RU2337507C1 - Method of manufacture of flat resistive electric heater and installation for its implementation - Google Patents

Abstract

FIELD: electricity.

SUBSTANCE: inventions are related to electrical engineering and may be used in manufacture of resistive type heaters. Method of flat resistive heater manufacture consists in the following: for formation of resistive element tape resistive material is used, which is shaped on insulating polymer base. During formation resistive element is installed in the form of several strips along base, for that purpose resistive tape is freely fixed in the beginning of insulating base in the form of sinusoid across it, then top loops of sinusoid are caught and stretched along base in the other direction to the necessary length in the form of strips that are parallel to lateral sides of base. Then strip ends are fixed on the other end of base, at the same time roll of aluminium foil is stretched with tension from the bottom between resistive tape element and insulating base as well as roll of insulating film on the top of resistive element, thus packet is formed, in which all specified elements are assembled. Prepared packet is subjected to thermal treatment, melting insulating films with the help of laminator and tightly pressing the packet as a whole. Suggested installation for manufacture of flat resistive electric heater includes the following units: device for installation of resistive element (2) with several protruding elements (3) - roll pins - and clamping accessory (4), transportation tape that stretches along trajectory corresponding to configuration of heater, gripping device, bypassing device for installation of resistive element (2) along specified trajectory, connection device for connection of heater parts. Movable carriage (10) and braking carriage (12) are connected between each other and to drive unit (13) with the help of pulling cable (20). The main units are mounted on technological table (21), which consists of field-cover fixed in supports, on which guides (22) are fixed for movement of carriages.

EFFECT: simplification of technology and equipment and reduction of manufacture labour intensity with increase of functional efficiency.

2 cl, 4 dwg

Description

The invention relates to electrical engineering and can be used in the manufacture of resistive heaters.

A known method of manufacturing a flat resistive electric heater, described in p. RF No. 2052907.

The known method is that they form a zigzag ribbon resistive element, performing counter-parallel alternating slots on the resistive tape, perpendicular to the axis of the tape. The resistive element is placed on an insulating base, insulating layers are installed outside and the elements are fastened with a binder, and the slots are made alternating through the same distance, of the same length, not reaching the edges of the tape on both sides by the size of the technological field and shifted alternately relative to one another across the width of the tape by a value equal to or greater than the alternation step, one of the technological fields of the tape is cut to the interface of the cut with the ends of the slots closest to this edge, forming a petal and, the placement of the resistive element on the base is performed by introducing the base from the side of the cut-off technological field between the petals, alternating through one insulating base, and then cut off the other technological field until the cut is mated with the ends of the slots closest to the tape edge. All elements are fastened together by a binder in the form of VK-350 glue.

The disadvantage of this method is the technological complexity of its implementation, which consists in the need to perform a large number of slots when forming a zigzag resistive element, the formation of the technological field and the gluing process. The product itself - the heater has a significant positive temperature coefficient (because of the complex chemical composition of the resistive layer is a non-linear element), which is why without special means it does not provide a stable temperature regime.

Closest to the technical nature of the claimed is a method of manufacturing a flexible resistive heater, described in the same patent of the Russian Federation No.2019065 class. HB05 3/34, z. 10/18/90, op. 08/30/94 and selected as a prototype.

A known method is as follows.

Electrodes are formed on one of the two polymer substrates, a resistive layer with a positive resistance coefficient is formed, an adhesive layer is applied, all these elements are combined into a bag and then heat treated, and initially, an adhesive layer made on the basis of each substrate is unwound from a roll a water-soluble acrylic copolymer and epoxy aniline resin, which is dried at a temperature of 110-120 ° C, form the specified resistive layer of a water-soluble copolymer OLD-02 EMA, epoxy anil a new resin, PDI-3AK rubber, graphite, carbon black, a water solvent or a water-alcohol mixture of a certain viscosity, which is then dried at a temperature of 110-120 ° C, and the insulating component of which is identical to the material of the adhesive layer on the second substrate, and when combined into a bag combine the resistive layer with the surface of the electrodes.

The disadvantage of this method is that it is quite complicated and time-consuming, because it involves applying an adhesive layer to each substrate, drying it at an elevated temperature, applying and drying a resistive layer of complex composition and not quite satisfactory heat transfer due to the implementation of its resistive layer from a water-soluble copolymer, epoxyaniline resin, rubber, graphite, carbon black, a solvent of water or a water-alcohol mixture.

