More particularly, the present invention relates to a method and system for manufacturing a bulb that can prevent waste of bulb material by providing a bulb material tube having a flare and a dome formed on both ends of which, heating the lower portion of the bulb material tube, and blowing the bulb material tube to form a bulb in a mold.

Background Art Small containers such as glass bottles or ampules and light bulbs are often manufactured by heating and sealing one end of a glass tube material, then by performing a blowing process of this area in a predetermined mold. Such methods for manufacturing bulbs from a glass tube material have been disclosed in Japanese Laid-Open Patent No.

Showa 52-31584 entitled"Method for Making Glass Tube Flare", in Japanese Patent Publication No. Showa 63-129029 entitled"Manufacturing Method of Glass Bulb Using Bulb Blowing Device", and U. S. Patent No. 4092142 entitled"Device for Manufacturing Container from Glass Tube". In these patents, a method is typically used in which a long glass tube material is directly supplied to a device, and one end of the glass tube material is formed into a predetermined shape.

FIG. 1 is a perspective view schematically showing a conventional apparatus for manufacturing a bulb by directly receiving the supply of a glass tube material. A conventional apparatus 80 for manufacturing a bulb includes a rotating table 82 that rotates at predetermined periods and by a predetermined angle, and a chuck 84 used for clamping a plurality of glass tube materials and that is mounted at a predetermined distance to an edge of the rotating table 82. A long glass tube material is inserted and clamped in the chuck 84 used for clamping glass tube material, and a gas injection nozzle 86a connected to a predetermined gas supply apparatus through a gas injection tube 86 is inserted in an upper hole of the glass tube material 81. Even if the glass tube material 81 is consumed and

moves downward, the gas injection nozzle 86a is fixed to a guide 88, which is supported by a guide rod 87 fixed to the rotating table 82 to allow up and down movement, such that the gas injection nozzle 86a moves downward in a state inserted in an upper entrance of the glass tube material 81. The glass tube material 81 supplied to the conventional apparatus 80 for manufacturing bulbs as described above undergoes successive production processes while circumnavigating the rotating table 82 through its rotation.

FIG. 2 schematically shows successive processes in directly working one end of the long glass tube material 81 to manufacture a bulb 82 using the conventional apparatus 80 for manufacturing bulbs described above. The hashed lines in the glass tube material 81 indicate an area that is heated by a torch 89. The processes are continuously repeated by rotation of the rotating table 82. In a first process, the glass tube material 81 that has been shortened under the chuck 84 for clamping glass tube material while passing through a sixth process is moved a predetermined distance downward by releasing the clamping force of the chuck 84 for clamping glass tube material. The glass tube material 81 always stops after moving a predetermined amount by a stopper 91. In a second process, a cutting knife 93 is used to cut a predetermined amount of a lower end of the glass tube material 81 and that has a shape unsuitable for bulb manufacture as a result of cutting in the sixth process and collision with the stopper 91 in the first process. At this time, the cutting knife 93 grabs and pulls downward a predetermined amount of the heated lower end of the glass tube material 81 such that a predetermined amount of scrap 81 a is separated from the glass tube material 81. At the same time, a lower end opening of the glass tube material 81 in which the scrap 8 la has been cut and removed is closed. In a third process, the lower end of the glass tube material 81 is heated, and its opening made into a convex shape to thereby form a dome 81b. In a fourth process, the lower end heated in the third process is positioned together with the dome 81b in a mold 95, and gas is injected through the gas injection nozzle 86a inserted in the upper entrance of the glass tube material 81 such that the lower end of the glass tube material 81 has the same shape as the mold 95. That is, a blowing process is performed to realize a bulb 82 with a bulb section 82a and a flare 82b.

The flare 82b enlarges an entrance to the bulb 82 to allow for easy bulb manufacture, and is a typical forming found in light bulbs. In a fifth process, an area of the flare 82b of the

bulb 82 made in the fourth process is heated. In a sixth process, severing is performed at an area above and adjacent to the flare 82b to thereby separate the bulb 82 from the glass tube material 81. If all of the glass tube material 81 is used up through the above processes, the worker inserts the gas injection nozzle 86a into a an upper entrance of a new glass tube material, and clamps the glass tube material to the chuck 84 for clamping glass tube material to thereby perform supply of a new glass tube material.

However, in the method of directly producing a bulb from a glass tube material using the above conventional apparatus for manufacturing bulbs, a significant amount of glass tube material is cut and thrown away as scrap in the process of manufacturing the bulb, and the inserted portion of the glass tube material into the chuck in order to clamp the glass tube material also discarded because that portion cannot be processed. There is significant waste of the glass tube material as a result.

Further, in the method of directly producing a bulb from a glass tube material using the above conventional apparatus for manufacturing bulbs, every time a glass tube material is used up, it is necessary for the worker to supply a new glass tube material to the chuck used for clamping glass tube material. The worker, therefore, must continuously wait until it is time to perform this operation.

In addition, with respect to the process of supplying a new glass tube material to the conventional apparatus for manufacturing bulbs, it is necessary that the worker performing this process be skilled since it is performed while the apparatus is operating.

Also, in the above conventional apparatus for manufacturing bulbs, since the flair of the bulb, which is a forming needed in the manufacture of bulbs, is formed in a mold, it is necessary to design and manufacture also the mold with an area form forming the flare.

Finally, in the above conventional apparatus for manufacturing bulbs, each of the plurality of glass tube materials clamped in the chuck used for clamping a plurality of glass tube materials must be provided with a gas injection tube and a guide that supports the gas injection tube, and the gas injection nozzle must rotate with the rotating table. Therefore, a structure in which a gas injection connecting tube that is joined to the gas injection nozzle is connected to a gas supply source is complicated.

Disclosure of Invention The present invention has been made in an effort to solve the above problems. It is an object of the present invention to provide a method and system for manufacturing a bulb that can prevent waste of bulb material by providing a bulb material tube having a flare and a dome formed on both ends of which, heating the dome portion of the bulb material tube, and performing blowing process in a state that the dome portion of the bulb material tube being inserted in a mold.

It is another object of the present invention to provide a method and system for manufacturing a bulb in which there is mounted a supply means that supplies a glass tube material one at a time to the system for manufacturing bulbs, a batch of a predetermined number of glass tube materials being supplied all at once such that a worker need not be continuously waiting at the system and can instead supply a batch of glass tube materials when all the plurality of the same have been used.

It is yet another object of the present invention to provide a method and system for manufacturing a bulb in which new glass tube materials are not directly supplied to the system for manufacturing bulbs during operation of the same, and, instead, the glass tube materials are arranged in a batch and simply supplied to an alignment stand such that the worker performing supply of the glass tube materials need not be experienced.

It is still yet another object of the present invention to provide a method and system for manufacturing a bulb in which only a lower portion of a glass tube material having a pre-formed flare is formed in a mold for bulb forming such that it is not necessary to manufacture a mold with a shape to form the flare.

It is still yet another object of the present invention to provide a method and system for manufacturing a bulb in which only a single a gas injection means, which operates to allow a gas injection nozzle to approach an entrance of a flare of a bulb material tube, is mounted at a suitable position in the vicinity of a rotating table to thereby obtain a simple structure.

To achieve the above objects, in one aspect, there is provided A method for manufacturing a bulb, comprising: forming flares of a glass tube at both ends having enlarged diameter by heating both ends of the glass tube of a predetermined length, then

applying pressure to both ends of the glass tube; separating the glass tube into two bulb material tubes with a separated center portion closed by heating the center portion of the glass tube while being rotated at a predetermined speed, and simultaneously applying forces to the direction of both ends of the glass tube; heating the lower closed portion of the bulb material tube while being rotated; and performing blow forming by injecting a gas into the bulb material tube through its flare, simultaneously rotating the heated bulb material tube in a state where its lower portion is placed in a mold for bulb forming.

In the method of the present invention, the step of heating the lower closed portion of the bulb material further comprising the step of supplying the bulb material tube to a chuck having clamps for clamping the flare of the bulb material tube before heating the lower closed portion, and the step of performing blow forming performs blow forming by injecting the gas into the bulb material tube through the chuck, simultaneously rotating the heated bulb material tube in a state where its lower portion is placed in the mold for bulb forming and the flare of the bulb is clamped by the chuck.

The step of forming flares forms flares by heating both ends of the glass tube of a predetermined length, then applying pressure simultaneously to both ends of the glass tube while the glass tube rotating.

In addition, the method further comprises the step of forming a dome by injecting gas into the bulb material tube through the flare of the bulb material tube to form the closed portion convex outwardly between the step of separating the glass tube and the step of heating the lower closed portion.

In the method of the present invention, the step of separating the glass tube separates the glass tube into two bulb material tubes with a separated center portion closed by heating the center portion of the glass tube while rotating the glass tube with lower rollers and upper rollers, and simultaneously applying forces in the direction of both ends by the upper rollers, wherein the glass tube is supported by the lower rollers and in contact with the upper and lower rollers and the lower rollers are disposed to be overlapped a portion of edges of them in series and the upper rollers are inclined in relation to the lower rollers.

In another aspect, there is also provided a system for manufacturing a bulb

including: a flare forming device including a second heating means for receiving a glass tube of a predetermined length and heating both ends thereof, and a flare processing means for applying pressure to both heated ends to form flares of an enlarged diameter at both ends; a bulb material tube separating device including a third rotating means for receiving the glass tube with flares at both ends and rotating it at a predetermined speed, a third heating means for heating a center portion of the glass tube, and a separating means for separating the glass tube into two bulb material tubes with the separated center portion closed by applying forces to the direction of both ends of the glass tube; and a blow forming device including a chuck for clamping the flare of the bulb material tube provided and rotating it, a fourth heating means for heating a lower portion of rotating bulb material tube, a bulb forming mold for receiving the lower portion of the rotating bulb material tube, and a second gas supply means for providing a bulb forming gas into the bulb material tube through the chuck.

The system of the present invention further includes a bulb material tube supply device for supplying the bulb material tube separated by the bulb material tube separating device to the chuck of the blow forming device.

The blow forming device comprises: a base; a circular rotary table rotatably mounted on the base, and on an edge of which a plurality of the chucks are mounted in a circumferential direction and at predetermined intervals; a rotary table driving means for intermittently rotating the rotary table; a clamping unit driving means for rotating the bulb material tube clamped in the chuck; and a control means for controlling the rotary table driving means and the clamping unit driving means, wherein each of the chucks includes a housing fixed to the edge of the rotary table; a clamping means mounted to the housing in such a manner that it is able to undergo rotation about a predetermined axial line, having formed a predetermined passage hole of a predetermined diameter along this axial line, and including the clamping unit for clamping an upper area of the bulb material tube under the passage hole such that a center axis of the bulb material tube is substantially identical to the predetermined axial line; a power transmitting means mounted to the housing and receiving power from the clamping unit driving means to transmit the power to the clamping means; and a clutch for controlling the power transmitted to the clamping means

from the power transmitting means, wherein if an external force of a predetermined level of greater is applied to the clamping means, the clamping means spreads apart the clamping unit to either clamp the flare of the bulb material tube or release the clamped bulb material tube, and the clutch discontinues the transmission of power to the clamping means, wherein the bulb forming mold is mounted so that it does not interfere with the rotation of the rotary table, and receives the bulb material tube when the rotary table is stopped, wherein the fourth heating means is mounted in the circumference of the rotary table such that it is able to heat the lower portion of the bulb tube material clamped in the clamping means, wherein the second supply means includes a gas injection nozzle that contacts the flare of the bulb material tube to supply gas therein through the passage hole of the clamping means of the chuck in the case where the bulb material tube clamped in a specific chuck is received in the bulb forming mold, wherein the bulb material tube supply device supplies the bulb material tube to the clamping means of the chuck of a specific location when the rotary table stops, and wherein the bulb material supply device further includes a clamping release device that applies an external force to the clamping means when the bulb material tube is supplied to the chuck of a specific location.

