JKL Miniature Integrated Lamp Assemblies

Transcription

1 JKL Miniature Integrated Lamp Assemblies Up to 300% Greater Lamp Life than Wedge Base Lamp & Socket Assemblies, With Six Sigma Performance! Innovative Solutions in Lighting Catalog WWT-0900

2 WWT Series Lamps: Outperformance at Every Criterion Achieves Six Sigma Standard; Sets Benchmark for Uniform Brightness, Optimized Life, Ultra-Tight Tolerances, and Up to 3 Times Greater Life Vacuum superiority is the ultimate key to uniform brightness, longest possible life and superior performance. These attributes have been achieved for the first time by JKL Components Corporation with its introduction of the new WWT Series of integrated lamps the first practical alternative to wedge base designs. A ruggedized, low-profile design boosts filament life and reliability threefold. This new design concept achieves lamp life predictability levels heretofore deemed impossible. Yet there is absolutely no premium in price! Time before first failure is dramatically increased. Performance variability spreads tighten, assuring longer life and consistent light output within more stringent tolerances. Overdriving lamps to increase brightness has nominal impact. Dual Contact to either top or bottom of PC Board Uniform Brightness with Significantly Longer Lamp Life Brightness uniformity can now be maintained throughout a useful lamp life that is up to 300% longer than wedge base lamp and socket approaches. The design weaknesses inherent in wedge base lamps mean first failures will start sooner, and variability in life and performance will be wider. The thoughtfully-engineered enhancements of the new WWT Series set a new standard for consistent performance and long life. Exceptional Performance with NO Premium in Price The new dual contact design allows more reliable attachment and detachment of WWT Series lamps to either side of a PC Board for maximum utility. The low profile design reduces front and rear space requirements by up to half that of wedge base lamp assemblies. Labor and insertion costs are greatly reduced. Gas-filled versions of the new WWT Series lamps are also available. Most important, all these measurable benefits have been achieved for the same price or even less than sadly inferior wedge base lamps. Residual Atmosphere is Up to X Higher in Wedge Base Lamps, Reducing Life. WWT Series Yields Up to 500% Greater Life at Same Cost Many unique design features have been incorporated into the new JKL integrated wire lamp assemblies. The lamp itself is of a totally new design, which has directly addressed the many problems associated with wedge base lamps. A critical design feature is the integration of lamp and socket, which eliminates the need for hard wiring. Attaching the lamp directly to the terminal increases life expectancy, strength and reliability up to five-fold. In addition, replacement in the event of a failure is much simpler than hard-wired wedge base designs. Simply replace the entire assembly, saving labor and production time. Copyright 2000, JKL Components Corporation The new WWT Series of Integrated lamps marks another major design innovation from JKL Components, integrating the lamp and socket, which eliminates the need for hard wiring while reducing labor and production. Comparing Manufacturing Processes WWT vs. Wedge Base WWT Series The one-piece lamp envelope is mated with an assembly of dumet leads, bead stem and a specially reinforced filament. After a thorough bake-out, high intensity vacuum removes any impure atmosphere through the wide lamp base, removing up to times residual atmosphere of that found in wedge base lamps. The interior is nitrogen-purged and heat-sealed. Each lamp is then burned-in and tested to insure dramatically superior lamp quality and life capabilities. Wedge Base Lamps (WBL) Unlike the JKL integrated lamp design, wedge base lamps have a much less-controlled assembly process, beginning with the joining of the dumet leads and bead stem to an inherently weak filament. The process has nominal bake-out. The base opening only one-fifth the size of the WWT series is ineffective, leaving a harmful residual atmosphere within the lamp. These impurities shorten life and diminished predictability of performance. Finally, there is absolutely no burn-in or testing. PAGE JKL COMPONENTS CORPORATION

