WO2006004235A1

WO2006004235A1 - The bulb included ignitor of a coil

Info

Publication number: WO2006004235A1
Application number: PCT/KR2004/001674
Authority: WO
Inventors: Young-Rok Kang
Original assignee: K.D.G. Eng
Priority date: 2004-07-07
Filing date: 2004-07-08
Publication date: 2006-01-12
Also published as: KR100618449B1; JP2008506234A; KR20060003751A

Abstract

A discharge bulb has a wound-coil type igniter integrated thereto. The discharge bulb is provided as one component of an HID lamp including a connecting jack in addition to the discharge bulb and the igniter. The wound-coil type igniter (20) is miniaturized in a cylindrical shape and integrally attached to the rear end of the discharge bulb. The discharge bulb is provided at the rear end of the wound-coil type igniter (20) with a connector (30) consisting of a plurality of pins for electric connection formed to allow a pin-to-pin connection to a socket of the connecting jack. The wound-coil type igniter (20) is miniaturized and integrally attached to the rear end of the discharge bulb, thereby simplifying the manufacturing process and reducing manufacturing costs, resulting in providing the HID lamp for a vehicle at a lower cost to users.

Description

THE BULB INCLUDED IGNITOR OF A COIL

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a discharge bulb having a wound-coil type igniter integrated thereto, and, more particularly, to a discharge bulb integrating a tube-shaped wound-coil type igniter, which may be securely connected to a rear end of the discharge bulb of a discharge lamp, such as an HED (High Intensity Discharge) lamp, available in various machines including a vehicle, and which provides enhanced adaptability in establishment of a vehicle lamp.

Description of the Related Art

Generally, an HID lamp for a vehicle is supplied with power of about 22,000 V for several seconds in order to start an initial discharge of a lamp, and is then supplied with power of about 88 V in order to maintain the discharge. After receiving power of about 12 V through an input line, the ballast supplies a discharge-start power for an initial time of about 30 seconds, and a discharge maintaining power thereafter.

The HTD lamp for the vehicle is lit after receiving the power of the ballast, and equipped at the front of the vehicle, as seen in the horizontal direction. Although the HID lamp is mainly used as a headlight, it can also be available for a taillight.

Although halogen lamps have mainly been used in the vehicle lamp field, the HID lamp has been recently used for the vehicle lamp due to its high discharge efficiency and high performance. Specifically, the HID lamp for the vehicle has a brightness about three times that of a typical halogen lamp, thereby providing a brightness close to a sunlight, and the HE) lamp for the vehicle provides lower power consumption, thereby decreasing a fuel consumption rate, and providing a long life span. Referring to Fig. I₅ such an HBD lamp generally comprises a ballast (stabilizer) 4 having an igniter contained therein, a high voltage wire 3, a connecting jack 2, and a high voltage discharge bulb 1.

In order to operate the HED lamp structure as described above, the ballast 4 with the igniter contained therein is connected to one end of the high voltage wire 3 having the other end connected to the rear end of the high voltage discharge bulb 1.

However, since the high voltage wire 3 is positioned in a restricted inner space defined within the headlamp of the vehicle, the wire 3 must be folded or a covering of the wire 3 can be removed off, thereby causing inconvenience when mounting a connector.

SUMMARY OF THE INVENTION

The present invention has been made to solve the above problems, and it is an object of the present invention to provide a discharge bulb integrating a tube-shaped wound- coil type igniter, designed to safely connect to the discharge bulb of an HID lamp, and to provide enhanced adaptability for establishment of the HED lamp.

In accordance with an aspect of the present invention, the above and other objects can be accomplished by the provision of a discharge bulb having a wound-coil type igniter and provided as one component of an HE) lamp including a connecting jack in addition to the discharge bulb and the igniter, wherein the wound-coil type igniter is miniaturized in a cylindrical shape and integrally attached to a rear end of the discharge bulb, and wherein the discharge bulb is provided, at a rear end of the igniter, with a connector consisting of a plurality of pins for electric connection protruded to allow a pin-to-pin connection.

