US3448320A - Electric lamp and method of manufacture - Google Patents

Electric lamp and method of manufacture Download PDF

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Publication number
US3448320A
US3448320A US601930A US3448320DA US3448320A US 3448320 A US3448320 A US 3448320A US 601930 A US601930 A US 601930A US 3448320D A US3448320D A US 3448320DA US 3448320 A US3448320 A US 3448320A
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United States
Prior art keywords
quartz
filament
tungsten
envelope
wire
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US601930A
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English (en)
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Roger C Millikan
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General Electric Co
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General Electric Co
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01KELECTRIC INCANDESCENT LAMPS
    • H01K1/00Details
    • H01K1/38Seals for leading-in conductors
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J5/00Details relating to vessels or to leading-in conductors common to two or more basic types of discharge tubes or lamps
    • H01J5/20Seals between parts of vessels
    • H01J5/22Vacuum-tight joints between parts of vessel
    • H01J5/24Vacuum-tight joints between parts of vessel between insulating parts of vessel
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01JELECTRIC DISCHARGE TUBES OR DISCHARGE LAMPS
    • H01J2893/00Discharge tubes and lamps
    • H01J2893/0033Vacuum connection techniques applicable to discharge tubes and lamps
    • H01J2893/0037Solid sealing members other than lamp bases
    • H01J2893/0038Direct connection between two insulating elements, in particular via glass material
    • H01J2893/004Quartz-to-quartz connection

