JP3879898B2 - Manufacturing method of fluorescent lamp - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to a method for manufacturing a fluorescent lamp using a recycled phosphor.
[0002]
[Prior art]
  Conventionally, as described in Japanese Utility Model Publication No. 59-7719, used fluorescent lamps have been collected and reused to dispose of phosphors as sludge.
[0003]
  On the other hand, in the fluorescent lamp manufacturing stage, out of the phosphor coating film applied to the entire inner surface of the glass bulb, the coating film formed on both ends of the bulb is obstructed to seal the stem and is wiped off and removed. The phosphor removed at this stage is reused because it has relatively few impurities.
[0004]
[Problems to be solved by the invention]
  However, in order to recover the phosphor contained in the used fluorescent lamp, the glass bulb must be broken, and glass fragments are inevitably mixed in. For this reason, separation of the glass fragments is troublesome and increases the cost.
[0005]
  On the other hand, Japanese Patent Application Laid-Open No. 62-116665 discloses a technique for inserting a nozzle that sucks only a phosphor without destroying a glass bulb of a used fluorescent lamp and collecting the phosphor from the end of the bulb. However, used fluorescent lamps have mercury attached during lighting, or mercury combines with phosphors to form mercury compounds. If mercury adheres to the phosphor, mercury will undesirably evaporate during the manufacturing process of the fluorescent lamp, which will deteriorate the environment, and must be removed in advance. Moreover, when the phosphor is combined with mercury to form a mercury compound, the performance of the phosphor is deteriorated.
[0006]
  Furthermore, commercially available fluorescent lamps are broadly classified into three-wavelength phosphors and halophosphate phosphors, which have distinct spectral emission characteristics. In order to achieve this, it must be collected separately for each type of phosphor.
[0007]
  Furthermore, fluorescent lamps have daylight color (6700K), daylight white color (5000K), warm white color (3500K), and light bulb color (3000K) depending on the light source color, and the color temperatures are different.
[0008]
  Recovering and recycling a phosphor from a used fluorescent lamp has been studied in the past because of the various problems described above, but has not been actively performed. However, there is a strong demand for recycling various articles because of the need to maintain the environment.
[0009]
  Therefore, the present inventor has reviewed the recycling of fluorescent lamps for each component and studied to enable the phosphors to be recycled. Further, when the fluorescent material of the fluorescent lamp is recycled, since the performance of the fluorescent material deteriorates as the number of times of recycling increases, it becomes difficult to recycle, and this point must be solved together. As a result of these studies, the present invention has been made.
An object of the present invention is to provide a fluorescent lamp manufacturing method in which a fluorescent material is recovered from a used fluorescent lamp, a recycled fluorescent material is obtained, and this is reused for a new fluorescent lamp.
It is another object of the present invention to provide a method for manufacturing a fluorescent lamp that makes it possible to identify that the fluorescent lamp is recycled when at least the phosphor of the fluorescent lamp is recycled.
[0010]
[Means for achieving the object]
  The method of manufacturing a fluorescent lamp according to the invention of claim 1 recovers the phosphor from the used fluorescent lamp,A recycled phosphor manufacturing process for obtaining a recycled phosphor by performing a surface treatment after performing a regeneration process including a step of removing the surface layer of the phosphor by at least an etching process by acid treatment; and a phosphor layer containing the recycled phosphor A phosphor layer forming step formed on the inner surface side of the glass bulb; a translucent discharge vessel forming step of forming a translucent discharge vessel by sealing a pair of electrodes on both ends of the glass bulb on which the phosphor layer is formed; An ionization medium enclosing step of evacuating the translucent discharge vessel and enclosing the ionization medium;It is characterized by comprising.
[0011]
  In the present invention and each of the following inventions, the definitions and technical meanings of terms are as follows unless otherwise specified.
[0012]
  (About fluorescent lamps)
[0013]
  The fluorescent lamp manufactured by the present invention includes a translucent discharge vessel, a phosphor layer formed on the inner surface side of the translucent discharge vessel, a pair of electrodes sealed at both ends of the translucent discharge vessel, and a translucent At least an ionization medium enclosed in the discharge vessel is provided. Furthermore, it is allowed to have a base or the like as necessary. Hereinafter, the fluorescent lamp manufactured by this invention is demonstrated for every component.
[0014]
    <About translucent discharge vessel>
[0015]
  The translucent discharge vessel is formed by sealing both ends of the glass bulb with a sealing member such as an end plate or by directly sealing with a pinch seal without using it. When sealing with an end plate, the end plate portion is generally constituted by a stem. In the case of using a stem, a known stem structure such as a flare stem, a bead stem, or a button stem can be employed.
[0016]
  The glass bulb allows it to be in the shape of a straight tube, a curved tube or a bent tube.
[0017]
  In addition, the glass bulb allows a structure in which a plurality of straight tubes, bent tubes, or bent tubes are connected by a connecting tube so that one discharge path is formed.
[0018]
  Furthermore, the tube diameter of the glass bulb and the tube axis of the translucent discharge vessel, in other words, the length along the discharge path are not limited. However, in general, the tube diameter of the translucent discharge vessel is 40 mm or less, and the length along the tube axis is 2400 mm or less. In the case of a fluorescent lamp for general illumination with a relatively small tube wall load, the tube diameter is 25 to 38 mm and the length along the tube axis is 300 to 2400 mm. In the case of a high-frequency lighting-only fluorescent lamp, the tube diameter is 15 to 25.5 mm, and the length along the tube axis is 500 to 2400 mm. Further, in the case of a compact fluorescent lamp, the tube diameter is 25 mm or less, for example, 12 to 22 mm, and the length along the tube axis is 2400 mm or less, for example, 200 to 2300 mm. Furthermore, in the case of a bulb-type fluorescent lamp, the tube diameter is 13 mm or less, for example, 8 to 12 mm, and the length along the tube axis is 500 mm or less, for example, 400 to 500 mm.
