JPH07332692A - Manufacture of panel heating - Google Patents

Abstract

PURPOSE:To easily and inexpensively build up a panel heater with a favorable appearance, which is thin and light-weight, has a favorable far infrared ray radiation efficiency, does not generate a temperature runaway, stably emit uniform far infrared rays by the whole body of the surface, and can quickly be heated to a specified temperature. CONSTITUTION:On the rear surface of a flat heating element 34 which is made of a carbon fiber-mixed paper and emits far infrared rays, a plate-form honeycomb core 35 wherein an aluminum sheet 36 is provided on the front surface, and an aluminum plate 41 is provided on the back surface is arranged with rods 37, and a frame body 43 which is equipped with a front wall, a rear wall and end walls on the periphery is fitted on and integrated to manufacture a panel heater.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a panel heater manufacturing method using a carbon fiber sheet heating element as a heat source.

[0002]

2. Description of the Related Art Oil and gas burning appliances, electric heating appliances and the like are widely used as heating devices, and in particular, a panel heater by electric heating is used as a heating appliance for performing localized heating. In such a panel heater using electric heat, a panel heater that emits far infrared rays has recently been
It has attracted attention because of its high penetration efficiency such as clothing and high heating efficiency.

As a heat source of a panel heater for radiating far infrared rays, a metal heating element such as a nichrome wire having a high electric resistance value is mainly used, carbon powder, ceramics, etc. are provided on the surface, and carbon or Far infrared rays are emitted from ceramics. Further, it has been proposed to use a carbon fiber sheet heating element as a heat source of the panel heater, but there are many problems to be solved for practical use, and it has not been spread.

[0004]

DISCLOSURE OF INVENTION Problems to be Solved by the Invention In a conventional panel heater in which carbon, ceramics or the like is provided on the surface of a metal heating element such as a nichrome wire, nichrome wire as a heat source and carbon or ceramics as a heat radiation source are used. Is bulky and heavy, so its range of use is limited,
Since far infrared rays transfer heat from a heat source to a far infrared radiation source, there is a drawback that heat transfer efficiency is poor and far infrared radiation efficiency is poor. In addition to uneven heat generation due to the arrangement of the nichrome wire as a heat source, the heat of the heat source is also transferred to the back surface, resulting in poor thermal efficiency. Will be done.

On the other hand, when the carbon fiber sheet heating element is used as a panel heater, a carbon fiber sheet heating element that generates heat uniformly over the entire surface of the panel and rapidly heats to a predetermined temperature has not been developed. In addition, since it is difficult to control the temperature to a low temperature and local thermal runaway may occur, it was extremely difficult to put it into practical use. In particular,
In order to solve the above-mentioned drawbacks of the carbon fiber sheet heating element, it is necessary to stack and integrate various members on the sheet heating element to form a panel heater, but an appropriate forming means and manufacturing method thereof have been developed. Was not done. In addition, while the carbon fiber sheet heating element is thin, lightweight, and has the advantage of being freely deformable, a reinforcing member and a frame body are required to maintain a predetermined shape. It is necessary to develop a method for manufacturing a panel heater that looks good and can be easily and inexpensively assembled.

Therefore, according to the present invention, the far-infrared radiation efficiency is thin and lightweight, and the far-infrared rays that are uniform over the entire surface can be stably radiated without causing temperature runaway and can quickly generate heat at a predetermined temperature. An object of the present invention is to provide a manufacturing method of a panel heater which can be easily mounted in a wide range of applications and can be easily and inexpensively assembled into a good-looking panel heater.

[0007]

In order to solve the above-mentioned problems, the present invention provides a sheet-like heating element made of carbon fiber mixed paper and emitting far infrared rays on the back side, an aluminum sheet on the front side and an aluminum sheet on the back side. A panel heater is manufactured by arranging a plate-shaped honeycomb core provided with a plate through a rod, and inserting and integrating a frame body having a front wall, a rear wall, and an end wall around the periphery.

[0008]

[Operation] Since the present invention is configured as described above, far infrared rays emitted from the carbon fiber mixed paper are uniformly emitted from the entire surface, and at the start of heat generation, a spacer action is provided on the back surface of the carbon fiber mixed paper. Located through the eggplant rod,
It is heated by the radiant heat of the sheet heating element itself, which is reflected by the reflector made of an aluminum sheet, and quickly rises to a predetermined temperature. A sheet heating element having such a function is formed from a front wall, a rear wall and a tongue wall of a frame body through a rod-shaped honeycomb core and a rod provided with an aluminum sheet on the entire surface and an aluminum plate on the back surface. By being inserted into the empty space, it is integrally fixed, and a strong panel heater can be easily manufactured. At that time, the edges of the laminated sheet heating element, the rod aluminum sheet reflecting plate, the honeycomb core, the aluminum plate, etc. are fitted into the frame body, so that they do not have to be formed into accurate shapes, respectively. These edges enter the frame and become invisible from the outside, improving the appearance.