Definitions

  • This application discloses improved electric lamps and similar structures utilizing an incandescent filament and is more specifically directed to such a structure in which a very thin filament is directly sealed through the ends of a quartz tabulation.
  • This scaling is accomplished by carefully controlling the diameter of the wire, the temperature of the wire and the quartz during sealing, and the ambient atmosphere within which the seal is made to produce an intimate bonding of the quartz to the incandescent filament by a seal which does not crack, craze, or separate during or after operation of the device at temperatures up to 1000 C.
  • incandescent lamp filaments typically represented by lamps known as the Quartzline type of incandescent lamp such as those disclosed by Fridrich et al., US. Patent No. 2,883,571, issued Apr. 21, 1959, and assigned to the General Electric Company, and by other related patents disclosing and claiming improvements thereupon.
  • Quartzline type lamps are characterized by a thin cylindrical tube of quartz having a relatively long, longitudinal concentric tungsten filament, the diameter of which constitutes a substantial fraction of the diameter of the inner wall of the quartz tube, whereby the inner wall of the quartz envelope is operated at a relatively high temperature.
  • Degeneration of the hot tungsten 3,448,320 Patented June 3, 1969 filament is prevented by the presence, within the quartz envelope, of a low partial pressure of iodine in a buffer gas which, at the operating temperature of the filament is responsible for the presence of a regenerative iodine cycle which prevents accumulation of tungsten from the filament upon the interior bulb walls.
  • This accumulation has the dual deleterious effect of lowering the transmissivity of the walls and causing the tungsten filament to be dissipated.
  • the tungsten on the bulb walls is recombined with iodine to form a tungsteniodine compound which migrates to the hot filament, is decomposed and causes the tungsten to be redeposited upon the filament.
  • lamps such as those described hereinbefore are among the most efficient and long-lived incandescent lamps available today and are highly effective in competition with other light sources, the necessary steps which must be taken in order to achieve the high efliciencies and long life characteristic of the lamps result in production costs which are highly undesirable for commercial manufacture of such lamps.
  • One such cost relates to the expensive double-welding process whereby the filament is welded to a foil of molybdenum which is then sealed through the quartz.
  • a lead wire having mechanical strength and durability must be welded to the opposite end of the molybdenum foil, thus requiring four welds and the use of a fragile molybdenum foil in fabrication of the lamps. Additionally, such structure requires the utilization of an inordinately large quantity of quartz which is uneconomical.
  • Still another object of the invention is to provide lamps having improved quartz to refractory metal seals.
  • I provide incandescent lamps having a quartz or quartz-like envelope and a refractory incandescent filament therein, wherein the incandescent filament is directly sealed through the wall of the quartz envelope without any intermediate element to facilitate the seal.
  • Such seals directly between the incandescent filament and the quartz envelope may readily be made by keeping the diameter of the wire constituting the filament at a value of less than 0.004 inch, by'out-gassing the filament wire prior to andduring sealing to preclude the presence of any adsorbed gas thereupon and by continuously flushing the filament and the quartz during sealing to preclude the presence of any molecular or gaseous impurities evolved from either during heating to be interposed between the quartz and metal in the final seal.
  • FIGURE 1 is a vertical cross-sectional view of an incandescent lamp constructed in accord with the present invention.
  • FIGURE 2 is a vertical cross-sectional view of an alternative embodiment of the device of FIGURE 1.
  • quartz was first used as an incandescent lamp envelope those skilled in the art have been attempting to make seals through quartz envelopes to incandescent lamp filament by a variety of methods. Since quartz has a temperature coeflicient of expansion that is exceedingly different from that of most metals and particularly different from that of refractory metals, this has presented a very serious problem in instances in which the area of the final seal is to be subjected to high temperature. As described hereinbefore, the most effective and efficient incandescent lamps now utilize a configuration wherein the quartz including that portion thereof which constitutes the seal is operated at a substantially higher than room temperature during normal operation.
  • Patent 1,271,245 to VonRecklinghausen in which one or more members having a portion thereof which is very small in one transverse dimension but very large in another transverse dimension, as for example by flattening a portion of the wire into a thin ribbon thus preserving the same total cross-section but maintaining at least one dimension thereof very small, attempts to seek release from the differential expansion problem.
  • Patent No. 1,922,536 Ericson sets forth an extremely complicated method whereby a thin intermediate member is sealed in a quartz tubulation and connected to at either end thereof to provide a seal.
  • Either end of the collapsed portion of the glass is then cut to provide an element comprising a thin piece of glass having a thin tungsten wire hermetically sealed thereto.
  • This piece of glass may then be used as a seal in a glass envelope for a variety of uses.
  • I avoid the extremely complicated and expensive expedients of the prior art by the simple approach of directly sealing the filament through a quartz envelope under such conditions as to form a strong, temperature-resistant seal which does not degrade or separate from the wire during operation at temperatures even as high as 1000 C. for example.
  • hermetically sealed envelope 1 includes a hollow cylindrical portion 2 with a closed tubular shaped end portion 3 at either end thereof.
  • An incandescent filament 4 is located concentrically along the axis of envelope 1 and passes completely through end portions 3 thereof without interruption or termination. As illustrated in FIGURE 1, the coil of the filament is terminated and the filament assumes a configuration of a straight wire upon emerging from envelope 1. This is optional, however, and the filament may emerge from envelope 1 in the same configuration as it exists within cylindrical portion 2 thereof or as a straight wire as illustrated in FIGURE 1.
