Horizontal Burning Metal Halide Lamp

The present invention relates to horizontal burning metal halide lamps with improved efficiency and improved color qualities.

It is well known that a dramatic difference exists in the color qualities of the light produced as a function of the vertical or horizontal positioning of metal halide arc lamps used for general lighting applications When such lamps are mounted in the preferable horizontal position, the arc tends to bow upwardly, tending to overheat the upper part of the arc tube and to create a cold spot along the bottom of the arc tube. The overheating tends to reduce the life of the arc tube and to degrade both the intensity and quality of color over the life of the lamp.

Metal halides tend to condense in the cold spots because of the temperature differential between the upper and lower regions of the arc tube. This condensation decreases the vapor pressure of the various elements of the lamp fill material which determine the color of the lamp, resulting in degradation of intensity and color quality.

The generally known prior art has attempted to accommodate the problem of a bow in the arc in several ways. One such approach has been the use of an electromagnetic field to hold the arc in a horizontal position. This approach generally results in a complex structure and has not found favor because of increased size and expense.

In another prior art approach such as disclosed in the Koury U.S. Pat. No. 3,858,078 dated Dec. 31, 1974 and the Karlotski, et al., U.S. Pat. No. 4,498,027 dated Feb. 5, 1985, the arc tube is arched to effectively center the arc tube about the bowed arc. However, the arch in the tube increases the effective diameter of the arc tube and thus the lamp, making the lamp unsuitable for many compact fixtures. The use of an arched tube also creates cold spots at both ends in the regions behind the electrodes, and the necessity for arching the tube increases the complexity and cost of manufacturing the lamp.

Still other known approaches, as disclosed for example in the Rigden U.S. Pat. No. 4,232,243 dated Nov. 4, 1980, and Howles, et al., U.S. Pat. No. 4,001,623 dated Jan. 4, 1977, lower the elevation of the electrodes within the arc tube to provide additional room for the upward bowing of the arc in the operation of the lamp. While lowering the electrodes reduces the overheating of the arc tube at its upper extremity and raises the temperature in the lower region, it generally does not raise the temperature of the lower regions of the arc tube sufficiently to obviate the problem of lamp fill condensation and associated reduction in vapor pressures particularly at the cold spots below and behind the electrodes at both ends of the arc tube.

In addition, the placement of the electrodes within the lower portion of the arc tube of the traditional symmetrical pinch design is difficult to control in manufacturing, and any tilting of the arc tube from a position other than horizontal creates wide variances in the color temperature of the discharge. Further, some of the metal halides typically condense at the cold spots in the seam of the pinch below the electrodes creating problems with the seam. Thus, lamp designs with lowered electrodes have not achieved a great deal of commercial success.

In attacking the cold spot problem, it is a common practice in metal halide arc discharge lamps to apply heat reflective coatings to the ends of the arc tube to reduce condensation of lamp fill material behind the electrodes. As disclosed for example in the Johnson U.S. Pat. No. 4,281,267 dated July 28, 1981, this heat reflective coating on the ends of an arched arc tube may be reduced in the area behind the electrodes in the upper surface of the tube to reduce the internal reflections and increase the upward exposure of a greater portion of the arc.

As disclosed in the Ramberg U.S. Pat. No. 3,963,951 dated June 15, 1976, a longitudinal stripe of heat reflective material also may be provided along the bottom of the arc tube to reduce condensation of the metal halides in the center thereof at the farthest distance from the upward bow in the arc. The use of such coatings is helpful in the elimination of the cold spots but does not impact on the hot spot problem. As earlier explained, the arched tube may require a larger diameter envelope and a corresponding larger fixture.

In another prior art approach to the cold spot problem, and in lieu of a coating, the arc tube may be constructed out of an ultraviolet absorbing quartz glass over the lower portion thereof. Such construction is disclosed, e.g., in the Meulemans, et el., U.S. Pat. No. 4,307,315 dated Dec. 22, 1981. While the temperature of the lower portion of the lamp is increased, this approach does not obviate the hot spot at the top of the lamp. In addition, multiple glass arc tubes are difficult to manufacture and relatively expensive.

It is, accordingly, an object of the present invention to obviate these and other problems of the known prior art horizontal burning metal halide lamps, and to provide a novel metal halide lamp for general lighting applications.

Another object of the present invention is to provide a novel horizontal burning metal halide lamp with greater efficacy and improved color uniformity.

Yet another object of the present invention is to provide a novel metal halide lamp less sensitive to changes in the position of the lamp from the horizontal.

A further object of the present invention is to provide a novel horizontal burning metal halide lamp with the electrodes lowered within the arc tube.

A still further object of the present invention is to provide an arc tube for a horizontal burning lamp with novel shapes and dimensions of the end chamber.

Yet a further object of the present invention is to provide a novel arc tube for a horizontal burning lamp with the cold spot located along the lower wall of the arc tube between the electrodes.

These and many other objects and advantages of the present invention will be readily apparent to one skilled in the metal halide lamp art upon a perusal of the claims and the following detailed description when read in conjunction with the appended drawings.

FIG. 1 is a side view of a conventional arc tube with electrodes offset below the axis of the arc tube.

FIG. 1A is a section taken through lines 1A--1A of FIG. 1.

FIG. 2 is a side view of a prior art arc tube with a modified pinch seal and end chamber shape.

FIG. 2A is a section taken through lines 2A--2A of FIG. 2.

FIG. 3 is a side view of a prior art arc tube showing a modification of the shape of the top portion of the arc tube.

FIG. 3A is a section taken through lines 3A--3A of FIG. 3.

FIG. 4 is a side view of an embodiment of an arc tube constructed in accordance with the present invention.

