KR101847008B1 - Carbon Heater Assembly and Manufacturing Method thereof - Google Patents

Abstract

The present invention relates to a carbon heater assembly method. A carbon heater includes: multiple carbon heating wires which are installed in parallel, have carbon conductors in straight lines, and have carbon heating wire coating units made of an insulating material to surround the carbon conductors; multiple connection wires which are arranged in a direction perpendicular to the longitudinal direction of the carbon heating wires and have core wires made of a conductive material as well as having connection wire coating units made of an insulating material surrounding the core wires individually; and a connection unit electrically interconnecting the connection wires and carbon heating wires. The carbon heating wires have contact grooves formed on a connection wire intersection area in a thickness direction to reach the carbon conductors. The connection wires have guide holes formed on the exposed part of the core wires and have cut areas intersecting the carbon heating wires to partially expose the core wires while being formed as a single body. The connection unit includes a coupler and a protection wrap. The coupler has a coupler head unit and a coupler body unit which is extended to have a smaller cross-sectional area than the coupler head unit from the lower surface of the coupler head unit, has the lower surface of the coupler head unit electrically connected to the exposed part of the core wires, and has the coupler body unit enter the inside of the contact groove through the guide hole to be electrically connected to the carbon conductors. The protection wrap is made of an insulation material and is installed on the carbon heating wires to surround the exposed parts of the core wires and coupler. Accordingly, the present invention enables a manufacturing operation without dividing the connection wires while maintaining the stable electrical connection between the connection wires and carbon heating wires.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a carbon heater assembly,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a carbon heater assembly, and more particularly, to a carbon heater assembly having a plurality of carbon hot-wire lines arranged in parallel with each other and a method of manufacturing the same.

Electric warming devices (electric mattresses, electric mattresses, floor electric mattresses, electric mattresses for beds, electric cushions, floor heating devices, heating heating pads, electric heating carpets, heating electric panels, etc.) .

Recently, a method of assembling a carbon heating wire including a carbon electric conductor having a resistance heating characteristic and using the heating wire as a resistance heating element of an electric heating device has been used have.

Fig. 11 is a view showing the entire configuration of a conventional carbon heater assembly, Fig. 12 is a view showing a connection region of a conventional carbon heater assembly, Fig. 13 is a view showing a connection port of a conventional carbon heater assembly, 16 and 17 are views respectively showing an upper protective envelope of a conventional carbon heater assembly, and Figs. 18 and 19 are views showing a conventional carbon heater assembly using a connecting portion, respectively, Fig. 2 is a view showing a method of forming an assembly.

As shown in these drawings, the conventional carbon heater assembly includes a carbon heating wire 111 arranged to be parallel to each other, a connecting line 112 disposed to be perpendicular to the longitudinal direction of the carbon hot wire 111, a connecting line 112, And a connecting portion 120 for electrically connecting the carbon heating wires 111 to each other.

Each carbon heating wire 111 has a linear carbon coating 111a and a carbon hot wire coating 111b of an insulating material (PP or the like) surrounding the carbon coating 111a so that both ends of the carbon coating 111a are exposed. Lt; / RTI >

Each of the carbon heating wires 111 is formed with a restraining hole 111c at both ends by a method such as drilling.

The connecting line 112 is divided so as to correspond to a section between the carbon hot wires 111. For convenience of explanation, each of the divided connecting lines is referred to as a divided connecting line 112 '.

The split connection line 112 'has a core wire 112'a of a conductive material and a connection wire cover 112'b of an insulating material surrounding the core wire 112'a.

The core wire 112'a may be composed of a single wire or a stranded wire.

The divided connection line 112 'having such a configuration is installed between the carbon heating wires 111.

Each connection unit 120 includes a connection port 130 coupled to the split connection line 112 ', a fastener 121 and a protective wrapper 140 provided on the carbon hot wire 111, And has an O-ring 122.

The connection port 130 has a connection port body 131 in which a fastening hole 131a is formed at the center and a pair of connection arms 132 extending in a direction away from the connection port body 131.