  • the filament is illustrated in FIGURE 1 as being a single wire and including a single helical coil in the central portion thereof any conventional or convenient filament configuration as for example those set forth in the copending application of P. D. Johnson, Ser. No. 580,995, filed Sept. 21, 1966, the entire specification of which is incorporated herein by reference thereto, may be utilized provided that the elemental Wire thereof from which the filament is fabricated meets the dimensional criteria set forth herein.
  • I find that an effective strong seal may be made between a tungsten filament and a quartz envelope if the elemental wire comprising the incandescent filament is less than 0.004" in diameter, if the wire is heated to a white heat prior to and during sealing to force the evolution therefrom of any adsorbed gasses, and if means are provided to remove all material ejected from the filament during the heating thereof and to prevent material ejected from the quartz from migrating to and contaminating the filament prior to or during sealing.
  • the incandescent filament 4 may conveniently be of any refractory material suitable for operation at incandescent temperatures, as for example tungsten, molybdenum, rhenium, but for purposes of simplicity in this application will be referred to as a tungsten wire.
  • the seal formed with quartz may be operated repeatedly and for many hours at a temperature up to 1000 C., for example, and repeatedly cooled back to room temperature without degradation of the seal. I believe this is possible due to the distribution of stresses along the radial and tangential directions of the circular cross-section of the wire is such that the difference between thermal coefficient of expansion and of the quartz and tungsten does not cause a separation between the two, provided the initial bond is between the two directly and there is no interposed impurity layer which tends to Weaken the same.
  • a filament wire diameter of 0.0005 represents the practical low limit with which one can make lamps in accord with the present invention.
  • the heating of the tungsten filament may be accomplished by passing an electric current therethrough
  • the gas utilized to heat the filament is preferably a gas which does not react with quartz or tungsten as for example nitrogen or one of the noble gasses.
  • the pressure at which the flushing gas is utilized may be any value in excess of 1 mm. of vmercury pressure although in general as the velocity of the flushing gas decreases it is preferred that the pressure of the gas increases. This is because, as stated hereinbefore, one essential function of the flushing gas is to shield the tungsten filament from any impurities evolved from the quartz during heating in sealing.
  • tungsten filament When quartz is heated to its softening point to the extent that it can be expected to contract around, and seal with, a tungsten filament, as for example, a temperature of 1750 to 2200 Water vapor is evolved therefrom. Water vapor in the presence of a hot tungsten filament can set up a deleterious cycle whereby the water molecules migrate to the tungsten, are decomposed thereat, forming tungsten oxide and a tungsten compound which migrates back to the quartz, removing tungsten from the filament. This cycle is very detrimental in the formation of tungsten filaments and, therefore, it is exceedingly important that, when the quartz is heated in the formation of the seal the water vapor evolved from the quartz be prevented from reaching the tungsten filament.
  • This may be achieved by the passage of high velocity gas between the two even at reduced pressures of for example 1 mm. of mercury of the flushing gas.
  • the same objectives may, however, be achieved at lower flushing velocities or even for brief periods of time at which the velocity of the gas between the quartz and the tungsten is essentially zero, as for example, just prior to making of the final seal in a closed system, unless some other orifice is provided to allow for a path for flushing of the gas.
  • a very high pressure of a high molecular weight inert or noble gas such as argon or krypton be provided in order that the mean free path of the water molecules be very short as compared with the distance between the quartz and the tungsten.
  • FIGURE 1 of the drawing it is convenient to take a section of quartz tubing as illustrated in FIGURE 1 of the drawing, having an outside diameter of approximately 10 mm. and an inside diameter of approximately 8 mm. with a necked down end section on either end thereof having an outside diameter of approximately 8 mm. and an inside diameter of approximately 2 mm.
  • the inside diameter of the constricted end portion of at least one of the ends of the quartz tube is made large enough to accommodate the outside diameter of the configuration of the coil of filament 4. Since the filament need be inserted in only one end this requirement need be present at only the end from which the filament is inserted.
  • the quartz tube may be provided with an exhaust-type tubulation at the center thereof for provision of a ready path of flushing for the second seal after the first seal is made and for evacuation or filling, as for example with low pressure iodine, of the enclosure within the envelope or raising or lowering of the pressure thereof, as desired.
  • the tubulation is closed off, leaving a nipple 5 which completes the hermetic sealing of the envelope. It is to be appreciated, however, that such a tubulation and remaining nipple are in accord with only one feature of the invention and the lamps in accord with the invention may be fabricated Without such tubulation.
  • fabrication of the lamp of FIGURE 1 may be as follows.
  • the quartz tube as described above, has a conveniently coiled or coiled-coil helical filament which may or may not have straightened ends but which, for convenience of description, will be assumed to have straightened ends as illustrated in FIGURE 1, is inserted thereinto through the larger diameter end portion 3 and the straightened end portion 6 is caused to emerge from the other end portion 3.
  • the quartz tube is then placed in a suitable fixture and a jet of argon, for example, at a pressure of, for example 10 mm. of mercury is directed into the aperture within the first end 3 to cause the flushing of the entire interior of the envelope with argon gas.
  • the flow of flushing gas and low internal pressure are maintained by any appropriate suction device.
  • This gas is heated to an elevated temperature by external torching or other application of heat to the quartz so as to cause the temperature of the filament to be raised to a temperature of from 1750 to 2200 C.
