JP4727644B2 - Heater and heating device - Google Patents

Description

The present invention is a heater using the carbon Motokei heating element, and a heating apparatus using a heater.

  In recent years, heaters using carbon-based materials as heating elements have been developed. Since the carbon-based material is a conductor, the electric resistance value is small. Therefore, in order to increase the resistance value of the heating element of the carbon-based material, various methods such as increasing the total length of the heating element, decreasing the cross-sectional area of the heating element, or increasing the specific resistance value of the heating element itself, etc. Has been put to practical use.

Japanese Patent No. 3319951 discloses a conventional heating element made of woven carbon fiber capable of obtaining a predetermined resistance and a method of using the carbon fiber heating element. A conventional heating element is formed of a fibrous carbon material substantially consisting of only carbon elements, and micro-unit bores (holes) are formed in each fiber. The electrical resistance value increases at the bore. Furthermore, the resistance value is adjusted by changing the thickness and amount of the carbon fiber. Thereby, the heater using the conventional carbon fiber heat generating body can be used as a heat source of a heating apparatus.
Japanese Patent No. 3319951

  Conventional heating elements are formed of warp yarns of a plurality of carbon fibers extending in the longitudinal direction. In the conventional heater, in order to increase the resistance value of the heating element, the carbon fiber is thinned or the amount of the carbon fiber is reduced. When the carbon fiber is made thin or the amount of the carbon fiber is reduced, there is a problem that each fiber is scattered or disconnection occurs.

An object of this invention is to provide the heater using the carbon-type heat generating body which carbon fiber does not disperse | distribute, and a heating apparatus provided with the heater.

In order to solve the above problems, the present invention has the following configuration.
The heater according to the present invention is
Formed by firing a plurality of warp yarns extending in the longitudinal direction and at least one weft yarn extending in the width direction and having at least one turn and interwoven so as to cross the upper and lower sides of the continuous warp yarns A carbon-based heating element;
A heat dissipation block formed of a conductive material electrically connected to the carbon-based heating element;
Internal lead wires electrically connected to the heat dissipation block;
Molybdenum foil connected to the internal lead wire;
An external lead connected to the molybdenum foil;
A glass tube enclosing the carbon-based heating element, the heat dissipation block, and the internal lead wire, sealed at a portion where the molybdenum foil is embedded, and having an inert gas sealed therein.
Here, the “thread” is used as a heating element, and is a material that becomes carbon fiber or carbon fiber after firing.

  The weft extending in the width direction may have a predetermined angle with respect to the vertical surface in the width direction. The weft may be folded back at both ends in the width direction.

  The weft yarn may be at least one continuous yarn. “Continuous yarn” means that the length of the yarn is considerably longer than the width of the carbon-based heating element.

  A cross section in the width direction of the carbon-based heating element may be folded into a cylindrical shape or a bag shape.

  The heater of the present invention has a configuration in which the carbon-based heating element is sealed in a glass tube. The heater may be formed by laminating a plurality of carbon-based heating elements.

  In this heater, the carbon-based heating element may include a thin warp extending in the longitudinal direction and a thick weft extending in the width direction. Alternatively, the carbon-based heating element may include a thick warp extending in the longitudinal direction and a thin weft extending in the width direction.

  In the heater, a holding member that holds the carbon-based heating element extending in the longitudinal direction may be provided at a position other than both ends of the carbon-based heating element.

  The heating apparatus of this invention has the said heater.

  According to the present invention, it is possible to achieve an advantageous effect that a carbon-based heating element in which carbon fibers are not scattered can be realized by folding so that the weft yarn has at least one turn and crosses the upper and lower sides of the warp yarn. . Further, according to the heater having the carbon-based heating element and the heating device including the heater, an effect that the carbon fibers of the carbon-based heating element are not scattered can be obtained.

  DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments that specifically show the best mode for carrying out the present invention will be described below with reference to the drawings.

