U.S. patent number 3,686,528 [Application Number 04/882,587] was granted by the patent office on 1972-08-22 for jet pinched plasma arc lamp and method of forming plasma arc.
This patent grant is currently assigned to Tamarack Scientific Company, Inc.. Invention is credited to Ronald E. Sheets.
United States Patent |
3,686,528 |
Sheets |
August 22, 1972 |
JET PINCHED PLASMA ARC LAMP AND METHOD OF FORMING PLASMA ARC
Abstract
A plasma arc is generated between an anode and a cathode in a
gas pressurized chamber. The plasma arc is stabilized to give
greater safety and concentrated to give greater irradiance by a jet
of gas coaxial with and pinching the plasma arc. Means are employed
for greatly reducing heat flux through the face of the anode. The
gas jet is created by forcing the gas through a nozzle type opening
positioned at one of the electrodes and antipodal the other of the
electrodes, while a second gas flow cools the chamber walls. The
gas is recirculated through a purifying medium to avoid
contamination.
Inventors: |
Sheets; Ronald E. (Westminster,
CA) |
Assignee: |
Tamarack Scientific Company,
Inc. (Orange, CA)
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Family
ID: |
25380920 |
Appl.
No.: |
04/882,587 |
Filed: |
December 5, 1969 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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655536 |
Jul 24, 1967 |
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Current U.S.
Class: |
315/111.21;
313/33; 313/35; 313/39; 313/40; 313/146; 313/545 |
Current CPC
Class: |
H05H
1/48 (20130101) |
Current International
Class: |
H05H
1/24 (20060101); H05H 1/48 (20060101); H01j
007/24 (); H05b 031/26 () |
Field of
Search: |
;313/33,146,174,176,178,179,231,39,40,35 ;315/111 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Kominski; John
Parent Case Text
This application is a continuation in part of the application of
Ronald E. Sheets, Serial No. 655,536 filed July 24, 1967 now
abandoned.
Claims
I claim:
1. A method of forming a plasma arc maintained between a pair of
electrodes concentrated at one electrode and flared at the other
comprising the step of:
applying to the arc a surrounding initially convergent sheath of
substantially non-vortical gas travelling essentially
longitudinally of the arc with progressively decreasing
constrictive force along the length of the arc to increase the
radiance at one electrode and reduce the energy flux at the other
electrode.
2. A method of stabilizing a plasma arc being maintained between a
first and a second electrode comprising the steps of:
flowing a jet of gas from the first electrode to the second
electrode coaxial to and around the plasma arc;
withdrawing a portion of said jet of gas from around the periphery
of said second electrode; and
deflecting another portion of said jet of gas at the second
electrode radially outward and back towards the first electrode so
as to form a toroidal ring circulation of gas around the plasma
arc.
3. A high intensity plasma arc lamp comprising:
means for providing a gas pressurized chamber;
a first electrode and a second electrode for maintaining a plasma
arc, said electrodes being positioned within said pressurized
chamber;
means for concentrating said arc along only a portion of its length
and stabilizing said arc along its entire length comprising means
proximate to said first electrode for introducing a jet of cooling
gas coaxial to said plasma arc, said jet of gas cooling the
periphery of the arc proximate said first electrode so that the arc
is concentrated at said first electrode and flares as it nears said
second electrode, the heat energy in the flared portion of the arc
being absorbed over a large area of said second electrode, thus
reducing the per unit area energy absorption and increasing the
useful life of said second electrode;
means proximate to the inner wall of said chamber for supplying a
boundary layer of moving gas adjacent to said inner wall for
cooling the chamber wall and providing a protective buffer between
the chamber wall and said jet of gas.
4. The high intensity plasma arc lamp defined in claim 3 further
comprising:
means for deflecting a small portion of the gas jet striking the
second electrode for forming a toroidal collar of gas surrounding
and concentric to the plasma arc, said collar of gas further
stabilizing the plasma arc and containing the hot gases therein to
prevent hot gas from directly contacting the chamber wall.
5. Apparatus for generating a plasma arc, comprising:
a transparent gas pressure chamber;
a cathode and an anode spaced apart along a longitudinal axis in
said chamber for an arc to be maintained therebetween;
said cathode having a generally conical portion coaxial with said
axis, whose conical exterior converges continuously and unbrokenly
to an arcing forward extremity facing along said axis toward said
anode;
a generally conical shroud encircling said conical portion of said
cathode with convergent annular space therebetween to define
therewith a generally conical nozzle, said shroud terminating short
of said arcing forward extremity of said cathode; and,
channel means directing pressurized gas into said annular space
generally and primarily longitudinally of said nozzle;
all in such manner as to form in said nozzle a convergent sheath of
gas travelling essentially longitudinally of the nozzle along the
portion of the conical cathode protruding therefrom so as to
surround the arc and impinge convergently thereon in a region
immediately beyond the cathode extremity and thereby locally
constrict said arc in said region.
6. The subject matter of claim 5, wherein said annular space, at
the gas discharge end portion thereof, is configured with a
longitudinally extending interior flow-path-defining structure
having an effective wetted perimeter for gas flowing therethrough
of sufficient extent to establish laminar flow characteristics in
the sheath of gas emitted from the nozzle and impinging
convergently on the arc.
7. The subject matter of claim 6, wherein the gas discharge end
portion of said annular space contains alternating ribs and
channels extending generally longitudinally of said longitudinal
axis.
8. The subject matter of claim 5, including flow passages for
flowing a pressurized inert gas into said pressurized chamber for
circulation therein about said cathode and anode and the arc
therebetween, and
means including a flow passage for feeding into said channel means
and thence through said nozzle a flow of pressurized inert gas
bearing a predetermined ratio to said flow into said chamber.
9. The subject matter of claim 8, wherein said flow passage,
channel means, and nozzle are proportioned so that the flow
quantity through said nozzle is a fixed minor fraction of the flow
quantity directly into said chamber.
10. Apparatus for generating a plasma arc, comprising:
a transparent gas pressure chamber;
a cathode and an anode spaced apart along a longitudinal axis in
said chamber for an arc to be maintained therebetween;
said cathode having a generally conical portion coaxial with said
axis, whose conical exterior converges unbrokenly to an arcing
forward extremity facing along said axis toward said anode; and
means for forming a sheath of gas around said conical portion of
said cathode and directing it to flow generally and primarily
longitudinally of and radially inwardly toward said axis and then
off said extremity of said cathode to impinge on and constrict said
arc in a region proximate to the arcing extremity of the
cathode.
11. The subject matter of claim 10, wherein
said anode has a generally dished annular face opposite to and
coaxial with the longitudinal axis of the cathode and anode, said
dished annular face of said anode being of substantially larger
area than that of the extremity of the cathode, said dished face
being an approximation of a spherical surface whose center of
curvature is located substantially at said extremity of said
cathode, whereby all points on said dished anode face are
substantially equidistant from said extremity of said cathode.
12. The subject matter of claim 10, wherein said pressure chamber
includes:
a pair of transparent annularly spaced cylinders fitted at opposite
ends to cathode end and anode end adapters;
means for admitting a pressurized gas inside the annular space
between said cylinders;
ports through the inner of said cylinders to pass pressurized gas
to the interior of said chamber and to form a boundary layer of
heat insulating gas along the inside surface of the inner of said
cylinders; and
passage means for conveying a portion of the pressurized gas within
said annular space to supply said sheath of gas formed around said
conical portion of said cathode and which is directed to impinge on
said arc.
13. The subject matter of claim 10, wherein said pressure chamber
includes:
a pair of transparent annularly spaced cylinders fitted at opposite
ends to cathode end and anode end adapters;
means for admitting a pressured gas inside the annular space
between said cylinders;
means for supplying a relatively large flow of gas from said
annular space to said chamber, including a flow of laminar
characteristics adjacent the inner wall surface of the inner of
said cylinders; and
means for conveying a relatively smaller flow of gas from said
annular space to supply said sheath of gas formed around said
conical portion of said cathode and which is directed to impinge on
said arc.
