CN1622695B - Method for producing carbon-based heating element, carbon-based heating element, heater, and heating device - Google Patents

Abstract

The present invention can provide a method for producing a carbon-based heating element, a carbon-based heating element, and a heater that use a carbon-based heating element that can maintain a predetermined strength without causing the individual carbon fibers to scatter even if the carbon fibers are made thin to obtain a predetermined resistance value. and heating device. The heater of the present invention has a structure in which a carbon-based heating element is sealed in a glass tube, and the carbon-based heating element is formed by sintering the following parts: a plurality of longitudinal carbon fibers continuous in the longitudinal direction; The carbon fiber in the width direction has at least one turn in the direction, and at least one of the carbon fibers continuous in the longitudinal direction is woven to cross up and down.

Description

Method for producing carbon-based heating element, carbon-based heating element, heater, and heating device

technical field

The present invention relates to a method for producing a carbon-based heating element, a carbon-based heating element, a heater using the carbon-based heating element, and a heating device using the heater.

Background technique

In recent years, heaters using carbon-based substances as heating elements have been developed. , Because carbon-based substances are conductors, the resistance value is small. For this reason, in order to increase the resistance value of the heating element of carbon-based materials, methods such as extending the overall length of the heating element, reducing the cross-sectional area of the heating element, or increasing the intrinsic resistance value of the heating element itself have been put into practical use.

Japanese Patent No. 3319951 discloses a conventional heating element made of fabric-like carbon fibers capable of obtaining a predetermined resistance value and a method of utilizing the carbon fiber heating element. The heating element of the conventional example is actually formed of a fibrous carbon-based material composed of only carbon elements, and each fiber forms pores in micron units. The resistance value increases at the portion of the hole. Furthermore, the resistance value is adjusted by changing the thickness and amount of carbon fibers. Thus, the conventional heater using the carbon fiber heating element can be used as the heat source of the heating device.

A conventional heating element is formed of a plurality of longitudinal threads of carbon fibers extending in the longitudinal direction. In conventional heaters, carbon fibers are thinned or the amount of carbon fibers is reduced in order to increase the resistance value of the heating element. However, if the carbon fiber is made thinner or the amount of carbon fiber is reduced, there is a problem that the individual fibers are scattered or disconnected.

Contents of the invention

An object of the present invention is to provide a method for producing a carbon-based heating element in which carbon fibers do not scatter.

Another object of the present invention is to provide a carbon-based heating element in which carbon fibers do not scatter.

Still another object of the present invention is to provide a heater using a carbon-based heating element capable of obtaining a predetermined resistance value while maintaining a predetermined strength without unraveling carbon fibers.

Still another object of the present invention is to provide a heating device having an arbitrary heating value with respect to the longitudinal direction.

In order to solve the above-mentioned problems, the present invention has the following constitutions.

A method for producing a carbon-based heating element according to an aspect of the present invention includes: a step of forming a heat generating portion with carbon fibers; a step of applying a resin to the heat generating portion; and sintering the heat generating portion coated with the resin. Step, the heat generation part is formed by a carbon fiber formed by weaving a plurality of carbon fibers continuous in the longitudinal direction and at least one of the carbon fibers continuous in the longitudinal direction having at least one turn in the width direction and intersecting up and down of.

According to the present invention, it is possible to securely fasten the wires. According to the present invention, a method for producing a carbon-based heating element capable of obtaining a predetermined resistance value while maintaining a predetermined strength without unraveling the wire can be realized. According to the present invention, a method for producing a carbon-based heating element having an arbitrary heating value can be realized.

A method for producing a carbon-based heating element according to another aspect of the present invention includes: a step of forming a heat generating part with carbon fibers; a step of impregnating the heat generating part with a resin; and a step of sintering the heat generating part impregnated with the resin. The heat generating portion is formed of a carbon fiber in which a plurality of carbon fibers each continuous in the longitudinal direction and at least one of the carbon fibers each continuous in the longitudinal direction having at least one turn in the width direction cross up and down.

