RU2380861C1 - Method for manufacturing of flat resistive electric heater and process line for its realisation - Google Patents

Abstract

FIELD: electric engineering.

SUBSTANCE: in order to form resistive element, resistive material is used in the form of strip with specific resistance of 0.8±0.05 microhm/m, out of which two tapes are cut preliminarily with the required width and separate resistive strips for further formation of conducting resistive field in the form of meander, for this purpose in process of heater manufacturing, separating elements are laid in the form of cross strips of material. Method is described for manufacturing of flat resistive element in the form of meander.

EFFECT: reduced consumption of resistive material with provision of high quality of electric heater.

2 cl, 1 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 the patent of the Russian Federation 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, after which the other technological field is cut before 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 (since, due to the complex chemical composition, the resistive layer is a nonlinear element), which is why without special means it does not provide a stable temperature regime.

A known method of manufacturing a flexible resistive heater, described in the same patent of the Russian Federation No.2019065 class. HB05 3/34, declared 10/18/90, publ. 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 coefficient of resistance is formed, an adhesive layer is applied, all these elements are combined into a bag, and then it is heat treated, and initially, an adhesive layer made on each of the substrates unwound from a roll based on a water-soluble acrylic copolymer and epoxy aniline resin, which is dried at a temperature of 110-120 ° C, the specified resistive layer is formed from the water-soluble copolymer OLD-02 EMA, epoxy anil a new resin, PDI-ZAK 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 connected to 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 a complex composition, and a not entirely satisfactory heat transfer capacity due to its resistive performance a layer of a water-soluble copolymer, epoxy aniline 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 the patent of the Russian Federation No. 2082282 according to class. HB05 3/34, declared 09/27/94, publ. 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.

A known installation for the manufacture of an electric heater from a metal wire (wire) described in application No. 98115303 "System and method for manufacturing an electric heater) according to class. Н05В 3/34, А47С 7/74, 21/04, declared 08/17/98, publ. 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 are essentially joined 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.

Closest to the technical nature of the claimed are the method and installation presented in the patent of the Russian Federation No. 2337505 in class. HB05 3/34, declared 07/09/07, publ. 10/27/08 and selected as a prototype.

A known 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 base for forming a meander ribbon. 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 insulating 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 for laying a resistive element with several protruding elements - roller pins - and a clamping device, a conveyor belt extending along the path corresponding to the configuration of the heater, a gripping device, a looping device for laying the resistive element according to the specified trajectories, a connecting device for connecting parts of the heater. At the same time, a stacking device with protruding elements is located at the beginning of the conveyor belt and is a carriage, respectively, of two parts sequentially located above the conveyor belt - stationary and movable carriages with roller pins located in a row perpendicular to the axis of the conveyor belt on adjacent edges of each of them. The clamping device is located on one of the sides of the fixed carriage, on the second side of it there is a coil with a resistive tape element. The gripping device is removable. In this case, the movable carriage, in combination with the brake carriage and the drive unit located successively behind it, together form a bypass device for laying the resistive element along the length of the heater. The connecting device is a laminating unit, which includes coils arranged consecutively in height one above the 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 heated rollers with a gap between them to pass the heater layers. The movable carriage and the brake carriage are connected to each other and to the drive unit using a pull cable. The main nodes are mounted on the technological table, consisting of a field-cover fixed on supports, on which guides for moving the carriages are fixed.

A disadvantage of the known means is as follows. In them, for the formation of the resistive field of the electric heater, a ready-made tape (narrow) resistive material is used and the necessary resistance of the current-carrying part is formed due to the length of the resistive, which leads to an overuse of the material. The formation of a meander line from one sinusoidal tape is also rather complicated. An illogical situation is created when a larger amount of resistive material is consumed on a flat electric heater (PLEN) of lower power than on a PLEN of higher power. The design of the device is also very complicated. It should be borne in mind that the quality of the resistive material can be different in terms of electrical characteristics, which ultimately affects the quality of the electric heater.

In addition, these method and device are not very convenient in operation, because, firstly, they require the use of a specific resistive material width (available from the manufacturer) supplied in the form of strips, and secondly, the manufacturing process carried out with their help is not completely completed , since it ends with the lamination of the incoming components, although in practice, the finished laminate-heater must still be sealed, soldered wires to supply voltage to the heater, etc.

The objective of the claimed technical solutions is to reduce the consumption of resistive material and ensure high quality electric heater, increasing the efficiency and ergonomics of its manufacture.