14. The subject matter of claim 10, wherein said pressure chamber
embodies a transparent cylinder and including:
means for introducing into said chamber a flow of gas adjacent and
longitudinally along the inner surface of said cylinder in a region
to surround the cathode and the arc between the cathode and the
anode to form a boundary layer adjacent said cylinder affording
heat insulation therefor.
15. The subject matter of claim 14, wherein said gas introducing
means is designed and arranged with a Reynold's Number sufficiently
low to cause discharge of said gas with laminar flow
characteristics.
16. The subject matter of claim 15, wherein said gas introducing
means comprises an annular body positioned inside said cylinder and
having gas inlet means and gas discharge means connected thereto,
said discharge means comprising an annular series of
circumferentially spaced discharge ports facing generally
longitudinally of the chamber cylinder and whose wetted port areas
at point of discharge are of sufficient perimeter to provide the
gas flow discharged therefrom with laminar flow
characteristics.
17. Apparatus for generating a plasma arc, comprising:
a transparent gas pressure chamber;
a cathode and an anode disk spaced apart along a longitudinal axis
in said chamber for an arc to be maintained therebetween;
said cathode having a generally conical portion coaxial with said
axis, whose conical exterior converges to an arcing forward
extremity of limited area;
said anode disk having a front arc footing area substantially
larger than said arcing extremity of said cathode, and
having a rearward face, also of materially larger area than said
arcing extremity of said cathode, and
liquid cooled heat exchange means for extracting heat from said
rearward face of said anode disk.
18. The subject matter of claim 17, wherein said arc footing area
of said anode disk is on a dished or concave front face which
approximates the curvature of a sphere whose center of curvature is
located substantially at said arcing extremity of said cathode.
19. The subject matter of claim 18, wherein said anode disk is
generally concavo-convex, with the rearward convex face thereof
larger in area than the arc footing area on the front face thereof,
whereby to effect divergence of heat energy during heat conduction
between said faces.
20. The subject matter of claim 19, wherein said heat exchange
means comprises a generally concavo-convex heat exchange wall whose
concave face conforms to and is in contact with the rearward
generally convex face of said anode disk, coolant wall means having
a generally concave face positioned at the rear of the generally
convex rearward face of said heat exchange wall, and a plurality of
concentric radially spaced ribs between said generally convex
rearward face of said heat exchange wall and said generally concave
face of said coolant wall means spaced rearwardly therefrom, said
ribs forming coolant flow passages therebetween, there being
diagonal, coolant flow slots through said ribs, said flow passages
and slots forming a labyrinth for flow of coolant, and coolant
entrance and exit channels, one communicating with a central region
of said labyrinth, and one communicating with a peripheral region
of said labyrinth.
21. The subject matter of claim 20, wherein the diagonal slots
through successive ribs are laterally offset relatively to one
another.
22. Apparatus for generating a plasma arc, comprising:
a transparent gas pressure chamber;
a cathode and an anode spaced apart along a longitudinal axis in
said chamber for an arc to be maintained therebetween;
said cathode having a generally conical portion coaxial with said
axis, converging to an arcing extremity of limited area facing
along said axis toward said anode;
said anode having an arc footing area substantially larger than the
arcing extremity of the cathode;
means for flowing a gas along said generally conical cathode,
thence in a moving sheath surrounding said arc to the footing of
the arc on the anode; and
a heat exchanger comprising annularly spaced side walls with gas
entrance walls for receiving the arc heated gas from around the
footing of the arc on the anode and conveying said gas into one end
of the annular space between said side walls;
gas discharge means leading from the opposite end of said annular
space; and
a series of annular ribs between said side walls, to define annular
gas channels therebetween, there being diagonal gas passing slots
in successive ribs to pass gas progressively from channel to
channel from said gas entrance walls to said gas discharge
means.
23. The subject matter of claim 22, wherein the diagonal slots
through said ribs are laterally offset from rib to rib.
24. A plasma arc lamp comprising:
a pressurized arc chamber;
a pair of electrodes positioned within said chamber to maintain an
electric arc;
means for flowing a gas through said pressurized chamber to
stabilize said electric arc;
a heat exchanger arranged to receive and cool said arc stabilizing
gas, said heat exchanger having gas ingoing and outgoing ends and a
gas passage therebetween, with a temperature gradient between said
ends, said gas passage including a region operating at a
temperature at which a selected getter material has a high
impurity-removing property; and
a getter material of such operating characteristic located in said
gas passage at said region.
25. The subject matter of claim 24, wherein there are a plurality
of regions in said gas passage operating at differing temperatures
at which different getter materials have optimum effectiveness,
with said different getter materials located in respective regions
of optimum effectiveness in said gas passage.
26. A plasma lamp comprising:
a transparent gas pressurized chamber;
an anode and a cathode in said chamber, normally separated by a
distance to define a predetermined normal arc length
therebetween;
a mounting stem for said cathode movable longitudinally on the axis
defined by said anode and cathode;
stop means for said stem and cathode when said cathode is retracted
to the normal separation distance from the anode;
spring means yielding urging said stem and cathode to return to
said stop means when separated therefrom in the direction of the
anode; and
means for moving said stem and cathode from said stop means in the
direction of said anode to strike the arc.
27. The subject matter of claim 26, wherein said stem and cathode
moving means embodies fluid pressure actuated means movable to
engage and displace said stem; and
return spring means for said fluid pressure actuated means.
28. The subject matter of claim 26, wherein said stop means
embodies a socket into which said cathode is receivable.
29. A plasma lamp comprising:
a transparent gas pressurized chamber;
an anode and a cathode in said chamber, normally separated by a
distance to define a predetermined normal arc length
therebetween;
means mounting said cathode for movement between a normal position
at a predetermined established arc length distance from the anode
and a striking position in closer proximity to the anode;
means for circulating a pressurized coolant through the lamp;
and
means utilizing said pressurized coolant to move said anode to said
striking position, so that said arc may not be struck in the event
of failure of circulation of said coolant.
30. A plasma lamp comprising:
a transparent gas pressurized chamber;
cathode and anode electrodes in said chamber, one movable relative
to the other on a longitudinal axis between a closed striking
position and an operating position spaced apart by a predetermined
arc length distance; and
means for moving said movable electrode to either of said two
positions, including spring means urging said movable electrode to
move to said operating position and pressure fluid actuated means
for overriding said spring means for moving said electrode to said
striking position.
31. The subject matter of claim 30, including an energizing circuit
for impressing a voltage between said cathode and anode electrodes,
and an electric starting circuit in conjunction therewith for
automatically actuating said pressure fluid actuated means to move
said movable electrode to said striking position in connection with
impression of said voltage between said cathode and anode
electrode.
32. The subject matter of claim 30, including:
an energizing circuit for said cathode and anode electrodes;
and,
means for limiting the arc current when the electrodes are
positioned in said striking position and the arc is struck, and
until said electrodes are repositioned at a spacing distance
substantially equal to said predetermined arc length distance.
33. The subject matter of claim 32, including also a sensing means
for sensing when said electrodes have become spaced at said
predetermined arc length distance, and for thereafter deactivating
said arc limiting means.
34. A plasma lamp comprising:
a transparent gas pressurized chamber;
cathode and anode electrodes in said chamber, one movable
relatively to the other on a longitudinal axis between a close
spaced striking position and an operating position spaced apart by
a predetermined arc length distance;
means including a pressure fluid actuated piston for moving said
movable electrode from said operating position to said striking
position;
return spring means for returning said movable electrode from said
striking position to said operating position, and for returning
said piston from a position in which it has moved said movable
electrode to said striking position, back to an initial starting
position;
means including a source of pressure fluid and a valve for
conveying said pressure fluid to said piston to actuate said piston
to move said movable electrode to said striking position, said
valve being operable to depressurize said piston to allow return to
said movable electrode to said operating position;
an energizing circuit for said cathode and anode electrodes,
including a DC power supply, and a current limiting resistor;
and
means responsive to depressurization of said pressure fluid
actuated piston to deactivate said current limiting resistor.