According to the present invention, the wires can be fixed reliably. According to the present invention, it is possible to realize a method of manufacturing a carbon-based heating element that can obtain a predetermined resistance value while maintaining a predetermined strength without the wires falling apart. According to the present invention, it is possible to Realize the manufacturing method of carbon-based heating elements with arbitrary calorific value.

A method for manufacturing a carbon-based heating element according to another aspect of the present invention includes: a step of forming a heating part by carbon fibers coated with a resin in advance; and a step of sintering the heating part. A plurality of carbon fibers each continuous in the width direction and at least one of carbon fibers each continuous in the longitudinal direction having at least one turn in the width direction are woven to cross up and down.

According to the present invention, it is possible to securely fasten the wires. According to the present invention, a method for producing a carbon-based heating element capable of obtaining a predetermined resistance value while maintaining a predetermined strength without unraveling the wire can be realized. According to the present invention, a method for producing a carbon-based heating element having an arbitrary heating value can be realized.

According to still another aspect of the present invention, in the method of manufacturing the carbon-based heat generating element, in the step of forming the heat generating part, at least one thread is braided so as to intersect other continuous threads up and down.

According to the present invention, since at least one wire intersects other continuous wires, it is possible to manufacture a carbon-based heating element having a predetermined strength without unraveling or disconnection of the wires of the carbon-based heating element. The carbon-based heating element produced by the present invention can obtain a predetermined resistance value, and can have an arbitrary heating value according to the application.

The "continuous line" in this specification means that the length of the line is sufficiently longer than the width of the carbon-based heating element. The continuous line preferably has a length reaching both ends of the carbon-based heating element in the longitudinal direction.

"Weaving one thread and other continuous threads so as to intersect up and down" means, for example, when multiple threads are composed of at least one horizontal thread and multiple vertical threads, each of the one horizontal thread and the multiple vertical threads alternates up and down. Ground crossing (every other ground crosses up and down), each vertical thread alternately passes through the weaving of the horizontal thread and weaves up and down the braided fabric.

A carbon-based heating element according to an aspect of the present invention includes: a heating part made of carbon fibers; One carbon fiber is sintered with at least one carbon fiber that is continuous in the longitudinal direction and has at least one fold in the width direction and is braided up and down.

According to the present invention, a carbon-based heating element capable of maintaining a predetermined strength without unraveling and obtaining a predetermined resistance value can be realized. According to the present invention, a carbon-based heating element having an arbitrary heating value can be realized.

A heater according to an aspect of the present invention is configured by sealing the carbon-based heating element in a glass tube.

According to the present invention, it is possible to realize a heater using a carbon-based heating element having a predetermined resistance value while maintaining a predetermined strength without unraveling the wire. According to the present invention, a heater using a carbon-based heating element having an arbitrary heating value can be realized.

In the heater according to another aspect of the present invention, the carbon-based heating element is obtained by sintering a braided fabric obtained by weaving a plurality of threads such that at least one thread crosses other continuous threads up and down.

According to the present invention, since at least one wire intersects other continuous wires, it is possible to realize a heater having a predetermined strength without unraveling or disconnection of the wires of the carbon-based heating element. The heater of the present invention can obtain a predetermined resistance value, and can have an arbitrary calorific value depending on the application.

In the above-mentioned heater according to another aspect of the present invention, among the plurality of wires, the horizontal or oblique wires extending in the width direction are one continuous wire.

According to the present invention, it is possible to realize a heater in which horizontal or oblique lines extending in the width direction do not fall off.

In the heater according to still another aspect of the present invention, the carbon-based heating element is formed by arranging a continuous line in the longitudinal direction and a horizontal or oblique line extending in the width direction having at least one return according to a predetermined rule. A braided fabric in which at least one thread is interwoven with other threads up and down is sintered.

According to the present invention, it is possible to realize a heater that ensures a predetermined tensile strength in the longitudinal direction for continuous lines in the longitudinal direction, and prevents unraveling of the transverse or oblique lines extending in the width direction. Since the horizontal or diagonal lines extending in the width direction have at least one turnback, they do not come off.

