Discharge lamp device

Abstract: A discharge lamp device includes a tube, and a cathode disposed in said tube and made of a valence-compensated semiconductor ceramic material, or a forcibly reduced semi­ conductor ceramic material, or a valence-compensated and forcibly reduced semiconductor ceramic material. Since the cathode does not include an electron-emitting material, but uses a semiconductor ceramic material, no vapor is produced by the cathode or the cathode does not react with mercury vapor filled in the tube. Therefore, the discharge lamp device has improved characteristics such as heat resistance, chemi­ cal resistance, and discharge characteristics. The discharge lamp device is less costly because the semiconductor cer­ amic material used as the cathode is inexpensive.

Description: The present invention relates to a discharge lamp device having a cathode made of a semiconductor ceramic material. There are known discharge lamp devices employing cold cathodes such as a sodium vapor lamp. The cathode or discharge electrode of such a discharge lamp comprises a coiled tungsten filament to be heated, that is coated on its surface with an electron-emitting material, which is an oxide mainly composed of barium, strontium, and calcium. Further there are known from US-A-2,251,045, US-A-3,911,309 and US-A-4,152,619 different discharge lamp devices comprising electron emitting electrodes. For example US-A-3,766,423 describes cathodes which have a longer life time than other known cathodes by providing more emissive material and which do not require a coiled heating filament because the cathode heating current flows within the body of said cathode. US-A-3,766,423 discloses an emissive electrode (and a method of its fabrication) of the type utilized in fluorescent lamps. Its electrode is made of a fused mixture of electron emissive material and a metal, consisting, among others, of the oxides of Ba/Ti, Ba/Zr, Ca/Ti, Ca/ZR, Sr/Ti, Sr/Zr and mixtures thereof. The materials are not stated to be doped on purpose. Such an electrode is stated, among others, to have a longer life time. DE-A-2501432 discloses an electrode suitable for high pressure sodium arc discharge lamps. D2 emphasizes the use of ceramic/metallic or cermet electrodes. Its constituents are metal oxides and (or) mixtures of metals and ceramics, which are more or less and depending on the requirements, reduced under hydrogen atmosphere. In D2 a possible electrode constituent is a mixture of Niobium (or W or Ta) with Titanium oxide (or ZrO). D2 does not state its constituents to be valence compensated semiconductors. D2 moreover does not address the problem of possible chemical reactions between the fill of the lamp and evaporating substances of the electrodes. DE-A-25 01 432 describes a discharge lamp device comprising an electron emitting electrode and a special sealing device for the end of the tube of said lamp. But all discharge lamp devices described in the state of the art do not contain an appropriate semiconductivity causing material. The conventional cathode has, however, been disadvantageous in that the electron-emitting material tends to evaporate and react with mercury vapor filled in the lamp tube, failing to meet various desired requirements as to heat resistance, chemical resistence, and discharge characteristics of discharge lamp devices. Another problem is that since tungsten is expensive, the cost of the discharge lamp devices is high. In view of the aforesaid drawbacks of the conventional discharge lamp devices, it is an object of the present invention to provide a discharge lamp device which can sufficiently meet various desired requirements as to heat resistance, chemical resistance, and discharge characteristics. Another object of the present invention is to provide a discharge lamp device which can be manufactured inexpensively. According to the present invention, there is provided a discharge lamp device including a tube, and a cathode disposed in said tube and made of a valence-compensated semiconductor ceramic material, or a valence-compensated and forcibly reduced semiconductor ceramic material, wherein said valence-compensated semiconductor ceramic material includes a valence-compensating additive selected from the group consisting of Y, Dy, Hf, Ce, Pr, Nd, Sm, Gd, Ho, Er, Tb, Sb, Nb, W, Yb, Sc, and Ta and wherein said cathode has an arcuate discharge surface, further including lead wires extending through an end of said tube and supporting said cathode. Since the cathode does not include an electron-emitting material, but uses a semiconductor ceramic material, no vapor is produced by the cathode or the cathode does not react with mercury vapor filled in the tube. Therefore, the discharge lamp device has improved characteristics such as heat resistance, chemical resistance, and discharge characteristics. The discharge lamp device is less costly because the semiconductor ceramic material used as the cathode is inexpensive. The above and other objects, features and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which preferred embodiments of the present invention are shown by way of illustrative example. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary cross-sectional view of a discharge lamp device according to an embodiment of the present invention; FIG. 2 is a schematic view of a system for experimenting a cathode in the discharge lamp device of the invention; FIG. 3 is a graph showing experimental data of the cathode; FIG. 4 is a fragmentary cross-sectional view of a discharge lamp device according to another embodiment of the present invention; FIG. 5 is a bottom view of a cathode in the discharge lamp device shown in FIG. 4; FIG. 6 is an enlarged fragmentary cross-sectional view of a cathode which is a modification of the cathode of FIG. 5; FIG. 7 is a fragmentary cross-sectional view of a discharge lamp device according to still another embodiment of the present invention; FIG. 8 is a bottom view of a cathode in the discharge lamp device shown in FIG. 7; FIG. 9 is an enlarged fragmentary cross-sectional view of a cathode according to a modification of the cathode of FIG. 8; FIG. 10 is a fragmentary cross-sectional view of a discharge lamp device according to yet still another embodiment of the present invention; FIG. 11 is a side elevational view of a cathode in the discharge lamp device shown in FIG. 10; FIG. 12 is an enlarged fragmentary cross-sectional view of a cathode that is a modification of the cathode of FIG. 11; FIG. 13 is a fragmentary cross-sectional view of a discharge lamp device according to a further embodiment of the present invention; FIG. 14 is a plan view of a cathode in the discharge lamp device illustrated in FIG. 13; FIGS. 15 and 16 are fragmentary cross-sectional views of cathode ends according to modifications of the cathode shown in FIG. 13; FIG. 17 is a fragmentary cross-sectional view of a discharge lamp device according to a still further embodiment of the present invention; FIG. 18 is a side elevational view of a cathode in the discharge lamp device shown in FIG. 17; FIGS. 19 and 20 are fragmentary cross-sectional views of discharge lamp devices employing cathode ends according to modifications of the cathode shown in FIG. 17. DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows a discharge lamp device according to an embodiment of the present invention. The discharge lamp device includes a tube 1 of glass having an end la through which a cathode 2 extends. The cathode 2 comprises a conical discharge surface 2a positioned in the tube 1, a cylinderical base portion 2b supported on the tube end 1a, and an outer end 2c projecting out of the tube end 1a. The cathode 2 is sealed in a sealing region 3 by a sealing layer 4 of glass disposed between the base portion 2b and the tube end la. The tube 1 is filled with mercury vapor. The cathode 2 is constructed of a semiconductor ceramic material. The semiconductor ceramic material may be a valence-compensated ceramic material, for example. One typical valence-compensated ceramic material is barium titanate. As is well known, valence compensation is achieved by adding as an impurity a metal ion with its valence different by ± 1 from a constituent metal ion of a metal oxide and compensating for an increase or reduction in the electric charge, caused by the addition of the impurity, with the valence number of the constituent metal ion. Examples of valence-compensating additives for making materials semiconductive are Y, Dy, Hf, Ce, Pr, Nd, Sm, Gd, Ho, Er, Tb, Sb, Nb, W, Yb, Sc, Ta, or the like. These additives may be used singly or in combination. The additive or additives should be added in an amount ranging from 0.01 to 0.8 mol%, and preferably from 0.1 to 0.5 mol%. The material of the cathode 2 is preferably one or a composite of titanates such as barium titanate, strontium titanate, calcium titanate, and lanthanum titanate. The titanic acid in the above titanates may be replaced with one or more of zircon acid, silicic acid, and tin acid. The semiconductor ceramic material of the invention may be a forcibly reduced semiconductor ceramic material. More specifically, rather than employing the reduction process as described above, the semiconductor ceramic material for use as the cathode may be produced, without using an additive as referred to above, under sufficient reducing conditions. In such a case, the reduction process is carried out in a reducing atmosphere of N2 or H2 and preferably at a temperature of 700°C or higher, or more preferably in the range of 1200 to 1450°C. The cathode may also be formed by combining the valence compensation process and the forced reduction process in the following manner: (a) An additive for making a cathode material semiconductive is added to produce a formed body of a valence-compensated semiconductor ceramic material; and (b) The formed body is directly calcined for reduction, or the ceramic material that has been sintered by being calcined in air is further calcined for reduction. Experiments conducted on semiconductor ceramic materials will be described below. The tip end of a valence-compensated semiconductor ceramic material was ground into a conical shape of 60°. The specific resistance of the semiconductor ceramic material thus obtained was 9.9 cm. The semiconductor ceramic material was further calcined in a reducing atmosphere of H2 + N2 with H2 at a density of 20% at 1250°C for 2 hours in a stable state. The specific resistance of the calcined material was 0.90 Ωcm. Substantially the same results were obtained from other titanates. Table, given below, shows specific resistances of various semiconductor ceramic materials for use as discharge lamp cathodes. No. Composition Before reduction Ωcm After reduction Ωcm (1) BaTiO 2 -Y 2 O 3 - 0.15mol% SiO 2 - 0.6wt% 9.9 0.90 (2) SrTiO 3 - Dy 2 O 3 0.3mol% - SiO 2 0.6mol% 0.50 0.048 (3) SrTiO 3 62wt% - La 2 O 3 3TiO 2 10wt%-CaTiO 3 27.7wt% - Nb 2 O 5 0.3wt% 0.35 0.032 Substantially the same results were obtained from those materials in which the titanic acid of the titanates was replaced with one or more of silicic acid and tin acid. To check the electron emission capability, the cathode materials (1) through (3) given above in Table 1 were measured for field intensities. Other materials such as Aℓ having relatively low work functions were also measured for comparison. The results of the measurement are shown in FIG. 3. The graph of FIG. 3 has a vertical axis representative of discharge voltages [kV] in a polyethylene container and a horizontal axis indicative of specimen cathodes which include comparison cathodes of Cu, Al, Fe, and the inventive cathodes (1) through (3). The experiments were carried out by a system shown in FIG. 2. A polyethylene container 5 had a width of 15 mm, a depth of 5 mm, and a height of 10 mm, and the bottom thereof was coated with a mercury paste layer 6. A specimen cathode 2' was placed over the container bottom, and an AC power supply 7 was connected between the specimen cathode 2' and the mercury paste layer 6. The spherical tip end of the specimen cathode 2' had a radius R of 20 micrometers, and was spaced from the mercury paste layer 6 by a distance D of 4 mm. The voltage applied by the AC power supply 7 between the specimen cathode 2' and the mercury paste layer 6 was 10 kV at first, and incremented by 1 kV at intervals of 1 minute. As is apparent from the results given in FIG. 3, the inventive cathodes can produce discharges at lower voltages than the comparative cathodes. It can be understood that the semiconductor ceramic materials of the present invention have discharge characteristics which are as well or better than those of metallic materials. The cathode 2 (FIG. 1) which is made of the semiconductor ceramic material of the invention has stable discharge characteristics and can be manufactured inexpensively. FIG. 4 shows a discharge lamp device according to another embodiment of the present invention. The discharge lamp device includes a tube 11, a cathode 12 made of a semiconductor ceramic material and disposed in the tube 11, and a pair of lead wires 13a, 13b supporting the cathode 12 in the tube 11 in the vicinity of a tube end 11a. As shown in FIG. 5, the cathode 12 has a circular cross section. The cathode 12 is of a semicircular shape including a base portion 12b having a semicircular discharge surface 12a. The opposite ends of the base portion 12b serve as connectors 12c, 12d joined to the lead wires 13a, 13b. The lead wires 13a, 13b extend through the tube end 11a and are spaced from each other. The lead wire portions extending through the tube end 11a are sealed by the tube end 11a. The lead wires 13a, 13b have end portions 13c, 13d projecting into the tube 11 and wound in several turns around the connectors 12c, 12d of the cathode 12 to support the cathode 12 such that the cathode 12 lies substantially perpendicularly to the tube end 11a. The lead wires 13a, 13b also have rear end portions 13e, 13f projecting out of the tube 11. A power supply is connected between the rear end portions 13e, 13f for passing an electric current through the cathode 12. As shown in FIG. 6 on an enlarged scale, an electrically conductive film 14 may be applied by vapor deposition or sputtering on the outer periphery of the connector 12c. Although not shown, the other connector 12d of the cathode 12 is also coated with the same electrically conductive film. The elctrically conductive film reduces the contact resistance between the lead wires 13a, 13b and the cathode 12. FIGS. 7 and 8 show still another embodiment of the present invention. Those parts in Fig. 7 which are functionally identical to those shown in FIG. 4 are denoted by identical reference characters. The cathode 12 of FIG. 7 differs from the cathode of Fig. 