JP4476392B2

JP4476392B2 - Incandescent bulb manufacturing method and manufacturing apparatus thereof

Info

Publication number: JP4476392B2
Application number: JP26213699A
Authority: JP
Inventors: 冨雄松崎
Original assignee: パナソニックフォト・ライティング株式会社
Priority date: 1999-09-16
Filing date: 1999-09-16
Publication date: 2010-06-09
Anticipated expiration: 2019-09-16
Also published as: JP2001084969A

Description

【０００１】
【発明の属する技術分野】
本発明は、内部にアルゴンガス等の希ガスを封入して形成される白熱電球の製造方法及び製造装置に関する。
【０００２】
【従来の技術】
従来より、白熱電球の製造方法及び製造装置としては、センターバルブを用いて排気及びガス封入を行う製造方法及び製造装置が一般的に知られ、周知となっている。
【０００３】
図１１は、従来の白熱電球の製造装置を示す概略図である。同図に沿って白熱電球の一般的な製造方法を説明する。
【０００４】
バルブ形成手段２でガラス材料から形成された白熱電球の外囲器であるバルブ１０１が、その内部に、マウント部材形成手段３で形成されたマウント部材１０２をマウント部材装入手段４により装入される。マウント部材１０２はバルブ１０１内部の所定の位置に固定又は仮止めされる。
【０００５】
マウント部材１０２を内装したバルブ１０１はバルブ投入手段５により、センターバルブ６の外側に設けられ、且つ、センターバルブ６と同軸に形成されるバルブ１０１の搬送手段である回転機６’に設けた取付部であるヘッド７へ取り付けられる。
【０００６】
センターバルブ６はヘッド７に取り付けられたバルブ１０１を排気手段８や封入ガス供給手段９等へ連結する連結具であり、図示しない粘性の高い油を介して密着される固定側センターバルブ６ａと、これと同心に設置されて間欠回転する回転側センターバルブ６ｂとからなる。また、回転機６’の上部には略等間隔にヘッド７を配置し、各ヘッド７にはバルブ１０１が気密に接続した状態で保持され、回転機６’は回転側センターバルブ６ｂと同期して回転する。
【０００７】
さらに、固定側センターバルブ６ａには、回転側センターバルブ６ｂの各ヘッド７との接続部と対応する位置に、白熱電球の製造工程を構成する排気手段８、封入ガス供給手段９、封止手段１０及び、製品取出手段１１がそれぞれ工程順に配置され、ヘッド７を介してバルブ１０１と気密に接続されている。
【０００８】
バルブ投入手段５で回転機６’のヘッド７に取り付けられたバルブ１０１は、回転側センターバルブ６ｂの間欠回転に伴って、上述した固定側センターバルブ６ａの各製造工程に配置される各手段に順次接続される状態で回転機６’の回転とともに搬送される。
【０００９】
まず、図１２のように、排気工程の位置で固定側センターバルブ６ａに結合された真空ポンプ等の排気手段８で、バルブ１０１の開口端側に形成される排気管１０３からバルブ１０１内部を真空排気する。
【００１０】
続いて、図１１に示すように、ガス封入工程で封入ガス供給手段９のガス供給源であるガスボンベ１２から供給される封入ガス、例えば、アルゴン等といった希ガスが、所定のガス圧となるようにメーター１５でガス圧を測定しながらガス圧調整器１４を調整してバルブ１０１内に封入ガスを充填する。
【００１１】
次に封止手段１０で、バルブ１０１に形成される排気管１０３の軸線方向中間部で所定の部位を加熱して溶融封止することにより、完成した白熱電球１００を形成して排気管１０３から切り離すとともに、完成した白熱電球１００を製品取出手段１１により取り出すことによって白熱電球を製造している。
【００１２】
最後に、ヘッド７に残った排気管１０３は排気管除去手段１６により取り外され、そのヘッド７は回転機６’により搬送されて再びバルブ投入手段５から新たなバルブ１０１を取り付けられ、繰り返し白熱電球１００が製造される。
【００１３】
マウント部材１０２を内装したバルブ１０１について、図１３により詳述する。ガラス管を所定の長さに切断して一端を頂部１０１ａとして溶融封止するとともに整形して形成されたバルブ１０１の開口部１０１ｂからマウント部材１０２を装入し、所定の位置に固定又は仮止めする。
【００１４】
マウント部材１０２は、端部１０４ａにフィラメント１０５が継線される導入線１０４，１０４をビードガラス１０６で支持して形成される。図示はしないが、マウント部材１０２はフィラメント１０５を吊持するアンカーを具備していてもよい。
【００１５】
なお、バルブ１０１の開口端側に形成される排気管１０３は、図１３（ａ）に示すように、バルブ１０１の軸線方向中間部で適当な位置に縮径部１０１ｃを形成することでバルブ１０１と連続して一体に設けられるものであってもよいし、同図（ｂ）のように、バルブ１０１の開口部１０１ｂを加熱しながら圧潰封着するとともにバルブ１０１よりも細径のガラス管を排気管１０３として溶着して設けられるものであってもよい。
【００１６】
【発明が解決しようとする課題】
図１１に示すように、上述した従来の白熱電球の製造装置１では、封入ガス供給手段９からバルブ１０１に供給される封入ガスのガス圧は、ガスボンベ１２から高圧で供給される封入ガスをガス圧調整器１４で適正範囲内に調圧（減圧）したものである。
【００１７】
バルブ１０１に供給される封入ガスの実際のガス圧はガス圧調整器１４の調整能力に限界があり微調整が難しいのに加えてメーター１５の精度及び読み取り誤差の影響により、設定圧にばらつきが生じやすく、ガス圧修正時の微妙な調整も困難であった。さらに、ガス圧はガスボンベ１２に充填された封入ガスの残量によっても影響を受けるため、ガスボンベ１２出口付近での封入ガスのガス圧をメーター１３で測定しながら、メーター１５に表示されるバルブ１０１への封入ガス圧をガス圧調整器１４で随時調整・修正する必要があった。
【００１８】
また、頂部１０１ａに形成される封止部が、例えば、クラックや微小な孔が発生した不完全なバルブ１０１が混入した場合、完成した白熱電球１００の中に内部へ充填した封入ガスが漏出してしまう不良品を混在させるおそれがある。
【００１９】
なお、完成した白熱電球１００の形成・取出後に排気管１０３内に残留する希ガスは、回収されることなく、排気管除去手段１６で排気管１０３がヘッド７から取り外されるときに雰囲気中に拡散され、再度使用できる封入ガスを捨ててしまうことになる。
【００２０】
したがって、本発明は、封入ガスである希ガスをバルブ１０１へ供給するにあたり、ガス圧を常に、所定範囲内に正確に調圧した状態で給送し、バルブ１０１に設けた頂部１０１ａの封止部の気密を確認した後に希ガスを封入することで、封入した希ガスが漏出する不良品が混入することを防止して封入ガス圧のばらつきを少なくし、さらには、白熱電球１００が形成・取出された後に、空気など他の気体が混入することなく排気管１０３内部に残留した希ガスを回収可能である白熱電球の製造方法及びその製造方法の実施に適する製造装置を提供することを目的とする。
【００２１】
【課題を解決するための手段】
本発明による白熱電球の製造方法は、バルブの頂部に形成される封止部の気密性を検査するバルブ気密検査工程と、その検査で合格したバルブ（気密性のバルブ）のみを選別するバルブ選別工程と、所望の封入ガスを蓄ガス容器内に所定ガス圧で一時的に貯留した後気密性のバルブに給送することで、所定ガス圧で封入ガスを気密性のバルブに封入する封入ガス供給工程と、完成した白熱電球を取り出した後に残る排気管に形成される閉塞部の気密性を確認する排気管気密検査工程及び残留ガスを回収する残留ガス回収工程とを含むことを特徴とする白熱電球の製造方法及びその製造方法の実施に適する製造装置を提供するものである。
【００２２】
【発明の実施の形態】
本発明の請求項１に記載の発明は、頂部に封止部を有する形状にガラス管の一端を封止してなる白熱電球の外囲器であるバルブを形成する工程と、端部にフィラメントを継線した一対の導入線がビードガラスに支持されてなるマウント部材を形成する工程と、当該マウント部材を前記バルブに装入し所定の位置に固定又は仮止めをする工程と、前記バルブのうち前記封止部が気密性を有する気密性のバルブのみを内部が真空排気された状態で次工程に供給する工程と、前記バルブの開口端側に形成される排気管の前記開口部を封入ガス供給手段に接続させて前記気密性のバルブ内部に所望の封入ガスを所定ガス圧で封入する封入ガス供給工程と、前記排気管の所定の部位を加熱して溶融封止するとともに、前記排気管から切り離されて完成した白熱電球を形成し、当該白熱電球を取り出す工程と、前記白熱電球の形成後に残される前記排気管の切り離し部に新たに形成された閉塞部の気密性を検査する工程と、前記封入ガス以外の気体の混入を防止して前記排気管の内部に残留する前記封入ガスのみを回収する残留ガス回収工程とを具備することを特徴とする白熱電球の製造方法であり、バルブ頂部の封止部から封入ガスが漏出する不良品の混入を防止するだけでなく、バルブ内に封入されるガス圧のばらつきを極めて小さいものとすることができ、完成した白熱電球を取り出した後に残る排気管内部に残留する封入ガスを空気等他の気体を混入させることなく回収し、無駄なく利用することができるという作用を有する。
【００２３】
請求項２に記載の発明は、前記気密性のバルブのみを内部が真空排気された状態で次工程に供給する工程が、内部を真空排気した状態又は雰囲気ガスが充満した状態の前記バルブに、前記封止部の気密性の検査に適した検査ガスを封入する工程と、前記封止部の気密性を検査する工程と、前記バルブのうち前記気密性の検査で気密性のあることが判定された前記気密性のバルブを選別する工程と、前記気密性のバルブの開口端側に形成される前記排気管の開口部に排気手段を接続して前記気密性のバルブ内部を真空排気する工程とを含むものである白熱電球の製造方法であり、請求項１と同様の作用を有する。
【００２５】
請求項３に記載の発明は、前記気密性のバルブのみを内部が真空排気された状態で次工程に供給する工程が、前記バルブに形成される前記排気管の開口部に排気手段を接続して前記バルブ内部を真空排気する工程と、前記バルブに形成される前記封止部の気密性を検査する工程と、前記バルブのうち前記気密性の検査で気密性のあることが判定された気密性のバルブを選別する工程とを含むものである白熱電球の製造方法であり、請求項１と同様の作用を有する。
【００２６】
請求項４に記載の発明は、前記封止部の気密性を検査する工程が、前記廃棄手段で前記バルブ内部を真空排気した後、前記バルブと前記排気手段とを隔絶し、前記バルブの内圧を断続的に少なくとも２回測定した平均値が、０〜７６０Ｔｏｒｒの範囲内で設定した基準値以下であれば気密性を有すると判断するものであり、前記平均値が前記基準値を上回る場合であっても、前記バルブの直前に測定されたバルブの測定平均値未満であれば、気密性を有すると判定されるものである、白熱電球の製造方法であり、請求項１と同様の作用を有する。
また、請求項５に記載の発明は、前記気密性のバルブを選別する工程が、前記気密性のバルブのみを搬送手段に残し、前記気密性のバルブ以外は前記搬送手段から除去することで前記バルブを選別するものである白熱電球の製造方法であり、請求項１と同様の作用を有する。
【００２８】
請求項６に記載の発明は、前記封入ガス供給工程が、前記封入ガス供給手段に設けたガス供給源から給送される前記封入ガスを蓄ガス容器内に一時的に貯留した後、前記排気管の前記開口部への取付部と前記蓄ガス容器とを継合する第１通路途中に設けられる弁を開放して前記気密性のバルブ内部に前記封入ガスを封入するものであり、前記封入ガスの貯留時に前記蓄ガス容器内部のガス圧を検出し、その検出結果を基に、前記ガス供給源と前記蓄ガス容器とを継合する第２通路途中に設けられる流量調節手段を制御して封入ガスの流量調節及び供給遮断を実行し、前記蓄ガス容器に貯留される封入ガスを所定ガス圧に調整するものである白熱電球の製造方法であり、請求項１と同様の作用を有する。
【００３０】
請求項７に記載の発明は、前記残留ガス回収工程が、前記排気管の前記閉塞部が気密でない場合には、前記封入ガス以外の気体が回収通路内へ混入するのを防止するために弁を開弁して前記排気管を除去し、前記弁よりも下流の前記回収通路及び前記排気管内に残留する既に前記封入ガス以外の気体が混入した封入ガスを廃棄し、一方、前記閉塞部が気密である場合には、前記混入防止弁を開弁した状態で前記排気管の前記開口部に接続吸気手段で、前記排気管及び前記回収通路内に残留する前記封入ガスを回収し、前記封入ガス供給手段での再利用を可能にするものである白熱電球の製造方法であり、請求項１と同様の作用を有する。
【００３１】
請求項８に記載の発明は、端部にフィラメントを継線した一対の導入線がビードガラスに支持されてなるマウント部材を内部に収容する白熱電球の外囲器であるバルブのうち、その頂部に形成される封止部が気密性を有する気密性のバルブのみを内部が真空排気された状態で供給する手段と、前記気密性のバルブ内部に所望の封入ガスを所定ガス圧で封入する封入ガス供給手段と、前記気密性のバルブの開口端側に形成される排気管の所定の部位を加熱して溶融封止するとともに、前記排気管から切り離されて完成した白熱電球を形成する封止手段と、前記白熱電球を取り出す製品取出手段と、前記白熱電球の形成後に残される前記排気管の切り離し部に新たに形成される閉塞部の気密性を検査する排気管気密検査手段と、前記封入ガス以外の気体の混入を防止して前記排気管の内部に残留した前記封入ガスのみを回収する残留ガス回収手段とを具備し、前記気密性のバルブのみを内部が真空排気された状態で供給する手段、前記封入ガス供給手段、前記封止手段、前記製品取出手段、前記排気管気密検査手段及び前記残留ガス回収手段を同一円周上に順次配置してなり、前記排気管の開口部と気密に接続された状態で前記バルブを保持するとともに、各前記製造工程間を間欠的に移動して前記バルブを搬送する搬送手段と、当該搬送手段に前記バルブを投入するバルブ投入手段と、前記搬送手段から前記排気管を除去する排気管除去手段とを備えることを特徴とする白熱電球の製造装置であり、請求項１ないし７のいずれかに記載の白熱電球の製造方法の実施に適し、バルブ頂部の封止部から封入ガスが漏出不良品の混入を防止するだけでなく、バルブ内に封入されるガス圧のばらつきを極めて小さいものとすることができ、完成した白熱電球を取り出した後に残る排気管内部に残留する封入ガスを空気等他の気体を混入させることなく回収し、無駄なく利用することができるという作用を有する。
【００３２】
請求項９に記載の発明は、前記気密性のバルブのみを内部が真空排気された状態で供給する手段が、少なくとも、前記バルブの前記封止部の気密性を検査するバルブ気密検査手段と、前記バルブのうち前記気密性の検査で気密性のあることが判定された気密性のバルブを選別するバルブ選別手段と、前記バルブ気密検査手段及び前記バルブ選別手段の前又は／及び後に前記バルブ内を真空排気する排気手段を含むものである白熱電球の製造装置であり、請求項８と同様の作用を有する。
【００３３】
請求項１０に記載の発明は、前記気密性のバルブのみを内部が真空排気された状態で供給する手段が、前記バルブ内を真空排気する排気手段と、前記バルブの頂部に形成される封止部の気密性を検査するのに適した検査ガスを前記バルブ内に封入する検査ガス供給手段と、前記バルブ気密検査手段と、前記バルブ選別手段と、前記気密性バルブ内を真空排気する排気手段とを含むものである白熱電球の製造装置であり、請求項８と同様の作用を有する。
【００３５】
請求項１１に記載の発明は、前記気密性のバルブのみを内部が真空排気された状態で供給する手段が、前記バルブ内を真空排気する排気手段と、前記バルブ気密検査手段と、前記バルブ選別手段とを含むものである白熱電球の製造装置であり、請求項８と同様の作用を有する。
【００３６】
請求項１２に記載の発明は、前記バルブ気密検査手段が、前記バルブの内圧を測定するバルブ内圧検出手段と、当該バルブ内圧検出手段で測定した結果から前記バルブの気密性を判定する判定部とを有するものであり、前記バルブ内部を前記排気手段で真空排気した後、前記バルブと前記排気手段とを隔絶し、前記バルブ内圧検出手段で前記バルブの内圧を断続的に少なくとも２回測定した結果の平均値を算出し、０〜７６０Ｔｏｒｒの範囲内で設定した基準値と前記判定部で比較して前記平均値が前記基準値以下であれば気密性を有すると判定するものであり、前記平均値が前記基準値を上回る場合であっても、前記バルブの直前に測定されたバルブの測定平均値未満であれば気密性を有すると判定するものである白熱電球の製造装置であり、請求項８に記載と同様の作用を有する。
また請求項１３に記載の発明は、前記バルブ選別手段が、前記気密性のバルブのみを前記搬送手段に残し、前記気密性のバルブ以外は前記搬送手段から除去するバルブ除去手段を有するものである白熱電球の製造装置であり、請求項８に記載と同様の作用を有する。
【００３８】
請求項１４に記載の発明は、前記封入ガス供給手段が、ガス供給源から給送される前記封入ガスを一時的に貯留する蓄ガス容器を有し、前記排気管の前記開口部への取付部と前記蓄ガス容器とを継合する第１通路途中に設けられる弁を開放して前記蓄ガス容器内に一時的に貯留した前記封入ガスを前記気密性のバルブ内部に封入するものであり、前記封入ガス貯留時に前記蓄ガス容器内部のガス圧を検出する内圧検出手段の検出結果を基に流量制御部が前記ガス供給源から供給される前記封入ガスの流量調節及び供給遮断を実行する流量調節手段の作動を制御し、前記蓄ガス容器内に貯留される前記封入ガスを所定ガス圧に調整することで前記気密性のバルブ内部に所望の前記封入ガスを所定ガス圧で封入するものである白熱電球の製造装置であり、請求項8と同様の作用を有する。
【００３９】
請求項１５に記載の発明は前記封入ガス供給手段が、前記ガス供給源を２個以上有し、その中から、供給ガス切り替え手段により１個の前記ガス供給源のみを選択するものであり、前記供給ガス切り替え手段の操作に伴う前記封入ガスの異種ガスへの変更時に、相異なる封入ガス同士の混合を防止する封入ガス置換手段が前記蓄ガス容器に接続して設けられるものである白熱電球の製造装置であり、請求項８と同様の作用を有する。
【００４１】
請求項１６に記載の発明は、前記残留ガス回収手段が、前記排気管内に残留する前記封入ガスを吸引する吸気手段と、前記封入ガス以外の気体が回収通路内へ混入するのを防止する弁とを有するものであり、前記排気管の前記閉塞部が気密でない場合には、、前記封入ガス以外の気体が回収通路内へ混入するのを防止するために前記弁を閉弁して前記排気管を除去し、前記弁よりも下流の前記回収通路及び前記排気管内に残留する既に前記封入ガス以外の気体が混入した封入ガスを廃棄し、一方、前記閉塞部が気密である場合には、前記弁を開弁した状態で前記排気管の前記開口部に接続される吸気手段で、前記排気管及び前記回収通路内に残留する前記封入ガスを回収し、前記封入ガス供給手段での再利用を可能にするものである白熱電球の製造装置であり請求項８と同様の作用を有する。
【００４２】
請求項１７に記載の発明は、ガラス管を所定の長さに切断し、その一端を封止して前記バルブを形成するバルブ形成手段と、前記マウント部材を形成するマウント部材形成手段と、前記マウント部材を前記バルブの開口端側から装入、前記バルブ内部の所定の位置へ固定又は仮止めをするマウント部材装入手段とを具備し、前記マウント部材装入手段で形成された前記マウント部材を内装する前記バルブが順次前記バルブ投入手段へ搬送されるものである白熱電球の製造装置であり請求項８と同様の作用を有する。
【００４３】
（実施例）
以下、本発明の実施例を図面とともに説明する。
【００４４】
図１は本発明による白熱電球の製造装置の一実施例を示す概略図であり、図中、図１１と同符号の構成要素は同一機能構成要素を示している。
【００４５】