  • temperatures below 1750 insufficient out-gassing and deadsorption of surface adsorbed gas particles is present and it is difficult to make good seals.
  • temperatures in excess of 2200" C. the effects upon the quartz envelope are such as to preclude its maintaining its structural rigidity. I have found that it is preferable, both from the point of view of forming optimum degassed tungsten surfaces and for maintaining the structural rigidity of the quartz during fusing, to cause the gas heating to provide a filament temperature of from 1800 to 2000 C.
  • the quartz is heated more intensely, which may for example be a second jet of high temperature gas directed thereabout, as for example from a peripheral nozzle located thereabout, or by an annular resistive heater encircling region 3, or by plasma torch or focussed laser heating to cause the temperature of the quartz to be raised above 2200 C., causing the quartz to collapse about the tungsten filament and form an hermetic seal therewith.
  • a second jet of high temperature gas directed thereabout as for example from a peripheral nozzle located thereabout, or by an annular resistive heater encircling region 3, or by plasma torch or focussed laser heating to cause the temperature of the quartz to be raised above 2200 C., causing the quartz to collapse about the tungsten filament and form an hermetic seal therewith.
  • the quartz may be caused to collapse about the filament and seal thereto by applying a constrictive force thereto.
  • a force may, for example, be supplied by pressure differential of, for example several pounds per square inch, caused by pumping the flushing gas out from the quartz envelope through the tubulation at nipple 5, as described above, so that the pressure within the envelope is slightly less than outside the envelope.
  • the end 3 may be mechanically squeezed by any suitable means. After one end of envelope 1 has been sealed, the process is repeated with the other end, the high temperature gas which is injected into the restricted diameter end portion 3 escaping through the tubulation at the center of the tube to allow free flushing of the device. After the second end portion has collapsed about the tungsten filament to cause the formation of an hermetic seal, the center tubulation is sealed off (after any desired filling or pressure change therethrough) leaving nipple 5, and the incandescent lamp fabrication is completed.
  • substantially the same procedure is utilized, as described above, with the exception that no center tubulation is provided and the second seal is made at a higher pressure of inert gas, as for example, approximately 1 atmosphere, thus relying upon the high pressure of inert gas molecules in the vicinity of the filament and the quartz to which it is to be sealed to reduce the mean free path of water evolved from the quartz so as to preclude the presence of a water cycle and the deposition of tungsten oxide upon the tungsten filament.
  • a higher pressure of inert gas as for example, approximately 1 atmosphere
  • FIGURE 2 of the drawing there is illustrated a lamp constructed in accord with another embodiment of the invention.
  • the lamp comprises a cylindrical quartz member having a central aperture 11 therein for the accommodation of a filament 12 which passes concentrically therethrough.
  • the quartz constituting cylinder 10 has been collapsed about filament 12, forming seal regions 13, which seals were made substantially as described with respect to the formation of the device of FIGURE 1.
  • the respective ends of cylindrical quartz tubulation 10 include reentrant openings 14, which are filled with an electrical contact-making and mechanically support-producing filling 15 of a suitable metal, as for example nickel, which is readily adaptable for making electrical contact to the emerging filament lead 16.
  • a suitable metal as for example nickel
  • the ends of the tubulation 10 are closed with metallic caps 17, which may conveniently be made of nickel and which are suitably soldered nickel inserts 15 within tubulation 10. Electrical contact to the lamp may then be made to end caps 17 to provide for the flow of electric current through filament '12 to produce incandescene therein and the subsequent emission of suitable and useful light.
  • metallic caps 17, which may conveniently be made of nickel and which are suitably soldered nickel inserts 15 within tubulation 10. Electrical contact to the lamp may then be made to end caps 17 to provide for the flow of electric current through filament '12 to produce incandescene therein and the subsequent emission of suitable and useful light.
  • lamps of the present invention In describing the formation of the lamps of the present invention, I have indicated a preference for nonreactive gassses as the medium for flushing the quartz tubulation and for heating the tungsten wire. Althrough this is the case, it is possible to form lamps in accord with the present invention using low pressure atmospheric air for these purposes. In this instance, provided the pressure of the air is low enough, as for example from 10 to 100 mm. of mercury, substantially little oxide is allowed to form upon the surface of the tungsten filament.
  • the solubility of tungsten oxide in quartz is sufiicient so that a very small amount of oxide may be absorbed within the quartz immediately upon making contact thereto, thus allowing the quartz to make intimate contact with the metallic tungsten of the filament which facilitates the formation of good seals in accord with the present invention.
  • One lamp in accord with the invention was made with a 3 long quartz tube of 0.250" OD. and 0.150 LD. and an exhaust tubulation of 0.100 O.D. at the longitudinal center thereof.
  • a 0.002 diameter tungsten wire having a helical coil having a diameter of 0.050 and a length of l" was suspended along the longitudinal axis of the quartz tube and extending along its entire length.
  • One end of the tube was closed by an O ring and an end clamp and the other end was connected temporarily to a source of dry nitrogen at a pressure of 10 mm. of Hg.
  • a mechanical fore pump was connected to the exhaust tubulation and operated to draw the nitrogen through one end of the quartz tube at a flow rate equivalent to 1 cc. per second at conditions of standard temperature and pressure.
  • An incandescent lamp comprising:
  • the lamp of claim 3 wherein the lamp envelope is in the form of an elongated cylindrical tube and said filament is in the form of an axial coiled helix, said helix occupying a substantial portion of the interior crosssectional area of said tube.

