JP2016091884A - Planar carbon heater and method of manufacturing planar carbon heater - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a planar carbon heater capable of facilitating adjustment of heating temperature and being applied to various purposes from a small-sized type to a large-sized type and also to provide a method of manufacturing the planar carbon heater.SOLUTION: In a planar carbon heater 1, a plurality of planar carbon heating elements 2 formed in a waveform are arranged in parallel to each other, both ends of each row of wave-shaped planar carbon heating elements 2 are connected with a conductive materials and an electrode 3 is formed, and then these front and back surfaces are laminated with the conductive material.SELECTED DRAWING: Figure 1

Description

  TECHNICAL FIELD The present invention relates to a heater using a planar carbon heating element, and more particularly to a planar carbon heater and a surface which can be easily downsized by forming the planar carbon heating element in a predetermined wave shape to easily control the heat generation temperature. The present invention relates to a method for manufacturing a carbon heater.

  Conventionally, various heating systems have been proposed, and one of them uses a planar carbon heating element. The planar carbon heating element is a thin material such as paper containing fibrous carbon, and emits far infrared rays when heated to generate heat. For this reason, the human body etc. can be warmed gently by far-infrared rays, and it attracts attention because it does not generate gas harmful to the environment such as carbon dioxide or the human body.

  In addition, the planar carbon heating element is easy to lay under the floor, does not require a boiler or the like, and has low power consumption. For this reason, the floor heating system using the planar carbon heating element can be installed under the floor easily and at a lower cost than the conventional piping floor heating system, and the running cost can be reduced.

  For example, JP 2013-155951 A proposes a planar carbon heating element formed in a mesh pattern in plan view as a planar carbon heating element for floor heating (Patent Document 1). According to Patent Document 1, by forming the carbon heating element in a mesh pattern instead of a linear pattern, a diffusion state of the energization path is obtained, and as a result, even when a partial load is applied after construction It is said that the energization path has flexibility and can prevent the generation of the bulk heat.

JP2013-155951A

  However, the invention described in Patent Document 1 has a problem that adjustment and control of the heat generation temperature are difficult due to having a large number of energization paths. That is, in the carbon heating element having the mesh pattern, the energization path is not determined, and the energization amount for each energization path is unbalanced.

  Further, the planar carbon heating element is composed of planar carbon paper containing carbon fibers, and is therefore soft and difficult to fix. For this reason, it is difficult to cut into a desired shape, and it is extremely difficult to form a curved shape. For example, an XY plotter 6 as shown in FIG. 5 is a cutting device capable of cutting into a complicated shape, and a cutting object is fixed by vacuum suction on a work board 61. Carbon paper cannot be fixed by suction because it has good air permeability. For this reason, the XY plotter 6 cannot be used to cut into a complicated shape such as a mesh pattern shown in Patent Document 1, and it is separately cut manually or an expensive mold or the like. Must be used to produce a carbon paper with a mesh pattern, which is not practical in terms of cost.

  The present invention has been made in order to solve such problems, and it is easy to adjust the heat generation temperature, and is a planar carbon that can be applied to various purposes from a small type to a large type. It aims at providing the manufacturing method of a heater and a planar carbon heater.

  In the planar carbon heater according to the present invention, a plurality of planar carbon heating elements formed in corrugations are arranged in parallel, and both ends of the corrugated planar carbon heating elements in each row are connected by a conductive material. Electrodes are formed, and these front and back surfaces are laminated with a conductive material.

  As one aspect of the present invention, the corrugated planar carbon heating element may have a width of 20 mm to 30 mm and a wave height of 50 mm to 150 mm.

  Furthermore, as one aspect of the present invention, the width and wave height of the corrugated planar carbon heating element may be formed such that the power consumption for one wavelength is 10 Wh to 20 Wh.

Moreover, as one aspect of the present invention, the length and the number of arrays of the corrugated carbon heating elements may be configured such that the power consumption per 1 m ² is 200 Wh or less.