The third rotating means includes a plurality of shafts mounted at the same horizontal height and uniformly at a predetermined interval to allow for rotation in the same direction and at the same speed, and a plurality of disks provided such that a plurality are fixed to each of the plurality of shafts and having a radius of a predetermined size such that a portion of edges of the disks overlap between adjacent shafts, and the glass tube with flares formed on both ends is supplied in a state extended lengthwise in an axial direction on the plurality of disks of the third rotating means such that the glass tube is rotated in a state where an outer circumferential surface of the glass tube simultaneously contacts outer circumferential surfaces of the plurality of disks of the third rotating means, and the flare forming device comprises a plurality of shafts mounted at the same horizontal height and uniformly at a predetermined interval to allow for rotation in the same direction and at the same speed, and a second rotating means including disks, a plurality of which are fixed to each of the plurality of shafts, and having a radius of a predetermined size such that such that a portion of edges of the disks overlap between adjacent shafts, and the glass tube of a

predetermined length is supplied in a state extended lengthwise in an axial direction on the plurality of disks of the second rotating means such that the glass tube is rotated in a state where an outer circumferential surface of the glass tube simultaneously contacts outer circumferential surfaces of the plurality of disks of the second rotating means.

The bulb material tube separating device further includes a first gas supply means for supplying gas into the glass tube materials, which are separated into two segments, through the flares.

The system further includes a transfer device for supplying the glass tube of a predetermined length and with a flare formed by the flare forming device from the flare forming device to the bulb material tube separating device.

The transfer device includes a plurality of shafts mounted uniformly at a predetermined interval to allow for rotation in the same direction and at the same speed between the flare forming device and the bulb material tube separating device, and a plurality of disks provided such that a plurality are fixed to each of the plurality of shafts at a predetermined interval and having a radius of a predetermined size such that a portion of edges of the disks overlap between the shafts, the disks including indentations formed in outer circumferences of the disks at positions corresponding to the same phase with respect to a line vertical to outer circumferences of the disks.

The system further includes a cutting device including a first heating means for heating an area of the glass tube material that is at a predetermined distance from one end thereof, a cutting knife mounted such that a blade thereof periodically contacts an outer circumference of the heated area of the glass tube material to circumnavigate the same, wherein the glass tube of a predetermined length supplied to the flare forming device is manufactured by the cutting device cutting the glass tube material into a predetermined length.

The cutting device further includes a plurality of shafts mounted at the same horizontal height and uniformly at a predetermined interval to allow for rotation in the same direction and at the same speed, and a first rotating means including disks, a plurality of which are fixed to each of the plurality of shafts, and having a radius of a predetermined size such that such that a portion of edges of the disks overlap between adjacent shafts,

wherein the glass tube material the glass tube material is supplied in a state extended lengthwise in an axial direction on the plurality of disks such that the glass tube material is rotated in a state where an outer circumferential surface of the glass tube material simultaneously contacts outer circumferential surfaces of the plurality of disks.

The system further includes a supply and feeding device having an alignment stand for uniformly aligning a plurality of glass tube materials; a supply means receiving a predetermined signal and extracting the glass tube materials one at a time according to their alignment for supply to the first rotating means; a feeder moving the extracted glass tube material rotated by the first rotating means in an axial direction thereof and by a predetermined amount for supply to the cutting device; and a sensor for detecting when all of the glass tube material supplied to the cutting device by a predetermined amount by the feeder is all used up, then generating a predetermined signal.

The system further includes a transfer device for supplying the glass tube cut to a predetermined length by the cutting device from the cutting device to the flare forming device.

The transfer device comprises a plurality of shafts mounted uniformly at a predetermined interval to allow for rotation in the same direction and at the same speed between the cutting device and the flare forming device, and a plurality of disks provided such that a plurality are fixed to each of the plurality of shafts at a predetermined interval and having a radius of a predetermined size such that a portion of edges of the disks overlap between the shafts, the disks including indentations formed in outer circumferences of the disks at positions corresponding to the same phase with respect to a line vertical to outer circumferences of the disks.

Brief Description of Drawings Further objects and advantages of the invention can be more fully understood from the following detailed description taken in conjunction with the accompanying drawings in which: FIG. 1 is a perspective view schematically showing a conventional apparatus for manufacturing a bulb by directly receiving the supply of a glass tube material;

FIG. 2 schematically shows processes involved in manufacturing a bulb in a conventional a conventional apparatus for manufacturing bulbs; FIG. 3 is a flow chart of a method for manufacturing a bulb according to an embodiment of the present invention; FIG. 4 is a plan view of a system for manufacturing a bulb according to an embodiment of the present invention; FIG. 5 is a plan view of a cutting device of a system for manufacturing a bulb shown in FIG. 4; FIG. 6 is a sectional view of the cutting device taken along line A-A of FIG. 5 ; FIG. 7 is a plan view of a supply and feeding device of the system for manufacturing a bulb of FIG. 4; FIG. 8 is a sectional view of a supply means of the supply and feeding device taken along line B-B of FIG. 7; FIG. 9 is a perspective view of a feeder of the supply and feeding device shown in FIG. 7; FIG. 10 is a plan view of a flare forming device of the system for manufacturing a bulb shown in FIG. 4; FIG. 11 is a sectional view of the flare forming device taken along line C-C of FIG.

10; FIG. 12 is a plan view of a bulb material tube separating device of the system for manufacturing a bulb shown in FIG. 4; FIG. 13 is a sectional view of the bulb material tube separating device taken along line D-D of FIG. 12; FIGS. 14A and 14B are sectional views conceptually showing an operation of a transfer device of the system for manufacturing a bulb shown in FIG. 4; FIG. 15 is a plan view of a bulb material tube supply device of the system for manufacturing a bulb shown in FIG. 4; FIG. 16 is a sectional view of a chuck taken along line E-E of FIG. 15; FIG. 17 is a plan view of a blow forming device of the system for manufacturing a bulb shown in FIG. 4;

FIG. 18 is a sectional view of a bulb forming mold unit and a gas supply means taken along line F-F of FIG. 17; Best Mode for Carrying out the Invention A system and method for manufacturing a bulb according to the present invention will now be described with reference to the drawings.

FIG. 3 is a flow chart of a method for manufacturing a bulb according to an embodiment of the present invention.

A method for manufacturing a bulb according to an embodiment of the present invention includes forming flares in step S10, performing separation of a bulb material tube in step S20, forming a dome in step S30, supplying a bulb material tube in step S40, performing lower portion heating in step S50, and performing blow forming in step S60.

In the step S10 of forming flares, both ends of a glass tube 21 of a predetermined length are heated, then a pressure is applied both ends of the glass tube 21 to form flares of an enlarged diameter on both ends. That is, in the step S10 of forming flares, both ends of the glass tube 21 of a predetermined length are heated by a second heating means that includes a torch, and pressure is applied to both heated ends of the glass tube 21 by a flare processing means such that entrances to both ends are formed into expanded flares that resemble the shape of a bell of a trumpet. Accordingly, in the method for manufacturing bulbs of the present invention, flares of a bulb 62, which are needed in step S60 of performing blow forming, are formed before step S60 of performing blow forming such that it is not necessary to form an area having a forming for forming flares in a mold used for bulb forming. The glass tube 21 of a predetermined length is made by cutting a long glass tube material 20 to a length to enable manufacture of two bulbs. Step S 10 of forming flares is preferably performed by rotating the glass tube 21 of a predetermined length to enable easy and uniform forming of the flares. The rotation of the glass tube 21 of a predetermined length is realized by a second rotating means, which will be described below.

In step S20 of performing separation of a bulb material tube, while a glass tube 30 having flares formed on both ends in step S10 of forming flares is being rotated, a center

portion thereof is heated, and, at the same time, a force is applied in the direction of both ends such that the separated center portion is formed into two closed off bulb material tubes 40. That is, in step S20 of performing separation of a bulb material tube, the glass tube 30 of a predetermined length having flares formed on both ends is rotated at a predetermined speed by a third rotating means, and its center portion is heated by a third heating means that has a torch. At the same time, force is applied to the glass tube 30 of a predetermined length in a direction toward both its ends by a separating means such that the glass tube 30 of a predetermined length is pulled in both directions. Therefore, the glass tube 30 of a predetermined length is separated into two parts to thereby make two bulb material tubes 40. A center portion that is separated becomes closed off while being separated to form the two bulb material tubes 40. In step S20 of performing separation of a bulb material tube, while the center portion of the glass tube having enlarged ends is heated, the glass tube 30 is rotated at a predetermined speed by a lower roller that is continuously mounted overlapping a portion of an edge, and by an upper roller that is mounted at an inclination to the lower roller. At this time, the flares are supported simultaneously on the lower roller and the upper roller. Also, the glass tube 30 having the flares is pulled in direction of both ends by the inclined upper roller, to thereby realize separation into two bulb material tubes 40 in which the separated center portion has been closed.

In step S50 of lower portion heating, the bulb material tube 40 made in step S20 of performing separation of a bulb material tube is rotated and its lower portion is heated.

That is, in step S50 of lower portion heating, the bulb material tube 40 is rotated by the chuck in a state where a flare 40a is formed clamped, and the lower portion that includes a dome 40b is evenly heated. An embodiment with respect to the chuck that forms the flare 40a of the bulb material tube 40 and rotates the bulb material tube 40 will be described below.

In step S60 of performing blow forming, the bulb material tube 61 with a lower portion heated in step S50 of lower portion heating is rotated in a mold used for bulb forming, and gas is injected to the flares to thereby form the bulb 62 in the shape of the mold used for bulb forming. That is, in step S60 of performing blow forming, the heated lower portion is positioned in the mold used for bulb forming, and while the bulb material

tube 61 is being rotated in this state, a gas injection nozzle of a second gas supply means is positioned in proximity to the bulb material tube 61 and gas is supplied therein. As a result, the lower portion of the bulb material tube 61 is inflated to thereby be formed into the shape of the mold used for bulb forming.

In a method for manufacturing a bulb according to another embodiment of the present invention, step S30 of forming a dome is performed between step S20 of performing separation of a bulb material tube and step S50 of performing lower portion heating.

In step S30 of forming a dome, gas is injected into the bulb material tube 40 through the flare 40a of the bulb material tube 40, which is formed in step S20 of performing separation of a bulb material tube. As a result, a closed end opposite the flare becomes convex-shaped to thereby form a bulb 40b. The end of the flare 40a of the bulb material tube 40 produced in step S20 of performing separation of a bulb material tube 40 is formed in a convex shape since a concave shape of this area is unsuitable for the blowing process.

Further, in a method for manufacturing a bulb according to yet another embodiment of the present invention, step S40 of supplying a bulb material tube is performed in which the bulb material tube 40 is supplied to the chuck before heating the lower portion of the bulb material tube 40 in step S50 of performing lower portion heating.

In step S60 of performing blow forming, the heated bulb material tube 61 is realized in a state clamped in the chuck. In step S40 of supplying a bulb material tube, the bulb material tube 40 is supplied to the chuck having a clamping unit that can clamp the flare of the bulb material tube 40. Accordingly, the bulb material tube 40 is clamped in the chuck having a clamping unit that can clamp the flare of the bulb material tube 40, and is heated while being rotated by the rotation of the clamping unit. Further, in step S60 of performing blow forming, the heated bulb material tube 61 is rotated in the mold for bulb forming in a state clamped to the chuck, and gas is injected to the flare through the chuck to thereby form the bulb 62.

FIG. 4 is a plan view of a system 1000 for manufacturing a bulb according to an embodiment of the present invention. The system 1000 performs the above method for

manufacturing a bulb of the present invention.

The system 1000 for manufacturing a bulb according to an embodiment of the present invention receives a glass tube material 20 and ultimately manufactures a bulb 62, and includes a supply and feeding device 100, a cutting device 200, a flare forming device 300, a bulb material tube separating device 400, a bulb material tube supply device 500, and a blow forming device 600.

The supply and feeding device 100 supplies glass tube materials 20 to the system 1000 for manufacturing a bulb. The supply and feeding device 100 performs feeding of a supplied glass tube material 20a to enable the cutting device 200 to cut the same into a glass tube 21 of a predetermined length. The cutting device 200 performs cutting of the glass tube material 20a that is fed by the supply and feeding device 100. The flare forming device 300 receives the glass tube 21 of a predetermined length from the cutting device 200, heats both ends thereof, and applies pressure to both heated ends to thereby form flares of an enlarged diameter on both ends. The bulb material tube separating device 400 receives from the flare forming device 300 a glass tube 30 with flares formed on both ends, then heats a center portion thereof while rotating the glass tube 30, while, at the same time, applying a force in the direction of both ends of the glass tube 30 to thereby realize separation at the center portion. The ends of the resulting two bulb material tubes 40 corresponding to where previously located at the center of the glass tube 30 are closed in this process. The bulb material tube supply device 500 supplies bulb material tubes 40 separated by the bulb material tube separating device 400 to the blow forming device 600 from the bulb material tube separating device 400. The blow forming device 600 receives the bulb material tubes 40 and heats a lower portion of each of the same while rotating the bulb material tube 40 at a predetermined speed. The lower portion of a resulting bulb material tube 61 with a heated lower portion is rotated in a mold for bulb forming and gas is injected to the flare to thereby form the bulb 62. In the system 1000 for manufacturing a bulb of the present invention, to enable continuous operation of the successive processes involving the supply of the glass tube material 20 and ultimately manufacturing the bulb 62, the above devices are mounted in order and assemblies to transfer the intermediate materials 21,30, and 40 produced in each device are mounted between the devices.

