KR20120035668A

KR20120035668A - Filament manufacturing method using carbon heating element and using the lamp

Info

Publication number: KR20120035668A
Application number: KR1020100097336A
Authority: KR
Inventors: 김재규
Original assignee: 김재규
Priority date: 2010-10-06
Filing date: 2010-10-06
Publication date: 2012-04-16

Abstract

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lamp using a carbon heating element, and in particular, a woven material using a carbon block, chopped or pulverized carbon fiber, a carbon nonwoven fabric, short carbon fiber and short carbon fiber as a raw material or a plurality of combinations of two or more thereof as raw materials. Selecting a first step; A second step of producing a polymer by using the material having a high melting point after curing after curing or at room temperature drying; A third step of uniformly infiltrating the polymer produced through the second step into the raw material selected through the first step; A fourth step of thermally compressing the raw material in which the polymer is uniformly infiltrated through the third step through a heat press process of less than about 300 ° C. in the form of a plate; And a fifth step of molding (cutting or bending) the plate pressed through the fourth step in a high temperature (950 ° C. to 3000 ° C.) vacuum or an inert atmosphere or a hydrocarbon atmosphere in a high temperature furnace. By providing a filament manufacturing method and a lamp using the same, the carbon heating element is formed into a plate-shaped plate, and then the shape and pattern of the filament can be arbitrarily formed by cutting the carbon heating element, thereby imparting various characteristics to one filament. And mass production is possible.

Description

Filament manufacturing method using carbon heating element and using the lamp}

The present invention relates to a lamp using a carbon heating element, and in particular, by forming the carbon heating element into a plate-shaped plate and then cutting it, the shape and pattern of the filament can be arbitrarily formed, thereby giving various properties to a single filament. The present invention relates to a filament manufacturing method using a carbon heating element and a lamp using the same, to enable mass production.

In general, a lamp is also called a light bulb, which uses a light generated by heating a high temperature by flowing an electric current through a filament installed inside the vacuum tube, or as a lamp for a heater using heat to generate heat if necessary. .

This may illustrate a configuration in which a filament is installed inside the vacuum state and a terminal connected to the filament is installed at both ends of the glass tube. In addition, when a tungsten platen is installed along the axis of the glass tube and the iodine gas is enclosed in the tube to send a current to the filament (when power is applied), the tungsten atoms generated in the filament are combined with iodine in the tube wall to become tungsten iodide and return to the filament, Here, it is used as a high efficiency lamp that can be used for a long time by a so-called iodine cycle that decomposes and leaves tungsten in the filament.

However, this type of lamp has a problem that the damage of the filament is weak to external impact, the durability is weak due to deformation of the shape due to heating, etc., there is a burden such as the cost of installing the coil.

On the other hand, carbon yarns used for surface heating elements and the like use carbon fiber bundles of fine thickness as a group. For example, if the carbon fiber consists of 26400 pieces, the resistance is about 60 ohms when the length is 1 meter and the diameter is 0.3 mm. Therefore, based on this design the desired output (watt) to produce a planar heating element. Of course, in this case, the resistance is

(R; resistance, rho; resistivity, l; length, s; unit area). However, these are used as a heat generating source of the planar heating element is mainly designed to dissipate the temperature of about 50 to 70 degrees, if there is a risk of fire, it is oxidized with air and the durability is significantly reduced.

On the other hand, a heater incorporating a carbon yarn as a heat source was developed in a vacuum tube, and the carbon yarn is set to provide a desired output by setting a resistance value in a constant bundle, or the technology of fixing the carbon yarn to a terminal and focusing the carbon yarn Due to the lack of technology, it is difficult to industrialize. An example of such a technique is known as a carbon-based heating element disclosed in Japanese Patent Application Laid-Open No. 2000-123960, which has a cap-type electrode part 2 at both ends of the carbon-based heating element 1 as shown in FIG. 1. ) And the cap-shaped electrode portion 2 are embedded in the vacuum sealing container 3, and the cap-shaped electrode portion 2 is connected to the lead wire 4 to apply power.