FIG. 4A is a section taken through lines 4A--4A of FIG. 4.

FIG. 5 is a top plan view of the arc tube of FIG. 4.

FIG. 6 is a section in elevation of a first jaw for pinching the arc tube to form an end chamber.

FIG. 7 is a section in elevation of a second jaw for pinching the arc tube to form an end chamber.

FIGS. 1, 2, and 3 depict prior art arc tube and FIGS. 4 and 5 show a preferred embodiment of the present invention. All of the illustrated arc tubes include a tube 10 of fused silica, generally cylindrical in shape and closed at their opposite ends by press seals 12 and 14. These press seals form the end chambers 16 to the discharge space within the arc tube. In an arc tube with a cylindrical shape, the open end of the end chambers is defined by the departure of the internal surface thereof from the surface of the cylinder, i.e., the plane of first reduction in cross-sectional area.

Each of the arc tubes has an exhaust tip-off 18 formed by removal of an exhaust tube and sealing off during manufacturing process. The two discharge electrodes 20 are positioned at opposite ends of the tube in the end chambers 16. As may be easily seen from the figures, the electrodes 20 are located below the axis 24 of the cylinder of the tubes of FIGS. 1, 2, and 4, and below the axis 26 of the cylindrical bottom portion of the arc tube of FIG. 3.

As also may be easily seen by a comparison of the prior art illustrated in FIGS. 1-3 to the preferred embodiment of the present invention illustrated in FIG. 4, the arc tube 10 of the present invention is cylindrical and therefore does not require any special forming or shaping of the silica.

In addition, the electrodes 20 may be positioned a greater distance below the cylindrical axis 24 of the arc tube 10 thereby increasing the temperature in the lower regions thereof. The electrodes 20 are centered in the extreme ends of the relatively narrow end chambers 16 to allow maximum clearance for the insertion of the electrode 20 into the end chamber greatly simplifying control of electrode placement during manufacture.

Note that the upper surface of the end chamber 16 is approximately equal distance from the bowed arc formed between the electrodes 20 when the lamp is in operation. The proximity of the lower portion of the end chamber 16 to the electrode 20 prevents a cold spot from forming behind or below the electrode and the slope of the lower portion of the end chamber intersects the lower portion of the arc tube cylinder beyond the free end of the electrode. A more uniform wall temperature throughout the discharge space results with the cold spot centered along the lower portion of the arc tube cylinder between the electrodes where it is more easily controlled. Greater uniformity of color is achieved even when the arc tube is tilted from the horizontal at an angle of up to as much as forty degrees.

As shown in FIG. 6, the shape of the end chambers in a vertical cross-section through the cylindrical axis of the tube may be formed by three portions, i e , a straight line portion 30 continuing the lower wall of the tube 32, a second portion 34 formed by the arc of a circle of relatively small radius R1 and a third portion 36 formed by the arc of a circle of relatively large radius R3 drawn from first center 38 displaced in the plane of the vertical cross section below the lower wall 32 of the arc tube.

Jaws for pressing quartz seals and forming such end shapes can be made as simple profiles as shown in FIGS. 6 & 7. A roughly circular cross section perpendicular to the axis of the arc tube can be maintained with careful control of the temperature of the quartz and the internal pressure of the arc tube at the instant the seal is pressed closed. A preferable method is to provide a fully molded end shape to simplify manufacture, reduce material losses in manufacture and provide the tightest possible control of geometrical tolerances.

For practical reasons a roughly circular cross section perpendicular to the axis of the arc tube is desired. However, choosing an exactly circular cross section (only excepting the press seal seams) leads to a surprisingly simple method for fabricating press seal jaws that provide fully molded end shapes. This is an important economic consideration, in that press seal jaws wear with use and are often made from materials that are expensive and difficult to fabricate. Alternatively less expensive jaw materials can be employed with reduced wear capabilities if the labor cost of fabrication is lowered by use of simple manufacturing methods.

In one such method, a rectangular block of jaw material, after a cavity is formed for the end shape, will be parted in the plane of the profiles of FIGS. 5 & 6 to form a pair of press seal jaws that will mold the arc tube end shape. The tools required are a ball end cutter of radius R1; a boring tool to hold the cutter from the center of the tool to a radius offset from the center of the tool nearly equal to the quartz tube radius; and by way of example, a milling machine to turn the boring tool on a vertical axis, and with a table to hold the jaw material and move in a vertical and at least one horizontal direction. To implement a particular design, R1 can be chosen considering the dimensions of the tube, the desired electrode offset and practical limitations of tolerances that can be achieved for a particular press seal operation, with the smallest practical value being preferred. If R1 is smaller than half the offset, the design of FIG. 7 is preferred. Next the depth of the jaw cavity must be chosen considering the amount of quartz that can be heated for a particular tube diameter and the desired intrelectrode spacing Angle A can then be chosen with angles in the range of 75 to 45 degrees providing satisfactory end shapes for a wide range of arc tube designs.

As apparent from the figures, FIG. 6 is a special case of FIG. 7 where R4 is infinite and R1 is equal to the electrode offset.

The trajectory of the boring tool axis in a vertical plane half way between the circular segments formed by radii R1 & R2, and the appropriate boring tool radial setting at a particular point along the axis can then be calculated and it has been found that a table of 20 to 40 increments will provide a very smooth shape and require 1 to 2 hours of labor from a reasonably skilled machinist to form a cavity.

While a preferred embodiment of the present invention has been described, other variations and modifications will naturally occur to those skilled in the art from a perusal hereof. It is therefore to be understood that the embodiment described is illustrative only, and that the scope of the invention is to be defined solely by the appended claims when accorded a full range of equivalents.