JP4634636B2 - Electric heating yarn and heater using the electric heating yarn - Google Patents

Description

【００４１】
この芯線は、加工率８０〜９０％で冷間加工した硬質ステンレス鋼細線によるものであり、これを撚り合わせた後、５００℃でテンパー処理したものであって、細径でありながらも強度、弾性、しなやかさに優れている。
【００４２】
この発熱線の合計太さはいづれも１００μｍより細いものであり、さらに強度アップの為に、補助芯材として、２００デニールのアラミド繊維ロービング材を前記発熱芯材に沿って配置した。
【００４３】
こうして組合わした複合芯材は巻線機にセットされ、一方、絶縁層としての巻糸として、前記同様の２００デニールのアラミド繊維ロービング材を用い、これを拡幅させながらカバーリング処理を行った。
その処理条件と、得られた電熱糸の強度特性は表２の通りであった。
【００４４】
【表２】

【００４５】
得られた電熱糸は、太さ０．３〜０．５ｍｍ程度の非常に細いもので巻きゆるみがなく、可撓性にも優れるものであった。またこの糸についての特性試験として、曲げｒ＝１ｍｍでの繰り返し曲げを行ったが、通常のニクロム線を用いたものでは数十〜百回程度の短時間で破断したのに対し、本例ではいづれも数千回以上の寿命特性を有していることが確認された。
【００４６】
【実施例２】
実施例１において得られた資料６の電熱糸（長さ５１ｃｍ）を６０×４０ｍｍ厚さ２ｍｍの耐熱フェルトの一面に、配線間隔５ｍｍで設け、その上を刺繍糸で止めることで固定し、しかもその配線回路が図６のように並列配線となるようにリード線とコネクタを接続するとともに、テフロン外皮で被包したヒーターを完成した。
【００４７】
そのヒーター数個を配管上に連接し、予めリード線とコネクタとの間に１５００Ｖを１分間印加し、絶縁性を調査したが、リーク電流は０．５ｍＡ以下で、十分な絶縁性を有していることが確認された。
【００４８】
次に、このヒーターについての長期連続使用に関する耐久性を評価することとした。その結果を表３に示す。
【００４９】
【表３】

【００５０】
この試験終了後、電熱糸を取り出し繰り返し曲げ試験を行ったが、いづれも数千回以上の寿命を有していることが確認され、使用前のものと比較して劣化はほとんど認められなかった。
【００５１】
【発明の効果】
本発明の電熱糸は、芯材に沿って絶縁繊維束を巻き付けることでなるものであり、絶縁性に優れ、高い可撓性を有するものである。また、絶縁繊維は単に巻き付けによって形成している為、これを部分的に解放する場合にあっても容易に解きほどく事ができ、配線作業効率を高めることができる。
【００５２】
またヒーターにあっても、電熱糸自体が細い糸状のものであることから狭い配線間隔で設けることができるとともに、コワゴワした違和感などを与えることもなく、厚さを減じることができる。
【図面の簡単な説明】
【図１】電熱糸を拡大して示す側面図である。
【図２】ステンレス鋼単線の熱処理温度に伴う電気抵抗変化を例示する線図である。
【図３】ヒーターの一例を示す部分断面正面図である。
【図４】ヒーターの縦断面図である。
【図５】ヒーターの使用状態を例示する斜視図である。
【図６】並列接続を例示する線図である。
【図７】ヒーターの他の形態を例示する平面図である。
【符号の説明】
１ 電熱糸
２ 芯材
２Ａ 細線
２Ｂ 複合細線
２Ｃ 補強芯材
３ 絶縁層
３Ａ 第一絶縁層
３Ｂ 第二絶縁層
２０ 基材
３０ ヒーター
３１ ガス供給配管
４０ リード線[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an electrothermal yarn having flexibility and insulation and excellent in reliability, and a heater using the same.
