Discharge lamp lightning apparatus and manufacturing method therefor

• US 6,201,350 B1
• Filed: 11/01/1999
• Issued: 03/13/2001
• Est. Priority Date: 11/20/1998
• Status: Expired due to Term

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Yamamoto, Noboru, Hiramatsu, Hiromi, Horii, Yasutoshi, Okuchi, Hiroaki
• Primary Examiner(s): Philogene, Haissa
• Application Number:
  US09/431,081
• Time in Patent Office: 498 Days
• Field of Search: 315/289, 315/290, 315/239, 315/240, 315/82, 315/DIG.5, 315/291, 315/57, 315/70, 315/85, 315/276, 315/282, 361/717-719, 361/722, 361/743, 361/836, 439/642
• US Class Current: 315/82
• CPC Class Codes: H05B 41/042 using semiconductor devices
• CPC Class Codes: H05B 41/2881 Load circuits; Control thereof
• CPC Class Codes: H05B 41/382 during the transitional start-up phase
• CPC Class Codes: H05B 41/384 in case of hot-restriking
• CPC Class Codes: Y02B 20/00 Energy efficient lighting technologies, e.g. halogen lamps or gas discharge lamps

Abstract

In a discharge lamp lighting apparatus for a discharge lamp, each circuit component including a starter transformer is assembled to a bus bar casing, and a high voltage terminal of the starter transformer is connected to one end of a connecting terminal. The bus bar casing is adhesive-cemented to a metal base to which a HIC is attached. Then, a sealing resin fills the bus bar casing to seal the starter transformer and the HIC with the sealing resin. After the sealing resin solidifies, the other end of the connecting terminal and an output cable are connected, and subsequently a resin cover is assembled to the metal base. A shielding sheath covering the output cable is fixed to the bus bar casing by a clip. A ground connection part of the bus bar connectable to the ground side of an electric power source is shaped to protrude from the bus bar casing. The cover, the clip, the ground connection part and the base are ground-connected by a thread.

Claims

1. A discharge lamp lighting apparatus comprising:

circuit components including a starter transformer;

a mounting member for mounting the circuit components; and

a connecting terminal having one end electrically connected to a high voltage terminal of the starter transformer and the other end electrically connected to an output cable,

wherein a connection part between the high voltage terminal of the starter transformer and the one end of the connecting terminal is sealed in an electrically insulated manner with a sealing resin.

2. A discharge lamp lighting apparatus as set forth in claim 1, wherein:

the connection part and the circuit components other than the starter transformer are sealed in the electrically insulated manner with the sealing resin.

3. A discharge lamp lighting apparatus as set forth in claim 1, wherein the other end of the connecting terminal and the output cable are connected through an electrical connector part.

4. A discharge lamp lighting apparatus comprising:

circuit components including a starter transformer;

a mounting member for mounting the circuit components; and

a connecting terminal having one end electrically connected to a high voltage terminal of the starter transformer and the other end electrically connected to an output cable,

wherein the starter transformer is assembled within the mounting member with its winding being exposed.

5. A discharge lamp lighting apparatus as set forth in claim 4, wherein:

the connecting terminal is constructed integrally with the mounting member.

6. A discharge lamp lighting apparatus as set forth in claim 4, further comprising:

a metal casing for accommodating the mounting member therein; and

a member provided between the connecting terminal and the metal casing to ensure a surface-to-surface distance therebetween.

7. A discharge lamp lighting apparatus as set forth in claim 4, wherein:

the other end of the connecting terminal and the output cable are connected through an electrical connector part.

8. A discharge lamp lighting apparatus comprising:

circuit components including a starter transformer;

a mounting member for mounting the circuit components; and

an output cable electrically connected to a high voltage terminal of the starter transformer,

wherein a connection part between the high voltage terminal of the starter transformer and the output cable and the circuit components other than the starter transformer are sealed in an electrically insulated manner with a sealing resin.

9. A discharge lamp lighting apparatus as set forth in claim 8, wherein:

the starter transformer is mounted on the mounting member with its winding being exposed; and

the winding is sealed in the electrically insulated manner with the insulating resin.

10. A discharge lamp lighting apparatus as set forth in claim 8, wherein the connection part is connected to the output cable through an electrical connector part.

11. A manufacturing method for a discharge lamp lighting apparatus comprising:

mounting circuit components including a starter transformer on a mounting member; and

sealing a connection part between a high voltage terminal of the starter transformer and an output cable and the circuit components other than the transformer in an electrically insulated manner with a sealing resin.

12. A manufacturing method for a discharge lamp lighting apparatus as set forth in claim 11, wherein:

the mounting member includes a connecting terminal which connects the high voltage terminal of the starter transformer and the output cable;

connecting the high voltage terminal of the starter transformer to one end of the connecting terminal and sealing a connection part therebetween in the electrically insulated manner with the insulating resin; and

the output cable is subsequently connected to the other end of the connecting terminal.

13. A manufacturing method for a discharge lamp lighting apparatus as set forth in claim 11, wherein:

the output cable is connected to the high voltage terminal of the starter transformer after mounting the circuit components including the starter transformer; and

the high voltage terminal and the output cable are subsequently sealed in the electrically insulated manner with the insulating resin.

