WO2013066064A1

WO2013066064A1 - Carbon heater and method of manufacturing same

Info

Publication number: WO2013066064A1
Application number: PCT/KR2012/009106
Authority: WO
Inventors: 이호재
Original assignee: 제이씨텍 주식회사
Priority date: 2011-11-03
Filing date: 2012-11-01
Publication date: 2013-05-10
Also published as: KR101125480B1

Abstract

The present invention relates to a carbon heater that is used as a heating element of an electric heater, and a method of manufacturing same that enables the mass production of a carbon fiber yarn. By performing polymer immersion and drying a plurality of times, the shape of a bundle body separated from a main shaft can be stably maintained even when a pre-sintering temperature is lowered, and a carbon coating layer of a uniform and stable thickness is formed through a polymer deposition process, so that product stabilization and manufacturing yield are improved.

Description

Carbon heating element and its manufacturing method

The present invention relates to a carbon heating element and a method for manufacturing the same, and more particularly to a carbon heating element and a method for manufacturing the carbon heating element used in the heating element of the electric heater and carbon fiber yarn forming process of the carbon heating element production in large quantities It is about.

In recent years, the use of a carbon heating element, which has been proven to have a relatively high radiant heat efficiency, compared to a heating element made of nickel chromium alloy (known as 'nickel wire'), which is widely used in recent years, is increasing.

In the past, it has been considered that carbon is not available as a heating element because it is known as a conductor having a low electrical resistance, but recently, it has a high level of resistance when carbonized with natural fibers to form carbon fibers with micro bubbles. It turned out to be used as a heating element.

Until now, the carbon heating element has been limited in the manufacture of the carbon heating element because it is intended to increase the radiant heat efficiency by simply adjusting the length or changing the thickness within the limited power consumption by using the resistivity of carbon.

As a result, many studies and efforts have been conducted in the art for improving the exothermic efficiency of the carbon heating element, securing stability, and improving the productivity, and the present inventors have been directly involved in many researches, efforts, and productions in the art field to the present. Many research results have been published, including Patent No. 10-2009-122779, Republic of Korea Patent No. 1006159, Republic of Korea Patent No. 923417, Republic of Korea Patent No.909881, and Republic of Korea Patent No. 983972.

The present invention provides a method for producing a carbon heating element and a carbon heating element for the stable production of the carbon heating element in the process of mass production, including the improvement of moldability, the improvement of production yield, the simplification of the manufacturing process and the reduction of manufacturing cost.

Carbon heating element manufacturing method according to an embodiment of the present invention for achieving the above object, the step of fixing the carbon fiber yarn twisted or woven body of the carbon fiber yarn to have a certain type of shape based on the main axis and ; Immersing the focusing body including the main shaft in a polymer; A plasticity step of removing the polymer from the polymer and heating the concentrator including the main shaft in a high pressure furnace of a reduced pressure atmosphere or an inert atmosphere; Separating the focusing body that has undergone the plasticization step from the main shaft; And carbonizing the separated focus body in a high-temperature furnace having any one of an environmental condition selected from a predetermined reduced pressure atmosphere, a hydrocarbon gas atmosphere, an inert gas atmosphere, and a mixed gas atmosphere of an inert gas and a hydrocarbon gas. Characterized in that performed.

On the other hand, the carbon heating element manufacturing method according to another embodiment of the present invention for achieving the above object comprises the steps of twisting the carbon fiber yarns or immersed in the polymer lumps of carbon fiber yarns; Fixing the focusing body to have a predetermined shape based on a main axis; A plasticizing step of heating the focusing body including the main shaft in a high temperature furnace in a reduced pressure atmosphere or an inert atmosphere; Separating the focusing body from the main shaft; And the main firing step of carbonizing the separated focus body in a high temperature furnace having any one of an environmental condition selected from a predetermined reduced pressure atmosphere, a hydrocarbon gas atmosphere, an inert gas atmosphere, and a mixed gas atmosphere of an inert gas and a hydrocarbon gas. Characterized in that consists of.

