Manufacturing method of heating bulb

Abstract

The invention relates to a manufacturing method of a heating bulb. The manufacturing method comprises the following steps that S1, an inner bulb is filled with rare inert gas; s2, the inner bulb and the core column are connected in a welded mode through spot welding; s3, the core column and the lamp holder are connected through phosphor-copper welding; s4, the inner bulb and the core column are placed in the outer bulb, and the lamp holder is screwed to an opening of the outer bulb through threads to prevent the lamp holder from falling off from the outer bulb; and S5, a heat outlet in the top of the outer bulb is subjected to transparentizing and sand blasting, then is coated with a red film layer after transparentizing, and is coated with the red film layer after sand blasting. According to the bulb, the bulb-in-bulb design that the inner bulb is arranged in the outer bulb is adopted, and rare inert gas is injected into the inner bulb for protection in the manufacturing process of the inner bulb, so that the service life of the inner bulb can be prolonged, and the phenomenon of breakage is avoided. And the core column and the contact of the lamp holder are welded through phosphor-copper welding, so that the contact can bear high temperature, and the problem that the contact is easy to melt off is solved. The outer bulb is of a double-layer glass structure and can bear higher problems, the top heat outlet of the outer layer is frosted, and the uniformity of heat radiation is effectively improved.

Description

Technical Field

[0001] The present invention relates to the technical field of heating bulbs, and particularly to a manufacturing method of a heating bulb. Background Art

[0002] The heating outer bulb is a lamp that generates heat through light emission to achieve the purpose of heating. Currently, there are many disadvantages for the heating outer bulbs on the market, such as short service life, uneven heat radiation, easy melting of contacts, and easy cracking of the outer bulb. Therefore, there is an urgent need to design a new method for manufacturing heating outer bulbs to solve the existing problems. Summary of the Invention

[0003] In order to overcome the deficiencies of the prior art, the purpose of the present invention is to provide a manufacturing method of a heating bulb, including the following steps:

[0004] S1. Fill the inner bulb with rare inert gas;

[0005] S2. Weld and connect the inner bulb and the core column by spot welding;

[0006] S3. Weld and connect the core column and the lamp cap by phosphor bronze welding;

[0007] S4. Place the inner bulb and the core column into the outer bulb, and screw the lamp cap onto the outer bulb opening to prevent the lamp cap from falling off the outer bulb;

[0008] S5. The heat outlet at the top of the outer bulb is treated by being transparent, sandblasted, transparent, then coated with a red film layer, and sandblasted and then coated with a red film layer.

[0009] A further embodiment of the present invention is that in step S1, it is carried out in sequence through the steps of inner bulb pretreatment, inner bulb internal vacuum pumping, gas replacement, and gradient pressure charging.

[0010] A further embodiment of the present invention is that in step S1, the pretreatment is carried out by baking the bubble in an environment of 300 - 400 °C for 30 min to remove the water vapor and impurities adsorbed on the inner wall.

[0011] A further embodiment of the present invention is that in step S1, the gas replacement is carried out by pre-filling N2 to 0.3 atm and maintaining it for 5 min, and then performing secondary vacuum pumping to 1×10 -2 Pa.

[0012] A further embodiment of the present invention is that in step S1, the gradient pressure charging is carried out in two times according to the volume ratio of Ar:N2 = 7:3. The first time is charged to 0.5 atm, and left standing for 2 minutes to make the gas evenly diffuse. The second time is charged to the target pressure of 1.0 ± 0.1 atm.

[0013] A further embodiment of the present invention is that in step S3, a CuP alloy with a phosphorus content of 0.1%-0.3% is selected. First, the contacts between the core column and the lamp cap are immersed in a 5% dilute hydrochloric acid solution for 10 s, then ultrasonically oscillated in an ethanol solution for 5 min, and a V-shaped groove is prefabricated at the contacts of the core column, and then phosphorous copper welding is performed by a high-frequency induction welding machine.

[0014] A further embodiment of the present invention is that in step S3, after phosphorous copper welding, the temperature is lowered to 300 °C and kept warm for 30 s, and a nickel plating layer is electroplated on the surface of the solder joint.