[0019]
  Next, the material of the glass bulb of the translucent discharge vessel is not particularly limited as long as it has airtightness, workability and fire resistance, but generally soft glass used for this kind of fluorescent lamp is suitable. It is. Soft glass includes lead glass and soda lime glass, either of which may be used. Soda lime glass is desirable as an environmental measure. However, soda lime glass and lead glass can be used in combination in terms of processability and the like. For example, the portion of the bulb where the most glass is used can be formed of soda lime glass, and the stem portion can be formed of lead glass.
[0020]
  Furthermore, if necessary, glass other than soft glass such as hard glass, semi-hard glass, and quartz glass can be used as the glass bulb. Moreover, the deterioration by precipitation of the alkali component of the fluorescent substance recycled using the glass with low content of alkali components, such as sodium, can also be suppressed.
[0021]
  Next, the shape of the translucent discharge vessel will be described.
[0022]
  The translucent discharge vessel may be either a straight tube shape or a ring shape. Furthermore, if necessary, it is allowed to have various shapes such as a U-shaped, semi-circular, or U-shaped portion connected in series and having an appropriate arrangement.
[0023]
    <About the phosphor layer>
[0024]
  The fluorescent lamp manufactured according to the present invention includes a phosphor whose phosphor layer is composed of a recycled phosphor and an unused phosphor.
[0025]
  The phosphor layer is formed on the inner surface side of the translucent discharge vessel. The “inner surface side” refers to an embodiment in which the inner surface is formed in direct contact with the inner surface of the translucent discharge vessel and an embodiment in which the inner surface is formed indirectly through a protective film such as alumina and / or a reflective film such as titanium oxide It means that either of them may be used.
[0026]
  Further, the composition of the phosphor used in the present invention is not limited. However, in consideration of recycling the phosphor from the used fluorescent lamp, either the three-wavelength phosphor or the halophosphate phosphor is actually used. It is convenient to select and use the main body. Further, if necessary, it can be collected separately for each number of times of recycling.
[0027]
  As the three-wavelength phosphor, for example, the following phosphors can be used.
    Blue light emitting phosphor
(1) Sr₅(PO₄)₃Cl: Eu
(2) (SrCaBa)₅(PO₄)₃Cl: Eu
(3) BaMg₂Al₁₆O₂₇: Eu
    Green light emitting phosphor
(4) LaPO₄: Ce, Tb
                (5) (CeTb) MgAl₁₁O₁₉
    Red phosphor
(6) Y₂O₃: Eu
Moreover, each luminescent color of a fluorescent lamp is realizable by selecting from said fluorescent substance, combining as follows, and setting the mixture ratio appropriately.
[0028]
    Daylight color (6700K): (3) + (4) + (6)
[0029]
    Day white (5000K): Same as above
[0030]
    Light bulb color (3000K): (4) + (6)
[0031]
    Warm white (3500K): (3) + (4) + (6)
[0032]
  Next, as the halophosphate phosphor, Ca₁₀(PO₄)₆FCl: Sb, Mn can be used.
[0033]
  Furthermore, the configuration of the phosphor layer will be described.
[0034]
  The phosphor layer may be formed from either a single phosphor coating film or a plurality of phosphor coating films.
[0035]
  In the case of a single phosphor coating film, an unused phosphor and a recycled phosphor are mixed and coated and baked to form a phosphor layer. In order to mix unused phosphors and recycled phosphors, both phosphors should be mixed in advance before adjusting the phosphor coating solution. Introduce and suspend the phosphor and a predetermined amount of recycled phosphor separately in a solvent and a binder, or adjust the coating solution of unused phosphor and the coating solution of recycled phosphor separately at a predetermined ratio It can be performed by a method such as mixing and using.
[0036]
  In the case of a plurality of phosphor coating films, an unused phosphor coating film mainly composed of unused phosphors and a recycled phosphor coating film mainly composed of recycled phosphors are separately applied and baked. To form a phosphor layer.
[0037]
    <About electrodes>
[0038]
  A pair of electrodes are sealed at both ends in the translucent discharge vessel, and a low-pressure mercury vapor discharge is generated between them.
[0039]
  As the electrode, a known electrode such as a filament electrode, a ceramic electrode, or a cold cathode can be used.
[0040]
  The filament electrode has a structure in which an electron emitting substance is applied to a tungsten double coil or triple coil, and both ends thereof are connected to the tip of a pair of internal lead-in wires that penetrate the translucent discharge vessel in an airtight manner. I have.
[0041]
  Ceramic electrodes are, for example, fruit-like, sponge-like, which are mainly composed of oxides of alkaline earth elements and transition metal elements in an electrically conductive container with openings, and the surfaces are coated with carbides or nitrides of transition metal elements. Or it has the structure which accommodates the thermoelectron emission substance which consists of block-like composite ceramics, and is supported by the front-end | tip of one internal lead-in wire.
[0042]
    <Ionization medium>
[0043]
  The ionization medium shall contain mercury and a noble gas to cause low pressure mercury vapor discharge. Further, in order to perform low-pressure rare gas discharge, a rare gas such as xenon is sealed at an appropriate pressure.
[0044]
  Mercury is encapsulated in the form of an amalgam that encloses liquid mercury or exhibits mercury vapor pressure characteristics close to that of liquid mercury, such as Zn-Hg or Ti-Hg amalgam.
[0045]
  In order to enclose liquid mercury, liquid mercury can be dropped or put into a capsule, and after encapsulation, the capsule can be broken by an appropriate means to take out the mercury.
[0046]
  Moreover, in order to enclose as amalgam, it can shape | mold into a pellet form or can carry | support amalgam by making a suitable metal plate into a base | substrate. That is, in the case of a Zn-Hg amalgam, it is suitable for being molded into a pellet and encapsulated. Moreover, in the case of Ti-Hg amalgam, it is suitable for carrying on a metal plate. The latter is also called a mercury-releasing alloy, but is heated to release mercury by applying a high frequency after encapsulation.
[0047]
  Next, the rare gas is used as a buffer gas for facilitating the start of the discharge of the fluorescent lamp, and argon Ar, krypton Kr, neon Ne and the like are enclosed in a translucent discharge vessel at about 200 to 400 Pa.