In addition, the fixing of the focusing body on the surface of the main shaft, the carbon fiber yarn 3 to 24 patterns arranged in one direction, twisting or weaving the focusing body immersed in the polymer at least 1 Characterized in that it is made after performing more than once.

In addition, the plasticity temperature of the high temperature furnace of the plasticity step is to be made in the range of 400 ~ 900 ℃, the firing temperature of the high temperature furnace of the main firing step is preferably to be made in the range of 1000 ~ 2500 ℃.

On the other hand, the carbon heating element according to the invention is characterized in that it is produced by the method for producing the carbon heating element.

According to the method of manufacturing a carbon heating element according to the present invention, from the converging body made of carbon fiber yarns to manufacturing the carbon heating element, not only extends the service life of the manufacturing parts including the main shaft, but also the advantages of simplifying the manufacturing process and reducing the time and accordingly It has the effect of reducing the manufacturing cost, and the improvement of formability through the plasticity step makes the pitch interval of the carbon heating element uniform by the deformation of the main shaft, and thus the heating distribution is uniform. Through the formation of a uniform and stable carbon film layer has the advantage of improving the stabilization and manufacturing yield of the product.

1 is a flowchart illustrating a process of manufacturing a carbon heating element according to an embodiment of the present invention.

2 is a flowchart illustrating a process of manufacturing a carbon heating element according to another embodiment of the present invention.

The terms used in the present specification and claims are not to be interpreted in a conventional or dictionary sense, and the inventors may appropriately define the concept of terms in order to describe their own invention in the best way. Based on the principle, it should be interpreted as meaning and concept corresponding to the technical idea of the present invention.

Therefore, the embodiments described in the specification and the drawings shown in the drawings are only exemplary embodiments of the present invention, and do not represent all of the technical idea of the present invention, which can be replaced at the time of the present application It should be understood that there may be various equivalents and variations.

In addition, the detailed description of the present invention relates to the raw material properties of PAN (polyacrylonitrile) -based carbon fiber yarn, pitch-based carbon fiber yarn and viscose-based carbon fiber yarn and the processing characteristics up to forming into a converging body such as twisting or weaving. The description will be made based on what is formed as a focusing body without.

That is, the invention of manufacturing a carbon heating element according to the present invention includes a pretreatment process before forming into a focusing body including material properties of each series of carbon fiber yarns as raw materials of the carbon heating element or processing characteristics up to formation of the focusing body. will be.

Looking at the manufacturing process of the carbon heating element according to an embodiment of the present invention from this, as shown in Figure 1, twisted carbon fiber yarns or woven body of a carbon fiber yarn woven form based on the main shaft Fixing to have a step (ST100), the step of immersing the focusing body including the main shaft in the polymer (ST110), the focusing body including the main shaft undergoing the drying process (ST120) taken out of the polymer to a high-temperature atmosphere of a reduced pressure or inert atmosphere The plasticizing step (ST130) for heating in the step, the step of separating the focusing body undergoing the plasticizing step from the main shaft (ST140) and the separated focusing body a predetermined reduced pressure atmosphere, hydrocarbon gas atmosphere, mixed gas atmosphere of inert gas and hydrocarbon gas The process including the main firing step (ST150) to be carbonized in a high temperature furnace having any one environment selected from among .

Here, the main shaft is selected from those of heat-resistant materials such as quartz, silica, ceramics, graphite, etc., which have a smooth surface and can withstand shape deformation at temperatures of about 900 ° C. or higher, and use round or tubular ones.

In addition, the fixing of the focusing body made of carbon fiber yarns with respect to the main shaft is wound in a spiral shape along the longitudinal surface of the main shaft when the focusing body has a straight shape having a predetermined width and thickness or a string having a predetermined thickness. Both ends of the sieve may be fixed to maintain the shape and position of the focusing body with a clip or the like provided at both ends of the main shaft.

In another form, when the focusing body has a cylindrical shape, it may be inserted into the tubular main shaft so as to be fixed by a conventional method using a jig or the like so that the shape and position of the focusing body do not change.

