Abstract: There is described a sealing composition for sealing aluminum nitride and aluminum oxynitride ceramics comprising: a mixture of SiO2, at least one other metal oxide, and a silicon additive comprising at least one of silicon metal or a silicide. The silicon additive acts to suppress the formation of nitrogen bubbles during the sealing of articles comprised of aluminum nitride or aluminum oxynitride ceramics, e.g., as in the case of a ceramic discharge vessel for a high intensity discharge lamp.

Abstract: There is described a brazing alloy having a first component comprising a source of molybdenum and a source of aluminum and a second component comprising boron, wherein a weight ratio of said second component to said first component is not greater than 1:20. The addition of boron results a substantially lower melting point than alloys employing molybdenum and aluminum alone. It is suitable for use in discharge vessels having a hollow bodies selected from the group of monocrystalline alumina, polycrystalline alumina and aluminum nitride; metallic electrode holders fitted into ends of the hollow body; and sealed thereto by a braze.

Abstract: There is described a lamp having a ceramic discharge vessel with a niobium feedthrough that has been coated with a layer of chromium to provide oxidation resistance. In a preferred method, a slurry containing chromium powder is applied to the niobium feedthrough and dried. A sub-assembly is formed by inserting the coated niobium feedthrough into an annular polycrystalline alumina (PCA) disc and heated in vacuum to 1700° C. to 1900° C. to bond the feedthrough to the PCA and form the sub-assembly and an oxidation-resistant coating on the feedthrough. The sub-assembly is then sealed to a ceramic body of the discharge vessel in a conventional manner.

Abstract: The present method uses a methane-containing nitrogen gas sintering atmosphere to sinter aluminum nitride (AlN) to a high transmittance. The methane gas replaces the solid carbon charge material used in prior art sintering methods as the source of gaseous carbon. The amount of carbon in the methane-containing nitrogen gas is easily controlled by varying the partial pressure of methane in the nitrogen gas. In addition, the methane flow is stopped prior to the end of the sintering cycle to prevent darkening of the sintered part.

Abstract: Aluminum nitride arc discharge vessels having a high total transmittance may be made by annealing the as-sintered AlN vessel in a nitrogen atmosphere, preferably at a temperature of at least about 1850° C. and for a time of at least about 50 hours. The annealing increases the total transmittance of the vessel to greater than 92% in the wavelength region from about 400 nm to about 700 nm. The annealed AlN discharge vessels are useful for lamp applications, such as metal halide lamps, and offer an improved durability and life over polycrystalline alumina (PCA).

Abstract: Polycrystalline alumina (PCA) that has been doped with magnesium oxide is converted to sapphire by additionally doping the PCA with boron oxide and sintering to induce abnormal grain growth. The boron oxide may be added to an already formed green PCA ceramic shape by applying an aqueous boric acid solution to the green ceramic and heating the green ceramic in air to convert the boric acid to boron oxide.

Abstract: An opaque zone in the polycrystalline (PCA) discharge vessel of a high intensity discharge lamp may be made by creating residual pores in predetermined regions of the final-sintered discharge vessel. The control over the placement of the opaque zone is achieved by forming a carbonaceous residue in a specific region of the discharge vessel prior to final sintering. During sintering, the carbonaceous material causes residual porosity in the sintered PCA. The higher emissivity of the opaque PCA provides localized cooling in order to provide more control over the condensate behavior in the discharge vessel.

Abstract: A discharge lamp having a visual-change timer is described. The visual-change timer is comprised of a ceramic material that provides an indication of the cumulative operating time of the lamp. The visual-change timer is expected be a help to consumers in avoiding unnecessary, premature, and costly lamp replacement and a help to lamp manufacturers in verifying the validity of warranty claims for replacement lamps.

Abstract: A ceramic discharge vessel is provided wherein the vessel comprises a hollow body for enclosing a discharge and the hollow body is made of a polycrystalline dysprosium oxide containing a luminescent dopant that emits one or more visible light wavelengths when stimulated by radiation generated by the discharge. Preferably, the polycrystalline dysprosium oxide has been doped with one or more of europium, cerium, or terbium in an amount from about 0.1 to about 10 percent by weight on an oxide basis.

Abstract: The invention relates to a high-pressure discharge lamp that has an electric power consumption of less than 50 watt and comprises a discharge vessel (1?) that is sealed on two sides and is made of a translucent ceramic material as well as electrodes (2?, 3?) which are disposed inside the discharge vessel (1?) and are used for generating a gas discharge. Xenon and metal halides are arranged within the discharge vessel (1?) which is embodied as a ceramic tube that has a uniform maximum inner diameter of 1.2 mm while the minimum cold filling pressure of the xenon amounts to 0.8 megapascal.

Abstract: The present invention is a ceramic discharge vessel for use in high-intensity-discharge (HID) lamps. The discharge vessel has a ceramic body and at least one seal region comprised of an aluminum oxynitride material. The seal region further has a surface layer for contacting a frit material wherein the surface layer is less reactive than the aluminum oxynitride material with respect to the molten frit during sealing. Preferably, the surface layer has a lower nitrogen content than the aluminum oxynitride material. The less reactive surface acts to minimize the formation of bubbles in the sealing frit during the sealing operation.

