JP2010267624A - Filament carbon heating element and planar heating element disposed with this - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a filament carbon heating element improving thermal efficiency without generating excess energy consumption, and to provide a planar heating element disposed with this. <P>SOLUTION: The filament carbon heating element 1 is formed by winding a carbon resistor 2 comprising a freely deformable carbon fiber thread on an elastic wire 3 and further coating the whole with an insulating coating material 4 such as a resin having flexibility. Further, the planar heating element 7 is formed by meandering and disposing the filament carbon heating element 1 on a planar member. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a filamentous carbon heating element and a planar heating element provided with the same.

  Conventionally, sheet heating elements such as electric blankets and electric carpets are generated by energizing a flexible heating wire (nichrome wire or tungsten wire) that is coated inside the blanket or carpet. Blankets and carpets are warmed by Joule heat. In addition, a heating wire is embedded in a planar member in a floor heating, a snow melting sheet, and the like, and the floor is warmed by Joule heat generated by energizing this, or the accumulated snow is melted.

Problems to be solved by the invention

  However, the electrical resistivity of nichrome wire or tungsten wire used as a heat source increases remarkably as the temperature rises, so the inrush current of the equipment using this is large and about 10 times the rating at the moment when the power is turned on. Rush current flows. For this reason, electromagnetic noise is generated, and there is a risk of causing electromagnetic interference to the device or electromagnetic waves adversely affecting the human body.

The present invention has been conceived in view of the conventional problems as described above, and does not cause excessive energy consumption, and on the surface on which the filamentous carbon heating element is arranged to improve the thermal efficiency. An object is to provide a heating element.
It is another object of the present invention to provide a filamentous carbon heating element free from electromagnetic interference to equipment and a planar heating element having the same.

Means for solving the problem

In order to achieve the above-mentioned object, the filamentous carbon heating element of the present invention is obtained by winding a carbon resistor made of a deformable carbon fiber yarn around an elastic wire, and further, insulating coating such as a resin having flexibility as a whole. It is characterized by being covered with a material.
The filamentous carbon heating element of the present invention is characterized in that a carbon resistor made of a deformable carbon fiber yarn is covered with an insulating coating material such as a flexible resin.
The planar heating element according to the present invention is characterized in that the above-described filamentous carbon heating element is arranged meandering on the planar member.

The effect | action by the said problem-solving means is as follows.
Carbon fiber has a large electric resistance value and easily generates heat. The carbon resistor generates heat by conducting to the carbon resistor made of such carbon fiber yarn. Since the carbon fiber has a negative resistance characteristic in which the resistance value decreases as the temperature rises, the inrush current during voltage application is reduced by using the filamentous carbon resistor of the present invention.

The invention's effect

  According to the present invention having the above configuration, since the inrush current can be reduced, no extra energy consumption occurs, the thermal efficiency can be improved, and the filamentous carbon heating element free from electromagnetic interference with the device and A planar heating element provided with this can be provided. In addition, far-infrared rays are emitted by heating the carbon fiber yarn, and there is little irritation to the skin, and a far-infrared effect such as acting gently on the human body can be expected.

  Embodiments according to the present invention will be described below with reference to the drawings.

(A) A filamentous carbon heating element (Figure 1)
The filamentous carbon heating element 1 is formed by winding a carbon resistor 2 made of carbon fiber yarn around an elastic wire 3 such as a wire or copper wire, and further covering the whole with an insulating coating material 4 such as a flexible resin. . Further, instead of coating with the insulating coating material 4, a liquid resin or the like may be applied to the carbon resistor 2 and cured. When the terminals 5 are attached to both ends of the filamentous carbon heating element 1 and are connected through the terminals 5, the filamentous carbon heating element 1 generates heat.

(B) Carbon resistor (Figure 2)
The carbon resistor 2 composed of carbon fiber yarn is a PAN-based carbon warp fiber yarn 22 formed by bundling a number of PAN-based carbon fiber wires 21 made of, for example, polyacrylonitrile, and a plurality of the PAN-based fiber yarns 22 are twisted together. It consists of twisted yarn. The carbon resistor 2 formed by twisting a number of PAN-based carbon fiber yarns 22 in this way has high elasticity and high strength characteristics. However, in order to maintain sufficient heat resistance and strength as a heating element, the carbon resistor 2 has a thickness. The (diameter) is desirably about 1 mm to 5 mm. By using the twisted yarn, the carbon resistor 2 is more difficult to unwind compared to the case where the PAN-based carbon fiber yarns 22 are simply bundled.
In order to improve processability such as coating, the carbon resistor 2 is preferably immersed in a liquid resin and cured. Further, the surface is coated and smoothened by immersing the carbon resistor 2 in a liquid resin or the like.