35. A plasma lamp comprising:
a transparent gas pressurized chamber;
cathode and anode electrodes in said chamber, one movable
relatively to the other on a longitudinal axis between a close
spaced striking position and an operating position spaced apart by
a predetermined arc length distance;
means including a pressure fluid actuated piston movable along said
axis from an initial position, to move said electrode from its said
operating position to its said striking position;
return spring means for returning said movable electrode from said
striking position to said operating position, and for returning
said piston to its said initial position;
means including a source of pressure fluid, and a valve movable to
a feeding position for conveying said pressure fluid to said piston
to actuate said piston and thereby move said movable electrode to
said striking position, said valve being movable to a second
position in which it exhausts said pressure fluid from said piston
and thereby depressurizes said piston to allow return of said
movable electrode and of said piston by said return spring
means;
a solenoid for moving said valve between said positions;
an energizing circuit for said cathode and anode electrodes
including a DC power supply and a current limiting resistor in
series;
a normally open switch in said energizing circuit by-passing said
current limiting resistor to deactivate said resistor;
an active circuit loop including said DC power supply, said current
limiting resistor shunted by said by-passing switch, and a device
conductive at and above a predetermined breakdown voltage which is
lower than the open circuit voltage across the electrodes, but
non-conductive at the lower voltage impressed thereon when an arc
has been generated between the electrodes;
an auxiliary power supply;
circuit means energized from said auxiliary power supply to
normally open said by-passing switch;
means responsive to current in said circuit loop for operating said
solenoid to move said valve to position to feed pressure fluid to
said piston and thereby move the movable electrode to striking
position;
means for moving said valve to its said second position upon
cessation of current in said circuit loop;
means in said circuit means also responsive to current in said
circuit loop to close said by-passing switch; and
a pressure sensitive electric switch operative on said circuit
means and responsive to pressurization and depressurization of said
piston means to hold said by-passing switch upon and during
pressurization of said piston means;
all in such manner that generation of an arc between the electrodes
stops current conduction in said circuit loop by reducing the
voltage across said conductive device, and thereby causes movement
of said valve to its second position to depressurize the piston,
and also closure of said by-passing switch to allow full arc
current between said electrodes.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to plasma apparatus and methods and more
specifically to apparatus and methods for concentrating and
stabilizing the plasma arc in a plasma lamp.
2. Description of the Prior Art
Devices employing a plasma arc provide compact high energy sources
having a plurality of contemporary uses including such diverse ones
as solar simulators, search lights, signaling beacons, projector
lamps and furnaces.
One type of prior art plasma lamp consists of a hermetically sealed
chamber spherical or ellipsoidal in shape having two antipodal
cylindrical extensions and made of clear fused silica containing a
gas such as argon or xenon. In each of the two cylindrical
extensions, there is an electrode usually made of tungsten;
supporting structure for the electrode; and connecting rods to
external electrical contacts.
It is established plasma arc phenomena that the centerline
irradiance of the plasma arc may be increased by cooling the
periphery of the arc and by concentrating the arc into a smaller
cross-section. Accordingly, most plasma arc lamps are operated with
several atmospheres pressure within the chamber to concentrate the
arc.
A plasma arc lamp is restricted to use in the vertical position
unless the plasma arc is stabilized in some manner. During
horizontal operation, an unstabilized plasma arc will tend to rise,
and if it contacts the chamber walls, will cause an explosion due
to its intense heat.
One type of device presently in use stabilizes the arc by forcing
gas tangentially into the chamber, thereby generating a vortex
through which the plasma arc passes. The vortex keeps the arc from
rising as it traverses from one electrode to another.
The vortex stabilized arc, however, will characteristically
dissipate electrodes quite rapidly. The vortex concentrates the
plasma arc along its entire length from the cathode electrode to
the anode electrode. Due to the concentration of the arc at the
anode, a high amount of energy must be absorbed over a relatively
small area. This energy absorption results in the vaporization of
the anode electrode.
The vortex stabilized arc apparatus of the prior art also fails to
benefit from the increased irradiance generated when the periphery
of the arc is cooled. The apparatus will generally introduce the
gas into the chamber at a point far removed from the plasma arc. By
the time the gas has reached the proximity of the arc, it has
increased tremendously in temperature and will have little cooling
effect upon the arc.
A second type of apparatus stabilizes the plasma arc by use of a
magnetic field. Such a device may generate a field by a coil
coaxial to the plasma arc and extending between electrodes. The
current passing through the coil establishes a magnetic field
longitudinal the axis of the plasma arc. This field stabilizes the
ions of the arc. Stabilization of the arc in this manner requires
additional power capability to maintain the field and additional
hardware for the coil. This coil, being coaxial to the plasma arc,
also reduces the usefulness of the lamp as a radiance source since
it intercepts a portion of the radiance generated.
SUMMARY OF THE INVENTION
The present invention provides a gas pressurized cylindrical
chamber formed by two concentric quartz cylinders having an annular
passageway between them for passing a gas which supplies the
plasma, and which serves also as a coolant. Within the chamber are
two electrodes, an anode and a cathode, in circuit with an external
high current source for generating a plasma arc between the
electrodes. The plasma arc generated in the chamber is stabilized
and concentrated and its periphery cooled by a convergent, but
non-vertical, hollow jet of gas coaxial to the arc and entering the
chamber through a nozzle concentric to the cathode.
The stabilization of the arc allows the plasma lamp to be employed
safely in any attitude and also the lamp to be accelerated in a
direction normal to the plasma arc.
The concentration of the plasma arc and the cooling of the
periphery of the arc increase the irradiance generated by the lamp.
Since the arc is concentrated by a gas jet emanating concentric to
the cathode, it flares as it nears the anode due to the decreased
pinching by the gas jet. This results in longer anode life since
the per unit area of energy absorption is reduced from what it
would be if the arc were not flared.
An additional benefit derived by the present invention is that the
arc is stabilized and concentrated without hardware which would
interfere with the radiant output of the arc.
In accordance with another aspect of the present invention, the gas
introduced into the chamber through the nozzle leaves the chamber
through openings adjacent the face of the anode. That portion of
the gas jet which does not pass out of the chamber through the
openings is deflected toward the cathode by a deflection rim formed
around the anode. The deflected gas forms a toroidal collar around
the plasma arc temporarily containing the gas. This feature of the
invention prevents the deflected hot gas from directly contacting
the chamber walls and depositing vaporized portions of the
electrodes thereon or in some instances causing a container wall
failure due to the temperature of the gas.
In accordance with yet another aspect of the present invention, the
inner cylinder forming the chamber is provided with a plurality of
gas ports about its periphery. A portion of the gas coolant flowing
in the passageway between the cylinders will enter the chamber
through the gas ports and form a boundary layer of moving gas
adjacent the inner wall of the cylinder. This moving layer of gas
cools the wall of the cylinder and prevents ambient gas within the
chamber from contacting the cylinder walls and depositing vaporized
electrode material. An alternate embodiment of the present
invention introduces this boundary layer gas from openings
concentric with the cathode to produce a laminar flow along the
chamber walls.
Another aspect of the present invention is the purification of the
gas as it is recirculated by placing metallic getters at a point in
the gas flow having a temperature at which the getter operates most
efficiently.
Another feature of this invention is the provision for initiating
the arc by moving the entire cathode toward the anode, while
limiting the current which can flow through the lamp circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view, partially in longitudinal-section
of a system including a plasma arc lamp and parabolic
reflector;
FIG. 2 is a perspective view of the plasma arc lamp chamber;
FIG. 3 is an end elevation view of the lamp shown in FIG. 2;
FIG. 4 is a sectional view of one embodiment of the plasma arc lamp
of FIG. 2, taken on section line 4--4 of FIG. 3, showing one
embodiment of the present invention;
FIG. 5 is a sectional view of the embodiment of the plasma arc lamp
of FIG. 4 illustrating the electrode coolant flow;
FIG. 6 is a perspective view of the anode assembly of the
embodiment of FIG. 4 showing the heat exchanger fins thereon;
FIG. 7 is a cross-sectional view of the cathode taken along line
7--7 of FIG. 4;
FIG. 8 is a cross-sectional view of the anode taken along line 8--8
of FIG. 4;
FIG. 9 is a cross-sectional view of the plasma lamp taken along
line 9--9 of FIG. 4;
FIG. 10 is a cross-sectional view of the pump shown in FIG. 1,
taken on section line 10--10 of FIG. 11, used to recirculate the
gas in the plasma arc lamp;
FIG. 11 is a cross-sectional view taken along line 11--11 of FIG.