The wound-coil type igniter integrally attached to a rear end of the discharge bulb may comprise an igniter-core, and a coil wound around the igniter-core and comprising a coil-core and three layers of insulation material extruded and coated around the coil-core.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects and features of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

Fig. 1 is a diagram illustrating a connection structure of a conventional high intensity discharge lamp; Fig. 2 is a perspective view illustrating a discharging tube having a wound-coil type igniter according to the present invention;

Fig. 3 shows one embodiment of a method of manufacturing a coil of the wound- coil type igniter according to the present invention;

Fig. 4 is a cross sectional view illustrating the wound-coil type igniter having a cylindrical shape according to the present invention;

Fig. 5 is a perspective view illustrating some portion of the coil among the components of the wound-coil type igniter according to the present invention, in which other portions of the coil wound around an igniter-core are omitted for the clarity of illustration;

Fig. 6 is a circuit diagram illustrating an equivalent circuit of the coil of the wound- coil type igniter according to the present invention;

Fig. 7 is a flow diagram of the method of manufacturing the coil of the wound-coil type igniter according to the present invention;

Figs. 8a and 8b show graphical representations, in which Fig. 8b shows a waveform of a foil-type igniter according to the prior art, and Fig. 8b shows a waveform of the wound- coil type igniter according to the present invention;

Fig. 9 shows a wound-coil type igniter having a box-shaped plug of a connector for two pins according to one embodiment of the present invention;

Fig. 10 shows a wound-coil type igniter having a cylindrical plug of a connector for one pin according to another embodiment of the present invention;

Fig. 11 shows a wound-coil type igniter having an L-shaped plug of the connector for two pins according to one embodiment of the present invention;

Fig. 12 shows a wound-coil type igniter having a plug of a connector for three pins according to another embodiment of the present invention; and Fig. 13 shows a wound-coil type igniter having a plug of the connector for two pins according to yet another embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preferred embodiments will now be described in detail with reference to the accompanying drawings wherein like reference numerals refer to like components of the conventional apparatus throughout the drawings.

Fig. 2 is a perspective view illustrating a discharging tube integrating a wound-coil type igniter according to the present invention. As shown in Fig. 2, a discharge bulb 10 according to the present invention is provided with a wound-coil type igniter 20, and a connector 30.

The wound-coil type igniter 20 is miniaturized in a cylindrical shape, and integrally provided at the rear end of the discharge bulb 10. The wound-coil type igniter 20 may comprise an igniter-core 21, and a coil 22, which comprises a coil-core, and three layers of insulation material extruded and coated around the coil-core. Each layer of the insulation material is formed of a resin selected from the group consisted of epoxy-based resin, urethane-basis resin, silicone-based resin, and combinations thereof. Meanwhile, as shown in Figs. 3, 4, and 7, the coil 22 is produced by a method comprising the first step (SI lO) of primarily insulating a coil core with a first insulation material layer extruded and coated around the coil core by an extrusion process, the second step (S 120) of secondarily insulating the coil core with a second insulation material layer extruded and coated around the first insulation material layer by the extrusion process, and the third step (S 130) of reinforcingly insulating the coil core with a third insulation material layer extruded and coated around the second insulation material layer by the extrusion process. That is, the coil 22 is laminated with three layers of the insulation material by the extrusion process such that the coil-core 21 of the coil can be coated with the extruded insulation materials. As such, the coil 22 is produced through the primary insulating step, the secondary insulating step, and the reinforcingly insulating step, thereby preventing electric breakdown and theπnal damage to the coil.

Here, when producing the coil, the rated temperature may be in the range of 100 ~ 130 °C, the rated voltage may be in the range of 1,000 Vims, and the diameter of the coil is in the range of 0.2 - 1.0 mm. This is attributed to the fact that, when the conditions of producing the coil are below these ranges, the time for laminating the insulation material on the coil-core is prolonged, whereas, when the conditions of producing the coil are above these ranges, the coil can be damaged.

The connector 30 is provided at the rear end of the coil- wound type igniter, and comprises a plurality of pins for electric connection protruded to allow a pin-to-pin connection. Referring to Fig. 2, the pins for electric connection comprise a first electrode pin 30a, and a second electrode pin 30b.