A known installation for the manufacture of a flat electric heater, described in p. RF No. 2082282 class. HB05 3/34, z. 09/27/94, op. 06/20/97.

The known installation includes a backlash-free stamp with paired punches with a given width of the groove and matrix and with cutting edges made with an inward slope for die cutting of the resistive element from the foil, rolls for rolling the foil tape, devices for rolling the resistive element onto a heat-resistant insulating tape, cutting device for cutting along the protruding edges of the die cuts.

A disadvantage of the known installation is that it is intended for the manufacture of a flat resistive electric heater in the form of short strips of resistive material arranged transversely along the length of the heater, glued to a heat-resistant base with leveling the fields, the manufacturing technology of which is quite complicated.

Closest to the technical nature of the claimed is the installation for the manufacture of an electric heater from a metal wire (wire), described in s. No. 98115303 "System and method for manufacturing an electric heater" according to class. Н05В 3/34, А47С 7/74, 21/04, з. 08/17/98, op. 06/20/2000 and selected as a prototype.

The known installation comprises a device for laying wire of several protruding according to the arrangement of elements corresponding to the desired configuration of the heater, a conveyor belt provided with a bypass means and extending along a path essentially corresponding to the configuration of the heater, said conveyor belt is moved around said protruding elements, while said conveyor belt the tool is arranged to lay the specified conductor along the specified path, and the specified height upayuschie elements form part of a first fixture for the heater. The protruding elements are placed in such a way that adjacent loops essentially fit together. There is a gripping device with the ability to transfer the first heater and part of the styling device. The device for laying the conductor contains a clamping device for fixing the specified layout. The installation also contains a connecting device for connecting the parts of the heater into a single unit, creating a support for maintaining the layer of tape at the connection points of the conductor, as well as a sensor.

A disadvantage of the known installation is that the production is discrete, since the heater is made in the shape of the back or seat of the car, and does not allow to obtain a dimensional heater, and also not very effective in terms of functionality, because Designed to use wire; in addition, the method of manufacturing such a heater is very time consuming.

The objective of the claimed technical solutions is to simplify technology and equipment and reduce the complexity of manufacturing while increasing the functional efficiency of the heater manufactured with their help.

The problem is solved in that:

- in the method of manufacturing a flat resistive electric heater, which consists in forming a resistive element on an insulating polymer base, at least one insulating layer is installed on the outside, all these elements are connected in a bag and heat treated, according to the invention, a resistive tape is used to form the resistive element material, which when forming a resistive element is arranged in the form of several strips along the base, for which the resistive tape is freely fixed at the beginning of the insulating base in the form of a sinusoid across it, then grab the upper loops of the sinusoid and stretch them along the base to the other side to the required length in the form of strips parallel to the sides of the base, fix the ends of the strips on the other end of the base, while simultaneously stretching between the bottom with a resistive tape element and an insulating base, a roll of aluminum foil and a roll of a polymer insulating film on top of the resistive element, forming a package whose heat treatment fected by melting using a laminator insulating film and impacting the entire package in a single unit;

- in the installation for the manufacture of a flat resistive electric heater, including a device for laying a resistive element with several protruding elements and a clamping device, a conveyor belt extending along the path corresponding to the configuration of the heater, a gripping device, a bypass device for laying the resistive element along the specified path, a connecting device for connecting parts of the heater according to the invention, a styling device with protruding elements of races laid at the beginning of the conveyor belt and is respectively a carriage of two parts sequentially located above the conveyor belt parts - a fixed and a movable carriage with roller pins located on the adjacent edges of each of them in a row perpendicular to the axis of the conveyor belt, the clamping device is located on one of the sides of the fixed carriage , on the second side of it is placed a coil with a resistive tape element, the gripping device is removable, while movable the carriage together with the brake carriage and the drive unit located sequentially behind it, connected by a pulling cable, together form a bypass device for laying the resistive element along the length of the heater, the lamination unit is a connecting device, which includes laminating units that are arranged sequentially in height one above the other coils for the first film, the second film, aluminum foil and the third film, and pairwise mounted two pairs of heated rollers with a gap between them for skipping Ia layers heater.

The use of tape resistive material as a preform and its arrangement in several strips along the base length by stretching from a sinusoid in combination with simultaneous drawing of layers of insulating, resistive material and aluminum foil successively arranged along the height and heat treatment of the resulting package using a laminator can simplify the technology and reduce labor intensity manufacturing a flat resistive electric heater. The placement of the resistive element on aluminum foil provides an increase in the heat-carrying ability of the electric heater, i.e. increases its functional efficiency.

