Integrated HID reflector lamp with HID arc tube in a pressed glass reflector retained in a shell housing a ballast

• US 6,111,359 A
• Filed: 05/09/1996
• Issued: 08/29/2000
• Est. Priority Date: 05/09/1996
• Status: Expired due to Term

• Current Assignee: Philips Electronics North America Corporation (Koninklijke Philips N.V.)
• Original Assignee: Philips Electronics North America Corporation (Koninklijke Philips N.V.)
• Inventors: Jackson, Andrew, Nelson, Gregory, Hendricx, Josephus C. M., Collins, Kent, Deurloo, Oscar J., Fellows, Mark, Seinen, Peter A., Work, Dale, Keyser, Robertus A. J., Van Den Hoek, Willem J., Linden, Aswin J. G., Van Esveld, Hendrik A.
• Primary Examiner(s): VU, DAVID HUNG
• Application Number:
  US08/647,385
• Time in Patent Office: 1,573 Days
• Field of Search: 315/56, 315/58, 315/59, 315/60, 315/61, 315/71, 315/72, 315/73, 315/246, 313/609, 313/634, 313/25, 313/17
• US Class Current: 315/56
• CPC Class Codes: H01J 61/025 Associated optical elements
• CPC Class Codes: H01J 61/125 having an halogenide as principal component
• CPC Class Codes: H01J 61/34 Double-wall vessels or containers
• CPC Class Codes: H01J 61/56 One or more circuit elements structurally associated with the lamp
• CPC Class Codes: H01J 61/827 Metal halide arc lamps
• CPC Class Codes: H05B 41/00 Circuit arrangements or apparatus for igniting or operating discharge lamps structurally associated with the discharge lamps H01J61/54, H01J61/56

Abstract

An integrated reflector lamp includes a sealed envelope enclosing a high pressure gas discharge device. A shell has a rim portion which receives the sealed envelope and an opposing basal portion carrying a screw base. A ballast for igniting and operating the discharge device is enclosed within the shell between the screw base and the sealed envelope. The sealed envelope includes a reflective surface which directs light emitted by the discharge device. The reflective surface also provides effective heat management for preventing overheating of the ballast by the heat generated by the discharge device. The integrated lamp has photometrics and luminous efficacy which exceeds that of corresponding halogen and halogen IR reflector lamps while having an overall planform which fits within that of the corresponding lamp. In a favorable embodiment, the ballast drives the discharge device at a high frequency above about 19 kHz and below the lowest acoustic resonant frequency of the discharge device, facilitating a small physical size for the ballast while also avoiding acoustic resonance. In one embodiment, the reflector lamp fits within the ANSI outline for a PAR 38 lamp and has total lumens at least substantially equal to and a luminous efficacy which substantially exceeds that of a corresponding PAR 38 lamp having an incandescent filament.

Claims

1. An integrated HID reflector lamp for retrofitting a corresponding incandescent reflector lamp comprising an incandescent filament, a reflector body and a screw base, the reflector lamp having a prescribed outline, total lumens and luminous efficacy, said HID reflector lamp comprising:

a shell having a wall enclosing an internal volume, said wall having a circumferential rim portion defining a light emitting opening of said shell and an opposing basal portion, said shell generally tapering with increasingly smaller diameter from said rim portion to said basal portion,

a screw base secured on said basal portion,

a high pressure arc discharge device arranged relative to said shell,

a reflective surface positioned within said shell for reflecting light emitted by said discharge device out through said light emitting opening, and

a ballast within said shell body for energizing said discharge device to emit light, said ballast including input terminals connected to said screw base and output terminals connected to said discharge device, said ballast being responsive, when an operating voltage from an ordinary electric utility line that normally powers said incandescent reflector lamp is applied to said shell on said screw base, to ignite and maintain a gas discharge within said discharge device,

said integrated HID lamp having an outline substantially entirely within the outline of the corresponding reflector lamp, and having total lumens at least substantially equal to and a luminous efficacy substantially greater than the corresponding reflector lamp.

2. An integrated HID reflector lamp according to claim 1, further comprising a sealed envelope of pressed glass enclosing said discharge device in a gas-tight manner and comprising said reflective surface, said reflective surface defining an optical axis and said sealed envelope having a largest internal diameter transverse to said optical axis, said discharge device being arranged transverse to said optical axis.

3. An integrated HID lamp according to claim 2, said sealed envelope having an outer diameter of about 110 mm, and

said shell, with said threaded base, said sealed envelope and said ballast received in said shell, having an outline substantially within that of the ANSI outline for a PAR 38 lamp.

