JP3883079B1 - Ceramic heating element - Google Patents

Abstract

An object of the present invention is to provide a ceramic heating element capable of easily forming an electrode on a carbonaceous film segment and having high mechanical connection strength of lead wires.
A ceramic heating element 10 is configured to generate heat by energizing a carbonaceous film segment 1 formed on one surface 11a of a porcelain plate 11 having a predetermined shape. 3a and a lead wire fixing portion 3 having a pair of insertion holes 3b and 3b formed along the longitudinal direction of the groove 3a, and a part of the insulating film is peeled to expose the conductor portion. The lead wire 4 is inserted into one of the insertion holes 3b from the other, and the conductor exposed portion 4a is conductively fixed to the groove 3a.
[Selection] Figure 1

Description

  The present invention relates to a ceramic heating element that generates heat by energizing a carbonaceous film formed on the surface of a ceramic plate by hatching or the like.

  Conventionally, a ceramic heating element that generates heat by energizing a carbonaceous film formed on a porcelain plate surface, or a snow-melting roof tile that generates heat by energizing a carbonaceous film formed on the surface of a roof tile that applies the same principle. Various proposals have been made.

  In particular, in Japanese Patent Application No. 2005-31482, which is a prior application by the same applicant as the present invention, an isolated carbonaceous film segment is formed on the back surface of a roof tile, and the size and number of the carbonaceous film segments can be selected. Thus, there has been proposed a ceramic heating element capable of adjusting the electric resistance value.

  By the way, in the invention described in the above prior application, the lead wire is connected to energize the carbonaceous film segment. However, since the lead wire has only one end connected with resin solder or the like, the lead wire is not fixed. There is a risk that the lead wire will be disconnected.

  The present invention has been proposed to solve such problems, and an object of the present invention is to provide a ceramic heating element that can easily form an electrode on a carbonaceous film segment and has high mechanical connection strength of lead wires. There is.

  In order to achieve the above object, the ceramic heating element according to claim 1 is a ceramic heating element configured to generate heat by energizing a carbonaceous film segment formed on one surface of a predetermined-shaped porcelain plate, A suitable part of the carbonaceous film segment is formed with a lead wire adhering portion having a groove and a pair of insertion holes formed along the longitudinal direction of the groove, and a part of the insulating film is peeled off. The lead wire with the conductor portion exposed is inserted from one of the insertion holes to the other, and the conductor exposed portion is conductively fixed in the groove.

  In claim 2, after applying oil-based ink on a predetermined pattern, applying glaze or heat-resistant paint to the entire surface of the ceramic plate and curing it, the oil-based ink is heat-dissipated by subjecting the entire surface to hatching, A carbonaceous film segment is formed in the remaining portion.

  In claim 3, a predetermined masking tape is applied on a predetermined pattern, and the glaze is applied to the entire surface of the ceramic plate and cured to form a glaze film, and then the masking tape is removed, and then the entire surface is removed. On the other hand, the carbonaceous film segment is formed in the portion where the masking tape is removed by impregnating a gas containing hydrocarbon without burning.

  In claim 4, after applying the masking agent to the circumference of the predetermined pattern, the entire surface of the porcelain plate is impregnated without burning the gas containing hydrocarbons, and then the portion where the masking agent is applied is applied. A carbonaceous film segment is formed on a predetermined pattern by etching the carbonaceous film together with a masking agent.

  According to a fifth aspect of the present invention, a waterproof coating is formed on the surface having the carbonaceous film segment.

  The present invention has the following effects.

  The ceramic heating element according to any one of claims 1 to 5, wherein a lead wire adhering portion having a pair of insertion holes formed along the longitudinal direction of the groove is formed at an appropriate position of the carbonaceous film segment, and a part of the insulating coating is peeled off. Since the lead wire with the conductor portion exposed is inserted from one of the insertion holes to the other, and the conductor exposure portion is conductively fixed in the groove, the lead wire is inserted into the insertion hole. The electrode can be easily formed simply by making it.

  Moreover, since it is the structure which fixes the conductor part exposed to the center of a lead wire, unless a lead wire is cut | disconnected, a lead wire does not remove | deviate from a carbonaceous film segment, and it can improve mechanical connection strength. In addition, since the electrode and the lead wire have an integral structure, it is electrically stable.

