Patent Publication Number: US-5252890-A

Title: Compact type fluorescent lamp device having crooked arc path

Description:
This is a continuation of Ser. No. 07/581,216, filed On Sep. 11, 1990, abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates, in general, to fluorescent lamp devices. In particular, the invention relates to a compact type fluorescent lamp device having a plurality of straight arc bulbs closely disposed in parallel to one another. One end of each arc bulb is connected to another are bulb to form a relatively long crooked arc path. 
     2. Description of the Related Art 
     In recent years, the external shape of the arc bulb of a fluorescent lamp device has been changed to reduce the size thereof without decreasing the entire arc path thereof. In such a compact type fluorescent lamp device, the arc bulb thereof is formed in a H shape, a U shape, or a W-shape. One of the conventional compact type fluorescent lamp device is shown in FIGS. 1, 2 and 3. A pair of straight-shaped bulbs 11a and 11b of the fluorescent lamp device is extended in parallel to one another from a base 15. The extended end of each arc bulb 11a, 11b is communicated through a connecting tube 17. Thus, a substantially U-shaped arc path is formed in the pair of straight-shaped bulbs 11a and 11b and connecting tube 17 extended between straight-shaped bulbs pair 11a and 11b, as shown in FIG. 2. A stem 19a, 19b is provided to the other end of each straight-shaped bulb 11a, 11b. A pair of electrodes 21a and 21b is respectively disposed in each bulb 11a, 11b and is supported by stem 19a, 19b. A fluorescent material 23 is coated on the inner surface of each bulb 11a, 11b. A prescribed amount of a fill including mercury and a starting rare gas is sealed in bulbs 11a and 11b. 
     Base 15 includes a connector portion 25 and a pedestal portion 27, which are formed with an insulating material, e.g., synthetic resin. A first pair of base pins 29a is extended outward from connector portion 25. Both terminals of electrode 21a and first base pins pair 29a are electrically connected through a lead wire 31a, respectively. A second pair of base pins 29b also is extended outward from connector portion 25 Both terminals of electrode 21b and second base pins pair 29b also are electrically connected through a lead wire 31b, respectively. As shown in FIG. 2, the other end of each bulb 11a, 11b at which the pair of electrodes 21a and 21b is disposed is respectively inserted into pedestal portion 27 through a pair of holes 33a and 33b. The inserted end portion of each bulb 11a, 11b is supported such that a space between the inner surface of pedestal portion 27 and the circumferential surface of tho inserted end portion of each bulb 11a, 11b is filled with an elastic bonding agent 35, e.g., silicone. 
     In the above-described conventional fluorescent lamp device, diameters of the holes pair 33a and 33b are slightly greater than the external diameters of the bulbs pair 11a and 11b to easily insert the other end of each bulb 11a, 11b into the corresponding holes 33a and 33b. According to a design practice, it is designed such that the axis of each bulb 11a, 11b is coincident with the center of the corresponding holes 33a and 33b. Thus, a constant gap is maintained between the circumferential surface of each bulb 11a, 11b and the corresponding holes 33a and 33b in a radial direction. In other words, as shown in FIG. 3, an inner distance (a) is formed between the edge of hole 33a and the inner side surface of bulb 11a adjacent to bulb 11b, and an outer distance (c) also is formed between the edge of hole 33a and the outer side surface opposite to the above-described inner side surface of bulb 11a. In the same manner, an inner distance (b) is defined between the edge of hole 33b and the inner side surface of bulb 11b adjacent to bulb 11a, and an outer distance (d) is formed between the edge of hole 33a and the outer side surface opposite to the inner side surface of bulb 11b. Thus, each distance (a), (b), (c), (d) has the same dimension as one another. 
     In the above-described conventional compact type fluorescent lamp device, the output power of the lamp device was at most 36 watt (W) because of its compact external size. However, in recent years, a high output power fluorescent lamp device of the type, e.g., 55 watt (W), 96 watt (W), etc., has been developed. In the above-described low output power fluorescent lamp device, an entire length h of the arc bulb thereof, shown in FIG. 2, is about 410 (mm). However, in the high output power fluorescent lamp device described above, a distance between a pair of electrodes (an arc path) is more than 1000 (mm), and an entire length h is more than 560 (mm). 