[0015] A further embodiment of the present invention is that in step S5, the outer bulb has a double-layer glass structure, the inner layer is quartz glass, the outer layer is soda-lime glass, and there is a gap between the inner layer and the outer layer. First, a red film layer is coated on the outer layer, a high-temperature resistant ceramic plate is used to cover the non-blast area, alumina particles are used to blast the heat outlet at the top of the outer bulb, and then a red film layer is coated again after blasting. A nano-silica heat insulation layer is coated at the heat outlet at the top of the outer bulb, and a layer of fluorosilicone resin is sprayed on the heat insulation layer.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0017] First, the bulb adopts a bulb-in-bulb design with the inner bulb placed inside the outer bulb. During the production process of the inner bulb, rare inert gas is filled into the inner bulb for protection, which can improve the service life of the inner bulb and avoid the phenomenon of rupture.

[0018] Second, the contacts between the core column and the lamp cap are welded by phosphorous copper welding, which can enable the contacts to withstand high temperatures, thus solving the problem that the contacts are easily melted off.

[0019] Third, the outer bulb adopts a double-layer glass structure, which can withstand higher temperatures, and the top heat outlet of the outer layer is frosted, which can effectively improve the uniformity of heat radiation.

[0020] The following further describes the present invention in detail with reference to the drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 is a schematic flow chart of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments.

[0023] Examples of the embodiments are shown in the drawings, where like or similar reference numerals designate like or similar elements or elements having like or similar functions throughout. The embodiments described below with reference to the drawings are exemplary and are intended to explain the present invention and should not be construed as limiting the present invention.

[0024] In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the present invention.

[0025] In the present invention, unless otherwise clearly specified and defined, the terms "mounted", "connected", "connected to", "fixed", etc. shall be construed in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral body; it may be a mechanical connection or an electrical connection; it may be directly connected or indirectly connected through an intermediate medium, and may be the internal communication of two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0026] As Figure 1 This embodiment provides a method for manufacturing a heating bulb, including the following steps:

[0027] S1. Filling the inner bulb with rare inert gas;

[0028] S2. Welding and connecting the inner bulb and the core column by spot welding;

[0029] S3. Welding and connecting the core column and the lamp cap by phosphor bronze welding;

[0030] S4. Placing the inner bulb and the core column into the outer bulb, and screwing the lamp cap onto the outer bulb opening to prevent the lamp cap from falling off the outer bulb;

[0031] S5. Processing the heat outlet at the top of the outer bulb through a process of transparent, sandblasting, transparent, then coating with a red film layer, and sandblasting then coating with a red film layer.

[0032] In the present invention, a further embodiment is that in step S1, it is carried out in sequence through the steps of inner bulb pretreatment, internal vacuum pumping of the inner bulb, gas replacement, and gradient pressurization.

[0033] Among them, more specifically, in step S1, the pretreatment is carried out by baking the bubble in an environment of 300 - 400 °C for 30 minutes to remove the water vapor and impurities adsorbed on the inner wall. The core function of this pretreatment step is to achieve deep purification of the inner bubble glass surface through thermodynamic desorption and chemical decomposition mechanisms; through precise thermodynamic control, the glass surface reaches atomic-level cleanliness (surface defect density < 10 3 pieces / cm 2 ), laying a foundation for subsequent key processes, directly extending the product life and energy efficiency stability.

[0034] Among them, more specifically, in step S1, the gas replacement is carried out by pre-filling N2 to 0.3 atm and maintaining it for 5 minutes, and then performing secondary vacuum pumping to 1×10 -2 Pa. First of all, pre-filling nitrogen (0.3 atm) reduces the partial pressure of initial residual impurities such as O2 / H2O / CO2 to 30% of the original value. When the nitrogen is filled and pressurized to 0.3 atm, the gas molecule collision frequency increases by 3 times (compared with normal pressure), forcing the impurity molecules (such as H2O) adsorbed on the inner wall of the glass to desorb, eliminating the hydrogen embrittlement corrosion of the tungsten filament by H2O. This gas replacement process realizes the preparation of a high-purity gas environment with low cost and high efficiency without damaging the glass structure through staged pressure regulation, making the inner bubble performance reach the aerospace-level reliability standard.