The connector 30 is provided at the rear end of the coil- wound type igniter as a connector for two pins, such as the first and second electrode pins 30a and 30b, or as a connector for three pins, and is connected to a socket for electrical connection.

Operation of the discharge bulb integrating the coil-wound type igniter according to the present invention will hereinafter be described in detail.

Referring to Figs. 4 and 5, the coil-wound type igniter 20 comprises the igniter-core

21 having a cylindrical shape provided at the center of the coil-wound type igniter, and the coil 22 having the three layers of insulation material extruded and coated on the coil-core.

The coil 22 is wound around the periphery of the igniter-core 21 several dozen or several hundred times.

Here, although only some coils, such as a first coil 1, a second coil 2, and a third coil 3, are shown in Fig. 5 for the clarity of illustration, it is noted that more coils can be wound around the coil-core.

Fig. 6 is a circuit diagram illustrating an equivalent circuit of the coils of the wound- coil type igniter according to the present invention, and this equivalent circuit can be applied to a model shown in Fig. 5.

Considering resistance R₅ inductance L, and capacitance C in the equivalent circuit of the coils, parameters according to a frequency in the equivalent circuit of the coils when producing the coil of the wound-coil type igniter will be described hereinafter.

Meanwhile, it is assumed that the capacitance is independent of the frequency. First, after establishing a circuit equation for the equivalent circuit according to a predetermined geometrical model as shown in Fig. 6, a solution for the circuit equation is obtained. At this time, by selecting integral numbers considering the geometrical model of the equivalent circuit, final circuit equations, such as Equation 1 and Equation 2, can be obtained.

Here, the circuit equation is established by considering various parameters, such as capacitance CA₁₃ between the first coil 1 and the third coil 3, capacitance CA₁₂ between the first coil 1 and the second coil 2, resistance Rl of the first coil 1, etc.

^ = (I-D)-¹CF, (1) wherein V is a total voltage of an inner winding, C and D are discrete sub matrixes of the Fredholm Equation, and VB is a voltage at both nodes.

Wherein I_B is a current at both nodes, and A and B are other discrete sub matrixes of the Fredholm Equation.

That is, if a voltage at both end nodes is known, a voltage at a node in the winding can be obtained using Equation 1, and a current at both end nodes can be obtained using Equation 2. On the contrary, if a current at both end nodes is known, a voltage at both end nodes can be obtained using Equation 2.

At this time, a transfer function (Equation 3) between an input voltage and an output voltage of the coil-wound type igniter can be obtained from Equation 1.

wherein a is a direct current term, δ _k is the thickness of a coating, h_k(s) is an equivalent subsystem, b_k is the radius of a coil, and ω _k is a resonance angular frequency of the subsystem.

As such, when the entire transfer function H(s) is completed from numerical data, such as a, δ _I0 h]_C(s), b^ and ω ^ Laplace transformation of a certain input value, and Laplace transfoπnation of an output value corresponding to the input value are obtained.

Furthermore, capacitance applied when producing the coil-wound type igniter according to the present invention can be expressed by series capacitance (Equation 4) showing capacitance between adjacent nodes from a certain node i to another node j, and parallel capacitance (Equation 5) showing capacitance between the coil and the outside, through a finite element analysis in the equivalent circuit shown in Fig. 6.

C = -ε _r ε ₀ * ° (4)

2 a

wherein d is a gap between disks, w is the thickness of a disk, r₀ is the average radius of the disk, ε _r is the dielectric constant between air and the coil, which has a value of 1.0.

wherein d is a gap between an outermost turn and the coil, h is a width of the coil, r is an average radius of the coil, ε _r is a dielectric constant between air and the coil, which has a value of 1.6. Next, inductance, and a core loss corresponding to the resistance will be described hereinafter.

A magnetic field created by winding of the coils generates eddy currents in the coil- core, which in turn, generates a new magnetic field to the outside of the coil. With this relationship, inductance between windings can be obtained through the Maxwell equation, and is expressed by Equation 6.