  Furthermore, as one aspect of the present invention, the laminate layer made of the conductive material may have a conductive resin layer formed inside and a conductive metal layer formed outside.

  Further, as one aspect of the present invention, a moisture-proof and heat-insulating sheet layer is formed on the lower layer side of the laminate layer made of the conductive material, and a breathable protective sheet is formed on the upper layer side of the laminate layer. Also good.

  Furthermore, as one aspect of the present invention, a breathable protective sheet is formed on the outside of the laminate layer made of the conductive material, and a punching reinforcing layer having a plurality of heat radiation holes formed on the outside is further provided. It may be.

  The method for producing a planar carbon heater according to the present invention includes a single-side laminating step of laminating only one side of the planar carbon paper with a conductive material, and a work board on which a plurality of holes are formed on the laminated single side. A suction fixing step of vacuuming and fixing by vacuum from the back side of the work panel, and a carbon heating element cutting for cutting a plurality of corrugated planar carbon heating elements from the planar carbon paper so as to be arranged in parallel A process, an electrode creation process for producing electrodes by connecting both ends of each corrugated carbon heating element with a conductive material, and a double-sided laminating process for laminating front and back surfaces with a conductive material.

  ADVANTAGE OF THE INVENTION According to this invention, adjustment of heat_generation | fever temperature is easy, and it can apply for the various objective from a small type to a large type.

It is a top view which shows one Embodiment of the planar carbon heater which concerns on this invention. It is a cross-sectional schematic diagram which shows the planar carbon heater of this embodiment. It is a block diagram which shows the case where the planar carbon heater of this embodiment is electrically arranged in series. It is a block diagram which shows the case where the planar carbon heater of this embodiment is electrically arranged in parallel. It is a perspective view which shows the XY plotter used in this embodiment. It is a top view which shows the waveform planar carbon heating element cut | disconnected by the carbon heating element cutting process in this embodiment. It is a top view which shows the state by which the electrode was connected with the waveform planar carbon heating element by the electrode preparation process in this embodiment. It is a cross-sectional schematic diagram shown about the case where the planar carbon heater in the present Example 1 is used as a multipurpose heater. It is a cross-sectional schematic diagram shown about the case where the planar carbon heater in the present Example 2 is used as a bedrock footbath heater. It is a cross-sectional schematic diagram shown about the case where the planar carbon heater in the present Example 3 is used as a corrugated cardboard heater. It is a cross-sectional schematic diagram shown about the case where the planar carbon heater in the present Example 4 is used as a hanger heater. It is a schematic diagram shown about the case where the planar carbon heater in the present Example 4 is used as a hanger heater.

  Hereinafter, an embodiment of a planar carbon heater and a method of manufacturing the planar carbon heater according to the present invention will be described with reference to the drawings.

  As shown in FIGS. 1 and 2, the planar carbon heater 1 of the present embodiment mainly includes a plurality of corrugated planar carbon heating elements 2 and electrodes connected to both ends of each corrugated planar carbon heating element 2. 3 and the corrugated carbon heating element 2 and the laminate layer 4 on the front and back surfaces of the electrode 3. Hereinafter, each configuration will be described in detail.

  The corrugated planar carbon heating element 2 is composed of planar carbon paper that generates heat when energized. As shown in FIG. 1, the corrugated planar carbon heating element 2 is formed into a corrugated shape so that the resistance value of electricity to be energized and the amount of power consumption can be easily adjusted. ing. That is, in the case of a linear carbon heating element, there is a problem that it is difficult to make a uniform distribution of temperature when it is applied to a planar heater because the electric resistance becomes small and the temperature tends to rise. On the other hand, in the case of an acute-angled carbon heating element, there is a problem that it is difficult to obtain a desired heating temperature because electric resistance increases, temperature does not easily rise, and temperature unevenness tends to occur at the bent portion. On the other hand, in the case of a corrugated carbon heating element, like a river flow, it is possible to appropriately secure energization while giving an appropriate electrical resistance in a curved portion, so when applied to a planar heater There is a practical merit that it is easy to achieve uniform distribution of temperature. Also, by increasing or decreasing the number and interval of the corrugated planar carbon heating elements 2, the amount of heat generated and the size of the entire heater can be adjusted according to needs, so that there is a high practical advantage in this respect. .

