JP2012004070A - Method of manufacturing fluorescent lamp and fluorescent lamp - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fluorescent lamp which can be manufactured while reducing the temperature in calcination process, and can improve the luminous flux by preventing extreme drop in luminous efficiency.SOLUTION: The method of manufacturing a fluorescent lamp 1 includes a step for forming a protective layer 11 composed of oxide particles on the inner surface of a glass tube 10, a step for preparing a binding agent by mixing barium oxide (BaO), boron oxide (BO) and calcium oxide (CaO) in specific proportions, a step for admixing phosphor with the binding agent in specific proportions, a step for forming a phosphor layer 12 of phosphor containing the binding agent on the protective layer 11, and a step for removing impurities by calcinating the glass tube 10 at a temperature of 520°C or above and below 590°C, preferably 540°C or below. The binding agent is produced by mixing barium oxide and boron oxide in a weight ratio of 1:1, and contains calcium oxide in a weight ratio of 2% or less of the binding agent. The phosphor contains the binding agent in a weight ratio of less than 3%.

Description

  The present invention relates to a fluorescent lamp manufacturing method and a fluorescent lamp.

  As a cost reduction measure, the production speed of fluorescent lamps is increasing year by year, and in recent years, production is performed at 7000 to 8000 pieces / hour.

In Patent Document 1, the surface of the phosphor particles is coated with a binder in advance, and then the phosphor particles are electrostatically coated to prevent the phosphor from peeling off, and the mixing ratio of the phosphor and the binder is A method of manufacturing a fluorescent lamp that does not change before and after electrostatic coating is described. As the binder, boron oxide B ₂ O ₃ or BaO · 0.45CaO · 2.57B ₂ O ₃ can be used.

  Patent Document 2 describes a bent fluorescent lamp in which a protective film for blocking ultraviolet rays is formed on the inner surface of a bent glass bulb, and a fluorescent film is attached to the protective film. The body film and the protective film contain a binder mainly composed of calcium-barium-boron oxides, and exhibit a sufficient ultraviolet blocking effect without causing peeling of the phosphor film.

JP 2002-216622 A JP 2006-0666104 A

  Patent Documents 1 and 2 of related technologies describe a technique for preventing the phosphor from peeling off, and Ca (calcium) and Ba are used as binders when the phosphor is applied to the inner surface of the glass tube. An oxide containing (barium) and B (boron) is used.

  Patent Document 1 describes that the mixing ratio of the phosphor and the binder does not change before and after electrostatic coating, and Patent Document 2 describes the ultraviolet blocking effect.

  During the manufacture of a fluorescent lamp, the firing temperature when removing the binder in the firing step is determined by the temperature at which the binder material melts, which is the temperature at which impurities can be removed, and is typically 600 degrees Celsius. The degree (about 590 degrees Celsius depending on the binder material).

  However, there is no description that the firing temperature is high, and the influence on the firing process is not considered.

  The present invention has been made in view of the above circumstances, and can provide a method for manufacturing a fluorescent lamp capable of reducing the temperature of the firing process, preventing an extreme decrease in luminous efficiency, and improving the luminous flux. An object is to provide a fluorescent lamp.

A method for manufacturing a fluorescent lamp according to a first aspect of the present invention includes:
Forming a protective layer composed of particulate oxide on the inner surface of the glass tube;
A step of preparing a binder by mixing barium oxide (BaO), boron oxide (B ₂ O ₃ ) and calcium oxide (CaO) at a predetermined ratio;
Mixing the binder with a phosphor in a predetermined ratio;
Forming a phosphor layer with a phosphor containing the binder on the protective layer;
Firing the glass tube at a temperature of 520 degrees Celsius or more and less than 590 degrees Celsius to remove impurities;
It is characterized by providing.

The fluorescent lamp according to the second aspect of the present invention is:
It manufactures with the manufacturing method of the fluorescent lamp concerning a 1st viewpoint.

  According to the present invention, the temperature of the baking process can be reduced, an extreme decrease in luminous efficiency is prevented, and the luminous flux is improved.

