A pulse-excited mercury-free lamp system, and method of sustaining the emission of light emission from such a lamp, is provided. The system includes a light-transmissive envelope having an inner surface and a phosphor layer coated thereon. A discharge-sustaining gaseous mixture of a noble gas, at a low pressure, and a metal halide, is retained inside the light-transmissive envelope. An electrical system provides a plurality of pulses to the discharge-sustaining gaseous mixture, resulting in a discharge, which causes the lamp system to emit light. The emission of light is maintained by turning the discharge on during a pulse width of each pulse in the plurality of pulses and by turning the discharge off during a remainder of each period in the plurality of pulses. Particularly in systems where the metal halide is indium-based, this maintains an efficient emission of light without the use of mercury.

TECHNICAL FIELD

The present invention relates to lighting, and more specifically, to mercury-free gas discharge lamps.

BACKGROUND

Typical gas discharge lamps include a small amount of mercury, which is used to excite the discharge that results in the lamp producing light. While mercury performs this function very well, the potential damage to the natural environment and to people that may be caused by mercury is now very well known. Thus, reducing and/or removing mercury from lighting has long been a desired goal.

One alternative to using mercury to excite a discharge is to use a low pressure indium chloride discharge instead of mercury. Under certain conditions, such as the discharge current, the temperature of the indium chloride concentrate, the temperature of the bulb wall, and the type and pressure of the fill gas within the lamp, an indium chloride discharge can effectively replace mercury within a low pressure discharge lamp, with minimal or no loss in lamp efficacy.

SUMMARY

Conventional techniques for replacing mercury in a low pressure gas discharge lamp with an indium chloride, or other type of metal halide, discharge suffer from a variety of issues. Most importantly, under certain conditions, the indium chloride experiences species segregation in the positive column. That is, if a cylindrical, extended positive column gas discharge filled with indium chloride and a noble gas is burned horizontally, the typical position for a low pressure gas discharge lamp, the desired indium emission slowly decreases in power, when the input power is fixed. The indium and indium chloride emission move upwards towards the top of the tube, reducing the efficiency of the discharge and thus of the lamp, by virtue of the reduced volume of excited gas and changed plasma conditions near the wall.

Embodiments as described herein overcome this limitation by providing a pulsed excitation, instead of a fixed sinusoidal excitation. In other words, a highly modulated periodic waveform that turns the discharge off for a period of time, and then back on, does not result in the reduced efficiency described above. Rather, in embodiments as described herein, by turning the discharge on and then off and then back on, etc., when turned back on, the indium and indium chloride emissions return to previous peak levels instead of decaying, and are spatially centered in the lamp instead of migrating to the top of the lamp. As described herein in greater detail, the time for which the discharge is turned off, i.e., the time between pulses or, equivalently, the remainder of each period, is short enough such that there is no visual manifestation of the lack of emission. Alternatively, or additionally, the remainder of each period may be defined as a time less than the ambipolar diffusion time, which will depend on the size of the lamp and the pressure of the rare fill gas (e.g., argon, krypton, neon, xenon, etc.), as well as potentially other conditions. For example, for a lamp having a diameter of approximately 2.5 centimeters and using argon as the fill gas at a pressure of approximately 133 Pascal, the remainder of each period needed to maintain the discharge at desirable stability and efficient for operation in place of a typical mercury-based low pressure discharge lamp would be approximately one millisecond. If the pulses are too close together, that is if the frequency decreases to the point where the pulses in essence disappear (i.e., steady state), then the discharge will dissipate after a time, depending on the operating conditions, and the lamp will cease to provide light.

In an embodiment, there is provided a gas discharge lamp system. The gas discharge lamp system includes: a light-transmissive envelope having an inner surface and a phosphor layer coated thereon; a discharge-sustaining gaseous mixture retained inside the light-transmissive envelope, the discharge-sustaining gaseous mixture comprising a noble gas, at a low pressure, and a metal halide; and an electrical system configured to provide a plurality of pulses to the discharge-sustaining gaseous mixture, wherein the plurality of pulses has a period, wherein each pulse in the plurality of pulses has a pulse width less than the period, wherein the plurality of pulses results in a discharge within the light-transmissive envelope turning on during the pulse width of each pulse in the plurality of pulses and turning off during a remainder of each period in the plurality of pulses, causing the lamp system to emit light.

In a related embodiment, the remainder of each period of the plurality of pulses may be less than an ambipolar diffusion time of the discharge. In another related embodiment, the period of the plurality of pulses may be at least substantially one millisecond greater than the pulse width. In yet another related embodiment, the noble gas may include argon, at substantially 133 Pascal. In still another related embodiment, the metal halide may include an indium halide. In a further related embodiment, the indium halide may include indium chloride. In another further related embodiment, the indium halide may include substantially one milligram indium chloride.

