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GB1559589A - Discharge lamp envelopes - Google Patents

Discharge lamp envelopes Download PDF

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Publication number
GB1559589A
GB1559589A GB3185776A GB3185776A GB1559589A GB 1559589 A GB1559589 A GB 1559589A GB 3185776 A GB3185776 A GB 3185776A GB 3185776 A GB3185776 A GB 3185776A GB 1559589 A GB1559589 A GB 1559589A
Authority
GB
United Kingdom
Prior art keywords
particles
envelope
oxide
coating
aluminium oxide
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
GB3185776A
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Electric Co
Original Assignee
General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US05/601,859 external-priority patent/US4012655A/en
Application filed by General Electric Co filed Critical General Electric Co
Publication of GB1559589A publication Critical patent/GB1559589A/en
Expired legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J61/00Gas-discharge or vapour-discharge lamps
    • H01J61/02Details
    • H01J61/30Vessels; Containers
    • H01J61/35Vessels; Containers provided with coatings on the walls thereof; Selection of materials for the coatings

Landscapes

  • Vessels And Coating Films For Discharge Lamps (AREA)
  • Formation Of Various Coating Films On Cathode Ray Tubes And Lamps (AREA)
  • Discharge Lamps And Accessories Thereof (AREA)

Description

(54) IMPROVEMENTS IN DISCHARGE LAMP ENVELOPES (71) We, GENERAL ELECTRIC COMPANY, a corporation organised and existing under the laws of the State of New York, United States of America, of 1 River Road, Schenectady 12305, State of New York, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: The invention relates to heat and light-reflective coatings on discharge lamp emvelopes operating at high temperatures and is particularly concerned with improving the coating strength and adherence.
High intensity metal halide lamps such as disclosed in U. S. Patent 3,234,421-Reiling, are widely used for commercial, industrial, and outdoor lighting. In appearance these lamps resemble a conventional high pressure mercury vapor lamp compnsing a quartz arc tube mounted within a glass outer jacket provided with a screw base at one end. Thermionic electrodes are mounted in the ends of the arc tube which contains a quantity of mercury and metal halides along with an inert gas for starting purposes. One commercially available lamp contains mercury, sodium iodide, thallium iodide and indium iodide, whereas another contains mercury, sodium iodide, scandium iodide and thorium iodide.
The portions of the arc chamber behind the electrodes, that is the end, of the arc tube, are the coolest regions in normal operation of such lamps. In the absence of special measures to raise the temperature of the ends, too much of the metal halide such as sodium iodide may remain condensed on the envelope wall behind the electrodes. To prevent this and cause the lamp to achieve its proper efficiency, heat and light reflective coatings are generally applied to the ends of the arc tube, sometimes to the lower end only in vertically operated lamps. A coating which has widely used is described in U. S. Patent No. 3,374,377 and consists essentially of zirconium oxide ZrO2.
While a zirconium oxide coating has been quite satisfactory in respect of reflectivity and avoidance of darkening or release of deleterious gases into the interenvelope space, it is quite fragile and will not withstand abrasion. Bumping of lamps during handling and even the mere heating and cooling from intermittent operation may cause the coating to flake off. This contributes to nonuniformitv in color from lamp to lamp and creates an appearance defect. Also the coating is limited in thickness, and thicker coatings having greater reflectivity are desirable. An aluminium oxide coating of equal reflectivity is even more fragile.
The present invention provides a discharge lamp envelope selected from fused silica or from alumina ceramic, having an optically reflective coating of Al. 03 particles in the case of fused silica, or by an optically reflective coating of ALO- ! particles or ZrO, particles in the case of alumina ceramic, the particles being adherent to the envelope by means of an adhesion layer consisting of colloidal aluminium oxide and boric oxide heat-reacted with the silica or alumina surface of the envelope and with the particles.
The present invention also provides a method of adhering reflective Al20l particles to the surface of a fused silica discharge lamp envelope or reflective Al, 03 or ZrO, particles to the surface of an alumina ceramic discharge lamp envelope which comprises: applying a layer of colloidal aluminium oxide and boric oxide to the surface to provide an intermediate adhesion layer, applying a coating of said reflective particles thereover, and heating to a temperature of at least 460 C in order to react the boric oxide with the aluminium oxide, the envelope surface and with the particles.
