Arc tube with a starting source

Abstract: An arc tube (40) having an interior provided with a seal (42) in which is provided a sealed cavity, the interior having a till material for supporting an arc discharge, the cavity in the seal having a fill material for supporting emission of ultraviolet radiation, and having means (44) provided for coupling electrical energy to the interior and to the cavity.

Description: This invention relates to a starting source for an arc tube. In particular this invention relates to an ultraviolet radiation starting source for an arc discharge lamp. High pressure metal halide arc discharge lamps typically comprise an arc tube which encloses an ionisable fill material and two electrodes at opposing ends of the tube. To reduce the time it takes to start the lamp, a starter electrode may be disposed inside the arc tube near one of the main electrodes, as shown in US-A-3,900,761. A discharge can be initiated between the starter electrode and one of the main electrodes at a voltage that is much lower than the voltage reguired to ignite an arc between the two main electrodes. The ultraviolet radiation from this discharge produces photoelectrons which enhance gas breakdown and discharge formation in the arc tube between the two main electrodes. US-A-4,818,915 discloses a UV enhancer which is separate from the arc tube. This patent, describes a UV enhancer which typically has a borosilicate glass envelope enclosing an ionisable fill material and a single electrode. The single electrode has a getter which can remove certain gases when the envelope heats and outgasses. When energized, the UV enhancer produces ultraviolet radiation which illuminates the path between the main electrodes within the arc tube, thus decreasing the time for generating a high intensity arc discharge. Viewed from one aspect the present invention provides an arc tube having an interior provided with a seal in which is provided a sealed cavity, the interior having a fill material for supporting an arc discharge, the cavity in the seal having a fill material for supporting emission of ultraviolet radiation, and means being provided for coupling electrical energy to the interior and to the cavity. According to preferred embodiments of the present invention, there may be provided an arc discharge lamp which comprises a light-transmissive arc tube which includes at least one press seal. A first fill material is contained in an interior of the arc tube for supporting an arc discharge. A means is provided for coupling electrical energy to the interior of the arc tube. A starting source is provided which comprises a sealed cavity in the press seal, a second fill material in the cavity for supporting emission of ultraviolet radiation, and a means for coupling electrical energy to the cavity. The starting source emits ultraviolet radiation which assists in initiation of an arc discharge within the interior of the arc tube. In preferred embodiments, the means for coupling electrical energy to the cavity comprises a fixture for coupling RF or microwave energy to the cavity. The arc tube assembly can further comprise a getter in the cavity for gettering a gas in the cavity when activated, or a dispenser for providing a material in the cavity which enhances ultraviolet radiation. In another aspect, the invention may feature an arc tube assembly which comprises a light-transmissive arc tube with electrodes mounted within an interior of the arc tube, a first fill material contained in the interior of the arc tube for supporting an arc discharge, and press seals at opposite ends of the arc tube. A means may be provided for coupling electrical energy to said electrodes. A starting source is provided which comprises a sealed cavity in one of the press seals, a second fill material in the cavity for supporting emission of ultraviolet radiation, and a means for coupling electrical energy to said cavity. The starting source emits ultraviolet radiation which assists in initiation of an arc discharge within the interior of the arc tube. In preferred embodiments, the means for coupling electrical energy to the electrodes includes a conductive foil in each of the press seals. The means for coupling electrical energy to said cavity comprises a portion of one of the conductive foils that extends into the cavity, and a conductor positioned adjacent to the press seal containing the cavity. The means for coupling electrical energy to the cavity may instead comprise a first conductor connected to one of the conductive foils and extending into the cavity and a second conductor located adjacent to the press seal containing the cavity. The first conductor has a sharp edge to provide breakdown at a lower voltage. In another preferred embodiment, the means for coupling electrical energy to said cavity comprises an electrode extending into the cavity for external application of electrical energy. The electrode extending into the cavity has a sharp edge. In still another preferred embodiment, the means for coupling electrical energy to the cavity comprises a portion of the conductive foil extending into the cavity, and a second conductive foil, having an external lead attached thereto, extending into the cavity. In yet another preferred embodiment, the arc tube assembly further