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US60192766A 1966-12-15 1966-12-15

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US601927A Expired - Lifetime US3448322A (en) 1966-12-15 1966-12-15 Direct filament enclosed incandescent lamps and contact means therefor

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US (2) US3448320A (de)
AT (1) AT281992B (de)
BR (1) BR6795177D0 (de)
CH (1) CH463620A (de)
DE (1) DE1589184A1 (de)
ES (2) ES348270A1 (de)
GB (1) GB1178127A (de)
NL (1) NL6716903A (de)
SE (1) SE335176B (de)

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3793615A (en) * 1970-11-04 1974-02-19 Gen Electric Oxidation-resistant lead-in conductors for electrical devices
US4236045A (en) * 1978-09-18 1980-11-25 U.S. Philips Corporation Electric lamp
US4453106A (en) * 1980-07-24 1984-06-05 The Perkin-Elmer Corporation Compression base lamp
US4751370A (en) * 1982-12-24 1988-06-14 Thorn Emi Patents Limited Heating apparatus
EP0330268A1 (de) * 1988-02-23 1989-08-30 Koninklijke Philips Electronics N.V. Elektrische Lampe
US4918355A (en) * 1985-04-01 1990-04-17 Gte Products Corporation Electric lamp with protective base
US5077505A (en) * 1989-07-24 1991-12-31 U.S. Philips Corporation Electric lamp and seal structure therefor
US5130604A (en) * 1991-01-18 1992-07-14 George J. Franks, Jr. Miniature incandescent lamp with curable electrically conductive adhesive
US5207503A (en) * 1992-02-05 1993-05-04 Lucifer Lighting Company Xenon festoon style lamp
EP1154460A1 (de) * 2000-05-08 2001-11-14 Welch Allyn, Inc. Elektrode für Lampe mit Quarzkolben
WO2003060953A3 (en) * 2001-12-27 2004-03-18 Koninkl Philips Electronics Nv Halogen incandescent lamps

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL6902805A (de) * 1969-02-21 1970-08-25
GB1327363A (en) * 1971-04-07 1973-08-22 Thorn Electrical Ind Ltd Electric lamps and electric discharge devices
NL183613B (nl) * 1978-03-15 1988-07-01 Philips Nv Elektrische lamp.
US4275329A (en) * 1978-12-29 1981-06-23 General Electric Company Electrode with overwind for miniature metal vapor lamp
NL7908214A (nl) * 1979-11-09 1981-06-01 Philips Nv Elektrische gloeilamp.
CN116125552A (zh) * 2022-12-27 2023-05-16 桂林理工大学 一种石英脉型钨矿外围的找矿勘查方法

Citations (6)