[0009]

Embodiments of the present invention will be described with reference to the drawings.
The carbon fiber sheet heating element to which the present invention is applied has a cross section thereof as shown in FIG. 6, and is made by mixing and mixing carbon fiber 22 with bast fiber 21 for Japanese paper made of Kozo, Manila hemp, Mitsumata and the like. Has been formed. As the carbon fibers, a mixture of about 5 to 15% of PAN-based carbon fibers having a filament diameter of 6.8 μ and a specific resistance of about 20 μΩm is used.

When such bast fibers are mixed and extracted, for example, mucus extracted from the root of Troloia mallow is mixed. The mucilage of the root of Troiloa mallow is used as "Neri" of Japanese paper, but it makes the dispersion of carbon fiber good especially when mixed with carbon fiber, and the viscosity disappears when dried after papermaking. The characteristics are good as a planar heating element, and this mucus adheres to the areas where the carbon fibers overlap with each other like an adhesive, stabilizes the contact resistance of the carbon fibers, and prevents the temperature heating of the planar heating element. However, it exhibits a constant temperature maintenance characteristic according to the applied current.

The carbon fiber sheet heating element material 2 having the above composition can be produced by a batch method or a continuous papermaking method using a Fourdrinier, and even when it is produced in a continuous length, The thickness of the carbon fiber planar heating element made of this material is about 0.3 mm, and since the carbon fibers are not clumps and are separated and dispersed into monofilaments of a few microns, it is easy to determine with a normal blade. Cut into long pieces, for example 800 x 60
An electric heating element having a desired shape and size such as a 0 mm rectangle can be formed.

For the sheet heating element formed as described above, for example, a rectangular carbon fiber sheet heating element 1 shown in FIG. 7 is used.
The electrodes 5 and 6 are provided along the side edges 3 and 4 on the longer sides facing each other by means to be described later in detail, and the lead wires 7 are led out from the terminals provided on the electrodes. The planar heating element thus formed does not pose a serious risk to the human body even if it is directly touched on the surface when, for example, an AC voltage of 100 V is applied between both electrodes. In order to make an electric product, as shown in FIG. 8, for example, a plastic film 8 including a portion of a heating element and an electrode for waterproofing, moisture proofing, and from the viewpoint of safety or preventing damage to the heating element. Laminate with. This plastic laminate is
It is preferable to apply this material in a state of being sealed from the outside air in order to protect the carbon fibers and the paper fibers from oxidative deterioration. The surface of such a laminate may be further covered with a flocked cloth 9 as shown in FIG. Instead of this flocked cloth, the surface of the plastic film 8 can be directly flocked.

As shown in FIG. 6, the electrode 5 is formed as shown in FIG. 7 on the carbon fiber sheet heating element material 2 which is prepared by mixing the bast fiber and the carbon fiber together with an adhesive such as a twist. At this time, as shown in the state after the electrodes are formed in FIG. 10, the silver paste is placed close to the side edge 3 of the carbon fiber planar heating element 2 and is heat-fused to heat the heating element material 2 into the heating element material 2. The impregnated electrode base 10 is formed. Since the electrode base 10 is also sufficiently impregnated with carbon fibers, the current-carrying characteristics between the heating element and the electrodes are extremely good. At this time, the surface of the electrode base 10 that has not been impregnated is exposed near the side edge of the heating element material 2.

A strip of copper foil 11 having a thickness of about 30 to 50 μ is placed on the exposed surface of the electrode base 10. For the surface 12 of this copper foil 11, the thickness 1 by plating etc.
A gold surface coating layer 13 of about 2 μm is formed. When gold plating is applied to the copper foil, a nickel plating layer having a thickness of about 0.5 μ is provided on the surface of the copper foil, and when gold plating is applied to the nickel plating layer, the contact resistance is reduced and the terminal exhibits favorable characteristics. . Also, after plating the surface of the copper foil with palladium,
Gold plating may be applied.

