maintained at 400°C. This is by laser irradiation through a window W in the shroud.
  • Step 8 The laser L is trepanned around the lip 121, which melts in against itself, thereby sealing the body, with the indium bromide sealed inside.
  • an annular cold trap T is positioned between the window and the lamp body.

Abstract

A lamp 1 has a body 2 of sintered alumina ceramic material and an artificial sapphire window 3. The body 2 is initially moulded in green state and the window is pressed into a front recess 4. The combination is fired at a temperature of the order of 1500 degrees Centigrade, to fuse the body into a coherent pressure-tight state with the window. After partial cooling to the order of 600 degrees Centigrade, a pellet of excitable material is added through a rear, charging aperture 5. A disc 6 of ceramic with frit 7 is placed over the aperture. The disc is irradiated by laser to fuse the frit and the disc to the body, thus sealing the excitable material into the lamp.

Description

ELECTRODELESS LAMP
The present invention relates to an electrodeless lamp, that is to say a hollow structure containing a material excitable by radio frequency energy to emit visible light.
It is known to fabricate such a lamp from sintered ceramic components. For instance, US Patent No 5,727,975 describes the production of lamps from components that are shrunk fitted to each other.
In my US patent application No. 60/173,214, dated 27th December 1999, 1 described an electrodeless lamp comprising:
• a hollow body of ceramic material having an open end and containing a charge of excitable material with a given melting point;
• a translucent closure at the open end of the body;
• a seal between the body and the closure, the seal being of fused material having a fusing point higher than that of the excitable material.
I had envisaged that the charge of excitable material would be contained in the hollow body prior to sealing of the closure onto the body. However, I now envisage that the translucent closure or window will be attached to the body prior to final closure.
The object of the invention is to provide an electrodeless lamp body having a translucent window.
According to the invention there is provided a body for an electrodeless lamp, the body comprising: • a body preform of sintered ceramic material, defining the shape of the body which is hollow; • an aperture in the preform for charging the excitable material into the hollow body; and
• a translucent window, the window and the preform being a coherent unit resulting from the window having been pressed onto the preform when green and the window having been united to the preform on firing of the ceramic material.
Preferably, the preform has a stepped recess at one end for receiving the window, which is accommodated in the stepped recess.
I envisage that the charging aperture may be sealed with a disc of sintered ceramic material fused to the body across the aperture. Alternatively, the body may be formed at the aperture with a collapsible lip, which seals the aperture on fusing of the lip.
The ceramic material of the preform can be of alumina ceramic or quartz.
The window can be of alumina ceramic, particularly artificial sapphire, or quartz.
According to another aspect of the invention there is a provided an electrodeless lamp having a body in accordance with the first aspect, with its charging aperture sealed and containing the excitable material.
According to a third aspect of the invention there is provided a method of manufacturing an electrodeless lamp, consisting in the steps of:
• forming a preform of green ceramic, the preform defining a hollow body shape with an aperture;
• pressing a window onto the preform; • firing the green ceramic to fuse it and unite the window to the preform;
• charging excitable material into the hollow body; • sealing the aperture.
Preferably, the excitable material is charged into the hollow body whilst the latter is still hot from the firing of the preform and the laser irradiation also is carried out whilst the hollow body is still hot.
Preferably, the lamp body is flushed with inert gas to cool it from its firing temperature and flush oxygen from it prior to injection of excitable material. Further the method preferably includes the evacuation of the lam body prior to injection of excitable material.
To help understanding of the invention, three specific embodiments thereof will now be described by way of example and with reference to the accompanying drawings, in which: Figure 1 is a cross-sectional view o f a first lamp of the invention, with a disc seal;
Figure 2 is a similar view of a seco nd lamp, with a collapsible lip aperture prior to sealing;
Figure 3 is a similar view of the second lamp after sealing; and Figure 4 is a process flow diagram for forming another lamp of the invention.
^Figure if).
Referring first to Figure 1, the lamp 1 has a body 2 of sintered alumina ceramic material and an artificial sapphire window 3. The body 2 is initially moulded in green state and the window is pressed into a front recess 4. The combination is fired at a temperature of the order of 1500°C, to fuse the body into a coherent pressure-tight state with the window. After partial cooling to the order of 600°C, a pellet of excitable material is added through a rear, charging aperture 5. A disc 6 of ceramic with frit 7 is placed over the aperture. The disc is irradiated by laser to fuse the frit and the disc to the body, thus sealing the excitable material into the lamp. Referring now to Figures 2 & 3, the lamp 11 has a body 12 and window 13 formed and sealed together in essentially the same manner as in the first embodiment. However, the charging aperture 15 has a lip 21 around its orifice 22, the lip being defined by a groove 23. The lip is such that on charging of the excitable material into the body, and laser irradiation of the lip, the lip collapses into a fused closure 26 to close the aperture at its orifice entrapping the excitable material.
The choice of the inert gas and the excitable material will be within the abilities of the man skilled in the art, as will be the choice of ceramic material. This can be of alumina ceramic or quartz. Equally, the window can be of alumina for example artificial sapphire or of quartz. The excitable material can be of indium bromide with argon or krypton or sulphur with krypton.
Referring now to Figure 4, there is shown a process flow diagram for forming another lamp of the invention. It will be described in accordance with the steps shown in the Figure.
Step 1. A preform for the lamp body 102 is moulded from green ceramic material. It has a circular cylindrical side wall 1021, with an end wall 1022, having a central sealing lip 121 defining a charging aperture 115. Its other end has a rim 1023 surrounding a recess 104.
Step 2. An artificial sapphire window 103 is pressed into the lamp body 102 at the recess 104.
Step 3. The body and window are fired at 1500°C. This unifies the body and the window to it. Step 4. The body and window are inverted and robotically placed centrally on a turntable T within an open topped dish D. A laser L is arranged above the body and used to maintain the temperature of the body at 1500°C by irradiation.
Step 5. A krypton injection needle N is inserted through the aperture 115 far enough for its end to be close to the window. Preferably the needle has a closed end with side ports. The krypton flushes oxygen from the body and flows into the dish D, where it is retained, whereby oxygen is displaced from the body. Step 6. Cooler krypton is now injected to cool the body to 400°C. The krypton needle is withdrawn and an indium bromide injection needle H3N is inserted into the body in its stead. The needle has a small, heated reservoir R of indium bromide with a piezoelectric crystal C in its side wall. Pulsing of the crystal forces a droplet of the molten indium bromide from the needle IBN into the body.
Step 7. Immediately after injection, the needle is withdrawn and a vacuum shroud S is dropped over the body 102 to seal with the dish. The shroud is evacuated swiftly to remove any possible trace of oxygen. The shroud is refilled with krypton and the lamp body maintained at 400°C. This is by laser irradiation through a window W in the shroud.
Step 8. The laser L is trepanned around the lip 121, which melts in against itself, thereby sealing the body, with the indium bromide sealed inside. To attract possible vaporised ceramic material from depositing on the window W, an annular cold trap T is positioned between the window and the lamp body. Step 9. The vacuum shroud is lifted and the finished lamp 101 is removed and set aside to cool.