  Further, the corrugated carbon heating element 2 in the present embodiment employs a carbon paper having a carbon content of 50% or more, preferably about 75%. Moreover, the width of the waveform is 20 mm to 30 mm, and the wave height is 50 mm to 150 mm or less. The waveform shape is adjusted according to the size of the planar heater required in the numerical range. Further, the width and wave height of the corrugated carbon heating element 2 are formed such that the power consumption for one wavelength (one element) is 10 Wh to 20 Wh. If the width is smaller than 20 mm, the electrical resistance increases and it becomes difficult to generate heat, resulting in poor heat generation efficiency. On the other hand, if it is larger than 30 mm, the waveform shape becomes large, the electric resistance becomes small and heat is easily generated, and the heat is excessively generated. On the other hand, if the wave height is smaller than 50 mm, it becomes close to a linear shape and the electric resistance becomes small and partly generates heat, and if it exceeds 150 mm, the electric resistance becomes too large and it becomes difficult to generate heat. The carbon density, width, and wave height of the corrugated carbon heating element 2 are not limited to the above numerical ranges, and can be appropriately selected and changed according to the purpose of use.

In the planar carbon heater 1, a plurality of corrugated planar carbon heating elements 2 are arranged in parallel. In this embodiment, the length and the number of arrangement of the corrugated carbon heating elements 2 are configured such that the power consumption per 1 m ² is 200 Wh or less in order to prevent burns and ignition due to overheating.

  The electrode 3 is made of a conductive material. The electrode 3 is a copper foil tape having a width of 12 mm to 20 mm, a thickness of about 25 μm to 35 μm, and a thickness of about 25 μm in this embodiment. The electrodes 3 are connected to both ends of the corrugated planar carbon heating elements 2 in each row, and current is passed through the corrugated planar carbon heating elements 2 in each row.

  The electrode 3 is not limited to copper foil, but is made of a conductive material such as aluminum foil, conductive polymer (many conductive polymers such as polyparaphenylene, polyaniline, polythiophene, polyparaphenylene vinylene). You may select suitably.

  The laminate layer 4 is a thin film layer made of a conductive material. As shown in FIG. 2, the laminate layer 4 in this embodiment has a conductive resin layer 41 formed on the inner side and a conductive metal layer 42 formed on the outer side. Specifically, a polyester film made of polyethylene terephthalate or the like having a thickness of about 150 μm to 250 μm and a thickness of about 150 μm in this embodiment is used as the conductive resin layer 41. Further, as the conductive metal layer 42, an aluminum vapor-deposited sheet having a thickness of about 50 μm to 250 μm, in which aluminum powder is vapor-deposited on a polyester film or the like, and a thickness of about 250 μm in this embodiment is used.

  The laminate layer 4 is not limited to the two layers composed of the conductive resin layer 41 and the conductive metal layer 42, and has at least one layer of the conductive resin layer 41 or the conductive metal layer 42. It only has to be. Further, the conductive metal layer 42 is not limited to the aluminum vapor deposition sheet, and may be an aluminum sheet in which aluminum is formed in a thin film shape. Furthermore, as the conductive metal layer 42, another metal sheet may be used instead of the aluminum vapor-deposited sheet or the aluminum sheet.

  A plurality of planar carbon heaters 1 according to the present embodiment can be arranged side by side in accordance with the installation area or the like. At this time, each planar carbon heater 1 may be electrically arranged in series with each other with respect to the power source 5, as shown in FIG. May be arranged in parallel.