(C) Terminal (Fig. 3)
The terminal 5 is composed of a bendable conductive band-like metal 50 and a lead wire 51 connected thereto (FIGS. 3C and 3D). In order to attach the terminal 5 to the carbon resistor 2, first, as shown in FIG. 3A, a T-shaped metal strip 50 is formed, both sides are bent vertically, and a notch 52 is formed in a part thereof, and a corrugated shape is further formed. The uneven portion 53 is formed (FIG. 3B).
One end of the carbon resistor 2 is inserted here, and the wavy uneven portion 53 is bent (FIG. 3B).
Further, the vertical bent portions on both sides are also bent to crimp the wavy unevenness 53 to the carbon resistor 2.
The lead wire 51 is spot welded to the tongue piece 54, and the terminal 5 is attached to both ends (FIGS. 3C and 3D).
The terminal 5 is not limited to the above, and any terminal can be used as long as one end of the carbon resistor 2 can be fixed, such as by simply winding the belt-shaped metal plate 50.

(D) Planar heating element (Fig. 4)
FIG. 4 shows a wiring state of a planar heating element (electric blanket, electric carpet, etc.) 7 in which the filamentous carbon heating element 1 is embedded. The filamentous carbon resistor 1 is meanderingly disposed on the heat radiation surface of the planar heating element 7, and the terminal 5 (lead wire 51) is connected to the energization control unit 8. A plug 10 is attached to the end of the energization control unit 8 via a cord 9. By inserting the plug 10 into an outlet (not shown), the filamentous carbon resistor 1 generates heat while being controlled by the energization control unit 8, and the planar heating element 7 radiates heat.
When manufacturing the sheet heating element 7, first, the carbon resistor 2 is wound around the elastic wire 3 and covered with the insulating coating material 4. The carbon resistor 2 has conductivity, and thus the element wire 21. The electrical conductivity (resistance value) can be adjusted as appropriate by adjusting the diameter, the number of strands of the strands 21 and the like.

(E) Operation When the terminal 5 of the filamentous carbon heating element 1 configured as described above is energized, a current flows through the carbon resistor 2 and the carbon resistor 2 generates heat. Since the carbon heating element 2 is made of a twisted yarn in which a plurality of carbon fiber strands 21 are twisted together, a current flows uniformly through the carbon resistor 2, and a high heat generation efficiency can be obtained uniformly over the entire surface. Further, since the carbon resistor 2 is covered with the insulating coating material 4, the carbon resistor 2 is not oxidized even when used in a high temperature environment, and the long-lasting filamentous carbon heating element 1 is obtained. For this reason, the lifetime of the planar heating element 7 using the filamentous carbon heating element 1 is greatly extended.
Further, the filamentous carbon heating element 1 can be bent according to the shape of the planar heating element 7 or can be appropriately deformed in the manufacturing process, so that the planar heating element 1 can be obtained. The degree of freedom of design 7 is increased.
Since the resistance value of the filamentous carbon heating element 1 is inversely proportional to the cross-sectional area and proportional to the length, the required output is designed by changing the diameter of the carbon fiber strands 21 to be twisted, the number of carbon fiber strands 21 being increased or decreased, and the like. be able to.

Next, another embodiment of the present invention will be described with reference to FIG.
In this example, the carbon resistor 2 is dipped in a liquid resin or the like and cured appropriately, and the carbon resistor 2 is covered with an insulating coating material 4 such as a flexible resin without being wrapped around the elastic wire 3. is there. Since the carbon resistor 2 is appropriately cured, it can be bent according to the planar heating element 7 or can be appropriately deformed in the manufacturing process.

The schematic perspective view which shows the filamentous carbon heat generating body of this invention. The perspective view of a carbon resistor. Schematic which shows the manufacturing process of a terminal. Schematic which shows the planar heating element of this invention. The schematic perspective view which shows the other example of a filamentous carbon heat generating body.

1. 1. A filamentous carbon heating element Carbon resistor 21. 2. PAN-based carbon fiber strand Elastic wire 4. 4. Insulation coating material Terminal 50. 6. Band-shaped metal plate Planar heating element 8. Energization controller

Claims (3)

  A yarn-like carbon heating element, wherein a carbon resistor made of a deformable carbon fiber yarn is wound around an elastic wire, and the whole is covered with an insulating coating material such as a flexible resin.   A yarn-like carbon heating element, wherein a carbon resistor made of a deformable carbon fiber yarn is coated with an insulating coating material such as a flexible resin.   An on-surface heating element, wherein the filamentous carbon heating element according to claim 1 or 2 is meanderingly disposed on an on-surface member.

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