  According to the ceramic heating element according to claims 2 to 4, since the carbonaceous film segment having a predetermined pattern is formed by various procedures, the electric resistance value can be adjusted by determining the size and number of the predetermined pattern in advance. Can be obtained.

  According to the ceramic heating element of claim 5, since the waterproof coating is formed on the surface having the carbonaceous film segment, there is no intrusion of moisture such as rain water or snow, and there is a risk of electric leakage due to it. Absent. For this reason, it can be used for snow-melting roof tiles, cold floor buildings, hotels, entrances to dwelling units, and road exterior materials.

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

  FIG. 1A is a plan view of a ceramic heating element according to the present invention, FIG. 1B is a partial cross-sectional view taken along the line AA, and FIG. 1C is an enlarged partial cross-sectional view before attaching a lead wire.

  The ceramic heating element 10 is formed by forming the carbonaceous film segment 1 isolated on the one surface 11a of the ceramic plate 11 from the opposite surface 11b or the side surface 11c via the insulating portion 2, and the carbonaceous film segment 1 has an appropriate position. A lead wire fixing portion 3 is provided, and the lead wire fixing portion 3 has a groove 3a processed to a predetermined length and a pair of insertion holes 3b, 3b formed in the groove 3a along the longitudinal direction. Yes. In the illustrated example, the insertion holes 3b and 3b are provided at both ends of the groove 3a. However, the insertion holes 3b and 3b may be provided in the middle of the groove 3a. Moreover, the glaze film layer (refer FIG. 5) is formed in the surface of the insulation part 2 shown in the present Example.

  The lead wire fixing portion 3 is preferably formed on the ceramic plate surface 11a before forming the carbonaceous film 1a, and the porcelain plate surface 11a formed with the lead wire fixing portion 3 is carbonized by hatching or the like. The film 1a is formed, and the carbonaceous film 1a is also formed in the groove 3a.

  Although the carbonaceous film 1a is indicated by a bold line in the sectional view of FIG. 1C, the illustration of the carbonaceous film 1a is omitted in FIG. 1B and FIG. 2 described later.

  Furthermore, in this ceramic heating element 10, the lead wire 4 from which a part of the insulating film is peeled to expose the conductor portion is inserted from one of the insertion holes 3b to the other, and the conductor exposed portion 4a is inserted into the carbonaceous film 1a. The groove 3a is formed to be conductively fixed. The conductor exposed portion 4a of the lead wire 4 is exposed according to the length between the insertion holes 3b and 3b, and a portion other than the carbonaceous film segment 1 (for example, if a carbonaceous film is also formed on the back surface 10b). An insulating cover 4b is formed so as not to contact the back surface 10b).

  Thus, since the conductor exposed portion 4a of the lead wire 4 is conductively fixed to the groove 3a of the lead wire fixing portion 3, the fixed portion becomes an electrode, and the carbonaceous film segment 1 is easily energized through the lead wire 3. Can be made. Moreover, unless the lead wire 4 is cut, the lead wire 4 is not detached from the carbonaceous film segment 1, and the mechanical connection strength can be improved. In addition, since the electrode and the lead wire 4 have an integral structure, they are electrically stable.

  FIGS. 2A and 2B are detailed explanatory views of the attachment of the lead wire 4 of the ceramic heating element 10 of the present invention. FIG. 2A shows the structure of the lead wire 4, and FIGS. 2B and 2C show the attachment procedure of the lead wire 4. FIG. 2 is a partial cross-sectional view of a ceramic heating element 10. FIG.

  The lead wire 4 includes a central conductor exposed portion 4a and insulating coating portions 4b and 4b sandwiching the conductor exposed portion 4a. The conductor exposed portion 4a can be easily formed if a part of the insulating coating covering the whole is peeled according to the dimension of the groove 3a.

  Then, as shown in FIGS. 2 (b) and 2 (c), such a lead wire 4 is passed through one insertion hole 3b to the other insertion hole 3b, and then resin solder (not shown) is applied in advance. Heating is performed in a furnace with the exposed conductor 4a attached to the bottom of the groove 3a. Then, the conductor exposed portion 4a of the lead wire 4 and the groove 3a are connected and fixed while maintaining conductivity. As the resin solder, epoxy resin in which silver powder is mixed is used.