白熱電球の製造装置１７は従来の装置と同様に、バルブ形成手段２、マウント部材形成手段３及び、マウント部材装入手段４を備え、マウント部材形成手段により形成されたマウント部材１０２を内装したバルブ１０１はバルブ投入手段５により、バルブ１０１の搬送手段である回転機１８’に設けた取付部であるヘッド７へ取り付けられる。
【００４６】
センターバルブ１８は図２に示すように、固定側センターバルブ１８ａと、これと同心に粘性の高い油を介して設置されて間欠回転する回転側センターバルブ１８ｂとからなる。回転機１８’の上部には、略等間隔に複数個のヘッド７を配置し、各ヘッド７にはバルブ１０１が気密に接続した状態で保持され、回転機１８’は回転側センターバルブ１８ｂと同期して回転する。
【００４７】
また、固定側センターバルブ１８ａには、回転側センターバルブ１８ｂの各ヘッド７との接続部と対応する位置に、白熱電球の製造工程を構成する排気手段８ａ、検査ガス供給手段２４、バルブ気密検査手段１９、バルブ選別手段２０、排気手段８ｂ、封入ガス供給手段２１、封止手段１０、製品取出手段１１、排気管気密検査手段２２及び、残留ガス回収手段２３がそれぞれ工程順に配置され、ヘッド７を介してバルブ１０１と気密に接続されている。
【００４８】
バルブ投入手段５でヘッド７に取り付けられ、マウント部材１０２を内装されたバルブ１０１は、回転側センターバルブ１８ｂの間欠回転に伴って上述した固定側センターバルブ１８ａの各製造工程に配置される各手段に順次接続される状態で搬送される。
【００４９】
以下、本発明による白熱電球の製造方法及び製造装置について、図１に示した上記のような構造からなる白熱電球の製造装置１７の動作について説明する。
【００５０】
まず、バルブ投入手段５により回転機１８’のヘッド７に投入されたバルブ１０１は、その開口端側に形成される排気管１０３の開口部１０３ａでヘッド７に保持され、従来技術と同様に排気工程の位置で固定側センターバルブ１８ａに結合された真空ポンプ等の排気手段８ａで内部を真空排気され、検査ガスを封入する工程へと搬送されて検査ガス供給手段２４に接続される。
【００５１】
図２のように、固定側センターバルブ１８ａに配置される検査ガス供給手段２４に連通するバルブ１０１は、封止部の気密性の検査に適した検査用ガス（空気を含む）を一定時間封入された後、バルブの封止部の気密性を検査する工程及び気密性のバルブを選別する工程へと搬送され、バルブ１０１と検査ガス供給手段２４とは隔絶した状態になる。このとき、バルブ１０１は図３のように、バルブ気密検査手段１９に接続され、バルブ１０１の頂部１０１ａに形成される封止部の気密性を確認する。
【００５２】
バルブ気密検査及びバルブ選別の工程では、図４に示すように、図３のバルブ１０１の内圧をバルブ内圧検知手段である圧力センサ２６で断続的に測定した１回目の結果をＰ１、２回目の結果をＰ２として、判定部２７でＰ１とＰ２の平均値Ｐavを算出するとともに基準値Ｐ０（７６０Ｔｏｒｒ≦Ｐ０≦１３００Ｔｏｒｒ）と比較し、Ｐ０≦Ｐavであれば判定部２７で合格と判定してバルブ１０１は回転機１８’の間欠回転によりそのまま次の位置（排気工程）へと搬送される。
【００５３】
一方、Ｐ０＞Ｐavであれば判定部２７で不合格と判定し、この判定部２７に制御されるバルブ選別手段２０の弁２８が閉弁するとともに図示しないバルブ除去手段によりバルブ１０１を除去する。
【００５４】
なお、合否の判定基準は、直前に検査されたバルブが気密性を有していなかった場合、検査開始時の通路等の内圧が通常と比べて非常に低くなっているため、検査ガス供給手段２４から一定時間バルブ１０１内に検査用ガスを供給した後でも十分に内圧が上がりきらないことがある。このような場合を考慮して、Ｐ０＞Ｐavであっても、直前に検査されたバルブの測定平均値Ｐ'avに対してＰ'av＜Ｐavであれば合格とするようにしてもよい。
【００５５】
検査ガス供給手段２４は、検査用ガスが充填されたガスボンベあるいは、圧縮空気を送給するコンプレッサ等、バルブ１０１の頂部１０１ａに形成される封止部の気密性を確認するのに適した検査用ガス（空気を含む）の供給源である。
【００５６】
バルブ気密検査手段１９で合格と判定された気密性を有したバルブ１０１は、回転機１８’の間欠回転により次の工程が配置される位置へと搬送され、従来技術と同様に排気手段８ｂと接続されて真空排気される。
【００５７】
続いて、図１に示す、封入ガス供給手段２１と接続する位置に搬送されて所望の封入ガス、例えば、アルゴン等の希ガスが所定のガス圧で封入される。
【００５８】
封入ガス供給手段２１では、ガス供給源であるガスボンベ２９から給送される封入ガスを、蓄ガス容器３０内に一時的に貯留した後、センターバルブ１８へと接続される第１通路３１途中に設けられる弁３２を開弁して、気密性のバルブ１０１へ供給する。
【００５９】
そして、蓄ガス容器３０内のガス圧を検知するために設けられた内圧検知手段である圧力センサ３３により検知したガス圧は電気信号として流量制御部３５へ入力される。
【００６０】
蓄ガス容器３０とガスボンベ２９とを接続する第２通路４０途中に封入ガスの流量調節手段３４が設けられており、これを流量制御部３５から出力される信号で制御することにより、蓄ガス容器３０内に流入する封入ガスの流量を調節及び遮断し、蓄ガス容器３０に所定のガス圧で封入ガスを貯留する。
【００６１】
このように、一旦、所定圧で貯留した封入ガスを気密性のバルブ１０１に給送することで、気密性のバルブ１０１に封入される封入ガスのガス圧を、常に所定範囲内に正確に調圧することができる。
【００６２】
この後、従来の製造方法と同様に、気密性のバルブ１０１に形成される排気管１０３の所定の部位を溶融封止する工程及び、このとき排気管１０３から切り離されて完成した白熱電球１００を製品取出手段により取り出す工程を経て、排気管気密検査手段２２と接続する位置へと搬送される。
【００６３】
排気管気密検査手段２２では、完成した白熱電球１００を溶融封止しながら切り離すときに、排気管１０３の先端部に形成される閉塞部１０３ｂの気密性が確認される。
【００６４】
その工程は、図５に示すように、図６の排気管の内圧を排気管内圧検知手段である圧力センサ４７で内圧を断続的に測定した１回目の測定結果をｐ１、２回目の測定結果をｐ２として、判定部４８でｐ１とｐ２の平均値ｐavを算出するとともに基準値ｐ０（０Ｔｏｒｒ≦ｐ０≦７６０Ｔｏｒｒ）と比較し、ｐ０≧ｐavであれば判定部４８で気密性を有すると判定してヘッド７に取り付けられた排気管１０３を回転機１８’の間欠回転によりそのまま次の位置（残留ガス回収工程）へと搬送する。
【００６５】
一方、ｐ０＜ｐavであれば判定部４８で気密性を有していないと判定し、この判定部４８で制御される弁５０を閉弁するとともに図示しない排気管除去手段で排気管１０３を除去し、他の気体が混入した封入ガスを廃棄する。
【００６６】
次いで、残留ガス回収手段２３と接続する位置へと搬送された排気管１０３は、図７に示す、排気管１０３の先端部に形成される閉塞部１０３ｂが気密性を有しているので、排気管１０３及び回収通路３６，３７に残留する封入ガスを吸気手段３８で回収する。
【００６７】
なお、吸気手段３８で回収された残留ガスは、図１のように、封入ガス供給手段２１に設けたタンク４９へ蓄えられ、ガスボンベ２９とともにガス供給源として順次気密性のバルブ１０１に給送される。
【００６８】
あるいは、図示しない独立したタンクに回収された残留ガスを蓄え、このタンクに一定量の残留ガスが充填されると封入ガス供給手段２１のガス供給源として利用するようにしてもよい。このようにして、完成した白熱電球１００に封入されることなく残留した封入ガスで、他の気体が混入していないものを無駄なく回収・再利用できる。
【００６９】
最後に、ヘッド７に残った排気管１０３は、従来の製造方法同様、排気管除去手段１６と接続する位置に搬送されてヘッド７から取り外され、ヘッド７はさらに搬送されて再びバルブ投入手段５と接続して繰り返し白熱電球１００が製造される。
【００７０】
図８は、封入ガス供給手段２１の別の実施例を示す。ガスボンベ群４６は、複数（例えば、２個）のガス供給源であるガスボンベ２９ａ，２９ｂと切り替え手段４１を有し、第２通路４０との連結部に設けた切り替え手段４１の操作で、いずれか１個のガスボンベだけが蓄ガス容器３０へ接続されるように選択することもできる。
【００７１】
各ガスボンベ２９ａ，２９ｂに充填される気体を同種のものとすれば、蓄ガス容器３０に接続されないガスボンベが予備となり、ボンベ交換に要する作業停止時間を短縮して作業効率を向上させることができる。
【００７２】
一方、各ガスボンベ２９ａ，２９ｂに充填される気体を異種のものとすれば、切り替え手段４１の操作だけで、気密性のバルブ１０１に封入する封入ガスを変更することが出来るようになる。
【００７３】
このとき、封入ガス置換装置３９を蓄ガス容器３０に接続させて設け、切り替え手段４１の操作に伴う封入ガスの変更時に、蓄ガス容器３０、第１通路３１及び、第２通路４０内で相異なる封入ガス同士が混合するのを防ぐようにすることが望ましい。
【００７４】
封入ガス置換装置３９は、蓄ガス容器３０と連通する真空ポンプ等の排気手段４２を備えるもので、ガスの置換作業時以外に蓄ガス容器３０と排気手段４２とを隔絶するための弁４３を設けてもよい。
【００７５】
図８においては、ガスボンベ群４６に配置されるガスボンベが２個の例を示したが、ガスボンベ群４６が、３個以上のガスボンベを具備している場合でも同様である。
【００７６】
残留ガス回収手段２３で回収された封入ガスが充填されるタンク４９は、図８に示すように、ガスボンベ２９ａ，２９ｂとは独立して配置され、タンク４９から優先的に封入ガスを給送するようにしてもよいし、ガスボンベ２９ａ，２９ｂと並列に配置され、切り替え手段４１の操作によって選択されるように設けてもよい。
【００７７】
流量調節手段３４は、図１の例のように、ガス供給源から供給される封入ガスの流量調節及び遮断の両方が可能なガス圧調整器であってもよいが、図８の例のように、流量調節のみ行うガス圧調整器４４と開閉弁４５とから成り、流量調節と遮断とを独立して作動させるようにしてもよい。
【００７８】
また、上述の例では、気密性のバルブ１０１のみを内部が真空排気された状態で封入ガス供給工程に供給する工程は、図１の固定側センターバルブ１８ａに配置される排気手段８ａ、検査ガス供給手段２４、バルブ気密検査手段１９、バルブ選別手段２０、排気手段８ｂに順次接続され、それら全てが作動するものであり、図９（ａ）に示すように、バルブ１０１内を排気した後検査ガスを７６０〜１３００Ｔｏｒｒで設定された所定のガス圧で封入し、気密性を有すると判定されたバルブ１０１のみ再び内部を排気して封入ガス供給工程へと搬送される。
【００７９】
しかし、バルブ１０１の気密性を検査する検査ガスがもともとバルブ１０１内に充満している雰囲気ガスと同一（例えば、空気）である場合、あるいは、封入する検査ガスと雰囲気ガスとが混合しても支障のない場合には、同図（ｂ）のように最初の排気手段８ａを休止させる又は、省略するようにしてもよい。
【００８０】
これら図９（ａ）、（ｂ）に示すいずれの場合も、回転機１８’の間欠回転に伴ってバルブ１０１が搬送されることで、バルブ１０１は検査ガス供給手段２４と隔絶されているが、検査ガス供給手段２４をバルブ気密検査及びバルブ選別の工程と同じ位置に配置して、図示しない弁でバルブ１０１と検査ガス供給手段２４との連通及び隔絶を可能にして封止部の気密性を確認するようにしてもよい。
【００８１】
また、図１０は、バルブ気密検査手段１９及びバルブ選別手段２０の別の実施例を示す。図９（ｃ）のように、図１に示した検査ガス供給手段２４及び排気手段８ｂを休止させる又は省略するものであり、排気手段８ａで一定時間バルブ１０１内を排気した後そのまま負圧の状態を保ち、バルブ１０１と排気手段８ａとを隔絶するようにバルブの封止部の気密性を検査する工程及び気密性のバルブを選別する工程へと搬送する。このとき、バルブ１０１は図３のように、バルブ気密検査手段１９に接続され、バルブ１０１の頂部１０１ａに形成される封止部の気密性を確認する。
【００８２】
あるいは、排気手段８ａをバルブ気密検査及びバルブ選別の工程と同じ位置に配置して、図示しない弁でバルブ１０１と排気手段８ａとの連通及び隔絶を可能にして封止部の気密性を確認するようにしてもよい。
【００８３】
バルブ気密検査及びバルブ選別の工程では、図１０に示すように、図３のバルブ１０１の内圧をバルブ内圧検知手段である圧力センサ２６で断続的に測定した１回目の結果をＰ１、２回目の結果をＰ２として、判定部２７でＰ１とＰ２の平均値Ｐavを算出するとともに基準値Ｐ００（０Ｔｏｒｒ≦Ｐ００≦７６０Ｔｏｒｒ）と比較し、Ｐ００≧Ｐavであれば判定部２７で合格と判定してバルブ１０１は回転機１８’の間欠回転によりそのまま次の位置（排気工程）へと搬送される。
【００８４】
一方、Ｐ００＜Ｐavであれば判定部２７で不合格と判定し、この判定部２７に制御されるバルブ選別手段２０の弁２８が閉弁するとともに図示しないバルブ除去手段によりバルブ１０１を除去する。
【００８５】
なお、合否の判定基準は、直前に検査されたバルブが気密性を有していなかった場合、検査開始時の通路等の内圧が通常と比べて非常に高くなっているため、一定時間バルブ１０１内を排気した後でも十分に内圧が下がりきらないことがある。このような場合を考慮して、Ｐ００＜Ｐavであっても、直前に検査されたバルブの測定平均値Ｐ'avに対してＰ'av＞Ｐavであれば合格とするようにしてもよい。
【００８６】
なお、上述したバルブ形成手段２、マウント部材形成手段３及び、マウント部材装入手段４を、白熱電球の製造装置１７の構成要素として、一連の白熱電球の製造工程に組み込み、マウント部材装入手段４で形成された、マウント部材１０２を内装するバルブ１０１を順次バルブ投入手段５に搬送して回転機１８’に配置されるヘッド７に投入するようにしてもよいし、バルブ形成手段２、マウント部材形成手段３及び、マウント部材装入手段４を、白熱電球の製造装置１７とは独立して設け、マウント部材１０２を内装するバルブ１０１を予め製造しておき、そのストックを白熱電球の製造装置１７の構成要素であるバルブ投入手段５に供給するようにしてもよい。
【００８７】
【発明の効果】
以上に述べたように、本発明の白熱電球の製造方法は、ガラスバルブの頂部に形成される封止部の気密性が不完全なバルブを排除する工程と、封入ガスを一旦蓄ガス容器に所定のガス圧で貯留してからバルブに封入する工程と、白熱電球が完成した後にヘッドに残った排気管の閉塞部の気密性を確認してから残留した封入ガスを回収する工程とを含むもので、この結果、バルブ頂部の封止部から封入ガスが漏出する不良品の混入を防止するだけでなく、バルブ内に封入されるガス圧のばらつきを極めて小さく設定することができ、完成した白熱電球を取り出した後に空気等他の気体が混入することなく排気管内部に残留した封入ガスを回収することのできる効果を有している。
【００８８】
また、本発明による白熱電球の製造装置は、バルブ頂部に形成される封止部の気密性を検査するバルブ気密検査手段と、封止部の気密性が不完全なバルブを排除するバルブ選別手段と、封入ガスを一旦蓄ガス容器に所定ガス圧で貯留した後にバルブに封入する封入ガス供給手段と、白熱電球が完成した後にヘッドに残った排気管の閉塞部の気密を検査する排気管気密検査手段と、他の気体が混入することなく排気管及び通路に残留した封入ガスを回収する残留ガス回収手段とを含むもので、この結果、バルブ頂部の封止部から封入ガスが漏出する不良品の混入を防止するだけでなく、バルブ内に封入されるガス圧のばらつきの極めて小さい白熱電球を製造することができ、完成した白熱電球を取り出した後に残る排気管内部に残留する封入ガスを回収することで、希ガスを無駄なく利用することのできる効果を有している。
【図面の簡単な説明】
【図１】本発明による白熱電球の製造装置の一実施例を示す概略図
【図２】検査ガス供給手段の拡大図
【図３】バルブ気密検査手段の拡大図
【図４】図３のバルブ気密検査手段の動作を示すフローチャート
【図５】排気管気密検査手段の動作を示すフローチャート
【図６】排気管気密検査手段の拡大図
【図７】残留ガス回収手段の拡大図
【図８】封入ガス供給手段の別の実施例を示す概略図
【図９】バルブ気密検査手段及び排気の工程の順序を示す説明図
【図１０】バルブ気密検査手段の別の実施例の動作を示すフローチャート
【図１１】従来の白熱電球の製造装置を示す概略図
【図１２】排気手段の拡大図
【図１３】マウント部材を内装するバルブの拡大図
【符号の説明】
２バルブ形成手段
３マウント部材形成手段
４マウント部材装入手段
５バルブ投入手段
７ヘッド
８，８ａ，８ｂ排気手段
１０封止手段
１１製品取出手段
１６排気管除去手段
１７白熱電球の製造装置
１８センターバルブ
１８’ 回転機
１８ａ固定側センターバルブ
１８ｂ回転側センターバルブ
１９バルブ気密検査手段
２０バルブ選別手段
２１封入ガス供給手段
２２排気管気密検査手段
２３残留ガス回収手段
２４検査ガス供給手段
２６圧力センサ（バルブ内圧検知手段）
２７，４８判定部
２８，３２弁
２９，２９ａ，２９ｂガスボンベ（ガス供給源）
３０蓄ガス容器
３１第１通路
３３圧力センサ（内圧検知手段）
３４流量調節手段
３５流量制御部
３６，３７回収通路
３８吸気手段
３９封入ガス置換装置
４０第２通路
４１切り替え手段
４６ガスボンベ群
４７圧力センサ（排気管内圧検知手段）
４９タンク（ガス供給源）
５０弁
１００白熱電球
１０１バルブ
１０１ａ頂部
１０２マウント部材
１０３排気管
１０３ａ開口部
１０３ｂ閉塞部[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an incandescent lamp manufacturing method and a manufacturing apparatus formed by sealing a rare gas such as argon gas inside.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, as an incandescent bulb manufacturing method and manufacturing apparatus, a manufacturing method and a manufacturing apparatus that perform exhaust and gas filling using a center valve are generally known and well known.
[0003]
FIG. 11 is a schematic view showing a conventional incandescent bulb manufacturing apparatus. A general method for manufacturing an incandescent lamp will be described with reference to FIG.
[0004]
A bulb 101 which is an envelope of an incandescent bulb formed from a glass material by the bulb forming means 2 is loaded with a mount member 102 formed by the mount member forming means 3 by the mount member inserting means 4. The The mount member 102 is fixed or temporarily fixed at a predetermined position inside the valve 101.
[0005]
The valve 101 with the mount member 102 installed therein is provided on the outside of the center valve 6 by the valve insertion means 5 and mounted on a rotating machine 6 ′ which is a conveying means for the valve 101 formed coaxially with the center valve 6. It is attached to the head 7 which is a part.