[0002]
[Prior art]
The electric heating wire (heating wire) is improved in versatility by insulating the surface of a heating core material such as a nichrome wire set to have a predetermined electric resistance. As a method, for example, heat-resistant rubber or resin material is melt-extruded and coated and molded, or an insulating fiber material is encapsulated with an outer shell made of a braided braid.
[0003]
These heating wires are set to various specifications according to the purpose, application, usage, etc., and in order to increase the calorific value of those that perform high temperature heating, such as an electric stove, rice cooker, etc., the heating wire itself is used. Insulation with a rigid outer skin such as a sheathed heater is frequently used because it is relatively thick and needs strength to prevent attachment during use and deformation during use.
[0004]
In contrast, in recent years, for example carpet, for use in freely Todan product bent like electric blankets, old example, Japanese 60-235386 discloses news JitsuHiraku Sho 61-206226 Patent Publication The heating wire proposed by the above is used.
[0005]
Further, as a new application of such a heating wire, there is a pipe heating heater which is attached to a process gas supply pipe used for manufacturing a semiconductor to prevent gas liquefaction. This heating heater is provided with a heating wire on the base of an elastic tube body with a tape shape, a half shape, or a split surface so that it can be easily attached to a necessary part of a gas pipe installed relatively densely. It is.
[0006]
[Problems to be solved by the invention]
However, the heating wire that has been used in these conventional applications is provided with insulation for the heat generating core material and surface by extrusion molding covering such as heat-resistant plastic, and the insulating layer is formed to be relatively thick. As a result, the heating wire becomes thick, and the rigidity of the heating wire tends to increase.
[0007]
Therefore, the shape of the heater itself using such a heating wire is relatively large or thick, and unevenness due to the heating wire is formed on the surface, which causes a sense of incongruity.
[0008]
Furthermore, such heating wires are liable to breakage or fatigue failure due to repeated bending, etc., reduce the service life, and even when this is attached to the base material, the interval cannot be reduced, and the temperature It tends to decrease the accuracy and quality of the heater, such as increasing unevenness.
[0009]
In addition, instead of such an insulating layer by extrusion coating, it is conceivable to provide flexibility by covering the surface of the heating wire with a mesh body in which an insulating fiber material is braided in the shape of a blade. However, if the diameter is as small as 0.8 mm or less, for example, a strong encapsulation cannot be made, and the heating wire tends to fall off the insulating layer.
[0010]
Even if the braiding process that is in close contact with the heating wire is possible, if you want to remove a part of the outer skin that is braided to connect it to the lead wire, etc., the braided mesh that makes up the braided mesh is difficult to see with the naked eye Therefore, it is extremely difficult to unravel each of the skin fibers individually, and even when only the braided skin is removed with a cutter or the like, the internal heating wire is easily damaged, and there is a risk of disconnection and the like. Therefore, skilled work using dedicated tools is required.
[0011]
Thus, even if the heating wire can be made somewhat thin in the conventional heating wire, there is a limit to reducing the overall thickness due to the insulating layer covering the surface, while having a predetermined strength, It was incomplete as a filamentous heating wire with sufficient potential.
[0012]
An object of the present invention is to solve such problems, and to provide a small-diameter electrothermal yarn excellent in strength, insulation and flexibility, and capable of improving quality and reliability, and a heater using the same.
[0013]
[Means for Solving the Problems]
The invention according to claim 1 of the present invention is the first formed by winding a heat-generating fiber bundle in a spiral shape while expanding the bundle of heat-resistant fibers along the core material in a flat shape. The core is made of an insulating layer composed of two or more multilayers of an insulating layer and a second insulating layer that is reversely wound with the first insulating layer, and has an overall thickness of 0.8 mm or less, and the core The material is an electrothermal yarn characterized in that it is a single wire of hard stainless steel fine wire that has been hard-finished by cold working, or a composite thin wire obtained by converging, twisting or knitting a plurality of wires .
[0014]
The invention according to claim 2, before SL core material is characterized by is obtained by forming a hard stainless steel fine wire or the composite thin line, in combination with the reinforcing core with a non-conductive refractory fibrous materials.