[0048]
  In addition, the rare gas may be sealed with Ar alone, or may be mixed with Ar—Kr, Ne—Ar—Kr, Ne—Ar, or the like.
[0049]
  (About fluorescent lamp manufacturing method)
[0050]
  In order to manufacture a fluorescent lamp according to the present invention, it is necessary to go through at least a recycled phosphor manufacturing process, a phosphor layer forming process, a translucent discharge container forming process, and an ionization medium enclosing process. The following is a separation.
[0051]
    <Recycled phosphor manufacturing process>
[0052]
  The recycled phosphor manufacturing process is a process for obtaining a recycled phosphor by collecting the phosphor from a used fluorescent lamp.
[0053]
  The phosphor recovery step is divided into a step of recovering the phosphor, a purification step of purifying the recovered phosphor, and a step of obtaining a recycling phosphor by heat-treating the purified phosphor.
[0054]
  The step of collecting the phosphor is performed as follows, for example. That is, the used fluorescent lamp is collected, the translucent discharge vessel is cut at approximately the center, and the phosphor is wiped off from the inner surface of the bulb, or an air blower or an air drawer is applied to the phosphor film and mechanically separated. Or you may collect | recover fluorescent substance by grind | pulverizing a translucent discharge vessel finely.
[0055]
  After collecting the phosphor, mercury and glass fragments are removed by a floating precipitation method or the like, and then the phosphor is selected. When collecting the phosphor, it is desirable that the fluorescent lamp using the three-wavelength light emitting phosphor and the fluorescent lamp using the halophosphate phosphor are classified in advance. This is because these phosphors have clearly different characteristics. Since the number of times of recycling increases and the degree of deterioration increases, the phosphor can be collected separately for each number of times of recycling.
[0056]
  The step of purifying the recycling phosphor is for making the recycling phosphor that has been aggregated and enlarged into a suitable particle size, and can be performed by sieving and / or milling.
[0057]
    <About the phosphor layer forming step>
[0058]
  The phosphor film forming step is a step for forming a phosphor coating film using an unused phosphor and a recycled phosphor on the inner surface side of the bulb and further firing it to obtain a phosphor layer.
[0059]
  The phosphor coating film may be formed by either a wet method or a dry method.
[0060]
  In the former case, the phosphor coating solution is prepared by suspending the phosphor in a solvent and binder solution. For example, the phosphor coating solution flows down from the top of the bulb, or the phosphor coating solution is blown up from the lower end of the bulb. Alternatively, the phosphor coating liquid can be applied to the inner surface of the bulb to form the phosphor coating film.
[0061]
  When the phosphor coating film is not formed on both ends of the bulb, an unnecessary portion at both ends of the bulb can be wiped off with a buff after forming the phosphor coating film on the entire inner surface of the bulb.
[0062]
  In the latter case, a powder coating method such as electrostatic coating can be used.
[0063]
  The phosphor coating film may be either single or plural.
[0064]
  In the case of a single phosphor coating film, a phosphor coating film in which a recycled phosphor and an unused phosphor are mixed at an appropriate ratio is prepared and used.
[0065]
  In the case of a plurality of phosphor coating films, an unused phosphor coating film and a recycled phosphor coating film are formed to overlap each other. The unused phosphor coating film is formed mainly of at least unused phosphor. Similarly, the recycled phosphor coating film is formed mainly of at least the recycled phosphor.
[0066]
  Next, the ratio of the recycled phosphor and the unused phosphor in the entire phosphor coating film is the total luminous flux, emission color, and color rendering of the completed fluorescent lamp, regardless of whether the phosphor coating film is single or plural. It may be selected from the viewpoint of minimizing undesirable effects on sex. From the viewpoint of the total luminous flux, the mixing ratio of the recycled phosphor can be increased as the luminance of the recycled phosphor is closer to that of the unused phosphor.
[0067]
  However, if the fluorescent lamps are not separately collected according to their emission colors, the recycled phosphors are mixed with the phosphors of each emission color of fluorescent lamps on the market. In order to stop the color deviation from the color within an allowable range, it is necessary to appropriately set and manage the mixing ratio with respect to the unused phosphor.
[0068]
  Next, an appropriate setting for the ratio of the recycled phosphor and the unused phosphor contained in the phosphor layer will be described.
[0069]
  For example, recycle phosphorAcid treatment and further surface treatmentAs a result, it is possible to obtain a luminous flux of about 96% of the unused phosphor. Therefore, a fluorescent lamp having a total luminous flux of up to 98% of a fluorescent lamp having a phosphor layer of only the unused phosphor is provided. In order to obtain this, the recycled phosphor may be mixed within a range of 50% by weight or less of the entire phosphor. In order to substantially recycle the phosphor, at least 5% by weight or more should be mixed with respect to the entire phosphor.
[0070]
  In addition, in order to obtain a suitable fluorescent lamp that has almost no difference in the total luminous flux as compared with a fluorescent lamp having a phosphor layer of only unused phosphors, and is close in terms of emission color and color rendering properties. The weight ratio is preferably set to a range of 30% or less with respect to the entire phosphor. In order to increase the rate of recycling, the recycled phosphor can be mixed by 10% or more by weight with respect to the whole.
[0071]
  Apart from the above, when the emission color of the recycled phosphor is shifted from the emission color of the newly manufactured fluorescent lamp, the emission color of the unused phosphor is insufficient to offset the color shift of the recycled phosphor It is also possible to prepare a large amount of the phosphors of the luminescent color. For example, since the color temperature of the average recycled phosphor is lower than the daylight color (6700K), if the newly produced fluorescent lamp is daylight color, the blue light emission in the unused phosphor The amount of the phosphor added is somewhat higher than that of the 6700K phosphor, and a color temperature higher than 6700K is prepared. By mixing this with the recycled phosphor, daylight color (6700K) is emitted as a whole. A fluorescent lamp having a color can be obtained.