Embodiment 1
The carbon-based heating element, heater, and heating device according to Embodiment 1 of the present invention will be described with reference to FIGS. 1 and 2. FIG. 1 is a diagram showing the structure of the heater according to Embodiment 1 of the present invention. The heater is formed by enclosing the heating element 2, the heat dissipation block 3 and the internal lead wire 4 in the glass tube 1.

  The glass tube 1 is an amorphous glass of transparent quartz glass (for example, # 214 manufactured by GE or Vycor glass manufactured by Dow Corning (product number # 7190)). The diameter of the glass tube is set to such a size that the heating element 2 does not hit even if it vibrates. In Embodiment 1, the size of the glass tube is 10.5 mm in diameter.

The heating element 2 is formed by weaving a plurality of warp yarns 2a that are carbon fibers extending in the longitudinal direction and one weft yarn 2b extending in the width direction. A method for manufacturing the heating element will be described.
One weft 2b is woven so that the top and bottom of the plurality of warps 2a are crossed in order (weaving step). The weft 2b is folded at both ends in the width direction of the plurality of warps 2a. The resin is thinly and evenly attached to the woven warp and weft (attachment step). The woven product (heat generating part) is fired to integrate the whole (firing step). By heating, the heating element is carbonized. The carbon-based heating element of the first embodiment is formed by only a plurality of yarns that are continuous between the ends in the longitudinal direction.

According to this manufacturing method, the carbon fibers of the warp 2a and the weft 2b can be knitted uniformly. The heating element 2 composed of a plurality of thin warps 2a and one thick weft 2b has a high resistance value. By forming a heating element by folding a single weft 2b at both ends of a plurality of warps 2a, it is possible to manufacture a heating element that does not disperse carbon fibers even when used for a long period of time and is less likely to break.
The yarn described in this specification is used as a heating element, and is a material that becomes carbon fiber or carbon fiber after firing.

The heating element 2 has a flat plate shape, for example, a width T = 6 mm, a thickness t = 0.5 mm, and a length L = 300 mm. By setting T ≧ 5t, a radiation intensity distribution characteristic having strong directivity in a direction perpendicular to the width portion of Tmm can be obtained.
The warp yarn 2a and the weft yarn 2b can be securely fixed by firing after the resin is attached.
As another effect, the specific gravity is changed from 0.8 to 2.0 by baking after the resin is added, and as a result, the rigidity strength is increased.

  Further, when a resin having a high carbon residue yield after firing is used as the resin to be attached, the infrared emissivity can be improved. In addition to chlorinated vinyl chloride and diallyl phthalate monomers, resins with high carbon residue yield after firing include polyvinyl chloride, polyacrylonitrile, polyvinyl alcohol, copolymers of polyvinyl chloride and polyvinyl acetate, and polyamides. Thermosetting resins such as thermoplastic resins such as phenol resins, furan resins, epoxy resins, unsaturated polyester resins, and polyimides can be used. Not only these simple substance but 2 or more types of mixtures may be sufficient.

  The heat dissipating block 3 is formed of a conductive material such as graphite and is electrically connected to one end of the heating element 2. The heat radiating block 3 has a cylindrical shape, and has a slit (not shown) extending from one cylindrical surface (the surface on the heating element 2 side) to the other surface (the surface on the internal lead wire 4 side). This slit does not penetrate. A heating element 2 composed of a plurality of thin warp yarns 2a and weft yarns 2b knitted into the warp yarns 2a is coated with a carbon-based adhesive and inserted into the slits of the heat dissipation block 3. After the heating element 2 is closely fitted to the heat dissipation block 3, it is dried and heated (fired). As a result, the heating element 2 and the heat dissipation block 3 are connected by a sintered body of adhesive having high conductivity.

  By adopting a configuration in which the heating element 2 and the heat dissipation block 3 are bonded with a carbon-based adhesive, the strength of the joint portion is increased. Since the adhesive is the same carbon-based material as the heating element 2 and the heat radiating block 3 and their respective thermal expansion coefficients are substantially equal, it is possible to provide a highly reliable heater that is resistant to temperature cycles caused by heating on / off. A general carbon-based adhesive is a paste obtained by blending carbon black with a thermosetting resin (preferably a polyester resin or a polyimide resin).