[0015]
Furthermore, the invention described in claim 3 is a heater that can heat the electric heating yarn according to any one of claims 1 and 2 along a heat-resistant base material and generate heat to a predetermined temperature by energizing the electric heating yarn. In addition, the invention of claim 4 is provided with an engaging means that can circulate around the heated body and that can join both ends when the base material has flexibility. It is characterized by being a planar body.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is an enlarged view illustrating an embodiment of an electrothermal yarn 1 according to the present invention. The electrothermal yarn 1 includes an exothermic core material 2 and an insulating insulator enclosing the periphery of the core material 2. It is a continuous filament formed of the layer 3, and its overall thickness is 0.8 mm or less.
[0017]
The core material 2 has a resistance value or conductivity that generates heat at a predetermined temperature when a predetermined voltage is applied, and the core material 2 focuses a thin single wire 2A made of stainless steel wire or the single wire, or It can be used as a composite fine wire 2B twisted or knitted. Particularly, stainless steel is excellent in strength and heat resistance even in a thin wire state, and can be suitably used in the present invention.
[0018]
In the case of a stainless steel wire, for example, a hard stainless steel thin wire obtained by hard finishing austenitic stainless steel such as SUS302, SUS304, SU310, and SUS205 by cold working has good strength and elasticity, excellent resilience, and is acceptable. Since it also has flexibility, it can be suitably employed as the core material 2 of the electrothermal yarn 1. In this case, the single wire 2A has a diameter of 0.1 mm or less, more preferably 5 to 60 μm, and the diameter of the single wire 2A is reduced by cold drawing (for example, a processing rate of 60% or more). Various materials such as metal fiber tows, twisted yarns, spun yarns, etc., by the converging wire drawing method proposed in Japanese Utility Model Laid-Open No. 47-22356 are used.
[0019]
FIG. 2 is an example of the results showing the influence of the processing state on such a stainless steel thin wire on the electrical resistance. According to this, the processed material was not heat-treated or processed at a relatively low temperature up to about 600 ° C. It can be seen that the electrical resistance is relatively large and the change is small. However, when heat treatment is performed at a high temperature exceeding 600 ° C. as in the annealing treatment, the electric resistance is drastically lowered, and the properties are soft and the strength itself is lowered. It is inferior in characteristics and is hardly preferred.
[0020]
The hard stainless steel fine wire thus cold-drawn has an advantage that the electric resistance is larger than that of the annealed state at a high temperature. Moreover, such a hard fine wire can be made into a core material 2 having further improved strength and flexibility by appropriately twisting a plurality of the wires (for example, about 3 to 10 wires).
[0021]
In the present invention, in order to further increase the strength of such a core material 2, a reinforcing core material 2C made of a non-conductive heat-resistant fiber material can be disposed and used in combination as shown in FIG. As the reinforcing core material 2C, for example, various high-strength and high-heat-resistant fiber materials are employed in addition to rovings such as aramid fibers and glass fibers such as Kevlar (trade name). Various conditions are set depending on the application and specifications used.
[0022]
On the other hand, the insulating layer 3 has a heat resistant surface on the surface of the core material 2 as illustrated in FIG. 1, instead of the insulating layer formed by the extrusion coating method and the mesh enveloping method conventionally used in the present invention. It is formed by laminating two or more insulating layers such as a first insulating layer 3A and a second insulating layer 3B wound with a fiber material. Further, at that time, for example, a fiber bundle such as roving is used so that each insulating layer can be wound while being flattened in the width direction, and the winding direction is changed to the first insulating layer 3A and the second insulating layer 3B. Therefore, it is possible to prevent the core material 2 from being exposed, thereby improving insulation and improving flexibility.
[0023]
As the fiber material for the insulating layer, for example, the aramid fiber, glass fiber, ceramic fiber, and the like are used. In particular, the aramid fiber is preferable because it has strength, heat resistance, insulation, and is flexible. Moreover, since aramid fibers do not generate harmful gases or the like even when heated, they are preferable as heaters used in an ultra-clean state such as in a semiconductor manufacturing environment.