[0006]
The center valve 6 is a connector for connecting the valve 101 attached to the head 7 to the exhaust means 8, the sealed gas supply means 9 and the like, and a fixed-side center valve 6a that is in close contact with a highly viscous oil (not shown); It consists of the rotation side center valve 6b which is installed concentrically and rotates intermittently. In addition, heads 7 are arranged at substantially equal intervals above the rotating machine 6 ′, and the valves 101 are held in airtight connection with each head 7, and the rotating machine 6 ′ is synchronized with the rotation-side center valve 6b. Rotate.
[0007]
Further, the fixed-side center valve 6a is provided with an exhaust means 8, an enclosed gas supply means 9, and a sealing means constituting the incandescent bulb manufacturing process at positions corresponding to the connecting portions of the rotation-side center valve 6b with each head 7. 10 and the product take-out means 11 are arranged in the order of processes, and are connected to the valve 101 through the head 7 in an airtight manner.
[0008]
The valve 101 attached to the head 7 of the rotating machine 6 ′ by the valve input means 5 is connected to each means arranged in each manufacturing process of the fixed-side center valve 6a described above with the intermittent rotation of the rotating-side center valve 6b. It is conveyed with the rotation of the rotating machine 6 'in a state of being sequentially connected.
[0009]
First, as shown in FIG. 12, the inside of the valve 101 is evacuated from the exhaust pipe 103 formed on the opening end side of the valve 101 by the exhaust means 8 such as a vacuum pump coupled to the fixed center valve 6a at the position of the exhaust process. Exhaust.
[0010]
Subsequently, as shown in FIG. 11, the filled gas supplied from the gas cylinder 12 which is the gas supply source of the sealed gas supply means 9 in the gas filling step, for example, a rare gas such as argon is set to a predetermined gas pressure. Further, the gas pressure regulator 14 is adjusted while measuring the gas pressure with the meter 15 to fill the valve 101 with the filled gas.
[0011]
Next, the sealing means 10 forms a completed incandescent lamp 100 by heating and sealing a predetermined portion at an intermediate portion in the axial direction of the exhaust pipe 103 formed in the valve 101, thereby The incandescent lamp is manufactured by taking out the completed incandescent lamp 100 by the product taking-out means 11 while cutting it off.
[0012]
Finally, the exhaust pipe 103 remaining on the head 7 is removed by the exhaust pipe removing means 16, and the head 7 is transported by the rotating machine 6 ′, and a new valve 101 is attached again from the valve throwing means 5, and the incandescent light bulb is repeated. 100 is manufactured.
[0013]
The valve 101 in which the mount member 102 is housed will be described in detail with reference to FIG. A glass tube is cut into a predetermined length, one end is melt-sealed as the top 101a, and the mount member 102 is inserted from the opening 101b of the bulb 101 formed by shaping and fixed or temporarily fixed at a predetermined position. To do.
[0014]
The mount member 102 is formed by supporting lead wires 104, 104, to which the filament 105 is connected to the end 104a, with a bead glass 106. Although not shown, the mount member 102 may include an anchor for suspending the filament 105.
[0015]
As shown in FIG. 13A, the exhaust pipe 103 formed on the opening end side of the valve 101 is formed by forming a reduced diameter portion 101c at an appropriate position at an intermediate portion in the axial direction of the valve 101. Or a glass tube having a diameter smaller than that of the bulb 101, while the opening portion 101b of the bulb 101 is crushed and sealed while heating, as shown in FIG. The exhaust pipe 103 may be welded.
[0016]
[Problems to be solved by the invention]
As shown in FIG. 11, in the conventional incandescent bulb manufacturing apparatus 1 described above, the gas pressure of the sealed gas supplied from the sealed gas supply means 9 to the valve 101 is the same as that of the sealed gas supplied from the gas cylinder 12 at a high pressure. The pressure is adjusted (decreased) within an appropriate range by the pressure regulator 14.
[0017]
The actual gas pressure of the sealed gas supplied to the valve 101 is limited in the adjustment capability of the gas pressure regulator 14 and difficult to finely adjust. In addition, the set pressure varies due to the accuracy of the meter 15 and the influence of reading errors. It was easy to occur and it was difficult to make fine adjustments when correcting the gas pressure. Further, since the gas pressure is also affected by the remaining amount of the sealed gas filled in the gas cylinder 12, the valve 101 displayed on the meter 15 while measuring the gas pressure of the sealed gas near the outlet of the gas cylinder 12 with the meter 13. It was necessary to adjust and correct the gas pressure charged into the gas pressure regulator 14 at any time.
[0018]
Moreover, when the sealing part formed in the top part 101a mixes the incomplete valve | bulb 101 with which the crack and the minute hole generate | occur | produced, for example, the filling gas with which the inside was filled in the completed incandescent bulb 100 leaked out There is a risk of mixing defective products.
[0019]
The rare gas remaining in the exhaust pipe 103 after the formation and removal of the completed incandescent bulb 100 is not recovered and diffuses into the atmosphere when the exhaust pipe 103 is removed from the head 7 by the exhaust pipe removing means 16. Therefore, the sealed gas that can be used again is discarded.
[0020]
Therefore, according to the present invention, when supplying the rare gas, which is the sealed gas, to the valve 101, the gas pressure is always supplied in a state where the gas pressure is accurately regulated within a predetermined range, and the top 101a provided in the valve 101 is sealed. By sealing the rare gas after confirming the airtightness of the part, it is possible to prevent the inclusion of defective products from which the enclosed rare gas leaks and reduce the variation in the enclosed gas pressure. An object of the present invention is to provide an incandescent bulb manufacturing method capable of recovering a rare gas remaining in the exhaust pipe 103 without being mixed with other gases such as air after being taken out, and a manufacturing apparatus suitable for carrying out the manufacturing method. And
[0021]
[Means for Solving the Problems]
The incandescent lamp manufacturing method according to the present invention includes a valve airtight inspection process for inspecting the airtightness of the sealing portion formed on the top of the bulb, and a valve selection for selecting only valves that have passed the inspection (airtight valve). A sealed gas that seals the sealed gas in the airtight valve at a predetermined gas pressure by temporarily storing the desired sealed gas in the gas storage container at a predetermined gas pressure and then feeding it to the airtight valve It includes a supply process, an exhaust pipe airtight inspection process for confirming the airtightness of the closed portion formed in the exhaust pipe remaining after taking out the completed incandescent bulb, and a residual gas recovery process for recovering the residual gas. An incandescent lamp manufacturing method and a manufacturing apparatus suitable for carrying out the manufacturing method are provided.
[0022]
DETAILED DESCRIPTION OF THE INVENTION
The invention according to claim 1 of the present invention includes a step of forming a bulb which is an envelope of an incandescent bulb formed by sealing one end of a glass tube in a shape having a sealing portion at the top, and a filament at the end A step of forming a mount member in which a pair of lead wires connected to each other is supported by bead glass, a step of inserting the mount member into the valve and fixing or temporarily fixing it to a predetermined position, Among them, the step of supplying only the airtight valve having the airtightness to the sealing portion to the next step in a state where the inside is evacuated, and the opening portion of the exhaust pipe formed on the opening end side of the valve are enclosed A sealed gas supply step of connecting a gas supply means and sealing a desired sealed gas at a predetermined gas pressure inside the airtight valve; heating and sealing a predetermined portion of the exhaust pipe; and Completed separated from the tube Forming an incandescent bulb, taking out the incandescent bulb, inspecting the airtightness of the closed portion newly formed in the cut-off portion of the exhaust pipe left after the formation of the incandescent bulb, and other than the enclosed gas A method of manufacturing an incandescent lamp, comprising: a residual gas recovery step for preventing only gas from being collected and recovering only the enclosed gas remaining in the exhaust pipe. Not only does it prevent the introduction of defective products that leak out of the sealed gas, it can also minimize the variation in gas pressure sealed in the bulb, and it remains in the exhaust pipe remaining after the completed incandescent bulb is taken out. The sealed gas to be collected can be recovered without mixing other gases such as air and can be used without waste.
