This section is from the book "Cyclopedia Of Architecture, Carpentry, And Building", by James C. et al. Also available from Amazon: Cyclopedia Of Architecture, Carpentry And Building.
The incandescent lamp is by far the most common type of lamp used, and the principle of its operation is as follows:
If the current, material, and conditions are so chosen that the substance may be heated in this way until it gives out light, becomes incandescent, and does not deteriorate too rapidly, we have an incandescent lamp. Carbon was the first successful material to be chosen for this conductor and for ordinary lamps it is formed into a small thread or filament. Very recently metallic filament lamps have been introduced commercially with great success but the carbon incandescent lamp will continue to be used for some time, especially in the low candle-power units operated at commercial voltages. Carbon is a successful material for two reasons: i. The material must be capable of standing a very high temperature, 1,280° to 1,330° C, or even higher.
2. It must be a conductor of electricity with a fairly high resistance.
Platinum was used in an early stage of the development, but, as we shall see, its temperature cannot be maintained at a value high enough to make the lamp as efficient as when carbon, or a metal having a melting point higher than that of platinum, is used. Nearly all attempts to substitute another substance in place of carbon have failed until recently, and the few lamps which are entirely or partially successful will be treated later. The nature of the carbon employed in incandescent lamps has, however, been much improved over the first forms, and owing to the still very great importance of this lamp, the method of manufacture will be considered.
Manufacture of Carbon Incandescent Lamps. Preparation of the filament. Cellulose,a chemical compound rich in carbon, is prepared by treating absorbent cotton with zinc chloride in proper proportions to form a uniform, gelatine-like mass. It is customary to stir this under a partial vacuum in order to remove bubbles of air which might be contained in it and destroy its uniformity. This material is then forced, "squirted," through steel dies into alcohol, the alcohol serving to harden the soft, transparent thread . These threads are then thoroughly washed to remove all trace of the zinc chloride, dried, cut to the desired lengths, wound on forms, and carbonized by heating to a high temperature away from air. During carbonization, the cellulose is transformed into pure carbon, the volatile matter being driven off by the high temperature to which the filaments arc subjected. The material becomes hard and stiff, assuming a permanent form, shrinking in both length and diameter - the form being specially constructed so as to allow for this shrinkage. The forms are made of carbon blocks which are placed in plumbago crucibles and packed with powdered carbon. The crucibles, which are covered with loosely fitting carbon covers, are gradually brought to a white heat, at which temperature the cellulose is changed to carbon, and then allowed to cool. After cooling, the filaments are removed, measured, and inspected, and the few defective ones discarded.
Fig. 1. Forms of Filaments now in Use.
In the early days, these filaments were made of cardboard or bamboo, and later, of thread treated with sulphuric acid.
A few of the shapes of filaments now in use are shown in Fig. 1, the different shapes giving a slightly different distribution of light. As here shown they are designated as follows: A, U-shaped; B, single-curl; C, single-curl anchored; D, double-loop; E, double-curl; F, double-curl anchored.
Mounting the Filament. After carbonization, the filaments are mounted or joined to wires leading into the globe or bulb. These wires are made of platinum - platinum being the only substance, so far as known, that expands and contracts the same as glass, with change in temperature and which, at the same time, will not be melted by the heat developed in the carbon. Since the bulb must remain air-tight, a substance expanding at a different rate from the glass cannot be used. Several methods of fastening the filament to the leading in wires have been used, such as forming a socket in the end of the wire, inserting the filament, and then squeezing the socket tightly against the carbon; and the use of tiny bolts when cardboard filaments were used; but the pasted joint is now used almost exclusively. Finely powdered carbon is mixed with some adhesive compound, such as molasses, and this mixture is used as a paste for fastening the carbon to the platinum. Later, when current is sent through the joint, the volatile matter is driven off and only the carbon remains. This makes a cheap and, at the same time, a very efficient joint.
Flashing. Filaments, prepared and mounted in the manner just described, are fairly uniform in resistance, but it has been found that their quality may be much improved and their resistance very closely regulated by depositing a layer of carbon on the outside of the filament by the process of flashing. By flashing is meant heating the filament to a high temperature when immersed in a hydrocarbon gas, such as gasoline vapor, under partial vacuum. Current is passed through the filament in this process to accomplish the heating. Gas is used, rather than a liquid, to prevent too heavy a deposit of the carbon. Coal gas is not recommended because the carbon, when deposited from this, has a dull black appearance. The effects of flashing are as follows:
1. The diameter of the filament is increased by the deposited carbon and hence its resistance is decreased. The process must be discontinued when the desired resistance is reached. Any little irregularities in the filament will be eliminated since the smaller sections, having the greater resistance, will become hotter than the remainder of the filament and the carbon is deposited more rapidly at these points.