The connection arm 132 is formed with a pair of core wire crimping vanes 132a.

The connection port 130 is made of a conductive material such as copper, nickel, or the like.

The connection port 130 having such a configuration is a method of pressing the core wire crimping vane 132a so that each connection arm 132 is brought into pressure contact with the core wire 112'a of the adjacent pair of split connection wires 112 ' Is coupled to the end of the split connection line 112 'of the pair.

The fastening tool 121 is installed along the thickness direction of the carbon hot wire 111 so as to pass through the fastening hole 131a. Here, the fastener 121 is installed so that the connection port body 131 is electrically connected to the carbon conductor 111a. In this embodiment, the fastening tool 121 is implemented as a screw.

The protective envelope 140 is divided into a lower protective envelope 141 and an upper protective envelope 142.

The lower protective envelope 141 is formed to have a substantially cross shape in its entire shape and a concave shape in its cross section.

The lower protective envelope 141 is formed with a lower exposed side wall 141a at one end of a cross shape and a lower end O-ring groove 141b at three ends where the lower exposed side wall 141a is not formed have.

The lower protective wrapper 141 has a restricting pin 141c and a coupling groove 141d formed on its inner surface.

The upper protective envelope 142 is formed in a substantially cross shape in its entire shape and a concave shape in its cross section.

The upper protective wrapper 142 is formed with an upper exposed outer wall 142a at one end of a cross shape and an upper upper outer ring groove 142b at three ends where the upper exposed outer wall 142a is not formed have.

The upper protective bell 142 has a pin escape groove 142c and a coupling protrusion 142d formed on its inner surface.

The protective envelope 140 having such a configuration is made of an insulating material such as ABS.

A method of manufacturing a carbon heater assembly having the above-described structure will be described with reference to FIGS. 11, 12, 18, and 19.

First, the two O-rings 122 are divided into adjacent split connecting lines 112 '(see FIG. 18).

Next, one O-ring 122 is installed in a region for installing the protective wrapper 140 of the carbon hot wire 111 (see Fig. 18).

Next, the connection port 130 is coupled to the end of the split connection line 112 '(see FIG. 18).

Next, the fastening tool 121 is mounted on the carbon hot wire 111 (see Figs. 18 and 19).

The lower protective sleeve 141 is installed on the carbon hot wire 111 so that the restraining pin 141c enters the restraining hole 111c and the three O-rings 122 enter the lower O-ring groove 141b 12). Here, the lower protection cover 141 is installed such that the lower exposed-face opening wall 141a surrounds the exposed surface of the carbon-made conductive body 111a.

Then, the engaging protrusion 142d enters into the engaging groove 141d, the upper exposed face wall 142a surrounds the exposed surface of the carbon coated body 111a, and an O-ring 122 is inserted into the upper O- The upper protective wrapper 142 is installed above the lower protective wrapper 141 (see FIG. 11). The upper end of the restraining pin 141c enters the pin escape groove 142c when the upper protective envelope 142 is installed.

Finally, the upper protective envelope 142 and the lower protective envelope 141 are joined by a heat fusion method or the like.

According to the above-described conventional carbon heater assembly and its manufacturing method, the carbon heater disclosed in Korean Patent Laid-Open Publication No. 10-2010-112914 (published on Oct. 20, 2010, entitled " It is possible to solve the problems of the assembly (that is, it is difficult to stably maintain the electrical connection state between the connection line and the carbon hot wire, and to assemble the core wire and the connection line so as to be electrically connected) , The following problems occur. Korean Patent Laid-Open Publication No. 10-2010-112914 does not divide the connection line. That is, the connection line is integrally formed.

According to the conventional carbon heater assembly and its manufacturing method, it is necessary to divide the connecting line 112, expose the core wire at both ends of each divided connecting line 112 ', electrically connect the divided connecting lines 112' There is a problem in that a manufacturing operation is complicated because a connection port 130 for electrically connecting the connection lines 112 'is required.