[0023]
In the invention according to claim 2, the step of supplying only the airtight valve to the next process in a state where the inside is evacuated to the inside of the valve is a state where the inside is evacuated or the atmosphere gas is filled. It is determined that there is airtightness in the step of enclosing an inspection gas suitable for the airtightness inspection of the sealing portion, the step of inspecting the airtightness of the sealing portion, and the airtightness inspection of the valve. A step of selecting the airtight valve, and a step of evacuating the inside of the airtight valve by connecting an exhaust means to an opening of the exhaust pipe formed on the opening end side of the airtight valve. And an incandescent lamp manufacturing method that has the same action as in the first aspect.
[0025]
Claim3According to the invention described in the above, the step of supplying only the airtight valve to the next step in a state where the inside is evacuated includes connecting an exhaust means to an opening of the exhaust pipe formed in the valve. A step of evacuating the interior, a step of inspecting the airtightness of the sealing portion formed in the valve, and an airtight valve determined to be airtight by the airtightness inspection among the valves The method for producing an incandescent lamp including the step of sorting the lamps has the same effect as that of the first aspect.
[0026]
  According to a fourth aspect of the invention, in the step of inspecting the airtightness of the sealing portion, after the inside of the valve is evacuated by the discarding means, the valve and the exhausting means are isolated, and the internal pressure of the valve is If the average value measured intermittently at least twice is less than or equal to the reference value set within the range of 0 to 760 Torr, it is determined that the gas has airtightness, and the average value exceeds the reference value. Even if it is, if it is less than the measurement average value of the bulb measured immediately before the bulb, it is a method for manufacturing an incandescent bulb, which is determined to have airtightness, and has the same effect as in claim 1. Have.
  Further, in the invention according to claim 5, the step of selecting the airtight valve leaves only the airtight valve in the conveying means, and removes other than the airtight valve from the conveying means. An incandescent lamp manufacturing method for selecting bulbs, which has the same effect as in the first aspect.
[0028]
  Claim6In the invention described in the above, after the sealed gas supply step temporarily stores the sealed gas supplied from a gas supply source provided in the sealed gas supply means in a gas storage container, Opening a valve provided in the middle of the first passage connecting the attachment portion to the opening and the gas storage container to seal the sealed gas inside the airtight valve, and storing the sealed gas Sometimes the gas pressure inside the storage gas container is detected, and based on the detection result, the flow rate adjusting means provided in the middle of the second passage connecting the gas supply source and the storage gas container is controlled to fill the gas The incandescent lamp manufacturing method is to adjust the sealed gas stored in the gas storage container to a predetermined gas pressure, and has the same operation as in claim 1.
[0030]
  Claim7The residual gas recovery step opens the valve in order to prevent gas other than the enclosed gas from entering the recovery passage when the closed portion of the exhaust pipe is not airtight. Then, the exhaust pipe is removed, the recovery passage downstream of the valve and the sealed gas mixed with gas other than the sealed gas remaining in the exhaust pipe are discarded, while the closed portion is airtight. In this case, the enclosed gas remaining in the exhaust pipe and the recovery passage is recovered by the intake means connected to the opening of the exhaust pipe with the mixing prevention valve opened, and the enclosed gas supply means This is a method for manufacturing an incandescent lamp that enables reuse in the same manner, and has the same effect as in the first aspect.
[0031]
  Claim8The invention described in the above is formed at the top of a bulb that is an envelope of an incandescent bulb that houses therein a mount member in which a pair of lead wires connected with filaments at the ends are supported by bead glass. Means for supplying only a gas-tight valve having a hermetic sealing portion in a state in which the inside is evacuated, and a sealed gas supply means for sealing a desired sealed gas at a predetermined gas pressure inside the gas-tight valve And sealing means for heating and melting and sealing a predetermined portion of the exhaust pipe formed on the opening end side of the airtight valve, and forming a completed incandescent bulb separated from the exhaust pipe, Product taking-out means for taking out the incandescent bulb, exhaust pipe airtight inspection means for inspecting the airtightness of the closed portion newly formed in the cut-off portion of the exhaust pipe left after the formation of the incandescent bulb, and other than the enclosed gas Gaseous Means for supplying only the gas-tight valve in a state where the inside is evacuated, comprising: a residual gas recovery means for recovering only the sealed gas remaining inside the exhaust pipe by preventing The gas supply means, the sealing means, the product take-out means, the exhaust pipe airtightness inspection means, and the residual gas recovery means are sequentially arranged on the same circumference and are airtightly connected to the opening of the exhaust pipe. A holding means for holding the valve in a state and moving the valve intermittently between the manufacturing steps, transferring the valve to the transferring means, a valve input means for putting the valve into the transferring means, and an exhaust from the transferring means. An incandescent lamp manufacturing apparatus comprising an exhaust pipe removing means for removing a pipe.7Suitable for the incandescent bulb manufacturing method described in any of the above, not only does the sealed gas leak from the sealing part at the top of the bulb, it also prevents the entry of defective products, but also the variation in the gas pressure enclosed in the bulb It can be made small, and it has the effect that the sealed gas remaining inside the exhaust pipe remaining after taking out the completed incandescent bulb can be recovered without mixing other gases such as air and used without waste. .
[0032]
  Claim9In the invention described in the above, the means for supplying only the airtight valve in an evacuated state inside is at least a valve airtight inspection means for inspecting the airtightness of the sealing portion of the valve; Among them, a valve selection means for selecting an airtight valve determined to be airtight in the airtightness inspection, and the inside of the valve is evacuated before and / or after the valve airtight inspection means and the valve selection means. An incandescent bulb manufacturing apparatus comprising exhaust means for performing8Has the same effect.
[0033]
  Claim10According to the invention, the means for supplying only the airtight valve in an evacuated state is an exhaust means for evacuating the inside of the valve, and an airtightness of the sealing portion formed at the top of the valve. An inspection gas supply means for enclosing a test gas suitable for inspecting the inside of the valve, the valve airtight inspection means, the valve selection means, and an exhaust means for evacuating the airtight valve. A device for producing an incandescent light bulb,8Has the same effect.
[0035]
  According to an eleventh aspect of the present invention, the means for supplying only the airtight valve in a state where the inside thereof is evacuated is an exhaust means for evacuating the inside of the valve, the valve airtight inspection means, and the valve selection. And an incandescent lamp manufacturing apparatus comprising:8Has the same effect.
