Sintered Glass Ring Hermetic Seal for Lamp Conductors
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Solution Overview
Problem
Existing methods for producing hermetic seals in high-temperature light sources, such as glass-tungsten discharge lamps, are complex due to the manual application and fusion of glass beads with specific expansion coefficients, which limits efficiency and scalability.
Innovation Solution
A method using sintered glass rings made from glass powder, applied to the conductor and fused to create a hermetic seal between the tubular glass or glass ceramic element and the conductor, offering improved ease of production and high-temperature gas tightness without the need for manual handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual glass bead application and fusion is used, then hermetic seal quality is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces manual mechanical application of glass beads with an automated glass frit dispensing system. The glass frit is applied in a controlled manner through a dispensing apparatus that can precisely place the sealing material at the joint between the tubular element and conductor, eliminating manual handling while maintaining seal quality
Solution Approach 2:
The patent changes the physical state and form of the sealing material from pre-formed glass beads to glass frit (a powdered or granular material). This parameter change allows for automated dispensing and fusion processes, reducing manufacturing complexity while maintaining the hermetic seal function. The glass frit can be applied as a paste or powder that fuses during the heating process
2Reliability
If manual glass bead application is used, then hermetic seal is achieved, but production time and cost increase
Solution Approach 1:
The manual mechanical process of applying and fusing glass beads is replaced with an automated system that can process multiple conductors simultaneously or in rapid sequence. The dispensing apparatus can be integrated into a production line, significantly increasing throughput while maintaining seal quality
Solution Approach 2:
The glass frit is prepared in advance as a dispensable material with appropriate viscosity and composition. This preliminary preparation allows for rapid application during the sealing process, eliminating the need for manual bead formation and placement, thereby increasing production efficiency
3Reliability
If glass bead sealing is used, then hermetic seal is achieved, but manufacturing cost increases
Solution Approach 1:
The automated dispensing system reduces labor costs and material waste associated with manual glass bead application. The precise control of glass frit application ensures optimal material usage, reducing waste and lowering overall manufacturing costs while maintaining seal reliability
Solution Approach 2:
Changing from glass beads to glass frit allows for more efficient material application and reduced waste. The glass frit can be dispensed in precise amounts and fused more efficiently, reducing both material costs and processing costs while maintaining the hermetic seal function
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The sintered glass rings provide a reliable, gas-tight seal at high temperatures (up to 2000°C) with reduced manufacturing complexity and cost, ensuring high operational safety and extended service life by minimizing leaks and crack propagation.
Implementation Method 1
the sintered glass material is melted, a hermetic seal is provided between the tubular body and the conductor
Implementation Method 2
it has become known for a glass-tungsten fusion in discharge lamps, the manual glassing of the glass bead from a sealing glass that has an expansion coefficient that lies between the expansion coefficient of the conductor and the filling glass
Data Source
Figure 1~2
AI summary
The invention relates in particular to a lamp body comprising a tubular element, wherein at least one conductor is inserted into the tubular element and a glass material encloses the conductor. The invention is characterized in that the glass material forms a seal between the tubular element and the conductor and the glass material comprises sintered glass, in particular a sintered glass ring, which preferably completely encloses the conductor.