Cold cathode lamp suitable for automotive vehicles

Abstract: A neon-type discharge lamp assembly (7) is provided including two spaced-apart electrodes (10), an elongated discharge path (12) having one of the electrodes (10) approximately at each respective end, the path (12) being partially limited by a first reflector surface (14) with a generally semicircular cross section having opposing ends (16,18) and a center (17), a pair of second semiparabolic reflector surfaces (20), each surface (20) having first (22) and second (24) ends, the first ends (22) being joined to the ends (16,18) of the first reflector surface (14) and the second ends (24) emanating outwardly therefrom; a transparent, generally concave volumetric concentrator (26) positioned generally opposite the first reflector surface (14) and spaced therefrom, the concentrator (26) having first (28) and second (31) ends; and a transparent cover (30) having two segments, each segment connecting an end (28,31) of the concentrator (26) with the second end (24) of a respective second reflector surface (20).

Description: The field of the present invention is that of cold cathode discharge lamps, in particular, but not exclusively, neon lighting suitable for signal lighting, particularly rear signal lighting, for automotive vehicles. The technology of cold cathode discharge lamps (commonly referred to as neon lights) is relatively well known and has not changed greatly for 50 years. However, several technical challenges have prevented the widespread use of neon lights for rear lighting and signalling applications. There are three main areas on which to concentrate when considering efficiency within a neon lighting system. The first is the cathode voltage fall, which within a normal neon lamp is approximately 150 volts for a typical electrode pair. The second is the voltage fall within the discharge, which is dependent upon the gas filling, pressure, current density and discharge length. The final area is the optical processing of the light produced, both by a reflector and a lens. The cathode voltage fall is mostly dependent upon the material used for the electrode. It has been shown that if a discharge is constrained within a small diameter, a higher proportion of the inputted energy is used changing the state of the gas molecules, which then revert back emitting light, than with an unconstrained discharge. However, constriction raises the resistance of the discharge and thus the voltage fall. Therefore, for a given current, the heat produced within a neon light tube will be higher, a factor that is compounded by the reduced surface area. The heat generation can create surface temperature problems for the neon lamp, though its efficacy will be considerably enhanced. Gas pressure is an important parameter when considering efficiency. In general, the lower the gas pressure, the higher the efficiency, though there is a point below which the efficiency falls again as the number of charge carriers (ions) within the lamp become insufficient to maintain a discharge. However, within the very small tubes necessary to take advantage of the gains mentioned above, the small gas volume available in a low pressure lamp may well cause a very limited life. The above action is caused by some of the gas molecules becoming adsorbed into the electrodes during operation of the lamp, thus reducing the gas pressure. This process is commonly known as gas clean-up and is an important factor in determining the life of a neon-filled discharge lamp. The optical performance of a lamp package is also an area which promises considerable performance gains. A neon lamp emits light evenly all around it circumference, and to provide the highest efficiency, this must be gathered up and emitted in the appropriate direction for each particular application. In addition, the light must be of the correct colour, and to date this has been achieved by filtering through the lens. The colour of the lens is also important from the styling point of view, as people generally expect an automotive stop lamp to appear red, even when unlit. In order to meet the technical challenges discussed above, tube diameters have been reduced, and internal diameters as small as 3 mm are being used. While this causes little problem at lower currents, the desire to design a relatively small lamp requires currents to reach up to 50 mA to achieve the required light output. This has the effect of raising the glass wall temperature up to as high as 180°C (356°F), which will melt most plastics. The temperature around the electrode will be even higher, so this is generally unacceptable. A neon-type discharge lamp also has its life defined by three additional factors: the volume of gas present, which naturally is affected by the pressure; the operating current; and the surface area of the electrodes. Essentially, the aging process occurs as molecules of neon gas are adsorbed into the electrodes. This rate of adsorption increases rapidly with increasing current, once the capacity of the electrode is passed, and this is broadly defined by the available surface area, though it can be affected by the electrodes' configuration. Above this critical point, the electrode will start to sputter, that is, lose material into the discharge, which is then likely to be deposited onto the glass wall