After laminating a copper foil having a gold surface coating on the heating element material 2, a suitable base 14 is placed on the back surface of the carbon fiber planar heating element material 2 as shown in FIG. The sewing machine needle 15 is applied from the surface of the copper foil 11 on the side of the gold surface coating 13, and the laminated terminal portion of the laminated sheet-like heating element with terminals is inserted by the sewing machine needle 15 by straight lines or zigzags.

It is desirable that the sewing needle 15 be inserted so that it penetrates the copper foil and sufficiently penetrates into the electrode base layer 10 impregnated with silver.
You may make it penetrate to the back surface of. Further, the pattern of the insertion hole formed by the sewing machine needle 15 may be a straight line, a zigzag pattern, or any pattern.

The electrode 18 of the sheet heating element, which is formed with the perforations 17 by the sewing machine needle 15 as described above, is formed on the outer periphery of the perforations 17 of the copper foil 11 as shown in FIG. A connecting portion 19 is formed which rushes into 10. Thereby, the copper foil 11 can be easily and firmly fixed to the electrode base layer 10 without using a conventional adhesive or the like. Alternatively, the carbon fiber planar heating element material 2 may be passed between a pair of needle rollers, and the sewing needle 15 may be used to perforate the carbon fiber planar heating element material 2 from both front and back sides with a sewing needle.

After the electrode 18 is provided, the terminal 20 is fixed to the end of the electrode 18 by an appropriate means such as riveting as shown in FIG. The lead wire is connected to the plug to enable current supply. Thereafter, as described above, the upper and lower surfaces including the electrode portion are laminated and covered with the plastic film 8 as shown in FIG.

In the above embodiment, an example in which a copper foil is fixed to the electrode base layer made of a silver material is shown. However, an aluminum foil may be used in addition to the copper foil, and when a gold plating layer is formed on the surface of the aluminum foil, It is preferable to apply nickel plating in advance.

When the surface coating layer of gold is applied to the surface of the metal foil such as the copper foil or the aluminum foil, various means such as vapor deposition can be adopted in addition to the plating in the above embodiment.

Further, in the above embodiment, an example in which the needle of the needle roller is used for perforation is shown, but various perforation means such as perforation means by sewing with a sewing machine can be adopted.

Further, in the above embodiment, the needle roller is applied to both sides and punched from both sides, but it is not always necessary to punch from both sides. For example, the back surface of the planar heating element material, that is, the electrode is fixed. The surface opposite to the surface to be covered may be perforated by applying a flat roller and applying a needle roller only from the side on which the metal foil is placed.

Next, the rivet 3 as shown in FIG.
Cap 14 made of synthetic resin such as nylon 66 on the head 14 of 0
A rivet 30 which covers 8 and is provided with a large number of knurled grooves 26 along the axial direction in a part of the shaft portion 25 near the head portion 27.
As shown in FIG. 15, a washer 33 made of synthetic resin such as nylon is incorporated, and the terminal 32 having the lead wire 7 is penetrated therethrough, and the tip 32 thereof is the end of the electrode plate formed as described above. When the tip 32 is pressed against a portion and pushed firmly into the caulking receiver arranged on the plastic film 8 side of the back surface of the heating element material 2, the tip 32 is caulked as shown in FIG.

At this time, the cap 28 made of synthetic resin covering the head 27 is plastically deformed by the strong pressure at the time of caulking, and strongly digs into the plastic film 8 on the surface. At the same time, the periphery of the head 27, including the terminals 25, is sealed with a strong force by a synthetic resin cap. At this time, the numerous grooves 26 formed on the outer periphery of the shaft portion 25 of the rivet 30 are
When penetrating the heating element material 2 made of carbon fiber mixed paper, it makes contact with the carbon fiber in a wide area in its periphery, and also makes contact with the electrode base 10 and the copper foil 11 of the electrode plate which penetrates in a wide area in its periphery. This means that the current from the terminal 31 can be surely passed through the electrodes and the heating element.

When the sheet heating element having the required electrodes formed as described above is used as a panel heater, as shown in FIGS. 1 to 4, a plate is provided on the back side of the sheet heating element 34. The honeycomb core 35 having the shape of a circle is arranged. An aluminum sheet 36 is provided on the side of the honeycomb core 25 facing the sheet heating element 34.
And the three rods 37 in the figure are fixed to the surface.
The both ends of the rod 37 are provided with notches 38 on the aluminum sheet side, and the back surface of the sheet heating element 34 is provided with the rod 37.
Is fixed to the front side of the sheet heating element, and thereby a gap 40 is formed between the back surface of the sheet heating element 34 and the aluminum sheet 36 as a reflector. Next, an aluminum plate 41 is placed on the back surface of the plate-shaped honeycomb core 35 and integrated.