  Finally, the entire surface of the ceramic heating element 10 to which the lead wire 4 is fixed is covered with a waterproof coating 5 such as a fluoro rubber having waterproof properties. Although it may be coated with asphalt, fluororubber resistant to heat is desirable.

  As described above, since the conductive carbonaceous film segment 1 is connected and fixed to the lead wire 4, the ceramic heating element 10 has female and male connectors by attaching both ends of the lead wire 4 to the connector. If a portion (not shown) is formed, the carbonaceous film segment 1 can be easily energized.

  When the connector of the lead wire 4 is connected to a power source or the like and the carbonaceous film segment 1 is energized, the carbonaceous film 1a generates heat, and the heat is transmitted to the opposite surface 11b through the interior of the ceramic plate 11, so To rise. In addition, since the carbonaceous film segment 1 is in an isolated state via the insulating portion 2, there is no risk of leakage or electric shock, and a 100V voltage can be applied.

  Further, it is desirable to use a ceramic plate 11 which is a substrate of the ceramic heating element 10 and has an excellent heat storage effect, and it is desirable to form the waterproof coating 5 from a heat resistant material.

  FIG. 3 is a plan view showing another example of the ceramic heating element 10 of the present invention. In this figure, since the lead wire 4 having the same structure as that shown in FIGS. 1 and 2 is used, its illustration is omitted.

  FIG. 3A shows a structure in which one carbonaceous film segment 1 is provided surrounded by the insulating portion 2, and FIG. 3B shows a structure in which one H-shaped carbonaceous film segment is provided. In addition, although the lead wire fixing | fixed part 3 has illustrated what provided two in 1 segment, it is not limited to this.

  Thus, if the carbonaceous film segment 1 is formed by appropriately selecting its shape and dimensions, various ceramic heating elements 10 having different electric resistance values can be formed.

  Further, the carbonaceous film segment 1 shown in FIG. 3A may be formed in an isolated state. If the plurality of carbonaceous film segments 1 are arranged in such an isolated state, the electrical resistance value can be adjusted by various connection modes such as series and parallel. For example, in order to adjust the electrical resistance value, a connection method that does not connect to a specific segment among a plurality of segments can be adopted. That is, the number of carbonaceous film segments 1 can also be selected.

  Next, a method for manufacturing the ceramic heating element 10 will be described.

  FIG. 4 is a flowchart showing an example of a method for manufacturing the ceramic heating element 10. FIGS. 5A to 5C are views showing a process for forming the carbonaceous film segment 1. FIG. 5 illustrates the carbonaceous film pattern shown in FIG.

  First, the clay clay (not shown) that is the raw material is crushed into a base, and the soil particle size is made uniform, then hydro-kneaded and laid to make the moisture uniform, and then a clay kneader ( (Not shown), and the air in the clay is pushed out (S1). Next, it is molded into a predetermined shape with a constant pressure (S2) and dried (S3). Thereafter, the ceramic plate 11 is obtained by firing in a clay kiln while adjusting the temperature to about 1200 to 1300 ° C., baking it uniformly (S4), and then cooling (S5).

  A predetermined pattern 12 that will later become a carbonaceous film 1a segment is specified on one surface 11a of the porcelain plate 11, and a groove 3a for fixing the lead wire 4 and two insertion holes 3b, 3b at appropriate positions of the pattern 12 Is processed (S6). In addition, in this figure, illustration of the groove | channel 3a and the insertion hole 3b is abbreviate | omitted.

  Next, the oil-based ink 13 was applied to the predetermined pattern 12 of the porcelain plate 11 (S7 and FIG. 5A), and the glaze 14 was applied to the entire surface 11a in that state, and the oil-based ink 13 was applied. Since the part repels the glaze 14, the glaze 14 is not applied to the part, and when it is cured, the glaze film 5 is formed on the entire surface except the predetermined pattern 12 (S8 and FIG. 5B).

  After that, when the hatching process is performed without removing the oil-based ink 13 (S9 and FIG. 5C), the oil-based ink 13 evaporates and disappears due to the heat of hatching. As a result, the gas is impregnated and the carbonaceous film segment 1 is formed. Of course, the carbonaceous film 1a is also formed in the groove 3a processed for fixing the lead wire 4.