[0072]
  Similarly, when the fluorescent lamp to be newly manufactured has a light bulb color, the color temperature of the recycled phosphor is higher than the light bulb color (3000 K), so the amount of red-emitting phosphor added in the unused phosphor is increased, A fluorescent lamp having a light emission color of 3000 K as a whole can be obtained by preparing a lamp having a color temperature lower than 3000 K and mixing it with a recycled phosphor.
[0073]
  After the phosphor coating film is formed, the phosphor coating film is then baked to form a phosphor layer. This phosphor layer baking step decomposes and removes the binder contained in the phosphor coating film by heating the bulb on which the phosphor coating film is formed to, for example, about 600 ° C. in a heating furnace, Is evaporated to form a phosphor layer.
[0074]
    <Translucent discharge vessel forming process>
[0075]
  The translucent discharge vessel forming step is a step for forming a translucent discharge vessel by sealing a pair of electrodes at both ends of the bulb on which the phosphor layer is formed and sealing both ends of the bulb. .
[0076]
  When a flare stem is used to seal a pair of electrodes at both ends of the valve and at the same time seal the both ends of the valve, an exhaust pipe is attached to the flare stem, so that it is easy to enclose an ionization medium in a later process. Become.
[0077]
  When both ends of the valve are sealed with pinch seals, an exhaust pipe can be attached to the side of the valve.
[0078]
  When the translucent discharge vessel is bent, for example, in an annular shape, a bending step can be provided after the translucent discharge vessel is formed. However, it is also possible to form the phosphor layer by the above process after forming a preliminarily bent translucent discharge vessel.
[0079]
    <Ionization medium encapsulation process>
[0080]
  An ionization medium enclosure process is a process for enclosing an ionization medium in a translucent discharge vessel.
[0081]
  (Operation of the present invention)
[0082]
  In the present invention, when the fluorescent material is recovered from the used fluorescent lamp to obtain a recycled fluorescent material, the recovered fluorescent material isacidProcess and furthersurface treatmentTherefore, the brightness of the obtained recycled phosphor is high, and a light flux close to that of the unused phosphor can be obtained.
[0083]
  Further, when forming the phosphor layer, the phosphor layer containing the recycled phosphor and the unused phosphorTheTherefore, a fluorescent lamp with practically less discoloration in terms of total luminous flux, emission color, and color rendering can be obtained as compared with a fluorescent lamp using only unused phosphors.
[0084]
  In the recycling process of the recycled phosphor, when the recycled phosphor is acid-treated and mercury or the like captured by the surface layer is removed by etching the surface layer of the phosphor, deterioration of the characteristics can be suppressed. However, on the other hand, phosphors subjected to acid treatment have a problem that mercury and gas are liable to adhere. This is because the surface of the phosphor particles is roughened by etching.
[0085]
  In the present invention, after the acid treatment is performed in the regeneration treatment step, the recycled phosphor is subjected to a surface treatment to reduce the adhesion of mercury and gas. The “regeneration process step” is a step for obtaining a reusable recycled phosphor by removing impurities from the phosphor collected from the used fluorescent lamp, and the specific content thereof is not limited. For example, a mercury / glass debris removal process that removes liquid mercury and glass fragments from a translucent discharge vessel, a purification process that purifies the aggregated phosphor to an appropriate particle size by sieving or milling, and heating the recycled phosphor Thus, a heating process for separating mercury adhering to the phosphor particles can be used alone or in combination as a plurality of processes as a pre-process of the acid treatment process.
[0086]
  The acid treatment process also removes the extremely thin surface layer of recycled phosphor particles by etching.is doing. For example, the recycled phosphor can be washed with a dilute nitric acid solution or the like, and then washed with pure water to perform the acid treatment. In addition, since the particle | grain surface of the fluorescent substance particle which performed acid treatment is rough, it can confirm by the comparison by the electron microscope with the fluorescent substance particle before acid treatment, or BE value comparison.
[0087]
  Furthermore, the surface treatment is a process for making it difficult for mercury and gas to adhere to the surface of the recycled phosphor particles. For example, metal oxide fine particles are adhered almost uniformly to the surface of the phosphor particles of the recycled phosphor. Alternatively, surface treatment can be performed by forming a continuous thin film of metal oxide on the surface of the phosphor particles. In the former case, the average particle diameter of the metal oxide fine particles is suitably about 10 to 100 nm. In addition, the particle diameter of the phosphor is about 5 to 8 μm for the three-wavelength emission type phosphor, and the average is about 10 μm for the halophosphate phosphor.
[0088]
  By the way, the use of alumina fine particles as a binder for phosphors has been conventionally known. However, in this case, alumina mainly aggregates between the phosphor particles and binds the phosphor particles, and does not uniformly adhere to the surface of the phosphor particles, so that adhesion of mercury or gas is suppressed. The action is substantially less likely to occur. These differences can be confirmed by comparative observation with an electron microscope. In order to make the metal oxide fine particles adhere substantially uniformly to the surface of the phosphor particles of the recycled phosphor, the metal oxide particles are directly coated on the recycled phosphor, or the metal oxide fine particles are 1 in the recycled phosphor suspension. It is better to disperse well in the form of secondary particles. In order to increase the dispersibility of the metal oxide fine particles, means such as using a dispersant such as a surfactant or increasing the viscosity of the dispersion to some extent are effective. The metal oxide fine particles can also act as a binder for the recycled phosphor. However, the metal oxide fine particles as the surface treatment and the metal oxide as the binder can be used in combination.
[0089]
  Moreover, when performing a surface treatment using a metal oxide, the addition amount is suitably about 0.1 to 10% by weight with respect to the phosphor. If it is less than 0.1% by weight, a sufficient effect cannot be obtained. On the other hand, if it exceeds 10% by weight, the light flux is lowered. Furthermore, alumina, silica, yttria, zirconia, lanthania, etc. can be used as the metal oxide effective for the surface treatment.
[0090]
  Thus, in the present invention, the acid treatment is performed in the recycling process of the recycled phosphor, and then the surface treatment is further performed, thereby suppressing the adhesion of mercury and gas to the phosphor particles of the recycled phosphor. Therefore, the luminous flux maintenance characteristic of the fluorescent lamp is improved.