[0035] In this embodiment, further, in step S1, the gradient pressurization is carried out in two times according to the volume ratio of Ar:N2 = 7:3. The first time it is filled to 0.5 atm and left standing for 2 minutes to allow the gas to diffuse evenly. The second time it is filled to the target pressure of 1.0 ± 0.1 atm. By distributed pressurization, turbulent mixing can be avoided. When the first time it is filled to 0.5 atm (50% of the total pressure), the gas flow rate is controlled in the laminar state (Reynolds number Re < 2300) to prevent the stratification effect caused by the density difference (Ar = 1.784 g / L, N2 = 1.251 g / L). Leave it standing for 2 minutes to allow the gas to be evenly mixed by molecular diffusion, and the remaining gas is replenished in the same proportion, using the established uniform atmosphere to reduce the mixing deviation. The staged pressurization reduces the sudden change of glass stress. The mechanical strength of the inner bubble is inversely proportional to the pressure change rate. The stepwise pressurization from 0.5 atm to 1.0 atm controls the stress growth rate to < 3 MPa / s (safety threshold 5 MPa / s). The gradient pressurization process achieves the best balance among cost, performance, and yield through physical mixing optimization and material protection design, and is especially suitable for the manufacture of high-power (> 500W) heating bulbs. Compared with the traditional method, its comprehensive benefit is increased by more than 30%, and there is no need to add complex equipment, which has significant industrial application value.

[0036] In this embodiment, further, in step S3, a CuP alloy with a phosphorus content of 0.1%-0.3% is selected. First, the contacts between the core column and the lamp cap are immersed in a 5% dilute hydrochloric acid solution for 10 s, then ultrasonically vibrated in an ethanol solution for 5 min, and a V-shaped groove is prefabricated at the contacts of the core column. Then, phosphorous copper welding is carried out by a high-frequency induction welding machine. The oxygen reaction between P and Cu in the phosphorous copper welding generates gas and escapes, which can avoid weld porosity, making the solder joints stronger. Through eutectic point regulation, it matches the glass softening point, avoiding thermal damage and not increasing conduction loss. Thus, the inner bulb and the core column can withstand higher temperatures and are not easily melted. The oxide layer is removed by hydrochloric acid etching, selectively corroding the grain boundaries to form a nano-scale honeycomb structure, increasing the specific surface area by 3 times, improving the wettability of the solder. Subsequently, ethanol can dissolve grease. Through ultrasonic cavitation, glass particle impurities are removed, the surface tension is reduced, and moisture is replaced to avoid secondary oxidation. Prefabricating a V-shaped groove at the contacts of the core column can increase the contact area with the inner bulb, which is not only convenient for welding but also makes the solder joint area larger, thus extending the service life. In addition, an Ag nanowire coating can be pre-coated in the V-shaped groove to improve conductivity and welding strength. At the same time, a laser displacement sensor is used to monitor the groove filling state in real time.

[0037] Further, in step S3, after phosphorous copper welding, the temperature is cooled to 300°C and held for 30 s, and a nickel layer is electroplated on the surface of the solder joint. The phosphorous copper solder (CuP) is prone to lattice distortion stress during rapid cooling. Holding at 300°C triggers the recovery-recrystallization process, avoiding cracking of the coating caused by stress release during subsequent electroplating. The diffusion rate of phosphorus atoms suddenly increases at 300°C, promoting the improvement of the conductivity of the contacts, and holding can improve the bonding strength of the solder joints. Finally, electroplating a nickel layer on the surface of the solder joint can not only improve corrosion resistance but also improve conductivity and heat conductivity, and enhance the mechanical properties of the solder joints. Through the combined strategy of controlled cooling + surface modification, the service life of the solder joints is improved.