10;
FIG. 12 is a longitudinal sectional view of the preferred
embodiment of the present invention taken along lines comparable to
those which produced FIG. 4, and showing a schematic diagram of a
starting circuit used to initiate the arc between the
electrodes.
FIG. 13 is a sectional view of the cathode housing of the preferred
embodiment taken along the line 13--13 shown in FIG. 12;
FIG. 14 is a sectional view of the cathode housing of the preferred
embodiment taken along the line 14--14 shown in FIG. 12;
FIG. 15 is an enlarged sectional view of the cathode tip assembly
as shown is FIG. 12;
FIG. 16 is a sectional view of the cathode tip assembly taken along
line 16--16 of FIG. 15;
FIG. 17 is an enlarged sectional view of the anode tip assembly as
shown in FIG. 12;
FIG. 18 is a sectional view of the anode tip assembly taken along
line 18--18 of FIG. 17;
FIG. 19 is a sectional view of the anode tip assembly taken along
line 19--19 of FIG. 17;
FIG. 20 is an enlarged partial sectional view of the anode tip
assembly as shown in FIG. 12, but with provisions for multiple
purifying agents;
FIG. 21 is an enlarged partial sectional view of the anode and
cathode tip assemblies of FIG. 12 with the cathode in the
arc-initiation position; and
FIG. 22 is an enlarged partial sectional view comparable to FIG.
21, but with the cathode midway between the arc-initiation and
steady state positions.
DESCRIPTION OF THE EMBODIMENT OF FIGS. 1-11
Referring to FIG. 1, there is shown a radiance directional system
10 having a gas pressurized plasma arc lamp 12 as its radiance
source, a pump 14 for recirculating the gas within the lamp 12 and
reflecting means shown as parabolic reflector 13 for directing the
radiance produced by the lamp 12. The heat generated by the lamp 12
and radiated to the reflector 13 is removed from the reflector 13
by a cooling means represented by cooling coils 16. The coil 16
forms a helix around the outside surface of the reflector 13. A
coolant pumped through coil 16 by a coolant recirculating means
(not shown) removes the heat from the reflector 13.
The high current source 18 is provided to sustain the plasma arc
within the lamp 12. In one embodiment of the present invention, the
source 18 is rated at 30 kw and is operable between 60 and 100
volts DC supplying up to 500 amps.
This embodiment of the lamp 12 has an efficiency of approximately
50 percent generating 15 kw radiant output for a 30 kw input and
develops a horizontal intensity of 180,000 candles.
One embodiment of the plasma arc lamp 12 is illustrated in FIGS. 2
through 9. Referring first to FIG. 2, the plasma arc lamp 12 is
shown to include gas recirculation inlet port 19, outlet port 20
and electrode coolant recirculation tubes 22. The pump 14 (FIG. 1)
receives gas from the lamp 12 via outlet port 20 and recirculates
the gas back into the lamp 12 through inlet port 19. A
non-conductive electrode coolant such as water is recirculated
between the electrodes within the lamp 12 by coolant recirculation
tubing 22.
Referring now to FIG. 4, the lamp is shown to include an electrode
means for maintaining a plasma arc column 30 comprising cathode
electrode assembly 32, anode electrode assembly 34 and a gas
pressurized chamber coaxial to the plasma arc 30.
The anode electrode assembly 34 is connected to the high current
source 18 by lead 17. The cathode electrode assembly 32 is
connected to high current source 18 by lead 15. The anode electrode
assembly 34 is electrically insulated from the remainder of the
lamp 12 by an insulating collar 21.
The chamber of lamp 12 is translucent and formed by two concentric
annularly spaced quartz cylinders 26 and 28. The outer cylinder 26
provides a pressure container for the apparatus and the inner
cylinder 28 serves as a heat shield for the cylinder 26. Walls of
the chamber are cooled by gas entering the lamp 12 through inlet
port 19 and flowing through an annular passageway 29 formed between
the cylinders 26 and 28. The inner chamber wall formed by cylinder
28 has a plurality of openings around its periphery represented by
openings 46 and 48 to allow a portion of the gas flowing through
the passageway 29 to enter the chamber. By way of specific example,
in one embodiment of the present invention, there are twenty
openings in each of two planes perpendicular to the longitudinal
axis of the chamber at points represented by openings 46 and
48.
The outer quartz cylinder 26 is shown in FIG. 4 to have flared ends
25 and 27 inserted into end adapters 63 and 65 respectively. The
cost of a commercially available cylinder having the close
tolerance required for a proper seal with end adapters 63 and 65
would be quite burdensome. Accordingly, the cylinder 26 is
advantageously formed by applying glass blowing techniques to a
standard wide tolerance cylinder to flare the ends to the required
tolerance.
Cathode electrode assembly 32 comprises a cylindroconical electrode
tip 33 advantageously formed of tungsten positioned in the nose of
a generally cone-shaped base 36 advantageously formed of copper.
The nose section 38 of the base 36 forms a shroud defining a
generally conical annulus around the electrode tip 33 leaving an
annular funnel-shaped or generally conical passage 37 between them
that leads to a convergent nozzle opening 39 circumscribing the
conical portion of the tip 33 and terminating short of the end
thereof, as shown. Gas exiting generally longitudinally from nozzle
opening 39 is thus directed and formed into a convergent,
non-vortical sheath moving in the direction toward the arc forming
extremity of the cone on the electrode tip, immediately beyond
which its momentum causes it to converge further, and thus pinch
the arc 30.
Nozzle opening 39 communicates with the passageway 29 formed
between the cylinders 26 and 28 by a channel system internal to the
electrode assembly 32. Gas flowing through the passageway 29 enters
the base 36 through a series of ports represented by port 42. In
one embodiment of the present invention, twenty ports are
positioned radially within the base 36, as shown in FIG. 7. Ports
42 allow the recirculating gas to enter chamber 44 and then channel
45; channel 45 represents a plurality of cylindrical channels
communicating between chamber 44 and the annular funnel-shaped
passageway 37. One embodiment of the present invention uses
cylindrical channels instead of a funnel-shaped passageway to allow
the heat from the plasma arc 30, which is intercepted by the face
of the base 36, to be conducted to the interior of the base by the
metal webs between the channels. The gas will be seen to be thus
directed into the nozzle 39 in a straightforward direction, instead
of tangentially, so that its components of velocity within the
nozzle are longitudinally of the cathode-anode axis, and radially
inward toward that axis.
A second channel system internal to the base 36 allows a coolant to
continuously circulate through the interior of the cathode
electrode assembly 32 removing heat conducted from the face of the
base 36. FIG. 5 shows the electrode coolant flow more clearly.
Coolant enters the base 36 from coolant tubing 22 through ports
represented by port 66. The coolant flows into chamber 67 removing
the heat from the base 36 and flowing out of the base 36 through
ports represented by ports 68 to the coolant tubing 22.
The anode electrode assembly 34 is shown in FIG. 4 as comprising a
cylindrical side wall assembly 49 made up of an exterior
cylindrical wall 49a, and an externally annularly channeled wall
49b immediately inside thereof. At the front or arc end of this
wall assembly is a frustoconical end or end wall 50, into which is
sunk an annular depression 50a. Towards the center, end wall 50
joins a tubular rearwardly extending core wall 50b, and this core
wall 50b and the walls 49a and 49b are fitted into the end adapter
65 (FIG. 4). Seated in the annular depression 50a is a hollow anode
face disk 59, which is on the front end of a nipple 61 set into the
front end of the anode core wall 50b. A plurality of gas outlet
channels 60 communicate from a position adjacent to the periphery
of anode face 59 to points within the electrode assembly 34. In one
embodiment of the present invention, there are twenty gas outlet
channels 60, as shown in FIG. 8. The frustoconical end 50 protrudes
about the periphery of the face 59 to form a gas deflection rim 70,
as seen in FIG. 6.