L≡μ,N_kNjra - {\~—)K(x)- E{x) (6) x

wherein μ o is a relative permeability of the core, N[_< and N₁₁₁ are the number of turns of a certain disk, a is a direct current term, and K is a constant.

The resistance for the core loss can be expressed with Equation 7 as follows.

wherein g is a circumference of the coil, 1 is a length of the coil, f is a frequency, and δ is a thickness of the coating. As such, the coil of the coil-wound type igniter according to the present invention is manufactured, considering the parameters according to the frequency of the coil, such as a

Laplace transformation value obtained through the transfer function between the input voltage of the coil and the output voltage of the coil, capacitance between adjacent coils, inductance between the windings, and resistance for the core loss. A waveform of the wound-coil type igniter according to the present invention, and a waveform of a foil-type igniter of the prior art were compared through experimentation, and the results of the experimentation will be described as follows.

In this experiment, an HED lamp for a vehicle is supplied with power of about 22,000

V for several seconds when starting an initial discharge of the HID lamp, and then supplied with power of about 88 V such that the discharge can be maintained.

Figs. 8a and 8b show graphical representations, in which Fig. 8b shows the waveform of the foil-type igniter of the prior art, and Fig. 8b shows the waveform of the wound-coil type igniter according to the present invention.

As shown in Fig. 8b, the wound-coil type igniter according to the present invention provides the waveform, which is maintained at a constant voltage of 5.0 kV or less in an initial lighting stage, is rapidly lowered, rises to a voltage of 25.0 kV, and is then constantly maintained at a voltage of 5.0 kV. As viewed in Fig. 8b, it can be appreciated that the entire waveform of the wound-coil type igniter according to the present invention is similar to that of the foil-type igniter of the prior art. Furthermore, a test for quality of the wound-coil type igniter according to the present invention was performed, and the results of the test are shown in Table 1 as follows. Table 1

Test item Coil-wound type igniter Foil type igniter Remarks

On/Offtest (3 seconds/3

Durability ( 10⁴ or more) Good Good seconds)

High temperature operation Good Good at 105 °C

High temperature operation Good Good at-40 °C

Humidity Good Good 85 % or more at 40 ^°C

EMI Good Good CISPR25

As such, from the results of the test, it can be appreciated that since the coil-wound type igniter according to the invention reaches a high voltage of about 25.0 kV at an initial lighting stage, there is no problems in operation of the coil-wound type igniter. Embodiments of the coil-wound type igniter of the present invention, satisfying these results of the test, integrally attached to the rear end of the discharge bulb for the vehicle will be described as follows.

Fig. 9 shows one embodiment of a wound-coil type igniter 20 having a box-shaped connector 30a for a two-pin socket according to the present invention, wherein the discharge bulb 10 is provided, at the rear end of the discharge bulb 10, with the wound-coil type igniter 20, which is miniaturized in a cylindrical shape and integrally attached thereto, and, at the rear end of the igniter 20, with the box-shaped connector 30a for the two-pin socket, corresponding to a bulb cap 3Oa-I of the two-pin socket.

Fig. 10 shows another embodiment of a wound-coil type igniter 20 having a cylindrical connector 30b for a one pin socket according to the present invention, wherein the discharge bulb 10 is provided, at the rear end of the discharge bulb 10, with the wound-coil type igniter 20, which is miniaturized in a cylindrical shape and integrally attached thereto, and, at the rear end of the igniter 20, with the cylindrical connector 30b for the one pin socket, corresponding to a bulb cap 30b-l of the one pin socket. Fig. 11 shows another embodiment of a wound-coil type igniter 20 having an: L- shaped connector 30c for a two-pin socket according to the present invention, wherein the discharge bulb 10 is provided, at the rear end of the discharge bulb 10, with the wound-coil type igniter 20, which is miniaturized in a cylindrical shape and integrally attached thereto, and, at the rear end of the igniter 20, with the L-shaped connector 30c for the two-pin socket, corresponding to that of a bulb cap 30c- 1 of the two-pin socket.