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US1293594A (en) * 1917-05-24 1919-02-04 George O Willey Incandescent electric lamp.
US2273437A (en) * 1939-08-25 1942-02-17 Westinghouse Electric & Mfg Co Beading process
US2276218A (en) * 1939-05-27 1942-03-10 Gen Electric Wire seal, particularly for use in incandescent lamps and discharge tubes
US3040204A (en) * 1960-03-04 1962-06-19 Donald J Belknap Microminiature incandescent lamp
US3080497A (en) * 1959-12-11 1963-03-05 Gen Electric Bent end incandescent lamp
US3211943A (en) * 1963-10-07 1965-10-12 Gen Electric Electric incandescent lamp

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US1531265A (en) * 1921-08-03 1925-03-24 Gen Electric Sealed-in conductor
US2009094A (en) * 1932-12-24 1935-07-23 Gen Electric Electric lamp or similar device

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1293594A (en) * 1917-05-24 1919-02-04 George O Willey Incandescent electric lamp.
US2276218A (en) * 1939-05-27 1942-03-10 Gen Electric Wire seal, particularly for use in incandescent lamps and discharge tubes
US2273437A (en) * 1939-08-25 1942-02-17 Westinghouse Electric & Mfg Co Beading process
US3080497A (en) * 1959-12-11 1963-03-05 Gen Electric Bent end incandescent lamp
US3040204A (en) * 1960-03-04 1962-06-19 Donald J Belknap Microminiature incandescent lamp
US3211943A (en) * 1963-10-07 1965-10-12 Gen Electric Electric incandescent lamp

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3793615A (en) * 1970-11-04 1974-02-19 Gen Electric Oxidation-resistant lead-in conductors for electrical devices
US4236045A (en) * 1978-09-18 1980-11-25 U.S. Philips Corporation Electric lamp
US4453106A (en) * 1980-07-24 1984-06-05 The Perkin-Elmer Corporation Compression base lamp
US4751370A (en) * 1982-12-24 1988-06-14 Thorn Emi Patents Limited Heating apparatus
US4864104A (en) * 1982-12-24 1989-09-05 Thorn Emi Patents Limited Heating assembly using tungsten-halogen lamps
US4868371A (en) * 1982-12-24 1989-09-19 Thorn Emi Patents Limited Heating assembly using tungsten-halogen lamps
US4918355A (en) * 1985-04-01 1990-04-17 Gte Products Corporation Electric lamp with protective base
US5159239A (en) * 1988-02-23 1992-10-27 U.S. Philips Corporation Electric lamp with SiO2 vessel and seal therefor
EP0330268A1 (de) * 1988-02-23 1989-08-30 Koninklijke Philips Electronics N.V. Elektrische Lampe
US5077505A (en) * 1989-07-24 1991-12-31 U.S. Philips Corporation Electric lamp and seal structure therefor
US5130604A (en) * 1991-01-18 1992-07-14 George J. Franks, Jr. Miniature incandescent lamp with curable electrically conductive adhesive
US5207503A (en) * 1992-02-05 1993-05-04 Lucifer Lighting Company Xenon festoon style lamp
WO1993016325A1 (en) * 1992-02-05 1993-08-19 Lucifer Lighting Company Xenon festoon style lamp
EP1154460A1 (de) * 2000-05-08 2001-11-14 Welch Allyn, Inc. Elektrode für Lampe mit Quarzkolben
US6626725B1 (en) 2000-05-08 2003-09-30 Welch Allyn, Inc Electrode treatment surface process for reduction of a seal cracks in quartz
US20040007978A1 (en) * 2000-05-08 2004-01-15 Welch Allyn, Inc. Electrode surface treatment process
US6774565B2 (en) 2000-05-08 2004-08-10 Welch Allyn, Inc. Electrode surface treatment process
WO2003060953A3 (en) * 2001-12-27 2004-03-18 Koninkl Philips Electronics Nv Halogen incandescent lamps
CN100437891C (zh) * 2001-12-27 2008-11-26 皇家飞利浦电子股份有限公司 卤素白炽灯

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NL6716903A (de) 1968-06-17
CH463620A (de) 1968-10-15
BR6795177D0 (pt) 1973-05-31
ES348270A1 (es) 1969-03-16
ES348283A1 (es) 1969-03-16
GB1178127A (en) 1970-01-21
SE335176B (de) 1971-05-17
AT281992B (de) 1970-06-10
US3448322A (en) 1969-06-03
DE1589184A1 (de) 1970-04-02

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