JPS6345809A - Manufacture of stabilizer for electric-discharge lamp - Google Patents

Abstract

PURPOSE:To omit the step of impregnating varnish in the whole of a stabilizer assembly by applying a low viscosity liquid adhesive to both end surfaces of an iron core for assembling the exposed type stabilizer. CONSTITUTION:In the main body 2 of a stabilizer consisting of an iron core 3 and a coil 4, an epoxy adhesive 81 is filled into the air gap 32 provided between the iron cores for adjusting the characteristics of the stabilizer and a top cover 6 and a base 7 which covers the bottom and the sides are screwed from above and below and caulked. A low viscosity liquid adhesive 82 is applied to both the end surfaces 34 of the iron core 3. The adhesive 82 is, after being coated, heated and hardened together with the epoxy adhesive filled into the air gap 32. Vibration can be prevented by fixing all the parts which are able to be vibrated of the iron core 3 in the stabilizer for an exposed type electric- discharge lamp.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method of manufacturing an exposed type discharge lamp ballast that is not housed in a case.

[Conventional technology]

In exposed type ballasts where the core with the coil is not housed in a metal case, an epoxy adhesive is filled in the air gap between the cores with the coil attached and heated to harden. The stabilizer was secured by tightening from the top and bottom, and then the entire stabilizer assembled as described above was impregnated with varnish and heated again to harden the varnish.

[Problem that the invention seeks to solve]

As described above, the conventional exposed type ballast requires two heating steps during manufacturing, and therefore requires a long time to manufacture, and the cost of the heat source accounts for a large portion of the cost. In addition, since the terminals of the ballast are covered with a varnish film due to varnish impregnation, it is necessary to remove the terminal film, and furthermore, when removing the varnish, there is a risk of accidentally breaking the terminal of the coil. There were problems. [Means for solving the problems] The present invention impregnates the entire ballast assembly with varnish by applying a low-viscosity liquid adhesive to both end faces of the exposed ballast assembly core. The aim is to abolish the process of

[Effect]

The purpose of impregnating the core assembly with varnish is to prevent mutual vibration between the stacked cores, so both side walls of the core are pressed together by the cover and base, and
A low viscosity adhesive is applied to both sides of the core, and the adhesive penetrates between the stacked cores and fixes them, preventing mutual vibration between the cores and eliminating the conventional varnish impregnation process. do. Therefore, heat curing only needs to be done once: curing the epoxy adhesive at the same time as curing the low-viscosity adhesive, reducing the cost of the heat source and eliminating the need to remove the varnish that adheres to the terminal as a film. Therefore, problems such as coil breakage caused by the above-mentioned removal work are also eliminated.

〔Example〕

Next, embodiments of the present invention will be described with reference to the drawings.

FIG. 1 is a plan view showing an embodiment of a ballast manufactured by the method for manufacturing a discharge lamp ballast according to the present invention, FIG. 2 is a side view of the above embodiment, and FIG. 3 is an iron core of the above embodiment. 4(a) to 4(c) are explanatory diagrams showing the method of applying adhesive, respectively. FIG. 5 is a noise comparison diagram between the ballast according to the present invention and a ballast according to the conventional method. The figures are manufacturing process diagrams of the present invention and a conventional method, where (a) is a diagram showing the method of the present invention and (b) is a diagram showing the conventional method. In Figures 1 to 3, 3 is an iron core made by laminating and combining E-shaped or machined cores, 5 is a bobbin provided with a terminal plate 51 having a terminal 52 at the end, and 4 is a coil wound around the bobbin. It is a coil. The ballast main body 2 consisting of the above-mentioned iron core 3 and coil 4 is constructed by filling the air gap 32 provided between the iron cores with epoxy adhesive 81 in order to adjust the characteristics of the ballast. and a base 7 covering the sides, which are tightened and caulked from above and below. The steps up to this point are completely similar to those for conventional exposed type ballasts, but the feature of the present invention is the subsequent steps.
For example, a low viscosity liquid adhesive 82 is applied. If the liquid adhesive has a high viscosity, it will not penetrate into the laminated cores due to capillary action, so it is desirable that the liquid adhesive has a low viscosity of 50 poise or less.

FIG. 4 is a diagram showing a method of applying the liquid adhesive 82 to both end surfaces 34 of the iron core 3. Namely.