There are schematically shown in FIG. 4 changes taking place by performing processes on the initial glass tube material 20 to realize the bulb 62 by passing through each of the devices of the system 1000 for manufacturing a bulb according to an embodiment of the present invention. Further, a different reference numeral is used for each of the different stages of the worked material. That is, reference numeral 20 is used for the glass tube material initially supplied to the system 1000 for manufacturing a bulb, reference numeral 21 is used for the glass tube that is cut to a predetermined length by the cutting device 200, reference numeral 30 is the glass tube of a predetermined length having flares formed by the flare forming device 300, reference numeral 40 is used to indicate the bulb material tubes separated by the bulb material tube separating device 400, reference numeral 61 is the bulb material tube that is supplied to the blow forming device 600 such that a lower portion thereof is heated, and reference numeral 62 is the bulb that has undergone the blowing process by injecting air in the mold.

The devices of the system 1000 for manufacturing a bulb will now be described in greater detail starting with the cutting device 200.

FIG. 5 is a plan view of a cutting device of a system for manufacturing a bulb shown in FIG. 4, and FIG. 6 is a sectional view of the cutting device taken along line A-A of FIG. 5.

The cutting device 200 cuts the glass tube material 20a fed by the supply and feeding device 100 to the glass tube 21 of a predetermined length. The cutting device 200 includes a first rotating means 210, a first heating means 220, a cutting knife 230, and a cutting tap 240.

The first rotating means 210 rotates the supplied glass tube material 20a, and includes two shafts 211 and 212, a plurality of disks 21 la and 212a, and drive assemblies.

The two shafts 211 and 212 are mounted at the same horizontal height and uniformly at a predetermined interval to allow for rotation in the same direction and at the same speed.

The plurality of disks 211 a and 212a are provided such that a plurality is fixed to each of the two disks 211 and 212 to thereby rotate together with the same. A radius of the plurality of disks 21 la and 212a must be at a least a predetermined size or greater such that a portion of edges of the disks 21 la and 212a between the two shafts 211 and 212 overlap.

With the use of the above structure, the glass tube material 20a supplied to the first rotating means 210 by the supply and feeding device 100 is extended lengthwise along a shaft direction between the adjacent disks 211 a and 212a having edge portions thereof overlapping. That is, an outer circumference of the glass tube material 20a simultaneously contacts outer circumferences of the adjacent disks 21 la and 212a to thereby be supported by the adjacent disks 21 la and 212a. The glass tube material 20a supported in this manner is rotated by the shafts 211 and 212 that rotate in the same direction and at the same speed.

Preferably, the first rotating means 210 is longer than a length of the glass tube material 20 supplied to the first rotating means 210 by the supply and feeding device 100.

That is, an alignment stand 110, which will be described below, is mounted to one side along an axial direction of the first rotating means 210, and the first heating means 220 and the cutting knife 230 that cut to a predetermined length one end of the glass tube material 20a that is supplied and rotated are mounted to another side along an axial direction of the first rotating means 210. Therefore, a length of the two shafts 211 and 212 of the first rotating means 210 is preferably greater than a sum of a length of the alignment stand 110 that corresponds to a length of the glass tube material 20 and a length to ensure a space to allow mounting of the first heating means 220 and the cutting knife 230.

The first rotating means 210 includes a structure for extracting from the first rotating means 210 the glass tube 21 of a predetermined length supplied to the subsequent flare forming device 300 among the glass tube materials 20a cut into two segments by the cutting device 210. That is, among the plurality of disks 21 la and 212a of the first rotating means 210, the plurality of disks contacting and supporting the glass tube 21 of a predetermined length supplied to the flare forming device 300 have formed indentations 211 b and 212b at positions corresponding to the same phase with respect to a line vertical to an outer circumference of the disks to thereby act as a transfer device that transfers the glass tube 21 to between adjacent disks of a transfer device, which will be described below.

Since this structure is almost identical to a structure of a transfer device that is described below, this will be expanded upon while describing the transfer device.

The first heating means 220 heats a predetermined point of the glass tube material 20a that is rotated by the first rotating means 210. With reference to the drawings, the first

heating means 220 includes a first heating means torch 221 and a torch driving arm 222.

The first heating means torch 221 emits a flame downward at a position distanced from one end of the glass tube material 20a, which is rotated by the first rotating means 210, by an amount corresponding to the length of the glass tube 21 of a predetermined length to thereby heat the glass tube material 20a. The first heating means torch 221 is connected to a combustion gas supply source (not shown). The first heating means torch 221 is fixed to one end of the torch driving arm 222 to be displaced upward and downward by the repeating rotating motion thereof.

An end of the torch driving arm 222 opposite that to which the first heating means torch 221 is mounted is connected to a hinge shaft 223 having a center axis that is uniform with an axial direction of the glass tube material 20a to thereby rotate above the first rotating means 210. Accordingly, the torch driving arm 222 undergoes repeated rotation by connection of the hinge shaft 223 to a predetermined torch rotating arm driving unit (not shown). The reason that the first heating means torch 221 is moved repeatedly up and down is so that during when the glass tube 21 of a predetermined length, which is one of the two segments of the cut glass tube material 20a, is extracted in the cutting device 200 and supplied to the flare forming device 300, and during when the other of the two segments of the cut glass tube material 20a is fed to the cutting device 200 for cutting, the first heating means torch 221 is moved upward and does not heat the glass tube material 20a.

The cutting knife 230 contacts the glass tube material 20 heated by the first heating means 220 at a predetermined point to cut the glass tube material 20a into two segments.

The cutting knife 230 is fixed to one shaft of the first rotating means 210 (an embodiment is shown where fixing is made to the shaft 212) to rotate together with the shaft 212 (or 211) under a predetermined point of the glass tube material 20a that is heated by the first heating means 220. The cutting knife 230 includes a blade 231 formed along a circumferential shape with a predetermined radius from a center of the shaft 212 (or 211).

The predetermined radius is substantially identical to a radius of the plurality of disks 21 la and 212a of the first rotating means such that the blade 231 is periodically contacted to the outer circumference of the glass tube material 20a, which is heated by the first heating

means 220, by the rotation of the cutting knife 230. Also, the blade 231 is periodically contacted to water filled in a cutting water container 240 that is positioned under the cutting knife 230. So that the glass tube material 20a is cut by contact with the blade 231, the blade 231 must contact the outer circumferential surface of the glass tube material 20a and circumnavigate the same. Therefore, the blade 231 is preferably at least long enough to contact an outer circumference of the glass tube material 20a.

The cutting water container 240 holds cutting water 240a that soaks the blade 231, and is mounted under the cutting knife 230 so as to not interfere with the cutting knife 230 during its rotation. The cutting of the glass tube material 20a by contact with the blade 231 while being heated by the first heating means 220 occurs as a result of the glass tube material 120a cracking by the abrupt change in temperature. That is, if the cold blade 231 of the cutting knife 230 contacts a local point of an outer circumference of the glass tube material 20a that is heated by the first heating means 220, a significant difference in temperature occurs between this local point and its surrounding areas such that a crack is formed in this local point of the glass tube material 20a. However, if the blade 231 of the cutting knife 230 periodically contacts the hot glass tube material 20a such that the temperature of the blade 231 is raised, it becomes necessary to cool the blade 231. Hence, the blade 231 is also periodically contacted to the cutting water 240a to thereby cool the blade 231. In fact, the moisture of the cutting water 240a that coats the blade 231 is supplied to the outer circumference of the glass tube material 20a to thereby further increase the above temperature difference.

The cutting device 200 further includes a first pressure means 250.

During when the glass tube material 20a is heated by the first heating means 220 while being rotated by the first rotating means 210 and cut by the cutting knife 230, the first pressure means 250 applies a force in a downward direction above the glass tube material 20a so that the same is stably and closely contacted to the disks of the first rotating means 210. To realize precision cutting of the glass tube material 20a, it is preferable that ends of the line drawn on the outer circumference of the glass tube material 20a by the blade 231 meet. Accordingly, during when the glass tube material 20a is being cut, it is necessary that the glass tube material 20a is rotated while being precisely

positioned by support of the adjacent disks 21 la and 212a. This is realized by the first pressure means 250 pressing down on the glass tube material 20a so that the same closely contacts the disks of the first rotating means 210. In particular, since the shorter of the two segments of the glass tube material 20a cut by the cutting device 200 may easily become unstably positioned, it is preferable that the first pressure means 250 presses on the glass tube material 20a at an outer circumference of a segment that becomes the glass tube 21 supplied to the flare forming device 300. Such a designation of position is made based on a point corresponding to where the glass tube material 20a is cut into two segments.

With reference to the drawings, the first pressure means 250 having the above operation includes a first pressure roller 251 and a first pressure roller rotating arm 252.

The first pressure roller 251 contacts the outer circumferential surface of the glass tube material 20a, which is rotated by the first rotating means 210, to press on the glass tube material 20a in a downward direction. The first pressure roller 251 is rotatably mounted to one end of the first pressure roller rotating arm 252 to thereby undergo repeated up and down movement by operation of the first pressure roller rotating arm 252. The repeated up an down movement of the first pressure roller 251 is such that it is positioned downward during when the glass tube material 20a is cut while being rotated by the first rotating means 210. It is also such that the first pressure roller 251 is positioned upward during when a segment of the two cut segments of the glass tube material 20a corresponding to the glass tube 21 of a predetermined length is extracted from the cutting device 200 and supplied to the flare forming device 300, and during when the other of the two segments of the cut glass tube material 20a is fed to the cutting device 200. The first pressure roller 251 is positioned upward so that it does not interfere with the extracting of the glass tube 21 of a predetermined length and the feeding of the glass tube material 20a.

The first pressure roller rotating arm 252 is connected to a predetermined rotating shaft on an end opposite the end to which the first pressure roller 251 is connected to thereby undergo rotation about the rotating shaft by operation of a first pressure roller rotating arm driver (not show). In the drawing, an embodiment is shown in which an additional rotating shaft is not provided and the first pressure roller rotating arm 252 is rota tably mounted on the hinge shaft 223 to which the torch driving arm 22 is fixed to thereby

rotate about the hinge shaft 223.

A description with respect to the supply and feeding device 100 will be provided below. The supply and feeding device 100 supplies the glass tube material 20 to the first rotating means 210, and feeds the supplied glass tube material 20a above the first rotating means 210 in an axial direction to thereby realize supply to the cutting device 200 in predetermined lengths.

FIG. 7 is a plan view of the supply and feeding device 100 of the system 1000 for manufacturing a bulb of FIG. 4, FIG. 8 is a sectional view of supply assemblies 120 of the supply and feeding device 100 taken along line B-B of FIG. 7, and FIG. 9 is a perspective view of a feeder 140 of the supply and feeding device 100 shown in FIG. 7.

The glass tube material supply and feeding device 100 is supplied to the first rotating means 210 of the system 1000 for manufacturing a bulb, and feeds the supplied and rotated glass tube material 20a along its axial direction for supply to the cutting device 200. The glass tube material supply and feeding device 100 includes the alignment stand 110, the supply assemblies 120, the feeders 140, and a sensor 160.

The alignment stand 110 uniformly arranges all of the plurality of the glass tube materials 20 supplied to the first rotating means 210, and includes two glass tube material end supports 111 and a glass tube material center support 112. Ends of the glass tube materials 20 are inserted in the two glass tube material end supports 111. The glass tube material end supports 111 each includes a rail groove I I I a formed along a lengthwise direction and having a width greater than a diameter of the glass tube materials 20 to allow the same to freely move therein. The two glass tube material end supports 111 are separated at a distance corresponding to a length of the glass tube materials 20 on one side of the first rotating means 210 and along an axial direction of the shafts 211 and 212 of the first rotating means 210, and are provided perpendicular to the axial direction of the shafts 211 and 212. Further, the rail grooves Illa oppose one another. The two glass tube material end supports 111 are provided at a predetermined slant with ends closest to the first rotating means 210 being positioned at a lower height. The glass tube material center support 112 has a predetermined length with one of its surfaces in a flat configuration. The one surface realizes the same surface with the lower side surface of the rail grooves 111 a of

the glass tube material end supports 111, and is parallel to the glass tube material end supports 111 to support a center portion of the glass tube materials 20, which are mounted and arranged between the glass tube material end supports 111.