comprises a getter located in the cavity for gettering a gas in the cavity, or a dispenser for providing a material which enhances ultraviolet radiation. By forming a cavity in the press seal and generating ultraviolet radiation within the cavity, a starting source which mainly uses existing components is provided. This starting source retires few, if any, additional components, saves manufacturing steps, and allows an arc discharge lamp to be produced at lower cost than prior art lamps. In addition, light piping action through the press sealed material efficiently couples radiation from the cavity to the arc tube. Radiation transfer is also improved because the cavity in the press seal is much closer to the arc tube than a typical starting source in a separate envelope. Embodiments of the present invention will now be discussed by way of example only, and with reference to the accompanying drawings, in which: Fig. 1 shows a view of a prior art metal halide arc discharge lamp; Figs. 2 and 3 show a side elevation and a partial cross-sectional view, respectively, of a first embodiment of the invention; and Figs. 4-8 show side elevations of additional embodiments of the invention. A prior art metal halide arc discharge lamp 10 is shown in Fig. 1. A sealed envelope 12 encloses a cylindrical quartz sleeve 14. The sleeve 14 surrounds an arc tube 16 which encloses two electrodes 18 located at opposite ends of the arc tube and a fill material, e.g., a combination of mercury, metal halides, and argon. Each electrode is coupled to a molybdenum ribbon 20 which is enclosed within a press seal 22 that hermetically seals the arc tube. Electrical energy is coupled from a lamp base 28 through a lamp stem 30 and leads 32 and 26 to the electrodes 18 in the arc tube 16. A UV enhancer 24 has a sealed envelope 34 that encloses an electrode 25. The electrode 25 is coupled to the lead 26, and is capacitively coupled to the lead 32, which may include a conductor that is helically wrapped around the envelope 34. A typical UV enhancer is about 4.0 mm in diameter and 15.0 to 20.0 mm in overall length. Other details relating to the prior art UV enhancer 24 are disclosed in US-A-4,818,915. A first embodiment of the invention is shown in Figs. 2 and 3. A quartz arc tube 40 is sealed by two press seals 42 at opposite ends of the tube. Within each press seal is a molybdenum foil 44. Electrodes 46 located within the arc tube 40 and external leads 48 are connected to the molybdenum foils 44. A cavity 50 is formed in the press seal 42 so that it encloses a portion 51 of the foil 44. The foil 44 has at least one very sharp edge 53 to provide high electric field concentration and to allow breakdown at lower voltages and higher pressures. The cavity 50 also encloses flush gases, such as nitrogen and argon, which are used in the press sealing process, a technique well known in the art. When the cavity 50 is formed, the flush gases are at a temperature near the melting point of the quartz arc tube 40. When these gases cool, the pressure within cavity 50 decreases to about one-third to one-quarter atmosphere. An external ground plane 54 is attached to existing grounded frame parts allowing capacitive coupling between the foil 44 and the ground plane 54. When the lamp is energized, electric fields are produced within cavity 50 by the voltage between foil 44 and ground plane 54. The electric fields cause ionization of the fill material within cavity 50 and generation of ultraviolet radiation. The ultraviolet radiation promotes formation of an arc between electrodes 46. Thus, the cavity 50, foil portion 51 and ground plane 54 constitute a UV enhancer, or starting source, that is integrally formed (except for ground plane 54) within the press seal 42 of arc tube 40. The cavity may be formed by drilling a small hole, e.g. 2.0 mm wide, or by forming an indentation, in the face of a press foot (not shown) at a location corresponding to the location where the cavity is to be formed. As flush gases flow through the tube and the tube is heated, the press feet force the end of the quartz tube together, thus driving the flush gases out. Where the indentation or hole is formed in the press foot, the quartz is not forced together and the cavity forms as the tube is press sealed. Cavities are sometimes formed inadvertently in a press seal, but no provision is made for an electrode in the cavity. Such cavities are considered harmless imperfections. The cavity can be spherical or some other shape, and can vary in size depending on the size of the press seal. Examples of cavities have ranged from 1.0 mm to 10.0 mm in length and from less than 1.0 mm to 5.0 mm in diameter. The gas pressure in the cavity can be reduced by flushing with a mixture of gases, such as argon and nitrogen, and adding a getter for one of the gases. After the cavity is sealed, the getter can be activated with heat or electrical energy. The getter absorbs a gas, thus reducing the pressure of the gettered gas and the total pressure in the cavity. Instead of a getter, or in combination with a getter, a dispenser may be added to the cavity. The dispenser is a composition that includes a material to be dispensed, such as mercury, which enhances ultraviolet radiation. The dispenser can also be activated with heat or