(a) shows a method of spraying the liquid adhesive from the nozzle 11, (b) shows a method of continuously supplying and applying the liquid adhesive 82 to the tip of the brush 12, and (c) shows a method of applying the liquid adhesive 82 to the tip of the brush 12.
The method of stamping by adsorbing the liquid adhesive 82 onto an absorbent material such as No. 3 is shown. The method for applying the liquid adhesive 82 may be any one of the above (a) to (c), or other methods may be used.

After the adhesive 82 is applied to both end faces of the iron core 30, it is heated and cured together with the epoxy adhesive filled in the air gap 32 in the above step.

In the exposed type discharge lamp ballast manufactured based on each of the above steps, the air gap 32 for adjusting characteristics provided at the tip of the E-shaped core central leg 31 of the iron core 3 is filled and fixed with an epoxy adhesive 81. However, in addition to the conventional method of fixing the legs 33 on both sides of the iron core 3 by tightening them from above and below with the cover 6 and the base 7,
Furthermore, by fixing the unfastened ends 34 of the iron core 3 with the low-viscosity liquid adhesive 82 as described above, all parts of the iron core 3 that are prone to vibration are fixed and vibrations are prevented. .

FIG. 5 is a diagram showing a comparison of noise test data between a ballast made by the method of the present invention and a ballast made by the conventional method, taking a fluorescent lamp glow set ballast for a 30W single lamp as an example. The data are the average values of 10 values, and the difference between the two is about 1 dB, so it can be said that they show approximately the same value. Therefore, by manufacturing according to the manufacturing method of the present invention, it is possible to completely eliminate the conventional varnish impregnation process. Figure 6 (a) is a diagram showing the process of the manufacturing method according to the present invention, and Figure 6 (b) is a diagram showing the conventional process. All steps are eliminated, including heat curing of the epoxy adhesive 81 and adhesive 8 on the end face of the iron core 3.
Since the heat curing step 2 is performed simultaneously, the heat treatment process can be completed in one time, and since there is no need to remove the varnish from the terminal portion, there is no risk of the end of the coil being disconnected after one assembly.

〔Effect of the invention〕

As described above, the method for manufacturing a ballast for a discharge lamp according to the present invention is a method for manufacturing an exposed type ballast for a discharge lamp in which a core equipped with a coil is exposed and used by bonding the ballast in an air gap provided in the core. Fill with agent.

By tightening both end faces of the above-mentioned core from above and below, and applying adhesive to both end faces that are not fastened, all the parts of the above-mentioned core that are prone to vibration are fixed, which makes it possible to fix all parts of the above-mentioned core that are prone to vibration. The manufacturing process has been significantly shortened, except for the varnish impregnation process that used to be performed in the manufacture of ballasts, and only one heating and drying process is required, reducing heat source costs. Since it is not necessary to carry out this process, it is possible to prevent the disconnection of the coil caused by the above-mentioned peeling, thereby improving the yield, and it is possible to obtain a low-cost exposed type ballast for a discharge lamp.

[Brief explanation of the drawing]

FIG. 1 is a plan view showing an embodiment of a ballast manufactured by the method for manufacturing a discharge lamp ballast according to the present invention, FIG. 2 is a side view of the above embodiment, and FIG. 3 is an iron core of the above embodiment. 4(a) to 4(c) are explanatory diagrams showing the adhesive application method, and FIG. 5 is a diagram showing a noise comparison between the ballast according to the present invention and the ballast according to the conventional method. FIG. 6 is a diagram showing the manufacturing process of the present invention and a conventional method, where (a) is a diagram showing the method of the present invention, and (b) is a diagram showing the conventional method. 3... Iron core, 4... Coil, 6... Cover, 7...
... Base, 32 ... Air gap, 81 ... Adhesive, 82 ... Adhesive. (,. $1 concave 7 $4 Figure (aI <1) r (C) , 14

Claims (1)

[Claims] 1. In the manufacturing method of an exposed discharge lamp ballast in which the iron core with the coil attached is exposed and used, the air gap provided in the iron core is filled with adhesive, and both sides of the iron core are tightened from above and below. A method for manufacturing a ballast for a discharge lamp, characterized in that adhesive is applied to both end faces that are attached and not attached, respectively, and fixed.