  Further, the portion to which the glaze 14 is applied has no carbonaceous fixed wearing, and can be easily removed by lightly brushing, and this portion becomes the insulating portion 2.

  Thereafter, the lead wire 4 composed of the conductor exposed portion 3a and the insulating coating portion 3b is attached to the lead wire fixing portion 3 of the carbonaceous film segment 1 so that the conductor exposed portion 3a is fixed to the groove 3a (S10), The entire surface 11a is covered with the waterproof coating 5 (S11).

  In the above method, only the oil-based ink 13 that repels the glaze 14 is applied to the place where the carbonaceous film segment 1 is to be formed, and the applied ink 13 is automatically applied by the heat of hatching in the subsequent hatching process. Therefore, the carbonaceous film segment 1 can be formed there. That is, since the oil-based ink 13 is automatically extinguished, it is not necessary to perform the ink 13 removing operation, and the efficiency and productivity are good.

  FIG. 6 is a flowchart showing another example of the method for manufacturing the ceramic heating element 10. FIGS. 7A to 7D are views showing a process of forming the carbonaceous film segment 1. Note that steps S21 to S26 shown in FIG. 6 are the same as S1 to S5 of the first embodiment, and thus the description thereof is omitted.

  After firing and cooling, a masking tape 15 having no water absorption is applied to the predetermined pattern 12 including the lead wire fixing portion 3 of the ceramic plate 11 (S27 and FIG. 7A). As the masking tape 8, one that does not absorb water and does not wear out in response to the glaze 14 is desired. As an example, a curing tape used in a construction site or moving can be used.

  With the masking tape 15 applied, the glaze 14 is applied to the entire surface 11a and cured to form the glaze coating 5 (S28 and FIG. 7 (b)), and then the masking tape 15 is removed. (S29 and FIG. 7C), the entire surface 11a is hatched (S30 and FIG. 7D).

  Then, since the glaze coating 5 is not formed at the location where the masking tape 15 is removed, the gas is impregnated by the hatching process, and the carbonaceous film 1a is formed at that location, but is covered with the surrounding glaze coating 5 As a result, the carbonaceous film segment 1 is formed in an isolated state only at the location where the masking tape 15 is peeled off.

  The glaze 14 is well known as “Waguri” applied to the surface of the pottery to improve the durability, but it is generally heat resistant and should be applied at room temperature and cured at room temperature. It is very easy to handle. Moreover, since the hardened film has the property of suppressing the impregnation of carbon particles, it functions as a mask during the formation of the carbonaceous film 1a by sputtering.

  Such a glaze 14 is constituted by combining alumina (neutral component), silica (acidic component), and alkali (base component), such as transparent glaze, gloss white glaze, milky haze, devitrification glaze and the like. As long as it is known, the type is not limited as long as it does not impregnate carbon particles during the formation of the carbonaceous film and can withstand the temperature rise.

  After the hatching process (S30), the lead wire 1 is attached (S31) and the waterproof coating is formed (S32), as in the first embodiment.

  In the method of the present embodiment, if the masking tape 15 is removed after the glaze 14 is applied to the one surface 11a of the ceramic plate 11, the glaze coating 5 is removed and the ceramic plate 11 is exposed on the surface. When the entire 11a is hatched, the gas component is impregnated only in the portion where the masking tape 15 is removed, and as a result, an isolated carbonaceous film segment 1 is formed. Therefore, the ceramic heating element 10 capable of adjusting the electric resistance value can be obtained by selecting the size and number of the isolated carbonaceous film segments 1.

  According to the method of the present embodiment, the curing tape used at the construction site or the like can be used as the masking tape, so that the carbonaceous film segment 1 can be easily generated on the ceramic plate 11.

  FIG. 8 is a flowchart showing another example of the method for manufacturing the ceramic heating element 10. FIG. 9 is a plan view of the porcelain plate 11, and FIGS. 10 (a) to 10 (c) are diagrams showing the steps of forming the carbonaceous film segment 1, and after the masking treatment to the porcelain plate surface 11a, the hatching treatment FIG. 10 is a cross-sectional view taken along line BB in FIG. 9 in each state after removal of masking. Since steps S41 to S46 shown in FIG. 8 are the same as S1 to S6 of the first embodiment, description thereof is omitted.