Since the split connection line 112 'and the carbon hot wire 111 are electrically connected through the connection port 130 and the fastening hole 121, the electrical connection state between the connection line 112 and the carbon hot wire 111 is stably maintained There is a problem in that it is difficult to do.

A related prior art document is Korean Patent Registration No. 10-1647403 (registered on Aug. 04, 2016, entitled: Carbon Heater Assembly), which discloses a conventional carbon heater assembly and a manufacturing method thereof Is disclosed.

Accordingly, it is an object of the present invention to provide a carbon heater assembly and a method of manufacturing the same, which can easily perform a manufacturing operation without dividing a connecting line and stably maintain an electrical connection state between a connecting line and a carbon hot wire.

According to the present invention, there is provided a method of manufacturing a carbon fiber heating structure, comprising a plurality of carbon heating wires provided in parallel with each other and having a carbon steel wire as a whole and a carbon steel wire covering material of an insulating material surrounding the carbon steel wire as a whole, A plurality of connection lines provided vertically and each having a conductor wire of a conductive material and an insulation material surrounding the core wire and a connection portion for electrically connecting the connection wire and the carbon hot wires to each other, Wherein a contact groove is formed along the thickness direction so that the carbon hot wire reaches an entire region of the carbon conductor in an area intersecting the connecting line; Wherein the connecting line is formed as a single body, a region intersecting with the carbon hot wire is partially cut so that the core wire is partially exposed, and a guide hole is formed through the exposed portion of the core wire; Wherein the connection portion has a fastener body portion extending from the bottom surface of the fastener head portion to have a cross-sectional area smaller than that of the fastener head portion, the bottom surface of the fastener head portion being electrically connected to the exposed portion of the core wire, Wherein the fastening body is formed of an insulating material so as to be inserted into the contact groove through the guide hole so as to be electrically connected to the entire carbon figure, A contact groove forming step of forming a contact groove along the thickness direction so as to reach the carbon conductor in an area intersecting the connection line of the carbon heater wire or the carbon heater wire; A core wire exposing step of cutting out a region intersecting the carbon hot wire of the connection wire to partially expose the core wire; A guide hole forming step of forming a guide hole through the exposed portion of the core wire among the connection wires; Wherein a fastener having a fastener body portion and a fastener body portion extending from the bottom surface of the fastener head portion to have a cross sectional area smaller than that of the fastener head portion is electrically connected to the exposed portion of the core wire, A fastener-installing step of inserting the fastener body into the contact groove through the guide hole so as to be electrically connected to the entire carbon frame; And installing a protective envelope made of an insulating material on the carbon hot wire to surround the fastener and exposed portions of the core wire.

It is preferable that the contact groove is formed so as to penetrate the carbon hot wire so that a fastener can be easily formed using the rivet.

Therefore, according to the present invention, the connecting wire is formed as a single body, the connecting wire is cut so that the core wire in the region intersecting with the carbon hot wire is partially exposed, and the core wire exposed portion and the carbon wire are electrically connected to each other The connection line is fixed to the carbon heating wire, so that the manufacturing work is facilitated without dividing the connection line.

Since the connecting wire and the carbon hot wire are electrically connected through the fastening hole only, the electrical connection state between the connecting wire and the carbon hot wire can be stably maintained.

1 is an overall structural view of a carbon heater assembly according to an embodiment of the present invention;
FIGS. 2, 3, 4, 5, 6, 7, 8, 8, 9, and 10 are views showing a structure and a manufacturing method of a carbon heater assembly according to an embodiment of the present invention, respectively. ,
11 is an overall structural view of a conventional carbon heater assembly,
12 is a view showing a connecting region of a conventional carbon heater assembly,
13 is a view showing a connection port of a conventional carbon heater assembly,
14 and 15 are views respectively showing a lower protective envelope of a conventional carbon heater assembly,
Figs. 16 and 17 are diagrams respectively showing an upper protective envelope of a conventional carbon heater assembly,
18 and 19 are views showing a method of forming a conventional carbon heater assembly using a connecting portion, respectively.