Abstract: A high intensity discharge lamp includes a ceramic envelope that defines an enclosed volume that is filled with a pressurized gas, the envelope having an exterior with axial poles and an equator and, when viewed in longitudinal cross section, plural exterior steps extending in series from the respective axial pole to the equator, each of the steps having a flat surface that is angled to refract light from inside the envelope toward a plane of the equator. The flat surfaces may be planar (plural facets in concentric tiers) or annular and the envelope may have a spherical interior surface. The lamp may have a reflector with an aperture that is aligned with the respective axial pole.

Abstract: The present invention is a ceramic discharge vessel for use in high-intensity-discharge (HID) lamps. The discharge vessel has a ceramic body and at least one seal region comprised of an aluminum oxynitride material. The seal region further has a surface layer for contacting a frit material wherein the surface layer is less reactive than the aluminum oxynitride material with respect to the molten frit during sealing. Preferably, the surface layer has a lower nitrogen content than the aluminum oxynitride material. The less reactive surface acts to minimize the formation of bubbles in the sealing frit during the sealing operation.

Abstract: A translucent polycrystalline material suitable for use in ceramic discharge vessels for metal halide lamps is produced by sintering an alumina powder doped with a MgO sintering aid in a nitrogen atmosphere containing a partial pressure of a vapor phase carbon-containing species. The sintered polycrystalline alumina has a grain boundary phase containing aluminum, oxygen and nitrogen. The formation of the AL—O—N grain boundary phase is believed to facilitate the transport of nitrogen from entrapped pores during sintering. Preferably, the PCA is sintered in a carbon-element furnace under flowing ultra-high-purity nitrogen.

Abstract: A method of producing a ceramic metal halide discharge lamp having a monolithic seal between a sapphire (single crystal alumina) arc tube and a polycrystalline alumina (PCA) end cap. The method includes the steps of providing an arc tube of fully dense sapphire and providing an end cap made of unsintered compressed polycrystalline alumina powder doped with magnesium oxide and yttrium oxide. The end cap is heated until it is presintered to remove organic binder material at a low temperature relative to the sintering temperature. The presintered end cap is placed on an end portion of the arc tube to form a close interface between the two. The presintered end cap and adjacent arc tube are then heated to until the end cap is fully sintered onto the arc tube and the sapphire tube grows into the end cap. A monolithic seal is formed along the interface between the end cap and the arc tube as the sapphire tube grows into the polycrystalline alumina end cap.

Abstract: A ceramic metal halide discharge lamp may be made having a monolithic seal between a sapphire arc tube and a polycrystalline alumina cap. The lamp is made by providing an arc tube of fully dense sapphire and providing a cap made of unsintered compressed polycrystalline alumina doped with magnesium oxide and yttrium oxide. The cap is presintered to remove binder material at a low temperature. The presintered cap is placed on an end of the arc tube to form a close interface. The presintered cap and arc tube are then heated to until the cap is fully sintered onto the arc tube and the sapphire tube grows into the cap. A monolithic seal is formed along the interface as the sapphire grows into the polycrystalline alumina.

Abstract: A transparent polycrystalline yttrium aluminum garnet (YAG) ceramic is described wherein the ceramic is colorless and transparent in both as-sintered and post-sinter, air-fired states which makes it highly desirable for lamp applications. The transparent YAG ceramic is co-doped with an amount of MgO and an amount of ZrO2 wherein the weight ratio of MgO to ZrO2 is from about 1.5:1 to 3:1.

Abstract: A method of producing a ceramic metal halide discharge lamp having a monolithic seal between a sapphire (single crystal alumina) arc tube and a polycrystalline alumina (PCA) end cap. The method includes the steps of providing an arc tube of fully dense sapphire and providing an end cap made of unsintered compressed polycrystalline alumina powder doped with magnesium oxide and yttrium oxide. The end cap is heated until it is presintered to remove organic binder material at a low temperature relative to the sintering temperature. The presintered end cap is placed on an end portion of the arc tube to form a close interface between the two. The presintered end cap and adjacent arc tube are then heated to until the end cap is fully sintered onto the arc tube and the sapphire tube grows into the end cap. A monolithic seal is formed along the interface between the end cap and the arc tube as the sapphire tube grows into the polycrystalline alumina end cap.

Abstract: A method of producing a ceramic metal halide discharge lamp having a monolithic seal between a sapphire (single crystal alumina) arc tube and a polycrystalline alumina (PCA) end cap. The method includes the steps of providing an arc tube of fully dense sapphire and providing an end cap made of unsintered compressed polycrystalline alumina powder doped with magnesium oxide and yttrium oxide. The end cap is heated until it is presintered to remove organic binder material at a low temperature relative to the sintering temperature. The presintered end cap is placed on an end portion of the arc tube to form a close interface between the two. The presintered end cap and adjacent arc tube are then heated to until the end cap is fully sintered onto the arc tube and the sapphire tube grows into the end cap. A monolithic seal is formed along the interface between the end cap and the arc tube as the sapphire tube grows into the polycrystalline alumina end cap.

Abstract: This invention involves a new type of feedthrough-plug member for metal halide HID lamp using PCA envelopes. The construction of the lamp housing consists of a PCA envelope and specially designed radially graded alumina-metal cermet multi-layers to eliminate cracking in cermet or PCA due to thermal stresses arising from thermal expansion mismatch. The fills are metal halides such as Na-Sc-I, rare earth halides, Hg, Sn, and inert gases. The PCA vessel and directly sealed cermetfeedthrough assemblies allow the metal halide lamps to operate at high wall temperatures with better lumen output, color temperature, and CRI.