JP5635440B2 - Seat with heater wire, method for manufacturing the same, and heater device - Google Patents

Description

  The present invention relates to a sheet with a heater wire in which a heater wire is sewn on a flexible sheet-like substrate, and a method for manufacturing the same. Moreover, this invention relates to a heater apparatus provided with the said sheet | seat with a heater wire.

  Conventionally, in order to heat piping and various apparatuses, a sheet with a heater wire in which a heater wire and a sheet-like heat insulating member are integrated is often used. This sheet with heater wires is manufactured by sewing the heater wires in a predetermined pattern on the surface of the sheet-like heat insulating member, but in order to increase productivity, the heater wires are sewn using a sewing machine. (See Patent Documents 1 to 4).

JP 2002-164156 A JP 2000-106268 A JP-A-5-226066 Japanese Laid-Open Patent Publication No. 1-169892

  When sewing a sheet with a heater wire, until now, the heater wire is arranged on the surface of the heat insulating member so as to match a predetermined pattern, and is temporarily sewn with a sewing machine in a state where the pattern is maintained. However, temporary fixing is performed manually and is reflected in the manufacturing cost. In addition, the heater wire is made to follow the pattern and simultaneously sewn with a sewing machine while being pressed with a finger, but this method is also a manual operation and is reflected in the manufacturing cost.

  Thus, the conventional sewing method using a sewing machine has a large part that relies on manpower, which is an obstacle to reducing the manufacturing cost. Therefore, an object of the present invention is to manufacture a sheet with a heater wire by a simpler method and to reduce the cost.

In order to achieve the above object, the present invention provides the following.
(1) A method for producing a sheet with a heater wire formed by sewing a heater wire to a flexible sheet-like base material having heat resistance,
Using a sewing machine, a heater wire that surrounds a heating element wire with a covering formed by braiding long fibers having electrical insulation properties and heat resistance is supplied in a sheet form with heat-resistant sewing thread while continuously supplying a heater wire along a predetermined pattern. A method for producing a sheet with a heater wire, characterized by being sewn to a substrate.
(2) The method for manufacturing a sheet with a heater wire as described in (1) above, wherein an embroidery sewing machine is used.
(3) The method for producing a sheet with a heater wire as described in (1) or (2) above, wherein the heater wire having a double structure is used.
(4) Obtained by the method according to any one of (1) to (3) above,
A heater wire that surrounds a heating element wire with a covering formed by braiding electrically insulating and heat-resistant long fibers on the surface of a flexible sheet-like substrate having heat resistance is heat-resistant along a predetermined pattern. A sheet with a heater wire, characterized by being sewn with natural sewing thread.
(5) The sheet with heater wire according to (4), wherein the covering has a double structure.
(6) The sheet with the heater wire according to (4) or (5), and a heat-resistant cover member having flexibility that covers at least a surface of the sheet with the heater wire on which the heater wire is sewn. A heater device characterized by that.
(7) The heater device according to (6), which is used for heating a pipe and is used in a clean room.

  According to the present invention, a manual operation such as a method of temporarily fixing the heater wire in conformity with the pattern or sewing it while following the pattern and pressing it with a finger becomes unnecessary, and the manufacturing cost can be reduced. In addition, since the heater wire covering is a braided long fiber, feeding when the heater wire is supplied to the sheet-like base material is smoothly performed, and a pattern in which the radius of curvature of the heater wire is small or It is possible to follow a complicated pattern well.

It is a perspective view which shows the external appearance of a mantle heater. It is an expansion perspective view which shows a part of heating part of the mantle heater shown in FIG. It is a side view which shows the state which mounted | wore piping with the mantle heater shown in FIG. It is an expansion perspective view which shows a heater wire. It is an expansion perspective view which shows the other example of a heater wire. It is a schematic diagram which shows an example (locking) of the sewing method of a heater wire.

  Hereinafter, the present invention will be described in detail with reference to the drawings.

  FIG. 1 is a perspective view showing an appearance of a mantle heater as an example of a heater device to which a sheet with a heater wire of the present invention is applied, FIG. 2 is an enlarged perspective view showing a part of a heating portion, and FIG. 3 is a mantle. It is a side view which shows the state which attached the heater to piping. As shown in the figure, the mantle heater A is sewed on the surface of the sheet-like base material 1 having heat insulation and flexibility on the surface on which the heater wires 4 are sewn in a predetermined pattern, and the heater wires 4 are further sewn. The heat insulating material 2 is laminated, the whole is surrounded by a bag-like cover member 3, and a power connection terminal or connector 7 is attached to a lead wire 6 drawn from a part of the cover member 3. Further, the mantle heater A is used by being wound around a pipe, and in order to maintain the wound state, a plurality of heat-resistant cloth belts 9 having fasteners 8 are sewn on the cover member 3, and a required portion In addition, a belt guide 10 made of a similar material is sewn, and the belt 9 is locked by a fastener 8. Then, as shown in FIG. 3, the mantle heater A is wound around the pipe B, and the belt 9 is fixed by the fastener 8. Instead of the fastener 8, a hook-and-loop fastener may be provided on the front and back surfaces of the end portion of the belt 9.