As shown in FIG. 2, the lead wires 4 form a fixed shape in which the outer periphery of the bundle of carbon-based carbon yarns 6 composed of a plurality of bundles is wound with a carbon chamber 7 to form a carbon flux 5.

FIG. 3 is an exemplary view configured to provide a bundle of carbon yarns 6 necessary in this case. Each of the three strands wound around a certain bundle of carbon yarns 6 with a carbon yarn 7 and wound with a carbon yarn 7 is shown. The carbon body 5 of the structure which winds together with the carbon chamber 7 'and makes it integral is shown.

That is, both ends thereof are formed by using a unit carbon body 5 as shown in FIG. 2 or a heating element 1 made up of a plurality of carbon bodies 5 wound with a carbon strand 7 'as shown in FIG. 3. It is molded to cover the vacuum sealing container (3) by coupling to the electrode portion (2) in the form of a cap.

However, this method uses the desired number of bundles of desired carbon yarns (6) to create the desired resistance value to use the desired output (W), but the hassle of having to bind the carbon yarn (6) to the carbon chamber (7), If necessary, there is a problem such as impregnating the liquid resin as necessary so that the bundled carbon chamber 7 is not peeled off.

On the other hand, instead of increasing the number of strands as a way to increase the output was proposed a way to increase the output by increasing the length, which is known as Japanese Patent Laid-Open No. 2002-63870 (US Patent Publication No. 2001 / 0055478A1). This can be illustrated as shown in Figure 4, the both ends of the vacuum sealing container (3) to the lead wires 4, the both ends of the vacuum sealing container (3) to the fixed terminal 3-1 for fixing the lead wire (4) ) And the electrode piece 4-1 which is placed so as to be conductive, and the coil band-shaped carbon filament 10 is provided with a space holder 11 at a predetermined length so as to be supported on the inner wall of the vacuum hermetic container 3. . Both ends of the carbon filament 10 is provided with a fixed terminal 20 having a sleeve 20-1 for applying power, and the fixed terminal 20 is a sleeve 20-1 and a sleeve 20-1. It is configured to include a connecting piece 20-2 integrally coupled to the intermediate terminal 20-3.

In one embodiment of the fixed terminal 20, the connecting piece 20-2 bent in a step shape as shown in FIG. 1) and the graphite paper 20-4, which is placed in the space of the sleeve 20-1 and the connecting piece 20-2, and functions to surround the coiled carbon filament 10.

Another embodiment of the fixed terminal 20 is a cylindrical sleeve 20-1 and the coil-shaped carbon yarn filament is placed in the inner diameter of the sleeve 20-1, as shown in FIG. 10) and the inner and outer graphite paper 20-4 and 20-41 surrounding the inner and outer diameter portions of the carbon filament 10, and the graphite paper 20-4 inside the inner graphite paper 20-4. ) And the inner sleeve 20-5 for clamping and fixing the carbon filament 10 with the elastic force to close and fix the inner diameter portion of the sleeve 20-1, and the end portion at the center of the inner sleeve 20-5. It consists of the connection piece 20-2 extended to and connected with the intermediate terminal 20-3.

However, such a technique is to perform the function of simply fixing the carbon filament 10 to the intermediate terminal 20, so that the function of positioning the center of the vacuum hermetic container 3 is weak so that a separate space holder 11 is installed. There is a problem to be done. And the structure of Figure 5 is simply bent structure to fix the carbon filament (10) is difficult to be fixed in place when the bending holding force is weakened durability is weakened, the structure of Figure 6 is the inner diameter portion of the cylindrical sleeve There is a problem in that it is easy to be separated when the impact due to the settlement method, workability is poor. In addition, since the carbon filament 10 is formed in a band shape by arranging the carbon yarns in a predetermined width, the binding strength between the carbon yarns is weak, so that the carbon yarns forming the carbon yarns during impact or long-term use are separated from each other and the durability is weakened. have.

