# Patent

## Title
Discharge tubes

## Abstract

Discharge tubes for a lamp include a body portion with a first end, a second end, and a tubular member defining an interior area. The tubular member extends along an elongated axis between the first end and the second end. The discharge tube further includes a first end portion provided at the first end of the body portion. The first end portion includes a first tubular extension having a first through passage in communication with the interior area. The first end portion further includes a first transition section connected between the first tubular extension and the body portion.

## Background
FIELD OF THE INVENTION
The present invention relates to illumination components, and more particularly to discharge tubes for a lamp.
BACKGROUND OF THE INVENTION
Certain lamps are known to include a discharge tube to facilitate the illumination function. For example, U.S. Pat. No. 6,137,229 discloses a conventional metal halide lamp with a ceramic discharge tube. As shown in U.S. Pat. No. 6,137,229, end portions of conventional discharge tubes are known to comprise ring portions with a wall thickness based on the power supplied to the lamp.
FIGS. 1-3 depict a further example of a conventional ceramic discharge tube 160. As shown, the discharge tube 160 includes end portions 164a, 164b disposed on opposite circumferential end portions of a substantially cylindrical tubular member 162. The discharge tube 160 is symmetrically disposed about an elongated axis 158 and includes an outer radius “r” of 9.35 millimeters. Each end portion 164a, 164b is substantially identical and includes a transition section 168 connected between a tubular extension 166 and the body portion. Each end portion further includes a ring portion 173 connected between the transition section and the body portion. As shown in FIG. 3, the transition section 168 includes an exterior radius “r1” of 2 millimeters and an interior radius “r2” of 0.81 millimeters wherein the ratio r1/r2 is 2.46. The ring portion includes a thickness “t1” of 1.5 millimeters and the end portion includes an outer radius “r3” of 8.55 millimeters wherein the ratio t1/r3 is 0.176. It is also known to provide an end portion with a ratio r1/r2 of 2.46 and a ratio t1/r3 of 0.23.
As shown in FIG. 2, the transition section 168 spans between a maximum extent 168a in the direction of the elongated axis 158 and a minimum extent 168b in the direction of the elongated axis 158. The minimum extent 168b has a first dimension “d1” of 1.5 millimeters with respect to an interior surface 172. The maximum extent 168a has a second dimension “d2” of 3.4 millimeters with respect to the interior surface 172.
Conventional end portions can have features that result in cracking due to heat-cycles during the lamp lifetime. There is a continued need to provide discharge tubes with features that inhibit cracking of one or more end portions of discharge tubes.
SUMMARY OF THE INVENTION
In accordance with one aspect, a discharge tube for a lamp is provided. The discharge tube comprises a body portion including a first end, a second end, and a tubular member defining an interior area, wherein the tubular member extends along an elongated axis between the first end and the second end. The discharge tube further includes a first end portion provided at the first end of the body portion. The first end portion includes a first tubular extension having a first through passage in communication with the interior area. The first end portion further includes a first transition section connected between the first tubular extension and the body portion. The first end portion is configured such that the temperature differential within the transition section does not exceed about 20 Kelvin when cooling the discharge tube from a temperature of from about 1100 Kelvin in air at a temperature of about 300 Kelvin.
In accordance with another aspect, a discharge tube for a lamp is provided. The discharge tube includes a body portion with a first end, a second end, and a tubular member defining an interior area. The tubular member extends along an elongated axis between the first end and the second end. The discharge tube further includes a first end portion provided at the first end of the body portion. The first end portion includes a first tubular extension having a first through passage in communication with the interior area. The first end portion further includes a first transition section connected between the first tubular extension and the body portion. The first transition section includes an exterior radius R1 and an interior radius R2, wherein the ratio R1/R2 is from about 0.5 to 2.40.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a conventional discharge tube;
FIG. 2 is an enlarged view of portions of the conventional discharge tube taken at view 2 of FIG. 1;
FIG. 3 is an enlarged view of portions of the conventional discharge tube taken at view 3 of FIG. 1;
FIG. 4 is a partial sectional view of an exemplary lamp including a discharge tube assembly with a discharge tube in accordance with an exemplary embodiment of the invention;
FIG. 5 is a partial sectional view of the discharge tube assembly of FIG. 4;
FIG. 6 is a sectional view of the discharge tube illustrated in FIGS. 4 and 5;
FIG. 7 is an enlarged view of portions of the discharge tube taken at view 7 of FIG. 6;
FIG. 8 is sectional view of a discharge tube in accordance with further embodiments of the present invention; and
FIG. 9 is an enlarged view of portions of the discharge tube taken at view 9 of FIG. 8.



DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
Discharge tubes of the present invention may be used as an illumination component in a wide variety of lamps having various structures, shapes, sizes, components and/or configurations. Just one example of a lamp 20 incorporating concepts of the present invention is illustrated in FIG. 4. The illustrative lamp 20 incorporates a discharge tube assembly 50 comprising a discharge tube 60 in accordance with the present invention. The lamp 20 can include an optional protective feature, such as a transparent quartz shroud 26, designed to contain explosions that might occur during a failure of the discharge tube 50. The lamp 20 can also include a support structure 24 designed to suspend the discharge tube assembly 50 within the interior area defined by outer bulb 22. Discharge tubes in accordance with the present invention may be used with a lamp having a power level of about 150 Watts or greater. In further examples, discharge tubes in accordance with the present invention may be used with a lamp having a power level of about 250 Watts or greater. In still further embodiments, discharge tubes in accordance with the present invention may be used with lamps having a lower power level.
Discharge tubes of the present invention may also be used as an illumination component in a wide variety of discharge tube assemblies having various structures, shapes, sizes, components and/or configurations. FIG. 5 illustrates just one example of a discharge tube assembly 50 having an exemplary discharge tube 60 incorporating aspects of the present invention. The discharge tube 60 defines an interior area 74 that can act as a discharge location for the lamp. The interior area 74 may be filled with an ionizable filling, such as various metal halides that are known for use with metal halide lamps. A first electrode 56a and a second electrode 56b can be positioned within the interior area 74. The first and second electrodes 56a, 56b can comprise a winding of tungsten wire that is wrapped around respective lead-in wires 52a, 52b. The lead-in wires might be formed of a niobium material and can include a winding 53 of molybdenum material. Each lead-in wire 52a, 52b extends through respective through passages 67 of end portions 64a, 64b of the discharge tube 60. Once appropriately positioned, a seal 54a, 54b may be applied to seal any interstitial space between the lead-in wires and the through passage. The seals 54a, 54b can comprise a ceramic sealing compound in exemplary embodiments.
Exemplary discharge tubes of the present invention include end portions with a configuration to inhibit cracking of the discharge tube during heating of the discharge tube when the lamp is turned on and cooling of the discharge tube when the lamp is turned off. In exemplary embodiments, the first end portion can be configured such that the temperature differential within the transition section does not exceed about 20 Kelvin when cooling the discharge tube from a temperature of about 1100 Kelvin in air at a temperature of about 300 Kelvin. Limiting the temperature differential in the transition section can inhibit cracking of the end portion during heating and cooling cycles of the lamp.
Various configurations in accordance with the present invention are possible to limit the temperature differential within the transition section. Exemplary configurations of the end portion are shown in a first exemplary discharge tube 60 shown in FIGS. 6 and 7 and a second exemplary discharge tube 260 shown in FIGS. 8 and 9. Further configurations of the end portion that limit the temperature differential in the transition section are within the scope of this invention.
FIGS. 6 and 7 illustrate the exemplary discharge tube 60 incorporating concepts of the present invention. As shown, the discharge tube 60 includes a body portion 61 with a first end 61a and a second end 61b. The body portion 61 further includes a tubular member 62 defining the interior area 74. The tubular member 62 extends along an elongated axis 58 between the first end 61a and the second end 61b of the body portion 61.
Exemplary discharge tubes in accordance with the present invention can comprise tubular members having a wide variety of shapes, sizes and can be oriented in a variety of positions with respect to other components of the discharge tube. In the illustrated embodiment, the tubular member 62 is substantially symmetrically disposed about the elongated axis 58 although it is contemplated that the tubular members may also be asymmetrically or otherwise disposed about the elongated axis 58 in further embodiments of the present invention. In the illustrated embodiment, the tubular members comprise circular peripheries along cross sections that are substantially perpendicular to the elongated axis 58. The circular peripheries may have a constant radius or a varying radius. In the illustrated embodiment, the radius is smaller towards a central section of the tubular member and gets larger toward each end (e.g., see reference number 63 in FIG. 7). It is contemplated that the tubular member may have substantially the same radius along the entire length. The tubular member can also be formed as a bulbous portion or may be formed without circular peripheries and therefore might not include a radius dimension from the elongated axis. For example, the tubular members can have an at least partially rectilinear periphery such as a polygonal periphery (e.g., triangular, rectangular, square or other polygonal arrangement).