[0036]
  According to a twelfth aspect of the present invention, the valve airtightness inspection means includes a valve internal pressure detection means for measuring the internal pressure of the valve, and a determination unit that determines the airtightness of the valve from the result measured by the valve internal pressure detection means. After the inside of the valve is evacuated by the exhaust means, the valve and the exhaust means are isolated, and the internal pressure of the valve is intermittently measured at least twice by the valve internal pressure detection means The average value is calculated and compared with a reference value set within a range of 0 to 760 Torr and compared with the determination unit, and the average value is determined to be airtight if the average value is equal to or less than the reference value. Even if the value exceeds the reference value, it is an incandescent lamp manufacturing apparatus that determines that it has airtightness if it is less than the measured average value of the valve measured immediately before the valve. , Claim8Has the same action as described in 1.
  AlsoThe invention according to claim 13 is an incandescent lamp in which the valve selecting means has a valve removing means for leaving only the airtight valve in the conveying means and removing other than the airtight valve from the conveying means. This is a light bulb manufacturing apparatus, and has the same operation as that of the eighth aspect.
[0038]
  Claim14In the invention described in the above, the sealed gas supply means has a gas storage container that temporarily stores the sealed gas fed from a gas supply source, and the attachment portion to the opening of the exhaust pipe and the Opening a valve provided in the middle of the first passage for joining the gas storage container and sealing the sealed gas temporarily stored in the gas storage container inside the airtight valve, the sealing A flow rate control unit for controlling the flow rate and shutting off the supply of the enclosed gas supplied from the gas supply source by the flow rate control unit based on the detection result of the internal pressure detection unit that detects the gas pressure inside the storage gas container during gas storage The incandescent heat is to seal the desired sealed gas at a predetermined gas pressure inside the airtight valve by controlling the sealed gas stored in the gas storage container to a predetermined gas pressure. A light bulb manufacturing device Item8Has the same effect.
[0039]
  Claim15According to the invention described in item 1, the sealed gas supply means has two or more gas supply sources, and only one gas supply source is selected by the supply gas switching means from among the gas supply sources. An incandescent bulb manufacturing apparatus in which, when the sealed gas is changed to a different gas in accordance with the operation of the switching means, sealed gas replacement means for preventing mixing of different sealed gases is connected to the gas storage container. And claims8Has the same effect.
[0041]
  Claim16The residual gas recovery means includes an intake means for sucking the sealed gas remaining in the exhaust pipe, and a valve for preventing gas other than the sealed gas from being mixed into the recovery passage. If the closed portion of the exhaust pipe is not airtight, the valve is closed to prevent the gas other than the enclosed gas from entering the recovery passage and the exhaust pipe is removed. And discarding the sealed gas mixed with a gas other than the sealed gas remaining in the recovery passage and the exhaust pipe downstream from the valve, and if the closed portion is airtight, With the intake means connected to the opening of the exhaust pipe in the opened state, the sealed gas remaining in the exhaust pipe and the recovery passage can be recovered and reused in the sealed gas supply means Incandescent bulb manufacturing equipment Yes claim8Has the same effect.
[0042]
  Claim17According to the invention described in the above, the glass tube is cut into a predetermined length, one end thereof is sealed to form the bulb, the valve forming means for forming the mount member, the mount member forming means for forming the mount member, and the mount member. A mounting member inserting means for charging from the opening end side of the valve and fixing or temporarily fixing the valve to a predetermined position inside the valve; and the mount member formed by the mounting member inserting means is internally provided. An incandescent light bulb manufacturing apparatus in which the bulb is sequentially conveyed to the bulb introduction means.8Has the same effect.
[0043]
(Example)
Embodiments of the present invention will be described below with reference to the drawings.
[0044]
FIG. 1 is a schematic view showing an embodiment of an incandescent lamp manufacturing apparatus according to the present invention. In the figure, components having the same reference numerals as those in FIG. 11 indicate the same functional components.
[0045]
The incandescent lamp manufacturing apparatus 17 includes a valve forming means 2, a mount member forming means 3, and a mount member inserting means 4 as in the conventional apparatus, and a valve having a mount member 102 formed by the mount member forming means. 101 is attached to the head 7 which is an attachment portion provided in the rotating machine 18 ′ which is the conveying means of the valve 101 by the valve insertion means 5.
[0046]
As shown in FIG. 2, the center valve 18 includes a fixed-side center valve 18a and a rotating-side center valve 18b that is installed concentrically with high-viscosity oil and rotates intermittently. A plurality of heads 7 are arranged on the upper portion of the rotating machine 18 'at substantially equal intervals, and the valves 101 are held in an airtight connection with each head 7, and the rotating machine 18' is connected to the rotation-side center valve 18b. Rotate synchronously.
[0047]
Further, the fixed-side center valve 18a is provided with exhaust means 8a, inspection gas supply means 24, and valve airtight inspection that constitute the incandescent bulb manufacturing process at positions corresponding to the connecting portions of the rotation-side center valve 18b with each head 7. Means 19, valve selection means 20, exhaust means 8 b, sealed gas supply means 21, sealing means 10, product take-out means 11, exhaust pipe airtightness check means 22, and residual gas recovery means 23 are arranged in the order of processes, and the head 7 The valve 101 is connected in an airtight manner.
[0048]
The valve 101 attached to the head 7 by the valve insertion means 5 and having the mount member 102 built therein is arranged in each manufacturing process of the fixed-side center valve 18a described above with the intermittent rotation of the rotation-side center valve 18b. Are sequentially connected.
[0049]
Hereinafter, the operation of the incandescent lamp manufacturing apparatus 17 having the above-described structure shown in FIG.
[0050]
First, the valve 101 introduced into the head 7 of the rotating machine 18 ′ by the valve introduction means 5 is held by the head 7 through the opening 103a of the exhaust pipe 103 formed on the opening end side thereof, and is exhausted in the same manner as in the prior art. The inside is evacuated by an evacuation means 8 a such as a vacuum pump coupled to the fixed center valve 18 a at the position of the process, and is transported to a process of enclosing a test gas and connected to the test gas supply means 24.
[0051]
As shown in FIG. 2, the valve 101 communicating with the inspection gas supply means 24 disposed in the fixed-side center valve 18a encloses a test gas (including air) suitable for airtightness inspection of the sealing portion for a certain period of time. After that, it is transported to the step of inspecting the airtightness of the sealing portion of the valve and the step of selecting the airtight valve, and the valve 101 and the inspection gas supply means 24 are in an isolated state. At this time, as shown in FIG. 3, the valve 101 is connected to the valve airtight inspection means 19 to check the airtightness of the sealing portion formed on the top 101 a of the valve 101.
[0052]
In the valve airtight inspection and valve selection processes, as shown in FIG. 4, the first result of intermittently measuring the internal pressure of the valve 101 of FIG. Assuming that the result is P2, the determination unit 27 calculates an average value Pav of P1 and P2 and compares it with a reference value P0 (760 Torr ≦ P0 ≦ 1300 Torr). 101 is conveyed as it is to the next position (exhaust process) by the intermittent rotation of the rotating machine 18 '.
[0053]