In yet still another related embodiment, the noble gas may include argon, the metal halide may include indium chloride, and the discharge-sustaining gaseous mixture may further include indium. In still yet another related embodiment, the metal halide may include one of gallium, tin, and zirconium.

In yet still another related embodiment, the gas discharge lamp system may further include a controller coupled to the electrical system, wherein the controller may be configured to modify the pulse width and/or the period so as to maintain the discharge as a substantially optimized discharge within the light-transmissive envelope. In still yet another related embodiment, the electrical system may include an electrical element and a pulse modulation generator, the pulse modulation generator may generate the plurality of pulses and the plurality of pulses may be provided to the discharge-sustaining gaseous mixture via the electrical element. In a further related embodiment, the electrical element may include an electrode within the light-transmissive envelope. In another further related embodiment, the electrical element may include an electrodeless coupler external to the light-transmissive envelope.

In still another related embodiment, the light-transmissive envelope may be oriented in a substantially horizontal direction.

In another embodiment, there is provided a method of sustaining an emission of light from a mercury-free lamp. The method includes: dispensing a discharge-sustaining gaseous mixture inside a light-transmissive envelope, the discharge-sustaining gaseous mixture comprising a noble gas, at a low pressure, and a metal halide; connecting an electrical system to the light transmissive envelope; providing a plurality of pulses, via the electrical system, to the discharge-sustaining gaseous mixture within the light-transmissive envelope, resulting in a discharge within the light-transmissive envelope; producing an emission of light from the mercury-free lamp; and sustaining the emission of light by turning the discharge on during a pulse width of each pulse in the plurality of pulses and by turning the discharge off during a remainder of each period in the plurality of pulses.

In a related embodiment, dispensing may include dispensing a discharge-sustaining gaseous mixture inside a light-transmissive envelope, the discharge-sustaining gaseous mixture comprising argon, at a low pressure, and an indium halide. In another related embodiment, dispensing may include dispensing a discharge-sustaining gaseous mixture inside a light-transmissive envelope, the discharge-sustaining gaseous mixture comprising argon, at a low pressure, and indium chloride. In still another related embodiment, dispensing may include dispensing a discharge-sustaining gaseous mixture inside a light-transmissive envelope, the discharge-sustaining gaseous mixture comprising a noble gas, at a low pressure, and one of gallium, tin, and zirconium.

In yet another related embodiment, sustaining may include sustaining the emission of light by turning the discharge on during a pulse width of each pulse in the plurality of pulses and by turning the discharge off during a remainder of each period in the plurality of pulses, wherein a period of the plurality of pulses may be at least substantially one millisecond longer than the pulse width of a pulse in the plurality of pulses. In still yet another related embodiment, sustaining may include sustaining the emission of light by turning the discharge on during a pulse width of each pulse in the plurality of pulses and by turning the discharge off during a remainder of each period in the plurality of pulses, wherein the remainder of each period of the plurality of pulses may be less than an ambipolar diffusion time of the discharge.

DETAILED DESCRIPTION

A mercury-free low pressure gas discharge lamp1, as a part of a system100, is shown in a cross-sectional view inFIG. 1and includes a light-transmissive envelope2and an electrical system3. The electrical system3, in some embodiments, includes a pulse modulation generator50and an electrical element. In some embodiments, such as shown inFIG. 1, the electrical element is an electrode51within the light-transmissive envelope2, though in other embodiments, such as shown inFIG. 2, the electrical element is an electrodeless coupler31(for example but not limited to a magnetic inductive coupler, a capacitive coupler, and/or any other known type of coupler) that is external to the light-transmissive envelope2. The electrical system3provides a plurality of pulses within the light-transmissive envelope2, as is described in greater detail below, to cause the mercury-free low pressure gas discharge lamp1to emit light. Some embodiments include more than one electrical element51,31. In embodiments where there is a plurality of electrical elements, the plurality of electrical elements may be arranged on one end or the other end of the light-transmissive envelope2, either inside or outside. Alternatively, or additionally, the plurality of electrical elements may be arranged on opposing ends of the light-transmissive envelope2, either inside or outside.