[0024]
For this winding, the fiber material is formed, for example, as a bundle of dozens to thousands of fine fibers having a fiber diameter of about 0.1 to 30 μm, and as shown by a broken line in FIG. For example, the fiber material is expanded so as to have a major axis in the length direction of the core material 2 while being spread to about 0.05 mm to 2 mm in the direction. By doing so, the smoothness in the longitudinal direction is maintained. If necessary, the third and fourth insulating layers can be stacked and laminated. In this case, the insulating layer, the cost, the flexibility, and the like are set.
[0025]
Further, as shown in FIG. 1 as the core material 2, when the thin wire 2A or the composite thin wire 2B is arranged so as to be wrapped by the reinforcing core material 2C, it can be wound more strongly by the elasticity of the bundle of the reinforcing fibers 2C, Problems such as the core material falling off after the encapsulation process are alleviated. In order to obtain such a strong winding state, for example, the winding pitch (P) is preferably about 300 to 2000 turns / m.
[0026]
The electrothermal yarn 1 of the present invention is obtained by winding and encapsulating the core material 2 with at least a second insulating layer 3B wound in the opposite direction to the first insulating layer 3A. Even if the core material 2 is exposed in the insulating layer 3A, it can be eliminated by the second insulating layer 3B applied to the surface, and the insulation can be improved. Further, the winding directions of both insulating layers are close to the bending direction received when the electric heating yarn 1 is obtained while intersecting with each other, and the thickness is 0.8 mm or less in the present invention. Flexibility can be increased.
[0027]
The reason why the thickness is 0.8 mm or less in the present invention is that the heating wire thicker than that is sufficient by a conventional braiding method, and the heating yarn 1 of the present invention is a braid for a large diameter. Flexibility and the like can be imparted in a small-diameter region that cannot be handled by the law. Further, the fiber bundle wound on the surface is also set to 0.8 mm or less, more preferably 0.5 mm or less, because the smaller the winding diameter, the smaller the rewinding and the stronger the winding state becomes possible. Note that such a winding process can be performed in the same manner as a covering yarn by a covering machine that is widely used in the yarn manufacturing industry such as decorative yarn.
[0028]
As described above, the electrothermal yarn 1 of the present invention uses the fine core material 2 and forms a plurality of wound layers while expanding the heat-resistant fiber bundle in the width direction as an insulating layer. It exhibits excellent flexibility with respect to deformation and can be used with the same feeling as ordinary fiber yarns. Further, even when this is connected to a lead wire or the like, it can be easily released by unwinding the fiber bundle wound as the insulating layer, and no special tool or technique is required.
[0029]
FIGS. 3 to 6 show an example of a heater using the electrothermal yarn 1, as shown in FIG. 5, by attaching to a semiconductor production gas supply or exhaust pipe 31 and indirectly heating from the outside of the pipe 31. It shows a one-touch heater that prevents liquefaction of gas fluid and is easy to attach and detach. 3 is a plan view with a part cut away in order to show the state of the attachment wiring of the electrothermal yarn 1, FIG. 4 is a cross-sectional view taken along the line AA in FIG. 3, and FIGS. It is a perspective view and a diagram showing a connection use state.
[0030]
As shown in FIG. 3, the heater 30 is attached to the electrothermal yarn 1 by meandering or zigzag wiring on one side of the substrate 20, and the surface is covered with a bag-like exterior material 22. 1 are taken out from the lead wires 40 and 40 so that they can be connected to the external power supply 50 via the connector terminals 44 and 45, and by applying a predetermined current to the connector terminals 44 and 45, the inner electrothermal yarn 1 is removed. Is heated to generate heat.