4 in that the opposite ends of the base portion 12b have connectors 12c, 12c of a smaller diameter than that of the base portion 12b, and the end portions 13c, 13d of the lead wires 13a, 13b are wound in several turns around the connectors 12c, 12d to support the cathode 12. The dishcarge lamp device of FIG. 7 functions in the same manner as that of the discharge lamp device of FIG. 4. Since the lead wires 13a, 13b are wound around the smaller-diameter connectors 12c, 12d, the process of winding the lead wires 13a, 13b is easy to perform. As illustrated in FIG. 9, an electrically conductive film 14 may be coated on the outer periphery of the connector 12c. The other connector 12d may also be coated with an electrically conductive film. FIGS. 10 and 11 illustrate a discharge lamp device according to a further embodiment of the present invention. The discharge lamp device includes a tube 21, a cathode 22 made of a semiconductor ceramic material and disposed in the tube 21, and a pair of lead wires 23a, 23b supporting the cathode 22 in the tube 11 in the vicinity of a tube end 21a. As shown in FIG. 11, the cathode 22 has a circular cross section. The cathode 22 is of a semicircular shape including a base portion 22b having a semicircular -discharge surface 12a. The opposite ends of the base portion 22b serve as connectors 22c, 22d joined to the lead wires 23a, 23b. The connectors 22c, 22d are formed as recessed portions of a smaller diameter than that of the base portion 22b by cutting off the peripheral surfaces of the base portion 22b which are positioned slightly inwardly of the opposite ends thereof. The lead wires 23a, 23b extend through the tube end 21a and are spaced from each other. The lead wire portions extending through the tube end 21a are sealed by the tube end 21a. The lead wires 23a, 23b have end portions 23c, 23d projecting into the tube 21 and wound in several turns around the connectors 22c, 22d of the cathode 22 to support the cathode 22 such that the cathode 22 lies substantially perpendicularly to the tube end 21a. The lead wires 23a, 23b also have rear end portions 23e, 23f projecting out of the tube 21. A power supply is connected between the rear end portions 23e, 23f for passing an electric current through the cathode 22. As shown in FIG. 12, an electrically conductive film 24 may be applied by vapor deposition or sputtering on the outer periphery of the connector 22c. Although not shown, the other connector 22d of the cathode 22 is also coated with the same electrically conductive film. The elctrically conductive film reduces the contact resistance between the lead wires 23a, 23b and the cathode 22. According to a still further embodiment shown in FIGS. 13 and 14, a discharge lamp device comprises a tube 41 made of glass, for example, a cathode 42 made of a semiconductor ceramic material and disposed in the tube 41, and a sealing portion 43 which sealingly secures an outer periphery of the cathode 42, or an intermediate barrel portion thereof, for example, to an end 41a of the tube 41. The cathode 42 includes a cylindrical base portion 42b having on one end thereof a circular discharge surface 42a, the base portion 42b extending through the tube end 41a. A sealing layer 44 made as of glass is formed by coating or baking on the outer periphery of the area of the base portion 42a which extends through the tube end 41a. The sealing portion 43 is formed by sealingly applying the sealing layer 44 to the portion of the cathode 42 which extends through the tube end 41a. The tube 41 and the sealing layer 44 are made of glass to faciliate the sealing process and increase airtightness of the sealing portion 43. The discharge surface 42a lies parallel to the tube end 41a. The cathode 42 has an outer projecting end 42c on which there is disposed an electrode 45 as of silver for external connection. An electric current can be passed through the cathode 42 by connecting the electrode 45 to a power supply (not shown). As illustrated in FIG. 15, a screw 47 joined to a lead wire 46 may be threaded into the outer projecting end 42c, instead of employing the electrode 45 of FIG. 13, and an electric current may be passed via the screw 47 to the cathode. Alternatively, as shown in FIG. 16, a cap 48 joined to a lead wire 46 may be mounted on the outer projecting end of the cathode for passing an electric current to the cathode. FIGS. 18 and 19 show a discharge lamp device according to a yet still further embodiment of the present invention. The discharge lamp device comprises a tube 51, a cathode 52 made of a semiconductor ceramic material and disposed in the tube 51, and a sealing support portion 53 which sealingly supports the cathode 52 in the tube 51 in the vicinity of an end 51a of the tube 51. As shown in FIG. 18, the cathode 52 is composed of a base portion 52b substantially in the form of a rectangular parallelepiped with upper opposite edges mitered to leave a