[0038] In the present invention, further, the outer bulb in step S5 is a double-layer glass structure, with the inner layer being quartz glass and the outer layer being soda-lime glass. There is a gap between the inner layer and the outer layer. Before sandblasting, a red film layer is coated first, and a high-temperature resistant ceramic plate is used to cover the non-sandblasted area. Alumina particles are used to sandblast the heat outlet at the top of the outer bulb. After sandblasting, a red film layer is coated again, which can improve the uniformity of heat radiation. A nano-silica heat insulation layer is coated at the heat outlet at the top of the outer bulb, and a layer of fluorosilicone resin is sprayed on the heat insulation layer. The inner layer can withstand temperatures above 800°C, the outer layer can absorb mechanical vibration energy, and the gap layer can form an aerogel effect, reducing the thermal conductivity. The nano-silica heat insulation layer can make the gas heat conduction path bend, and the fluorosilicone resin can perform hydrophobic self-cleaning, reducing the dust adhesion rate and also improving the light transmittance. At the same time, paraffin can be injected into the gap to improve the heat buffer capacity, making the service life of the light bulb longer.

[0039] The above embodiments are only the preferred embodiments of the present invention, and the scope of protection of the present invention cannot be limited thereby. Any non-substantive changes and substitutions made by those skilled in the art on the basis of the present invention fall within the scope of protection required by the present invention.

Claims

1. A manufacturing method of a heating bulb, characterized in that, It includes the following steps: S1. Fill the inner bulb with rare inert gas; S2. Weld and connect the inner bulb and the stem by spot welding; S3. Weld and connect the stem and the lamp cap by phosphor bronze welding; S4. Place the inner bulb and the stem into the outer bulb, and screw the lamp cap onto the outer bulb opening by thread to prevent the lamp cap from falling off the outer bulb; S5. The heat outlet at the top of the outer bulb is treated by being transparent, sandblasted, transparent, then coated with a red film layer, and coated with a red film layer after sandblasting.

2. The manufacturing method of a heating bulb according to claim 1, characterized in that, In the step S1, it is carried out through the steps of inner bulb pretreatment, inner bulb internal vacuum pumping, gas replacement and gradient pressurization in sequence.

3. The manufacturing method of a heating bulb according to claim 2, characterized in that, In the step S1, the pretreatment is carried out by baking the bubble in an environment of 300 - 400 °C for 30 min to remove the water vapor and impurities adsorbed on the inner wall.

4. The manufacturing method of a heating bulb according to claim 3, characterized in that, In the step S1, the gas replacement is carried out by pre-filling N2 to 0.3 atm and maintaining it for 5 minutes, and then performing a secondary evacuation to 1×10 -2 Pa.

5. The manufacturing method of a heating bulb according to claim 4, characterized in that, In the step S1, the gradient pressurization is carried out by filling in two times according to the volume ratio of Ar:N2 = 7:

3. The first time it is filled to 0.5 atm, and left standing for 2 minutes to make the gas diffuse evenly. The second time it is filled to the target pressure of 1.0 ± 0 - 1 atm.

6. The manufacturing method of a heating bulb according to claim 1, characterized in that, In the step S3, a CuP alloy with a phosphorus content of 0.1% - 0.3% is selected. First, the contacts of the stem and the lamp cap are immersed in a 5% dilute hydrochloric acid solution for 10 s, then ultrasonically oscillated in an ethanol solution for 5 min, and a V-shaped groove is prefabricated at the contacts of the stem, and phosphor bronze welding is carried out by a high-frequency induction welder.

7. The manufacturing method of a heating bulb according to claim 6, characterized in that, In the step S3, after the phosphor bronze welding, the temperature is lowered to 300 °C and kept warm for 30 s, and a nickel plating layer is electroplated on the surface of the solder joint.

8. The manufacturing method of a heating bulb according to claim 1, characterized in that, In the step S5, the outer bulb is a double-layer glass structure, the inner layer is quartz glass, the outer layer is soda-lime glass, and there is a gap between the inner layer and the outer layer. First, a red film layer is coated on the outer layer, a high-temperature resistant ceramic plate is used to cover the non-sandblasted area, the heat outlet at the top of the outer bulb is sandblasted with alumina particles, then a red film layer is coated after sandblasting, a nano-silica heat insulation layer is coated at the heat outlet at the top of the outer bulb, and a layer of fluorosilicone resin is sprayed on the heat insulation layer.

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