It is a schematic sectional drawing of the fluorescent lamp which concerns on this invention.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the drawings, the same or corresponding parts are denoted by the same reference numerals.

  FIG. 1 is a schematic sectional view of a fluorescent lamp according to the present invention. The fluorescent lamp 1 includes a glass tube 10, a protective layer 11, and a phosphor layer 12. The glass tube 10 used for the fluorescent lamp 1 has a diameter of 16 mm to 18 mm.

The protective layer 11 is a fine particle oxide such as alumina or yttria, and is formed at 0.01 mg or more and 0.05 mg or less per cm ² . This is because when the amount is 0.01 mg or less, the function as the protective layer 11 is not sufficient, and when it is 0.05 mg or more, the transmittance of the fluorescent lamp 1 is lowered.

The phosphor layer 12 is formed on the protective layer 11 with a phosphor agent containing a binder in a light emitting phosphor. The phosphor layer 12 is formed with 4 mg or more and 8 mg or less per 1 cm ² . As the light emitting phosphor used at this time, it is desirable to use a phosphor having a mean particle size of 4 to 6 μm, which is a size that allows the phosphor layer 12 to stably output light.

The phosphor agent used for the phosphor layer 12 contains a binder at a ratio of less than 3% by weight of the light emitting phosphor. The binder is a mixture of barium oxide (BaO) and boron oxide (B ₂ O ₃ ) at a weight ratio of 1: 1, and calcium oxide (CaO) at a ratio of 2% or less of the total binder amount. The one containing is used. When the binder is mixed with the light emitting phosphor, the binder is mixed in a slurry state and sufficiently stirred.

The light-emitting phosphors are europium-activated yttrium oxide (Y ₂ O ₃ : Eu) that is a red phosphor, terbium and cerium-activated lanthanum phosphate (LaPO ₄ : Ce, Tb) that are green phosphors, and blue phosphors. Some europium activated barium magnesium aluminate (BaMg ₂ Al ₁₆ O ₂₇ : Eu, Mn) and europium activated strontium chlorophosphate, calcium, barium ((Sr, Ca, Ba) ₅ (PO ₄ ) ₃ Cl: Eu) A light emitting phosphor capable of emitting three wavelengths is used in which either or both are mixed at a predetermined ratio. However, the above-mentioned red phosphor, green phosphor, and blue phosphor are examples, and other red phosphors, green phosphors, and blue phosphors may be used, and can emit light at three wavelengths according to the light emitting phosphor used. Mix at a predetermined ratio.

  Finally, in the firing process of the fluorescent lamp production process, the glass tube 10 on which the protective layer 11 and the phosphor layer 12 are formed is fired at a temperature of less than 590 degrees Celsius, preferably 540 degrees Celsius or less. However, the firing temperature is 520 degrees Celsius or higher. In the firing step, other impurities including a polymer material mixed when the phosphor agent is made into a slurry are removed.

  Hereinafter, the manufacturing method of the fluorescent lamp according to the present invention will be described in detail.

First, a layer serving as the protective layer 11 is formed on the inner surface of the glass tube 10 having a diameter of 16 mm to 18 mm so that the fine particle oxide such as alumina and yttria is 0.01 mg to 0.05 mg per cm ^2. .

Next, the phosphor layer 12 is formed on the protective layer 11 so as to be 4 mg or more and 8 mg or less per 1 cm ² . Specifically, the phosphor layer 12 is formed by applying a phosphor agent in which about 2% by weight of a binder is mixed and contained in a slurry with respect to the light emitting phosphor portion.

As the binder, barium oxide (BaO) and boron oxide (B ₂ O ₃ ) are mixed at a weight ratio of 1: 1, and calcium oxide (2% or less by weight with respect to the total binder amount) CaO) is contained.

As the light-emitting phosphor, a light-emitting phosphor capable of emitting three wavelengths, in which a red phosphor and a green phosphor and a blue phosphor are mixed so as to emit predetermined light, is used. The red phosphor is europium activated yttrium oxide (Y ₂ O ₃ : Eu), the green phosphor is terbium, cerium activated lanthanum phosphate (LaPO ₄ : Ce, Tb), and the blue phosphor is europium activated barium aluminate. Magnesium (BaMg ₂ Al ₁₆ O ₂₇ : Eu, Mn), europium activated strontium chlorophosphate, calcium, barium or both are used.