[0091]
  Claim2The manufacturing method of the fluorescent lamp of the invention of claim1In the described method for manufacturing a fluorescent lamp, the surface treatment is performed by attaching a metal oxide to the surface of the recycled phosphor particles.
[0092]
  The present invention defines a method for manufacturing a fluorescent lamp using recycled phosphor particles that have undergone surface treatment.
[0093]
  The recycled phosphor subjected to the surface treatment according to the present invention is confirmed by the fact that the metal oxide is substantially uniformly attached to the surface of the phosphor particles. Further, a continuous film of these metal oxides may be formed on the surface of the phosphor particles by hydrolysis of the metal alkoxide solution.
[0094]
  Thus, according to the present invention, a fluorescent lamp with improved luminous flux maintenance characteristics can be obtained.
[0095]
  Claim3The manufacturing method of the fluorescent lamp according to the present invention is as follows.Or 2The method for manufacturing a fluorescent lamp described above is characterized in that it includes a step of providing a display indicating that it is a recycled product on either the light-transmitting discharge vessel or the base.
[0096]
  In the phosphor layer, part or all of the phosphor to be used is composed of a recycled phosphor.
[0097]
  “Indicating that it is a recycled product” means that at least the phosphor layer contains a recycled phosphor, and if necessary, a glass bulb, a base, etc. may be recycled. In addition, the display may be provided on either the light-transmitting airtight container or the base of the fluorescent lamp. Then, if it is known that the display mode is recycling, the display mode may be any one of symbols, marks and characters, or a plurality of combinations of symbols. A bar code can be adopted as the symbol. In addition to the above, a display indicating the number of times of recycling may be performed. If a bar code is used as a part of the display indicating that the product is a recycled product, the number of times of recycling, the type of fluorescent lamp, and the like can be displayed mechanically and easily. In order to distinguish between three-wavelength phosphors and halophosphate phosphors when collecting fluorescent lamps, the spectrum of visible light is examined by irradiating ultraviolet rays. Since the type of the fluorescent material can be easily and reliably identified, the fluorescent lamps can be automatically selected.
[0098]
  When fluorescent lamps are distributed in the market, it is common to place fluorescent lamps in individual packaging boxes and then store them in carton packaging boxes, so it is easy for fluorescent lamps to be recycled even when packaged. It is desirable to make it identifiable. Therefore, it is possible to display these packaging boxes as being recycled products. In this case, any one or any combination of symbols, marks, and characters can be adopted for display as in the fluorescent lamp.
[0099]
  The fluorescent lamp obtained by the method for manufacturing a fluorescent lamp according to the present invention can be used while being supported by a lighting device body of the lighting device.
[0100]
  The “illumination device” is a broad concept including all devices that use the light emitted from a fluorescent lamp for some purpose. Illustrative lighting devices include lighting fixtures, direct backlight devices, display devices and signal lamp devices.
[0101]
  The lighting fixture is suitable for a household lighting fixture, but is not limited to this, and is applicable to a store lighting fixture, an office lighting fixture, an outdoor lighting fixture, and the like.
[0102]
DETAILED DESCRIPTION OF THE INVENTION
  Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0103]
    FIG. 1 shows the present invention.Other inventions related toIt is a front view which shows the fluorescent lamp manufactured by 1st Embodiment of the manufacturing method of this fluorescent lamp.
[0104]
    FIG. 2 is a side cross-sectional view of the enlarged main part.
[0105]
  In each figure, 1 is a translucent discharge vessel, 2 is a phosphor layer, 3 is an electrode, 4 is an internal lead wire, 5 is an external lead wire, and 6 is a base.
[0106]
  (Structure of fluorescent lamp)
[0107]
  The fluorescent lamp of this embodiment is an FCL30S-type annular fluorescent lamp, and the translucent discharge vessel 1 has a tube diameter of 29 mm, an outer ring diameter of 225 mm, and an inner ring diameter of 167 mm.
[0108]
    <About translucent discharge vessel 1>
[0109]
  The translucent discharge vessel 1 includes a bulb 1a and a pair of flare stems 1b, and an end portion 1c forming a sealing portion at both ends is formed to form a grip portion at the time of bending.
[0110]
  The bulb 1a is made of soda-lime glass and has a substantially annular shape with a tube diameter of 29 mm, an annular outer diameter of 225 mm, and an annular inner diameter of 167 mm.
[0111]
  Each of the pair of flare stems 1b is made of lead glass, includes an exhaust pipe 1b1 and a flare 1b2, and seals the pair of internal introduction lines 4 and external introduction lines 5.
[0112]
  The exhaust pipe 1 b 1 is tip-off at the base end and communicates with the translucent discharge vessel 1 at the tip end.
[0113]
  The flare 1b2 is sealed at both ends of the elongated tube 1a to form an airtight translucent discharge vessel 1.
[0114]
  The internal lead-in wire 4 and the external lead-in wire 5 are connected to each other inside the flare stem 1b via a dumet wire, and maintain airtightness with respect to the flare stem.
[0115]
  The exhaust pipe 1b1 shown in FIG. 2 is sealed after the translucent discharge vessel 1 is exhausted and sealed.
[0116]
    <About phosphor layer 2>
[0117]
  The phosphor layer 2 is made of a three-wavelength light emitting phosphor, and is formed on the inner surface side of the translucent discharge vessel 1 by mixing unused phosphors and recycled phosphors in a weight ratio of 7: 3. is doing.
[0118]
  The unused phosphor is for blue light emission BaMgAl₁₆O₂₇: Eu, Mn, green light emission is LaPO₄: CeTb, Y for red light emission₂O₃: Eu.
[0119]
    <About electrode 3>
[0120]
  The electrode 3 has a double coil filament shape, and is connected to the distal ends of a pair of internal lead-in wires 4.