The light-transmissive envelope2is made from any material that is capable of containing the components of the mercury-free low pressure gas discharge lamp1, as described herein, and that is capable of transmitting light. In some embodiments, the light-transmissive envelope2is made from glass. Alternatively, or additionally, in some embodiments the light-transmissive envelope2is made from a composite of materials including glass. The light-transmissive envelope2includes an inner surface7and an outer surface17. The outer surface17of the light-transmissive envelope2is visible when looking at the lamp1. In some embodiments, the outer surface17of the light-transmissive envelope2includes a protective coating that prevents spreading of the material and/or materials comprising the outer surface17, should the outer surface17break. The inner surface7of the light-transmissive envelope2contains a light scattering reflective layer4, which in some embodiments additionally serves as a barrier and is formed from, for example, fumed alumina. Fumed alumina has a high ultraviolet (UV) light reflectance and good visible light transmittance. Of course, any known light scattering reflective material may be used, regardless of its UV light reflectance properties. In some embodiments, the light scattering reflective layer4is disposed on the entire inner surface7of the light-transmissive envelope2. Alternatively, in other embodiments, the light scattering reflective layer4is disposed on a portion of the inner surface7of the light-transmissive envelope2. In some embodiments, the light-transmissive envelope2includes a heat reflecting coating, such as but not limited to indium-tin-oxide (ITO), to maintain the temperature required for the discharge within the lamp1.

In addition to the light scattering reflective layer4, a phosphor layer5is also coated on the inner surface7of the light-transmissive envelope2. In some embodiments, the phosphor layer5is coated on an inner surface8of the light scattering reflective layer4. The phosphor layer5serves to achieve a variety of spectral power distributions and colors for the light emitted by the mercury-free low pressure gas discharge lamp1. In some embodiments, the phosphor layer5is coated on the entire inner surface8of the light scattering reflective layer4. Alternatively, in other embodiments, the phosphor layer5is coated on a portion of the inner surface8of the light scattering reflective layer4. The light scattering reflective layer4reflects any UV light not initially captured by the phosphor layer5back into the phosphor layer5, thereby maximizing the effectiveness of the phosphor layer5. As stated above, the light scattering reflective layer4may also serve as a barrier layer so as to prevent migration of materials inside the mercury-free gas discharge lamp1into the material of the light-transmissive envelope2during usage. By preventing such migration, graying and lowered efficiency of the material of the light-transmissive envelope2are reduced, and service life and efficiency are increased.

A discharge-sustaining gaseous mixture6is also supplied inside of the light-transmissive envelope2. The discharge-sustaining gaseous mixture6is at a low pressure, and is comprised of at least one noble gas and a metal halide. The discharge-sustaining gaseous mixture6is retained within the interior of the light-transmissive envelope2. In some embodiments, the discharge-sustaining gaseous mixture6contains argon, at a low pressure, such as but not limited to 133 Pascal and/or substantially 133 Pascal. Of course, other noble gases such as helium, neon, krypton, and xenon may be, and in some embodiments are, used. In some embodiments, a combination of two or more noble gases is used. In some embodiments, the metal halide is an indium halide, and in some embodiments, the indium halide is indium chloride. In some embodiments, the amount of indium chloride present in the discharge-sustaining gaseous mixture6is substantially one milligram. In some embodiments, in addition to an indium halide, the discharge-sustaining gaseous mixture also includes indium, in some embodiments, substantially one milligram of indium. Though embodiments are described primarily with reference to indium halide, of course other metal halides, such as but not limited to gallium, tin, and/or zirconium, and/or combinations thereof, may be, and in some embodiments are, used without departing from the scope of the invention. As is known in the art, the discharge-sustaining gaseous mixture6is at a conventional fill temperature appropriate for operation of the mercury-free gas discharge lamp1.