On the outer periphery of the heating element integrated in this way, four divided frame bodies 43-1 to 43-4 are abutted so as to face the left and right and upper and lower side edges. The frame body 43 has a substantially E-shaped cross-sectional shape as shown in FIG. 2, and the front wall 44, the rear wall 45, and the intermediate wall 46 between them are connected by an end wall 47 to be integrated. The end portions of the sheet heating element 34 and the rod 37 are fitted in the front groove 48 between the intermediate wall 46 and the intermediate wall 46, and the rear groove 50 between the intermediate wall 46 and the rear wall 45 is entirely covered with aluminum as a reflection plate. The sheet 36 is attached, and the end portion of the plate-shaped honeycomb core 35 provided with the aluminum plate 41 on the rear surface is fitted, and the intermediate wall 46 is arranged in the notch 38 provided at the end portion of the rod 37. The rear wall 45 has a hole 51, the intermediate wall 46 is provided with a screw hole 52 facing the hole 51, and the aluminum plate 41, the honeycomb core 35, and the aluminum sheet 36 integrated as described above are provided. The through holes 53 are formed at positions facing the holes 51 and the screw holes 52. After these are assembled to the frame body 43, the screws 42 are inserted from the rear side, and the screw holes 52 are formed in the intermediate wall 46. The frame is fixed by screwing. In this way, all the frame bodies 43-1 to 43-4 are fixed. At this time, it is preferable that the edge 54 bent inward of the front wall 44 of the frame body elastically contacts the entire surface of the sheet heating element 34.

The frame body 4 which is one of the four-divided frame bodies 43
A storage groove 55 is formed in 3-3.
A controller 56 can be housed in the unit 5, which includes a temperature controller, a power switch, a timer, and other adjusting sections, an operating section, and a control section inside thereof, thereby saving the intermediate switch and saving space. Is possible. Also, when storing and assembling it, the storage groove 55
Insert the screw 60 into the hole 59 of the protrusion 58 formed in a part of the
Secure by screwing in. This control 56
One of the conducting wires 58 guided to the above is connected to the electrode terminal portion of the planar heating element 34, and the other of the conducting wires 58 is connected to the frame body 43-3.
It is communicated with the plug 62 through a cord winding portion 61 fixed by a screw 60 on the back surface of the.

On the back surface of the panel heater thus formed, a magnet plate 63 is fixed to the back surface of the aluminum plate 41 with an adhesive or the like. The magnet sheet 63 may be provided on substantially the entire back surface of the aluminum plate 41, but may be provided at any position such as four corners or edges. Can be adopted.

When the panel heater constructed as described above is used, for example, the attraction force of the magnet plate is applied to the inner side surface of the foot or the inner side surface of the back of a steel desk such as an office desk or the lower surface of the drawer. It is used after being fixed by adsorption. Further, without fixing the magnet plate on the back surface of the panel heater, a double-sided adhesive tape, a suction cup, a hanger, etc. are provided, and it is possible to fix the foot, knees, thighs, etc. in the vicinity of places where heat retention and heating are required, Thereby,
It can be used for heat retention and heating in winter and heat retention for knees and waist when using air conditioning in summer, and can also be used for warming treatment. In addition, it can be installed at any location in the room such as a toilet or a small kitchen, and it is also effective for local heating at ticket handling locations or police boxes.

Further, the panel heater can be made flexible by forming the frame body in whole or in part with a flexible material, whereby it can be formed into a cylindrical shape.
It can be wound around a tubular body and used for a wide range of heat radiation. For example, when the drum can is heated, the front surface side can be applied to the outer peripheral surface of the drum can to form a tubular shape, and the heating can be performed. In addition, by utilizing the elastic force when making it into a cylindrical shape, and inserting this cylindrical panel heater into the inside of a cylindrical object, it sticks elastically to the inner surface of the object without the need for special fixing means. Can be fixed to.

Since the sheet heating element used in this panel heater is made of a paper material, it is possible to laminate polyester or epoxy resin on the FRP reinforced with glass fiber. The sheet-like heating element consisting of can generate heat even if cut into any size and shape, so it can be formed into an ultra-wide shape, a rectangular shape, or any three-dimensional shape. It can be used for heating various objects.