Discharge tubes in accordance with the present invention can include an end portion or a plurality of end portions. For example, a plurality of end portions can be provided with similar or substantially identical structural features. Alternatively, the plurality of end portions may comprise different structural features wherein at least one end portion incorporates aspects of the present invention. Discharge tubes can also include a single end portion incorporating aspects of the present invention. For example, the tubular member can comprise a closed end tube wherein only one end of the tube includes an end portion in accordance with aspects of the present invention.
As shown in FIG. 6, the illustrated example depicts a first end portion 64a provided at the first end 61a of the body portion 61 and a second end portion 64b provided at the second end 61b of the body portion 61. In the illustrated example, the first and second end portions 64a, 64b are substantially identical to one another. As shown in FIG. 7, the first end portion 64a includes a tubular extension 66 extending from a transition section. The first end portion 64a can further include one or more through passages to accommodate one or more lead-in wires. In embodiments with a single end portion, two or more through passages may be provided or a single through passage can be provided that is sufficient to accommodate both lead-in wires. In the illustrated exemplary embodiment, each end portion 64a includes a single through passage 67 that extends through the tubular extension 66 and the transition section along the elongated axis 58.
As shown in FIG. 7, the transition section can comprise a tapered portion 68 connected between a tubular extension 66 and the body portion 61. The tapered portion 68, if provided, is tapered in a direction 59 extending substantially perpendicular from the elongated axis 58. The tapered portion 68 includes an interior surface 72 facing the interior area 74. The interior surface 72 can comprise a substantially flat surface and can extend substantially perpendicular from the elongated axis 58. In alternative embodiments, the interior surface 72 may comprise a nonplanar surface and/or can extend at an angle other than 90 degrees from the elongated axis 58.
The tapered portion 68 spans between a maximum extent 68a in the direction of the elongated axis 58 and a minimum extent 68b in the direction of the elongated axis 58. For example, as shown the maximum and minimum extent 68a, 68b can extend substantially parallel with respect to the elongated axis. The minimum extent 68b includes a first dimension D1 with respect to the interior surface 72 and the maximum extent 68a includes a second dimension D2 with respect to the interior surface 72. For example, as shown, the first and second dimensions D1, D2 can be measured with respect to a plane 71 along which the interior surface 72 extends.
Discharge tubes in accordance with aspects of the present invention can have various shapes and sizes depending how the tapered portion spans from the maximum extent to the minimum extent. As shown in FIG. 7, the tapered portion tapers in the direction 59 that is perpendicular from the elongated axis to form a surface 70. In exemplary embodiments, the surface 70 can comprise a flat surface when the tapered portion does not extend perpendicularly from the elongated axis in all directions. In the illustrated embodiment, the tapered portion tapers in all directions that are perpendicular from the elongated axis to form a conical surface 70. The conical surface 70 can have a variety of surface characteristics to provide a linear, convex, concave, stepped or other conical surface arrangements. In the illustrated embodiment, the tapered portion 68 comprises a linear conical surface 70 that faces away from the interior area 74 of the tubular member.
The first and second dimensions can have a wide range of values depending on the size of the discharge tube. Regardless of the size of the discharge tube, exemplary embodiments of discharge tubes in accordance with the present invention can be arranged with a ratio between D1 and D2 that can inhibit cracking of the end portion. For example, a ratio D1/D2 from about 0.07 to 0.43 can inhibit cracking of the end portion during heating and/or cooling. In another example, a ratio D1/D2 from about 0.15 to about 0.3 can inhibit cracking of the end portion during heating and/or cooling. In a further example, a ratio D1/D2 from about 0.18 to about 0.25 can inhibit cracking of the end portion during heating and/or cooling. Providing ratios D1/D2 within the ranges above can reduce stresses resulting from temperature differentials as the discharge tube heats when the lamp is turned on and/or as the discharge tube cools after the lamp is turned off.