On the other hand, if P0> Pav, the determination unit 27 determines that the determination is rejected, and the valve 28 of the valve selection unit 20 controlled by the determination unit 27 is closed and the valve 101 is removed by a valve removal unit (not shown).
[0054]
Note that the pass / fail judgment criterion is that if the valve inspected immediately before is not airtight, the internal pressure of the passage etc. at the start of the inspection is much lower than normal, so the inspection gas supply means Even after the test gas is supplied into the valve 101 for a certain time from 24, the internal pressure may not be sufficiently increased. Considering such a case, even if P0> Pav, it may be acceptable if P′av <Pav with respect to the measurement average value P′av of the valve inspected immediately before.
[0055]
The inspection gas supply means 24 is an inspection gas suitable for confirming the airtightness of the sealing portion formed on the top 101a of the valve 101, such as a gas cylinder filled with an inspection gas or a compressor for supplying compressed air. A source of gas (including air).
[0056]
The valve 101 having airtightness determined to be acceptable by the valve airtight inspection means 19 is transported to a position where the next step is arranged by intermittent rotation of the rotating machine 18 ', and the exhaust means 8b as in the prior art. Connected and evacuated.
[0057]
Then, it is transported to a position connected to the sealed gas supply means 21 shown in FIG. 1, and a desired sealed gas, for example, a rare gas such as argon is sealed at a predetermined gas pressure.
[0058]
In the sealed gas supply means 21, the sealed gas fed from the gas cylinder 29, which is a gas supply source, is temporarily stored in the gas storage container 30 and then in the middle of the first passage 31 connected to the center valve 18. The provided valve 32 is opened and supplied to the airtight valve 101.
[0059]
And the gas pressure detected by the pressure sensor 33 which is an internal pressure detection means provided in order to detect the gas pressure in the gas storage container 30 is input into the flow control part 35 as an electrical signal.
[0060]
An enclosed gas flow rate adjusting means 34 is provided in the middle of the second passage 40 connecting the gas storage container 30 and the gas cylinder 29, and is controlled by a signal output from the flow rate control unit 35. The flow rate of the sealed gas flowing into 30 is adjusted and cut off, and the sealed gas is stored in the gas storage container 30 at a predetermined gas pressure.
[0061]
In this way, once the sealed gas stored at a predetermined pressure is fed to the airtight valve 101, the gas pressure of the sealed gas sealed in the airtight valve 101 is always accurately adjusted within a predetermined range. Can be pressed.
[0062]
Thereafter, similar to the conventional manufacturing method, a step of melting and sealing a predetermined portion of the exhaust pipe 103 formed in the airtight valve 101, and the incandescent lamp 100 completed by being separated from the exhaust pipe 103 at this time, are performed. After being taken out by the product take-out means, it is transported to a position where it is connected to the exhaust pipe airtightness check means 22.
[0063]
In the exhaust pipe airtight inspection means 22, when the completed incandescent lamp 100 is cut off while being melt-sealed, the airtightness of the closing portion 103 b formed at the tip of the exhaust pipe 103 is confirmed.
[0064]
As shown in FIG. 5, the first and second measurement results obtained by measuring the internal pressure of the exhaust pipe in FIG. 6 intermittently with the pressure sensor 47, which is the exhaust pipe internal pressure detection means, are shown in FIG. 5. Is determined as p2, and the determination unit 48 calculates the average value pav of p1 and p2 and compares it with the reference value p0 (0 Torr ≦ p0 ≦ 760 Torr). If p0 ≧ pav, the determination unit 48 determines that the airtightness is present. Then, the exhaust pipe 103 attached to the head 7 is conveyed to the next position (residual gas recovery step) as it is by intermittent rotation of the rotating machine 18 '.
[0065]
On the other hand, if p0 <pav, the determination unit 48 determines that there is no airtightness, the valve 50 controlled by the determination unit 48 is closed, and the exhaust pipe 103 is removed by an exhaust pipe removing means (not shown). Then, the sealed gas mixed with other gases is discarded.
[0066]
Next, the exhaust pipe 103 transported to the position where it is connected to the residual gas recovery means 23 has an airtight property because the closed portion 103b formed at the tip of the exhaust pipe 103 shown in FIG. The filled gas remaining in the pipe 103 and the collection passages 36 and 37 is collected by the intake means 38.
[0067]
As shown in FIG. 1, the residual gas collected by the intake means 38 is stored in a tank 49 provided in the sealed gas supply means 21 and is sequentially fed to the airtight valve 101 together with the gas cylinder 29 as a gas supply source. The
[0068]
Alternatively, the recovered residual gas may be stored in an independent tank (not shown) and used as a gas supply source of the sealed gas supply means 21 when the tank is filled with a certain amount of residual gas. In this way, the sealed gas remaining without being sealed in the completed incandescent bulb 100 and not mixed with other gases can be recovered and reused without waste.
[0069]
Finally, the exhaust pipe 103 remaining in the head 7 is transported to a position where it is connected to the exhaust pipe removing means 16 and removed from the head 7 in the same manner as in the conventional manufacturing method, and the head 7 is further transported and again is the valve input means 5. And the incandescent lamp 100 is manufactured repeatedly.
[0070]
FIG. 8 shows another embodiment of the sealed gas supply means 21. The gas cylinder group 46 includes a plurality of (for example, two) gas cylinders 29a and 29b, which are gas supply sources, and a switching means 41, and any one of the gas cylinder groups 46 can be operated by operating the switching means 41 provided at the connection portion with the second passage 40. It is also possible to select so that only one gas cylinder is connected to the gas storage container 30.
[0071]
If the gas filled in each gas cylinder 29a, 29b is of the same type, the gas cylinder not connected to the gas storage container 30 becomes a spare, and the work stop time required for cylinder replacement can be shortened to improve the work efficiency.
[0072]
On the other hand, if different gases are filled in the gas cylinders 29a and 29b, the sealed gas sealed in the airtight valve 101 can be changed only by operating the switching means 41.
[0073]
At this time, the sealed gas replacement device 39 is provided to be connected to the gas storage container 30, and the phase in the gas storage container 30, the first passage 31, and the second passage 40 is changed when the sealed gas is changed by the operation of the switching means 41. It is desirable to prevent mixing of different encapsulated gases.
[0074]
The sealed gas replacement device 39 includes an exhaust means 42 such as a vacuum pump communicating with the gas storage container 30, and a valve 43 for isolating the gas storage container 30 and the exhaust means 42 other than during the gas replacement operation. It may be provided.
[0075]
Although FIG. 8 shows an example in which two gas cylinders are arranged in the gas cylinder group 46, the same applies to the case where the gas cylinder group 46 includes three or more gas cylinders.
[0076]
As shown in FIG. 8, the tank 49 filled with the sealed gas recovered by the residual gas recovery means 23 is arranged independently of the gas cylinders 29 a and 29 b and feeds the sealed gas from the tank 49 with priority. Alternatively, the gas cylinders 29a and 29b may be arranged in parallel so as to be selected by the operation of the switching means 41.
[0077]
The flow rate adjusting means 34 may be a gas pressure regulator capable of both adjusting and shutting off the flow rate of the enclosed gas supplied from the gas supply source as in the example of FIG. 1, but as in the example of FIG. In addition, the gas pressure regulator 44 and the on-off valve 45 that perform only the flow rate adjustment may be operated independently of the flow rate adjustment and the shutoff.
[0078]