The installation of the installation device in the form of two consecutive fixed and movable carriages with protruding elements in the form of roller pins located on them in conjunction with the construction of the bypass device from the brake carriage and the drive unit when using a laminator and coils with insulation and conductive as a connecting device material provides a simple and reliable installation design, which allows to obtain a dimensional flat resistive heater, providing the specified result.

EFFECT: simplification of technology and device for manufacturing a film resistive heater while increasing its heat-carrying ability.

The inventive method has a novelty in comparison with the prototype, differing from it by such significant features as the use of tape resistive material, its location when forming the resistive element in the form of several strips along the base, by fixing the resistive tape freely at the beginning of the insulating base in the form of a sinusoid across it, subsequent capture of the upper loops of the sinusoid, stretching them along the base to the other side to the required length in the form of strips parallel to the side sides on the base, and fixing the ends of the strips on the other end of the base, simultaneous with stretching the resistive element, pulling with tension from below between the resistive tape element and the insulating base of the aluminum foil roll and above the resistive element of the insulating film roll to form a packet and heat treat the latter with a laminator, providing collectively achieving a given result.

The inventive installation has a novelty in comparison with the prototype, differing from it by such significant features as the location of the styling device with protruding elements at the beginning of the conveyor belt, its execution in the form of a carriage of two parts sequentially located above the conveyor belt - a fixed and a movable carriage with adjacent edges of each of them in a row perpendicular to the axis of the conveyor belt with roller pins, the placement of the clamping device on one of the sides a movable carriage, and a coil with a resistive tape element on the second side of it, the presence of a gripping device, a bypass device for laying the resistive element along the length of the heater from the movable carriage in conjunction with a brake carriage and a drive unit located successively behind it, use as a connecting devices of the lamination unit, including coils arranged sequentially in height one below the other for the first film, second film, aluminum foil and the third film, and pairwise installed two pairs of heated rollers with a gap between them to pass the heater layers, which together provide the desired result.

The applicant does not know the technical solutions possessing the indicated distinguishing features, which together ensure the achievement of the desired result, therefore, he considers that the claimed technical solution meets the criterion of "inventive step". The claimed technical solutions can find wide application in electrical engineering, and therefore meet the criterion of "industrial applicability". The claimed technical solutions are illustrated by drawings, where are shown on:

- figure 1 is a General top view of the installation for the manufacture of a flat resistive electric heater;

- figure 2 is a sectional view of the finished film electric heater;

- figure 3 is one of the possible positions of the carriages in the manufacturing process PEN;

- figure 4 is a schematic view of a laminator.

The inventive method of manufacturing a flat resistive electric heater is as follows. To form a resistive element, a tape resistive material is used, which is formed on an insulating polymer base. When forming, the resistive element is placed in the form of several strips along the base, for which the resistive tape is freely fixed at the beginning of the insulating base in the form of a sinusoid across it, then the upper loops of the sinusoid are captured and stretched along the base to the other side to the required length in the form of strips parallel to the side sides of the foundation. Then, the ends of the strips are fixed at the other end of the base, while simultaneously pulling a roll of aluminum foil between the resistive tape element and the insulating base and a roll of insulation film above the resistive element, forming a packet into which all these elements are connected. The resulting package is subjected to heat treatment, melting with a laminator, insulating films and tightly compressing the entire package into a single unit.

The inventive installation for the manufacture of a flat resistive electric heater includes the following nodes: a device 1 for laying a resistive element 2 with several protruding elements 3 - roller pins and a clamping device 4, a conveyor belt 5 extending along a path corresponding to the configuration of the heater, a gripping device 6, a bypass device 7 for laying the resistive element 2 along the specified path, a connecting device 8 for connecting the parts of the heater. At the same time, the stacking device 1 with the protruding elements 3 is located at the beginning of the conveyor belt 5 and is a carriage, respectively, of two parts sequentially located above the conveyor belt 5 parts - a fixed and a movable carriage 9 and 10 with rows located on the adjacent edges of each of them in a row perpendicular to the axis the conveyor belt 5 with roller pins 3. The clamping device 4 is located on one of the sides of the fixed carriage 9, on the second side of it there is a coil 11 with a resistive tape element 2. The gripping device 6 is removable. In this case, the movable carriage 10 in conjunction with the brake carriage 12 located successively behind it and the drive unit 13 together form a bypass device 7 for laying the resistive element 2 along the length of the heater. The connecting device 8 is a laminating unit, which includes coils 14-17 arranged sequentially in height beneath each other for the first film, second film, aluminum foil and third film, and a roll laminator of the KDFM-720 type, which is pairwise mounted two pairs of rollers 18 and 19 with heating with a gap between them for passing layers of the heater. The movable carriage 10 and the brake carriage 12 are connected to each other and to the drive unit 13 by means of a pulling cable 20. The main nodes are mounted on the technological table 21, which consists of a cover-field mounted on supports, on which the guides 22 are mounted for moving the carriages.