The adhesion layer may be applied as a distinct intermediate layer and the refractory metal oxide particles applied thereover, or the adhesion components and the refractory metal oxide particles may be mixed and applied together. For instance, the fused silica tube may be dipped into a suspension of a colloidal aluminium oxide and boric oxide powders and the coating allowed to dry. The coating of refractory metal oxide particles is then applied alone or may first be admixed with colloidal aluminium oxide and boric oxide powders for even greater coating strength if desired. The silica tube is then heated to a temperature greater than 460 C. Alternatively, the intermediate adhesion layer may be applied and then heated. Subsequently the suspension of aluminium oxide in a binder may be sprayed onto the hot surface. The mixed components and refractory metal oxide particles may also be applied directly without precoat. The improved coating strength prevents flaking off and permits the use of a thicker layer of AI, 03 reflective particles for higher optical and thermal reflection than previously possible.
In the past zirconium oxide was preferred for the reflective coating on metal halide lamps because its higher index of refraction permitted a thinner layer to suffice than when aluminium oxide was used. This avoided the problem of lack of adequate adhesion and permitted a thinner layer to be used. Our invention has made possible the good adherence of aluminium oxide by means of an adhesion coat. For many applications, aluminium oxide is now prepared because it provides adequate reflectivity and it lower in cost. Also alumina is available in much purer form than zirconia at a reasonable price, whereby it has less tendency to darken and a white coat throughout life is achieved.
The present invention will be further described, by way of example, with reference to the accompanying drawing which is a side view of a metal halide lamp in which the arc tube is provided with an improved refractory metal oxide reflector coating embodying the invention.
The difficulty in achieving reliable adherence of Zr02 to fused silica arc tubes appears to be due at least in part to the mismatch in thermal expansion and the tremendous temperature range involved. The coefficient of thermal expansion of quartz is 0.56 x 10-6 cm/cmi"C while that of Zr02 is 7.5 x 10-6 cm ! cm/ C, about 12 times greater. The arc tube wall temperature at the hottest coated spot, located slightly above the tip of the electrode, may be as high as 925 C. Thus in a lamp operating outdoors, the interface between the quartz and the ZrO. coating mav pass through a temperature swing of close to 1000 C.
Aluminium oxide has a coefficient of thermal expansion of 8.0 x 10-6 cm/cm/ C and is almost a perfect match for ZrO. The boric oxide B melts at 460 C and heating above that temperature permits reaction between B20, and Si 2 and between B203 and colloidal A1 03.
We believe our invention thus provides an A'203 intermediate adhesion material firmly attached to the fused silica between the A1. particles and the silica. At the interfaces between the colloidal alto0; and and A1. 03 particles, the rates of thermal expansion match, resulting in a much stronger bond. Ho\vever the improved adherence and thicker coatings achieved by our invention are facts irrespectively of the validity of the foregoing explanation.
The adhesion layer may conveniently be applied as a wet coating by dipping the quartz arc tube or envelope into a suspension of the aluminium oxide and boric oxide powders in an organic vehicle. Table I below lists representative formulations which were tested and studied to determine and optimize the permissible range with regard to A T0 B () 3 ratio, the liquid to solid ratio and the ratio of high volatile to low volatile components in the organic liquid vehicle.
Table I Formula Methanol Cellosolve Al203 B201 1 60 ci 20 cc 8. 37 gm 5.32 gm 2 60 20 4. 78 3.04 3 60 0 19 7.40 4. 71 4 60 12 4. 23 2. 70 5 60 20 12. 56 2.67 6 60 20 7. 17 1. 52 7 60 12 11. 09 2.35 8 60 1'tS. 32 1.34 9 60 16.'6 6.50 2.91 The A 15 used zas vérs fine submicron size (collidal) alumina such as is commercially available under the trade mark"ALON C"The B used was in the hydrate form of boric acid HBO, and the weight given above is the B equivalent. Substantially all water present in borix oxide and aluminium oxide is removed in subsequent heating of the quartz tube. For the highly volatile organic component, methanol of high purity (electronic grade) was used and for the nonvolatile component ethylene glycol monoethyl ether acetate commonly referred to as cellosolve acetate was used. The ingredients for each formulation were measured as indicated, placed in a one-third liter porcelain ball mill containing alumina pebbles, and intermately mixed by rolling for several hours.