  Finally, in the firing process of the fluorescent lamp production process, the glass tube 10 on which the protective layer 11 and the phosphor layer 12 are formed is fired at a temperature of less than 590 degrees Celsius, preferably 540 degrees Celsius or less. However, the firing temperature is 520 degrees Celsius or higher. In the firing step, other impurities including a polymer material mixed when the phosphor agent is made into a slurry are removed.

In the fluorescent lamp 1 according to the present invention, barium oxide (BaO) and boron oxide (B ₂ O ₃ ) are mixed with the phosphor layer 12 at a weight ratio of 1: 1, and the weight ratio of the binder is 2% or less. By using a phosphor agent containing calcium oxide (CaO) at a ratio of 5%, it is possible to reduce the firing temperature, usually performed at about 590 degrees Celsius, by 50 degrees or more in the firing process at the time of lamp production. Even when the firing temperature is reduced, the thermal load on the phosphor layer 12 can be reduced while maintaining the effect of removing impurities, and the deterioration of the light emitting phosphor can be prevented. As a result, it is possible to prevent the luminous efficiency from being extremely lowered and improve the luminous flux.

  Further, when a fine particle oxide such as alumina or yttria is used for the protective layer 11, the film quality tends to be rough, and when the film is thickened, the phosphor layer 12 to be formed thereafter is peeled off, and when the film is thinned It is difficult to form a continuous film, and the protective effect is reduced, and it is difficult to increase the resistance on the phosphor layer 12 side, resulting in a blackening phenomenon. In the fluorescent lamp 1 according to the present invention, since the binder is mixed in the phosphor layer 12 and the continuity with the protective layer 11 can be improved, blackening phenomenon or peeling off due to the malfunction of the protective layer 11 is prevented. Can be prevented.

  As described above, according to the present embodiment, it is possible to reduce the temperature of the firing step, prevent an extreme decrease in luminous efficiency, and improve the luminous flux.

  The light emitting phosphor used in the fluorescent lamp may be any light emitting phosphor capable of emitting three wavelengths using a red phosphor, a green phosphor, and a blue phosphor, and is not limited to the above example.

  The type of fluorescent lamp is not limited to a cold cathode fluorescent lamp, but may be a hot cathode fluorescent lamp or an external electrode fluorescent lamp. The diameter size of the glass tube is not limited to 16 mm to 18 mm, but may be 32 mm to 38 mm. The shape of the fluorescent lamp can be arbitrarily set such as a straight tube shape or a ring shape. The fluorescent lamp using the present invention may be a liquid crystal monitor and display used as a backlight light source as well as a lighting fixture.

  The characteristics of the fluorescent lamp are not limited to the high-frequency lighting type, but can be applied to other general types.

  A part or all of the above-described embodiment can be described as in the following supplementary notes, but is not limited thereto.

(Supplementary note 1) A step of forming a protective layer made of fine particle oxide on the inner surface of the glass tube, and barium oxide (BaO), boron oxide (B ₂ O ₃ ), and calcium oxide (CaO) at a predetermined ratio A step of mixing and preparing a binder, a step of mixing the binder with the phosphor at a predetermined ratio, and a phosphor layer containing a phosphor containing the binder on the protective layer. And a step of firing the glass tube at a temperature of 520 ° C. or higher and lower than 590 ° C. to remove impurities.

  (Additional remark 2) The manufacturing method of the fluorescent lamp of Additional remark 1 characterized by the temperature which bakes the glass tube of the process of removing the said impurity is 520 degreeC or more and 540 degrees C or less.

  (Additional remark 3) The said binder mix | blends the said barium oxide and boron oxide by weight ratio 1: 1, and contains the said calcium oxide in the ratio of 2% or less of weight ratio of this binder. The manufacturing method of the fluorescent lamp of Additional remark 1 or 2.