  Next, the manufacturing method of the planar carbon heater 1 of this embodiment is demonstrated.

  The manufacturing method of the planar carbon heater 1 includes a single-sided laminating step, a suction fixing step, a carbon heating element cutting step, an electrode creating step, and a double-sided laminating step.

  The single-sided laminating step is a step of laminating only one side of the planar carbon paper with a conductive material. Specifically, a polyester film made of polyethylene terephthalate or the like having a thickness of several tens of μm, for example, a thickness of about 20 μm to 25 μm, in this embodiment about 20 μm, is adhered to only one side of the planar carbon paper. Yes. The single-sided laminate material is not limited to polyester film, and other resins and other materials may be used, and the thickness of the film may be changed as necessary while considering heat conduction. May be.

  The suction fixing step is a step of fixing the planar carbon paper by placing the laminated one side surface on a work board on which a plurality of holes are formed and sucking it by vacuum from the back side of the work board. In this embodiment, the planar carbon paper is cut using an XY plotter 6 as shown in FIG. 5, and is sucked and fixed on the work panel 61 of the XY plotter 6 by vacuum. ing. At this time, since the laminated one surface does not have air permeability, it can be fixed by vacuum.

  As shown in FIG. 6, the carbon heating element cutting process is a process of cutting the planar carbon paper and forming it like a ladder in which a plurality of corrugated planar carbon heating elements 2 are arranged in parallel. In the present embodiment, as described above, the planar carbon paper is cut by the XY plotter 6. Since the planar carbon paper is strongly fixed on the work panel 61 by vacuum suction, even a complex waveform having a curve can be easily and accurately cut into a desired width and wave height.

  As shown in FIG. 7, the electrode creation process is a process of creating the electrode 3 by connecting both end portions of each corrugated carbon heating element 2 with a conductive material. In the present embodiment, a copper foil tape having a thickness of about 25 μm to 35 μm and a width of 12 mm to 20 mm is attached to one side of each corrugated carbon heating element 2 that is not laminated.

  The double-sided laminating step is a step of laminating the front and back surfaces of each corrugated carbon heating element 2 to which a copper foil tape is connected with a conductive material. In this embodiment, the conductive resin layer 41 and the conductive metal layer 42 are formed as the laminate layer 4 on both surfaces. The conductive resin layer 41 is laminated by thermally melting a polyethylene terephthalate film having a thickness of about 150 μm to 250 μm. Further, an aluminum vapor-deposited sheet having a thickness of about 50 μm to 250 μm obtained by vapor-depositing aluminum powder on a polyethylene terephthalate film or the like as the conductive metal layer 42 is fixed with an adhesive. In addition, when laminating the conductive resin layer 42, it is not limited to lamination by heat melting, but may be a so-called cold lamination using an adhesive or the like.

  Next, the operation of the planar carbon heater 1 of the present embodiment will be described.

  In the planar carbon heater 1 of the present embodiment, a current of 100 V is supplied from the power source 5 to the electrode. The current flows from one electrode 3 to the other electrode 3 through a plurality of planar carbon heating elements 2 formed in a waveform.

  In each planar carbon heating element 2, it becomes resistance which interrupts the flow of current, and it generates heat by this resistance. At this time, in each planar carbon heating element 2, the resistance can be adjusted according to the width and wave height of the planar carbon heating element 2. For example, the resistance decreases as the width of the planar carbon heating element 2 increases, and the resistance increases as the width decreases. The resistance increases as the wave height of the planar carbon heating element 2 increases, and the resistance decreases as the wave height decreases. Therefore, in each planar carbon heating element 2, it is possible to finely adjust the heat generation temperature by adjusting the resistance by selecting the waveform shape according to the desired heat generation amount.