The formulas were tested on the quartz arc tubes of metal halide lamps of conventional construction as illustrated in the drawing. The lamp 1 comprises an outer glass envelope 2 containing a quartz arc tube 3. The arc tube contains electrodes 4,5 set in opposite ends and has sealed therein a filling comprising mercury, sodium iodide, thallium iodide, indium iodide, and an inert starting gas such as argon. The electrodes are connected to inleads 6,7 sealed through press 8 of stem 9 of outer envelope 2. The inleads are connected externally to the contact surface of screw base 10 attached to the neck end of the envelope.
The illustrated lamp is intended for base-up operation and the reflective coating 11 has been applied to the lower end of the arc tube only. In a lamp intended for base-down operation, the coating would be applied to the opposite end of the arc tube. The outer envelope 2 may be evacuated as a heat conservation measure, or it may be filled with an inactive gas. The illustrated lamp corresponds to a 400-watt size wherein the outer envelope is generally evacuated; in larger sizes an inactive gas, generally nitrogen, is provided in the interenvelope space.
The amount of B203 in the adhesion layer can be from 0.05 to 0.5 mg/cm and the weight of the colloidal A1203 can be from 0.05 to 1.5 mglcm2.
An example of a reflective coating utilising aluminium oxide is as follows. The precoat may be applied in the same fashion as previously described. Thereafter the reflective metal oxide layer may be applied by spraying or alternatively by dipping. Since a thicker layer is desirable when A1203 particles are used, they are first admixed with colloidal Aland B203 for better adhesion. An experimental formulation successfully used for dipping with a suitable binder such as that earlier described is as follows: 270 grams A1, 0 ; particles (average particle size 0.5 micron) 5.0 gram colloidal alumina (Alon-C-. 01 to. 02 microns) 2.0 grams H3B03-boric acid The composition is milled three hours in a 1.0 liter alumina ball mill with alumina stones.
The material is applied by dip coating dried and lehred above 460 C to react the materials.
In the wating, the weight of the A1203 may be from 5 to 30 Mg/CM2. A particularly useful embodiment of this invention is one in which the silica envelope has an intermediate layer where the weight of B20.'i is about 0.1 mg/cm2 and that A1203 particles in the coating is from 5 to 30 mg/cm.
Coating the refractory metal oxide particles in this way. that is by first precoating the fused silica surface with the colloidal alumina and boric oxide and thereafter overcoating with the refractory metal oxide particles admixed again with colloidal alumina and boric oxide achieves maximum adhesion. In such case the colloidal aluminum oxide and the boric oxide are present both in a layer intermediate the silica surface and the refractory metal oxide particles, and also dispersed between the refractory metal oxide particles. The method is particularly suitable for applying aluminum oxide coatings which need to be somewhat thicker in order to achieve the same reflectivity as previously known, zirconium oxide coatings on silica as described and claimed in our U. S. Patent No. 3,879,625. The aluminum oxide coatings are lower in cost and are more stable and resistant to darkening over the life of the lamp.
The reflective coating of refractory metal oxide particles may also be applied admixed with colloidal alumina and boric oxide to a surface which has not been precoated with colloidal alumina and boric oxide. Good adherence may be achieved in this way at reduced cost. The colloidal aluminum oxide and boric oxide is then dispersed between the refractory metal oxide particles. We have found this method to be particularly suitable for applying a reflective coating to alumina ceramic, for instance to the end of a polycrystalline alumina ceramic tube such as is used in high pressure sodium vapor lamps.
With alumina ceramic arc tubes the mismatch between alumina ceramic and zirconia is not nearly so great and bonding between the surfaces is not as important as binding of the reflective particles to each other for greater impact resistance. The coating may be applied using either alumina or zirconia particles admixed with colloidal alumina and boric oxide in a formulation such as previously described, and excellent interoxide particle bonding is achieved upon heating above 460 C. Tlle bonding can be demonstrated by peeling the coating after rection with a razor sharp knife. The coating can be sliced into small cut peels. The coating is somewhat fragile due to its low density and is readily removable from the alumina tube surface. Coatings without the boric oxide were attempted and the interparticle bonding was so weak that peeling was not possible; the coating simply crumbled into dust. Particles of alumina oxide can be made to adhere to alumina ceramic in the same fashion as zirconium oxide.