In addition to the above-described methods, there are types of cylindrical meshes, each of which has the above-mentioned disadvantages, and methods using carbon filaments, which have been proposed so far, are difficult to mass-produce, and difficult to control characteristics or heat distribution. Yes, it is limited.

An object of the present invention for solving the above problems, relates to a lamp using a carbon heating element, in particular, by forming the carbon heating element into a plate-shaped plate and then cutting the shape and pattern of the filament arbitrarily through this The present invention provides a method of manufacturing a filament using a carbon heating element and a lamp using the same to impart various properties to a single filament and to enable mass production.

Features of the filament manufacturing method using a carbon heating element according to the present invention for achieving the above object is a single type or a woven material using a carbon block, cut or pulverized carbon fiber, carbon nonwoven fabric, short carbon fiber and short carbon fiber A first step of selecting a plurality of kinds through a combination of two or more as raw materials; A second step of producing a polymer by using the material having a high melting point after curing after curing or at room temperature drying; A third step of uniformly infiltrating the polymer produced through the second step into the raw material selected through the first step; A fourth step of thermally compressing the raw material in which the polymer is uniformly infiltrated through the third step through a heat press process of less than about 300 ° C. in the form of a plate; And a fifth step of molding (cutting or bending) the plate pressed through the fourth step in a high temperature (950 ° C. to 3000 ° C.) vacuum or a high temperature furnace in an inert atmosphere or a hydrocarbon atmosphere.

An additional feature of the filament manufacturing method using a carbon heating element according to the present invention for achieving the above object is a powder having stability at high temperature by combining with carbon block or carbon in the process of producing a polymer in the second step. To mix.

An additional feature of the filament manufacturing method using the carbon heating element according to the present invention for achieving the above object is that in the forming step of the fifth step, the molding pattern is regularly or in a pattern intended for the heating distribution It is to process regularly.

An additional feature of the filament manufacturing method using the carbon heating element according to the present invention for achieving the above object is the heat treatment in a furnace (2500 ℃ or more) of the inert and vacuum atmosphere material formed through the fifth step It further comprises the step of high purity graphite.

As expected effects due to the above-described features of the present invention, a uniform and transparent light can be obtained without black wire (non-heating) due to protruding of the filament fibers, which is a disadvantage of the carbon fiber, and a wider range than the existing carbon heater. Power Density and Line Density can be obtained, and it is possible to design and manufacture easily in the manufacture of lamps requiring the intended temperature distribution. (For example, in the case of printing lamps, the light distribution is 110% (left)-100%) (Central part)-110% (right part)

In addition, by using a low-cost carbon block as well as a simple carbon fiber, it can bring down the cost and mass production.

1 is a configuration diagram of a typical carbon-based heating element
FIG. 2 is an enlarged view of main parts of the carbon body used in FIG. 1; FIG.
3 is an exemplary view showing a state of binding using three carbon flux bodies of FIG.
4 is a plan view of a typical spring-type carbon yarn lamp heater
5 is an enlarged cross-sectional view showing an embodiment shown in the state AA line of FIG.
6 is an enlarged cross-sectional view showing another embodiment shown in the BB line state of FIG.
7 is an exemplary view showing a shape example of a filament using the carbon heating element according to the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS The above and other objects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings, in which: FIG.

7 is an exemplary view showing a shape example of a filament using the carbon heating element according to the present invention.

First, looking at the filament manufacturing method using a carbon heating element according to the present invention.

Step 1: The raw material is selected from a single type or a combination of two or more of the woven materials using carbon black, cut or pulverized carbon fibers, carbon nonwoven fabrics, short carbon fibers and short carbon fibers.

Step 2: A polymer is produced by utilizing a substance which is cured during waste play or room temperature drying and has a high melting point after curing. At this time, it is preferable to mix the powder having stability at high temperature by combining with the carbon block or carbon in the process of producing a polymer.

Step 3: The polymer produced through the step 2 is uniformly infiltrated into the raw material selected through the step 1, in which an immersion method or the like may be used.

Step 4: The raw material in which the polymer is uniformly infiltrated through Step 3 is thermally compressed in a plate form using a heat press process of less than about 300 ° C. to make a very thin and uniform surface.