  The heat generation of the heat dissipating block 3 itself is sufficiently smaller than the heat generating element and can be ignored. Although heat is transmitted from the heating element 2 to the heat radiating block 3, since the heat radiating block 3 has a large surface area (radiation area), a part of the heat is diffused from the surface of the heat radiating block. Therefore, the temperature rise of the coil-shaped part 4a which is a connection part of the thermal radiation block 2 and the internal lead wire 4 can be prevented.

  The internal lead wire 4 has a coil-like portion 4a formed at one end thereof, and an elastic spring-like portion 4b is formed following the coil-like portion 4a. The coiled portion 4 a of the internal lead wire 4 is wound in close contact with the outer peripheral surface of the heat dissipation block 3 and is electrically connected. The spring-like portion 4 b of the internal lead wire 4 is disposed at a predetermined interval from the outer peripheral surface of the heat dissipation block 3. The role of the spring-like portion is to apply tension to the heating element 1 and prevent the heating element 1 from being bent when the heating element 1 generates heat and expands due to thermal expansion. The spring-like portion is configured to be able to absorb a dimensional change due to expansion of the heating element 2.

  The internal lead wire 4 is connected to the external lead wire 6 via the molybdenum foil 5. An inert gas such as argon gas is sealed in the glass tube 1, and the end of the glass tube 1 including the molybdenum foil 5 is melted and crushed into a flat plate shape for sealing. This prevents the heating element 2 of the carbon-based material from reacting with oxygen in the air and being oxidized, thereby shortening the lifetime of the heating element.

  When power is applied to the external lead wire 6, a current flows through the heating element 2. Heat is generated by the resistance of the heating element to the current, and infrared rays are emitted from the heating element.

The holding member 7 is provided at a position other than both ends of the carbon-based heating element 2 in the glass tube 1. In the first embodiment, one holding member 7 is provided near the center of the heating element.
FIG. 2 is a perspective view showing the holding member. The holding member 7 is made of a carbon-based material. The holding member 7 is formed with a notch 7 a having a width slightly larger than the plate thickness of the heating element 2. The heating element 2 is inserted into the cutout portion 7a, and the holding member 7 and the heating element 2 are joined with a carbon-based adhesive.

  The circular plate-shaped holding member 7 has an outer shape slightly smaller than the inner diameter of the glass tube 1. Thus, even when vibration or impact is applied to the heater from the outside, the outer shape of the holding member comes into contact with the inner wall of the quartz glass tube, and the amplitude of vibration of the heating element 2 is suppressed to a small value. As a result, it is possible to provide a heater in which the heating element does not cause a resonance phenomenon and the heating element collides with the inner wall of the quartz glass tube 1 so that the heating element is not scraped or damaged.

  Since the holding member 7 only needs to have a function of holding the heating element 2 near the center of the quartz glass tube 1, the thickness of the holding member 7 is within the range allowed by the strength of the plate material, so that the heat dissipation through the holding member is less. Therefore, it is preferable.

  The heater according to the first embodiment configured as described above can obtain a predetermined resistance value while maintaining a predetermined strength without the carbon fibers being scattered. The resistance value of the heating element increases as the warp yarns extending in the longitudinal direction become thinner and as the number of warp yarns decreases. Even when the warp yarn is thinned, the heating element can maintain a predetermined strength by cross-weaving the warp yarn while crossing the one weft yarn at both ends of the plurality of warp yarns. The weft does not fall out and the heating element does not come apart.

  Further, the thicker the warp yarn and the more the number of warp yarns, the smaller the resistance value of the heating element, thereby realizing a heater with a large calorific value. Furthermore, a heater having a larger calorific value can be realized by stacking a plurality of carbon-based heating elements.

The heating device using the heater of the present invention can obtain a predetermined heat generation amount by changing the thickness and number of warp threads of the heating element.
By reducing the warp yarn (or reducing the number of warp yarns) and thickening the weft yarn (or increasing the number of weft yarns), the calorific value of the heating element is reduced while maintaining the strength of the carbon-based heating element above a predetermined level. I can do it.
By increasing the warp yarn (or increasing the number of warp yarns) and thinning the weft yarn (or reducing the number of weft yarns), the calorific value of the heating element is increased while maintaining the size of the carbon-based heating element below a certain level. I can do it.

