Linear LED light source and manufacturing method

Abstract

The present invention relates to a method for manufacturing a linear LED light source, comprising: providing a tubular glass envelope that is open at its proximal end and its distal end; inserting a light source mount assembly comprising one or more LED units into the tubular glass envelope; forming a distal hermetic seal at the distal end such that a distal opening remains at the distal end; forming a proximal hermetic seal at the proximal end such that a proximal opening remains at the proximal end; filling the tubular glass envelope with a gas filling; and sealing the distal and proximal openings to obtain a sealed lamp envelope; wherein a flow of coolant gas through the tubular glass envelope is maintained during the formation of the proximal hermetic seal and/or distal hermetic seal if the light source mount assembly is inserted before the formation of the respective hermetic seal.

Claims

1. A method for manufacturing a linear LED light source, comprising: providing a tubular glass envelope that is open at its proximal end and its distal end; inserting a light source mount assembly comprising one or more LED units into the tubular glass envelope; forming a distal hermetic seal at the distal end such that a distal opening remains at the distal end; forming a proximal hermetic seal at the proximal end such that a proximal opening remains at the proximal end; maintaining a flow of coolant gas through the tubular glass envelope during the formation of one or both of the hermetic seals, wherein the insertion of the light source mount assembly is performed before the formation of said one or both hermetic seals; filling the tubular glass envelope with a gas filling; and sealing the distal and proximal openings to obtain a sealed lamp envelope.

2. The method according to claim 1, wherein the diameter of the distal opening, the proximal opening, or both openings has a smaller diameter than the diameter of the tubular glass envelope.

3. The method according to claim 1, wherein the forming of the distal hermetic seal comprises the steps of: inserting a second glass tube into the distal end such that an end of the second glass tube protrudes beyond the distal end to the outside of the tubular glass envelope; and forming the distal hermetic seal at the junction of the tubular glass envelope and the second glass tube by heating the distal end in order to collapse the distal end around the second glass tube.

4. The method according to claim 1, wherein the forming of the proximal hermetic seal comprises the steps of: inserting a third glass tube into the proximal end such that an end of the third glass tube protrudes beyond the proximal end to the outside of the tubular glass envelope; and forming the proximal hermetic seal at the junction of the tubular glass envelope and the third glass tube by heating the proximal end in order to collapse the proximal end around the third glass tube.

5. The method according to claim 1, wherein the light source mount assembly is provided with at least one electrical feedthrough component connected thereto, wherein the electrical feedthrough component is arranged to protrude beyond the proximal end to the outside of the tubular glass envelope when the light source mount assembly is inserted into the tubular glass envelope, and wherein, in the forming of the proximal hermetic seal, the proximal end is heated such that the proximal end collapses around the electrical feedthrough component to form a hermetic seal around the electrical feedthrough component.

6. The method according to claim 1, further comprising, before inserting the light source mount assembly into the tubular glass envelope: providing a stem assembly with an integral gas flow tube through which gas can flow, which stem assembly is hermetically sealed to an electrical feedthrough component; and connecting the electrical feedthrough component to the light source mount assembly; wherein, when inserting the light source mount assembly into the tubular glass envelope, the stem assembly is partially inserted into the tubular glass envelope, with the integral gas flow tube protruding beyond the proximal end, and wherein the forming of the proximal hermetic seal is performed at the junction of the tubular glass envelope and the stem assembly by heating the proximal end in order to collapse the proximal end around the stem assembly.

7. The method according to claim 5, wherein the electrical feedthrough component comprises a controlled expansion alloy.

8. The method according to claim 1, comprising the step of applying bases at the distal end, the proximal end, or both ends of the sealed lamp envelope.

9. The method according to claim 1, wherein the distal hermetic seal is formed before the light source mount assembly is inserted into the tubular glass envelope.

10. The method according to claim 9, wherein the flow of coolant gas is introduced through the third glass tube before forming the proximal hermetic seal and maintained throughout the formation of the proximal hermetic seal.

11. The method according to claim 1, wherein the sealing of the first opening, the sealing of the second opening, or the sealing of both openings comprises fusing and removing the protruding ends of the second glass tube, the third glass tube, or both the second and third glass tubes.