  (Additional remark 4) The said fluorescent substance contains the said binder in the ratio of less than 3% of weight ratio of this fluorescent substance, The manufacturing method of the fluorescent lamp in any one of Additional remark 1 thru | or 3 characterized by the above-mentioned.

(Additional remark 5) The said protective layer is fine particle oxides, such as an alumina and a yttria, Comprising: It forms in 0.01 mg or more and 0.05 mg or less per cm < ² >, The additional description 1 thru | or 4 characterized by the above-mentioned. Manufacturing method of fluorescent lamp.

(Additional remark 6) The said fluorescent substance layer is formed in 4 mg or more and 8 mg or less per cm < ² >, The manufacturing method of the fluorescent lamp in any one of Additional remark 1 thru | or 5 characterized by the above-mentioned.

(Supplementary note 7) The phosphors include europium activated yttrium oxide (Y ₂ O ₃ : Eu) which is a red phosphor, terbium and cerium activated lanthanum phosphate (LaPO ₄ : Ce, Tb) which are green phosphors, and Europium activated barium magnesium aluminate (BaMg ₂ Al ₁₆ O ₂₇ : Eu, Mn) and / or europium activated strontium chlorophosphate, calcium, barium ((Sr, Ca, Ba) ₅ (PO ₄ ) ) 3 _Cl: fluorescent lamp manufacturing method according to any one of appendices 1 to 6, characterized in that the Eu) is a 3-wavelength light emitting fluorescent material was mixed at a predetermined ratio.

  (Additional remark 8) The fluorescent lamp manufactured with the manufacturing method of the fluorescent lamp in any one of additional marks 1 thru | or 7.

1 fluorescent lamp 10 glass tube 11 protective layer 12 phosphor layer

Claims (8)

Forming a protective layer composed of particulate oxide on the inner surface of the glass tube;
A step of preparing a binder by mixing barium oxide (BaO), boron oxide (B ₂ O ₃ ) and calcium oxide (CaO) at a predetermined ratio;
Mixing the binder with a phosphor in a predetermined ratio;
Forming a phosphor layer with a phosphor containing the binder on the protective layer;
Firing the glass tube at a temperature of 520 degrees Celsius or more and less than 590 degrees Celsius to remove impurities;
A method for manufacturing a fluorescent lamp, comprising:   2. The method of manufacturing a fluorescent lamp according to claim 1, wherein a temperature for firing the glass tube in the step of removing impurities is 520 degrees Celsius or more and 540 degrees Celsius or less.   The binder is characterized in that the barium oxide and boron oxide are mixed at a weight ratio of 1: 1, and the calcium oxide is contained at a ratio of 2% or less by weight of the binder. 3. A method for producing a fluorescent lamp according to 1 or 2.   The method for manufacturing a fluorescent lamp according to any one of claims 1 to 3, wherein the phosphor contains the binder in a proportion of less than 3% by weight of the phosphor. The fluorescent layer according to any one of claims 1 to 4, wherein the protective layer is a fine particle oxide such as alumina or yttria, and is formed with 0.01 mg or more and 0.05 mg or less per 1 cm ^2. A method of manufacturing a lamp. 6. The method of manufacturing a fluorescent lamp according to claim 1, wherein the phosphor layer is formed at 4 mg or more and 8 mg or less per 1 cm ² . The phosphor includes europium activated yttrium oxide (Y ₂ O ₃ : Eu) which is a red phosphor, terbium which is a green phosphor, cerium activated lanthanum phosphate (LaPO ₄ : Ce, Tb) and a blue phosphor. Some europium activated barium magnesium aluminates (BaMg ₂ Al ₁₆ O ₂₇ : Eu, Mn) and / or europium activated strontium chlorophosphate, calcium, barium ((Sr, Ca, Ba) ₅ (PO ₄ ) ₃ Cl: 7. The method of manufacturing a fluorescent lamp according to claim 1, wherein the phosphor is a phosphor capable of emitting three wavelengths by mixing Eu) at a predetermined ratio.   The fluorescent lamp manufactured with the manufacturing method of the fluorescent lamp of any one of Claim 1 thru | or 7.

Images