  The sheet-like substrate 1 is not limited as long as it has heat resistance and flexibility. For example, a sheet made of silicon sponge, an inorganic fiber blanket, a heat resistant rubber sheet, glass fiber, silica fiber, alumina fiber, silica alumina fiber, etc. An inorganic fiber cloth woven with heat-resistant fibers can be used.

  As the heat insulating material 2, an inorganic fiber mat in which glass fibers, ceramic fibers, silica fibers and the like are assembled and subjected to needle processing can be used. Further, it may be formed into a mat shape with an inorganic binder such as colloidal silica, alumina sol or sodium silicate, or an organic binder such as starch. Alternatively, a porous molded body made of a heat-resistant organic resin such as aramid, polyamide, or polyimide can be used. 5-100 mm is suitable for the thickness of such a heat insulating material, 5-50 mm is suitable, and 8-30 mm is still more suitable.

  The cover member 3 is a member that suppresses the generation of dust from the inside. For example, an inorganic fiber cloth (woven cloth) made of inorganic fibers such as glass fiber, silica fiber, alumina fiber, silica alumina fiber, and such inorganic fiber cloth. Further, a cloth made of a fluororesin-coated inorganic fiber obtained by coating the fluororesin can be used. Therefore, the mantle heater A is suitable for use in a clean room.

  Moreover, as the cover member 3, PTFE (polytetrafluoroethylene), PFA (tetrafluoroethylene-perfluoroalkoxyethylene copolymer), FEP (tetrafluoroethylene-hexafluoropropylene copolymer), PCTFE (polychlorotriethylene). Fluoroethylene), ETFE (tetrafluoroethylene-ethylene copolymer), ECTFE (chlorotrifluoroethylene-ethylene copolymer), PVDF (polyvinylidene fluoride) and other fluororesin-made sheets, or the above It is also possible to use a fluororesin fiber cloth (woven fabric) knitted with fluororesin fibers.

  In addition to the above fluororesins, polyamide, polycarbonate, polyacetal, polybutylene terephthalate, modified polyphenylene ether, polyphenylene sulfide, polysulfone, polyethersulfone, polyarylate, polyetheretherkelton, polyphthalamide, polyimide, polyetherimide, Although it is heat resistant such as polymethylpentene, a resin having a lower melting point than that of a fluororesin can be used.

  The heater wire 4 is a heating element wire such as a nichrome wire or a Kanthal wire, a long fiber having electrical insulation and heat resistance, for example, a fiber thickness of 10 to 300 tex, more preferably 50 to 200 tex, such as glass fiber, It is coated with a covering formed by braiding long fibers such as silica fibers, alumina fibers, and silica alumina fibers. Here, the long fibers refer to yarns including yarns, rovings, strands, filaments and the like. By using the long fiber, the insulating property is improved and the slidability is also improved. As will be described later, when sewing to the sheet-like base material 1, it becomes easy to push out from the sewing machine into a predetermined pattern. In addition, it is preferable that the covering body is knitted with long fibers on the outer peripheral surface of the heating element wire because the adhesiveness between the heating element wire and the covering body is increased rather than the tubular covering body is fitted on the heating element wire. That is, according to such a braided covering body, the heating element wire can be knitted so as to be tightened, so that the adhesion between the heating element wire and the covering body can be improved.

  The covering is preferably a double structure. For example, as shown in FIG. 4, the inner layer 42 made of alumina long fibers having high heat resistance and excellent protective effect, and the protective effect is inferior to alumina fibers. A two-layer structure with an outer layer 43 made of inexpensive silica-based long fibers can be employed. Further, both the inner layer 42 and the outer layer 43 can be composed of silica-based long fibers. Thereby, pattern followability improves with protection of the heater wire 4. Note that reference numeral 41 in the figure is the above-described heating element wire.