  In the first embodiment, the resin is thinly and uniformly attached to the heat generating portion (weaved warp and weft). Alternatively, the heat generating portion may be impregnated with resin and fired. Alternatively, the heating element may be manufactured by forming a heating portion using a yarn to which a resin is previously attached and firing the yarn. Even when the heating element is manufactured by any of the manufacturing methods, it is possible to connect and reinforce between the yarns constituting the heating portion with the resin (holding portion). It is also possible to prevent the yarn from separating.

  In the first embodiment, the spring-like portion 4b is provided in a part of the internal lead wire. However, the holding member 7 can sufficiently suppress the deflection due to the thermal expansion during the heat generation of the heating element. In this case, it is not necessary to provide a spring-like part.

  Although the holding member 7 is provided in the embodiment, if the heating element 2 does not collide with the inner wall of the glass tube 1 when vibration or impact is applied from the outside, the holding member may not be provided. For example, when the glass tube is sufficiently large with respect to the size of the heating element, or when the heating element is short and the heating element is stable, the holding member may not be provided.

  In the first embodiment, one weft 2b is folded back at both ends in the width direction of the heating element 2. Alternatively, the weft 2b may be folded back at both ends. For example, a configuration in which at least one weft having a length substantially the same as the width of the heating element 2 is woven into the warp may be used.

Note that the following carbon-based heating element may be used in place of the carbon-based heating element of the first embodiment in which the warp yarns 2a and the weft yarns 2b are alternately woven like a cloth-like configuration.
After the resin is attached to the yarn, a thin plate is formed with a plurality of yarns. For example, a thin plate of a plurality of warp yarns (yarn extending in the longitudinal direction) and a thin plate of a plurality of weft yarns (yarn extending in the width direction) are formed. A plurality of the thin plates are overlapped to form a laminated flat plate. For example, a thin plate formed of a plurality of warp yarns and a thin plate formed of a plurality of weft yarns are alternately overlapped. Since the resin is attached to the yarn in advance, the shape of the flat plate is retained (shaped) by the resin. The flat plate is fired to form a carbon-based heating element. Thereby, the heater which has the carbon-type heat generating body of the structure by which the weft and the warp were laminated | stacked alternately can be created. According to this method, it is possible to produce a heating element that has the same rigidity as that of the heating element having the crossed structure and that does not cause yarn breakage or breakage.

Also, instead of pre-adhering the resin to the yarn, the plate shape is maintained (shaped) by impregnating the resin into a flat plate in which a thin plate of weft and a thin plate of warp are overlapped, and then fired to form a plate A carbon-based heating element may be created.
Furthermore, the thin plates may be formed and overlapped so that the warp and weft are at right angles, or the thin plates may be formed and overlapped so that the warp and weft are at an oblique angle.

<< Embodiment 2 >>
A carbon-based heating element, heater, and heating device according to Embodiment 2 of the present invention will be described with reference to FIG. FIG. 3 is a diagram illustrating the structure of the heating device and the heater according to the second embodiment of the present invention. The difference between the heater of the second embodiment and the heater of the first embodiment is a heating element. Other configurations are the same as those in the first embodiment, and thus description thereof is omitted.

  A method for manufacturing the carbon-based heating element of the second embodiment will be described. One weft 31b, which is a carbon fiber, is woven so as to cross the top and bottom of the plurality of warps 31a in order (weaving step). The weft 31b is folded back at both ends in the width direction of the plurality of warps 31a. The resin is thinly and evenly attached to the woven warp and weft (attachment step). The interwoven material is fired to integrate the whole (firing step). The integrated heating element is divided into two in the longitudinal direction. According to the manufacturing method of the second embodiment, two heating elements can be manufactured from one plate-like woven fabric, and the manufacturing efficiency is improved.