     In the above described high output power fluorescent lamp device, cracks were observed in connecting tube 17, shown in FIGS. 1 and 2, during the operation of the lamp device. The inventor discovered cause of the cracks occurring in connecting tube 17 of the lamp such as a H-shaped fluorescent lamp device. When the H-shaped fluorescent lamp device shown in FIG. 2 is operated, arc tube 13 is heating and the temperature of the inner side surface of each bulb 11a, 11b facing to one another becomes greater than that of the outer side surface of each bulb 11a, 11b. This is because heat from the outer side surface of each bulb 11a. 11b is smoothly radiated. However, the inner Side surface of each bulb 11a, 11b is subject to a heat radiation from the inner side surface of the other bulb. Furthermore, an air convection scarcely occurs in a space defined by bulbs 11a and 11b adjacent to one the other. Thus, the inner side surface of each bulb 11a, 11b is expanded toward its opposite ends and the end portion of each bulb 11a, 11b in which electrodes 21a and 21b are respectively disposed is warped outwardly so as to move apart from one another, as indicated by an imaginary line m in FIG. 2. In addition, the temperature of the inner side surface of connecting tube 17 exposed to the space between bulbs 11a and 11b is higher than that of other surfaces thereof in a circumferential direction. For instance, when the H-shaped fluorescent lamp device of a 55 watt (W) rating was operated in a horizontal state at a room temperature of 25 degree centigrade (°C.), the temperature of the inner side surface of bulb 11b at a point A shown in FIG. 2 was 90 degree centigrade (°C.) and the temperature of the outer surface of bulb 11b at a point B was 70 degree centigrade (°C.). Thus, it was observed that the distance between end portions of bulbs 11a and 11b was expanded to 3 to 5 (mm). 
     However, the mutual outward movement of the end portions of bulbs 11a and 11b is forcibly prevented by the corresponding edges of each hole 33a, 33b of base 15. Thus, connecting portion 17 receives a force caused by the expansion of the inner side surface of each bulb 11a, 11b. This results cracking of connecting portion 17. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present invention to avoid cracking of the connecting portion of a compact type fluorescent lamp device. 
     It is another object of the invention to absorb a force acting on the connecting portion of the arc tube which is caused by the Outward expansion of the opposite inner side surfaces of the arc tube under the influence of heat in a compact type fluorescent lamp device. 
     To accomplish the above-described objects, a compact type fluorescent lamp device includes a bent bulb for defining a crooked arc path therein, a pair of electrodes each disposed in the opposite sealed ends for producing an arc therebetween along the crooked arc path, a base for elastically supporting the opposite sealed ends of the bent bulb, and an allowing construction formed in the base for ensuring a variable moving distance of the opposite ends of the bent bulb caused by the outward expansion of the opposite inner side surfaces of the bent bulb. The allowing construction includes first and second holes formed in the base for respectively receiving the opposite ends of the bent bulb. The opposite ends each have an inner side surface facing each other and an outer side surface opposite to the inner side surface. The inner side surface of one of the opposite ends and the inner side edge of the first hole define a first inner distance A. The outer side surface of the one of the opposite ends and the outer side edge of the first hole define a first outer distance C greater than the first inner distance A. The inner side surface of the other end and the inner side edge of the second hole define a second inner distance B. The outer side surface of the other end and the outer side edge of the second hole define a second outer distance D which is greater than the second Inner distance B. The first and second inner distances A and B and the first and second outer distances C and D satisfying the following relationship: 
     
         A+B&lt;C+D. 