Ends of the plurality of glass tube materials 20 are inserted for supply in the rail grooves 11 la of the glass tube material end supports 111 on a side that is placed at a higher position and that is farthest from the first rotating means 210. Ends of the glass tube materials 20 supplied to the alignment stand 110 are supported by the lower side surfaces of the rail grooves 11 la, and centers are supported by the glass tube material center support 112 such that the glass tube materials 20 roll along the slant toward the first rotating means 210. With respect to the plurality of the glass tube materials 20 that roll along the slant toward the first rotating means 210, the glass tube material 20 at the lowest position is stopped by the supply assemblies 120 mounted between the alignment stand 110 and the first rotating means 210 such that the glass tube materials 20 are neatly stacked and otherwise uniformly arranged. The plurality of the glass tube materials 20 arranged in the alignment stand 110 are supplied to the first rotating means 210 one at a time by the supply assemblies 120.

The supply assemblies 120 are positioned between adjacent disks 21 la and 212a of the first rotating means 210 and act to supply the glass tube materials 20 arranged in the alignment stand 110 one at a time. The supply assemblies 120 each includes a guide 121, two stopping rods 122 and 123, a link rod 124, and a stopping rod driver 125.

The guide 121 supports the stopping rods 122 and 123 to enable the repeated up and down movement of the two stopping rods 122 and 123. The guide 121 is positioned under the shaft that is closest to the alignment stand 110 (this corresponds to the shaft 212 in the drawings), and is fixed to a predetermined base (not shown). Two guide holes in which the stopping rods 122 and 123 are inserted are formed parallel to one another and symmetrically about the shaft (the shaft 212 in the drawing) above the guide 121.

The two stopping rods 122 and 123 are inserted in the guide holes such that they are able to undergo repeated up and down movement. A protruding area of each of the stopping rods 122 and 123 protruded above the guide 121 is extended higher than the shaft 212 of the first rotating means 210 with the shaft 212 positioned there between. That is, the

shaft 212 of the first rotating means 210 is positioned between the stopping rods 122 and 123 above the guide 121. Further, stopping rod extensions 122a and 123a are mounted respectively to the stopping rods 122 and 123 extended as described above. The stopping rod extensions 122a and 123a oppose one another and extend higher than the stopping rods 122 and 123 above the shaft positioned above the guide 121. The stopping rod extensions 122a and 123a are extended until the glass tube material 20 at a lowermost position on the slant of the alignment stand 110 is caught on the stopping rod extensions 122a and 123.

Further, upper ends of the stopping rod extensions 122a and 123a are formed into a point to enable easy extraction of the glass tube materials 20. One side of each of the guide holes is opened such that a center of the stopping rods 122 and 123 is exposed to one side. The exposed centers of the stopping rods 122 and 123 are interconnected by the link rod 124 such that the two stopping rods 122 and 123 move in opposite directions. That is, ends of the link rod 124 are rotatably connected to the centers of the stopping rods 122 and 123, and a center of the link rod 124 is rotatably mounted to a link rod rotating shaft 124a mounted between the guide holes and to one side of the guide 121. Accordingly, if one of the two stopping rods 122 and 123 moves upward (or downward), the link rod 124 hingedly connected to the stopping rods 122 and 123 rotates about the link rod rotating shaft 124a, and the other stopping rod 123 (or 122) moves downward (or upward). That is, by the connection to the link rod 124, the two stopping rods 122 and 123 always move simultaneously but in opposite directions. The stopping rod driver 125 repeatedly drives the stopping rods 122 and 123 in upward and downward directions, and is connected to a lower portion of one of the stopping rods 122 and 123. Since the supply assemblies 120 supply the glass tube materials 20 one at a time to the first rotating means by the quick repeated driving of the two stopping rods 122 and 123, an air pressure cylinder is suitable for use for the stopping rod driver 125. The stopping rod driver 125 operates by receiving signals transmitted from the sensor 160.

Since one of the supply assemblies 120 is mounted to both sides between the first rotating means 210 and the alignment stand 110 in an axial direction of the shafts 211 and 212 of the first rotating means 210, the stopping rods 122 and 123 support both ends of the glass tube materials 20.

The supply assemblies 120 structured as in the above are operated as follows.

In the case where the glass tube material 20a is supplied to the first rotating means 210 and continuously fed to the cutting device 200 for cutting, but not yet separated from the alignment stand 120, the glass tube materials 20 arranged on the alignment stand 120 are held in place by the upward positioning of the furthermost positioned stopping rod 123.

Accordingly, the glass tube materials 20 arranged on the alignment stand 110 are blocked by the stopping rod 123 such that they are not supplied to the first rotating means 210. If the glass tube material 20a supplied to the first rotating means 210 and fed to the cutting device 200 becomes fully detached from the alignment stand 110, the sensor 160 detects this fact and transmits a corresponding signal to the stopping rod driver 125. The stopping rod driver 125 that receives this signal drives the stopping rod 123 downward, and, at the same time, moves the other stopping rod 122 upward. As a result, the plurality of the glass tube materials 20 caught on the stopping rod 123 move downward along the slant of the alignment stand 110. The furthermost lower glass tube material passes over the stopping rod 123 to roll down and come to be positioned between the two adjacent disks 211 a and 212a of the first rotating means 210 for supply to the same. However, the one glass tube material immediately behind this furthermost lower glass tube material is caught on the stopping rod 122 that is moved upward. After one of the glass tube materials 20 is supplied to the rotating means 210, the stopping rod driver 125 performs control for return to an original state. That is, the stopping rod 123 is moved upward and the other stopping rod 122 is moved downward. Accordingly, the plurality of glass tube materials 20 previously blocked by the stopping rod 122 is now stopped from further movement by the upwardly displaced stopping rod 123.

The feeders 140 act to feed the cutting device 200 and by predetermined lengths the glass tube material 20a supplied on the adjacent disks 21 la and 212a of the first rotating means 210. Each of the feeders 140 includes a feeding unit, a pressure unit, and a stopper unit.

The feeding unit applies a force along an axial direction to the glass tube material 20a supplied to the first rotating means 210 and that is rotating on the disks 21 la and 212a of the first rotating means 210. The feeding unit includes a feeding roller 141, a feeding

base 142, a roller rotating driver, and a base driver.

An upper outer circumferential surface of the feeding roller 141 contacts a lower portion of the glass tube material 20a, which rotates on the disks 211 a and 212a of the first rotating means 210, and rotates to thereby apply a force in the axial direction of the glass tube material 20a. That is, a direction of a linear velocity of the upper outer circumferential surface of the feeding roller 141 is uniform with the axial direction of the glass tube material 20a, and the feeding roller 141 rotates such that this direction becomes a direction faced by the stopping unit. Force is applied to the glass tube material 20a in the axial direction of the same by friction generated by an area of contact with the glass tube material 20a. If during when the glass tube material 20a supplied on the first rotating means 210 is fed by a predetermined length thereof to the cutting device 200 to be cut while being rotated by the first rotating means 210, the glass tube material 20a contacts the feeding roller 141, and smooth rotation by the first rotating means does not occur as a result of the friction generated for feeding. Accordingly, the feeding roller 141 must be able to move up and down under the glass tube material 20a such that it contacts the glass tube material 20a only during when the glass tube material 20a is being fed and is separated from the same during all other times. This is realized by a base driver, which is described below. The roller rotating driver rotates the feeding roller 141, and includes a motor 143c. The motor 143c is fixed to the feeding base 142, and generates a rotational force that can rotate the feeding roller 141. The rotational force generated by the motor 143c is transmitted to the feeding roller 141 by predetermined axes and a chain 143a and a belt 143b connected these axes. The feeding base 142 is mounted on a base 148 in such a manner that it is able to undergo up and down movement by the base driver. That is, the feeding base 142 supports the feeding roller 141 and the motor 143c mounted thereon, and repeatedly undergoes up and down movement together with these elements. The base driver performs this operation of moving the feeding base 142 up and down, and includes a cylinder 144, a guide rod 145, and a guide 146. The guide 146 has formed in a center portion thereof a passage hole into which the guide rod 145 is inserted and mounted. An upper end of the guide 146 is fixed to a lower surface of the base 148 on which the feed base 142 is mounted. A hole is formed in the base 148 (to which the guide 146 is fixed)

that communicates with the passage hole of the guide 146. The guide rod 145 is inserted in the passage hole of the guide 146 such that an upper end is able to protrude above the base 148 and so that it is able to undergo up and down movement. The upper end of the guide rod 145 that protrudes above the base 148 is fixedly connected to the lower surface of the feeding base 142. Accordingly, if the guide rod 145 undergoes up and down movement, the feeding base 142, the motor 143c connected to the feeding base 142, and the feeding roller 141 also move up and down. The cylinder 144 is connected to a lower portion of the guide rod 145 to move the guide rod 145 up and down, and is mounted to a predetermined fixing member. With reference to the drawing, the cylinder 144 is fixed to a cylinder fixing bracket 146a that extends in one direction under the guide 146, and a lower portion of a cylinder shaft of the cylinder 144 is connected to the lower portion of the guide rod 145 via a cylinder shaft fixing bracket 144a.

The pressure unit applies downward pressure to the glass tube material 20a that is moved in its axial direction by the feeding unit such that the glass tube material 20a is closely contacted to the feeding roller 141, and also includes a structure to repeatedly displace feeder pressure rollers 151.

The feeder pressure rollers 151 are rotatably mounted to the first rotating means 210 in such a manner to contact an upper area of the glass tube material 20a that is being fed by contact to the feeding roller 141. As shown in the drawing, a feeder pressure roller rotating arm support 153 is mounted to the base 148 such that it extends above the rotating means 210 on one side thereof. A feeder pressure roller rotating arm 152 is hingedly connected to an upper area of the feeder pressure roller rotating arm support 153 in such a manner that the feeder pressure roller rotating arm 152 is able to undergo rotation about a rotating axis that is uniform with a long axis of the glass tube material 20a. The feeder pressure rollers 151 are rotatably mounted an end of the feeder pressure roller rotating arm 152 that extends in the direction of the feeding roller 141. Further, a cylinder shaft of a cylinder 154 is connected to another end of the feeder pressure roller rotating arm 152 opposite that to which the feeder pressure rollers 151 are mounted. The cylinder 154 is fixed to an extension bracket 153a that extends from an upper area of the feeder pressure roller rotating arm support 153 in a direction toward the cylinder 154. Accordingly, if the

cylinder 154 operates, the feeder pressure roller rotating arm 152 undergoes repeated back and forth rotation, and the feeder pressure rollers 151 therefore also move repeatedly up and down. The feeder pressure rollers 151 are moved repeatedly up and down so that they do not interfere with a new glass tube material 20 supplied to the first rotating means 210, and so that the feeder pressure rollers 151 are distanced from the glass tube material 20a to enable smooth rotation by the first rotating means 210 when the glass tube material 20a is not being fed.

The glass tube material 20a must be fed by predetermined length amounts by the feeders 140. Accordingly, each of the feeders 140 may further include a stopper unit mounted to a forward position with respect to the path that the fed glass tube material 20a travels. The stopper unit includes a stopper 156 that makes contact with an end of the glass tube material 20a that is moved by the feeders 140 to thereby limit the feeding length of the glass tube material 20a. The stopper 156 is moved forward and backward along the axial direction of the glass tube material 20a by a stopper driver 156a. The stopper 156 is moved forward and backward so that during when a segment of the glass tube material 20a cut into two segments by the cutting device 200 corresponding to the glass tube 21 of a predetermined length is supplied to the flare forming device 300, an end thereof is not caught on an end of the stopper 156 by the moving of the stopper 156 backward. That is, the stopper 156 is moved forward when the glass tube material 20a is being fed by the feeders 140, and moved backward when the glass tube 21 of a predetermined length is extracted from the cutting device 200 and supplied to the flare forming device 300.

Two of the feeders 140 are mounted to a side opposite where the stoppers 156 are positioned and based on points where the cutting knife 230 of the cutting device 200 is mounted. One of the feeders 140 is mounted in close proximity to the cutting device 200 to perform the final feeding of the glass tube material 20a to the cutting device 200 as the glass tube material 20a becomes increasingly shorter.