12. The method according to claim 1, wherein the flow of coolant gas comprises nitrogen or argon or a mixture thereof.

13. The method according to claim 1, wherein the gas filling comprises hydrogen or helium or a mixture thereof.

14. The method according to claim 1, wherein at least one LED unit is constituted by a LED filament.

15. The method according to claim 1, wherein the distance between the proximal end of the sealed lamp envelope and the nearest LED unit is smaller than four times the diameter of the sealed lamp envelope, and/or wherein the distance between the distal end of the sealed lamp envelope and the nearest LED unit is smaller than four times the diameter of the sealed lamp envelope.

16. A linear LED light source, made by the method according to claim 1, comprising: the sealed lamp envelope having a cylindrical shape having a diameter; and the light source mount assembly with the one or more LED units arranged inside the sealed lamp envelope; wherein the distance between the LED unit and one or both of the distal end and proximal end is smaller than four times the diameter of the sealed lamp envelope.

17. The linear LED light source according to claim 16, wherein the LED units are sequentially arranged along the longitudinal axis of the sealed lamp envelope.

18. The linear LED light source according to claim 16, wherein at least one of the LED units include a LED filament.

19. The linear LED light source according to claim 16, wherein the light source mount assembly comprises support frames to which the LED units are mounted, and that are configured to conduct electric power for driving the LED units.

20. The linear LED light source according to claim 19, wherein the light source mount assembly comprises buffer springs that are configured to support the support frames against an inner wall of the sealed lamp envelope.

21. The linear LED light source according to claim 19, wherein: the support frames are metallic; and the light source mount assembly comprises isolating bridges that are provided between the support frames and are configured to maintain a fixed relative position between the support frames.

22. The method according to claim 1, wherein the maintained flow of coolant gas is introduced via one of the openings and exits the other of the openings.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) The above and further features and advantages of the invention will become more readily apparent from the following detailed description of preferred embodiments of the invention with reference to the accompanying drawings, in which like reference signs designate like features, and in which:

(2) FIG. 1 shows a schematic view of a linear LED light source according to an embodiment of the present invention;

(3) FIG. 2 is a schematic view of the linear LED light source of FIG. 1 in which relevant dimensional parameters are specified;

(4) FIG. 3a-3g illustrate a method for manufacturing a linear LED light source according to an embodiment of the present invention;

(5) FIG. 4a-4h illustrate a modified method for manufacturing a linear LED light source according to an embodiment of the present invention;

(6) FIG. 5a-5h illustrate another modified method for manufacturing a linear LED light source according to an embodiment of the present invention.

DETAILED DESCRIPTION

(7) FIG. 1 is a schematic view of a linear LED light source according to an embodiment of the present invention. The linear LED light source comprises a sealed lamp envelope 11 of essentially cylindrical shape that is translucent and made of glass. A light source mount assembly 10 is arranged inside the sealed lamp envelope 11. In the present embodiment, the light source assembly 10 comprises multiple LED units 12 mounted to metallic support frames 13a, 13b optionally via metallic spacer components 14, isolating bridges 15 and buffer springs 16.

(8) The light source assembly 10 is connected to an electrical feedthrough component 17. Specifically, the metallic support frames 13a, 13b are conductively connected, e.g. welded or soldered to the electrical feedthrough component 17.

(9) The LED units 12 of the present embodiment are constituted by LED filaments. The LED units 12 are sequentially aligned along the longitudinal axis of the sealed lamp envelope 11 and disposed essentially along the entire length of the sealed lamp envelope 11.

(10) The metallic support frames 13a, 13b which carry the LED units 12 are supported against the inner wall of the sealed lamp envelope 11 by buffer springs 16 which serve to maintain the LED units 12 and the support structure of the support frames 13a, 13b along the axis of the sealed lamp envelope 11. They also serve to prevent physical damage by absorbing mechanical shocks that may be experienced during handling and transportation of the linear LED light source.

(11) The optional metallic spacer components 14 may serve to orientate the LED units 12 in a particular mechanical configuration—in the present embodiment, in a linear configuration extending over the most part of the length of the sealed glass envelope 11. However it will be appreciated that many different mechanical configurations of the LED units 12 are possible, which may or may not require the utilisation of metallic spacer components 14. In order to further stabilise the assembly of the LED units 12 and metallic spacer components 14, electrically isolating bridges 15 are provided near the respective ends of the sealed lamp envelope 11 to maintain a fixed relative position between the metallic support frames 13a, 13b, and may also optionally be provided at intermediate locations.