3 One Piece Design Prolongs Life, Reduces Labor Costs New Design Integration of Lamp and Socket Eliminates Need for Hard Wiring; Replaces Wedge Base Lamps with No Redesign The WWT Series integrated lamp assemblies make the use of wedge base lamps obsolete. They extend lamp life, and provide for direct replacement of all existing wedge base assemblies with no redesign! A revolutionary new lamp structure design and proprietary manufacturing process integrates the lamp and socket, eliminating the need for hard wiring. Attachment of a WWT Series lamp directly to the terminal increases life expectancy and results in positive price/performance enhancements: Greatly Improved Light Distribution Increased Filament Strength and Enhanced Lamp Reliability Significantly Lower Labor and Insertion Costs Luminous Flux & Current Maintenance Over Time 1% 1% 0% 0% 90% 80% 70% 60% 50% WBL WWT BRIGHTNESS 98% 96% 94% 92% WBL WWT CURRENT (ma) 40% Hrs 00 Hrs 1500 Hrs 90% Hrs 00 Hrs 1500 Hrs Wide Variety of Electrical Variations Unlike the very limited selection available with wedge base lamps, the new JKL WWT Series is offered in a wide variety of electrical variations, and dozens of wattage and brightness configurations. Labor-Saving Design is Ideal for Automation The one-piece design of the WWT Series eliminates several labor-intensive steps during installation, and makes change-out (if necessary) quick and easy. Performance data has been verified using helium leak detection and mass spectrometer test procedures. The ruggedized construction, and resistance to G loads and vibration, make this new line excellent for use with auto-insertion and vibratory bowl feeder applications. Call today for all the details, and mark an end to the use of outdated, short-lived wedge base lamps. Lamp Filament Stability is Key to Extended Life & Reliability Low Profile WWT Series vs Standard Wedge Base The above illustration shows that the distance of the WWT Series filament attachment points (measured from seal area) is less than one half that of the wedge base lamp. The longer that distance, the poorer its resistance to shock and vibration. This critical difference translates to >3x greater reliability, tighter performance characteristics, and more uniform brightness over a dramatically extended lamp life JKL COMPONENTS CORPORATION PAGE 3

4 Lamp Life Extension Proven Under Test Conditions WWT Series versus Wedge Base Lamps Results That Validate Performance Superiority Residual Gas Content (O 2, CO-N 2, & CO 2 Measured Inside Lamp) WWT Series Integrated Lamp (A) - -9 (A) F(t) CO 2 O 2 CO 2 O 2 Wedge Base Lamp CO+N 2 CO+N 2 Lamp Life Testing (Accelerated Test 14V@0mA) WBL WWT Greater the Vacuum, Longer the Life Notice the dramatic difference in vacuum levels between the JKL Integral Lamp and the standard wedge base lamp, performed under stringent laboratory conditions. Residual atmosphere within the new WWT Series design is nominal, while that of the wedge base model is nearly ten times greater. Shock Test Performance Characteristics Current (ma) Before Test After Test Change (%) (ma) (ma) Incidence (%) 1 + Spec Legend: V 0mA WWT Series Lamp Wedge Base Lamp Proven Performance at High Temperatures Clearly superior performance is demonstrated in this life testing graph, showing first failure of wedge base lamps occurred at 81 hours, compared to 1,675 hours for the new WWT Series. At any measurement milestone, the new JKL lamp design delivers demonstrable superiority which averages in excess of 400% across the entire spectrum. The delta difference is even greater in any of the progressive failure rates measured Filter Caps Save Inventory Cost, With Absolute Color Match Color is a very important consideration by some of America s largest companies, whose products new displays and instrumentation must have a clearly identifiable look. JKL provides a thoughtfully-engineered solution to matching these companies special color of lighting, used in applications ranging from automotive instrument panels to radios, and even to convert the light output of a powerful blue LED into up to 30 different shades of white! JKL Series 39 Silicone Filter Caps can be formulated in virtually any color (on special order) or lamp size, using x-y positioning of the spectral chart. It permits you the luxury of only stocking one clear lamp size, and utilize the farless-expensive slip-on filter cap to make the project conform to color standards. Think of the many advantages of silicone filters: They re re-usable They re interchangeable They re non-breakable They re highly color-stable They re lightweight And they re affordable. Standard sizes range from T 1 to T 3 1/4. Pick the filter cap that s right for your needs, provide us the specs on your color match, and we ll take it from there. Try it! x 2 (h) Failures Wedge Base WWT Series Average 766 hours 3,336 hours B 281 hours 2,455 hours B3 145 hours 2,006 hours B1 81 hours 1,675 hours PAGE JKL COMPONENTS CORPORATION

5 JKL Welded Wire Lamp Assemblies Product Specifications, Performance Characteristics & Electrical Variations Part Number Voltage Rated Current Amps ±% MSCP ±25% Life Hours (DC) WWT1-EW ,000 WWT1-EW ,500 WWT1-EW ,000 WWT1-EW ,500 WWT1-EW ,000 WWT1-EW ,000 WWT1-EW ,000 WWT1-EW ,500 WWT1-HW ,000 WWT1-EW ,000 WWT2-EW ,000 WWT2-EW ,500 WWT1-EW ,000 WWT2-EW ,500 WWT1-EW ,000 WWT2-EW ,000 WWT2-EW ,000 WWT2-EW ,500 WWT2-EW ,000 WWT2-EW ,000 WWT1 Series WWT2 Series R1 COPPER ø 12.3 This new welded wire miniature lamp assembly provides three times longer lamp life than traditional wedge base lamps. They perform better and cost less because its special manufacturing process creates a superior sealed atmosphere that results in brighter, more reliable performance JKL COMPONENTS CORPORATION PAGE 5 ø 8.5

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