    
     The base may include a bonding agent for elastically supporting the opposite ends of the bent bulb in the base. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These and other objects and advantages of this invention will become apparent from the following detailed description of the presently preferred embodiment of the invention, taken in conjunction with the accompanying drawings, wherein like reference numerals throughout the various figures denote like structural elements and wherein: 
     FIG. 1 is a perspective view illustrating a conventional compact type fluorescent lamp device; 
     FIG. 2 is a sectional view illustrating the compact type fluorescent lamp device shown in FIG. 1; 
     FIG. 3 is a sectional view taken on line III--III of FIG. 1; 
     FIG. 4 is a perspective view illustrating a compact type fluorescent lamp device of one embodiment of the present invention; 
     FIG. 5 is a cross sectional view illustrating the compact type fluorescent lamp device shown in FIG. 4; 
     FIG. 6 is a sectional view taken on line VI--VI of FIG. 4; 
     FIG. 7 is an elevational view illustrating a compact type fluorescent lamp of a second embodiment of the invention; 
     FIG. 8 is a sectional view taken on line VIII--VIII of FIG. 7; 
     FIG. 9 is an elevational view illustrating a compact type fluorescent lamp of a third embodiment of the present invention; and 
     FIG. 10 is an enlarged sectional view taken on line IX--IX of FIG. 9. 
    
    
     DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS 
     Three preferred embodiments of the present invention will no be described in more detail with reference to the accompanying drawings. In FIGS. 4, 5 and 6, however, the same numerals are applied to the elements similar to those in FIGS. 1, 2 and 3, and therefore, the detailed descriptions thereof are not repeated. 
     A major difference between the compact type fluorescent lamp device of one embodiment and the conventional lamp device is the structure of a pair of holes 51a and 51b formed in pedestal portion 27 of base 15. In this embodiment, short inner distances (a) and (b) are defined between the inner side surface of each bulb 11a, 11b facing one another and the corresponding edge of each hole 51a, 51b, as shown in FIG. 6. Relatively long outer distances (c) and (d), compared with inner distances (a) and (b), are also defined between the outer side surface of each bulb 11a, 11b opposite to the inner side surface thereof and the corresponding edge of each hole 51a, 51b. In view of a design practice, the relationship between inner distances (a) and (b) and outer distances (c) and (d) is determined such that inner distance (a) is shorter than outer distance (c) in hole 51a, and inner distance (b) is shorter than outer distance (d) in hole 51b when the lamp device is not operated. Considering unavoidable errors in dimension when forming, processing or assembling arc bulbs 11a and 11b and the pair of holes 51a and 51b, it is preferable to determine the relationship between inner distances (a) and (b) and outer distances (c) and (d) as follows: a+b&lt;c and a+b &lt;d. However, at least a following relationship should be satisfied: a+b&lt;c+d. 
     With the above-described construction of one embodiment of the present invention, since outer distances (c) and (d) of holes 51a and 51b are relatively longer and bonding agent 35 has an elasticity, the distances (c) and (d) of holes 51a and 51b ensure the outward movement of the end portion of each bulb 11a, 11b over a variable moving distance of each end portion in base 15 when the inner side surface of each bulb 11a, 11b is expanded under the influence of heat during operation of the lamp, as indicated by an imaginary line m in FIG. 5. 
     As described above, since the end portions of bulbs 11a and 11b at which the pair of electrodes 21a and 21b is disposed can be moved outwardly in the corresponding holes 51a and 51b, the force acting on connecting tube 17 is absorbed. Thus, cracking of connecting tube 17 is avoided. 
     In the above-described embodiment, the present invention is applied to the H-shaped arc bulb. However, the invention may by applied to a U-shaped arc bulb formed by bending a straight-shaped arc bulb. Similar effects can also be obtained in the U-shaped arc bulb. 