Each of the feeders 140 structured as in the above operates as described below.

During when the glass tube material 20a is cut by the cutting device 200 while being rotated by the first rotating means 210, the feeding roller 141 is moved downward and the feeder pressure rollers 151 are moved upward such that they are both maintained in

a state distanced from the glass tube material 20a. Next, if the glass tube 21 of a predetermined length, which is cut by cutting one end of the glass tube material 20a by the cutting device 200, is transferred from the cutting device 200 to the flare forming device 300, the feeding roller 141 moves upward such that the glass tube material 20a is raised slightly from the adjacent disks 211a and 212a of the first rotating means 210, then is rotated in this state. At the same time, the feeder pressure rollers 151 are moved downward such that the glass tube material 20a is pressed in the same direction. Accordingly, the glass tube material 20a is fed along its axial direction until striking the stopper 156 that is moved forward in the direction of the glass tube material 20a. When the feeding roller 141 and the feeder pressure rollers 151 are separated from the glass tube material 20a, feeding of the same is discontinued.

The supply and feeding device 100 includes the sensor 160. The sensor 160 detects when a predetermined amount of the glass tube material 20a is fed to the cutting device 200 and the segment positioned at the alignment stand 110 of the first rotating means 210 is fully detached. The sensor 160 then generates a corresponding signal for supply to the first rotating means 210. The sensor 160 is mounted at a location at a slight distance from the glass tube material end support 111 of the alignment stand 110 that is closest to the cutting device 200. The sensor 160 mounted in this manner detects when an end of the glass tube material 20a opposite that closest to the cutting device 200 passes the sensor 160 after being continuously fed, then generates a corresponding signal.

In the following, the flare forming device 300 that receives the supply of the glass tube 21 of a predetermined length cut by the cutting device 200 and that forms flares on both ends of the glass tube 21 will be described.

FIG. 10 is a plan view of the flare forming device 300 of the system 1000 for manufacturing a bulb shown in FIG. 4, and FIG. 11 is a sectional view of the flare forming device 300 taken along line C-C of FIG. 10.

The flare forming device 300 includes a second rotating means 310, a second heating means torch 321, a flare processing means 330, a second pressure means 340, and first alignment assemblies 350.

In order to rotate and transmit the glass tube 21 of a predetermined length supplied

to the flare forming device 300, the second rotating means 310 includes a plurality of shafts 311 to 315, and a plurality of disks 311a to 315a fixed to the plurality of shafts. The plurality of shafts 311 to 315 are mounted at the same horizontal height and uniformly at a predetermined interval to allow for rotation in the same direction and at the same speed.

The plurality of disks 311a to 315a are provided such that a plurality are fixed to each of the plurality of shafts 311 and 315 to thereby rotate together with the same. A radius of the plurality of the disks 31 la to 315a must be at least a predetermined size or greater such that a portion of edges of the disks 311 a to 315a overlap between the two shafts 311 and 312 or 312 and 313 or 313 and 314 or 314 and 315.

With the use of the above structure, the glass tube material 21 of a predetermined length supplied to the flare forming device 300 from the cutting device 200 is rotated by the second rotating means 310 in a state extended lengthwise in an axial direction on the adjacent disks 311a and 312a or 312a and 313a or 313a and 314a or 314a and 315a that are partially overlapped between the shafts 311 and 312 or 312 and 313 or 313 and 314 or 314 and 315. That is, an outer circumferential surface of the glass tube 21 of a predetermined length simultaneously contacts outer circumferential surfaces of the adjacent disks 311a and 312a or 312a and 313a or 313a and 314a or 314a and 315a to thereby be supported by the same, and the supported glass tube 21 of a predetermined length rotates in the same direction and at the same speed as the adjacent shafts 311 and 312 or 312 and 313 or 313 and 314 or 314 and 315.

Indentations 31 lb to 315b are formed in outer circumferences respectively of the plurality of disks 311a to 315a, the indentations 3 lib to 315b being formed at positions corresponding to the same phase with respect to a line vertical to outer circumferences of the disks 311a to 315a such that the second rotating means 310 acts as a transfer device that transfers the glass tube 21 to the next pair of adjacent disks. This will be described in detail while describing the transfer device.

The second heating means includes a plurality of torches 321, and a combustion gas supply source connected to the torches 321 for supplying combustion gas. As shown in the drawing, the plurality of torches 321 are arranged in two rows to both sides of the plurality of disks 311 a to 315a and separated by an amount corresponding to a length of the

glass tube 21 of a predetermined length supplied to the flare forming device 300. The glass tube 21 is transmitted to the flare processing means 330 while both ends of the glass tube 21 of a predetermined length are heated by the torches 321 formed in two rows.

The flare processing means 330 includes a pressure shaft 331, a pressure shaft rotating driver 332, and a pressure shaft rectilinear driver 333. One end of the pressure shaft 331 has a diameter that is greater than a diameter of entrances to both ends of the glass tube 21 of a predetermined length, and a flare processing unit 331a having a circular cone shape is formed on the furthermost distal area of this end of the pressure shaft 331.

The flare processing unit 331a allows for easy insertion into the entrances of the ends of the glass tube 21. A motor is typically used for the pressure shaft rotating driver 332, and a rotating axis thereof is connected to the other end of the pressure shaft 331 to thereby rotate the pressure shaft 331. The pressure shaft rectilinear driver 333 moves the pressure shaft 331 together with the pressure shaft rotating driver 332 to which the pressure shaft 331 is connected along an axial direction of the pressure shaft 331. With reference to the drawings, there are provided two of the flare processing assemblies 330 in such a manner that their pressure shafts are at a distance greater than the length of the glass tube 21 of a predetermined length and with their flare processing units 331a opposing one another. This allows both ends of the glass tube 21 to be simultaneously pressed. Accordingly, the pressure shafts 331 are moved forward toward entrances of both ends of the glass substrate 21 of a predetermined length, which are heated by the torch 321 of the second heating means, and are inserted a predetermined depth simultaneously into the entrances of the glass tube 21. Therefore, the heated entrances to the glass tube 21 of a predetermined length are spread apart into the shape of a bell of a trumpet. So that this process may be smoothly realized, it is preferable that there is some sliding between the pressure shafts 331 and an area of contact with the glass tube 21 in a state where the pressure shafts 331 are inserted a predetermined depth into the entrances of the glass tube 21. This sliding is generated by the pressure shaft rotating drivers 332 rotating the pressure shafts 331.

The second pressure means 340 presses the glass tube 21 of a predetermined length downward such that the glass tube 21, both ends of which are formed into flares by the flare processing means 330 while being rotated by the second rotating means 310, is

rotated on the adjacent two disks 314a and 315a of the second rotating means 340 in a stable and closely adhered manner. The second pressure means 340 includes a pressure roller 341, a pressure roller rotating arm 342, and a pressure roller rotating arm driver 343.

The pressure roller 341 of the second pressure means 340 contacts an upper area of the glass tube 21 of a predetermined length, and presses the glass tube 21 of a predetermined length downward while being rotated. The pressure roller 341 is rotatably mounted to one end of the pressure roller rotating arm 342 to thereby be repeatedly moved up an down by the corresponding operation of the pressure roller rotating arm 342. The pressure roller 341 is moved up and down so that during when the glass tube 21 of a predetermined length that had been rotated while extended on the disks 314a and 315a catches on the indentation 315b and is transferred to the next adjacent disks, and during when the glass tube 21 of a predetermined length that had been rotated while extended on the disks 313a and 314a catches on the indentation 314b and is transferred to the next adjacent disks, the pressure roller 341 is moved upward so as to not hinder the movement of the glass tube 21.

The flare processing device 300 further includes first alignment assemblies 350 for aligning the glass tube 21 of a predetermined length during when ends of the same are heated by the torches 321 while being rotated in a state extended between the plurality of the disks 311a to 315a and prior to when the glass tube 21 of a predetermined length is transmitted between the adjacent disks 341a and 315a such that the flares are symmetrically formed on both ends by the flare processing means 330. Each of the first alignment assemblies 350 includes a plurality of alignment pads 351 that closely contact both ends of the glass tube 21 of a predetermined length, both ends of which are heated by the plurality of torches 321 while extended across the plurality of disks 31 la to 314a and rotated; an alignment pad fixing bracket 352 on which the alignment pads 351 are mounted; and a bracket displacing means 353 that moves the alignment pad fixing bracket 352 forward and backward along the axial direction of the glass tube 21 of a predetermined length. The first alignment assemblies 350 are mounted such that the plurality of pads 351 oppose each other to both sides of the glass tube 21 of a predetermined length, both ends of which are heated by the plurality of torches 321 while extending on and being rotated by

the plurality of disks 311a to 314a. The alignment pads 351 are separated from both ends of the glass tube 21 of a predetermined length by the bracket displacing means 353 during when the glass tube 21 is transmitted between the plurality of disks 311a to 314a, and closely contacted to both ends of the glass tube 21 of a predetermined length during when both ends thereof are heated by the torches 321 while extending on and being rotated by the plurality of disks 311a to 314a. Accordingly, during when both ends of the glass tube 21 are heated by the torches 321 while extending on and being rotated by the plurality of disks 311 a to 314a, the glass tube 21 of a predetermined length is aligned to be positioned at a center portion of the second rotating means 320.

FIG. 12 is a plan view of the bulb material tube separating device 400 of the system 1000 for manufacturing a bulb shown in FIG. 4, and FIG. 13 is a sectional view of the bulb material tube separating device 400 taken along line D-D of FIG. 12.

With reference to the drawings, the bulb material tube separating device 400 includes a third rotating means 410, a second heating means having torches 421, separating assemblies 430, third pressure assemblies 440, second alignment assemblies 450, and first gas supply assemblies 460.

The third rotating means 410 rotates the glass tube 30 formed with flares on both ends thereof and that is supplied to the bulb material tube separating device 400, and includes for transmission of the glass tube 30 a plurality of shafts 411 to 416 and a plurality of disks 41 la to 416a. A plurality of disks 41 la to 416a are fixed to each of the plurality of shafts 411 to 416. The plurality of shafts 411 to 416 are mounted at the same horizontal height and uniformly at a predetermined interval to allow for rotation in the same direction and at the same speed. The plurality of disks 411 a to 416a are provided such that a plurality are fixed to each of the plurality of shafts 411 to 416 to thereby rotate together with the same. A radius of the plurality of the disks 411 a to 416a must be at least a predetermined size or greater such that a portion of edges of the disks 41 la to 416a overlap between the two shafts 411 and 412 or 412 and 413 or 413 and 414 or 414 and 415 or 415 and 416.

With the use of the above structure, the glass tube 30 supplied from the flare forming device 300 to the bulb material tube separating device 400 is rotated by the third

rotating means 410 in a state extended lengthwise in an axial direction on the adjacent disks 411 a and 412a or 412a and 413a or 413a and 414a or 414a and 415a or 415a and 416a that are partially overlapped between the shafts 411 and 412 or 412 and 413 or 413 and 414 or 414 and 415 or 415 and 416. That is, an outer circumferential surface of the glass tube 30 with formed flares simultaneously contacts outer circumferential surfaces of the adjacent disks 41 la and 412a or 412a and 413a or 413a and 414a or 414a and 415a or 415a and 416a to thereby be supported by the same, and the supported glass tube 30 with formed flares is rotated in the same direction and at the same speed as the adjacent shafts.

As with the second rotating means 310, indentations 411b to 416b are formed in outer circumferences respectively of the plurality of disks 41 la to 416a, the indentations 411 b to 416b being formed at positions corresponding to the same phase with respect to a line vertical to outer circumferences of the disks 41 la to 416a such that the third rotating means 410 acts as a transfer device that transfers the glass tube 30 with formed flares to the next pair of adjacent disks. This will be described in detail while describing the transfer device.

The third heating means heats a center portion of the glass tube 30 with formed flares that is supplied to the third rotating means 410 for rotation in a state simultaneously contacting outer circumferential surfaces of the adjacent disks 41 la and 412a or 412a and 413a or 413a and 414a or 414a and 415a or 415a and 416a. The third heating means includes a plurality of torches 421 arranged in one row at a center of the plurality of disks 411a to 415a of the third rotating means 410 that are arranged in two rows, and a combustion gas supply source connected to the torches 421 for supplying combustion gas to the same. The glass tube 30 with formed flares is heated by the third heating means at an extremely high temperature so that a center thereof may be separated.