In the heater according to another aspect of the present invention, the carbon-based heating element is formed in a flat plate shape.

According to the present invention, a directional heater having a high heat collection rate in a predetermined heating direction can be realized.

In the heater according to another aspect of the present invention, the carbon-based heating element is formed by laminating multiple layers.

According to the present invention, a heater with a large calorific value can be realized.

In the heater according to another aspect of the present invention, the plurality of wires are composed of thin vertical wires extending in the longitudinal direction and thick horizontal wires extending in the width direction.

According to the present invention, it is possible to realize a heater that uses a carbon-based heating element with a high resistance value, has a predetermined strength, and has a small calorific value.

In the heater according to still another aspect of the present invention, the carbon-based heating element is composed of thick vertical lines extending in the longitudinal direction and thin horizontal lines extending in the width direction.

According to the present invention, it is possible to realize a heater having a predetermined strength and a large calorific value using a carbon-based heating element with a low resistance value.

In the heater according to another aspect of the present invention, a part of the carbon-based heating element in the longitudinal direction is formed by crossing the plurality of wires.

The portion where the horizontal line extending in the width direction intersects the vertical line extending in the longitudinal direction has a low heat generation temperature, and the portion where the horizontal line does not intersect has a high heat generation temperature. According to the present invention, a heater having an arbitrary radiation intensity distribution with respect to the longitudinal direction can be realized by providing a weft-woven portion and a non-woven portion.

In the heater according to another aspect of the present invention, a thin plate is formed by a plurality of wires, a laminated flat plate in which a plurality of the thin plates are stacked is manufactured, and the flat plate is sintered with the shape held (shaped) by the resin, The carbon-based heating element is formed.

In the present invention, for example, a plurality of wires are arranged in the same direction to form a thin plate. A thin plate formed of lines (longitudinal lines) aligned in the longitudinal direction of the heater and a thin plate formed of lines (horizontal lines) aligned in the width direction of the heater were fabricated. When the thin plates made of vertical lines and the thin plates made of horizontal lines are alternately stacked to form a flat plate, it has the same rigidity as that of the heating element formed by crossing. Accordingly, a heater in which the wires of the carbon-based heating element do not unravel and do not break can be realized.

In the heater according to still another aspect of the present invention, the carbon-based heating element is in a laminated shape obtained by applying resin to a plurality of wires in advance and stacking a plurality of thin plates composed of the plurality of wires. Formed by flat sintering.

Accordingly, a heater in which the wires of the carbon-based heating element do not unravel and do not break can be realized.

In the heater according to still another aspect of the present invention, the carbon-based heating element is formed by coating and impregnating a resin on a laminated flat plate formed by stacking a plurality of thin plates made of a plurality of wires, followed by sintering.

Accordingly, a heater in which the wires of the carbon-based heating element do not unravel and do not break can be realized.

In the heater according to still another aspect of the present invention, a holding member for holding the carbon-based heating element extending in the longitudinal direction is provided at a position other than both ends of the carbon-based heating element.

According to the present invention, it is possible to realize a heater which prevents the shaking of the heating element and is resistant to vibration and shock caused by external force.

A heating device according to an aspect of the present invention includes the heater.

According to the present invention, a heating device using an inexpensive carbon-based heating element having an arbitrary resistance value can be realized.

The heating device according to another aspect of the present invention has a heater including a plurality of longitudinal wires extending in the longitudinal direction and horizontal wires extending in the width direction and oblique direction with only one return, and the heater is Configured so that the folded side of the horizontal line is placed on top.

The present invention can realize a heating device in which the horizontal lines extending in the width direction do not fall off.

The present invention has an advantageous effect of being able to realize a method for producing a carbon-based heating element in which carbon fibers do not scatter.

The present invention has the advantageous effect of being able to realize a carbon-based heating element in which carbon fibers do not scatter.

The present invention has the advantageous effect of being able to realize a heater using a carbon-based heating element that does not scatter carbon fibers, maintains a predetermined strength, and has a predetermined resistance value.