  After firing and cooling, a masking agent 17 is applied to the circumferential pattern 16 of the predetermined pattern 12 including the lead wire fixing portion 3 formed on the ceramic plate 11, dried and fixed (S47). The masking agent 17 is preferably a silane-based or alumina-based brick adhesive, but is not limited thereto.

  With the masking agent 17 applied, the entire surface of the porcelain plate 11a is brought into contact without burning a gas containing hydrocarbons, and the porcelain plate surface 11a is impregnated with the gas component (S48). The entire surface 11a including the masking agent 17 thus fixed is covered with a carbonaceous film 1a formed by smoldering.

  After the hatching process, after cooling, the masked circular pattern 16 portion is etched and peeled together with the carbonaceous film 1a covered with the masking agent 17 (S49). Then, the portion surrounded by the circulation pattern 16 becomes the carbonaceous film segment 1 isolated from the surroundings.

  After removing the masking (S49), the lead wire 1 is attached (S50) and the waterproof coating is formed (S51) as in the first embodiment.

  In the method of the present embodiment, since the carbonaceous film 1a is first formed on the whole and then the circuit pattern 16 is peeled off, the carbonaceous film segment 1 can be insulated almost certainly from the surroundings.

(A) is a top view of the ceramic heating element of this invention, (b) is the fragmentary sectional view of the AA line, (c) is an expanded partial sectional view before lead wire attachment. FIG. 2 is a detailed explanatory view of lead wire attachment of the ceramic heating element of the present invention, wherein (a) is a structural diagram of the lead wire, and (b) and (c) are partial cross-sectional views of the ceramic heating element showing the attachment procedure. (A), (b) is a top view which shows the other example of the ceramic heat generating body of this invention. It is a flowchart which shows an example of the manufacturing method of a ceramic heat generating body. (A)-(c) is the figure which showed the formation process of the carbonaceous film segment. It is a flowchart which shows the other example (Example 2) of the manufacturing method of a ceramic heat generating body. (A)-(d) is the figure which showed the formation process of the carbonaceous film segment (Example 2). It is a flowchart which shows the further another example (Example 3) of the manufacturing method of a ceramic heat generating body. (Example 3) which is a top view of a ceramic board surface. (A)-(c) is the figure which showed the formation process of the carbonaceous film segment (Example 3).

Explanation of symbols

10 Ceramic heating element 10A, 10B, 10C Ceramic heating element (other examples)
10a One side 11 Porcelain plate 1 Carbonaceous film segment 1a Carbonaceous film 2 Insulating part 3 Lead wire fixing part 3a Groove 3b Insertion hole 4 Lead wire 4a Conductor exposed part 4b Insulating coating part 5 Glazing coating

Claims (5)

A ceramic heating element adapted to generate heat by energizing a carbonaceous film segment formed on one side of a ceramic plate of a predetermined shape,
A lead wire adhering portion having a groove and a pair of insertion holes formed along the longitudinal direction of the groove is formed at an appropriate position of the carbonaceous film segment,
A ceramic heating element having a structure in which a lead wire from which a part of an insulating film is peeled to expose a conductor portion is inserted from one of the insertion holes to the other, and the conductor exposed portion is conductively fixed in the groove. In claim 1,
After applying oil-based ink on a predetermined pattern and applying a glaze or heat-resistant paint to the entire surface of the ceramic plate and curing it, the entire surface is hatched to heat-dissipate the oil-based ink and apply to the remaining part. A ceramic heating element characterized by forming a carbonaceous film segment. In claim 1,
A predetermined masking tape is applied on a predetermined pattern, and glaze is applied to the entire surface of the ceramic plate and cured to form a glaze film. After that, the masking tape is removed and then the entire surface is carbonized. A ceramic heating element characterized in that a carbonaceous film segment is formed in a portion where masking tape is removed by impregnating a gas containing hydrogen without burning. In claim 1,
A masking agent is applied to the circumference of a predetermined pattern, and then the entire surface of the porcelain plate is impregnated without burning hydrocarbon-containing gas, and then the carbonaceous film in the portion where the masking agent is applied is masked. A ceramic heating element, wherein a carbonaceous film segment is formed on a predetermined pattern by etching together with an agent. In any one of Claims 1-4,
A ceramic heating element, wherein a surface having the carbonaceous film segment is covered with a waterproof coating.

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