Claims (13)

WHAT WE CLAIM IS:
1. A discharge lamp envelope selected from fused silica or from alumina ceramic, having an optically reflective coating of A1203 particles in the case of fused silica, or by an optically reflective coating of AI203 particles or Zr02 particles in the case of alumina ceramic, the particles being adherent to the envelope by means of an adhesion layer consisting of colloidal aluminium oxide and boric oxide heat-reacted with the silica or alumina surface of the envelope and with the particles.
2. An envelope as claimed in claim 1 wherein the colloidal aluminium oxide and boric oxide are present primarily in a layer intermediate the envelope surface and the particles.
3. An envelope as claimed in claim 1 wherein the colloidal aluminium oxide and boric oxide are dispersed between the particles.
4. An envelope as claimed in any one of the preceding claims wherein the envelope is a fused silica envelope and the weight of B203 in said adhesion layer is from 0.05 to 0.5 mg/cm2 and the weight of colloidal A1203 is from 0.05 to 1.5 mg/cm2.
5. An envelope as claimed in claim 4 wherein the weight of A1203 particles in said coating is from 5 to 30 mg/cm2
6. An envelope as claimed in claim 4 or claim 5 wherein the weight of B203 in said intermediate layer is about 0.1 mglcm2 and that the colloidal A1203 is about 0.3 mglcm2, and the weight of A1203 particles in said coating is from 5 to 30 mg/cm2.
7. A method of adhering reflective A1203 particles to the surface of a fused silica discharge lamp envelope or reflective A1203 or Zr02 particles to the surface of an alumina ceramic discharge lamp envelope which comprises: applying a layer of colloidal aluminium oxide and boric oxide to the surface to provide an intermediate adhesion layer, applying a coating of said reflective particles thereover, and heating to a temperature of at least 460 C in order to react the boric oxide with the aluminium oxide, the envelope surface, and with the particles.
8. A method as claimed in claim 7 wherein said layer of aluminium oxide and boric oxide is applied as a suspension in a liquid which is then dried to make the intermediate adhesion layer.
9. A method as claimed in claim 7 wherein said layer of aluminium oxide and boric oxide is applied as a suspension in a liquid which is then dried to make the intermediate adhesion layer, and said coating of aluminium oxide is applied as a suspension in a binder.
10. A method as claimed in claim 9 wherein the envelope is a fused silica, the intermediate adhesion layer thereon is heated, and the suspension of aluminium oxide in a binder is sprayed onto the hot surface.
11. A discharge lamp envelope as claimed in claim 1 substantially as hereinbefore described with reference to and as illustrated in the accompanying drawing.
12. A method of reflective A1203 particles to the surface of discharge lamp envelope as claimed in claim 11 as hereinbefore exemplified.
13. A coated discharge lamp envelope when prepared by a method as claimed in any one of claims 7 to 10 and ~ ~ ~
GB3185776A 1975-08-04 1976-07-30 Discharge lamp envelopes Expired GB1559589A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US05/601,859 US4012655A (en) 1975-02-03 1975-08-04 Refractory metal oxide reflector coating on lamp envelope

Publications (1)