According to the present invention, an advantageous effect is obtained that a heating device having an arbitrary radiation intensity distribution with respect to the longitudinal direction can be realized.

The novel feature of the present invention is the content recorded in the claims. It is believed that the structure, content, purpose and features of the present invention can be better understood and evaluated through the accompanying drawings and the following detailed description.

Description of drawings

Fig. 1 is a diagram showing the configuration of a heater according to Embodiment 1 of the present invention.

Fig. 2 is a diagram showing the structure of a holding member according to Embodiment 1 of the present invention.

Fig. 3 is a diagram showing the configuration of a heating device according to Embodiment 2 of the present invention.

Fig. 4 is a diagram showing the configuration of a heater according to Embodiment 3 of the present invention.

Fig. 5 is a diagram showing the heat generation temperature distribution in the longitudinal direction of the heater according to Embodiment 3 of the present invention.

Fig. 6 is a diagram showing the configuration of a heater according to Embodiment 4 of the present invention.

Please note that part or all of the drawings are described in schematic representation for the purpose of illustration, and do not necessarily faithfully reflect the actual relative sizes and positions of the components shown.

Detailed ways

Hereinafter, an embodiment specifically showing the best mode for carrying out the present invention will be described with reference to the drawings.

(Embodiment 1)

A method for producing a carbon-based heating element, a carbon-based heating element, a heater, and a heating device according to Embodiment 1 of the present invention will be described with reference to FIGS. 1 and 2 . Fig. 1 is a diagram showing the structure of a heater according to Embodiment 1 of the present invention. The heater is formed by encapsulating the heating element 2 , the cooling block 3 and the internal wire 4 into the glass tube 1 .

The glass tube 1 is amorphous glass such as transparent quartz glass (for example, #214 produced by GE or borosilicate heat-resistant glass (product number #7190) produced by Dow Corning Co.). The diameter of the glass tube is made such that it does not collide with the heating element 2 even if it vibrates. In Embodiment 1, the size of the glass tube is 10.5 mm in diameter.

The heating element 2 is formed by making carbon fibers, that is, a plurality of longitudinal threads 2a extending in the longitudinal direction and a single transverse thread 2b extending in the width direction, into a plain weave. Next, a method of manufacturing the heating element will be described.

One weft yarn 2b and a plurality of warp yarns 2a are woven so as to intersect each other up and down in order (knitting step). The horizontal wires 2b are folded back at both ends in the width direction of the plurality of vertical wires 2a. A thin layer of resin is evenly applied to the braided warp and weft threads (coating step). The braided fabric (heat generating part) is sintered to integrate the whole (sintering step). The heating element is carbonized by sintering. The carbon-based heat generating element of Embodiment 1 is formed only of a plurality of continuous wires with no breaks between both ends in the longitudinal direction.

According to the manufacturing method of the present invention, the carbon fibers of the vertical wires 2a and the horizontal wires 2b can be evenly woven. The heating element 2 made of a plurality of thin vertical wires 2a and one thick horizontal wire 2b has a large resistance value. A horizontal wire 2b turns back at both ends of multiple vertical wires 2a to form a heating element. Even if the carbon fiber is used for a long time, it will not spread out, and a heating element that is not easy to break can be manufactured.

The wire described in this specification is used as a heating element and is made of carbon fiber or sintered carbon fiber.

The shape of the heating element 2 is flat, for example, a width T = 6 mm, a thickness t = 0.5 mm, and a length L = 300 mm. By setting T≧5t, a radiation intensity distribution characteristic having strong directivity in the direction perpendicular to the width portion of Tmm can be obtained.

By firing the resin after coating, the vertical wires 2a and the horizontal wires 2b can be reliably fixed.

In addition, as another effect, the specific gravity is changed from 0.8 to 2.0 by applying and firing the above-mentioned resin, resulting in increased rigidity.