The separating assemblies 430 apply a force to the glass tube 30 with formed flares, a center portion of which is heated. The force is applied in directions toward both ends of the glass tube 30 such that the separated center portion is blocked to result in the forming of two bulb material tubes 40. The separating assemblies 430 include two angled rollers 431, and angled roller driver arms 432. The two angled rollers 431 are rotatably mounted to an end of each angled roller driver arm 432, and the angled roller driver arms

432 repeated move the angled rollers 431 up and down.

The angled roller driver arms 432 are repeatedly moved up and down by a predetermined driving means such that at the instant the glass tube 30 with formed flares is moved between the two disks 413a and 414a, the angled rollers 431 are moved upward so as to not interfere with this operation. Also, when the glass tube 30 simultaneously makes contact with and is supported by the two disks 413a and 414a, the angled rollers 431 are moved downward to closely contact the glass tube 30 with formed flares. The two angled rollers 431 are rotatably mounted to the angled roller driver arms 432 to rotate by the rotation of the glass tube 30 with formed flares by contact to an upper outer circumferential surface of both ends of the glass tube 30 with formed flares, which has a center portion that is heated and that is rotated and supported by simultaneously contacting the adjacent disks 413a and 414a. Each of the rotational axes of the two angled rollers 431 is mounted at a predetermined angle to the rotational axis of the glass tube 30 with formed flares to be provided in a symmetrical configuration. In more detail, in order for each of the linear velocity directions of the angled rollers 431 at the contact points of the outer circumferential surfaces of the angled rollers 431 with the outer circumferential surface of the glass tube 30 to operate in a direction away from the center portion of the glass tube 30 with formed flares, rotating axes of the angled rollers 431 have a predetermined angle with the rotating axis of the glass tube 30 with formed flares. Accordingly, the angled rollers 431 apply a force in the direction toward both ends of the glass tube 30 with formed flares while rotating. Since the center portion of the glass tube 30 with formed flares receiving such a force is heated to a high temperature, the center portion becomes stretched then separated into two bulb material tubes 40. Entrances to the center portion are blocked off as a result of the center portion becoming separated after being heated to a high temperature then stretched. So that such separation is smoothly realized, the center portion of the glass tube 30 with formed flares is heated by the torches 421 also at the instant when separated by the separating means 430.

The bulb material tube separating device 400 further includes the second alignmen t assemblies 450 such that the center portion of the glass tube 30 with formed flares is precisely heated by the third heating means 420 and precisely separated by the separating

means 430. The second alignment assemblies 450 are substantially identical in structure and operation to the first alignment assemblies 350. Each of the second alignment assemblies 450 includes a plurality of alignment pads 451 that closely contact both ends of the glass tube 30 with formed flares when the center portion is heated by the plurality of torches 421 in a state extended across and rotated by the adjacent disks 41 la and 412a, the adjacent disks 412a and 413a, and the adjacent disks 413a and 414a; an alignment pad fixing bracket 452 on which the alignment pads 451 are mounted; and a bracket displacing means 453 that moves the alignment pad fixing bracket 452 forward and backward along the axial direction of the glass tube 30. Since the bulb material tubes 40 that are heated while being rotated by the adjacent disks 413a and 414a, and, at the same time, separated into two elements by the separating means 430 become distanced from a center of the third rotating means 410, the bulb material tubes 40 are distanced from each other and the alignment pads 451 are moved backward so that the bulb material tubes 40 do not strike the alignment pads 451.

The bulb material tube separating device 400 further includes first gas supply assemblies 460 that operate to form domes that concavely protrude outward from the blocked ends of the two bulb material tubes 40 realized by separating the center portion by the separating device 430. The first gas supply assemblies 460 include gas injection nozzles 461 that approach entrances to the flares of each of the two bulb material tubes 40 to supply gas to inside the bulb material tubes 40, and nozzle drivers 462 fixed to the gas injection nozzles 461 for repeatedly moving the gas injection nozzles 461 forward and backward along the axial direction of the bulb material tubes 40. With reference to the drawings, the first gas supply assemblies 460 are mounted symmetrically to both sides of the bulb material tubes 40 that are supplied to between the adjacent disks 415a and 416a to contact outer circumferential surfaces of the disks 415a and 416a for rotation by the same.

Normal air is used as the gas supplied to inside the bulb material tubes 40.

So that the bulb material tubes 40 closely contact the outer circumferential surfaces of the adjacent disks 415a and 416a during when gas is supplied to each of the bulb material tubes 40 by the first gas supply means 460, the bulb material tubes 40 are given a force downwardly by the third pressure assemblies 440. Each of the third pressure

assemblies 440 includes a pressure roller 441, and a pressure roller support arm 442 to which the pressure roller 441 is rotatably mounted and that repeatedly moves the pressure roller 441 up and down. That is, one pressure roller 441 is positioned to both sides above the third rotating means 410 in such a manner to contact the upper outer circumferential surface of each of the two bulb material tubes 40, and the pressure rollers 441 undergo repeated up and down movement by operation of the pressure roller support arms 442. The pressure rollers 441 are moved up and down so as to not interfere with the bulb material tubes 40 when transferred between adjacent disks.

The system 1000 for manufacturing bulbs according to an embodiment of the present invention described above further includes transfer devices 710 for transferring the intermediate materials to a subsequent device after production by each of the devices. Such transfer occurs between the cutting device 200 and the flare forming device 300, between the flare forming device 300 and the bulb material tube separating device 400, and between the bulb material tube separating device 400 and the bulb material tube supply device 500 (to be described below). The transfer devices 710 will be described below.

FIGS. 14A and 14B are sectional views conceptually showing an operation of one of the transfer devices 710 of the system 1000 for manufacturing a bulb shown in FIG. 4.

With reference to the drawings, the transfer device 710 is substantially identical in structure and operation to the first through third rotating assemblies 210, 310, and 410.

One of the transfer devices 710 is mounted between the first rotating means 210 and the second rotating means 310, and between the second rotating means 310 and the third rotating means 410. The transfer device 710 is extended from the third rotating means 410 for use between the bulb material separating device 400 and the bulb material tube supply device 500.

With reference to the drawings, each of the transfer devices 710 includes a plurality of shafts 711 to 715 and a plurality of disks 711 a to 715a. A plurality of disks 71 la to 715a are fixed to each of the plurality of shafts 711 to 715. The plurality of shafts 711 to 715 are mounted at the same horizontal height and uniformly at a predetermined interval to allow for rotation in the same direction and at the same speed. The plurality of disks 711a to 715a are provided such that a plurality are fixed to each of the plurality of

shafts 711 to 715 to thereby rotate together with the same. A radius of the plurality of the disks 711a to 715a must be at least a predetermined size or greater such that a portion of edges of the disks 71 la to 715a overlap between the two shafts 711 and 712 or 712 and 713 or 713 and 714 or 714 and 715. Indentations 711b to 715b are formed in outer circumferences respectively of the plurality of disks 71 la to 715a, the indentations 71 lb to 715b being formed at positions corresponding to the same phase with respect to a line vertical to outer circumferences of the disks 71 la to 715a. The indentations 7 lib to 715b are of a sufficient size to catch the materials 21,30, and 40 rotated between the plurality of disks 71 la to 715a.

Transfer devices 710 having the above structure operate as described below.

As with the first through third rotating assemblies 210, 310, and 410, the materials 21,30, and 40 supplied to the transfer devices 710 rotate between the plurality of disks 711a to 715a. The materials 21,30, and 40 rotating in this fashion are caught on the indentations 71 lb to 715b during every one rotation of the plurality of disks 71 la to 715a to thereby be transferred to the subsequent disk in the direction of rotation.

The transfer devices 710 are mounted between the first through third rotating assemblies 210,310, and 410, and are linked to the operation of the first through third rotating assemblies 210,310, and 410. To realize such operation, all shafts of the transfer devices 710, and of the first through third rotating assemblies 210, 310, and 410 must be uniformly mounted at predetermined intervals, and all disks must have substantially the same radius. Further, the indentations of the transfer devices 710, and that of the first through third rotating assemblies 210,310, and 410 must be formed at positions corresponding to the same phase with respect to a line vertical to outer circumferences of the disks. Accordingly, the intermediate materials 21,30, and 40 positioned on the disks of the transfer devices 710 and the first through third rotating devices 210,310, and 410 rotate simultaneously, and are simultaneously caught in the indentations to be transferred to the subsequent disk. That is, as described above, the first through third rotating assemblies 210,310, and 410 are interconnected through the transfer devices 710 to be successively arranged. As a result, the cutting of the glass tube material 20a, the forming of the flares in the glass tube 21 of a predetermined length, and the separation into the two

bulb material tubes 40 are performed in succession. In addition, the operations of the supply and feeding device 100, the cutting device 200, the flare forming device 300, the bulb material tube separating device 400, the bulb material tube supply device 500, and the blow forming device 600 are controlled to synchronize with the operations of the first through third rotating assemblies 210,310, and 410, and the transfer devices 710. To realize such synchronization, a method of controlling each of these devices may be either an electrical control method using a computer and actuator, or a mechanical control method using a device such as a cam apparatus. This structure may be integrated with the control means below.

In the following, the blow forming device 600 for performing a blowing process on the bulb material tube 40 to realize forming into a bulb 62 will be described.

FIG. 17 is a plan view of the blow forming device 600 of the system 1000 for manufacturing a bulb shown in FIG. 4. FIG. 17 shows one of the two blow forming devices 600 of the system 1000 for manufacturing a bulb provided to opposing sides at an area where the bulb material tube separating device 400 ends (see FIG. 4).

The blow forming device 600 includes a base 601, a rotary table 602, a rotary table driving means, chuck clamping unit driving means having a drive gear 604, a control means, a plurality of chucks 610, a third heating means having a plurality of torches 631, a bulb forming mold unit 640, and a second gas supply means 650.

The base 601 is a support structure of the blow forming device 600 on and within which various devices and assemblies are mounted such as a first driving means, a second driving means, and a controller. A motor, a shaft, a gear, and a cam are concrete examples.

The rotary table 602 is rotatably mounted on the base 601 to undergo intermittent rotation such that the bulb material tube 40 clamped under the plurality of chucks 610 that are mounted at predetermined intervals along an edge of the rotary table 602 in a circumferential direction is moved along the circumferential direction to undergo various processes. If this is described in greater detail, the rotary table 602 is rotatably mounted on the base. The plurality of chucks 610 are mounted at predetermined intervals along an edge of the rotary table 602 in a circumferential direction. The rotary table 602 receives a drive force of a rotary table movement means (not shown) to be periodically rotated by a

predetermined angle. By the rotation of the rotary table 601, the bulb material tubes 40 clamped in the plurality of chucks 610 are moved from one process to a subsequent process. That is, the rotary table 601 intermittently rotates in one direction by an amount corresponding to the distance between the plurality of chucks 610 and synchronized to the periods at which the bulb material tubes 40 are supplied to the blow forming device 600.

By such intermittent and periodic rotation of the rotary table 610, lower portions of the bulb material tubes 40 clamped in the plurality of chucks 610 are heated by the plurality of torches 631, and the bulb material tubes 40 having heated lower portions undergo forming into a bulb 62 by applying a blowing thereto in a state positioned in a mold.

The rotary table driving means is mounted to the base 601 but does not appear in the drawing. The rotary table driving means rotates the rotary table 602, and includes a power source such as a motor, and a power transmitting means for transmitting power generated by the drive source to the rotary table 602. A feature of the rotary table driving means is the driving of the rotary table 602 intermittently and periodically by a predetermined angle. To realize this, the rotary table driving means is controlled by a control means.

The clamping unit driving means is mounted to the base but is not shown in the drawing. The clamping unit driving means rotates a clamping unit of a clamping means 620 of the chucks 610 to be described below. The clamping unit driving means includes a power source such as a motor, and a power transmitting means for transmitting power to a chuck power transmitting means (to be described below) of the chucks 610. With reference to the drawing, in the embodiment of the present invention, the power transmitting means of the clamping unit driving means includes the drive gear 604 to enable rotation above the rotary table 602 but about the same axis as the rotary table 602. A chuck gear 614 of the chuck power transmitting means of the chucks 610 rotates in a state meshed with the drive gear 604.