The method is carried out using the inventive installation as follows.

Before starting the formation of the resistive layer, the resistive tape is wound on the coil 11. In the initial stage of the formation process, the carriages are in the following position: the fixed and movable carriages 9 and 10 are next to each other at the beginning of the transporting tape 5, i.e., in the refueling position of the resistive, the carriage 9 is at a certain distance from the carriage 10. Refueling is performed by winding the resistive tape onto the roller pins 3 of the movable and fixed carriages 10 and 9, as if tying them to each other. The free end of the resistive tape 2 is fixedly attached to the clamping device 4. The process of forming the resistive field is carried out by turning on the drive unit 13, which leads to the movement of the movable carriage 10 and the brake carriage 12, winding the resistive tape from the coil 11 and stretching it from the sinusoid into strips. One of the positions of the carriages is shown in figure 3. In the process of movement of the carriage 10 to the laminator 8, the length of the resistive tapes 2 increases. The movement of the carriage 10 occurs until the length of the resistive tapes reaches a predetermined length of the resistive field. The carriage 10 is stopped by a limit switch 23 (not shown in the drawings) installed in a place corresponding to the length of the resistive element 2. After stopping the movable carriage 10, the brake carriage 12 moves to the stationary carriage 9. Using the gripper 6, the ends of the resistive tape located on the roller pins 3 fixed carriages 9 are transferred to the brake carriage 12. The end of the resistive tape located on the movable carriage 10, using the gripper 6 is fed into the rollers of the laminator 8. The laminator 8 pulls You are the resistor 2, the tension of which occurs with the help of the brake carriage 9. Simultaneously with the resistive tape 2, the laminator 8 pulls the first film from the coil 14, the second film from the coil 15, the aluminum foil from the coil 16 and the third film from the coil 17. The hot rolls of the laminator 8 are melted polyethylene layers of films and tightly compress the entire layer and from the output of the laminator 8, the heater comes out as a whole.

In comparison with the prototypes of the claimed means of manufacture are simpler and allow to obtain a more highly efficient electric heater.

Claims (2)

1. A method of manufacturing a flat resistive electric heater, which consists in forming a resistive element on an insulating polymer base, installing at least one insulation layer on the outside, connecting all these elements into a bag and heat treating it, characterized in that a tape is used to form the resistive element resistive material, which during formation is placed along the base, for which the resistive tape is freely fixed at the beginning of the insulating base in the form of a sine ides across it, then grab the upper loops of the sine wave and stretch them along the base to the other side to the required length in the form of strips parallel to the sides of the base, fix the ends of the strips at the other end of the base, while simultaneously stretching the roll between the resistive tape element and the insulating base aluminum foil and on top of the resistive element a roll of insulating film, forming a package, the heat treatment of which is carried out by melting with an aid of a laminator nki and tightly compressing the entire package into a single whole. 2. Installation for the manufacture of a flat resistive electric heater, including a device for laying a resistive element with several protruding elements and a clamping device, a conveyor belt extending along the path corresponding to the heater configuration, a gripping device, a loop around the device for laying the resistive element along the specified path, a connecting device for connection of heater parts, characterized in that the styling device with protruding elements laid at the beginning of the conveyor belt and is respectively a carriage of two parts sequentially located above the conveyor belt parts - a fixed and a movable carriage with roller pins located on the adjacent edges of each of them in a row perpendicular to the axis of the conveyor belt, the clamping device is located on one of the sides of the fixed carriage , on the second side of it is placed a coil with a resistive tape element, the gripping device is removable, while movable the carriage together with the brake carriage located successively behind it and the drive unit together form a bypass device for laying the resistive element along the length of the heater, the lamination unit is used as a connecting device, including coils arranged for the first film, the second film located sequentially in height one above the other , aluminum foil and a third film, and pairwise mounted two pairs of heated rollers with a gap between them to pass heater layers.

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