The problem is solved in that:

- in the method of manufacturing a flat resistive electric heater, which consists in the fact that at the preparatory stage they take resistive material, aluminum foil and insulating material and wrap them on coils, then they make semi-finished laminate from these materials, for which a resistive element is formed on an insulating polymer base from 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 parallel to the side on the other side of the base, is fixed on the other end of the base, while simultaneously pulling a roll of aluminum foil from the bottom between the resistive tape element and the insulation base and the roll of insulation film above the resistive element, forming a package that is heat-treated by melting the insulation films with a laminator and tightly compressing the entire package as a whole, ACCORDING TO THE INVENTION, at the preparatory stage for the subsequent formation of the resistive element as a resistive material Ala take a cloth with a given specific resistance of 0.8 + -0.05 μOhm / m, then, based on the required resistance of the heater, calculate the necessary geometric dimensions and cut out two resistive tapes of the required width and wrap them on two separate coils, as well as cut individual strips of the same material, at the stage of manufacturing a semi-finished product - laminate, at a certain distance between each other, unwind prepared coils with resistive material, place them parallel to each other and stretching them for the next laminating it with tension from below and from above, lay cut across strips of the same resistive material across the moving resistive tapes as the tapes, and also lay separating strips in the form of transverse strips of non-laminating material at a distance between them, determined by the length of the future electric heater, forming image of the package, which is then subjected to heat treatment, getting a laminated sheet, which at the output is also wound on a coil, getting a semi-finished laminate, and then They stage the production of a finished heater, on which a laminated sheet is unwound from a coil, transverse resistance strips are welded to resistive tapes in it, the elements of the latter are cut to form a conductive resistive field in the form of a meander, the fabric is cut in the middle of dividing non-laminating elements, soldering voltage to the ends of the resistive tapes wires and cover the ends of each heater with an insulating film.

-in a production line for manufacturing a flat resistive electric heater, including a device located at the beginning of a conveyor belt extending along a path corresponding to the configuration of a heater, a device for laying a resistive element along a specified path, including a block of coils arranged sequentially in height above each other with heater components including with an insulating tape, resistive and aluminum foil, as well as a guide device, a connecting device for unity in the web of heater elements in the form of a laminator, which includes two pairs of heated rollers installed in pairs with a gap between them for passing heater layers, ACCORDING TO THE INVENTION, at the beginning of the line in front of the stacking device, an additional machine for cutting the resistive sheet is installed in the device for laying guides the device is guide shafts, there is an automatic ejector of inter-membrane separating elements, and a winding device for winding a laminated prefabricated web a, and after the laminator there is an assembly table with knives and a welding machine installed on it.

The use of a resistive web with predetermined electrical parameters at the first preparatory stage allows one to more economically prepare one of the main constituent elements of a film heater, namely, to cut high-quality resistive material of the required longitudinal and transverse dimensions, depending on the required heating resistance, which together with their subsequent winding on separate coils and preparation of transverse resistive strips for feeding to the following the first stage - the manufacture of a semi-finished product - laminate in the form of a package - makes it possible to simplify and speed up the next, stage - assembly of the package. At the second stage, the spacing of the coils with the resistive tape between themselves and the arrangement of the resistive tapes in parallel with each other, together with the transverse strips of the resistive tape and dividing non-laminated transverse strips across them while they are moving, while unrolling the resistive tape from the coils, simplifies the process and design of the device for the subsequent receipt of the meander shape of the resist and the required length of the electric heater. At the third stage introduced additionally, the assembly stage of the finished electric heater, welding transverse strips made of the same resistive material to resistive longitudinal tapes and cutting out pieces of tape with the formation of a meander pattern makes it possible to simplify the formation of the meander field and to obtain a prefabricated film electric heater in the form of a coil wound on a reel tapes, which in conjunction with cutting along dividing unlaminated strips of the electric heater coil web unwound from the coil and welded to it wires for voltage supply and isolation of all and for the voltage supply and isolation of all makes it possible on a single production line is easy and inexpensive to get ready for electric power and a predetermined size.

The introduction of a resistive sheet cutting machine into the production line makes it possible to save on raw materials and prepare the resistive tape of the dimensions required for the given power of the electric heater, which in combination with the use of a guide device of simple construction in design and the presence of a winding device for the laminated sheet in it when installed in assembly line with knives and welding machine provides a simple and reliable design of the processing line, allowing b Leah cheap and easy to obtain dimensional planar resistive heater as a finished product, ensuring achievement of the desired result.