The sheet heating element made of carbon fiber mixed paper feels hot when directly touching the heater surface, but the heat of the portion touching the heater surface is immediately absorbed by the skin and becomes low in temperature. Since the effect of increasing the temperature of the low temperature portion does not exist on the heater side, even if the heater surface is continuously touched, it is not burned and is extremely safe.

In particular, when the panel heater according to the present invention is used, when the sheet heating element is energized, the sheet heating element gradually rises in temperature due to its own heat generation property. Far infrared rays will be gradually emitted from, but the far infrared rays emitted to the back side will be emitted to the aluminum sheet reflecting plate and heat the sheet heating element itself,
In combination with the heat insulating property of the honeycomb core, the sheet heating element rapidly rises to a predetermined temperature. As a result, the time required for the sheet to be heated to a predetermined temperature after being energized is shortened.

[0034]

EFFECTS OF THE INVENTION Since the present invention is constructed and operates as described above, it is thin and lightweight, and the radiation efficiency of far infrared rays from the surface of the planar heating element is good due to the heat insulating function of the reflector and the honeycomb core. In particular, it is possible to shorten the time required to reach the predetermined temperature after the sheet heating element is energized. Further, since the carbon fiber mixed paper is used as the sheet heating element, it can be formed in an arbitrary size and shape, and can be used for wide range local heating and heating of various objects. In particular, according to the method for manufacturing a panel heater of the present invention, a sheet heating element having various effects as described above, a rod that acts as a spacer, an aluminum sheet reflector that performs efficient heating and heat insulation, By integrating the honeycomb core and the aluminum plate, which have a heat insulating function, with a frame body, it is possible to manufacture them firmly and easily, and the edges of each of the laminated members are formed into exactly the same shape as described above. Even if it is not molded, each edge is fitted into the frame body and cannot be seen from the outside, so that each member can be easily molded and an inexpensive panel heater can be obtained.

Further, in the case where the flocked layer is provided on the surface of the planar heating element, it is safe even if the skin comes into contact with the planar heating element, and soft far infrared rays can be radiated,
In the case where the magnet is fixed to the back surface of the aluminum plate, it can be easily attached to and detached from the required place such as a steel disk, and in the case where the unitized controller is incorporated in the frame, various equipment such as intermediate switches can be installed. It is not necessary to install it separately, and it is compact and easy to handle.

[Brief description of drawings]

FIG. 1 is an exploded perspective view showing an embodiment of the present invention.

FIG. 2 is a partial cross-sectional view of the assembled state.

FIG. 3 is a front view of the same.

FIG. 4 is a rear view of the same.

FIG. 5 is a partially enlarged plan view showing a state in which electrodes and terminals are provided on the planar heating element used in the present invention.

FIG. 6 is an enlarged cross-sectional view of the heating element material of the planar heating element used in the present invention.

FIG. 7 is a plan view showing the entire planar heating element.

FIG. 8 is a sectional view of the same.

FIG. 9 is a cross-sectional view showing an example in which a flocked cloth is provided on the planar heating element.

FIG. 10 is a cross-sectional view showing a state in which a member forming an electrode is placed on the material of the planar heating element.

FIG. 11 is a cross-sectional view showing a state in which the member shown in FIG.

FIG. 12 is a cross-sectional view showing a state after the perforation.

FIG. 13 is a cross-sectional view showing a state before terminals are provided on the electrodes of the heating element.

FIG. 14 is a perspective view of a rivet used for fixing a terminal.

FIG. 15 is a cross-sectional view showing a state in which terminals are attached to the sheet heating element with rivets.

[Explanation of symbols]

 8 Plastic film 9 Protective material 11 Copper foil 13 Gold surface coating layer 18 Electrode 21 Bast fiber 22 Carbon fiber 34 Sheet heating element 35 Honeycomb core 36 Aluminum sheet 37 Rod 43 Frame body

Claims (4)

[Claims] 1. A sheet-shaped honeycomb core comprising carbon fiber-blended paper, which emits far infrared rays, has an aluminum sheet on the front side and a plate-shaped honeycomb core having an aluminum plate on the back side via rods. A panel heater manufacturing method is characterized in that a frame body having a front wall, a rear wall and an end wall is fitted and integrated around the periphery. 2. The method for manufacturing a panel heater according to claim 1, wherein a flocked layer is provided on the surface of the planar heating element. 3. The method of manufacturing a panel heater according to claim 1, wherein a magnet is fixed to the back surface of the aluminum plate. 4. The panel heater manufacturing method according to claim 1, wherein a unitized controller is incorporated in the frame body.