Further, in the above-described example, the process of supplying only the airtight valve 101 to the sealed gas supply process with the inside being evacuated is the exhaust means 8a disposed in the fixed-side center valve 18a in FIG. The supply means 24, the valve airtight inspection means 19, the valve selection means 20, and the exhaust means 8b are connected in sequence, and all of them are operated. As shown in FIG. Gas is sealed at a predetermined gas pressure set at 760 to 1300 Torr, and only the valve 101 determined to have airtightness is exhausted again and transferred to the sealed gas supply process.
[0079]
However, when the inspection gas for inspecting the airtightness of the valve 101 is the same (for example, air) as the atmosphere gas originally filled in the valve 101, or even when the inspection gas to be sealed and the atmosphere gas are mixed. If there is no hindrance, the first exhaust means 8a may be suspended or omitted as shown in FIG.
[0080]
In both cases shown in FIGS. 9A and 9B, the valve 101 is transported with the intermittent rotation of the rotating machine 18 ′, so that the valve 101 is isolated from the inspection gas supply means 24. The inspection gas supply means 24 is arranged at the same position as the valve airtight inspection and valve selection processes, and the valve 101 and the inspection gas supply means 24 can be communicated and isolated with a valve (not shown), so that the sealing portion is airtight. You may make it confirm.
[0081]
FIG. 10 shows another embodiment of the valve airtight inspection means 19 and the valve selection means 20. As shown in FIG. 9 (c), the inspection gas supply means 24 and the exhaust means 8b shown in FIG. 1 are suspended or omitted. The state is maintained, and the process is carried out to the step of inspecting the airtightness of the sealing portion of the valve and the step of selecting the airtight valve so as to isolate the valve 101 and the exhaust means 8a. At this time, as shown in FIG. 3, the valve 101 is connected to the valve airtight inspection means 19 to check the airtightness of the sealing portion formed on the top 101 a of the valve 101.
[0082]
Alternatively, the exhaust means 8a is arranged at the same position as the valve airtight inspection and valve selection processes, and the valve 101 and the exhaust means 8a can be communicated and disconnected with a valve (not shown) to check the airtightness of the sealing portion. You may do it.
[0083]
In the valve airtight inspection and valve selection processes, as shown in FIG. 10, the first result of intermittently measuring the internal pressure of the valve 101 of FIG. Assuming that the result is P2, the determination unit 27 calculates an average value Pav of P1 and P2 and compares it with a reference value P00 (0 Torr ≦ P00 ≦ 760 Torr). 101 is conveyed as it is to the next position (exhaust process) by the intermittent rotation of the rotating machine 18 '.
[0084]
On the other hand, if P00 <Pav, the determination unit 27 determines that the determination is unsuccessful, and the valve 28 of the valve selection unit 20 controlled by the determination unit 27 is closed and the valve 101 is removed by a valve removal unit (not shown).
[0085]
Note that the pass / fail judgment criterion is that if the valve inspected immediately before is not airtight, the internal pressure of the passage and the like at the start of the inspection is much higher than normal, so the valve 101 for a certain period of time. Even after exhausting the inside, the internal pressure may not be sufficiently reduced. Considering such a case, even if P00 <Pav, if P′av> Pav with respect to the measurement average value P′av of the valve inspected immediately before, it may be acceptable.
[0086]
The bulb forming means 2, the mount member forming means 3 and the mount member inserting means 4 described above are incorporated as a component of the incandescent lamp manufacturing apparatus 17 in a series of incandescent lamp manufacturing processes, and the mount member inserting means 4, the valve 101 that houses the mount member 102 may be sequentially transferred to the valve insertion means 5 and introduced into the head 7 disposed in the rotating machine 18 ′, or the valve formation means 2 and the mount The member forming means 3 and the mount member inserting means 4 are provided independently of the incandescent bulb manufacturing apparatus 17, the bulb 101 in which the mount member 102 is installed is manufactured in advance, and the stock is used as the incandescent lamp manufacturing apparatus. You may make it supply to the valve injection | throwing-in means 5 which is 17 components.
[0087]
【The invention's effect】
As described above, the method of manufacturing an incandescent lamp according to the present invention includes a step of eliminating a valve with an incomplete hermeticity of a sealing portion formed on the top of a glass bulb, and a sealed gas once in a gas storage container. A process of storing in a bulb after storing at a predetermined gas pressure, and a process of collecting the remaining sealed gas after confirming the airtightness of the closed portion of the exhaust pipe remaining in the head after the incandescent bulb is completed. As a result, not only was it possible to prevent the introduction of defective products from which the sealed gas leaked out from the sealing part at the top of the valve, but also the variation in the gas pressure sealed in the valve could be set to be extremely small, which was completed. After taking out the incandescent light bulb, the sealed gas remaining inside the exhaust pipe can be recovered without mixing other gases such as air.
[0088]
Further, the incandescent lamp manufacturing apparatus according to the present invention includes a valve airtight inspection means for inspecting the airtightness of the sealing portion formed at the top of the valve, and a valve selection means for eliminating a valve with an incomplete airtightness of the sealing portion. And a sealed gas supply means for sealing the sealed gas in a gas storage container at a predetermined gas pressure and then sealing the valve; Inspection means and residual gas recovery means for recovering the sealed gas remaining in the exhaust pipe and the passage without mixing with other gases. As a result, the sealed gas is not leaked from the sealing part at the top of the valve. In addition to preventing contamination of non-defective products, it is possible to manufacture an incandescent bulb with extremely small variation in gas pressure enclosed in the bulb, and the enclosed gas remaining in the exhaust pipe remaining after the completed incandescent bulb is taken out. By recovering, it has an effect which can be utilized without waste noble gas.
[Brief description of the drawings]
FIG. 1 is a schematic view showing an embodiment of an incandescent lamp manufacturing apparatus according to the present invention.
FIG. 2 is an enlarged view of the inspection gas supply means.
FIG. 3 is an enlarged view of valve airtightness inspection means.
4 is a flowchart showing the operation of the valve airtightness checking means of FIG.
FIG. 5 is a flowchart showing the operation of the exhaust pipe airtightness checking means.
FIG. 6 is an enlarged view of exhaust pipe airtightness inspection means.
FIG. 7 is an enlarged view of the residual gas recovery means.
FIG. 8 is a schematic view showing another embodiment of the sealed gas supply means.
FIG. 9 is an explanatory diagram showing the order of valve airtightness inspection means and exhaust processes;
FIG. 10 is a flowchart showing the operation of another embodiment of the valve airtightness checking means.
FIG. 11 is a schematic view showing a conventional incandescent bulb manufacturing apparatus.
FIG. 12 is an enlarged view of exhaust means.
FIG. 13 is an enlarged view of a valve having a mounting member built therein.
[Explanation of symbols]
2 Valve forming means
3 Mount member forming means
4 Mount member charging means
5 Valve input means
7 heads
8, 8a, 8b Exhaust means
10 Sealing means
11 Product removal means
16 Exhaust pipe removal means
17 Incandescent bulb manufacturing equipment
18 Center valve
18 'rotating machine
18a Center valve on the fixed side
18b Center valve on the rotation side
19 Valve airtightness check means
20 Valve sorting means
21 Filled gas supply means
22 Exhaust pipe airtightness inspection means
23 Residual gas recovery means
24 Inspection gas supply means
26 Pressure sensor (valve internal pressure detection means)
27, 48 judgment part
28, 32 valves
29, 29a, 29b Gas cylinder (gas supply source)
30 Gas storage container
31 1st passage
33 Pressure sensor (internal pressure detection means)
34 Flow rate adjusting means
35 Flow controller
36, 37 Collection passage
38 Air intake means
39 Filled gas replacement device
40 Second passage
41 Switching means
46 Gas cylinders
47 Pressure sensor (exhaust pipe internal pressure detection means)
49 Tank (Gas supply source)
50 valves
100 Incandescent light bulb
101 Valve
101a top
102 Mount member
103 exhaust pipe
103a opening
103b Blocking part