Claims

CLAIMS:
1. A body for an electrodeless lamp of ceramic material and containing excitable material, the body comprising: • a body preform of sintered ceramic material, defining the shape of the body which is hollow;
• an aperture in the preform for charging the excitable material into the hollow body; and
• a translucent window, the window and the preform being a coherent unit resulting from the window having been pressed onto the preform when green and the window having been united to the preform on firing of the ceramic material.
2. An electrodeless lamp body as claimed in claim 1, wherein the preform has a stepped recess at one end for receiving the window, which is accommodated in the stepped recess.
3. An electrodeless lamp body as claimed in claim 1 or claim 2, wherein the body has a flat end opposite from the window for receiving a disc of sintered ceramic material for sealing the aperture.
4. An electrodeless lamp body as claimed in claim 1 or claim 2, wherein the aperture in the preform has a surrounding formation which is collapsible on laser irradiation to seal the aperture, the aperture preferably being at an end of the preform opposite from the window.
5. An electrodeless lamp body as claimed in claim 4, wherein the surrounding formation comprises an annular lip around the aperture.
6. An electrodeless lamp body as claimed in any preceding claim, wherein the ceramic material of the preform is of alumina ceramic or quartz.
7. An electrodeless lamp body as claimed in any preceding claim, wherein the window is of artificial sapphire or of quartz.
8. An electrodeless lamp comprising a lamp body as claimed in any preceding claim, the body being sealed at its charging aperture and containing excitable material.
9. An electrodeless lamp as claimed in claim 8, as appendant to claim 3, a ceramic disc being adhered to the preform across the aperture sealing it, with the interposition of frit material.
10. An electrodeless lamp as claimed in claim 8, as appendant to claim 4, the formation around the aperture being collapsed to seal it.
11. A method of manufacturing an electrodeless lamp, comprising the steps of:
• forming a preform of green ceramic, the preform defining a hollow body shape with an aperture;
• pressing a window onto the preform; • firing the green ceramic to fuse it and unite the window to the preform;
• charging excitable material into the hollow body;
• sealing the aperture.
12. A method of manufacturing an electrodeless lamp as claimed in claim 11- including the step of placing a ceramic disc across the aperture and sealing it to the body.
13. A method of manufacturing an electrodeless lamp as claimed in claim 12, wherein the ceramic disc is sealed to the body by irradiation with a laser.
14. A method of manufacturing an electrodeless lamp as claimed in claim 11, wherein the aperture has a surrounding formation and it is sealed by collapsing the formation on itself by laser irradiation.
15. A method of manufacturing an electrodeless lamp as claimed in claim 13 or claim 14, wherein the excitable material is charged into the hollow body whilst the latter is still hot from the firing of the preform and the laser irradiation also is carried out whilst the hollow body is still hot. 16. A method of manufacturing an electrodeless lamp as claimed in claim 15, including flushing the lamp body with inert gas to cool it from its firing temperature and flush oxygen from it prior to injection of excitable material.
17. A method of manufacturing an electrodeless lamp as claimed in claim 15 or claim
16. including evacuating the lamp body prior to injection of excitable material.
PCT/US2001/046900 2000-12-06 2001-12-06 Electrodeless lamp WO2002047102A2 (en)

Priority Applications (1)

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Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US25171200P 2000-12-06 2000-12-06
US60/251,712 2000-12-06

Publications (1)

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