The technical result is the simplification of the technology and the technological line for the manufacture of a film resistive heater while ensuring high quality electric heater and increasing the efficiency and ergonomics of production.

The inventive method has a novelty in comparison with the prototype, differing from it by such significant features as the use at the preliminary stage for the subsequent formation of the resistive element of the resistive material in the form of a strip with a given specific resistance of 0.8 + -0.05 μΩ / m, at the manufacturing stage prefabricated product - parallel arrangement of resistive tapes and superposition of transverse strips of the same resistive material as the tape and laying washing separating elements in the form of transverse strips of non-laminated material at a distance between them, determined by the length of the future electric heater, winding the prefabricated coil in the form of a laminated web, performing the assembly step here, including unwinding the laminated web, forming a meander tape by welding transverse resistive strips to resistive ones ribbons and cutting out the elements of the latter for the formation of a conductive resistive field in the form of a meander and obtaining a finished electron of the arrester by cutting the canvas with the meander tape in the middle of the dividing non-laminating elements, soldering the wires supplying voltage to the ends of the resistive tapes and insulating the ends of each electric heater with an insulating film, which together achieve the desired result.

The inventive production line has a novelty in comparison with the prototype, differing from it by such significant features as the installation of an additional machine for cutting a resistive blade at the beginning of the line in front of the laying device, the use of a guide device of simple design in the form of guide shafts in the device for laying the resistive element it contains an automatic reset device of inter-membrane separating elements and a winding device, and the presence of an assembly table after the laminator with the installed and on it with knives and a welding machine, which together ensure the achievement of a given 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 the drawing, which shows a functional diagram of the technological line for the manufacture of a flat resistive electric heater.

The inventive method of manufacturing a flat resistive electric heater contains three stages, which are as follows.

Preparatory stage

To form a resistive element, a resistive material is used in the form of a strip with a width of at least 10 cm with a given thickness of 6-15 μm and a specific resistance of 0.8 + -0.05 μOhm / m, from which two tapes of the required width and resistive strips are pre-cut for subsequent meander formations; also cut from non-laminated material dividing inter-film strips for separating electric heaters.

Resistive tapes are wound on two coils.

Three rolls of insulating film wound on coils and an aluminum foil also wound on a coil are prepared.

At the stage of manufacturing the prefabricated laminate perform the following operations. The resistive tapes are pulled parallel at a certain distance from each other, unwinding the coils, and the transverse resistive strips for forming the meander and the interfilm dividing strips of non-laminated material are laid out on a given heater length on the moving resistive tapes. A layer of resistive longitudinal tapes with transverse strips and aluminum foil, and laid at a distance determined by the size of the future electric heater, with inter-film dividing strips of non-laminated material, is laminated with rollers with heating of the insulating film, and the resulting laminated prefabricated material is wound on a coil.

At the stage of obtaining the finished electric heater, the laminated semi-finished product is unwound and the transverse resistive strips are welded to the resistive longitudinal tapes. Then the parts of the tape are cut to obtain a conductive meander-shaped resistive field, and the finished web is cut into dividing non-laminated strips into finished electric heaters. Next, the voltage supply wires are soldered to the ends of the resistive meander lines of each electric heater and the ends of each heater are covered with an insulating film.

The inventive production line includes located at the beginning of the conveyor belt 1, extending along the path corresponding to the configuration of the heater, a machine 2 for cutting a resistive web with a winding device 3, a laminator 4 and an assembly table 5. In this case, the laminator 4 contains a device 6 sequentially placed along the conveyor belt 1 for laying the resistive element along the specified path and directly to the lamination unit 7. The stacking device 6 includes a block 8 of coils 9, 10, 11 arranged in height one above the other with an insulating film, coils 12, 13 with a resistive element, coils 14 with aluminum foil, guide shafts 15 and an automatic reset device 16 of inter-duplex separating elements in the form of strips 17, as well as an automatic meter 18 of the heater meter. The lamination unit 7 includes two pairs of heating rollers 19 installed in pairs and a coil 20 for winding the laminated heater web. Knives 21 and a welding machine 22 are installed on the assembly table 5.

The manufacture of a film resistive electric heater using the inventive means is as follows.

At the preparatory stage, resistive tapes 23 and 23 'of the required width and longitudinal resistive strips 24 of the required length are cut from the web with a width of at least 20 cm using a machine 2. Using a winding device 3, the resistive tapes 23 and 23 'are wound on two separate coils 12, 13, an aluminum foil sheet 25 of the required width is wound on the coil 14, and an insulation film 26 and 26', 26 '' is wound on three coils 9-11 necessary width. Interfilm spacer elements 27 are also prepared from non-laminated material.