     A second embodiment of the present invention will be described with reference to FIGS. 7 and 8. In this embodiment, the present invention is applied to a reverse W-shaped arc bulb 61. As shown in FIG. 7, reverse W-shaped arc bulb 61 includes a first U-shaped bulb 63a and a second U-shaped bulb 63b. The outside surface of one of the ends 64a of first U-shaped bulb 63a is heated and the corresponding surface of one of the ends 64b of second U-shaped bulb 63b is also heated. Each heated portion of first and second U-shaped bulbs 63a and 63b is closely opposed and is connected to one another by the blow off process to fluidly communicate to one another. A first electrode 21a, shown in FIG. 8, is disposed in the other end 66a of first U-shaped bulb 63a, and a second electrode 21b also is arranged in the other end 66b of second U-shaped bulb 63b. Thus, a substantially W-shaped arc path is formed in the connected first and second U-shaped bulbs 63a and 63b. As shown in FIG. 8, a wide recess 65 is formed at the center of pedestal portion 27 of base 15 to house the connected portion of first and second U-shaped bulbs 63a and 63b. The pair of holes 33a and 33b is respectively formed at the opposite sides of wide recess 65 in pedestal portion 27. The other ends 66a and 66b of first and second U-shaped bulbs 63a and 63b at which the first and second electrodes 21a and 21b are disposed are respectively inserted into the corresponding holes 33a and 33b, and are supported with the elastic bonding agent (not shown) filled in pedestal portion 27. 
     In the above-described second embodiment, a circumferential gap 67a is formed between the other end 66a of first U-shaped bulb 63a and hole 33a. A first inner distance (a) between the inner side surface of the other end 66a of first U-shaped bulb 63a closely facing the one of the ends 64a of first U-shaped bulb 63a and the edge of hole 33a is smaller than a first outer distance (c) between the outer side surface of the other end 66a opposite to the inner side surface and the edge of hole 33a when the lamp device is not operated. In the same manner, a circumferential gap 67b is formed between the other end 66b of second U-shaped bulb 63b and hole 33b. A second inner distance (b) between the inner side surface of the other end 66b of second U-shaped bulb 63b closely facing the one of the ends 64b of second U-shaped bulb 63b and the edge of hole 33b is smaller than a second outer distance (d) between the outer side surface of the other end 66b opposite to the inner side surface and the edge of hole 33b when the lamp device is not operated. In the above-described inner and outer distances (a), (b), (c) and (d), at least a following relationship should be satisfied: 
     
         a+b&lt;c+d. 
    
     In a conventional fluorescent lamp of the reverse W-shape type, it was observed that cracks occurred at each bent portion of U-shaped bulbs 63a and 63b. However, in this embodiment, the outward movement of each the other end 66a, 66b of first and second U-shaped bulbs 63a and 63b is allowed by first and second outer distances (c) and (d) of the corresponding holes 33a and 33b over a variable moving distance of each the other end 66a, 66b. Thus, occurrence of cracks in each bent portion 69a, 69b of reverse W-shaped arc bulb 61 can be avoided. 
     A third embodiment of the present invention will now be described with reference to FIGS. 9 and 10. As shown in FIG. 9, first, second third and fourth straight bulbs 71, 73, 75 and 77 are rectangularly arranged on pedestal portion 27 of base 15, and perpendicularly extend from pedestal portion 27. 27 The extended end portion 71a of first bulb 71 is connected to the extended end portion 73a Of second bulb 73 by a first connecting tube 79a to fluidly communicate to one another. The base end portion 71b of first bulb 71 opposite to the extended end portion 71a is disposed in a first hole 81a formed in pedestal portion 27 of base 15. The base end portion 73b of second bulb 73 opposite to the extended end portion 73a is disposed in a second hole 81b formed in pedestal portion 27. The inner side surface of second bulb 73, facing third bulb 75, in the visinity of base end portion 73b is connected to the corresponding portion of third bulb 75 by a second connecting tube 79b, as shown in FIG. 9. Thus, second bulb 73 and third bulb 75 are fluidly communicated to one another. The extended end portion 75a of third bulb 75 is connected to the corresponding portion 77a of fourth bulb 77 by a third connecting tube 79c to fluidly communicate to one another. The base end portion 75b of third bulb 75 is disposed in a third hole 81c formed in pedestal portion 27, and the base end portion 77b of fourth bulb 77 is disposed in a fourth hole 81d in pedestal portion 27. Each base end portion 71b, 73b, 75b, 77b of first, second, third and fourth bulbs 71, 73, 75 and 77 is supported by an elastic bonding agent (not shown) filled in pedestal portion 27. A first electrode 83 is supported in the base end portion 71b of first bulb 71, and a second electrode 85 is supported in the base end portion 77b of fourth bulb 77. Thus, a relatively long arc path is formed through first bulb 71, first connecting tube 79a, second bulb 73, second connecting tube 79b, third bulb 75, third connecting tube 79c and fourth bulb 77. 