(12) The isolating bridges 15 may be formed, for instance, from a dielectric material such as glass or ceramic bearing electrically isolated metallic wires for convenient welding to the support frames 13a 13b. The buffer springs 16 may be combined into the same physical assembly as the isolating bridges 15, as can be seen at the right end of the sealed lamp envelope 11.

(13) The sealed lamp envelope 11 is filled with a gas filling 18 that is preferably a gas of low atomic weight like hydrogen, helium or a mixture thereof.

(14) The sealed lamp envelope 11 may optionally be capped by bases 19 at one or both ends. The left base 19 is equipped with electrical contacts 17a that are connected to the electrical feedthrough components 17. The bases 19 are attached to the sealed lamp envelope 11 by an adhesive 19a. Although FIG. 1 depicts a linear LED light source with a pair of electrical contacts 17a at the same end of the linear LED light source, it should be noted that the electrical contacts 17a may also be arranged with one electrical contact 17a at each end of lamp, or with a plurality of electrical contacts 17a at both ends of the lamp.

(15) The electrical feedthrough components 17 electrically connect the light source mount assembly 10 to the exterior of the sealed lamp envelope 11. The electrical feedthrough components 17 are hermetically sealed into the sealed lamp envelope 11 in a gas-tight fashion to avoid leakage of the gas filling 18.

(16) Electrical power is fed to the linear LED light source via the electrical contacts 17a, through the electrical feedthrough components 17 to the metallic support frames 13a, 13b. If present, the metallic spacer components 14 are connected to the metallic support frames 13a, 13b and provide a conductive connection between the metallic support frames 13a, 13b and the LED units 12. Alternatively the LED units 12 may be connected directly to the metallic support frames 13a, 13b without the use of intermediate metallic spacer components 14. The metallic spacer components 14 and LED units 12 are arranged such that the LED units 12 are connected in parallel between the metallic support frames 13a, 13b. However, it should be noted that the scope of the present invention is not limited to constructions in which the LED units 12 are operated in parallel. Other mount frame constructions might be applied for series operation.

(17) The metallic support frames 13a, 13b and the metallic spacer components 14 not only serve not only serve as mechanical support frame for the LED units 12, but also as supply conductors via which electrical power supplied from the electrical contacts 17a is fed to the LED units 12.

(18) The metallic components of the light source mount assembly 10 and the electrical feedthrough component 17 can be connected in any suitable manner that ensures a conductive connection between them, e.g. by welding.

(19) FIG. 2 serves to illustrate relevant dimensional parameters of the linear LED light source of FIG. 1. The outer diameter of the sealed glass envelope 11 and, thus, of the linear LED light source, is denoted by d. The inner diameter of the sealed glass envelope is denoted by d.sub.i. L designates the inner length of the sealed glass envelope 11, which represents a usable length L of the linear LED light source from which light can be potentially emitted.

(20) As can be seen in FIG. 2, the light-emitting source constituted by the sequentially arranged LED units 12 extends substantially over the entire usable length L of the linear LED light source. More precisely, the distance between the inner ends of the sealed glass envelope 11 and the nearest LED unit 12 is smaller than twice the outer diameter of the sealed lamp envelope 11. Thus, the length of the non-radiating zones at each end of the linear LED light source does not exceed two times the outer diameter d of the linear LED source. This limitation is a preferred embodiment—the length of the non-radiating zones at each end of the linear LED light source could also be limited to not exceed three times or four times the outer diameter d of the linear LED source.

(21) FIGS. 3a to 3g illustrate steps of a method for manufacturing the linear LED light source of FIGS. 1 and 2. As is shown in FIG. 3a, in a first step, a tubular glass envelope 20 is provided. The tubular glass envelope 20 has a proximal end 21 and a distal end 22 and is open at both ends. A first glass exhaust tube 23 with smaller diameter than the tubular glass envelope 20 is inserted into the tubular glass envelope 20 at the distal end 22 such that a part of the first exhaust tube 23 is arranged inside the tubular glass envelope 20 and the remaining part of the first exhaust tube 23 protrudes beyond the distal end 22 of the tubular glass envelope 20 to the outside. The first exhaust tube 23 is also open at both ends, thus being essentially formed as a cylinder sleeve that is open at the two ends.