4. An integrated HID reflector lamp according to claim 3, wherein said lamp emits total lumens of at least about 1100 lumens.

5. An integrated HID reflector lamp according to claim 4, wherein said lamp has luminous efficacy of at least about 60 LPW.

6. An integrated HID reflector lamp according to claim 5, wherein said discharge device has a fill of a buffer, a metal halide and a rare gas.

7. An integrated lamp according to claim 2, wherein said shell comprises a synthetic resin material.

8. An integrated lamp according to claim 1, wherein said shell comprises a synthetic resin material.

9. An integrated HID reflector lamp according to claim 1, wherein said lamp has an outline substantially within the ANSI outline for a PAR 38 lamp.

10. An integrated HID reflector lamp according to claim 1, wherein said discharge device has a rated power of about 20 W.

11. An integrated HID reflector lamp according to claim 10, wherein said lamp emits total lumens of at least about 1100 lumens.

12. An integrated HID reflector lamp according to claim 10, wherein said lamp has luminous efficacy of at least about 60 LPW.

13. An integrated HID reflector lamp according to claim 10, wherein said discharge device has a fill of mercury, a metal halide and a rare gas.

14. An integrated HID reflector lamp according to claim 1, wherein said discharge device has a lowest lamp resonant power frequency greater than about 38 kHz, said ballast operates said discharge device with a fundamental power frequency and with harmonies which are integer multiples of the fundamental power frequency, said fundamental power frequency being greater than about 38 kHz and lower than the lowest lamp resonant power frequency, and said harmonics above said lowest lamp resonant frequency having amplitudes which are insufficient to induce acoustic resonances.

15. An integrated HID reflector lamp according to claim 14, wherein said discharge device comprises a ceramic wall.

16. An integrated lamp according to claim 14, wherein said discharge space has a lowest longitudinal acoustic resonance frequency and a lowest azimuthal/radial acoustic resonance frequency, said discharge space being dimensioned such that said lowest longitudinal acoustic resonance frequency and said lowest azimuthal/radial frequency are substantially the same.

17. An integrated HID reflector lamp according to claim 16, wherein said discharge device has a rated power of about 20 W.

18. An integrated HID reflector lamp according to claim 1, wherein said ballast comprises switching means for providing a current through the discharge vessel having a constant polarity.

19. An integrated HID reflector lamp according to claim 18, wherein said discharge device comprises a ceramic wall.

20. An integrated lamp according to claim 19, wherein said ballast maintains said fundamental frequency substantially constant during steady state lamp operation.

21. An integrated lamp according to claim 20, wherein said discharge vessel includes a central circular-cylindrical zone with substantially planar end walls, said end walls being spaced by an axial distance L, said central zone having a substantially constant inner diameter ID over said distance L, and the ratio L:

ID is about 1;

1.

22. An integrated reflector lamp according to claim 21, wherein said lamp has an outline fitting substantially within the ANSI specified outline for a PAR 38 lamp.

23. An integrated lamp according to claim 22, wherein said lamp has luminous efficacy of at least about 60 LPW.

24. An integrated lamp according to claim 23, wherein said discharge device has a fill of a buffer, a metal halide and a rare gas.

25. An integrated lamp according to claim 24, wherein said dimensions L and ID are each about 3 mm.

27. An integrated lamp according to claim 20, wherein said discharge device has a lowest longitudinal acoustic resonance frequency and a lowest azimuthal/radial acoustic resonance frequency, said discharge space being dimensioned such that said lowest longitudinal acoustic resonance frequency and said lowest azimuthal/radial frequency are substantially the same.

28. An integrated reflector lamp according to claim 20, wherein said lamp has an outline fitting substantially within the ANSI specified outline for a PAR 38 lamp.

29. An integrated lamp according to claim 20, wherein said lamp has luminous efficacy of at least about 60 LPW.

30. An integrated lamp according to claim 20, wherein said discharge device has a fill of mercury, a metal halide and a rare gas.

26. An integrated, high frequency metal halide reflector lamp, comprising:

a) a sealed reflector unit comprising

a reflector envelope comprising a pressed glass reflector body having a basal portion, a parabolic reflector surface extending from said basal portion and terminating at a circumferential rim of said reflector body, a light reflective material on said reflector surface, said reflector surface having an optical axis and a focus on said optical axis, and a light transmissive lens hermetically sealed to said rim of said reflector body,

a metal halide discharge device comprising a discharge vessel of ceramic material enclosing a discharge space, an ionizable fill comprising mercury, a metal halide and a rare gas within said discharge space, a pair of discharge electrodes within said discharge space and between which a discharge is maintained during lamp operation, and a respective current conductor extending from each discharge electrode to the exterior of said discharge vessel in a gas-tight manner, said discharge device having a major axis, said discharge device being positioned with said major axis transverse to said optical axis and with said discharge space between said electrodes coinciding with said optical axis, and