[0031]
As the base material 20, for example, a non-conductive felt having a thickness of about 0.5 to 3 mm made of a heat-resistant fiber material such as aromatic polyamide, or a cloth-like body such as a woven fabric is used. In this example, when the wiring is attached, as shown in FIG. 3, a method is adopted in which it is pressed by the sewing thread 24 that is folded back while alternately straddling the arranged electrothermal threads 1. By such a method, it is possible to securely fix the wiring, and it is possible to perform automation work by a computer-controlled embroidery sewing apparatus.
[0032]
The base material 20 obtained in this way is covered in the exterior material 22 by covering the surface with the exterior material 22 having heat resistance insulation such as a Teflon sheet and sewing the mating portion 23 together. As a result, overall flexibility and heat retention are enhanced, and even when this is attached to the pipe 31, it can be easily attached and the surroundings of the pipe can be effectively wrapped.
[0033]
In designing the heater, regarding the specifications of the electrothermal yarn 1 to be used and the base material 20 to which the electrothermal yarn 1 is attached, considering the additional current, the reached temperature, the use environment, etc., the thickness and length of the heating yarn, or the base material For example, in order to reduce the number of parts by interposing a heat insulating material 21 between the base material 20 and the exterior material 22 or improving heat transfer It is also possible to attach the electrothermal yarn 1 directly to the exterior material 22.
[0034]
Further, in the heater 30 of the present invention, as shown in FIG. 5, as a compact heating element that connects a plurality of heaters 30 along the piping 31, the handling property and versatility are improved, and only the necessary number is used at the necessary locations. It can also be. About the magnitude | size in the case of such usage, it is comprised, for example as a rectangular planar heater about 30-200 mm in one side.
[0035]
Further, in the case of such connection use, it is desirable that the heaters 30 generate heat equally. Therefore, as shown in FIG. 6, a parallel circuit is used so that no difference is made in the current applied to the heaters, and the heating temperature is stabilized. It is preferable to make it easier.
[0036]
Reference numerals 46A and 46B in the figure are male and female hooks as an example of engaging means for fixing the heater 30 when the heater 30 is attached to the pipe 31, and these hooks 46A and 46B are shown in FIG. By fitting in this manner, it can be easily attached to and detached from the pipe 31. Further, it can be widely applied to pipes of various shapes such as T type and L type. In addition, as another engaging means, it is also possible to provide and bind a string body in addition to, for example, a magic tape and a hook.
[0037]
Moreover, the electrothermal yarn 1 of the present invention is a thin and fine yarn having excellent flexibility, and also has an insulating layer on the surface thereof, so that it is used in the same manner as ordinary woven yarn and knitting yarn. For example, as shown in FIG. 7, the woven fabric is made by weaving the electrothermal yarn 1 as a weft yarn or the like in a woven base material 20 woven or knitted with a heat-resistant yarn 51 such as an aramid fiber, or the woven fabric. It is also possible to form the tape-like heater 30 by sewing the electrothermal yarn directly into the shaped substrate 20. In addition, at this time, the electrothermal yarn 1 can be continued without breaking the entire length while being folded back at the side.
[0038]
In particular, the tape used as the weft of the tape body 50 is not directly subjected to bending or winding tension when using the tape body 50, has an excellent life, and its wiring is also used for the tape body 50. Since it extends over the entire width, the heating efficiency is enhanced as a whole.
[0039]
[Example 1]
Stainless steel fibers and ultrafine single wires shown in Table 1 were selected as the core wire for heat generation, and twisted to give composite thin wires. The results of measuring the electrical resistance are also shown.
[0040]
[Table 1]

[0041]
This core wire is a hard stainless steel fine wire that has been cold-worked at a processing rate of 80 to 90%. After twisting the wire, it is tempered at 500 ° C. Excellent elasticity and suppleness.
[0042]
The total thickness of the heat generation lines is smaller than 100 μm, and a 200 denier aramid fiber roving material is disposed along the heat generation core material as an auxiliary core material for further increasing the strength.