around the electrode. This deposition is then likely to trap more molecules of gas, thus reducing the gas pressure still further. Once this process has started, it is likely to accelerate until the gas pressure becomes so low that there are insufficient charge carriers to maintain the discharge, and the lamp will fail. A discharge lamp is known from US-A-2 135 480 in which a hollow body defining an elongate gaseous path with an electrode at each end has a reflector surface and a transmitting surface for producing a beam of desired shape and direction. To meet the above-noted challenges, the present invention seeks to provide a cold cathode discharge lamp suitable for automotive application which improves lighting efficiency while providing a design which improves operational life. This is achieved according to the present invention by the features recited in the characterising part of claim 1. More particularly, the present invention provides a discharge lamp having a first semicircular reflector surface joined to a semiparabolic reflector surface. Additionally, the discharge lamp of the present invention has a volumetric concentrator which aids in maintaining the position of the electron discharge path of the lamp while at the same time allowing for a greater volume of gas such as neon, thereby increasing lamp life while retaining better properties of focusability. The above and other advantages of the present invention will be made more apparent to those skilled in the art as the present invention is explained in greater detail in the following detailed description and accompanying drawings. Figure 1 is a front elevational view, partially sectioned, of a preferred embodiment of a neon discharge lamp according to the present invention; Figure 2 is a view taken along line 2-2 of Figure 1; and Figure 3 is an enlarged view of a portion of the lamp shown in Figure 1. Referring to Figures 1, 2 and 3, the signal lamp 7 for automotive vehicles according to the present invention is shown in an embodiment of a tail lamp or center high mounted stop lamp (CHMSL). The lamp has two electrodes 10. Each electrode 10 is typically fabricated from iron or a kovar (Registered Trade Mark) material and has a voltage across the electrode of approximately 150 volts. The electrodes 10 will be connected to a ballast which provides an output wattage which is matched to the discharge lamps specific voltage-current characteristics at the light output desired. One electrode 10 is placed at each end of a gaseous path 12 of elongate serpentine shape. The gaseous path 12 is defined by a hollow body which, as best shown in Figure 3, includes a first substantially semicircular reflector surface 14 (formed from a borosilicate material) having a center 17. The radius of reflector surface 14 is approximately 2.5 mm. Reflector surface 14 has a surface roughness of 0.000254 mm (10 µin.) and typically will be provided with a phosphor coating. The first reflector surface 14 has opposing ends 16 and 18. Joined to the ends 16 and 18 of the first reflector surface are second semiparabolic reflector surfaces 20. The second reflector surfaces 20 are integrally joined to the first reflector surface 14. The second reflector surfaces have a first end 22, which is joined to the ends 16 and 18 of the first reflector surface 14, and have a second end 24 emanating outwardly from the junction of the first and second reflector surfaces. A line drawn from end 24 to end 22 of the second reflector surface 20 intersects with a line drawn between the two ends 16 and 18 of the first reflector surface 14 at approximately a 140 degree angle. Although the second reflector surface 20 is nearly parabolic, it will not be totally parabolic but rather will be formulated to project the light pattern generally required of a stop signal or CHMSL light assembly. The second reflector surface 20 will have a phosphor coating similar to that provided for the first reflector surface 14. Spaced generally opposite the first reflector surface 14 is a transparent volumetric substantially concave concentrator 26. The concentrator has first and second ends 28 and 31, respectively, which are integrally joined to a multiple part cover 30 which connects the concentrator 26 with the second ends 24 of the second reflector surfaces 20. The concentrator 26 helps to retain the center of the volumetric area of the gaseous path 12 at center 17. The concentrator 26 and cover 30 will typically be integrally formed from a borosilicate material which is joined to the first and second reflector surfaces 14, 20 along intersection 34 by one of two processes. There are two possible methods of sealing reflector surfaces 14, 20 to the cover 30. In one method, the reflector surfaces 14, 20 and cover 30 are preformed to the correct shape by sheet forming techniques. Then a small bead of frit material is laid down between each channel and around the outer periphery of the reflector surfaces along surface interface 34. The cover 30 is then aligned on top of the reflector surfaces. The reflector surfaces 14, 20 and cover 30 are then put in a kiln or lehr and slowly brought up to a temperature required for fusing the frit material to the separate glass surface interface 34. The lamp is then brought back to room temperature after a hermetic seal has been achieved. Another method is