(22) Subsequently, the distal end 22 of the tubular glass envelope 20 is heated at the junction of the first exhaust tube 23 and the tubular glass envelope 20. The glass at the distal end 22 of the tubular glass envelope 20 softens and is formed around the first exhaust tube 23. Thus, a distal hermetic seal 24 is formed at the distal end 22, wherein a distal opening 25 is present along the axis of the distal hermetic seal 24. This is shown in FIG. 3b.

(23) The distal opening 25 is provided by the first exhaust tube 23 around which the distal hermetic seal 24 is formed. The distal opening 25 will later be required for allowing a flow of coolant gas 29 through the tubular glass envelope 20. It is therefore pivotal that the formation of the distal hermetic seal 24 is performed such that the distal opening 25 is present after the formation. This can be alleviated, for example, by limiting the temperature attained by the first exhaust tube 23 during formation of the distal hermetic seal 24 and by forming the distal opening 22 of the tubular glass envelope 20 around the first exhaust tube 23 in such a way that any mechanical forces acting on the first exhaust tube 23 are not sufficiently high as to constrict or seal the distal opening 25. Alternatively the first exhaust tube 23 may be fabricated from a type of glass having a slightly higher softening temperature than the tubular glass envelope 20, or other mechanical means may be temporarily or permanently located in the distal opening 25 to maintain its integrity during the formation of the distal hermetic seal 24.

(24) As shown in FIG. 3c, the light source mount assembly 10 with the electrical feedthrough component 17 attached thereto is then inserted into the proximal end 21 of the tubular glass envelope 20. The electrical feedthrough component 17 comprises a controlled expansion alloy, i.e., it is at least partially made of a controlled expansion alloy over the length that it is to be hermetically sealed into the distal hermetic seal 24.

(25) The light source mount assembly 10 is arranged such that the electrical feedthrough component 17 protrudes beyond the proximal end 21 of the tubular glass envelope 20 to the outside of the tubular glass envelope 20. The electrical feedthrough component 17 is illustrated in the form of a hairpin to bring two separate sections of wire through the glass, but this is only for the purposes of illustration—it may alternatively be provided as two discrete wires, or a different quantity of wires may be arranged to pass through the hermetic seal.

(26) Next, as shown in FIG. 3d, a second exhaust tube 26 with smaller diameter than the tubular glass envelope 20 is inserted into the proximal end 21. The second exhaust tube 26 is placed adjacent to the electrical feedthrough component 17, and although located substantially outside the tubular glass envelope 20 the second exhaust tube 26 passes a short distance into the proximal end 21 of the tubular glass envelope 20. As with the first exhaust tube 23, the second exhaust tube 26 is also open at both ends, thus being essentially formed as a cylinder sleeve that is open at the two ends. The second exhaust tube 26 is arranged such that a part of the electrical feedthrough component 17 is positioned in an annular space between the second exhaust tube 26 and the tubular glass envelope 20.

(27) A flow of inert coolant gas 29, for instance nitrogen or argon, is then introduced into the proximal end of the second exhaust tube 26 and the gas issuing from its distal end impinges upon the adjacent LED unit 12 of the light source mount assembly to provide a temporary cooling effect. Thus, it can be ensured that the adjacent LED unit 12 is not damaged when the proximal end 21 of the tubular glass envelope 20 is sealed. Owing to the presence of the first and second exhaust tubes 23, 26 for the influx and egress of coolant gas, the flow of coolant gas 29 can be maintained throughout the entire sealing process.

(28) The proximal end 21 of the tubular glass envelope 20 is then heated and collapsed around the electrical feedthrough component 17 and the second exhaust tube 26 to form a proximal hermetic seal 27 with a proximal opening 28, as shown in FIG. 3e. Since the electrical feedthrough component 17 is made of a controlled expansion alloy having good adhesion to glass at least in the region that it penetrates the proximal hermetic seal 27, no imperfections are formed in the proximal hermetic seal 27 due to differing thermal expansions of the electrical feedthrough component 17 and the tubular glass envelope 20.