Publication Number Publication Date
GB1559589A true GB1559589A (en) 1980-01-23

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ID=24409048

Family Applications (1)

Application Number Title Priority Date Filing Date
GB3185776A Expired GB1559589A (en) 1975-08-04 1976-07-30 Discharge lamp envelopes

Country Status (5)

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JP (1) JPS5219483A (en)
AR (1) AR209977A1 (en)
BR (1) BR7605133A (en)
DE (1) DE2634533A1 (en)
GB (1) GB1559589A (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0342721A1 (en) * 1988-04-15 1989-11-23 North American Philips Corporation Electric discharge lamp with reduced internal photoelectron production
EP0270866A3 (en) * 1986-11-12 1990-06-13 Gte Products Corporation Aluminum oxide reflector layer for fluorescent lamps
GB2406566A (en) * 2003-10-01 2005-04-06 Patent Treuhand Ges Fuer Elektrische Gluehlampen Mbh An aluminium oxide particle mixture for use as a reflection layer

Families Citing this family (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6040656B2 (en) * 1977-03-22 1985-09-12 株式会社日立製作所 Manufacturing method of metal vapor discharge lamp
DE2823866C2 (en) * 1978-05-31 1983-10-20 Mabeg Maschinenbau Gmbh Nachf. Hense & Pleines Gmbh & Co, 6050 Offenbach Suction device for pneumatic separating and / or conveying devices
DE2823864C2 (en) * 1978-05-31 1983-07-28 Mabeg Maschinenbau Gmbh Nachf. Hense & Pleines Gmbh & Co, 6050 Offenbach Suction device for pneumatic separating and / or conveying devices
JPS5561541A (en) * 1978-10-27 1980-05-09 Toray Ind Inc Absorption apparatus by air-power
US4890030A (en) * 1984-06-18 1989-12-26 Gte Products Corporation Metal halide discharge lamp with arc tube temperature equalizing means
US4620125A (en) * 1984-10-29 1986-10-28 Gte Products Corporation Low wattage metal halide lamp with inverted domed sleeve
US4625141A (en) * 1984-10-29 1986-11-25 Gte Products Corporation Low wattage metal halide discharge lamp electrically biased to reduce sodium loss
JPS63174161U (en) * 1986-12-24 1988-11-11
JPH01107504U (en) * 1987-12-30 1989-07-20
US5506474A (en) * 1995-03-31 1996-04-09 General Electric Company Compact fluorescent lamp using a light reflecting adhesive material
GB9707291D0 (en) * 1997-04-04 1997-05-28 Gen Electric Ceramic metal halide arc lamp and method of making it

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5043774A (en) * 1973-08-20 1975-04-19
US3879625A (en) * 1973-10-09 1975-04-22 Gen Electric Zirconia reflector coating on quartz lamp envelope

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0270866A3 (en) * 1986-11-12 1990-06-13 Gte Products Corporation Aluminum oxide reflector layer for fluorescent lamps
EP0342721A1 (en) * 1988-04-15 1989-11-23 North American Philips Corporation Electric discharge lamp with reduced internal photoelectron production
GB2406566A (en) * 2003-10-01 2005-04-06 Patent Treuhand Ges Fuer Elektrische Gluehlampen Mbh An aluminium oxide particle mixture for use as a reflection layer
US7193355B2 (en) 2003-10-01 2007-03-20 Patent-Treuhand-Gesellschaft Fuer Elektrische Gluehlampen Mbh Reflection layers formed from an aluminum oxide particle mixture
GB2406566B (en) * 2003-10-01 2008-06-25 Patent Treuhand Ges Fuer Elektrische Gluehlampen Mbh Reflection layers formed from an aluminum oxide particle

Also Published As

Publication number Publication date
JPS5219483A (en) 1977-02-14
BR7605133A (en) 1977-08-02
DE2634533A1 (en) 1977-02-10
AR209977A1 (en) 1977-06-15

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Legal Events

Date Code Title Description
PS Patent sealed
PCNP Patent ceased through non-payment of renewal fee

Effective date: 19940730