At the stage of manufacturing a semi-finished product, when forming a resistive element, coils with a resistive tape are installed in the production line, the tapes are distributed along the guides, the ends of the tapes are fixed in the laminator, and the head end of the semi-finished product is formed. They install a coil with a resistive tape, a coil with an aluminum foil, and coils with an insulating film above and between them.

Then, the resistive tapes 23 and 23 'are arranged in the form of two strips along the base, for which the resistive tapes 23 and 23' are freely fixed at the beginning of the insulating base 26, then they are stretched along the base 26 to the other side to the required length in the form of strips parallel to the sides grounds. The tapes 23 and 23 'are pulled out, unwinding the coils 12 and 13 and fixing the ends of the tapes 23 and 23' at the other end of the base and the transverse resistive strips 24 for forming the meander and the interfilm dividing elements 27 are laid out on the given heater length on the moving resistive tapes 23 and 23 ' from non-laminated material. A layer of resistive tapes 23 and 23 'with transverse gaskets 24 and aluminum foil 25, and laid at a distance determined by the size of the future electric heater, is laminated using heated rollers 19 and heating film 26, 26' and 26 '' non-laminated material. The resulting laminate package 28 is wound on a coil 20 in the form of a finished product.

At the stage of obtaining the finished electric heater, the prefabricated fabric 28 is unwound from the coil 20 and the transverse resistive strips 24 are welded to the longitudinal longitudinal resistive tapes 23 and 23 'using a welding machine 22. Then 21 parts of tapes 23 and 23 'are cut with knives, obtaining a conductive resistive field 29 meander-shaped, and the finished web is cut into inter-film spacer elements 27 into finished electric heaters. Next, the voltage supply wires 30 are soldered to the ends of the resistive meander lines of each electric heater and the ends of each heater are covered with an insulating film.

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 the fact that at the preparatory stage they take resistive material, aluminum foil and insulating material, which are wound on coils, then they make semi-finished products - a laminate from these materials, for which a resistive element is formed from an insulating polymer base 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 parallel the shackled sides of the base are fixed on the other end of the base, while simultaneously pulling a roll of aluminum foil from the bottom between the resistive tape element and the insulating base and a roll of insulation film above the resistive element, forming a package that is heat treated by melting the insulation films with a laminator and tightly compressing the whole package as a whole, characterized in that at the preparatory stage as a source material for the subsequent formation of the resistive element nt take a resistive cloth with a specific resistance of 0.8 + -0.05 mkom / m, based on the required resistance of the future electric heater, calculate the geometric dimensions of the resistive tape, cut out two identical resistive tapes from the cloth and wound them on two separate coils, and also cut separate resistive strips of the same size at the stage of manufacturing a semi-finished product - a laminate for forming a resistive element, resistive strips are unwound at a certain distance from each other and placed in parallel, stretching them with tension for subsequent lamination, cut strips of the same resistive material as the strips are applied across the moving resistive tapes across the strips, as well as laying separating elements in the form of transverse strips of non-laminated material at a distance between them, determined by the length of the future electric heater, then formed a laminated prefabricated bag is also wound on a coil, then a ready-made electric heater is obtained, for which a coil with a prefabricated product is unwound - a laminate ohm, and, stretching the latter, it welds transverse resistive strips to resistive tapes, cuts out the elements of the latter to form a conductive resistive field in the form of a meander, cuts the web in the middle of interfilm separating non-laminating elements, solders the voltage supply wires to the ends of the resistive tapes and closes the ends of each electric heater insulating film. 2. A production line for manufacturing a flat resistive electric heater, including a device located at the beginning of the conveyor belt extending to the path corresponding to the configuration of the heater, a device for laying the resistive element along the specified path, including a block of coils arranged sequentially in height above each other with heater components , including with an insulating tape, resistive and aluminum foil, as well as a guide device, a connecting device for unity in the web of heater elements in the form of a laminator, including two pairs of heated rollers installed in pairs with a gap between them for passing heater layers, characterized in that at the beginning of the line, an additional machine for cutting the resistive web is installed in front of the stacking device, in a device for the guiding shafts serve as a guiding device, there is an automatic machine - a stripper of inter-film linings and a winding device for winding a laminated prefabricated web, and after laminates torus is an assembly table with knives mounted thereon and welding machine.

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