Embodied in the cylindrical wall assembly 49 is a heat exchanger 52
shown in FIG. 6. The heat exchanger 52 comprises a network of fins
49c which form a labyrinth of interconnected channels. The fins are
formed by oblique slots 49d through spaced radial or
circumferential ribs 49e about the cylindrical wall 49b. The
oblique slots 49d are preferably offset from rib to rib, so that
the flow through the slots will not be straight through, but
deflected by the next rib after passing through each slot.
The gas outlet channels 60 leading from adjacent the anode face 59
terminate in the heat exchanger 52. Gas flowing into channels 60
from the chamber will enter the heat exchanger 52 and pass through
the labyrinth of channels to leave the lamp 12 through gas outlet
port 20 (FIG. 4). In the process of passing through the labyrinth
the gas transmits its heat into the fins of the heat exchanger 52
and is cooled. The heat received by the heat exchanger 52 from the
flowing gas, and the heat from the plasma arc 30 intercepted by the
electrode assembly 34, is conducted internally.
The flow of the non-conducting coolant through the electrode
assembly 34 can be seen in FIG. 5 in conjunction with FIG. 4.
Coolant enters the lamp 12 through inlet port 62 and circulates
through the electrode assembly 34, entering along core 50b to
extract anode heat from the latter, then returns outside a dividing
wall 50d to sweep and extract heat from heat exchanger walls, and
finally entering coolant recirculation tubing 22 through ports
represented by port 64. The circulating coolant conducts heat away
from the electrode assembly 34.
The arc 30 maintained between the electrode assemblies 32 and 34 is
initiated by an arc initiating means shown in FIG. 4 as comprising
a displaceable rod 53 positioned in the hollow nipple 61 and core
50d of the electrode assembly 34, and a rod positioning means 55
for advancing the rod 53 through the hollow center 61 to contact
the electrode tip 33. Once an arc is established between the rod 53
and the electrode tip 33, the rod positioning means 55 retracts the
rod into the electrode assembly 34 drawing the arc with it. Once
the rod 53 has been retracted within the proximity of the anode
face 59, the arc leaves the rod taking the path of least resistance
to the face 59 and is thereafter sustained between the electrode
tip 33 and the face 59, as shown.
The rod positioning means 55 comprises a cylinder 54, a piston 56
and spring 58. A fluid or gas entering cylinder 54 exerts a force
upon piston 56 which advances the rod 53 against the opposition of
loading spring 58. The reduction in fluid pressure within cylinder
54 will allow spring 58 to retract rod 53 to a normal position.
The rod 53 is constructed of two cylindrical sections 71 and 73.
The smaller cylinder 71 is advantageously made of tungsten and is
gold soldered to the larger cylinder 73 advantageously made of
stainless steel. The bimetallic construction allows the cylinder 71
to perform its function as an electrode during arc initiation and
yet due to the stainless steel cylinder 73, the intense heat of the
arc is not conducted to the rod positioning means 55. It is to be
understood that other metals of high temperature resistivity may be
substituted for stainless steel in the construction of cylinder
73.
A high current source 18 is connected between electrode assemblies
32 and 34 to maintain the plasma arc 30 between them. The plasma
arc 30 (FIG. 4) is stabilized, concentrated, and has its periphery
cooled by a gas jet formed coaxial to the arc 30. The gas jet is
formed concentric to the electrode tip 33 by a gas flow
constricting means comprising the convergent funnel-shaped annular
channel 37 between the electrode tip 33 and annulus 38 and flows to
the anode face 59 of electrode assembly 34. The gas enters the lamp
12 by inlet port 19 and flows down the passageway 29 with a portion
entering the chamber directly through the ports represented by
ports 46 and 48. The remainder of the gas enters the chamber
through the nozzle opening 39 after passing through the electrode
assembly 32. The gas flowing through the passageway 29 acts as a
coolant for the quartz cylinders 26 and 28. Pressure within the
chamber is maintained due to the flow of gas through ports 46 and
48.
One embodiment of the present invention typically employs xenon gas
and maintains a pressure of 14 atmospheres within the chamber. It
is understood that the present invention may be practiced in an
atmosphere comprised of any inert gas and under any pressure the
particular container is capable of withstanding.
The gas jet emerging around electrode tip 33 is in the form of a
convergent, non-vertical sheath which constricts the plasma arc 30
severely and as a result concentrates the arc 30 into a small
cross-section, thus increasing its radiance. The expression
"substantially non-vortical," as used herein may here be defined as
excluding a rapidly spinning gas, i.e., where a major portion, or
nearly all, of its kinetic energy is involved in spinning motion,
but not necessarily excluding some minor degree of swirl, such as
would not largely increase the residence time of the gas flowing
along the conical cathode to the arc, and thereby permit material
heating of the gas. The expression thus denotes herein that a large
proportion, if not all, of the kinetic energy of the gas flow is
along and toward the axis of the jet, rather than around it. The
expression substantially non-vortical, or essentially non-vortical,
thus denotes simply that the flow of the gas is primarily, or
essentially, if not exclusively, longitudinally of and convergently
with the common axis of the arc column and gas jet, in a sense
consistent with avoidance of the long average residence time of gas
particles following vortical spin paths to the arc as distinguished
from paths which are generally longitudinal of the axis of the arc.
It should be stressed in this connection that long residence time
while undergoing a vortical flow path affords time for undue
heating of the gas, and thus detracts from the arc cooling effect
that is so important to achieve. As the gas jet flows toward the
anode face 59, the pressure upon the arc 30 is reduced owing to
expenditure of its kinetic energy through encounter with the arc,
and the arc 30 flares, as shown. The flare of the arc 30 allows the
face 59 of the anode assembly 34 to absorb the high energy of the
arc 30 over a large area, thus reducing the per unit area energy
absorption or flux. This important feature of the invention
substantially increases the useful life of the anode.
The gas jet flowing from the nozzle opening 39 strikes the anode
face 59 and all but a small portion of it passes directly out of
the chamber through gas outlet channels 60. The portion of the gas
jet which does not enter channel 60 is deflected from the anode
face 59 by the deflection rim 70 (FIG. 6) and forms a spinning
toroidal collar of gas concentric to the plasma arc 30 shown by
arrows 75 in FIG. 4. This gas toroid is very stable and exerts an
additional stabilizing force upon the plasma arc 30. The toroidal
containment of this circulating portion of the gas jet also
prevents the hot gas from directly striking the chamber walls. The
temperature of the gas approaches 6,000.degree. F. and if it
contacted the walls directly, could result in a failure of the
quartz cylinder 28. In addition, the flowing gas will absorb
particles from the electrodes which vaporize slightly during
operation and will deposit them upon the chamber walls if not
deflected.
Another important feature of the present invention is a boundary
layer of moving gas adjacent to the inner wall of cylinder 28
formed by the gas which enters the chamber from passageway 29
through ports 46 and 48. This layer of gas serves to both cool the
walls of the chamber and provide a protective buffer which prevents
the ambient gas within the chamber from contacting the walls of
cylinder 28 and depositing vaporized electrode material.
An improved pump 14 for recirculating the gas in lamp 12 is shown
in detail in FIGS. 10 and 11 and comprises a centrifugal gas
impelling means 101, a switching means 103 responsive to the flow
of gas through the pump 14, and a gas filtering means 105.
The centrifugal gas impelling means 101 is provided by a
disc-shaped impeller 106. This impeller is affixed to the end of
motor shaft 102 which in turn is fixed to the rotor 104 of motor
100. Advantageously, motor 100 comprises an electric induction
motor 100 operated on 400 cycle, three-phase AC power.
The recirculating gas of lamp 12 enters the pump 14 through port
108 and passes to the center of the impeller 106. As the impeller
106 is rotated, the gas is accelerated from the center to the
periphery of the impeller 106 through a plurality of radial
channels in the impeller 106, one such channel being shown at 109.
The gas passes through passageway 107, to the chamber 110
containing filtering means 105. Filter 105 removes impurities from
the gas acquired during recirculation. The gas then passes through
port 112 to chamber 114.