[0121]
    <About the base 6>
[0122]
  The base 6 is provided with a molded product of two-part synthetic resin, and is attached to both ends of the substantially annular translucent discharge vessel 1 by bridging between both ends. A ring is formed. Also, four external lead wires provided with four base pins 6a projecting obliquely downward from the center toward the inner side of the ring, each base pin 6a being led out of the flare stem 1b from the pair of electrodes 3 are provided. 5 is connected.
[0123]
    <Ionization medium>
[0124]
  As the ionization medium, liquid mercury and argon Ar are sealed in the translucent discharge vessel 1 at a pressure of 330 Pa.
[0125]
  (About manufacturing fluorescent lamps)
[0126]
    FIG. 3 is a process diagram showing a first embodiment of a method for manufacturing a fluorescent lamp according to the present invention.
[0127]
  Hereinafter, a manufacturing method is demonstrated for every process based on a figure.
[0128]
    <Recycled phosphor manufacturing process>
[0129]
  The recycling phosphor manufacturing process cuts the translucent discharge vessel of the collected fluorescent lamp almost at the center, mechanically removes the phosphor from the bulb, collects the phosphor, and collects mercury and glass fragments by the floating precipitation method. After dehydration, heat treatment at 600 ° C. was performed, and further sieving using a mesh, and the phosphor particle size was adjusted by milling and purified to obtain a recycled phosphor.
[0130]
    <About the phosphor layer forming step>
[0131]
  As described above, a phosphor coating solution in which unused phosphors and recycled phosphors were mixed with a solution composed of water and a binder at a weight ratio of 7: 3 was prepared.
[0132]
  Next, the phosphor coating film was formed by flowing down into the bulb 1a, and the phosphor coating film at both ends of the bulb 1a was removed.
[0133]
  The bulb 1a on which the phosphor coating film was formed was placed in a heating furnace, heated to about 600 ° C. and fired, the binder was decomposed and removed, and the phosphor layer 2 was formed.
[0134]
    <Translucent discharge vessel forming process>
[0135]
  By sealing a flare stem 1b that supports a pair of electrodes 3 at both ends of the bulb 1a, that is, a flare stem electrode assembly, both ends of the bulb 1a are sealed, and the pair of electrodes 3 and 3 are sealed to transmit light. A discharge vessel 1 was formed.
[0136]
  Next, the translucent discharge vessel 1 was heated to about 700 ° C. in a heating furnace to soften the glass, and wound around a mold (not shown) to form a substantially annular shape.
[0137]
    <About other processes>
[0138]
  The inside of the translucent discharge vessel 1 was evacuated through the exhaust pipe 1b1, and then mercury was dropped, and after argon was sealed, the exhaust pipe 1b1 was sealed off to obtain a fluorescent lamp.
[0139]
  (About the performance of fluorescent lamps)
[0140]
  The ring-shaped fluorescent lamp obtained as described above was about 99% of the total luminous flux as compared with a fluorescent lamp manufactured using only unused phosphors, which was not inferior.
[0141]
  The total luminous flux of the fluorescent lamp using only the recycled phosphor that was collected was 66%.
[0142]
  The total luminous flux of the fluorescent lamp using only the recycling phosphor from which mercury and glass fragments were removed by the floating precipitation method was 88%.
[0143]
  Further, the total luminous flux of the fluorescent lamp using only the heat-treated recycling phosphor was 90%.
[0144]
  Furthermore, the total luminous flux of the fluorescent lamp using only the phosphor subjected to purification by sieving and milling after the heat treatment was 96%.
[0145]
  FIG. 4 is a partially cutaway front view showing the fluorescent lamp obtained by the second embodiment of the manufacturing method of the fluorescent lamp of the present invention.
[0146]
  FIG. 5 is an enlarged cross-sectional view of an essential part.
[0147]
  In each figure, the same parts as those in FIG. 1 and FIG.
[0148]
  The fluorescent lamp obtained according to the present embodiment is a FL40SS type straight tube fluorescent lamp having a tube diameter of 28 mm and a tube length of 1198 mm.
[0149]
  Further, the phosphor layer 2 has a two-layer structure. That is, the unused phosphor layer 2a is formed on the inner surface of the translucent discharge vessel 1, and the recycled phosphor layer 2b is further formed on the inner surface. The ratio of the phosphor used for the unused phosphor layer 2a and the recycled phosphor layer 2b is 5: 5 by mass ratio.
[0150]
  FIG.Other inventions aboveIt is process drawing which shows the manufacturing process in 2nd Embodiment of the manufacturing method of this fluorescent lamp.
[0151]
  That is, in the first phosphor coating liquid adjustment step, a phosphor coating solution using an unused phosphor is adjusted, and this is applied to the inner surface of the bulb in the first phosphor coating step. The phosphor coating film is formed.
[0152]
  Next, the recycled phosphor is manufactured in the recycled phosphor manufacturing process, the phosphor coating liquid using the recycled phosphor is adjusted in the second phosphor coating liquid adjusting process, and this is used as the second phosphor. In the body coating step, the second phosphor coating film is formed by being applied on the first phosphor coating film.
[0153]
  Thereafter, in the phosphor firing step, the first and second phosphor coating films are fired to form a phosphor layer.
[0154]
  Further, a fluorescent lamp is completed through a translucent discharge vessel forming step and an ionized medium enclosing step.
[0155]
  Thus, in the obtained fluorescent lamp, the total luminous flux was 98% compared to the fluorescent lamp manufactured using only unused phosphors.
[0156]
  FIG.Other inventions aboveIt is process drawing which shows the manufacturing process in 3rd Embodiment of the manufacturing method of this fluorescent lamp.
[0157]
  That is, when forming a phosphor layer containing a recycled phosphor, a phosphor reflectance measurement step for measuring the reflectance of the phosphor in advance, and a phosphor so as to have a predetermined reflectance based on the measured reflectance And a phosphor mixing step of mixing.
[0158]
  In the phosphor reflectance measurement step, the reflectances of the recycled phosphor and the unused phosphor are individually measured.
[0159]
  In the phosphor mixing process, the reflectance of the recycled phosphor is calculated when the reflectance of the unused phosphor is 100%, and the required mixing ratio is calculated so that the reflectance when mixed is 95%. Determine by mixing. The phosphors are mixed by regulating the amount of each phosphor charged when adjusting the phosphor coating liquid.