In this way, the shape of the focusing body based on the main axis is independent of the shape of the focusing body unless the external physical force is applied even when the main shaft is separated and then put into the main firing process after the plasticity process in the next step. It is intended to have tolerance that can be maintained within. In addition, this resistance allows the shape to be maintained within a certain range even after the firing process.

As described above, the focusing body fixed to the main shaft to have a certain form and shape is polymerized on the surface of each carbon fiber yarn constituting the focusing body by immersing the main shaft with a polymer containing a large amount of carbon such as a phenol solution and a benzene compound. Is to be applied.

The focus is then subjected to a process of drying the liquid polymer, the drying process for this may be made by natural drying at room temperature, or may be made through a rapid drying process in an oven having a temperature condition of less than 350 ℃.

At this time, the drying temperature of the polymer with respect to the focusing body is limited to less than 350 ° C, which is a reason for preventing the problem of oxidizing even the polymer and carbon fiber yarn.

The application of polymers to such a concentrator increases the distribution of carbon due to the thermal decomposition of the polymer in contact with or adjacent to each surface of carbon fiber yarns due to the high temperature atmosphere of the firing process, thereby increasing the possibility of vapor deposition of carbon molecules. It is for forming a carbon film layer.

Therefore, in order to control the electric resistance value through the thickness of the carbon film layer, the effect of the carbon heating element can be obtained by repeating the above-described series of steps 1-5 times, followed by the immersion process and the drying process. .

When the immersion process and the drying process of the polymer are performed five times or more, the deposition thickness of the polymer on the surface of the carbon fiber yarns will be improved, but as a result, the thickness of the carbon film and the corresponding resistance value are lowered. In addition to the problems that occur, there is an uneconomical problem such as increasing the manufacturing period and manufacturing cost.

In addition, another reason for applying the polymer to the focusing body, which will be described later, even after the plasticity step of the degree of drying again the polymer is not pyrolyzed before the main firing process, even if the shape of the focusing body based on the main shaft is separated from the main shaft To be maintained.

In this way, the focusing body after the immersion and drying process of the polymer is put into a high-temperature furnace of a predetermined pressure-reducing atmosphere or an inert atmosphere in a state fixed to the main shaft to perform a plasticity process.

The above-described plasticity process is carried out in the temperature range of 400 ~ 900 ℃, this temperature range is for fixing the shape of the focusing body wound in the spiral shape on the main axis of the polymer in a state that the polymer is almost no pyrolysis.

Thus, plasticity in the temperature range of 400 to 900 ° C is the shape of the focusing body wound around the main shaft compared to the case of drying the polymer in the natural state of the prior art and the example of oven drying below 350 ° C in an air atmosphere such as air Hardening more stably has the effect of reducing the moldability defect rate.

In addition, if the temperature rises above 900 ℃ during the plasticity process, the polymer is thermally decomposed, and when the separation from the main shaft occurs, the spiral shape of the main body as well as the main body wound around the main shaft is not stable and loosened. .

In addition, the temperature range of the above-described plasticity process is lower than the first heat treatment temperature of the prior art, and it is not difficult to select a heat-resistant spindle material without shape deformation or physical property change such as bending or twisting in this temperature range. It can be adopted as the main spindle of the main shaft, and even if a high level of heat-resistant material is selected, it can be expected to extend the service life of the main shaft.

In addition, the focusing body undergoes a plasticity process has the ability to maintain the shape based on the main axis along with the ability to maintain the shape as the polymer is dried.

After the completion of the plasticity process, the focusing body is separated from the cooled spindle, and the separated focusing body is any one selected from a predetermined pressure reducing atmosphere, a hydrocarbon gas atmosphere, an inert gas atmosphere, and a mixed gas atmosphere of an inert gas and a hydrocarbon gas. The firing process is carried out by putting in a high temperature furnace having an environment of.

The temperature of the firing process described above is in the range of 1,000 to 2,500 ° C., and this temperature range not only carbonizes the carbon fiber yarns constituting the concentrator, but also thermally decomposes the polymer coated on these surfaces, causing impurities to evaporate, Carbon molecules induce vapor deposition on the surface of each carbon fiber yarn of the focusing body to form a carbon film layer.