The control means is not shown in the drawing. The control means controls the rotary table drive means such that the rotary table drive means rotates the rotary table 602 intermittently. This may be easily accomplished by an electrical method utilizing a computer, or a mechanical method utilizing a cam apparatus. Further, since the devices of

the system 1000 for manufacturing bulbs according to the present invention are operated by being synchronized with one another, it is necessary that control of the devices must be linked. Accordingly, in addition to the structure in the control means controlled by operation of the rotary table drive means, the devices of the system 1000 for manufacturing bulbs according to the present invention may include structures to enable control for operation synchronized with one another.

The blow forming device 600 of the system 1000 for manufacturing bulbs according to the present invention includes the chucks 610 suitable for clamping the bulb material tubes 40 to receive the bulb material tubes 40 and enable easy heating and blowing processes to be performed on the same.

FIG. 16 is a sectional view of one of the chucks 610 taken along line E-E of FIG.

15. The chuck 610 is shown in a state where a clamping unit is spread apart by a clamping release device (to be described below), and the bulb material tube 40 is supplied.

The chuck 610 receives the bulb material tube 40 to clamp its flare 40b and rotate the bulb material tube 40. The chuck 610 includes a housing 611, a power transmitting means including a chuck gear 614, a clutch 615, and a clamping means 620.

The housing 611 is a container type of structure with a passage hole formed therein. The passage hole is fixed to the rotary table 602 able to undergo up and down movement. The clamping means 620, the power transmitting means, and the clutch 615 are mounted in the housing 611. Bearings 611 a and 616b are inserted and mounted respectively in upper and lower portions of the passage hole of the housing 611, and a guide 621 (to be described below) is inserted into the passage hole passing through the bearings 611a and 611b. A gear connecting window 612 is formed to one side of a side wall of the housing 611 between the two bearings 611a and 611b. The gear connecting window 612 is formed to allow the chuck gear 614 mounted in the housing 611 to protrude outward and be meshed with the drive gear 604. The chuck 610 becomes extremely hot as a result of the heat used to raise the temperature of the bulb material tube 40. Since the bearings 61 la and 61 Ib may deteriorate as a result, it is necessary to cool the chuck 610 to prevent such an occurrence. A cooling water passage 613 through which cooling water passes is formed in the housing 611. One end of a water supply pipe 613a shown in FIG.

17 is connected to one side of the cooling water passage 613, and one end of a drainage pipe (not shown) is connected to the other side. Accordingly, cooling water flows from a cooling water storage container 616, which is fixed to an upper area of the rotary table 602 to rotate together with the same, to the cooling water passage 613 through the water supply pipe 613a, after which the cooling water is exhausted to the outside through the drainage pipe.

The clamping means 620 is mounted to the housing 611 in such a manner that it is able to undergo rotation about a predetermined axial line. The clamping means 620 has formed a predetermined passage hole 621 a according to this axial line, and clamps the flare 40b of an upper area of the bulb material tube 40 of a predetermined length under the passage hole 621 such that a center axis of the bulb material tube 40 is substantially identical to the predetermined axial line. The clamping means 620 includes a guide 621, a clamping unit, and a clamping unit driving means. In the case where clamping release devices 720 and 730 (to be described below) apply an external force of a predetermined intensity or greater to the clamping means 620, the bulb material tube 40 is received by the clamping means 620 and its upper area is either clamped, or the clamping used is spread apart so that the clamped bulb material tube 40 is released.

The guide 621 is used for mounting of the clamping unit and the clamping unit driving means. In the embodiment shown in the drawing, an outer circumference of the passage hole 621a is extended a predetermined length along a predetermined axial line direction, which is a rotational center axis of the clamping means 620, and the clamping unit is mounted to its lower end. The clamping unit driving means is mounted to an upper end of the clamping unit for driving the same. An upper area of the guide 621 is inserted into the bearings 611 a and 61 lob such that the clamping means 620 is rotatably mounted to the housing 611.

The clamping unit clamps an upper area of the bulb material tube 40 of a predetermined length under the passage hole 62 la of the guide 621 such that a center axis of the bulb material tube 40 substantially corresponds to the predetermined axial line. So that part of the clamping unit, which clamps the bulb material tube 40, is positioned under the passage hole 621 a of the guide 621, the clamping unit is mounted under the guide 621.

The clamping unit includes a clamp base 622 mounted under the guide 621, and clamps 623 rotatably mounted radially and symmetrically on outer edges of the clamp base 622.

That is, the clamps 623 are mounted on the same circle circumference and at a predetermined distance, and are rotatably mounted to the clamp base 622 on a planar surface that includes the predetermined axial line. Accordingly, if a lower end of the clamps 623 rotate about the predetermined axial line in a direction toward each other, the clamps 623 contact the upper outer circumferential surface of the bulb material tube 40 to clamp onto the same. If the lower ends of the clamps 623 rotate to spread apart, the clamps 623 are distanced from the outer circumferential surface of the bulb material tube 40 to release the same. The clamps 623 contact a lower surface of a pressing plate 624, which will be described below, to receive a force. To realize this, upper ends of the clamps 623 extend above the clamp base 622. Further, the upper ends of the clamps 623 contact the lower surface of the pressing plate 624, and the upper ends of the clamps 623 and the pressure plate 624 undergo relative motion at this contacting surface. To reduce friction generated by this operation, clamp rollers 623a are mounted to the upper ends of the clamps 623.

The clamping unit driving means is mounted to the guide 621, and acts to rotate the clamps 623 such that lower ends thereof move in a direction to close together or spread apart about the predetermined axial line. In the embodiment shown in the drawing, the clamp unit driving means includes a fixing element 625 mounted at an upper area of the guide 621 at a predetermined distance from the clamp base 622, the pressing plate 624 mounted to the guide 621 such that it is able to undergo up and down movement along the guide 621 between the fixing element 625 and the clamp base 622, and a spring 626 mounted on the guide 621 such that an upper end thereof is supported by the fixing element 625 and a lower end thereof is supported by the upper surface of the pressure plate 624. The pressing plate 624 moves downward by the elastic force of the spring 626, and moves upward by a predetermined outward force and above that is exerted by the clamping release devices 720 and 730 (to be described below).

The clamping means 620 structured as described above operates as follows.

If the pressure plate 624 applies a force to the clamp roller 623a while moving

downward by the elastic force of the spring 626, the lower ends of the rotating clamps 623 rotate in a direction closing together about the predetermined axial line under the clamp base 622. Accordingly, the lower ends of the clamps 623 clamp onto the supplied bulb material tube 40. This clamping action is maintained by the elastic force of the spring 626.

If the clamping release devices 720 and 730 (to be described below) apply an external force of a predetermined intensity or greater under the pressing plate 624 to push the pressing plate 624 upward, the clamp rollers 623a become distanced from the lower surface of the pressing plate 624. At the same time, the lower ends of the clamps 623 rotate from the predetermined axial line in a direction to spread apart by their own weight.

Accordingly, the clamping unit may either receive a new bulb material tube 40 or release the clamping force applied to the processed bulb 61. In order to realize smooth operation of the clamping means 620, the clamping means 620 has the following feature. To begin with, so that the clamps 623 receive the force of the pressing plate 622 to undergo smooth rotation, the line extending from the direction that the force applied to the clamp rollers 623a by the pressing plate 624 must pass through an outer area of the circumference about which the clamps 623 are mounted to the clamp base 622. Further, to enable the clamps 623 to undergo rotation by the use of its own weight, a line extending along a direction that gravity is applied to the center of gravity of the clamps 623 must pass through an area within the above circumference. As will be described below, in the case where the clamping unit receives a new bulb material tube 40 or releases a clamping force applied to the processed bulb 62, it is necessary to discontinue rotation of the clamping unit. The clamping means 620 of the chucks 610 is discontinued in operation by the external force applied to the pressing plate 624 by the clamping release devices 720 and 730.

The chuck power transmitting means is mounted to the housing 611, and receives power for rotating the clamping means 620 from the clamping unit driving means and transmits the power to the clamping means 620. In the embodiment shown in the drawings, the chuck power transmitting means includes the chuck gear 614. The chuck gear 614 is inserted for mounting in the guide 621 to be positioned within the housing 611 and in such a manner to enable relative rotation with the guide 621. Some of the gear teeth of the chuck gear 614 are exposed through the gear connecting window 612 to enable meshing of

the gear teeth of the chuck gear 614 with the drive gear 604. The chuck gear 614 meshed with the drive gear 604 receives a rotational force from the drive gear 604 to transmit this rotational force to the guide 621 through the clutch 615.

The clutch 615 controls the rotational force transmitted to the guide 621 from the chuck power transmitting means. The clutch 615 operates such that if an external force of a predetermined level or greater is applied to the clamping means 620 by the clamping release devices 720 and 730, the rotational force transmitted to the guide 621 is discontinued. Various different structures may be used for the clutch 615. However, in the embodiment shown in the drawing, a friction clutch is used in which a hole is formed passing through the chuck gear 614 in a direction of its radius from an exterior thereof and extending in the direction of the guide 621. Further, an adjustment screw 615a, a friction pad pressure spring 615b, and a friction pad 615c are mounted within the hole and in this sequence starting from the exterior of the chuck gear 614. With this structure, the friction pad 615c receives an elastic force of the friction pad pressure spring 615b to be closely contacted to an exterior surface of the guide 621 such that friction is generated at the area of contact between the friction pad 615c and the guide 621. Accordingly, if the chuck gear 614 rotates, the guide 621 also rotates. If a torque is applied between the guide 621 and the chuck gear 614 that is greater than a torque generated by this friction, slipping in the contact surface between the friction pad 615c and the guide 621 occurs. That is, even if rotational force is received from the drive gear 604 such that the chuck gear 614 rotates, the clutch slips if a torque of at least a predetermined level is applied to the clamping means 620. As a result, relative rotation occurs between the guide 621 and the chuck gear 614. Accordingly, if it is necessary for the bulb material tube 40 to rotate in order to evenly heat the clamped bulb material tube 40 or perform blowing of the same into a uniform shape, the clutch 615 transmits rotation to enable the bulb material tube 40 to rotate together with the clamping means 620. Also, in the case where the clamping unit is spread apart to supply a new bulb material tube 40 to the clamping means 620 or separate a processed bulb 62 from the clamping means 620, the clutch 615 acts so that rotation is discontinued by the slipping generated in the clutch 615. The torque applied between the guide 621 and the chuck gear 614 so that the clutch 615 slips is generated by an external

force of at least a predetermined intensity applied to the lower surface of the pressing plate 624 by the clamping release devices 720 and 730. That is, not only is the pressing plate 624 pushed upward by the external force of at least a predetermined level applied to the lower surface of the pressing plate 624 so that the clamping release devices 720 and 730 push the pressing plate 624 in an upward direction, but the friction generated in the contact area between the pressing plate 624 and the clamping release devices 720 and 730 becomes the torque needed to cause slipping of the clutch 615 to thereby stop the rotation of the clamping means 620.

A fourth heating means heats a lower portion of the bulb material tubes 40 that are clamped in the chucks 610 and moved by rotation of the rotary table 602. The fourth heating means includes the plurality of torches 631, and a combustion gas supply source (not shown in the drawings) connected to the plurality of torches 631 to supply combustion gas to the same. With reference to the drawings, the plurality of torches 631 are mounted to a circumference of the rotary table 602. That is, the plurality of torches 631 are mounted to the circumference of the rotary table 602 between where the bulb material tubes 40 are supplied to the chucks 620 and where the bulbs 62 undergo a blowing process in a state clamped to the chucks 620. Accordingly, prior to when the bulb material tubes 40 supplied to the chucks 610 undergo blowing processes, lower portions of the bulbs 40 including the domes 40a are heated by the torches 631 while being rotated by the rotary table 602.

The bulb material tubes 61 with lower portions heated by the fourth heating means undergo a blowing process by the bulb forming mold unit 640 and the second gas supply means 650.

FIG. 18 is a sectional view of the bulb forming mold unit 640 and the second gas supply means 650 taken along line F-F of FIG. 17.

The bulb forming mold unit 640 receives the lower end of one of the heated bulb material tubes 61 to enable the same to be formed into a uniform shape as it undergoes a blowing process by injection of a gas therein. The bulb forming mold unit 640 includes bulb forming molds 64 la and 641 b, and a mold opening and closing means having a mold opening and closing link rod 642.