  At this time, the planar carbon heating element 2 in the present embodiment can be formed to have an arbitrary width and wave height by the XY plotter 6, and therefore, waveform shapes of various patterns can be easily created. Further, the calorific value can be made uniform or partially changed.

Further, the current is converted into heat by the resistance of each planar carbon heating element 2 and consumed. In the present embodiment, the waveform shape is determined so that the power consumption for one wavelength is 10 Wh to 20 Wh. In addition, the length and the number of arrangement of the corrugated carbon heating elements 2 are configured such that the power consumption per 1 m ² is 200 Wh or less. As a result, the planar carbon heater 1 is maintained at a maximum heat generation temperature of 80 ° C. or lower when left at room temperature.

  The conductive metal layer 42 in the laminate layer 4 disperses heat over the entire surface of the planar carbon heater 1. Thereby, the imbalance of the temperature difference between the surface of the portion where each corrugated carbon heating element 2 exists and the surface of the gap portion where each corrugated carbon heating element 2 does not exist is eliminated. The entire surface of the carbon heater 1 is uniformly warmed.

  Moreover, since the conductive resin layers 41 on the front and back surfaces are in close contact with each other in the gaps between the corrugated planar heating elements 2, the adhesion strength is increased, it is difficult to peel off, and the durability is high.

According to the planar carbon heater 1 and the planar carbon heater manufacturing method of the present embodiment as described above, the following effects can be obtained.
1. By forming the plurality of planar carbon heating elements 2 in an arbitrary waveform, the heating temperature can be finely adjusted.
2. By laminating only one side of the planar carbon paper with a conductive material in advance, the planar carbon paper can be stably fixed and can be easily cut into a waveform having a desired width and wave height.
3. By using the conductive metal layer 42 for the laminate layer 4, the entire surface of the planar carbon heater 1 can be evenly warmed.
4). The durability can be enhanced by bringing the conductive resin layers 41 of the laminate layer 4 on the front and back surfaces into close contact with each other.

  Example 1 shows an example in which the planar carbon heater 1 is applied to a multipurpose mat heater 1a. As shown in FIG. 8, the multipurpose mat heater 1 a has a moisture-proof and heat-insulating sheet layer 7 on the lower layer side of the laminate layer 4 made of a conductive material, and has an air permeability that is breathable on the upper layer side of the laminate layer 4. A protective sheet 8 is formed.

  Soft moisture made by Sekisui Chemical Co., Ltd. having a thickness of 3 mm was used for the moisture-proof and heat-insulating sheet layer 7 in Example 1. The breathable protective sheet 8 was a non-woven fabric having a thickness of 2 mm.

  By providing the moisture-proof and heat-insulating sheet layer 7 on the lower layer side of the laminate layer 4, it can be placed in various places regardless of outdoors or indoors. Further, by providing a breathable protective sheet 8 made of a breathable nonwoven fabric on the upper layer side of the laminate layer 4, heat can be raised from the gap between the nonwoven fabrics and can be used as a portable foot heater or the like. .

  Example 2 is an example applied to the bedrock footbath heater 1b as an application example of the planar carbon heater 1. As shown in FIG. 9, the bedrock footbath heater 1 b is provided with a breathable protective sheet 8 and a moisture-proof / heat-insulating sheet layer 7 on the lower layer side of the laminate layer 4 made of a conductive material, and on the upper layer side of the laminate layer 4. A bedrock 9 is provided.

  As the bedrock 9 in Example 2, a ceramic plate having a thickness of 17 mm obtained by blending and firing black silica and clay was used. Thereby, the planar carbon heater 1b can exhibit a heating effect effectively not only by the far infrared rays emitted from the corrugated planar carbon heating element 2 but also by the far infrared rays emitted from the black silica. It is also convenient to carry as a compact foot temperature heater that can be used for bedrock bathing without using hot water.