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

FIG. 1 is an overall structural view of a carbon heater assembly according to an embodiment of the present invention, and FIGS. 2, 3, 4, 5, 6, 7, 8, 8, 9, 1 is a view showing a structure and a manufacturing method of a carbon heater assembly according to an embodiment of the present invention. 9 is a sectional view taken along the line A-A 'in Fig.

As shown in these drawings, the carbon heater assembly according to the embodiment of the present invention includes a carbon hot wire 11 installed so as to be parallel to each other, a connection line 12 disposed to be perpendicular to the longitudinal direction of the carbon hot wire 11, , And a connecting portion (20) for electrically connecting the connecting wire (12) and the carbon hot wire (11).

Each carbon heating wire 11 has a linear carbon coating 11a and a carbon hot wire coating 11b of an insulating material (PP or the like) surrounding the carbon coating 11a so that both ends of the carbon coating 11a are exposed. Lt; / RTI >

A contact groove 11c is formed at both ends of each of the carbon heating wires 11 by a method such as drilling.

The contact groove (11c) is formed in a region intersecting with the connecting line (12) through the thickness direction. The contact groove 11c need not necessarily be formed to penetrate the carbon hot wire 11, but it is sufficient to form the contact groove 11c so as to reach at least the carbon conductor 11a.

Each connecting line 12 is formed as a single body. In this specification, a unitary body is not divided to correspond to a section between the carbon hot wires 11.

Each connecting line 12 has a core wire 12a made of a conductive material and a connecting wire covering 12b made of an insulating material surrounding the core wire 12a.

The core wire 12a may be composed of a single wire or a stranded wire.

Each of the connecting lines 12 is cut in a region intersecting with the carbon hot wire 11 so that the core wire 12a is partially exposed.

The guide hole 12d is formed to penetrate through the exposed portion 12c of the core wire 12a (hereinafter referred to as "core wire exposed portion").

Each connecting portion 20 has a fastener 21 and a protective envelope 40 provided on the carbon hot wire 11.

The fastening tool 21 has a fastener head 21a and a fastener body 21b extending from the bottom of the fastener head 21a to have a cross sectional area smaller than that of the fastener head 21a.

The fastener 21 having such a configuration is configured such that the bottom surface of the fastener head portion 21a is electrically connected to the core exposed portion 12c and the fastener body portion 21b is in contact with the contact groove 12c through the guide hole 12d 11c so as to be electrically connected to the carbon conductor 11a.

The fastening tool 21 may be implemented using rivets, screws, or the like.

The protective envelope 40 is installed in the carbon hot wire 11 so as to surround the fastener 21 and the core exposed portion 12c.

The protective envelope 40 may be formed by molding, a method similar to the conventional protective envelope shown in Figs. 14 and 16, or the like. The protective envelope 40 is made of an insulating material such as ABS.

A method of manufacturing a carbon heater assembly according to an embodiment of the present invention will now be described with reference to FIGS. 2 to 10. FIG.

First, a contact groove 11c is formed in a region of the carbon hot wire 11 which intersects with the connecting line 12 (see FIG. 2).

Next, a portion of the connecting line 12 intersecting with the carbon hot wire 11 is cut off to partially expose the core wire 12a (see FIG. 3).

Next, a guide hole 12d is formed in the core exposed portion 12c (see FIG. 4 and FIG. 5).

The bottom surface of the flange 21'a is electrically contacted to the core wire exposed portion 12c and the rivet body portion 21'b is passed through the contact groove 11c and the guide hole 12d so that the blind rivet , 21 ', Figs. 6 and 7).