14. A manufacturing method for a discharge lamp lighting apparatus as set forth in claim 13, wherein:

the starter transformer is assembled on the mounting member with its winding being exposed; and

the winding is sealed in the electrically insulated manner with the sealing resin.

15. A manufacturing method for a discharge lamp lighting apparatus as set forth in claim 11, wherein the connection part is connected to the output cable through an electrical conductor part.

16. A manufacturing method for a discharge lamp lighting apparatus comprising:

providing a mounting member having a connecting terminal;

assembling a starter transformer on the mounting member by connecting a high voltage terminal of the starter transformer to one end of the connecting terminal;

assembling circuit components other than the starter transformer on the mounting member;

sealing a connection part between the high voltage terminal of the starter transformer and the one end of the connecting terminal in an electrically insulated manner with an insulating resin; and

connecting an output cable to the other end of the terminal;

wherein a bus bar casing is used as the mounting member in which the connecting terminal and a bus bar are insert-molded; and

the circuit components including the starter transformer are assembled within the bus bar casing.

17. A manufacturing method for a discharge lamp lighting apparatus comprising:

connecting a high voltage terminal of a starter transformer to one end of a connecting terminal with its winding being exposed;

insert-molding the high voltage terminal and the connecting terminal with a bus bar to provide a bus bar casing;

assembling the circuit components other than the starter transformer within the bus bar casing; and

connecting an output cable to the other end of the connecting terminal.

18. A manufacturing method for a discharge lamp lighting apparatus as set forth in claim 17, wherein:

the bus bar casing is fixed within a metal casing; and

a member is provided between the connecting terminal and the metal casing to ensure a surface-to-surface distance therebetween.

19. A manufacturing method for a discharge lamp lighting apparatus as set forth in claim 17, wherein:

the other end of the connecting terminal and the output cable are connected through an electrical connector part.

20. A manufacturing method for a discharge lamp lighting apparatus which includes a starter transformer for activating a discharge lamp at the time of starting to light the discharge lamp, an output cable connectable to the discharge lamp, a bus bar casing for accommodating the starter transformer, the output cable and a bus bar connecting the starter transformer and the output cable, and a connecting terminal for connecting the starter transformer, the method comprising:

electrically connecting the starter transformer and the connecting terminal after accommodating the starter transformer in the bus bar casing;

filling the starter transformer with a resin;

placing the output cable in the bus bar casing; and

electrically connecting the output cable and the connecting terminal.

21. A manufacturing method for a discharge lamp lighting apparatus as set forth in claim 20, wherein:

the starter transformer and another transformer are placed at opposite end sides in the bus bar casing.

22. A manufacturing method for a discharge lamp lighting apparatus as set forth in claim 20, wherein:

the bus bar casing has its wall height greater than a height of electrical circuit components mounted on the bus bar.

23. A discharge lamp lighting apparatus comprising:

a circuit unit having a bus bar connectable to an electric power source and circuit components connected to the bus bar for controlling lighting of a high voltage discharge lamp;

an output cable for connecting the circuit unit and the high voltage discharge lamp;

a shielding member covering the output cable; and

a base accommodating the circuit unit therein,

wherein a ground connection part of the bus bar which is connectable to a ground side of the electric power source, the shielding member and the base are constructed to be grounded at one location under a condition that the circuit unit is accommodated within the base.

24. A discharge lamp lighting apparatus as set forth in claim 23, wherein:

the circuit unit has a casing member for mounting the circuit components therein;

the shielding member is fixed to the casing member through a fixing member; and

the shielding member is grounded through the fixing member.

25. A discharge lamp lighting apparatus comprising:

a circuit unit having a bus bar member connectable to an electric power source and circuit components connected to the bus bar member for controlling lighting of a high voltage discharge lamp;

an output cable for connecting the circuit unit and the high voltage discharge lamp;

a shielding member covering the output cable; and

a metal base member and a metal cover member for accommodating the circuit components,

wherein the circuit unit has a casing member for mounting the circuit components therein and the shielding member is fixed to the casing member through a fixing member, and

wherein the cover member, a ground connection part of the bus bar member which is connectable to a ground side of the electric power source, the fixing member and the base member are constructed to be grounded through a thread engagement under a condition that the circuit unit and the cover member are assembled to the base member.

26. A discharge lamp lighting apparatus as set forth in claim 25, wherein:

the base member has a thread stopper part protruding outwardly; and

the ground connection part, the fixing member and the cover member are constructed to be stopped at the thread stopper part when the circuit unit and the cover member are assembled to the base member.

27. A discharge lamp lighting apparatus comprising:

a circuit unit having a bus bar member connectable to an electric power source and circuit components connected to the bus bar member for controlling lighting of a high voltage discharge lamp;

an output cable for connecting the circuit unit and the high voltage discharge lamp;

a shielding member covering the output cable;

a metal base member having a box-like shape which is open at an upper part; and

a metal cover member having a flat plate shape,

wherein the circuit unit has a casing member for mounting the circuit components therein, the shielding member is fixed to the casing member through a clip, and a ground connection part of the bus bar member connectable to a ground side of the electric power source is protruded from the casing member, and

wherein the cover member, the ground connection part, the clip and the base member are constructed to be grounded by a thread engagement under a condition that the cover member is mounted in an open part of the base member.