electrical energy after the cavity is sealed. Either a getter or a dispenser composition can be conveniently added onto a portion 53 of the molybdenum foil 44. Compositions for gettering and dispensing are generally known in the art. Additional embodiments of the invention are shown in Figs. 4-8. Referring to Fig. 4, if there is concern about the integrity of the seal, a second molybdenum foil 60 can be spot welded to foil 20 and used as a separate electrode. At least a portion of foil 60 extends into a cavity 62 formed in press seal 42. In this case, cavity 62 does not come into contact with the foil 20. A getter or dispenser 55 is provided on to the foil 60 as discussed above. In the embodiment shown in Fig. 5, an external metal ground plane 64 is provided. The ground plane 64 is a U-shaped conductor, such as stainless steel, which is attached to the outside of the press seal 42 or mounted close to the press seal. Referring to Fig. 6, if a separate connection to the UV enhancer is desired, an electrode 66 can extend from outside the press seal 42 into the cavity 62, and a getter or dispenser 57 can be provided on the electrode 66. In the embodiment of Fig. 7, a cavity 70 encloses a portion of foil 44 and also a portion of an electrode 72 which extends outside the press seal 42. For each of the embodiments described in connection with Figs. 2-7, the lamp is otherwise similar to the lamp described above in connection with Fig. 1. An RF type light source can have a starting source in a press seal. Referring to Fig. 8, a cavity 80 is formed in the press seal 82 of an RF arc tube 84 which encloses no electrodes. In this embodiment, a concentrator 88 enhances the electric field in the region of cavity 86. The concentrator can inductively or capacitively couple a high frequency electric field to the cavity 86. Plates or windings can be used for this purpose. A getter or dispenser 81 can be provided in the cavity 80. The getter or dispenser 81 can be mounted at the end of a rod or wire 83. The starter electrode approach and the separate UV enhancer each require additional parts and manufacturing steps. The extra parts and steps add to the lamp manufacturing cost. Embodiments of the present invention may provide an improved starting source for an arc discharge lamp which has fewer components than prior art devices; which is easy to manufacture; and which efficiently couples radiation to the interior of the arc tube.

Claims: An arc tube assembly comprising: a light-transmissive arc tube (40;84) containing a first fill material for supporting an arc discharge, a seal (42;82), means (44) for coupling electrical energy to the interior of said arc tube, a starting source (50; 62;72) containing a second fill material for supporting emission of ultraviolet radiation and means (44,54;44, 60,64;44,66;44,72;83,88) for coupling electrical energy to the starting source characterised in that said starting source (50;62;72) comprises a sealed cavity in said seal (42;82). An arc tube assembly as claimed in claim 1 characterised in that said starting source (50;62;72) further includes a dispenser (53;55;57;81) in said cavity for providing a material which enhances ultraviolet radiation when the dispenser is activated. An arc tube assembly as claimed in claims 1 or 2 characterised in that said starting source (50;62;72) further includes a getter (53;55;57;81) in said cavity for at least one of the gases in the fill material when activated. An arc tube assembly as claimed in any of the preceding claims characterised in that said means (44) for coupling electrical energy to said arc tube includes a conductive foil (44) in the seal (42;82). An arc tube assembly as claimed in claim 4 characterised in that said electrical energy coupling means (44,54;44,60,64) for said cavity (50;62;72) comprise a portion of said conductive foil (44) which extends into said cavity and a conductor (54;64) positioned adjacent the seal (42). An arc tube assembly as claimed in claim 4 characterised in that said electrical energy coupling means (44,60,64) for said cavity (50) comprise a first conductor (60) connected to said conductive foil (44) and extending into said cavity and a second conductor (64) located adjacent to the seal (42). An arc tube assembly as claimed in any of claims 1 to 4 characterised in that said electrical energy coupling means (83,88) for said cavity (80) comprise an electrode (83) extending into said cavity for external application of electrical energy. An arc tube assembly as claimed in claim 7 characterised in that said electrical energy coupling means for said cavity (70) comprise a portion of said conductive foil (44) extending into said cavity and a second conductive foil (72) extending into said cavity, said second conductive foil having an external lead attached thereto. An arc tube assembly as claimed in any of claims 4 to 8 characterised in that the conductive foil (44) in said seal has a sharp edge which extends into the cavity. A lamp having an arc tube assembly as claimed in any preceding claim, wherein the lamp is either an electroded or an electrodeless lamp.

Inventors: MORRIS JAMES C, MORRIS, JAMES C.
Applicants: FLOWIL INT LIGHTING, FLOWIL INTERNATIONAL LIGHTING (HOLDING) B.V.
Application year: 1993
Main classification: H01J61
IPC codes: H01J61