(29) During the entire sealing process, the flow of coolant gas 29 is maintained. The flow of coolant gas 29 enters the proximal end 21 of the tubular glass envelope 20 through a proximal opening 28 that is provided by the second exhaust tube 26, flows through the tubular glass envelope 20 to its distal end 22, from which it is issued via its pre-formed constriction that is constituted by the first exhaust tube 23 with the distal opening 25. Both the proximal and the distal openings 25, 28 should remain substantially unobstructed in order to maintain the flow of coolant gas 29 during the formation of the proximal hermetic seal 27.

(30) After the formation of the proximal hermetic seal 27 is completed and the glass has cooled down sufficiently, the tubular glass envelope 20 is evacuated via one or both exhaust tubes 23, 26, and backfilled with a suitable thermally conductive gas filling 18 that serves to cool the LED units 12 during the subsequent operation of the linear LED light source. The gas filling 18 is introduced via one or both of the exhaust tubes 23, 26 at either or both ends of the tubular glass envelope 20.

(31) The light source mount assembly 10 and the gas filling 18 are then permanently sealed inside the tubular glass envelope 20 by fusion and removal of the excess length of the protruding ends of the exhaust tubes 23, 26. With the fusion and removal process, a proximal sealing tip 27a and a distal sealing tip 24a are formed at the respective ends 21, 22 of the tubular glass envelope 20, thus sealing the openings 25, 28 and forming the sealed lamp envelope 11. This is depicted in FIG. 3f.

(32) Finally, bases 19 for forming the electrical and/or mechanical interface between the linear LED light source and corresponding sockets or holders may optionally be applied over the proximal and/or distal ends 21, 22 of the sealed lamp envelope 11. In order to establish an electrical contact to the outside, the electrical feedthrough component 17 is shortened to a suitable length and connected to electrical contacts 17a of the base 19 at the proximal end 21.

(33) In an alternative, modified embodiment, the formation of the proximal hermetic seal 27 is performed in a different manner. This is schematically depicted in FIGS. 4a to 4h. Here, the fusing of glass around the electrical feedthrough components 17 and exhaust tubes is performed in a separate process, before connecting the electrical feedthrough components 17 to the light source mount assembly 10. Thus, the modification only concerns the formation of at least the proximal hermetic seal 27, and optionally also the distal hermetic seal 24. The formation of the distal hermetic seal 24 may be performed either as described before or according to this alternative modified embodiment.

(34) In the first step shown in FIG. 4a, an exhaust tube 31 made of glass is provided and inserted into a flare tube 32 of larger diameter that is also made of glass, so that an annular space between the outer wall of the exhaust tube 31 and the inner wall of the flare tube 32 remains.

(35) One or more electrical feedthrough components 17 may be inserted between the exhaust tube 31 and the flare tube 32 so as to protrude beyond both ends of the flare tube 32. As can be seen in FIG. 4a, the electrical feedthrough components 17 are inserted into the annular space between the exhaust tube 31 and the flare tube 32.

(36) Subsequently, the exhaust tube 31 and the flare tube 32 are joined at their distal ends so as to form a stem assembly 34 that comprises a fused hermetic seal 33 in which the electrical feedthrough components 17 (if present) are hermetically sealed. The joining may be performed by heating and fusing. The finished stem assembly 34 with hermetically sealed electrical feedthrough components 17 is shown in FIG. 4b. The electrical feedthrough components 17 protrude beyond both ends of the fused hermetic seal 33, so as to enable an electrical connection on both ends of the electrical feedthrough components 17.

(37) The stem assembly 34 still is configured as a tube, that is, it has an integral gas flow tube constituted by the exhaust tube 31 that has been fused to the flare tube 32 that allows for a gas flow. This channel is formed between the hermetically sealed parts of the electrical feedthrough components 17. It should be noted that the electrical feedthrough component 17 used in this embodiment again comprises a controlled expansion alloy at least in the portion of its passing through the fused hermetic seal 33, so as to have a good adhesion to glass to attain a satisfactory hermetic seal.