Switching means responsive to the flow of gas through pump 14
comprises a magnetic piston 116 and spring assembly 118 within the
chamber 114, and magnetic electrical switch 122. The gas entering
the chamber 114 has sufficient energy imparted to it by the
impeller 106 to force the piston 116 to the rear of the chamber
114, compressing spring 118. The rearward movement of piston 116
exposes port 120 through which the recirculating gas leaves the
pump 14. The piston 116 will remain at the rear of chamber 114 so
long as the pumping action of the motor 100 continues. If the gas
flow should stop, the loaded spring 118 forces piston 116 to the
front of the chamber 114.
Magnetic electrical switch 122 is magnetically responsive to the
movement of magnetic piston 116 and remotely controls the high
current source 18. The contacts of the switch 122, shown in FIG.
11, are in series with the coil of a control relay (not shown)
within the high current source 18. When the contacts of switch 122
are closed, the control relay enables the source 18 and when the
contacts are open, the source 18 is disabled. The contacts of
switch 122 will be closed when piston 116 is in the rear of chamber
114 and will be open when piston 116 is in the front of the chamber
114.
Accordingly, the source 118 is operable when gas is recirculating
through the lamp 22 and is inoperable when gas is not
recirculating.
This aspect of the present invention provides a failsafe feature.
Without the flow of gas in the form of a gas jet concentric to the
plasma arc, the arc would impinge upon the chamber walls during
horizontal operation of the lamp, resulting in catastrophic
failure. Such an occurrence is automatically inhibited by the
present invention since the lamp 22 will not operate due to open
switch 122 if gas is not recirculating through the pump 14.
The preferred embodiment of the present invention is illustrated in
FIGS. 12 through 22. Referring first to FIG. 12, the preferred
embodiment plasma arc lamp 200 is shown to include an electrode
means for maintaining a plasma arc 202, including a cathode
electrode assembly 204, an anode electrode assembly 206, and a gas
pressurized chamber coaxial to the plasma arc 202.
The anode electrode assembly 206 is connected to the high current
source 208 by lead 210. The cathode electrode assembly 204 is
connected to high current source 208 by lead 212. The anode
electrode assembly 206 is electrically insulated from the remainder
of the lamp housing 200 by an insulating collar 214.
The pressurized chamber of lamp 200 is translucent and formed by
two concentric quartz cylinders 216 and 218. The outer cylinder 216
provides a pressure container for the apparatus, and the inner
cylinder 218 serves as a heat shield for the cylinder 216. The
outer quartz cylinder 216 has flared ends 220 and 222 which are
inserted into a pair of end adapters 224 and 226 respectively. The
purpose of the flared ends 220 and 222 is the same as that
explained in reference to the flared ends 25 and 27 of the
embodiment shown in FIG. 4.
The cathode electrode assembly 204 comprises an electrode tip 228
advantageously formed of tungsten and conically formed at each end.
This tip 228 is mounted within a cavity formed by an annular shroud
or nose section 230 and a cathode base 232 which has a conical
recess to receive the tip 228. The cathode base 232 is mounted on a
tubular sleeve 234 which is slidably positioned within a recessed
cathode housing 236. This housing 236 has a machined conical recess
which is adapted to receive the conical end of the cathode base 232
when the sleeve 234 is retracted to its fullest extent.
The anode electrode assembly 206 comprises a disk-like anode tip
237, which has a recessed semi-spherical face 298 opposite the
cathode tip 228 and a generally conical face on the opposite side.
This conical face fits closely within the concave side of a
generally conical anode-face heat exchanging disk 238, which in
turn is mounted with its convex side within a generally conical
concavity in the end of a core cylinder 308 mounted inside the main
anode heat exchanger 240.
Both the arc gas and an electrode coolant are recirculated through
the lamp structure. The gas is introduced into the lamp structure
through a gas inlet aperture 242 and passes into an annular cavity
244 to enter the annular space 246 between the cylinders 216 and
218, thereby cooling these cylinders. At the opposite end of the
annular cavity 246 the gas flows into an annular cavity 248 in the
cathode assembly and then through a series of apertures 250 into an
annular cavity 252, at which point the gas flow separates,
approximately 95 percent of the gas flow going directly into the
pressurized chamber through a series of ports 254 and approximately
5 percent of the gas following a series of tubes 256 and an annular
channel 258 to pass through a series of holes 260 and thereby flow
longitudinally towards the cathode into the tube 234. From the tube
234, the small percentage gas flow enters the cathode base 232
through a series of channels 262 to flow through an annular
convergent or frustoconical annular nozzle 264 defined by and
between the forward conical or frustoconical portion of the cathode
tip 228, and the opposed frustoconical internal surface of the
aforementioned annular shroud 230. It will be noted that the
cathode tip tapers substantially conically to a blunt forward
arcing extremity and is thus in the form of a frustum of a cone;
and that the surrounding conical shroud 230 terminates short of the
conical terminus of the cathode, and thus short of this blunt
forward extremity, providing an annular or ring shaped, convergent
gas discharge orifice at that point. Thus, the nozzle passage 264
and nozzle direct the gas in a convergent, conical, non-vortical
sheath along the surface of the frusto-conical cathode and off the
end thereof in a still convergent but non-vortical manner so as to
impinge directly on and thus pinch as well as cool the column of
the arc issuing from the cathode. Attention is drawn to the
essentially non-vortical character of the gas flow issuing from the
nozzle, which assures only fleeting residence time for the gas
within the convergent nozzle, thus minimizing heating of the gas.
The termination of the shroud short of the arcing end of the
cathode is a feature of importance, since it avoids overheating and
burning of the shroud, it removes the shroud from a prominent
forward position where it could occlude a fraction of the radiant
energy from the most intense region of the arc column, and it also
frees the convergent hollow gas jet soon enough that it will still
have the necessary pinching effect on the arc, but will be "soft"
enough so that after initial impingement on the arc, it will tend
more readily to thereafter spread, and so permit the desired final
flare of the arc toward the anode. Both the large percentage gas
flow entering the chamber through the ports 254 and the small
percentage gas flow entering the chamber through the annular space
264 are exhausted from the chamber through an annular recess 266
between the anode tip 237 and a frustoconical end 268 of the anode
assembly 206. The gas then flows through the main anode heat
exchanger 240 and is exhausted from the plasma arc lamp 200 through
an annular channel 270 by a tubular port 272.
The electrode coolant enters the lamp 200 through a central bore
274 in the anode core 308 and initially flows through the
anode-face heat exchanger 238 to enter an annular channel 276
around core 308 and inside the cylindrical side wall of heat
exchanger 240. The coolant then, following extraction of heat from
heat exchanger 240, passes out of the anode assembly 206 through a
port 278 and is conducted by a tube (not shown) into a coolant
recirculation tube 280. This tube 280 conducts the coolant to the
cathode assembly 204 where the coolant passes successively through
a pair of concentric annular channels 282 and 284 and is exhausted
through a second coolant recirculation tube 286 to an exhaust port
288 on the anode end of the lamp 200.
Portions of both the coolant fluid flow path and the gas flow path
are substantially improved in the embodiment of FIG. 12 and
following from that which was described in reference to FIGS. 4
through 11. These changes are described in detail below.
FIGS. 12, 13, and 14 illustrate the gas flow channels within the
cathode assembly 204. On entering the cathode assembly 204 from the
annular space 246 between the cylinders 216 and 218, the gas is
circulated into the annular cavity 248. This gas then passes
through a series of portals 250, best illustrated in FIG. 13, to
enter an annular cavity 290. The metallic webs 292 between the
apertures 250 serve to conduct heat from a ring-shaped member 294,
which forms the outer wall of the cathode- electrode assembly 204.
From the annular cavity 290 the gas flows into an adjoining annular
cavity 252 at which point the flow separates, 95 percent of the
flow passing through a series of aperatures 254, best illustrated
in FIG. 14, and 5 percent of the flow passing through a series of
tubes 256.
The larger percentage flow which passes through the apertures 254
enters the cylindrical chamber around the arc 202 in the form of a
laminar flow which separates the region adjoining the quartz tube
218 from the region in the vicinity of the arc 202. This flow,
therefore, tends to cool the quartz tube 218 and to prevent
impurities which form on the electrodes 204 and 206 from reaching
the quartz tube 218. The series of ports 254 greatly increases the
wetted area past which the large percentage gas flow must flow
before entering the arc chamber. This increased wetted area reduces
the Reynolds number of the flow and therefore makes this large
percentage gas flow in the vicinity of the quartz tube 218 more
laminar than would a simple annular opening at the extremity of the
cathode assembly.