With reference to the drawings, the bulb forming molds 64 la and 641 b are formed

such that a space for receiving a lower end of one of the bulb material tubes 61 is divided into two sections, i. e. , two spaces. The two sections are hingedly interconnected on one side to be opened and closed. The spaces are concavely formed into a shape corresponding to the shape of the bulbs 62. One end of the mold opening and closing link rod 642 is connected to an exterior of each of the bulb forming molds 641a and 641b. Accordingly, the bulb forming molds 641a and 641b connected to the mold opening and closing link rod 642 are opened and closed by operation of the mold opening and closing means.

The bulb forming mold unit 640 structured as in the above operates as follows.

If one of the bulb material tubes 61 clamped in one of the chucks 610 and with a lower end thereof heated arrives at a position able to be received in the spaces of the bulb forming molds 641a and 641b by rotation of the rotary table 602, the two bulb forming molds 641a and 641b receive the lower end of the bulb material tube 61 in the spaces by the operation of the mold opening and closing means then close. If the bulb material tube 61 received in the bulb forming molds 641a and 641b receive the injection of gas therein by the second gas supply means 650, it is formed into the shape of the spaces of the bulb forming molds 641 a and 641b.

The second gas supply means 650 injects bulb forming gas into the flare of the bulb material tube 61 received in the bulb forming molds 641a and 641b through the chuck 610. The second gas supply means 650 includes a gas injection nozzle 651.

The gas injection nozzle 651 is connected to a bulb forming gas supply source (not shown) through a gas supply hose 65 la to receive the supply of gas. Air is typically used as the gas. The gas injection nozzle 651 is fixed to one end of a gas injection nozzle support arm 652 such that a nozzle hole is directed downwardly above the passage holes 621 a of the chucks 610. The gas injection nozzle support arm 652 is connected to a support arm drive rod 653 such that it is able to undergo up and down moved on a support arm guide support stand 654, which is mounted on the base 601. The support arm drive rod 653 undergoes repeated up and movement by operation of a predetermined drive means such that the gas injection nozzle support arm 652 moves up and down repeatedly along the support arm guide support stand 654.

The second gas supply means 650 having the above structure operates as in the

following.

If a lower end of one of the bulb material tubes 61 is received in the bulb forming molds 641a and 641b, the support arm drive rod 653 is moved downward by the predetermined drive means. Accordingly, the gas injection nozzle 651 is inserted into the upper area of the passage hole 621a of the chuck 610 such that a lower end contacts the flare of the glass tube material 61 that passes through the passage hole 621a and that is clamped on the chuck 610. In this state, if gas is supplied to inside the bulb material tube 61 through the gas injection nozzle 651, the lower portion of the bulb material tube 61 expands to the shape of the spaces of the bulb forming molds 641a and 641b such that the bulb material tube 61 is formed into a bulb 62. After completion of supplying gas, the gas injection nozzle 651 moves upward by the movement of the support arm drive rod 653 in an upward direction to thereby be removed from the passage hole 621a. Next, the bulb forming molds 641a and 641b are opened and the bulb 62 clamped in the chuck 610 is moved toward the clamping release device 730 by rotation of the rotary table 602. By operation of the clamping release device 730, the bulb 62 is distanced from the chuck 610 and moved to final processes such as annealing and inspection through a slide 740 (see FIG. 17).

As described above, the blow forming device 600 includes the chucks 610 suitable for clamping onto the bulb material tubes 40. Accordingly, each of the bulb material tubes 40 divided into two segments by the bulb material tube separating device 400 is extracted from the bulb material tube separating device 400 by the bulb material tube supply device 500, which will be described below, to be supplied for clamping to the chucks 610 of the blow forming device 600. That is, the system 1000 for manufacturing bulbs according to the present invention further includes the bulb material tube supply device 500.

FIG. 15 is a plan view of the bulb material tube supply device 500 of the system 1000 for manufacturing a bulb shown in FIG. 4.

For the bulb material tube supply device 500, there may be used a robot (not shown) provided with a clamping means at an end that can clamp the bulb material tubes 40, or a joint device (not shown) for performing the same function as that of the robot.

However, in the drawing, an embodiment of the bulb material tube supply apparatus 500 is

shown that is suitable for placement of the bulb material tube separating device 400 and the blow forming device 600. The bulb material tube supply apparatus 500 includes a bulb material tube extracting unit 510 and a bulb material tube supply unit 530.

The bulb material tube extracting unit 510 extracts the bulb material tubes 40 from the bulb material tube separating device 400 for supply to the bulb material tube supply unit 530. The bulb material tube extracting unit 510 includes a suction unit 511 that attaches to an outer surface of the bulb material tube 40 positioned at the bulb material tube separating device 400 to clamp onto the bulb material tube 40, a rotating arm 512 on one end of which the suction unit 511 is attached, an arm pivoting cylinder 514 for repeatedly pivoting the rotating arm 512 over a predetermined angle in a vertical surface, and an arm rotating cylinder 513 rotating the rotating arm 512 by a predetermined angle about an axis that is uniform with a lengthwise direction of the rotating arm 512. Accordingly, the suction unit 511 attaches to the bulb material tube 40 positioned at the bulb material tube separating means 400. The bulb material tube 40 attached to the suction unit 511 in this manner is moved from the bulb material tube separating device 400 to a bulb material tube holder 531 of the bulb material tube supply unit 530 that is on the opposite side and waiting to receive the bulb material tube 40. This is accomplished by pivoting the rotating arm 512 by 180 degrees through the pivoting of the arm pivoting cylinder 514. Occurring at the same time as the pivoting of the rotating arm 512 is the rotation of the rotating arm 512 by 90 degrees by operation of the arm rotating cylinder 513. This is done so that the bulb material tube 40 to which the suction unit 511 is attached is in a position able to be inserted into the bulb material tube holder 531. Next, if the suction unit 511 releases the bulb material tube 40, the bulb material tube 40 is inserted in the bulb material tube holder 531.

The bulb material supply unit 530 supplies the bulb material tube 40 received from the bulb material tube extracting unit 510 to one of the chucks 610 of the blow forming device 600.

The bulb material supply unit 530 includes the bulb material holder 531 into which the bulb material tube 40 released by the suction unit 511 is inserted, and a holder rotating arm 532 on one end of which the bulb material holder 531 is mounted, and provided able

to undergo rotation by a predetermined angle about a vertical axial line as well as up and down movement. The holder rotating arm 532 moves the bulb material tube holder 531 to a lower portion of the clamping means 620 of one of the chucks 610, which is moved to a specific location by rotation of the rotary table 602 and stopped, at the location where the bulb material tube 40 is released by the suction unit 511. The other end of the rotating arm 532 is fixed to a holder rotating arm rotating shaft 533, which is vertical to the center axial line, and undergoes repeated rotation by a predetermined angle and about the vertical axial line by rotation of the holder rotating arm rotating shaft 533. With reference to FIG. 16, during when the bulb material tube 40 is supplied to the chuck 610, the bulb material tube 40 is supplied while being moved from below the chuck 610 to above the same so that the bulb material tube 40 and the bulb material tube holder 531 do not interfere with the clamping means 620 of the chuck 610. To realize this, the holder rotating arm rotating shaft 533 to which the holder rotating arm 532 is fixed is able to undergo up and down movement. That is, the holder rotating arm rotating shaft 533 undergoes movement in which it is lowered and raised while simultaneously rotating. Accordingly, the holder rotating arm 632 starts to rotate while being moved downward, and ends rotation while being moved upward.

The operation of the bulb material supply device 500 structured as in the above in which the bulb material tube 40 is supplied to the blow forming device 600 from the bulb material tube separating device 400 is synchronized with the operations of the bulb material tube separating device 400 and the blow forming device 600. Such synchronization is realized by the above control means.

With reference to FIG. 16, in order to spread apart the clamping unit of the clamping means during when the bulb material supply device 500 supplies the bulb material tubes 40 to the chucks 610, the clamping release device 720 applies an upward external force to the pressing plate 624 of the clamping means 620 to release the clamping operation of the clamping means 620, and, at the same time, disengages the clutch 615 such that rotation of the clamping means 620 is discontinued.

The clamping release device 720 includes two pressing elements 721 that both contact opposite sides of the lower surface of the pressure plate 624; pressing element

support rods 722, on upper ends of which the pressing elements 721 are respectively mounted, and extending downwardly a predetermined length; a pressing element support rod bracket 723, on opposite ends of which lower ends of the pressure element support rods 722 are mounted; and a repeated movement means 724, an upper end of a drive shaft of which is fixed to a center portion of the pressing element support rod bracket 723. To receive supply of the bulb material tubes 40, the clamping release device 720 is mounted under the chuck 610 that is stopped at a specific location. By operation of the repeated movement means 724, the pressing elements 721 are contacted to the lower surface of the pressing plate 624 to push the pressing plate 624 upward. With reference to Fig. 17, two of the clamping release devices 720 and 730 are mounted to the circumference of the rotary table 602. The clamping release device 720 is used to spread apart the clamping unit of the clamping means 620 when the bulb material tube 40 is supplied to the chuck 610, while the clamping release device 730 is used to spread apart the clamping unit of the clamping means 620 to release the formed bulb 62 from the chuck 610 from a state where the bulb 62 is clamped to the chuck 610.

The system 1000 for manufacturing bulbs according to the present invention and structured as in the above operates as follows.

The glass tube materials arranged in the arrangement stand are supplied to the supply means one at a time by the first rotating means after the reception of signals from the sensor. The supplied glass tube material is continuously fed by a predetermined amount to the cutting device by the feeder. The glass tube material fed to the cutting device in this manner is cut into a glass tube of a predetermined length by the first heating means and the cutting knife while being rotated by the first rotating means. The glass tube of a predetermined length cut in this manner is supplied to the flare forming device by the transfer means. Both ends of the glass tube of a predetermined length supplied to the flare forming device are heated by the second heating means, and entrances to both ends are spread apart in the shape of the bell of a trumpet by the flare forming means. The glass tube with formed flares is supplied to the bulb material tube separating device by the transfer means, and the glass tube with formed flares supplied to the bulb material tube separating device is separated into two bulb material tubes with one of the ends thereof

closed off. This is realized by heating a center portion of the glass tube with formed flares by the third heating means while the glass tube is rotated by the third rotating means, and, at the same time, separated by the separating means. Further, gas is received in the bulb material tubes, which are separated in the bulb material tube separating device, by operation of the first gas supply means such that the closed off ends are concavely formed into domes. Each of these bulb material tubes is extracted from the bulb material tube separating device by the bulb material tube supply device for supply to one of the chucks of the blow forming device. The bulb material tube supplied to the chuck is moved by rotation of the rotary table in a state where its flare is clamped by the clamping means, and a lower portion thereof is heated by the fourth heating means. The bulb material tube with its lower end heated in this manner is received in the bulb forming mold, and in a state where the lower portion of the bulb material tube is received in the bulb forming mold, the second gas supply means injects gas into the bulb material tube through the flare of the same. Accordingly, the bulb material tube undergoes blow forming into a bulb. The bulb formed in this manner is removed from the chuck and undergoes final processes such as undergoing heat treating and inspection.

Industrial Applicability In the method and system for manufacturing a bulb of the present invention described above, a bulb material tube is produced in which a flare and a dome are formed on ends of a glass tube of a predetermined length, and blowing is performed in a state where the dome of the bulb material tube is heated and positioned in a mold such that waste of glass tube material is prevented.

Further, in the method and system for manufacturing a bulb of the present invention, there is mounted a supply means that supplies a glass tube material one at a time to the system for manufacturing bulbs, a batch of a predetermined number of glass tube materials being supplied all at once such that a worker need not be continuously waiting at the system and can instead supply a batch of glass tube materials when all the plurality of the same have been used.

Also, in the method and system for manufacturing a bulb according to the present

invention, new glass tube materials are not directly supplied to the system for manufacturing bulbs during operation of the same, and, instead, the glass tube materials are arranged in a batch and simply supplied to an alignment stand such that the worker performing supply of the glass tube materials need not be experienced.

Also, in the method and system for manufacturing a bulb of the present invention, only the dome area of a glass tube material having a pre-formed flare is formed in a bulb forming mold such that it is not necessary to manufacture a mold with a shape to form the flare.

Further, in method and system for manufacturing a bulb of the present invention, only a single a gas injection means, which operates to allow a gas injection nozzle to approach an entrance of a flare of a bulb material tube, is mounted at a suitable position in the vicinity of a rotating table to thereby obtain a simple structure.

While the present invention has been described with reference to the particular illustrative embodiments, it is not to be restricted by the embodiments but only by the appended claims. It is to be appreciated that those skilled in the art can change or modify the embodiments without departing from the scope and spirit of the present invention.