  Example 3 is an example in which the planar carbon heater 1 is attached to the corrugated cardboard 10 as an application example of the planar carbon heater 1 and applied to the corrugated cardboard heater 1c. As shown in FIG. 10, the corrugated cardboard heater 1 c has a corrugated cardboard 10 layer formed on the front and back surfaces of the planar carbon heater 1.

  Thereby, it is lightweight and can be easily carried and installed, and can be used as a heating facility useful in an evacuation area at the time of a disaster.

  Example 4 is an example in which the planar carbon heater 1 is applied to a hanger heater 1d. As shown in FIG. 11, the planar carbon heater 1 in Example 4 has a breathable protective sheet 8 formed on the outer side of the laminate layer 4 made of a conductive material, and a plurality of heat radiating holes on the outer side. A punching reinforcing layer 11 is provided. The punching reinforcing layer 11 is composed of an aluminum composite plate such as plastic metal, and a large number of heat radiation holes 12 are formed over the entire surface, as shown in FIG. This hanger heater 1d is intended to be hung from a ceiling or a pillar for use in dairy farms such as a pig barn or a cow barn. In addition, the heat radiation performance is maintained by the large number of heat radiation holes 12. Thus, when used in a barn, the running cost is low, the economy is good, and the natural environment is taken into consideration, so the product is highly practical.

  The planar carbon heater and the method for manufacturing the planar carbon heater according to the present invention are not limited to the above-described embodiments, and can be changed as appropriate.

  For example, although not shown, the planar carbon heater 1 may be three-dimensionally assembled to form a three-dimensional heater.

DESCRIPTION OF SYMBOLS 1 Surface carbon heater 2 Surface carbon heating element 3 Electrode 4 Laminating layer 5 Power supply 6 XY plotter 7 Moisture-proof / heat-insulating sheet layer 8 Breathable protective sheet 9 Rock bed 10 Corrugated board 11 Punching reinforcement layer 12 Heat radiation hole 41 Conductive resin layer 42 Conductive metal layer

Claims (8)

  A plurality of planar carbon heating elements formed in corrugations are arranged in parallel, and both ends of the corrugated planar carbon heating elements in each row are connected by a conductive material to form electrodes, and these front and back surfaces Is a planar carbon heater laminated with a conductive material.   The planar carbon heater according to claim 1, wherein the corrugated planar carbon heating element has a width of 20 mm to 30 mm and a wave height of 50 mm to 150 mm or less.   3. The planar carbon heater according to claim 1, wherein a width and a wave height of the corrugated planar carbon heating element are formed such that power consumption for one wavelength is 10 Wh to 20 Wh. 4. The planar carbon heater according to claim 1, wherein the corrugated planar carbon heating elements are configured such that the power consumption per 1 m ² is 200 Wh or less. .   5. The planar carbon according to claim 1, wherein the laminate layer made of the conductive material has a conductive resin layer formed on the inner side and a conductive metal layer formed on the outer side. heater.   The moisture-proof and heat-insulating sheet layer is formed on the lower layer side of the laminate layer made of the conductive material, and the breathable protective sheet is formed on the upper layer side of the laminate layer. The planar carbon heater according to any one of the above.   The breathable protective sheet is formed on the outer side of the laminate layer made of the conductive material, and a punching reinforcing layer in which a plurality of heat radiation holes are formed on the outer side of the laminate layer. The planar carbon heater according to any one of 6. A single-sided laminating step of laminating only one side of the planar carbon paper with a conductive material;
A suction fixing step of placing the laminated one side on a work board in which a plurality of holes are formed and sucking and fixing by vacuum from the back side of the work board;
A carbon heating element cutting step for cutting a plurality of corrugated planar carbon heating elements so as to be arranged in parallel from the planar carbon paper;
An electrode creating step of creating an electrode by connecting both ends of each corrugated planar carbon heating element with a conductive material;
A double-sided laminating step of laminating the front and back surfaces with a conductive material;
The manufacturing method of the planar carbon heater which has this.

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