linear discharge surface 52a, and a cylindrical projection 52c projecting downwardly from a lower central surface of the base portion 52b. The sealing support portion 53 has a lead wire 54 extending through the tube end 51a and sealingly supported on the tube end 51a. The lead wire 54 has an inner end portion 54a disposed in the tube 51 and wound around the projection 52c to support the cathode 52 in the tube 51 with the discharge edge 52a lying parallel to the tube end 51a. The opposite end 54b of the lead wire 54 extends out of the tube end 51a. FIG. 19 shows a modification of the cathode of FIG. 17. Those components in FIG. 19 which are functionally identical to those of FIG. 17 are designated by identical reference characters. In FIG. 19, the projection 52c extends centrally through the tube end 51a and has its outer end 52d projecting from the tube end 51a. A screw 55 in which an upper end 54a of the lead wire 54 is embedded is threaded into the projecting end 52d, thus forming a sealing support portion 54. The lead wire 54 is connected to a power supply (not shown) for passing an electric current through the cathode. As illustrated in FIG. 20, the lead wire 54 and the cathode 52 may be interconnected by fitting a cap 56 with the upper end 54a of the lead wire 54 fixed thereto over the projecting end 52d of the projection 52c. Although certain preferred embodiments have been shown and described, it should be understood that many changes and modifications may be made therein without departing from the scope of the appended claims.

Claims: A discharge lamp device comprising a tube, and a cathode disposed in said tube and made of a valence-compensated semiconductor ceramic material, or a valence-compensated and forcibly reduced semiconductor ceramic material, wherein said valence-compensated semiconductor ceramic material includes a valence-compensated additive selected from the group consisting of Y, Dy, Hf, Ce, Pr, Nd, Sm, Gd, Ho, Er, Tb, Sb, Nb, W, Yb, Sc, and Ta and wherein said cathode has an arcuate discharge surface, further including lead wires extending through an end of said tube and supporting said cathode. A discharge lamp device according to claim 1, wherein said semiconductor ceramic material includes a principal component selected from the group consisting of oxides of titanium, barium, strontium, calcium, lanthanum, zirconium, and tin. A discharge lamp device according to claim 1, wherein said cathode includes a base portion having a semicircular discharge surface and connectors on opposite ends thereof, further including lead wires extending through an end of said tube and supporting said connectors, respectively. A discharge lamp device according to claim 3, wherein each of said connectors is coated on its surface with an electrically conductive film. A discharge lamp device according to claim 1, wherein said cathode has a linear discharge surface, said tube having a sealing support portion by which said cathode is supported. A discharge lamp device according to claim 5, wherein said sealing support portion comprises lead wires extending through and sealingly secured to an end of said tube, said lead wires having end portions wound around a projection disposed on said cathode remotely from said discharge surface. A discharge lamp device according to claim 5, wherein said sealing support portion comprises a projection disposed on said cathode remotely from said discharge surface and sealingly secured to en and of said tube. A discharge lamp device according to claim 5, wherein said sealing support portion comprises a projection disposed on said cathode and having an end projecting out of said tube, and a lead wire connected to said projecting end of said projection. A discharge lamp device according to claim 1, wherein said cathode has an arcuate discharge surface and recesses defined respectively in opposite ends thereof, further including lead wires engaging in said recesses and supporting said cathode in said tube. A discharge lamp device according to claim 9, wherein said cathode is coated with an electrically conductive film in each of said recesses. A discharge lamp device according to claim 1, wherein said cathode comprises a cylindrical member having a discharge surface on one end thereof, said cylindrical member having an opposite end extending through and sealingly secured to an end of said tube. A discharge lamp device according to claim 11, wherein said tube is made of glass, further including a layer of glass disposed around said cylindrical member and sealingly attached to said tube. A discharge lamp device according to claim 1, wherein said cathode has an electrode disposed outside-of said tube for external connection.

Inventors: HAMADA MUNEMITSU, IWAYA SHOUICHI, MASUMURA HITOSHI, HAMADA, MUNEMITSU, IWAYA, SHOUICHI, MASUMURA, HITOSHI
Applicants: TDK CORP, TDK CORPORATION
Application year: 1987
Main classification: H01J61
IPC codes: H01J61