b) a shell of synthetic resin material having a circumferential rim portion receiving said rim of said reflector body and a base portion for receiving a lamp base, said shell generally tapering from said rim portion towards said base portion;

c) a lamp base on said base portion of said shell and having a pair of lamp contacts; and

d) a ballast within said shell between said sealed reflector unit and said lamp base for energizing said discharge lamp to maintain a gas discharge between said discharge electrodes,

during normal lamp operation said discharge device being free of acoustic resonances at alternating lamp currents below a lowest lamp resonant frequency, and

the ballast circuit energizes the discharge lamp so as to have an alternating lamp current having a fundamental frequency and harmonics which are integral multiples of the fundamental frequency,

the fundamental frequency and the lowest lamp resonant frequency are greater than about 19 kHz, and

the harmonics above the lowest lamp resonant frequency have amplitudes which are insufficient to induce acoustic resonance.

31. A reflector lamp comprising a light source energizeable for emitting light, a reflector body having a reflective surface for directing light emitted by said light source, and a lamp base having lamp contacts electrically connected to a light source capsule, characterized in that:

said light source is a high pressure gas discharge device, and

the lamp further comprises

a pressed glass lamp envelope sealed in a gas tight manner and enclosing the high pressure gas discharge device, the pressed glass lamp envelope including said reflector body having said reflective surface,

(i) a shell having a first end portion carrying said lamp base and a second end portion receiving said lamp envelope;

(ii) a ballast for energizing said discharge device to emit light, said ballast being mounted within said shell between said pressed glass lamp envelope and said first end portion, said ballast including a pair of input terminals each electrically connected to a respective contact on said lamp base and a pair of output terminals each electrically connected to a respective one of said current conductors of said discharge device; and

(iii) said lamp envelope being received at said second end portion with said reflective surface positioned to reflect light and heat generated by said discharge device away from said ballast.

32. A reflector lamp according to claim 31, wherein said reflector body carrying said reflective surface has a thickness of greater than about 3 mm.

33. A reflector lamp according to claim 31, wherein said ballast includes a circuit board having a first side and a second side carrying circuit components of said ballast, said circuit board being mounted within said shell with said first side facing said reflector body and with said second side facing said lamp base, said circuit board defining a first compartment within said shell between said reflector body and said circuit board and a second compartment between said circuit board and said lamp base, and said circuit board being substantially imperforate and being secured to said shell to substantially completely retard communication of air between said first compartment and said second compartment within said shell.

34. A reflector lamp according to claim 31, wherein said reflective surface defines an optical axis, said discharge device includes discharge electrodes defining a major axis of the discharge device, the discharge device being arranged with said major axis transverse to and substantially coincident with said optical axis.

35. A reflector lamp according to claim 31, wherein said shell consists of a synthetic material.

36. A reflector lamp according to claim 31, wherein during normal lamp operation said discharge device is free of acoustic resonances at alternating lamp currents below a lowest lamp resonant frequency, and

said ballast circuit energizes said discharge lamp so as to have an alternating lamp current having a fundamental frequency and harmonics which are integral multiples of the fundamental frequency, said fundamental frequency and said lowest lamp resonant frequency being greater than about 19 kHz, and any said harmonics greater than said lowest lamp resonant frequency having magnitudes which are insufficient to induce acoustic resonance.

37. An integrated lamp according to claim 36, wherein said ballast maintains said fundamental frequency substantially constant during steady state lamp operation.

38. An integrated lamp according to claim 37, wherein said discharge vessel encloses a circular-cylindrical discharge space substantially planar end walls, said end walls being spaced by an axial distance L said discharge space having a substantially constant inner diameter ID over said distance L, and the ratio L:

ID is about 1;

1.

39. An integrated lamp according to claim 37, wherein said dimensions L and ID are each about 3 mm.

40. An integrated HID reflector lamp according to claim 31, wherein said ballast comprises switching means for providing a current through the discharge device having a constant polarity.

41. An integrated HID reflector lamp according to claim 40, wherein said discharge device comprises a ceramic wall.

42. A high frequency metal halide lamp system according to claim 31, further comprising a starting aid for said discharge device, said starting aid comprising a length of conductive material extending from one said current conductor to the area of the other said current conductor and terminating adjacent the discharge vessel wall of the other said current conductor, said discharge vessel wall of the other said current conductor enclosing a narrow gap with the other said current conductor in which said discharge sustaining fill is present.