     In the above-described embodiment, a circumferential gap 87a is formed between the base end portion 71b of first bulb 71 and first hole 81a. A first inner distance (a) is defined by the inner side surface of the base end portion 71b closely facing the base end portion 73b of second bulb 73 and the edge of first hole 81a, as shown in FIG. 10. A first outer distance (c) is defined by the outer side surface of the base end portion 71b opposite to the inner side surface of the base end portion 71b and the edge of first hole 81a. First outer distance (c) is greater than first inner distance (a) when the lamp device is not operated. In second hole 81b, a circumferential gap 87b also is formed between the base end portion 73b of second bulb 73 and second hole 81b. A second inner distance (b) is defined by the inner side surface of the base end portion 73b closely facing the base end portion 71b of first bulb 71 and the edge of second hole 81b. A second outer distance (d) is defined by the outer side surface of the base end portion 73b of second bulb 73 opposite to the inner side surface of the base end portion 73b and the edge of second hole 81b. Second outer distance (d) is greater than second inner distance (c) when the lamp device is not operated. Thus, a value obtained by adding first outer distance (c) to second outer distance (d) is usually greater than a value obtained by adding first inner distance (a) to second inner distance (b) when the lamp device is not operated even if an error in measurement in assembling is taken into consideration. In the same manner, a circumferential gap 87c is formed between tho base end portion 75b of third bulb 75 and third hole 81c. A third inner distance (a) is defined by the inner side surface of the base end portion 75b and the edge of third hole 81c. A third outer distance (c) is also defined by the outer side surface of the base end portion 75b of third bulb 75 opposite to the inner side surface of the base end portion 75b and the edge of third hole 81c. Third outer distance (c) is greater than third inner distance (a) when the lamp device is not operated. In fourth hole 81d, a circumferential gap 87d is formed between the base end portion 77b of fourth bulb 77 and fourth hole 81d. A fourth inner distance (b) is defined by the inner side surface of the base end portion 77b closely facing the base end portion 75b of third bulb 75 and the edge of fourth hole 81d. A fourth outer distance (d) is defined between the outer side surface of the base end portion 77b opposite to the inner side surface of the base end portion 77b and the edge of fourth hole 81d. Fourth outer distance (d) is greater than fourth inner distance (b) when the lamp device is not operated. In this case also, a value obtained by adding third outer distance (c) to fourth outer distance (d) is usually greater than a value obtained by adding third inner distance (a) to fourth inner distance (b) when the lamp device is not operated. Second hole 81b and third hole 81c may be communicated to one another, as a substantially common hole. However, the above-described relationship between second inner and outer distances (c) and (d) should be maintained. The relationship between third inner and outer distances (a) and (b) should also be maintained, as described above. 
     In the above-described embodiment, the outward movement of each first and second bulbs 71 and 73 occurs between first and second bulbs 71 and 73 whose extended end portions 71a and 73a are connected by first connecting tube 79a during the operation of the lamp device. However, since relatively long first and second outer distances (c) and (d) are formed between the first outer surface of the base end portion 71b and the edge of first hole 81a and the second outer surface of the base end portion 73b and the edge of second hole 81b, the base end portion 71b of first bulb 71 and the base end portion 73b of second bulb 73 move outward in the corresponding distances (o) and (d) to absorb a force acting on first connecting tube 79a. Thus, cracking of first connecting tube 79a can be avoided. In the same manner as described above, when the outward movement of each third and fourth bulb 75 and 77 occurs, the base end portion 75b of third bulb 75 and the base end portion 77b of fourth bulb 77 move outward in the corresponding distances (c) and (d) to absorb a force acting on third connecting tube 79c. Thus, cracking of third connecting tube 79c can also be prevented. 
     The present invention has been described with respect to specific embodiments. However, other embodiments based on the principles of the present invention should be obvious to those of ordinary skill in the art. Such embodiments are intended to be covered by the claims.