  Moreover, as shown in FIG. 5, you may use the felt made from inorganic fiber for the inner layer 42a. In order to manufacture this felt-shaped inner layer 42a, the inorganic short fibers are formed on the surface of the heating element 41 by immersing and passing the heating element 41 in a slurry in which the inorganic short fibers are dispersed in a binder solution. The assembled felt can be fixed. Since the inner layer 42a is intricately entangled with the short fibers, once formed, the inner layer 42a can maintain the fixed state even if the binder disappears by heating. Therefore, the binder does not require heat resistance, and general binders such as polyvinyl alcohol, polyethylene oxide, silicon oxide, and sodium glycolate can be used. Moreover, as an inorganic short fiber, inorganic short fibers, such as a silica fiber, an alumina fiber, and a silica alumina fiber, etc. can be used, for example. Such a felt-like inner layer 42a is strong and has high flexibility, does not peel even when heated to a high temperature, and generates less fine powder.

  Although there is no restriction | limiting in the thickness of a coating body, in the case of a two-layer structure, it is preferable that the inner layers 42 and 42a are 100 micrometers or more, and 300-1000 micrometers is more preferable. The thickness of the felt inner layer 42a can be controlled by the concentration of ceramic short fibers in the slurry solution. The thickness of the outer layer 43 is preferably 100 μm or more, and more preferably 300 to 1000 μm. When one layer of braided long fibers is used, it is preferably 100 μm or more, more preferably 300 to 2000 μm.

  The sewing thread for sewing the heater wire 4 is made by twisting fibers having heat resistance, and for example, a glass yarn or a silica yarn can be used.

  In the present invention, when manufacturing the mantle heater A described above, a sewing machine is used, and the heater wire 4 is supplied to the surface of the sheet-like substrate 1 and is sewn with a sewing thread. To carry out such sewing, an embroidery sewing machine can be used. The embroidery sewing machine can be sewn on the cloth so that the embroidery thread constituting the line of the embroidery pattern is wound on the sewing thread. By using the heater wire 4 instead of the embroidery thread, the sheet-like substrate 1 is attached. The heater wire 4 can be sewn.

  There are no restrictions on how to sew, but it is possible to perform lock stitching or single-ring stitching. As shown in FIG. 6, in the main stitch, the upper thread 55 passed through the hole 51 of the sewing needle 50 having a hole penetrates the sheet-like base material 1 together with the needle 50 from above the sheet-like base material 1. At this time, the lower thread 56 on the back side of the sheet-like base material 1 is crossed to create a seam, which has the advantage that it is difficult to unravel and has excellent strength.

  The heater wire 4 is sewn on the surface of the sheet-like substrate 1 according to a predetermined pattern, but the pattern data is stored in a computer not shown, and the movement of the lifting cylinder of the sewing machine is controlled in accordance with the pattern by the computer. Can be automated. Moreover, since the heater wire 4 is sewn with the upper thread and the lower thread almost simultaneously with the supply to the sheet-like substrate 1, the heater wire 4 is temporarily fixed and fixed as before, or the heater wire 4 is sewn at the time of sewing. There is no need to press line 4 with a finger.

A Mantle heater 1 Sheet-like base material 2 Heat insulating material 3 Cover member 4 Heater wire 8 Fastener 9 Belt 41 Heating element wires 42 and 42a Inner layer 43 Outer layer

Claims (5)

A method for producing a sheet with a heater wire by sewing a heater wire to a flexible sheet-like substrate having heat resistance,
A heater wire that surrounds a heating element wire with a covering formed by braiding long fibers having electrical insulation and heat resistance using a sewing machine and continuously supplying a heater wire along a predetermined pattern. all SANYO sewn into a sheet-like substrate by the yarn and the lower yarn,
The covering has a double structure of an outer layer and an inner layer, and both the outer layer and the inner layer are braided with silica-based long fibers, or the outer layer is braided with silica-based long fibers, and the inner layer has A method for producing a sheet with a heater wire, characterized by braiding alumina-based long fibers .   2. The method for manufacturing a sheet with a heater wire according to claim 1, wherein an embroidery sewing machine is used. Obtained by the method according to claim 1 or 2 ,
A heater wire that surrounds a heating element wire with a covering formed by braiding electrically insulating and heat-resistant long fibers on the surface of a flexible sheet-like substrate having heat resistance is heat-resistant along a predetermined pattern. Whether the covering is a double structure of an outer layer and an inner layer, and both the outer layer and the inner layer are braided with silica-based long fibers. Alternatively, the sheet with a heater wire, wherein the outer layer is a braided silica-based long fiber, and the inner layer is a braided alumina-based long fiber .   A heater device comprising: the heater wire-equipped sheet according to claim 3; and a heat-resistant cover member having flexibility to cover at least a surface of the sheet with the heater wire to which the heater wire is sewn.   The heater device according to claim 4, wherein the heater device is used for heating a pipe and is used in a clean room.

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