In exemplary embodiments, the first dimension D1 can range from about 1 millimeter to about 4 millimeters. In additional embodiments, the first dimension D1 can range from about 1 millimeter to about 2 millimeters. In further embodiments, the first dimension D1 can range below 1 millimeter or above 4 millimeters depending on the size of the lamp. One example of a discharge tube can have a first dimension D1 of about 1.5 millimeters and a second dimension D2 of about 8 millimeters wherein the ratio D1/D2 is about 0.19. It is further understood that the first dimension D1 can be selected based on the desired size of the lamp wherein the second dimension D2 can be determined to provide a ratio D1/D2 within a range discussed above to inhibit cracking of the discharge tube.
Exemplary embodiments of the invention can also include a discharge tube that has various periphery shapes, such as a circular periphery disposed at a radius “R” about the elongated axis. If the discharge tube has a circular periphery, the ratio between the second dimension D2 and the radius “R” can be provided within a range to reduce stresses after the lamp is turned off. Thus, if the discharge tube has a circular periphery, the ratio D2/R and/or the ratio D1/D2 can be provided within ranges discussed herein to reduce stresses when turning the lamp on and/or when turning the lamp off. For example, in the illustrated embodiment, the discharge tube 60 has a circular periphery 63 disposed at a radius “R” about the elongated axis 58. The radius “R” can have a wide range of values depending on the size of the discharge tube. Regardless of the size of the discharge tube, exemplary embodiments of discharge tubes in accordance with the present invention can have a ratio between D2 and “R” that can inhibit cracking of the end portion. For example, a ratio D2/R from 0.40 to about 2.2 can inhibit cracking of the end portion during heating and/or cooling. In another example, a ratio D2/R from about 0.5 to about 1 can inhibit cracking of the end portion during heating and/or cooling. In a further example, a ratio D2/R from about 0.8 to about 0.9 can inhibit cracking of the end portion during heating and/or cooling. Providing a ratio D2/R within the ranges above can reduce stresses resulting from temperature differentials as the discharge tube heats when the lamp is turned on and/or as the discharge tube cools after the lamp is turned off.
In exemplary embodiments, the radius “R” can range from about 4 millimeters to about 15 millimeters. In further embodiments, the radius “R” can range below 4 millimeters or above 15 millimeters depending on the size of the lamp. One example of a discharge tube can have a radius “R” of about 9.35 millimeters and a second dimension D2 of about 8 millimeters wherein the ratio D2/R is about 0.86. It is further understood that the radius “R” can be selected based on the desired size of the lamp wherein the second dimension D2 can be determined to provide a ratio D2/R within a range discussed above to inhibit cracking of the discharge tube.
If the discharge tube has a circular periphery, the ratio D2/R and/or the ratio D1/D2 can be provided within ranges discussed above. In addition, a discharge tube with a circular periphery can include ratios D2/R and D1/D2 that both fall within any of the ranges discussed above to inhibit cracking during heating and/or cooling of the end portion. For example, a discharge tube may be provided wherein the ratio D2/R is from 0.40 to about 2.2 and the ratio D1/D2 is from about 0.07 to 0.43. In another example, the ratio D2/R is from about 0.5 to about 1 and the ratio D1/D2 is from about 0.15 to about 0.3. In a further example, the ratio D2/R is from about 0.8 to about 0.9 and the ratio D1/D2 is from about 0.18 to about 0.25.
FIGS. 8 and 9 depict additional embodiments of an exemplary discharge tube 260 incorporating concepts of the present invention. The discharge tube 260 can have a wide range of applications and can be incorporated in the discharge tube assembly of the lamp illustrated in FIG. 4. The discharge tube 260 can be formed with similar or identical features and can have similar alternative aspects as discussed with respect to the discharge tube 60. For example, the discharge tube 260 includes a body portion 261 including a first end 261a and a second end 261b. The body portion 261 further includes a tubular member 262 defining an interior area 274 and extending along an elongated axis 258 between the first end 261a and the second end 261b. 
The embodiment of FIGS. 8 and 9 includes one or more end portions that have a further configuration adapted to inhibit cracking of the discharge tube during the heating and cooling process. Although not necessary, the first end portion 264a and the second end portion 264b are substantially identical to one another as shown in FIG. 8. Each end portion can include a tubular extension 266 having a through passage 267 in communication with the interior area 274. As shown in FIG. 9, the first end portion 264a further includes a transition section 268 connected between the tubular extension 266 and the body portion 261. In exemplary embodiments, the transition section 268 includes an exterior radius R1 and an interior radius R2, wherein the ratio R1/R2 is from about 0.5 to 2.40 to inhibit cracking during heating and/or cooling of the end portion. In further embodiments, the ratio R1/R2 is from about 1.2 to about 1.7 to inhibit cracking during heating and/or cooling of the end portion.
