Patent Publication Number: US-2011048313-A1

Title: Indicating thermal dosage exposure of electric lamps

Description:
BACKGROUND OF THE DISCLOSURE 
     Electric lamps, particularly incandescent halogen lamps of the type employed for automotive applications, have experienced premature failures in service; and, it has been quite difficult to determine whether the failure was due to faulty lamp construction or intervals of exposure to excessive supply voltage to the lamp. Excessive supply voltage, even for a relatively limited interval, can cause the lamp to operate at above-normal temperatures which results in shortening the expected life of the lamp as expected with the nominal supply voltage. Where the lamp is exposed to excessive supply voltages for such limited periods, it is virtually impossible to detect such occurrences by visual examination of the lamp until failure occurs. 
     Thus, it has been long desired to provide a way or means of determining whether an electric lamp has been exposed to over voltage in service resulting in excessive temperatures of the lamp. It has been desired to provide such a determination of excessive voltage in a manner which is readily detectable by the user during service and by the manufacturer after the lamp has failed. 
     In addition, when the lamp is put into service with insufficient air circulation thereabout, even at nominal operating voltage, the lamp can experience excessive temperatures resulting in premature failure. 
     SUMMARY OF THE DISCLOSURE 
     The present disclosure describes a technique for providing visual indication on a an electric lamp of the thermal dosage the lamp has been exposed to during service, and particularly thermal dosage resulting in temperatures considered to be excessive in terms of the normal expected operating voltage for the lamp. In one version, thermally responsive coating is applied to a selected spot on the lamp or its base. The coating is responsive to exhibit different colors based upon the temperature to which the coating has been exposed and the time that the lamp was exposed to such excessive temperature which together provide an indication of a thermal dosage. This information may then be used to determine the reduction in the expected service life of the lamp. In another version, a semiconductor element is attached to a designated portion of the exterior surface of the lamp or either one of the interior or exterior of its base and the electrical properties found in the semiconductor are monitored during service. From a look-up table of electrical properties as a function of temperature, it can be determined what temperatures the lamp has experienced during sensing of the certain electrical properties. In another version, a cell of carbon material of predetermined dimensions is disposed in a designated area of the surface of the lamp or its base and; upon operation of the lamp the dimensions of the carbon may be measured at intervals. From a look-up table of changes in the dimensions as a function of thermal dosage, it can be determined what temperatures the lamp has experienced during the intervals. From this information the reduction in normal service life due to exposure to the high temperatures for a particular interval can be estimated. Carbonaceous material may also be employed as a cell of predetermined dimensions. 
     The disclosure describes a way or means to determine the operating temperature exposure and cumulative time of operation of the lamp; and, from the combination of these two, the cumulative thermal dosage is determined. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side elevation view of an electric lamp with portions of the bulb broken away to illustrate the internal elements; 
         FIG. 2  is a portion of a view of the upper segment of the bulb of an electric lamp; and, 
         FIG. 3  is a look-up table of temperature as a function of expected life. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring  FIG. 1 , an electric lamp according to the present disclosure is indicated generally at  10  an includes a bulb attached to a base indicated generally at  14  which may be attached to a support structures such as  16 , as for example, the sheet metal portions of the structure of a motor vehicle. The lamp  10  includes a pair of externally extending terminals  18 ,  20  which may be engaged with a suitable receptacle (not shown) or connected to a wiring harness (not shown). Bulb  12  may be formed of suitable transparent glass material and houses the illuminating element that is indicated generally at  22  which is connected via electrodes  24 ,  26  to the terminals  18 ,  20  respectively. 
     A spot of thermally responsive coating  28  is provided on a designated region of portion of the base  14 ; and, the coating  28  is formed of suitable materials such as acrylate/resin and changes color as the coating is exposed to elevated temperatures for various time intervals. The coating may alternatively be provided on a designated region of an internal surface portion of the base  14 . 
     Referring  FIG. 3 , a graphical presentation of temperature and exposure of time in hours is shown for various combinations of temperature and time wherein the color of the coating may be determined from the numeral indicated in the graph. Table 1 gives the color description for the numerical values shown in  FIG. 3 . 
     