  In the heating element 31 of the second embodiment, the weft has one turn at one end in the width direction of the heating element and is not folded at the other end. In the heating device 32 of the second embodiment, the heater is arranged with the side where the weft 31b is turned up facing upward. Thereby, even if a heating element is heated, the weft yarn does not fall out, and an inexpensive heating device that can be used for a long time without carbon fibers being scattered can be realized.

<< Embodiment 3 >>
A carbon-based heating element, heater, and heating device according to Embodiment 3 of the present invention will be described with reference to FIGS. 4 and 5. FIG. 4 is a diagram showing the structure of the heater according to Embodiment 3 of the present invention. The heating apparatus according to Embodiment 3 includes the heaters shown in FIGS. 4 (a) and 4 (b). In the third embodiment, the heating device sets a narrow paper (copy object) in the center of the table (the center line of the wide paper setting position is the same as the center line of the narrow paper setting position). This is a heating device for fixing toner in a copying machine.

  Fig.5 (a) is a figure which shows temperature distribution with respect to the longitudinal direction of the heater of Fig.4 (a). FIG.5 (b) is a figure which shows the temperature distribution with respect to the longitudinal direction of the heater of FIG.4 (b). FIG.5 (c) is a figure which shows the temperature distribution with respect to a longitudinal direction at the time of heating both the heaters of Fig.4 (a) and (b). In FIG. 5, the vertical axis represents temperature, and the horizontal axis represents the distance in the longitudinal direction of the heater. The origin corresponds to the boundary between the heat dissipation block 3 and the coiled portion 4a on the left side of the heater.

The difference between the heater of Embodiment 3 and the heater of Embodiment 1 is a heating element. Other configurations are the same as those in the first embodiment, and thus description thereof is omitted.
The heating element 41 of the heater shown in FIG. 4 (a) interweaves the weft yarn to the portion excluding both ends of the warp yarn. The heating element 42 of the heater shown in FIG. 4 (b) weaves the weft yarns at both ends of the warp yarn, and does not weave the weft yarns at the center portion. Since the portion where the weft is woven is smaller in resistance than the portion where the weft is not woven, the temperature is lowered.

  For example, the heating device of the third embodiment supplies power only to the heating element 42 when copying an A4 size landscape sheet (FIG. 5B). When copying an A3 size landscape sheet, electric power is supplied to both the heating element 41 and the heating element 42 (FIG. 5C). When electric power is applied to both of the heating elements 41 and 42, the effective heat generation amount per unit area becomes substantially uniform in the longitudinal direction.

  Embodiment 3 of the present invention can adjust the heat generation temperature distribution in the longitudinal direction of the heating element by providing a plurality of warp yarns, which are carbon fibers, with a portion where the weft yarn is woven and a portion where the weft yarn is not woven. Thereby, the heating apparatus which has arbitrary exothermic temperature distribution in a longitudinal direction is realizable.

<< Embodiment 4 >>
A carbon-based heating element, heater, and heating device according to Embodiment 4 of the present invention will be described with reference to FIG. FIG. 6 is a diagram showing the structure of the heater according to Embodiment 4 of the present invention. The difference between the heater of Embodiment 4 and the heater of Embodiment 1 is the structure of the heating element. The heating element 61 according to the fourth embodiment includes a plurality of warp yarns 61a extending in the longitudinal direction and one bias yarn 61b extending in an oblique direction. In the fourth embodiment, the bias yarn 61b is woven so that the upper and lower portions of the plurality of warp yarns are sequentially crossed at a predetermined angle (45 degrees in FIG. 6) with respect to the longitudinal direction of the warp yarn 61a. The bias yarn 61b is folded at both ends in the width direction of the plurality of warp yarns 61a. The carbon-based heating element of the fourth embodiment is formed by only a plurality of yarns that are continuous between the ends in the longitudinal direction.

  Thereby, the bias yarn does not fall out, and the heater using the carbon-based heating element having the predetermined resistance value can be realized while maintaining the predetermined strength without the carbon fibers being scattered. The resistance value can be changed by changing the thickness and number of the warps 61a.