Fig. 12 shows another embodiment of a wound-coil type igniter 20 having a connector 3Od for a three-pin socket according to the present invention, wherein the discharge bulb 10 is provided, at the rear end of the discharge bulb 10, with the wound-coil type igniter 20, which is miniaturized in a cylindrical shape and integrally attached thereto, and, at the rear end of the igniter 20, with the connector 3Od for the three-pin socket, having a shape corresponding to a bulb cap 30d-l of the three-pin socket.

Fig. 13 shows yet another embodiment of a wound-coil type igniter 20 having a connector 30e for the two-pin socket according to the present invention, wherein the discharge bulb 10 is provided, at the rear end of the discharge bulb 10, with the wound-coil type igniter 20, which is miniaturized in a cylindrical shape and integrally attached thereto, and, at the rear end of the igniter 20, with the connector 3Oe for the two-pin socket, having a shape corresponding to a bulb cap 3Oe-I of the two-pin socket.

As such, the wound-coil type igniter, comprising the coil having three layers of insulation material extruded and coated around the coil, is miniaturized, and integrally attached to the rear end of the discharge bulb, whereby the discharge bulb is compatibly available to the EQD lamp for the vehicle.

Industrial Applicability

As apparent from the description, according to the present invention, the wound- coil type igniter is miniaturized and integrally attached to the rear end of the discharge bulb, thereby simplifying the manufacturing process and reducing manufacturing costs, resulting in providing the HID lamp for a vehicle at a lower cost to users. Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.

Claims

WHAT IS CLAIMED IS:

1. A discharge bulb having a wound-coil type igniter and provided as one component of an HID lamp including a connecting jack in addition to the discharge bulb and the igniter, wherein the wound-coil type igniter 20 is miniaturized in a cylindrical shape and integrally attached to a rear end of the discharge bulb, and wherein the discharge bulb is provided, at a rear end of the wound-coil type igniter 20, with a connector 30 consisting of a plurality of pins for electric connection formed to allow a pin-to-pin connection to a socket of the connecting jack.

2. The discharge bulb as set forth in claim 1, wherein the wound-coil type igniter 20 comprises a coil 22 comprising a coil-core and three layers of insulation material extruded and coated around the coil-core.

3. The discharge bulb as set forth in claim 1, wherein the connector 30 provided at the rear end of the wound-coil type igniter 20 is a box-shape connector 30a for a two-pin socket, and corresponds to a bulb cap 30a-l of the two-pin socket.

4. The discharge bulb as set forth in claim 1, wherein the connector 30 provided at the rear end of the wound-coil type igniter 20 is a cylindrical connector 30b for a one-pin socket, and corresponds to a bulb cap 30b-l of the one-pin socket.

5. The discharge bulb as set forth in claim 1, wherein the connector 30 provided at the rear end of the wound-coil type igniter 20 is an L-shaped connector 30c for a two-pin socket, and coiτesponds to a bulb cap 3Oc-I of the two-pin socket.

6. The discharge bulb as set forth in claim 1. wherein the connector 30 provided at the rear end of the wound-coil type igniter 20 is a connector 30d having a shape corresponding to that of a three-pin socket, and corresponds to a bulb cap 30d-l of the three- pin socket.

7. The discharge bulb as set forth in claim 1, wherein the connector 30 provided at the rear end of the wound-coil type igniter 20 is a connector 3Oe having a shape corresponding to that of a two-pin socket, and corresponds to a bulb cap 30e-l of the two-pin socket.

8. The discharge bulb as set forth in claim 2, wherein the coil 22 is produced by a method comprising the steps of primarily insulating a coil core with a first insulation material layer extruded and coated around the coil core by an extrusion process (SIlO), secondarily insulating the coil core with a second insulation material layer extruded and coated around the first insulation material layer by the extrusion process (S 120), and reinforcingly insulating the coil core with a third insulation material layer extruded and coated around the second insulation material layer by the extrusion process (S 130), so that the coil 22 is laminated with three layers of the insulation material by the extrusion process.

9. The discharge bulb as set forth in claim 8, wherein the coil is produced at a rated temperature in the range of 100 ~ 130 ^°C, a rated voltage in the range of 1,000 Vπns, and a diameter of the coil in the range of 0.2 - 1.0 mm.