       
         
           
               
               
             
               
                 TABLE 1 
               
               
                   
               
               
                 Ref. Numeral 
                 Color Description 
               
               
                   
               
             
            
               
                 1 
                 hardly darkening 
               
               
                 2 
                 visible darkening 
               
               
                 3 
                 yellowed, coloring 
               
               
                 4 
                 browned, coloring 
               
               
                 5 
                 black: burned 
               
               
                   
               
            
           
         
       
     
     From  FIG. 3  and Table 1, it will be readily seen that the higher the temperature exposure of the lamp the shorter interval is required to produce the greatest change in the thermal dosage indicating coating. 
     In the present practice, it has been found satisfactory to employ a material for the coating  28  of the version of  FIG. 1  having a manufacturers designation K2 experimental mix and obtainable from Budalakk Innova Kft., 1044 Budapest, Váci út40. The acrylate/resin coating exhibits the properties of turning to the color brown at 20 hours exposure to 230 degrees centigrade, the color of yellow at 40 hours exposure to 220 degrees centigrade and the color of black at 60 hours exposure to 250 degrees centigrade with no visible color change at 60 hours exposure to 200 degrees centigrade. 
     Alternatively, the thermally responsive coating  28  may be replaced by a temperature indicating semiconductor which is electrically connected to circuitry for monitoring the electrical properties of the semiconductor. In this version, the change in electrical properties of the semiconductor may be compared with a look-up table (not shown) of values of temperature as a function of the electrical properties such as drain current change; and, thus the temperature exposure of the lamp determined by the change in electrical properties. 
     Referring to  FIG. 2 , another version of the technique of the present disclosure is illustrated wherein the thermally responsive coating material is deposited on the bulb  12 ′ with numerals in reverse order, e.g. (5,4,3,2,1); and, the material for each numeral is of a different thickness layer or weakness insofar as thermal dosage produces change in appearance. For example, for the indicated 5 reference numerals in  FIG. 2 , after 100 hours exposure only numerals 2, 3, 4, 5 would be visible; after 300 hours exposure only numerals 4 and 5 would be visible and after 500 hours exposure none of the numerals would be visible. It would be understood that other combinations of indicia and temperature may be employed for the reference characters. 
     With continued reference to  FIG. 2 , an alternative version of the technique of the present disclosure is illustrated in the form of a carbon cell thermal dosage indicator  40  which is initially formed to predetermined dimensions; and, as the carbon is exposed to higher temperatures, sublimation occurs and the dimensions of the cell are reduced. From the look up table (not shown) of dimensions of the cell versus time at temperature the thermal dosage to which the cell has been exposed by its presence on the surface of the bulb can be determined. 
     Alternatively, the cell  40  may be formed of suitable carbonaceous material which exhibits the properties of sublimation at temperature as does the carbon material cell. 
     The present disclosure thus describes a technique for providing an indication in real time of the thermal dosage or time at temperature exposure of an electric lamp in service, particularly to excessive temperatures such as would be caused by excessive voltage applied to the lamp. In one version, a coating applied to a designated region of the lamp undergoes different color changes when exposed to different combinations of temperature of specified intervals. In another version, a semiconductor is monitored for changes in its electrical properties to give an indication of the thermal exposure of the semiconductor on the lamp. In another version, carbon or carbonaceous material in the form of a cell of specified dimensions is applied to the surface of the lamp; and, changes in the dimension of the cell leads to sublimation from temperature exposure employed to determine the degree of thermal dosage to which the cell has been exposed. The technique of the present disclosure thus provides the unique and simple way of determining whether an electric lamp has been exposed to excessive thermal dosage or high temperatures for specified intervals of time which would result in a reduction in the normal expected life. 
     The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations and is limited only by the following claims.