to again use a sheet forming method to form the cover 30 and the reflector surfaces 14, 20. Thereafter, cover 30 and reflector surfaces 14, 20 are pressed together while they are still almost in their molten state and fusion occurs to create a hermetic seal. When such a technique is utilized, the phosphor coating on the inside reflector surfaces 14, 20 usually cannot be done. Therefore, the opposite side 42 or the outer surfaces of the reflector surfaces 14, 20 will be metallised to achieve a high minor light reflector surface. Neon or other low pressure gasses such as argon, helium or a mixture is delivered into the gaseous path via a fill tube. The above is accomplished by connecting the chamber to a manifold and evacuating it to approximately 530-660 Pascal (4-5 mm/Hg). Then a high current is run through the channel to heat up the electrodes and the gas to remove any impurities or undesired gas. The chamber is then evacuated to .13 Pascal (10 -3 mm/Hg) to remove the impurities. The chamber is then backfilled with the desired gas (neon) to approximately 2.6 x 10 3 Pascal (20 mm/Hg) and sealed by taping off the glass tube with a flame torch or pinch seal at 37. In operation, the arc will generally be coterminous with the center 17. Light emanating rearwardly (or downwardly as shown in Figure 3) from the center 17 will impinge upon the first reflector surface 14 and then will either reflect directly into the concentrator 26 or the cover 30 or indirectly into the second reflector surface 20 before contacting the cover 30 or the concentrator 26. Other light which will radiate forwardly or upwardly, depending on the angle given, will hit the second reflector surface 20 or go directly into the concentrator 26 or the cover 30. The total light emitted will be four times greater than the output pattern desired for an automotive signal lamp than if a simple circular tube was utilized. In addition, with the reflector portion of each channel basically touching the reflector portion of the channel next to it, a uniform and evenly distributed light pattern will appear across the surface of the lamp 7, giving a very smooth appearance. Typically, the cover 30 will be tinted to give a red appearance. The addition of the side wings 36 allows the total volumetric amount of gas to be 30 percent higher than if a simple circular tube were utilized. This additional 30 percent volume of gas typically increases the life of the lamp 7 by 30 percent over a more simple circular neon tube design. While this invention has been described in terms of a preferred embodiment thereof, it will be appreciated that other forms could readily be adapted by one skilled in the art. Accordingly, the scope of this invention is to be considered limited only by the following claims.

Claims: A cold cathode discharge lamp suitable for automotive vehicles comprising: two spaced-apart electrodes (10); an elongate gaseous path (12) having one of the electrodes (10) approximately at each respective end, the path (12) being defined by a hollow body having a transverse cross-section including a reflector surface (14, 20) and a transmitting surface (26, 30) characterised in that the reflector surface (14, 20) comprises a first substantially semicircular reflector surface (14) having opposing ends (16, 18) and a center (17) and a pair of second semiparabolic reflector surfaces (20), each second reflector surface (20) having first and second ends (22,24), the first ends (22) being joined to the ends (16, 18) of the first reflector surface (14) and the second ends (24) emanating outwardly therefrom; the transmitting surface (26, 30) comprising a transparent, substantially concave volumetric concentrator (26) positioned generally opposite the first reflector surface (14) and spaced therefrom, the concentrator (26) having first and second ends (28, 31); and a transparent cover (30) connecting the ends (28, 31) of the concentrator (26) with the second ends (24) of the second reflector surface (20). A lamp as described in claim 1 characterised in that the gaseous path (12) takes a serpentine shape. A lamp as described in claim 1 or claim 2 characterised in that the gaseous path (12) contains neon, argon, helium or a mixture. A lamp as described in any preceding claim characterised in that a current path between the electrodes (10) is generally coterminous with the center (17) of the first reflector surface (14). A lamp as described in any preceding claim characterised in that the first and second reflector surfaces (14, 20) are integrally joined. A lamp as described in any preceding claim characterised in that the reflector surfaces (14, 20) are provided with a phosphor coating. A lamp as described in any one of claims 1 to 5 characterised in that the reflector surfaces (14, 20) are metalised on outer surface (42) of the hollow body. A lamp as described in any preceding claim characterised in that the cover (30) is sealed to the reflector surfaces (14, 20) at an interface (34). A lamp as described in any preceding claim characterised in that the cover (30) is tinted red. Use of a lamp as described in any preceding claim as a tail lamp or center high mounted stop lamp.

Inventors: HAAG RONALD HELMUTH, HAAG, RONALD HELMUTH
Applicants: GUIDE CORP, GUIDE CORPORATION
Application year: 1996
Main classification: H01J61
IPC codes: H01J61