[0160]
  FIG.Other inventions aboveIt is process drawing which shows the manufacturing process in 4th Embodiment of the manufacturing method of this fluorescent lamp.
[0161]
  That is, when forming a phosphor layer containing a recycled phosphor, a phosphor luminance measurement step for measuring the luminance of the phosphor in advance, and a fluorescence in which the phosphor is mixed so as to have a predetermined luminance based on the measured luminance A body mixing step.
[0162]
  In the phosphor luminance measurement step, the luminances of the recycled phosphor and the unused phosphor are individually measured. The phosphors are mixed in the same manner as in the third embodiment.
[0163]
  FIG. 9 shows a first method of manufacturing a fluorescent lamp according to the present invention.1It is process drawing which shows the recycle fluorescent substance manufacturing process in the embodiment.
[0164]
  That is, an acid treatment step for acid treatment of the recycled phosphor is finally provided in the regeneration treatment step after the phosphor collection step for collecting the phosphor from the used fluorescent lamp, and the recycled phosphor particles are provided after the acid treatment step. The surface treatment process is provided.The manufacturing method of the present embodiment is the same as that of the first embodiment of the invention other than the above, except for the recovery treatment step of the recovered phosphor.
[0165]
  The regeneration treatment process includes a mercury / glass fragment removal process, a phosphor purification process, a heating process, and an acid treatment process. And the acid treatment process is positioned after the heating process. Then, the recycled phosphor is washed with pure water after the extremely thin layer on the surface of the phosphor particles is etched and removed by washing the recycled phosphor with a dilute nitric acid solution.
[0166]
  The surface treatment step is performed in advance with Al having an average particle diameter of 15 nm.₂O₃After preparing the metal oxide fine particle dispersion of fine particles and washing the recycled phosphor with pure water in the above acid treatment step, the metal oxide fine particle dispersion is charged, stirred well, and filtered. In this configuration, a recycled phosphor obtained by drying and surface treatment is obtained. By this step, the metal oxide fine particles adhere to the surface of the phosphor particles almost uniformly.
[0167]
  The other steps of manufacturing the fluorescent lamp are the same as the manufacturing steps shown in FIG. That is, a phosphor suspension composed of a recycled phosphor, a binder, a binder and a solvent is prepared, applied to the inner surface of the glass bulb, and baked to form a phosphor layer. An electrode is sealed at both ends of the transparent electrode to form a translucent discharge vessel. And the inside of a translucent discharge container is exhausted, a discharge medium is enclosed, and a fluorescent lamp is obtained.
[0168]
  FIG. 10 shows a fluorescent lamp obtained by the fluorescent lamp manufacturing method of the present invention.Other inventions aboveIt is a conceptual principal part expanded sectional view in 1st Embodiment.
[0169]
  In the figure, the same parts as those in FIG. In the present embodiment, the phosphor layer 2 has a three-wavelength emission type recycled phosphor particle 2a that is surface-treated, and as a result, Al having an average particle diameter of 15 nm is formed on the surface of the recycled phosphor particle 2a.₂O₃The fine particles 2b adhere almost uniformly. Al₂O₃The adhesion amount of the fine particles 2b is about 4% with respect to the recycled phosphor.
[0170]
  Then, as a fluorescent lamp of this embodiment, a FL20SS type straight tube fluorescent lamp was manufactured together with a comparative fluorescent lamp of the same specification except that surface treatment was not performed, and a comparative lighting test was performed. In time, the total luminous flux was about 95% in this embodiment, whereas the comparative fluorescent lamp was about 90%.
[0171]
  FIG. 11 is a conceptual enlarged front view of recycled phosphor particles in the second embodiment of the fluorescent lamp obtained by the fluorescent lamp manufacturing method of the present invention.
[0172]
  That is, a continuous film 2c of yttrium oxide is formed on the surface of the three-wavelength emission type phosphor particles 2a by the CVD method.
[0173]
  FIG. 12 is a partially cutaway front view of a fluorescent lamp according to a third embodiment obtained by the fluorescent lamp manufacturing method of the present invention.
[0174]
  In the figure, the same parts as those in FIG. M is a lamp mark.
[0175]
  The fluorescent lamp of the present embodiment is a FL20SS type straight tube fluorescent lamp having a tube diameter of 28 mm and a tube length of 580 mm.
[0176]
  The lamp mark M is divided into three display contents. The upper part is a manufacturer display 7a, a Japanese Industrial Standard mark 7b and an inspection mark 7c, and the middle part is composed of a recycle display 7d and a model name display 7e.
[0177]
  The recycle display 7d is composed of a recycle mark 7d1 and a “recycle” character 7d2.
[0178]
  FIG. 13 is a partially cutaway front view of a fourth embodiment of a fluorescent lamp obtained by the fluorescent lamp manufacturing method of the present invention.
[0179]
  In the figure, the same parts as those in FIG.
[0180]
  The lamp mark M includes a recycle number display 7d3 (one time) following the word “recycle”. For this reason, the fluorescent lamp manufacturer can easily determine whether or not to further recycle by looking at the number-of-recycles display 7d3.
[0181]
  FIG. 14 is a cross-sectional view showing a cord pendant type lighting fixture as one example of use of the fluorescent lamp obtained by the method for manufacturing a fluorescent lamp of the present invention.
[0182]
  In the figure, 11 is a lighting fixture body, and 12A and 12B are fluorescent lamps as discharge lamps.
[0183]
  The lighting fixture body 11 includes a fixture case 11a, a pendant cord 11b, a hooking sealing cap 11c, and a shade 11d.
[0184]
  The appliance case 11a has a lower surface bulged and an outer surface formed as a reflective surface, and houses a lighting circuit 11a1, an connector 11a2, a switch unit 11a3, and a nightlight 11a4 including an inverter.
[0185]
  The instrument case 11a includes a lamp holder 11a5 on the outer periphery. A cord suspension / storage device 11a6 is disposed on the upper surface.