(38) It is essential that the fusing of the exhaust tube 31 and the flare tube 32 is performed such that the exhaust tube 31 is not fully collapsed, so that the integral gas flow tube forming a channel for a gas flow can be provided. This can be achieved, for example, by first fusing the distal ends of the exhaust tube 31 and the flare tube 32 together in the vicinity of the hermetic seal 33, and then introducing air pressure into the proximal end of the exhaust tube 31 with sufficient force as to blow one or more small holes in the side of the hermetic seal 33. In the embodiment shown in FIG. 4b, the joining of the exhaust tube 31 and the flare tube 32 was performed such that an opening 28 at the distal end of the fused exhaust tube 31 and flare tube 32 remained.

(39) As previously stated, the formation of the distal hermetic seal 24 may be performed in accordance with the embodiment of FIGS. 3a and 3b, but may also be provided in accordance with the same method for the sealing of a stem assembly 34 of the kind just described, into the tubular glass envelope 20 and as illustrated in FIGS. 4c and 4d. In this case a distal stem assembly 34a is inserted into the distal end 22 of the tubular glass envelope 20 such that the rim of the flared portion is approximately aligned with the rim of the distal end 22.

(40) Heat is subsequently applied to the region to be sealed and the distal end 22 of the tubular glass envelope 20 is collapsed onto the flared rim of the distal stem assembly 34a so as to form a distal hermetic seal 24. For the embodiment illustrated in FIGS. 4c and 4d no electrical feedthrough components 17 have been provided within the distal stem assembly 34a.

(41) After the formation of the distal hermetic seal 24, a proximal stem assembly 34b, this time bearing the electrical feedthrough components 17 as illustrated in FIG. 4b, is connected to the light source mount assembly 10, which is inserted into the tubular glass envelope 20 via its open proximal end 21. This is shown in FIG. 4e.

(42) A flow of coolant gas 29 is then introduced through the exhaust tube of the proximal stem assembly 34b and enters the tubular glass envelope 20 through the opening 28, to provide a cooling effect on the LED units 12 in the vicinity of the proximal end 21. Again, the provision of the proximal opening 28 and the distal opening 25 is pivotal for ensuring the maintenance of the flow of coolant gas 29 throughout the entire formation of the proximal hermetic seal 27 that is performed next.

(43) FIG. 4f illustrates the formation of the proximal hermetic seal 27. The proximal end 21 of the tubular glass envelope 20 is heated and collapsed around the flared rim of the proximal stem assembly 34b. Thus, the proximal end 21 is hermetically fused with the proximal stem assembly 34b. Since the electrical feedthrough components 17 are already hermetically sealed in the proximal stem assembly 34b in this embodiment, the step in FIG. 4f only comprises the joining of two glass components which may simplify the formation of the proximal hermetic seal 27. The formation of the proximal hermetic seal 27 can be performed before, during or after the formation of the distal hermetic seal 24, as long as the flow of coolant gas 29 through the exhaust tube of the proximal stem assembly 34b is ensured during the fusion process in which the proximal hermetic seal 27 is formed.

(44) As in the previous embodiment (see FIG. 3f), after the formation of the proximal hermetic seal 27 is completed and the glass has cooled down, the tubular glass envelope 20 is filled with a suitable thermally conductive gas filling 18. Again, the gas filling 18 may be introduced via the openings 28 and/or 25 of the fused stem assemblies 34a and/or 34b. The light source mount assembly 10 and the gas filling 18 are then permanently sealed inside the tubular glass envelope 20 by fusion, and removal of the excess length of the protruding ends of the exhaust tubes of the stem assemblies 34a and 34b, to form a distal sealing tip 24a and a proximal sealing tip 27a and provide a sealed lamp envelope 11. This is shown in FIG. 4g.

(45) Finally, as in the previous embodiment, the optional bases 19 for forming the electrical and/or mechanical interface between the linear LED light source and corresponding sockets or holders may be applied over the proximal and/or distal ends 21, 22 of the sealed lamp envelope 11. In order to establish an electrical contact to the outside, the electrical feedthrough components 17 are shortened to a suitable length and connected to electrical contacts 17a of one or both of the bases 19. This is shown in FIG. 4h.

(46) A third preferred embodiment with a modified stem assembly will now be described with reference to FIG. 5.