Furthermore, if a resin having a high carbon remaining rate after sintering is used as the resin for the coating, the infrared emissivity can be increased. As a resin with a high carbon remaining rate after sintering, in addition to chlorinated vinyl chloride and diallyl phthalate monomers, polyvinyl chloride, polyacrylonitrile, polyvinyl alcohol, polyvinyl chloride and polyvinyl alcohol can also be used. Thermosetting resins such as copolymers of vinyl acetate, thermoplastic resins such as polyamides, phenolic resins, furan resins, epoxy resins, unsaturated polyester resins, and polyimide resins. Not only these monomers but also mixtures of two or more can be used.

The heat radiating block 3 is made of conductive material such as graphite, and is electrically connected to one end of the heating element 2 . The heat radiation block 3 has a cylindrical shape and has a notch (not shown) extending from one surface of the cylindrical shape (the surface on the heating element 2 side) to the other surface (the surface on the inner lead 4 side). The slot is not through. A carbon-based adhesive is applied to the heat generating body 2 composed of a plurality of thin longitudinal threads 2a and the transverse threads 2b woven on the longitudinal threads 2a, and inserted into the slot of the heat dissipation block 3. After the heating element 2 and the heat dissipation block 3 are closely fitted, they are dried and heated (sintered). As a result, the heating element 2 and the heat radiation block 3 are connected by a sintered body of an adhesive with high conductivity.

The strength of the junction can be increased by making the heating element 2 and the heat radiation block 3 bonded with a carbon-based adhesive. The adhesive is the same carbon-based material as the heating element 2 and the heat dissipation block 3, and its thermal expansion coefficient is approximately the same, so it can provide a heater that can withstand temperature cycles caused by heating on and off, and has good reliability. A general carbon-based binder is made by mixing carbon black into a thermosetting resin (preferably polyester resin and polyimide resin) and making it into a slurry.

Compared with the heating body, the heat generation of the heat dissipation block 3 itself is extremely small and negligible. The heat from the heating element 2 is transferred to the heat dissipation block 3, but since the heat dissipation block 3 has a large surface area (radiation area), part of the heat is dissipated from the surface of the heat dissipation block. Therefore, it is possible to prevent the temperature rise of the connection portion between the heat sink block 2 and the inner lead wire 4 , that is, the spiral portion 4 a.

One end of the inner lead wire 4 forms a coil-shaped portion 4a, and an elastic spring-shaped portion 4b is formed continuously to the coil-shaped portion 4a. The coil-shaped portion 4 a of the internal lead 4 is wound around the outer peripheral surface of the heat sink block 3 in close contact and electrically connected. The spring-shaped portion 4 b of the internal lead 4 is arranged at a predetermined interval from the outer peripheral surface of the heat sink block 3 . The function of the spring-like part is to apply tension to the heating element 2, which can prevent the heating element 2 from being bent due to thermal expansion and elongation caused by heat generation. The spring-like portion is configured to absorb a dimensional change caused by the expansion of the heating element 2 .

The inner wire 4 is connected to the outer wire 6 through the molybdenum foil 5 . The glass tube 1 is filled with inert gas such as argon, and the end of the glass tube 1 including the molybdenum foil 5 is melted and pressed into a flat plate for sealing. This prevents the heating element 2 of the carbonaceous material from being oxidized by reacting with oxygen in the air, thereby shortening the service life of the heating element.

When electric power is applied to the external wire 6 , current flows in the heating element 2 . Heat is generated by the resistance of the heating element to the electric current, and infrared rays are radiated from the heating element.

The holding members 7 are provided at positions other than both ends of the carbon-based heating element 2 in the glass tube 1 . In Embodiment 1, one holding member 7 is additionally provided in the center of the heating element.

Fig. 2 is a perspective view showing a holding member. The holding member 7 is formed of a carbon-based material. A notch 7 a having a width slightly larger than the plate thickness of the heating element 2 is formed in the holding member 7 . The heating element 2 is inserted into the notch 7a, and the holding member 7 is bonded to the heating element 2 with a carbon-based adhesive.