The transition section 268 can be provided with an internal and external radius that may vary depending on the size of the discharge tube. In one example embodiment, the exterior radius R1 is about 3 millimeters and the interior radius R2 is about 1.96 millimeters wherein the ratio R1/R2 is about 1.53.
In further examples, the first end portion 264a includes an outer radius R3 and can also include a ring portion 273 connected between the transition section 268 and the body portion 261. As shown, the ring portion 273 extends between broken lines 273a, 273b and includes a thickness T1. Although not necessary, the ratio T1/R3 can also be controlled, in addition to the ratio R1/R2, to further inhibit cracking during heating and/or cooling of the end portion. In exemplary embodiments, the ratio T1/R3 is from 0.20 to about 0.65 to inhibit cracking during heating and/or cooling of the end portion. In further embodiments, the ratio T1/R3 is from about 0.28 to about 0.4 to inhibit cracking during heating and/or cooling of the end portion.
The end portions may have different sizes and configurations depending on the size of the discharge tube. In one example embodiment, the thickness T1 of the ring portion is about 2.6 millimeters and the outer radius R3 of the end portion is 8.55 millimeters wherein the ratio T1/R3 is about 0.3.
Therefore, embodiments having ring portions and transition sections can include ratios R1/R2 that fall within any of the ranges discussed above to inhibit cracking during heating and/or cooling of the end portion. Further embodiments having ring portions and transition sections can include ratios R1/R2 and T1/R3 that both fall within any of the ranges discussed above to further inhibit cracking during heating and/or cooling of the end portion. For example, a discharge tube may be provided wherein the ratio R1/R2 is from about 0.5 to 2.40 and the ratio T1/R3 is from 0.20 to about 0.65. In another example, the ratio R1/R2 is from about 1.2 to about 1.7 and the ratio T1/R3 is from about 0.28 to about 0.4.
The discharge tube in accordance with the present invention may be formed from a wide range of materials and processes while incorporating the concepts of the present invention. For example, the discharge tube can be formed from a ceramic material although other materials can be used to facilitate appropriate lamp function. If fabricated from ceramic, the ceramic material can comprise AL203, Y203 or YAG ceramic material although other ceramic materials are contemplated. The tubular member can also be initially formed separately from the end portions for later assembly. For example, the tubular member can be formed and cut to the desired length. As shown in FIG. 7, each end portion can have a circumferential lip 69 designed to fit within a corresponding end of the tubular member 62. Once the end portions are in place, the assembly can be sintered together wherein the end portions are attached to the tubular member at a sintered location 65. It is understood that other process techniques may be used to form the discharge tube in accordance with concepts of the present invention.
From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims.

## Claims

1. A discharge tube for a lamp comprising:
a body portion including a first end, a second end, and a tubular member defining an interior area, wherein the tubular member extends along an elongated axis between the first end and the second end; and
a first end portion provided at the first end of the body portion, the first end portion including a first tubular extension having a first through passage in communication with the interior area, the first end portion further including a first transition section connected between the first tubular extension and the body portion, wherein the first transition section includes an exterior radius R1 and an interior radius R2, wherein the ratio R1/R2 is from about 0.5 to 2.40.

2. The discharge tube of claim 1, wherein the ratio R1/R2 is from about 1.2 to about 1.7.

3. The discharge tube of claim 1, wherein the first end portion further comprises a first ring portion connected between the first transition section and the body portion, wherein the first ring portion includes a thickness T1 and the first end portion includes an outer radius R3, wherein the ratio T1/R3 is from 0.20 to about 0.65.

4. The discharge tube of claim 3, wherein the ratio T1/R3 is from about 0.28 to about 0.4.

5. The discharge tube of claim 1, further comprising a second end portion that is substantially identical to the first end portion, wherein the second end portion is provided at the second end of the body portion.

6. The discharge tube of claim 1, wherein the discharge tube comprises a ceramic material.