Next, the shank 21'c is pulled so as to be separated from the flange 21'a and the rivet body portion 21'b so that the outer surface of the rivet body portion 21'b is inserted into the contact groove 11c (See Figs. 8 and 9). When the outer surface of the rivet body portion 21'b is brought into contact with the inner surface of the contact groove 11c, the core wire exposed portion 12c and the carbon conductor 11a are electrically connected. When the outer surface of the rivet body portion 21'b contacts the inner surface of the contact groove 11c, the fastener setting step is completed.

The flange 21'a forms the fastener head 21a and the rivet body 21'b is in the state where the shank is separated from the flange 21'a and the rivet body 21'b, Thereby forming the fastener body 21b.

Finally, a protective envelope 40 is installed on the carbon hot wire 11 (see Fig. 10).

As described above, according to the embodiment of the present invention, the connecting line 12 is formed as a single body, the connecting line 12 is cut so that the core wire 12a in the region intersecting the carbon hot wire 11 is partially exposed, The core wire exposed portion 12c and the carbon conductor 11a are electrically connected to each other and the connecting wire 12 is fixed to the carbon hot wire 11 by using the ball 21 so that the connecting wire 12 is not divided The manufacturing work is facilitated.

Since the connecting wire 12 and the carbon hot wire 11 are electrically connected to each other only through the fastener 21, the electrical connection state between the connecting wire 12 and the carbon hot wire 11 can be stably maintained.

Further, by forming the contact groove 11c so as to penetrate the carbon hot wire 11, the fastener 21 can be easily formed by using the rivet.

11, 111: carbon hot wire 12, 112: connecting wire
20, 120: connecting portion 21, 121:
40, 140: Protective wrapper 130:

Claims (4)

A plurality of carbon heating wires provided so as to be parallel to each other and each having a straight carbon wire conductor and an insulating carbon carbon wire wrapping surrounding the carbon conductor; And a connection portion for electrically connecting the connection line and the carbon hot wire to each other, the carbon heater assembly comprising: a plurality of connection lines,
A contact groove is formed along the thickness direction so that the carbon hot wire reaches an entire region of the carbon conductor in an area intersecting the connecting line;
The connecting line is formed as a single body, a region intersecting with the carbon hot wire is partially cut so that the core wire is partially exposed, a guide hole is formed through the exposed portion of the core wire,
Wherein the connection portion has a fastener body portion extending from the bottom surface of the fastener head portion to have a cross-sectional area smaller than that of the fastener head portion, the bottom surface of the fastener head portion being electrically connected to the exposed portion of the core wire, Wherein the fastening body is formed of an insulating material so as to be inserted into the contact groove through the guide hole so as to be electrically connected to the entire carbon figure, And a protective envelope provided on the outer surface of the carbon heater assembly. The method according to claim 1,
And the contact groove is formed to penetrate the carbon hot wire. And a plurality of carbon hot-wire lines, each of the carbon hot-wire lines being disposed in parallel with each other and each having a straight carbon footprint and an insulating carbon-sheathed sheath surrounding the entire carbon footprint, A plurality of connection lines provided with a plurality of connection lines each provided with a conductor wire of a conductive material and an insulation material surrounding the core wire and a connection portion for electrically connecting the connection line and the carbon heating wires, A method of manufacturing a heater assembly,
A contact groove forming step of forming a contact groove along the thickness direction so as to reach the carbon conductor in an area intersecting the connecting line among the carbon heating wires;
A core wire exposing step of cutting out a region intersecting the carbon hot wire of the connection wire to partially expose the core wire;
A guide hole forming step of forming a guide hole through the exposed portion of the core wire;
Wherein a fastener having a fastener body portion and a fastener body portion extending from the bottom surface of the fastener head portion to have a cross sectional area smaller than that of the fastener head portion is electrically connected to the exposed portion of the core wire, A fastener-installing step of inserting the fastener body into the contact groove through the guide hole so as to be electrically connected to the entire carbon frame;
And installing a protective envelope made of an insulating material on the carbon hot wire so as to surround the fastener and exposed portions of the core wire. The method of claim 3,
Wherein the contact groove forming step is carried out such that the contact groove is penetrated through the carbon hot wire.

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