(47) FIG. 5a illustrates the stem components comprising the flare tube 32, the exhaust tube 31 and the electrical feedthrough components 17. FIG. 5b illustrates the modified stem assembly 34′ produced by the fusion of these parts. Whereas in the stem assembly detailed in FIG. 4b the opening 28 is blown laterally in the side wall of the fused hermetic seal 33 of the stem, in this modified assembly the opening 28 passes axially along the entire length of the stem assembly 34′.

(48) FIG. 5b through 5h illustrate the subsequent assembly of the linear LED light source using the modified stem assembly 34′ of FIG. 5b, and will not be described in detail owing to the similarity of the process already described with relation to FIG. 4c-4h. The main difference is that when the coolant gas flow 29 is introduced into the fused exhaust tube 31 of the stem assembly 34′, the gas flows in a straight line through the stem and into the tubular glass envelope 20 without deviation from its axis. The flow of coolant gas 29 therefore impinges directly on the LED units 12 with reduced contact with the hot sidewall of the tubular lamp envelope 20, thereby reducing the risk of chilling the hot glass and producing stresses which may later cause residual stress of the glass.

(49) Three modifications of a method for manufacturing a linear LED source according to the present invention have been described above. The three methods differ in the formation of the hermetic seals 27, 24. It is conceivable that the proximal hermetic seal 27 according to the modification of FIGS. 4a to 4i is further modified by carrying out the steps shown in FIGS. 4a and 4b, inserting the stem assembly 34 thus formed into the proximal end 21 of the tubular glass envelope 20 and collapsing the proximal end 21 of the tubular glass envelope 20 around the stem assembly 34 in order to form the proximal hermetic seal 27, and connecting the light mount assembly 10 to the electrical feedthrough components 17 at the proximal end 21 of the tubular glass envelope 20 that are already fused in the proximal hermetic seal 27.

(50) The formation of the distal hermetic seal 24 could be modified as well. Furthermore, the stem assembly 34a bearing the electrical feedthrough components 17 could be inserted into and fused with the tubular envelope 20 before connecting the light source mount assembly 10, so that the connection of the light mount assembly 10 to the electrical feedthrough component 17 is performed with the electrical feedthrough component 17 already being hermetically sealed to the tubular glass envelope 20.

(51) However, in any conceivable modification of the manufacturing process, a central concept of the present invention that needs to be accounted for is the provision and maintenance of the flow of coolant gas 29 through the tubular envelope 20 during every hermetic seal operation that is performed when the light source mount assembly 10 is already inserted into the tubular envelope 20, in order to prevent damages to the LED units 12 during the hermetic seal formation.

(52) In the description, the term “proximal” designates the side of the linear LED light source from which the light source mount assembly is inserted and is used to distinguish the two sides of the linear LED source in the description. It is not intended to imply any further limitations. The light source mount assembly could also be inserted from the distal end, using one of the described alternatives for forming a hermetic seal, or using another method altogether.

(53) It is noted that the present invention has been motivated in the context of LED filament light sources. It is, however, emphasised that the present invention is also applicable to conventional linear LED light sources in which the one or more LED units 12 are constituted by LEDs mounted on a printed circuit board or an equivalent carrier and arranged inside the sealed lamp envelope 11. The one or more LED units 12 may also be constituted by LED packages as defined in the International Electrotechnical Vocabulary (IEC 60050). According to this definition, a LED package is an electric component comprising at least one LED die, and can include optical elements, light converters such as phosphors, thermal, mechanical and electric interfaces, as well as components to address ESD concerns.

LIST OF REFERENCE SIGNS

(54) 10 light source mount assembly 11 sealed lamp envelope 12 LED unit 13a, 13b support frame 14 spacer component 15 isolating bridge 16 buffer spring 17 electrical feedthrough component 17a electrical contact 18 gas filling 19 base 19a adhesive 20 tubular glass envelope 21 proximal end 22 distal end 23 first exhaust tube 24 distal hermetic seal 24a distal sealing tip 25 distal opening 26 second exhaust tube 27 proximal hermetic seal 27a proximal sealing tip 28 proximal opening 29 flow of coolant gas 31 exhaust tube 32 flare tube 33 fused hermetic seal 34, 34a, 34b, 34′ stem assembly L length d diameter d.sub.i inner diameter