As briefly discussed above, the electrical system3causes a discharge within the light-transmissive envelope2that results in the mercury-free gas discharge lamp1emitting light. More specifically, the electrical system3provides a plurality of pulses within the light-transmissive envelope2that excites the discharge-sustaining gaseous mixture6, creating a discharge. In embodiments where the electrical system3includes a pulse modulation generator50, the pulse modulation generator50provides the plurality of pulses to the discharge-sustaining gaseous mixture6via the electrical element (for example but not limited to the electrode51shown inFIG. 1or the electrodeless coupler31shown inFIG. 2). The plurality of pulses may take any known shape, and includes but is not limited to a continuous square wave. In such embodiments, the pulse modulation generator50includes a square wave generator. The plurality of pulses has a period, measured in a unit of time. During each period of the plurality of pulses, there is a first segment of time (also referred to herein as a pulse width) in which the pulse is provided to the discharge-sustaining gaseous mixture6, resulting in a discharge within the lamp1. Thus, during the pulse width, the discharge may be said to have be turned on. There is then a second segment of time in which no pulse is provided, and there is no discharge within the lamp1. During this second segment of time, which is also referred to as a remainder of the period, the discharge may be said to have been turned off. The pulse width of each pulse is less than the period. The remainder of the period is, in some embodiments, less than the ambipolar diffusion time of the discharge. Such pulsed excitation of the discharge-sustaining gaseous mixture6, which includes an indium halide or other metal halide, sustains the emission of light from the mercury-free gas discharge lamp1, particularly when the light-transmissive envelope2is in a horizontal and/or substantially horizontal position. The indium halide and/or other metal halide remains in a central portion of the mercury-free gas discharge lamp1, instead of migrating towards the inner surface7of the light-transmissive envelope3. This results in a sustained and efficient emission of light from the mercury-free gas discharge lamp1, particularly when the mercury-free gas discharge lamp1is installed horizontally and/or substantially horizontally. In some embodiments, the period of the plurality of pulses is one millisecond, and/or substantially one millisecond, longer than a pulse width. Thus, the discharge-sustaining gaseous mixture6is excited for the pulse width, and then not excited for one millisecond and/or substantially one millisecond, and then excited for the pulse width, etc. In some embodiments, the period of the plurality of pulses is at least one millisecond, and/or substantially one millisecond, longer than a pulse width. For example, in some embodiments, the pulse width is ten milliseconds and/or substantially ten milliseconds, and the period is thirteen point three milliseconds and/or substantially thirteen point three milliseconds. This results in, for each pulse in the plurality of pulses, the discharge-sustaining gaseous mixture6being excited (i.e., having a discharge) for ten milliseconds and/or substantially ten milliseconds, and then undergoing no excitation (i.e., having no discharge) for three point three milliseconds and/or substantially three point three milliseconds, in repetition as long as the plurality of pulses is provided to the mercury-free gas discharge lamp1by the electrical system3.

In some embodiments, the electrical system3, and more particularly the pulse modulation generator50, is controlled by a controller75. The controller75is, in some embodiments, coupled to the pulse modulation generator50, and in some embodiments, is part of the pulse modulation generator50. The controller75is configured to modify the pulse width and/or the period so as to maintain a substantially optimized discharge within the light-transmissive envelope2. Differing pulse widths and/or periods of the plurality of pulses may be needed depending on the metal halide present in the discharge-sustaining gaseous mixture6, the operating time and/or age of the mercury-free gas discharge lamp1, the noble gas and/or gases used, as well as other factors.

FIG. 3shows a method300of sustaining an emission of light from a mercury-free lamp, such as but not limited to the mercury-free gas discharge lamp1shown inFIGS. 1 and 2. A discharge-sustaining gaseous mixture, such as but not limited to the discharge-sustaining gaseous mixture6described throughout, is dispensed inside a light-transmissive envelope, such as but not limited to the light-transmissive envelope2shown inFIGS. 1 and 2, step301. The discharge-sustaining gaseous mixture includes a noble gas, at a low pressure, and a metal halide. In some embodiments, a discharge-sustaining gaseous mixture comprising argon, at a low pressure, and an indium halide, is dispensed inside the light-transmissive envelope, step306. In some embodiments, a discharge-sustaining gaseous mixture comprising argon, at a low pressure, and indium chloride, is dispensed inside the light-transmissive envelope, step307. In some embodiments, a discharge-sustaining gaseous mixture comprising a noble gas, at a low pressure, and one of gallium, tin, and zirconium, is dispensed inside the light-transmissive envelope, step308. An electrical system, such as but not limited to the electrical system3described throughout in relation toFIGS. 1 and 2, is connected to the light transmissive envelope, step302. A plurality of pluses is then provided, via the electrical system, to the discharge-sustaining gaseous mixture within the light-transmissive envelope, resulting in a discharge within the light-transmissive envelope, step303. An emission of light from the mercury-free lamp is then produced, step304. The emission of light is sustained by turning the discharge on during a pulse width of each pulse in the plurality of pulses and by turning the discharge off during a remainder of each period in the plurality of pulses, step305. In some embodiments, the emission of light is sustained by turning the discharge on during a pulse width of each pulse in the plurality of pulses and by turning the discharge off during a remainder of each period in the plurality of pulses, wherein a period of the plurality of pulses is at least substantially one millisecond longer than the pulse width of a pulse in the plurality of pulses, step309. In some embodiments, the emission of light is sustained by turning the discharge on during a pulse width of each pulse in the plurality of pulses and by turning the discharge off during a remainder of each period in the plurality of pulses, wherein a remainder of each period of the plurality of pulses is less than ambipolar diffusion time of the discharge, step310.

Throughout the entirety of the present disclosure, use of the articles “a” and/or “an” and/or “the” to modify a noun may be understood to be used for convenience and to include one, or more than one, of the modified noun, unless otherwise specifically stated. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.