The circular plate-shaped holding member 7 has an outer shape slightly smaller than the inner diameter of the glass tube 1 . Thus, even if vibration or impact is applied to the heater from the outside, the outer shape of the holding member contacts the inner wall of the quartz glass tube, and the vibration amplitude of the heating element 2 can be suppressed to be small. As a result, a resonance phenomenon does not occur in the heating element, and a heating element can be provided in which the heating element does not collide with the inner wall of the quartz glass tube 1 to cause the heating element to be cut or damaged.

The holding member 7 only needs to have the function of holding the heating element 2 near the center of the quartz glass tube 1, so the thinner its thickness is within the allowable range of the strength of the plate, the less heat will be dissipated via the holding member, which is easier. good.

In the heating tube according to Embodiment 1 having the above-mentioned configuration, a predetermined resistance value can be obtained without the carbon fibers being scattered and maintaining a predetermined strength. The thinner the longitudinal wires extending in the longitudinal direction and the smaller the number of the longitudinal wires, the greater the resistance value of the heating element. According to the manufacturing method of the carbon-based heating element of the present invention, even if the longitudinal thread is made thin, it is also possible to weave one transverse thread at both ends of a plurality of longitudinal threads and intersect with the longitudinal thread to form the heating element. The specified strength can be maintained. The horizontal line will not fall off, and the heating element will not scatter.

In addition, the thicker the longitudinal wires are, and the larger the number of vertical wires is, the lower the resistance value of the heating element is, and a heater with a large heat generation can be realized. Furthermore, by laminating and forming the carbon-based heating element in multiple layers, a heater with a larger calorific value can be realized.

A heating device using the heater of the present invention can obtain a predetermined heat generation amount by changing the thickness and number of longitudinal wires of the heat generating element.

By making the vertical wires thinner (or reducing the number of vertical wires) and making the horizontal wires thicker (or increasing the number of horizontal wires), the strength of the carbon-based heating element can be reduced while maintaining the strength of the carbon-based heating element above the specified value. Calorific value.

By making the vertical wires thicker (or increasing the number of vertical wires) and making the horizontal wires thinner (or reducing the number of horizontal wires), the heating element can be enlarged while maintaining the size of the carbon-based heating element below a certain value of calorific value.

In Embodiment 1, a thin resin is uniformly applied to the heat-generating portion (the warp and weft threads after weaving), but instead, the heat-generating portion may be impregnated with resin and then sintered. In addition, it is also possible to form a heat generating part by using a wire coated with resin in advance, and then sinter it to manufacture a heat generating body. No matter which manufacturing method is used to manufacture the heating element, the resin can be used to strengthen the connection between the wires constituting the heating part. Prevents threads from unraveling.

In Embodiment 1, the spring-shaped portion 4b is provided in a part of the inner wire, but if the holding member 7 can sufficiently suppress deflection due to thermal expansion when the heating element generates heat, the spring-shaped portion may not be provided.

In the embodiment, the holding member 7 is provided, but the holding member may not be provided as long as the heating element 2 does not collide with the inner wall of the glass tube 1 when vibration and impact are applied from the outside. For example, when the size of the glass tube is sufficiently large for the heating element, or the overall length of the heater is short, and the heating element is stable, the holding member may not be provided.

In Embodiment 1, one horizontal wire 2b is folded back at both ends in the width direction of the heating element 2, but instead, the horizontal wire 2b may not be folded back at both ends. For example, at least one horizontal thread and a vertical thread of substantially the same length as the width of the heating element 2 may be interwoven.

However, instead of the carbon-based heating element of Embodiment 1 in which the longitudinal threads 2a and the horizontal threads 2b are alternately woven in a cloth-like configuration, the following carbon-based heating elements may be used.

After coating the resin on the wire, a thin plate is formed by passing multiple wires. For example, a thin plate with a plurality of vertical lines (lines extending in the longitudinal direction) and a thin plate with a plurality of horizontal lines (lines extending in the width direction) are formed separately. The Multiple thin plates are stacked to form a laminated flat plate. For example, thin plates formed by multiple vertical lines and thin plates formed by multiple horizontal lines are alternately stacked. Since the resin is coated on the lines in advance, the flat plate maintains its shape through the resin (giving Shape). The flat plate is sintered to form a carbon-based heating element. Thus, a heater having a carbon-based heating element with a horizontal line and a vertical line alternately laminated can be produced. According to this method, a heating element with the above-mentioned interwoven structure can be produced. It is a heating element with the same rigidity and the thread will not scatter or break at the same time.