[0043]
The composite core material combined in this way was set in a winding machine, and on the other hand, a 200 denier aramid fiber roving material similar to the above was used as a wound yarn as an insulating layer, and the covering process was performed while widening this.
The treatment conditions and the strength characteristics of the obtained electrothermal yarn are shown in Table 2.
[0044]
[Table 2]

[0045]
The obtained electrothermal yarn was very thin with a thickness of about 0.3 to 0.5 mm, had no winding looseness, and had excellent flexibility. In addition, as a characteristic test for this yarn, repeated bending at a bending r = 1 mm was performed, but in the case of using a normal nichrome wire, it was broken in a short time of about several tens to hundred times, whereas in this example It was confirmed that all have life characteristics of several thousand times or more.
[0046]
[Example 2]
The electrothermal yarn (length: 51 cm) of the material 6 obtained in Example 1 is provided on one surface of a heat-resistant felt of 60 × 40 mm and a thickness of 2 mm with a wiring interval of 5 mm, and the top is fixed by fastening with an embroidery thread, A lead wire and a connector were connected so that the wiring circuit was parallel wiring as shown in FIG. 6, and a heater encapsulated with a Teflon sheath was completed.
[0047]
Several heaters were connected on the pipe, and 1500V was applied between the lead wire and the connector in advance for 1 minute to investigate the insulation, but the leakage current was 0.5 mA or less and it had sufficient insulation. It was confirmed that
[0048]
Next, it was decided to evaluate the durability of the heater for long-term continuous use. The results are shown in Table 3.
[0049]
[Table 3]

[0050]
After completion of this test, the electric heating yarn was taken out and subjected to repeated bending tests, but it was confirmed that each had a life of several thousand times or more, and almost no deterioration was observed compared to the one before use. .
[0051]
【The invention's effect】
The electric heating yarn of the present invention is formed by winding an insulating fiber bundle along a core material, and has excellent insulating properties and high flexibility. Further, since the insulating fiber is simply formed by winding, it can be easily unwound even when it is partially released, and the wiring work efficiency can be improved.
[0052]
Even in the heater, since the electric heating yarn itself is a thin thread, it can be provided with a narrow wiring interval, and the thickness can be reduced without giving a sense of incongruity.
[Brief description of the drawings]
FIG. 1 is an enlarged side view showing an electric heating yarn.
FIG. 2 is a diagram illustrating a change in electrical resistance with a heat treatment temperature of a stainless steel single wire.
FIG. 3 is a partial cross-sectional front view showing an example of a heater.
FIG. 4 is a longitudinal sectional view of a heater.
FIG. 5 is a perspective view illustrating a use state of a heater.
FIG. 6 is a diagram illustrating parallel connection.
FIG. 7 is a plan view illustrating another form of the heater.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Electrothermal yarn 2 Core material 2A Fine wire 2B Composite fine wire 2C Reinforcement core material 3 Insulating layer 3A First insulating layer 3B Second insulating layer 20 Base material 30 Heater 31 Gas supply piping 40 Lead wire

Claims (4)

A core material for heat generation, and a first insulating layer formed by spirally winding a bundle of heat-resistant fibers along the core material in a flat shape, and the first insulating layer is reversely wound An insulating layer composed of two or more multilayers with the second insulating layer,
And the overall thickness is a thread shape of 0.8 mm or less ,
The electrothermal yarn , wherein the core material is a single wire of hard stainless steel fine wire that is hard-finished by cold working, or a composite thin wire obtained by converging, twisting, or knitting a plurality of wires . The electrothermal yarn according to claim 1, wherein the core material is formed by a combination of a hard stainless steel fine wire or the composite fine wire and a reinforcing core material made of a non-conductive heat-resistant fiber material . A heater capable of generating heat to a predetermined temperature by wiring the electrothermal yarn according to any one of claims 1 and 2 along a heat-resistant substrate and energizing the electrothermal yarn. The base material is a planar body that has flexibility so that it can circulate around a heated body and has engaging means that can join both ends. The heater according to claim 3 .

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