Step 5: The plate pressed through the step 4 is molded (cut or bent) into a pattern as shown in FIG. 7 attached in a high temperature (950 ° C. to 3000 ° C.) vacuum or a high temperature furnace in an inert atmosphere or a hydrocarbon atmosphere. )

Therefore, in the molding process as shown in FIG. 7, the molding pattern may be processed regularly or irregularly in a pattern intended for heat generation, and thus may have a plurality of characteristics through one filament. It is possible to form in any of a variety of shapes that are most suitable for the lamp in accordance with the form applied to the lamp in the future.

Step 6: In addition, the material molded through Step 5 may be heat treated in a furnace (at 2500 ° C. or higher) in an inert and vacuum atmosphere for high purity graphite.

Therefore, if the filament manufacturing method using the carbon heating element according to the present invention is applied, a uniform and transparent light can be obtained without black wire (non-heating) due to the protruding of the filament fiber, which is a disadvantage of the carbon fiber, and is wider than the conventional carbon heater. Power Density and Line Density in the range can be obtained, and in the manufacture of lamps that require the intended temperature distribution, for example, in the case of printing lamps, the light distribution is 110% (left)-100% (center)-110% (right) Since differentiation is required, it is possible to easily design and manufacture by adjusting the cutting thickness and bending degree as shown in FIG. 7 in one carbon filament (heating element).

At this time, the drawing shown in the upper portion of Figure 7 is purely cut to the carbon plate of the flat planar, in such a cutting, the resistance value is changed according to the thickness of the cutting and the characteristics are changed accordingly.

On the contrary, the attached drawing shown in the lower part of FIG. 7 performs the bending process based on the state of being primarily cut as shown in the upper part of FIG. 7, which affects the arrangement of the filament and the characteristics of the lamp. Element.

In addition, by using not only simple carbon fiber but also expensive carbon block, etc., the cost can be reduced. The process can be automated and mass-produced as it is completed by forming a plate and then cutting it.

Looking at the performance by comparing the filament and the conventional filament completed through such a manufacturing process, as shown in the table summarized below.

While the invention has been shown and described with respect to the specific embodiments thereof, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined by the appended claims. Anyone with it will know easily.

Claims

A first step of selecting a single kind or a plurality of kinds through a combination of two or more among the woven materials using carbon black, cut or pulverized carbon fibers, carbon nonwoven fabrics, short carbon fibers and short carbon fibers;
A second step of producing a polymer by using the material having a high melting point after curing after curing or at room temperature drying;
A third step of uniformly infiltrating the polymer produced through the second step into the raw material selected through the first step;
A fourth step of thermally compressing the raw material in which the polymer is uniformly infiltrated through the third step through a heat press process of less than about 300 ° C. in the form of a plate; And
And a fifth step of forming (cutting or bending) the plate pressed through the fourth step in a high temperature (950 ° C. to 3000 ° C.) vacuum or an inert atmosphere or a hydrocarbon atmosphere in a high temperature furnace. Filament manufacturing method using.

The method of claim 1,
The method of producing a filament using a carbon heating element, characterized in that in the second step of producing a polymer in combination with a carbon block or carbon powder having stability at high temperature.

The method of claim 1,
The filament manufacturing method using the carbon heating element, characterized in that in the molding step of the fifth step, the molding pattern is cut regularly or irregularly cut into a pattern intended for heat generation distribution.

The method according to claim 1 or 3,
In the forming step of the fifth step, the filament manufacturing method using a carbon heating element, characterized in that the secondary processing by bending the workpiece in the state in which the cutting process is finished uniformly or non-uniformly.

The method of claim 1,
A method of manufacturing a filament using a carbon heating element further comprising the step of heat-treating the material formed through the fifth step in a furnace (at 2500 ° C. or higher) in an inert and vacuum atmosphere.

A lamp using a carbon heating element, characterized in that made using the filament using the carbon heating element according to the manufacturing method described in claim 1 to claim 5.