[0186]
  The lower end of the pendant cord 11b is drawn into the cord suspension / storage device 11a6 of the instrument case 11a and connected to the connector 11a2. The upper end of the pendant cord 11b is connected to the hooking sealing cap 11c. And a lighting fixture is suspended and used from a ceiling via the pendant cord 11b and the hooking sealing cap 11c.
[0187]
  The hanging length of the lighting fixture can be set to a desired hanging height by storing the surplus portion of the pendant cord 11b in the cord hanging / storage device 11a6.
[0188]
  The hooking ceiling cap 11c can be mechanically and electrically connected to the lighting fixture by being attached to and detached from the hooking sealing body that is previously arranged on the ceiling and connected to the power source with one touch.
[0189]
  The fluorescent lamp 12A is an FCL30 type, and 12B is an FCL32 type.
[0190]
  These fluorescent lamps 12A and 12B have the same configuration as that of the fluorescent lamp shown in FIGS. 1 and 2, and the phosphor layer is composed of unused phosphors and recycled phosphors, and is supported by the lamp holder 11a5. At the same time, a lamp socket (not shown) is attached to the base pin.
[0191]
  The shade 11d is made of a translucent synthetic resin, has a shade shape, and is supported by the instrument case 11a with its upper end locked around the cord suspension / storage device 11a6. The air inside the shade 11d whose temperature has risen due to heat generated by the fluorescent lamps 12A and 12B is discharged to the outside of the lighting fixture through the vent hole 11d1, thereby being cooled by the thermal convection of the room air.
[0192]
【The invention's effect】
  Claim1According to the invention, the phosphor is recovered from the used fluorescent lamp, and at least the etching treatment by the acid treatmentRemoving the phosphor surface layerIs provided with a recycled phosphor manufacturing process for obtaining a recycled phosphor by performing a surface treatment after performing a regeneration treatment, and thereby suppressing the adhesion of mercury and gas to the particles of the recycled phosphor, thereby maintaining a luminous flux maintenance characteristic. An improved fluorescent lamp manufacturing method can be provided.
[0193]
  Claim2According to the invention, by including a step of applying a surface treatment by attaching a metal oxide to the surface of the phosphor particles, adhesion of mercury or gas to the particles of the recycled phosphor is suppressed, and the luminous flux maintenance characteristics are improved. A method of manufacturing a fluorescent lamp can be provided.
[0194]
  Claim3According to this invention, it is possible to provide a method for manufacturing a fluorescent lamp that can easily determine whether or not the phosphor is recycled by including a step of displaying an indication that the product is a recycled product.
[Brief description of the drawings]
FIG. 1 shows the present invention.Other inventions related toThe front view which shows the fluorescent lamp manufactured by 1st Embodiment of the manufacturing method of the fluorescent lamp of this
[Fig. 2] Partial side sectional view of the same enlarged main part
[Fig. 3]Other inventions aboveProcess drawing which shows 1st Embodiment of the manufacturing method of the fluorescent lamp of this
[Fig. 4]Other inventions abovePartially cutaway front view showing a fluorescent lamp manufactured according to a second embodiment of the fluorescent lamp
FIG. 5 is a cross-sectional view of an enlarged main part
[Fig. 6]Other inventions aboveProcess drawing which shows the manufacturing process in 2nd Embodiment of the manufacturing method of the fluorescent lamp of this
[Fig. 7]Other inventions aboveProcess drawing which shows the manufacturing process in 3rd Embodiment of the manufacturing method of the fluorescent lamp of this
[Fig. 8]Other inventions aboveProcess chart showing the manufacturing process in the fourth embodiment of the manufacturing method of the fluorescent lamp
FIG. 9 shows a first method of manufacturing a fluorescent lamp according to the present invention.1Diagram showing a process for producing a recycled phosphor in the embodiment of the present invention
FIG. 10 shows a fluorescent lamp obtained by the fluorescent lamp manufacturing method of the present invention.Other inventions aboveFIG. 3 is an enlarged sectional view of a conceptual main part of the first embodiment of the present invention.
FIG. 11 is a conceptual enlarged front view of recycled phosphor particles in a second embodiment of a fluorescent lamp obtained by the fluorescent lamp manufacturing method of the present invention.
FIG. 12 is a partially cutaway front view of a fluorescent lamp obtained by a fluorescent lamp manufacturing method according to a third embodiment of the present invention.
FIG. 13 is a partially cutaway front view of a fourth embodiment of a fluorescent lamp obtained by the fluorescent lamp manufacturing method of the present invention.
FIG. 14 is a cross-sectional view showing a cord pendant type lighting fixture as one example of use of a fluorescent lamp obtained by the method for manufacturing a fluorescent lamp of the present invention.
[Explanation of symbols]
  1 ... Translucent discharge vessel
  1a ... Valve
  1b Flare stem
  1b1 ... exhaust pipe
  1b2 ... Flare
  1c ... end
  2 ... phosphor layer
  3 ... Electrode
  4 ... Internal lead-in line
  5 ... External lead-in line

Claims (3)

Recycled phosphor manufacturing process in which a phosphor is collected from a used fluorescent lamp and subjected to a regeneration process that includes at least a process of removing the surface layer of the phosphor by an acid treatment etching process, followed by surface treatment to obtain a recycled phosphor When;
A phosphor layer forming step of forming a phosphor layer containing a recycled phosphor on the inner surface side of the glass bulb;
A translucent discharge vessel forming step of forming a translucent discharge vessel by sealing a pair of electrodes at both ends of the glass bulb on which the phosphor layer is formed;
An ionization medium enclosing step of evacuating the translucent discharge vessel and enclosing the ionization medium;
A method for manufacturing a fluorescent lamp, comprising: Fluorescent lamp manufacturing method of according to claim 1, comprising a step of depositing a metal oxide on the surface of the recycled phosphor particles subjected to a surface treatment. 3. The method of manufacturing a fluorescent lamp according to claim 1, further comprising a step of displaying an indication indicating that the product is a recycled product on either the translucent discharge vessel or the base.

Images