The focusing body that has undergone the above process is made of a carbon heating element having a carbon coating layer, and then connecting the terminals of the carbon heating element to the both ends of the carbon heating element and putting the inside of the quartz tube. The carbon heater is completed by sealing after treating with a predetermined vacuum pressure.

On the other hand, the carbon heating element manufacturing method according to another embodiment of the present invention, as shown in Figure 2, through the immersion process (ST200) and drying process (ST210) for the polymer, the main body made of carbon fiber yarns Winding in a spiral shape (ST220), a plasticizing step (ST230) for heating the focusing body including the main shaft in a high-temperature furnace in a reduced pressure atmosphere or an inert atmosphere, and separating the focusing body undergoing the plasticizing step from the main shaft ( ST240) and the separated firing body is carbonized in a high temperature furnace having any one selected from a predetermined reduced pressure atmosphere, a hydrocarbon gas atmosphere, a mixed gas atmosphere of an inert gas and a hydrocarbon gas (ST250) This is done sequentially.

As such, a feature of another embodiment which is distinguished from one embodiment of the present invention is that the process of fixing the focusing body based on the main shaft is performed after immersing the focusing body in a polymer and then drying to a certain level. have.

That is, according to another embodiment, the process of immersing the above-described polymer and drying to a certain level is not at the limiting condition that proceeds after fixing to the main shaft, but at the same time in the process before cutting the length of the focusing body to the desired length. It has the advantage that it can be implemented in turn.

Furthermore, the process of immersing the polymer in the focusing body is supplied continuously through an automated facility, and the process of immersing the polymer just before the focusing body is wound around the main shaft during the winding on the main shaft, and drying the polymer after winding up the main shaft after immersion. It is not necessary to make enough.

Although the above has been described as a preferred embodiment of the present invention, various modifications and modifications by those skilled in the art to which the present invention pertains within the technical scope of the present invention can be claimed. It is said to belong to the range.

Claims

Twisting the carbon fiber yarns or winding the focusing body woven from the carbon fiber yarns in a spiral shape to fix them in a spiral shape;

Immersing the focusing body including the main shaft in a polymer;

A plasticity step of removing the polymer from the polymer and heating the concentrator including the main shaft in a high pressure furnace of a reduced pressure atmosphere or an inert atmosphere;

Separating the focusing body that has undergone the plasticization step from the main shaft; And

Carrying out the main firing step of carbonizing the separated focusing body in a high temperature furnace having any one of an environmental condition selected from a predetermined reduced pressure atmosphere, hydrocarbon gas atmosphere, inert gas atmosphere, mixed gas atmosphere of inert gas and hydrocarbon gas Method for producing a carbon heating element comprising the step of performing.
Twisting the carbon fiber yarns or immersing the lump of carbon fiber yarns in the polymer;

Winding the focusing body in a spiral shape on a main shaft;

A plasticizing step of heating the focusing body including the main shaft in a high temperature furnace in a reduced pressure atmosphere or an inert atmosphere;

Separating the focusing body from the main shaft; And

Carrying out the main firing step of carbonizing the separated focusing body in a high temperature furnace having any one of an environmental condition selected from a predetermined reduced pressure atmosphere, hydrocarbon gas atmosphere, inert gas atmosphere, mixed gas atmosphere of inert gas and hydrocarbon gas Carbon heating element manufacturing method characterized in that performed.
The method of claim 2,

The fixing of the concentrator on the surface of the main shaft is performed by sequentially arranging 3 to 24 carbon fiber yarns in one direction, immersing them in a polymer, or immersing them in a polymer and then sequentially drying them. The method of producing a carbon heating element, characterized in that made after performing a series of at least one to five times.
The method according to any one of claims 1 to 3,

The plasticity temperature of the high temperature furnace of the plasticity step is the carbon heating element manufacturing method, characterized in that in the range of 400 ~ 900 ℃.
The method according to any one of claims 1 to 3,

The firing temperature of the high temperature furnace of the firing step is characterized in that the carbon heating element manufacturing method characterized in that the range of 1000 ~ 2500 ℃.
Carbon heating element produced by the carbon heating element manufacturing method of claim 4.