Instead of coating the resin on the wires in advance and then sintering them to produce a plate-shaped carbon-based heating element, it is also possible to impregnate the flat plate after the horizontal thin plate and the vertical thin plate are overlapped with resin to maintain the plate shape (give shape).

Furthermore, the thin plates may be formed so that the vertical lines and the horizontal lines are at right angles and overlap each other, or the thin plates may be formed so that the vertical lines and the horizontal lines are at an oblique angle and overlap each other.

(Embodiment 2)

A method for producing a carbon-based heating element, a carbon-based heating element, a heater, and a heating device according to Embodiment 2 of the present invention will be described with reference to FIG. 3 . Fig. 3 is a diagram showing the structure of a heating device and a heating pipe according to Embodiment 2 of the present invention. The heating tube of the second embodiment differs from the heating tube of the first embodiment in that the heating element is used. The rest of the structure is the same as that of Embodiment 1, so description thereof will be omitted.

Next, a method for producing a carbon-based heating element using Embodiment 2 will be described. One horizontal yarn 31b of carbon fibers and the upper and lower sides of the plurality of longitudinal yarns 31a are sequentially cross-woven (weaving step). The horizontal wires 31b are folded back at both ends in the width direction of the plurality of vertical wires 31a. A thin layer of resin is evenly applied to the braided warp and weft threads (coating step). The braided fabric after weaving is sintered to integrate the whole (sintering step). The integrated heating element is divided into two in the length direction. According to the manufacturing method of the second embodiment, two heat generating elements can be manufactured from one braided plate-like fabric, and the manufacturing efficiency is high.

In the heating element 31 according to the second embodiment, the horizontal line is turned once at one end in the width direction of the heating element, and is not turned back at the other end. The heating device 32 according to the second embodiment is arranged so that the side of the heating pipe having the horizontal line 31b turned back is placed on the top. Thereby, even if the heating element is heated, the horizontal wire does not fall off, and the carbon fiber does not scatter, and an inexpensive heating device that can be used for a long time can be realized.

(Embodiment 3)

A method for producing a carbon-based heating element, a carbon-based heating element, a heater, and a heating device according to Embodiment 3 of the present invention will be described with reference to FIGS. 4 and 5 . Fig. 4 is a diagram showing the structure of a heater according to Embodiment 3 of the present invention. The heating device according to the third embodiment has the heating pipe shown in Fig. 4(a) and Fig. 4(b). In Embodiment 3, the heating device is a toner for a copier that places a small-width paper (copying object) in the center of the table (the center line of the large-width paper and the small-width paper is placed on the same axis). A heating device for agent fixing.

Fig. 5(a) is a diagram showing the temperature distribution in the longitudinal direction of the heating pipe of Fig. 4(a). Fig. 5(b) is a diagram showing the temperature distribution in the longitudinal direction of the heater in Fig. 4(b). Fig. 5(c) is a diagram showing the temperature distribution in the longitudinal direction when the heaters in Fig. 4(a) and Fig. 4(b) are both heated. In FIG. 5 , the vertical axis represents the temperature, and the horizontal axis represents the distance in the longitudinal direction of the heater. The origin corresponds to the boundary portion between the heat radiation block 3 and the coil-shaped portion 4 a on the left side of the heater.

The heater of the third embodiment differs from the heater of the first embodiment in that the heating element is used. The rest of the structure is the same as that of Embodiment 1, so description thereof will be omitted.

The heating element 41 of the heater shown in Fig. 4 (a) is to weave the weft portion except the two ends of the longitudinal thread. The heating element 42 of the heater shown in Fig. 4 (b) is to weave the weft and Both ends of the longitudinal thread are woven, and the center part is not woven with a weft. The resistance value of the part where the weft is woven is lower than that of the part without weaving, so the temperature is lower.