  Note that the number of bias yarns is not limited to one, and two or more bias yarns may intersect with the warp yarns. For example, one bias yarn is inserted at an angle of −45 degrees with respect to the warp yarn 61a, and the other bias yarn is inserted at an angle of 45 degrees with respect to the warp yarn 61a. The plurality of bias yarns are folded back at both ends in the width direction of the warp yarn.

  Note that the heating element may be formed by weaving warp threads extending in the longitudinal direction into a braid, braid, or Sanada string. Further, the string of the heating element may be formed as a string knitted in a tubular shape or a bag-woven string. Accordingly, it is possible to realize a heater using a carbon-based heating element that can obtain a predetermined resistance value while maintaining a predetermined strength without carbon fibers being scattered.

  In addition, since the strength is high at the portion where the wefts are woven together, in a curved heater, it is preferable to weave the wefts into the curved portion.

The heater of the present invention includes a heating device (for example, a stove, kotatsu, an air conditioner, an infrared treatment device, etc.), a drying device (for example, clothing drying / futon drying / food drying / garbage disposal / heating deodorizer), cooking device (For example, oven, microwave oven, oven toaster, toaster, roaster, incubator, yakitori, stove, refrigerator, etc.) Heating for the purpose of heating the object to be heated by a heat source, such as a device that displays toner as a medium, such as LBP, PPC, or fax, or a device that uses heat to thermally transfer from the original film to the transfer object Applicable to equipment.

  The carbon-based heating element of the present invention has an effect that carbon fibers are not scattered, and is useful for a heater and a heating device having the heater.

The figure which shows the structure of the heater of Embodiment 1 of this invention. The figure which shows the structure of the holding member of Embodiment 1 of this invention. The figure which shows the structure of the heating apparatus of Embodiment 2 of this invention. The figure which shows the structure of the heater of Embodiment 3 of this invention. The figure which shows the exothermic temperature distribution of the longitudinal direction of the heater of Embodiment 3 of this invention The figure which shows the structure of the heater of Embodiment 4 of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Glass tube 2, 31, 41, 42, 61 Heating body 3 Holding block 4 Internal lead wire 5 Molybdenum foil 6 External lead wire 7 Holding member 32 Heating device

Claims (11)

A plurality of warp yarns extending in the longitudinal direction, at least one weft yarn extending in the width direction, having at least one turn, and interwoven so as to cross the upper and lower sides of the continuous warp yarns;
A carbon-based heating element formed by firing
A heat dissipation block formed of a conductive material electrically connected to the carbon-based heating element;
Internal lead wires electrically connected to the heat dissipation block;
Molybdenum foil connected to the internal lead wire;
An external lead connected to the molybdenum foil;
A glass tube containing the carbon-based heating element, the heat dissipation block, and the internal lead wire, sealed at a portion where the molybdenum foil is embedded, and filled with an inert gas;
Having a heater. The heater according to claim 1, wherein in the carbon-based heating element, the weft yarn is woven in an oblique direction with respect to the warp yarn extending in the longitudinal direction. The heater according to claim 1, wherein in the carbon-based heating element, the weft yarn is folded and woven at both ends in the width direction. The heater according to claim 1, wherein in the carbon-based heating element, the weft is at least one continuous yarn. The heater according to claim 4, wherein a cross section in the width direction of the carbon-based heating element is woven into a tubular shape or a bag shape. The heater according to claim 1 formed by laminating a plurality of carbon-based heating elements. The heater according to claim 1, wherein the carbon-based heating element includes a warp extending in the longitudinal direction and a weft extending in the width direction, and the warp is thinner than the weft. The heater according to claim 1, wherein the carbon-based heating element includes a warp extending in the longitudinal direction and a weft extending in the width direction, and the warp is thicker than the weft. The heater according to claim 1, wherein a holding member that holds the carbon-based heating element extending in the longitudinal direction is provided at a position other than both ends of the carbon-based heating element. The heater according to claim 1, wherein in the carbon-based heating element, the weft yarn is folded and woven at one end in the width direction. A heating apparatus comprising the heater according to claim 1.

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