The small percentage gas flow which enters the series of tubes 256
and flows through the annular cavity 258 and the series of holes
260, flows through the tubular sleeve 234 to the vicinity of the
cathode electrode tip 228. This flow is best described in reference
to FIGS. 15 and 16. On leaving the tubular sleeve 234, this small
percentage gas flow passes into a series of channels 262 and enters
the large end of the frustoconical annular space 264. At the small
end of this annular space 264 proximate to the outer extremity of
the cathode tip 228 the annular space 264 is broken by a series of
longitudinal ribs 296. These ribs greatly increase the effective
perimeter of the wetted area through which the gas must flow on
leaving the cathode tip assembly 204 and therefore, by reducing the
Reynolds number of that flow, make the flow more laminar. In
addition, these ribs allow easy assembly of the annular nose
section or shroud 230 over the cathode electrode tip 228 while
still accurately defining the width of the annular nozzle space 264
at the point where the gas exits the cathode tip assembly. Since,
in prior art gas jet assemblies, the annular nose section 230 in
the vicinity of the cathode required accurate machining to define
the width of the annular jet cavity 264, these ribs 296 reduce the
cost and complications of assembling the cathode electrode assembly
204.
The highly laminar flow which exits from the annular cavity 264
tends to hug the surface of the cathode electrode tip 228 and this
effect allows increased pinching of the arc in the vicinity of the
cathode electrode tip 228 while still allowing the shroud 230 to be
positioned away from the arc to avoid its overheating.
The preferred means for recirculating the coolant fluid and gas
through the anode assembly is best described in reference to FIGS.
12, 17, 18 and 19. The anode tip of the present embodiment, best
shown in FIG. 17, has a face 298 which is formed in a frustoconical
or disked shape which generally coincides with the shape of a
sphere generated around the center of the extremity or tip of the
cathode. Such a formation increases the region over which the anode
tip 298 and the cathode tip 228 are equidistant, and in which the
electric field lines between cathode and anode are of substantially
uniform length and spacing, and therefore spreads the arc 202
toward and at the anode footing while it is being concentrated at
the extremity of the cathode. The anode footing of the arc 202 is
likewise increased by the fact that the low percentage gas flow
which emanates from the tip of the cathode assembly 204 is directed
into the center of the spherical segment anode tip 237 and produces
a higher pressure at the center of this anode tip 237 due to the
impact or stagnation of this high velocity jet. This increased
pressure on the center line produces an outward radial flow of
plasma along the surface 298 of the anode tip 237.
An added advantage of the spherical anode tip 237 is the
enhancement of the effective cooling of the anode footing area. The
plasma arc 202 will rapidly destroy the face 298 of the anode tip
237 even when the anode footing area of the arc 202 is relatively
large if effective means are not utilized to cool the anode tip
237. Since the heat incident at the face 298 is transferred through
the anode in a diverging manner due to the generally spherical
geometry of the device, each of the isotherms within the anode tip
being spherical in shape, the heat flux at the larger rearward face
300 of the anode tip 237 is of reduced unit intensity. The
increased radius of curvature increases the surface area at the
rear face 300 of the anode tip 237 from which the heat may be
extracted. In a similar manner, the concave or disked end of the
anode face heat exchanging element 238 which fits with the face 300
of the anode tip 237 further reduces the density of the heat energy
such that when the heat flows from the surface 302 of the heat
exchanger element 238, it may be extracted over a considerably
larger area than the footing area on the divergent arc column on
the anode surface 298.
In order to enhance the ability of the coolant liquid to remove the
heat from the anode tip 298, an improved anode tip heat exchanging
element 238 is utilized in this embodiment. This element is best
described with reference to FIGS. 17 and 19. The element fits flush
with the surface 300 of the anode electrode tip 237 and
incorporates a series of ribs 304 which form circular paths for the
cooling fluid. These ribs are slotted in various places to allow
the coolant fluid to pass from the center of the heat exchanging
element 238 to the periphery. However, the slots 306 are oblique
from the radius of the heat exchanger as viewed in FIG. 19.
Therefore, the coolant liquid in passing from the center of the
heat exchanging element 238 to the periphery is forced by the
oblique slots 306 to flow tangentially as well as radially through
the heat exchanging ribs 304. This bi-directional flow greatly
increases the Reynold's number of the flow of coolant liquid
through the heat exchanging element 238 and therefore increases the
turbulence of that flow. This increased turbulence, in turn,
increases the efficienty of the heat exchanger 238. As shown in
FIG. 17, the cylindrical wall 308 forces the coolant liquid which
enters the central bore 274 to pass radially and tangentially
through the heat exchanger before exiting through the annular
channel 276.
The main anode heat exchanger 240 is similar in construction and
operation to the heat exchanger which was described in reference to
FIG. 6 and has oblique or diagonal slots 308 as shown in FIG. 18 to
increase the turbulence of the gas flow through the heat exchanger
240 and thereby increase the efficiency of this heat exchanger. As
the gas passes from the forward extremity 310 of the heat exchanger
240 to the rear extremity 312 of this heat exchanger 240, heat is
transferred from the arc gas into the coolant liquid in the annular
channel 276. The gas therefore goes through a large temperature
reduction between the extremities 310 and 312. It has been found,
in the past, that contamination of the arc gas, of even a very
small percentage, will produce performance degradation and will
eventually lead to electrode failure. Metallic getters have been
used in the prior art by placing the getter in the arc chamber and
depending upon convection currents of the arc gas to bring the gas
past the getter material to purify the gas. The present invention
utilizes a bed of getter material 314 such as titanium, tantalum or
barium, which materials, when properly heated, will combine with
the impurities in the gas flow to form oxides, hydrides, nitrides
and carbides, thereby removing the impurities from the gas flow.
Each such metallic getter has a particular temperature at which it
operates most efficiently to purify the arc gas. The getter
material in the present embodiment may therefore be carefully
positioned in the heat exchanger 240 so that it is placed in a
temperature zone in this heat exchanger 240 to provide an optimum
gas purification reaction. As an additional feature of this
placement of the getter material 314 within the heat exchanging
element 240, it is possible to recirculate all of the arc gas
through the getter material and therefore assure purification of
the arc gas in an organized rather than a random gas flow
manner.
Referring to FIG. 20, an alternate method of utilizing the metallic
getter in the heat exchanging element 240 allows placement of a
variety of metallic getter materials 314, 316 and 318, each of
which has a different optimum temperature for reaction with the
impurities in the gas flow. Alternately, the materials 314, 316,
and 318 may all be formed of one metal, where that metal most
effectively combines with different gas impurities at different
temperatures. These temperatures again may be selected along the
temperature gradient between the extremities 310 and 312 of the
heat exchanger 240. It has been found that these beds of getter
material 314, 316 and 318 may be formed either by wrapping fine
wire formed of the metallic getter within the recesses of the heat
exchanger 240 or by placing a semi-porous ring of metallic getter
within these recesses.
An additional improvement of the present embodiment is the means
for initiating the arc within the arc chamber and is best described
in reference to FIGS. 12, 21 and 22. Electrical pulsing techniques
which have been utilized in the past to initiate the arc within
plasma lamps become increasingly difficult as the pressure within
the arc chamber is increased to increase the light output of the
arc lamp. Similarly, a movable rod, such as the element 71 as shown
in FIG. 4, has the disadvantage that the electrode configurations
must be altered to allow utilization of such an element. The
present embodiment includes a movable cathode mechanism which
allows the entire cathode assembly 204 to be positioned proximate
the anode tip assembly 206 to initiate the arc. The configuration
of the electrodes at their extremities which determines the arc
shape is therefore not limited.