Claims

A step of forming a bulb, which is an envelope of an incandescent bulb formed by sealing one end of a glass tube into a shape having a sealing portion at the top, and a pair of lead wires connected with a filament at the end are bead glass A step of forming a mount member that is supported; a step of inserting the mount member into the valve and fixing or temporarily fixing the mount member at a predetermined position; and an airtight property in which the sealing portion of the valve has airtightness. Supplying only the valve to the next process in a state where the inside is evacuated; and connecting the opening of the exhaust pipe formed on the opening end side of the valve to an enclosed gas supply means to connect the inside of the airtight valve A sealed gas supply step of sealing a desired sealed gas at a predetermined gas pressure, and heating and sealing a predetermined portion of the exhaust pipe, and forming a completed incandescent bulb separated from the exhaust pipe; The incandescent bulb A step of inspecting the airtightness of the newly formed closed portion in the cut-off portion of the exhaust pipe remaining after the formation of the incandescent bulb, and the introduction of the exhaust gas by preventing the mixture of gases other than the enclosed gas A method of manufacturing an incandescent lamp, comprising: a residual gas recovery step of recovering only the sealed gas remaining inside the tube.

The step of supplying only the airtight valve to the next step with the inside being evacuated is an inspection of the airtightness of the sealing portion in the state where the inside is evacuated or filled with atmospheric gas. A step of enclosing a gas suitable for inspection, a step of inspecting the airtightness of the sealing portion, and selecting the airtight valve determined to be airtight by the airtightness inspection among the valves 2. The method of claim 1, further comprising a step of connecting an exhaust means to an opening of the exhaust pipe formed on an opening end side of the airtight valve to evacuate the inside of the airtight valve. Incandescent bulb manufacturing method.

The step of supplying only the airtight valve to the next step in a state where the inside is evacuated is a step of evacuating the inside of the valve by connecting an opening exhaust means of the exhaust pipe formed in the valve. And a step of inspecting the airtightness of the sealing portion formed in the valve, and a step of selecting an airtight valve determined to be airtight by the airtightness inspection among the valves. The incandescent lamp manufacturing method according to claim 1, comprising:

The step of inspecting the hermeticity of the sealing portion is an average obtained by isolating the valve from the exhaust unit after the inside of the valve is evacuated by the exhaust unit, and intermittently measuring the internal pressure of the valve twice If the value is less than or equal to the reference value set in the range of 0 to 760 Torr, it is determined that the container has airtightness. Even if the average value exceeds the reference value, it is measured immediately before the valve. The incandescent lamp manufacturing method according to claim 3, wherein if it is less than the measured average value of the bulb, it is determined that the valve has airtightness.

The step of selecting the airtight valve leaves only the airtight valve in the transfer means, and removes the valve other than the airtight valve from the transfer means, thereby selecting the valve. An incandescent lamp manufacturing method according to any one of claims 2 to 4.

After the sealed gas supply step temporarily stores the sealed gas fed from a gas supply source provided in the sealed gas supply means in a gas storage container, the mounting portion to the opening of the exhaust pipe A valve provided in the middle of the first passage connecting the gas storage container and the gas-tight valve to enclose the sealed gas inside the gas-tight container, Based on the detection result, the flow rate adjusting means provided in the second passage connecting the gas supply source and the gas storage container is controlled to control the flow rate of the sealed gas and shut off the supply. The incandescent lamp manufacturing method according to any one of claims 1 to 4, wherein the sealed gas stored in the gas storage container is adjusted to a predetermined gas pressure.

In the residual gas recovery step, when the closed portion of the exhaust pipe is not airtight, a valve is opened to prevent the gas other than the enclosed gas from entering the recovery passage, and the exhaust pipe is opened. Removing and discarding the sealed gas already mixed with gas other than the sealed gas remaining in the exhaust passage and the recovery passage downstream of the valve, and if the closed portion is airtight, With the intake means connected to the opening of the exhaust pipe with the prevention valve opened, the sealed gas remaining in the exhaust pipe and the recovery passage is recovered and reused in the sealed gas supply means The method for manufacturing an incandescent lamp according to any one of claims 1 to 6.

Among the bulbs that are envelopes of incandescent bulbs that house a mounting member in which a pair of lead wires connected with filaments at the ends are supported by bead glass, the sealing portion formed at the top of the bulb is airtight Means for supplying only a gas-tight valve having a characteristic in a state where the inside is evacuated, a gas supply means for sealing a desired gas to be filled in the gas-tight valve at a predetermined gas pressure, and the gas-tight valve A sealing means for heating and sealing a predetermined portion of the exhaust pipe formed on the opening end side of the bulb, forming a completed incandescent bulb separated from the exhaust pipe, and a product for taking out the incandescent bulb Taking out means, exhaust pipe airtight inspection means for inspecting the airtightness of the closed part newly formed in the cut-off part of the previous exhaust pipe left after the formation of the incandescent bulb, and prevention of mixing of gases other than the enclosed gas Before A residual gas recovery means for recovering only the sealed gas remaining inside the exhaust pipe, and supplying only the airtight valve in a state where the inside is evacuated, the sealed gas supply means, the sealed gas The stop means, the product take-out means, the exhaust pipe airtight inspection means, and the residual gas recovery means are sequentially arranged on the same circumference, and the valve is held in an airtight connection with the opening of the exhaust pipe. And a conveying means that moves completely between the manufacturing steps to convey the valve, a valve input means that introduces the valve into the conveying means, and an exhaust pipe that removes the exhaust pipe from the conveying means An incandescent bulb manufacturing apparatus comprising a removing means.

The means for supplying only the airtight valve with its inside being evacuated is at least valve airtight inspection means for inspecting the airtightness of the sealing portion of the valve, and the airtightness inspection of the valve And a valve selection means for selecting an airtight valve determined to be airtight, and an exhaust means for evacuating the valve before or after the valve airtight inspection means and the valve selection means. The incandescent lamp manufacturing apparatus according to claim 8.

The means for supplying only the airtight valve with its inside being evacuated is used to inspect the airtightness of the exhaust means for evacuating the inside of the valve and the sealing portion formed at the top of the valve. 10. The apparatus according to claim 9, further comprising inspection gas supply means for enclosing a suitable inspection gas in the valve, the valve airtight inspection means, the valve sorting means, and an exhaust means for evacuating the airtight valve. The incandescent lamp manufacturing apparatus described.

The tightness of the valve only the means for supplying in a state in which inside is evacuated is, an exhaust means for evacuating the inside of said valve, said valve leak test unit, to the claim 9 is intended to include a valve sorting means The incandescent bulb manufacturing apparatus described.

The valve airtight inspection means includes a valve internal pressure detection means for measuring the internal pressure of the valve, and a determination unit for determining the airtightness of the valve from the result measured by the valve internal pressure detection means, Is evacuated by the evacuation unit, the valve and the evacuation unit are isolated, and an average value of results obtained by intermittently measuring the internal pressure of the valve at least twice by the valve internal pressure detection unit is calculated. When the average value is equal to or less than the reference value by comparing the reference value set within the range of 760 Torr with the determination unit, it is determined that there is airtightness, and the average value exceeds the reference value. The incandescent lamp manufacturing apparatus according to claim 9 or 11, wherein even if it is less than the measured average value of the bulb measured immediately before the bulb, it is determined that the bulb has airtightness.

Previous SL valve selecting means, only said air-tightness of the valve and has a valve removing means for removing from said conveyor means, the manufacturing apparatus of the light source device according to any one of claims 8 to 12

The sealed gas supply means has a gas storage container for temporarily storing the sealed gas fed from a gas supply source, and connects the attachment portion to the opening of the exhaust pipe and the gas storage container. The valve provided in the middle of the first passage to be combined is opened and the sealed gas temporarily stored in the gas storage container is sealed inside the airtight valve. Based on the detection result of the internal pressure detection means for detecting the gas pressure inside the container, the flow rate control unit controls the operation of the flow rate adjustment means for performing flow rate adjustment and supply cutoff of the enclosed gas supplied from the gas supply source, The desired sealed gas is sealed at a predetermined gas pressure inside the airtight valve by adjusting the sealed gas stored in the gas storage container to a predetermined gas pressure. Incandescent light bulb Manufacturing equipment.

The sealed gas supply means has two or more gas supply sources, from which only one gas supply source is selected by the supply gas switching means, and the operation of the supply gas switching means is performed. The incandescent lamp manufacturing method according to claim 14, wherein, when the enclosed gas is changed to a different gas, enclosed gas replacement means for preventing mixing of different enclosed gases is provided connected to the gas storage container. apparatus.

The residual gas recovery means includes an intake means for sucking the sealed gas remaining in the pipe, and a valve for preventing a gas other than the sealed gas from entering the recovery passage. When the closed portion of the pipe is not airtight, the exhaust valve is removed by closing the valve in order to prevent gas other than the enclosed gas from being mixed into the recovery passage, and downstream of the valve. When the sealed gas that is already mixed with gas other than the sealed gas remaining in the recovery passage and the exhaust pipe is discarded, and the closed portion is airtight, the exhaust gas is opened with the valve opened. 9. The intake means connected to the opening of the pipe recovers the sealed gas remaining in the exhaust pipe and the recovery passage, and enables reuse in the sealed gas supply means. Or white according to any one of 15 Light bulb manufacturing equipment.

A glass tube is cut into a predetermined length, one end of which is sealed to form the bulb, a valve forming means for forming the mount member, a mount member forming means for forming the mount member, and the mount member on the opening end side of the bulb Mounting member insertion means for inserting, fixing or temporarily fixing to a predetermined position inside the valve, and the valves containing the mount member formed by the mounting member insertion means are sequentially inserted into the valve The incandescent lamp manufacturing apparatus according to any one of claims 8 to 16, wherein the incandescent lamp manufacturing apparatus is conveyed to a means.