Referring to FIG. 12, the actuating mechanism for advancing the
cathode tip assembly 204 toward the anode tip assembly 206 will
first be explained. This mechanism is hydraulic and uses the high
pressure coolant fluid which typically has a pressure of 200 to 300
psig at the lamp as the driving force. By using the coolant fluid
for actuation of this starting mechanism, an interlock is afforded,
since the lamp cannot be started without the coolant system
operating satisfactorily. The high pressure coolant is fed by means
of a high pressure tube 320 into the end of a cylinder 322 in which
a piston 324 is slideably mounted. The pressure of the high
pressure coolant drives the piston 324 toward the anode assembly
206. When this occurs the piston will engage a cap 326 which is
fitted within the end of the sleeve 234, thus driving the sleeve
234 toward the anode assembly 206 and, in turn, bringing the
cathode assembly 204 adjacent the anode assembly 206. When the high
pressure coolant 320 is removed from the cylinder 322, the piston
is biased to return to its retracted position by a first spring
328; and the cathode assembly, with the sleeve 234, is biased by a
spring 330 to return to a position wherein the cathode base 232
abuts and fits within the recessed cathode housing 236.
Referring now to FIGS. 21 and 22, the cathode is shown in FIG. 21
in its most extended condition with the cathode tip 228 adjacent
the anode tip 237. With the lamp in this condition, an arc is
easily generated, even if the pressure within the lamp is extremely
high. With the arc thus initiated between the cathode tip 228 and
the anode tip 237, the cathode is slowly retracted by the spring
330 into the recessed cathode housing 236, and is shown at a
position midway through this travel in FIG. 22. The arc, once it is
initiated, is thus drawn across the chamber between the electrodes
eliminating the need for high voltage pulses or for irregularities
in the anode configuration.
The hydraulic actuation of the starting assembly facilitates the
introduction of a starting circuit which is shown in FIG. 12 which
automatically places the lamp in a starting mode when the main DC
power supply 208 is energized. This starting circuit functions as
follows:
To start, an auxiliary power supply 252 is turned on, energizing a
relay coil 338 to close a normally open switch 336. The DC power
supply 208 is then turned on, which developes the full open circuit
voltage of the power supply between the separated anode and cathode
by a circuit lead 210 to the anode assembly 206, and a circuit lead
332, the now closed switch contacts 336 of relay 338, and the wire
212, to the cathode. Since the cathode assembly 204 is fully
retracted, an arc will not be generated between the cathode tip 228
and the anode tip 237 and no current will be drawn by the lamp 200
from the DC power supply 208. The full open circuit voltage of the
DC power supply is therefore presented to a series circuit
comprising a lead 240 which is connected to the lead 212, a zener
diode 242, a resistor 244, a relay 246, and a lead 248 which is
connected to lead 210. The zener diode 242 has a breakdown voltage
which is high enough to allow the relay 246 to be energized by the
DC power supply 208 only if the DC power supply is operating in an
open circuit configuration. For example, if the open circuit
voltage of the DC power supply 208 is 160 volts, while the nominal
operating voltage under the lamp load is 80 volts, the zener diode
242 advantageously has a breakdown voltage of 130 volts and the
relay 246 advantageously operates at 24 volts DC, such that when
the DC power supply 208 is operating into an open lamp circuit, the
relay 246 will be energized; whereas, when the DC power supply 208
is driving an arc in the lamp 200 the voltage at the zener diode
falls between its breakdown level, and, the relay 246 will become
deenergized. When the relay 246 is energized, it opens a switch 260
in an auxiliary power circuit from power supply 252, and which
includes a normally closed switch 258, opening in response to fluid
pressure in a coolant tube 320, and which also includes the coil of
relay 338. Switch 336 is thus opened and a by-passing, current
limiting resistor 234 cut into the lamp supply circuit. Relay 246
also closes a switch 250 completing a circuit from an auxiliary
power supply 252 to a three-way hydraulic solenoid valve 254. This
solenoid valve 254, when energized, conducts high pressure coolant
liquid from a high pressure coolant liquid source 256 into the tube
320 to advance the cathode assembly 204 toward the anode assembly
206, thus overriding or overcoming the springs 328 and 330. The
rate of this advancement is limited by a throttling orifice 257
between the source 256 and the valve 254. Likewise, the application
of pressure to the tube 320 opens the normally closed pressure
sensitive switch 258 which is in communication with the tube 320.
This pressure sensitive switch 258 is connected in series with
normally closed contact 260 of the relay 246. The normally closed
switches 258 and 260 are series connected between the relay 338 and
the power supply 252, such that a lack of pressure in the tube 320
and a deenergized condition of the relay 246 are required before
the relay 338 becomes energized to close the normally-open contacts
of switch 336. Thus, at the outset, with power supply 252 on, and
power supply 208 not yet switched on, switch 258 is closed, relay
246 is deenergized, so switch 260 is closed; and relay 338 is
therefore energized and switch 336 closed.
When the DC power supply 208 is initially energized, the relay 246
is in turn energized and closes the switch 250 to actuate the
three-way solenoid valve 254 and thus feed high pressure coolant to
line 320 to advance the cathode assembly 204 toward the anode
assembly 206. Energization of relay 246 also opens switch 260 which
deenergizes relay 338 and opens switch 336. Thus, the resistor 334
is added in series to the DC power supply 208 circuit to limit the
current which can flow from the cathode tip 228 to the anode tip
237, and also to form a circuit maintaining temporarily the
energization of relay 246. It will be noted that the rise in
pressure in the system driving the cathode to striking position
also acts at pressure switch 258 to open it, so the circuit
energizing the relay 238 to close switch 336 is then open at two
points, switch 258, and switch 260, in series, and both must close
before switch 326 can close to short out current limiter resistor
334. Now, when the cathode tip 228 touches the anode tip 237,
current is drawn from the DC power supply 208 through the resistor
334 to initiate conduction through the interface of the cathode and
anode. This current conduction through the resistor 334 lowers the
voltage impressed on the zener diode to a level below its cutoff
voltage, such that initiation of current conduction through the
lamp deenergizes the relay 246, thereby closing switch 260. Also,
when the relay 246 deenergizes, the switch 250 returns to its
normally open condition driving the three way solenoid valve 254 to
exhaust the fluid from the cylinder 322 through the tube 320,
allowing the cathode assembly 204 to retract. The speed of
retraction of the cathode assembly is determined by a throttling
valve 262 in the exhaust orifice of the three way solenoid valve
254. With the pressure removed from the cylinder 322, the cathode
is withdrawn slowly, drawing the arc 202 across the pressure
chamber of the lamp 200. The deenergization of the relay 246 allows
the switch 260 to return to its normally closed position. However,
the switch 258 remains open until the cathode assembly 204 becomes
fully retracted, due to the hydraulic pressure caused by the spring
328 driving the piston 324. When the cathode assembly 204 is fully
retracted, pressure within the tube 320 will subside and the switch
258 will return to its normally closed position, completing a
circuit through normally closed switch 260 to the relay 338 to
energize the relay 338. Energization of the relay 338 closes the
switch 336, which allows the DC power supply 208 to directly drive
the lamp assembly 200. In this condition the voltage of the DC
power supply is below the open circuit voltage due to the lamp
load, and therefore the zener diode 242 will continue to maintain
the relay 246 in a deenergized condition.
Should the arc 202 within the lamp 200 cease for any reason during
the operation of the lamp, the output voltage of the DC power
supply 208 will return to the open circuit level and a new starting
sequence will begin.
This preferred embodiment lamp described in reference to FIGS. 12
through 22 is capable of operating at higher efficiencies and input
power levels, while extending electrode usable life. One such lamp
has been operated at an input power level of 50 kw with
comparatively short distances between the anode tip 237 and the
cathode tip 228, specifically 6 mm between the cathode tip 228 and
the frustoconical end 268 of the anode assembly 206. This lamp
exhibited an extremely high power density within the arc 202,
namely 10,000 W-cm.sup..sup.-2 -ster.sup..sup.-1, while operating
at an input voltage of 67 volts and having an arc current of 760
amps.
Besides this capability for increased brilliance, this lamp of
FIGS. 12 through 22 extends the usable lifetime of the electrode
elements. For example, one such lamp has been successfully operated
at an input power level of 30 kw in excess of 400 hours without
failure. When this lamp was dismantled, there was negligible
degradation of the electrode elements, indicating a probable
electrode life well in excess of 400 hours.
* * * * *