For example, in the heating device of Embodiment 3, power is supplied only to the heating element 42 when copying A4-size paper whose length is in the horizontal direction (FIG. 5(b)). When copying A3-size paper whose length is in the horizontal direction, power is supplied to both the heating element 41 and the heating element 42 (FIG. 5(c)). When electricity is supplied to both of the heating elements 41 and 42, the effective heat generation amount per unit area is substantially uniform in the longitudinal direction.

In Embodiment 3 of the present invention, by providing weft woven parts and non-woven parts on a plurality of longitudinal wires of the carbon fibers, the heating temperature distribution of the heating element in the longitudinal direction can be adjusted. Thereby, a heating device having an arbitrary heating temperature distribution in the longitudinal direction can be realized.

(Embodiment 4)

A method for producing a carbon-based heating element, a carbon-based heating element, a heater, and a heating device according to Embodiment 4 of the present invention will be described with reference to FIG. 6 . Fig. 6 is a diagram showing the structure of a heater according to Embodiment 4 of the present invention. The heater of the fourth embodiment differs from the heater of the first embodiment in the structure of the heating element. The heating element 61 according to Embodiment 4 is composed of a plurality of longitudinal wires 61a extending in the longitudinal direction and one oblique wire 61b extending obliquely. In Embodiment 4, the diagonal yarns 61b are woven sequentially across the top and bottom of the plurality of warp yarns at a predetermined angle (45° in FIG. 6 ) with respect to the longitudinal direction of the warp yarns 61a. The diagonal lines 61b are turned back at both ends in the width direction of the plurality of vertical lines 61a. The carbon-based heat generating element of Embodiment 4 is formed of only a plurality of continuous wires without breaks between both ends in the longitudinal direction.

Accordingly, it is possible to realize a heater using a carbon-based heating element having a predetermined resistance value while maintaining a predetermined strength without falling off the diagonal lines and maintaining a predetermined strength without spreading the carbon fibers. The resistance value can be changed by changing the thickness and number of the vertical wires 61a.

However, the diagonal thread is not limited to one, and two or more diagonal threads may intersect the vertical thread. For example, one diagonal thread is inserted at an angle of -45 degrees with respect to the vertical line 61a, and the other diagonal thread is inserted at an angle of 45 degrees with respect to the vertical line 61a. A plurality of diagonal lines are folded back at both ends in the width direction of the vertical lines.

The heating element can also be formed by braiding the longitudinal threads extending in the longitudinal direction into a three-ply braid, a rope, or a flat tape. In addition, the form of the cord of the heating element may be a tubular cord or a pocket-woven cord. Accordingly, a heater using a carbon-based heating element that can obtain a predetermined resistance value while maintaining a predetermined strength without unraveling carbon fibers can be realized.

Since the strength of the portion where the weft is woven is increased, the weft can be woven into the bent portion of the bent heater.

The heater of the present invention can be applied to heating equipment (such as electric furnace, Japanese kotatsu, air conditioner, infrared therapy instrument, etc.), drying equipment (such as clothes drying, quilt drying, food drying, fresh garbage processing machine, heating type disinfection equipment, etc.) Odor, etc.), cooking appliances (such as ovens, ovens, toaster ovens, toasters, grid electric ovens, warmers, chicken roasters, stoves, refrigerators for thawing, etc.), beauty appliances (such as drying Hair dryers, curling heaters, etc.), devices that fix text and images on films (such as LBP, PPC, fax, etc., that use toner as a medium for display, and use heat to heat transfer the film as it is to Equipment on the object to be transferred, etc.), etc., a heating device for the purpose of heating a non-heating object by a heat source.

The heater of the present invention is useful as a heating source of a heating device, and the heating device of the present invention can be applied to various applications.

The present invention has been described in detail using a preferred form, but the content disclosed in the preferred form can be changed in the details of the structure, and the combination and order of each component can be changed without departing from the scope and spirit of the present invention.

Claims (17)

1. the manufacture method that carbon is heater is characterized in that, comprising: with the step of heat generating part with the carbon fiber formation; Step in described heat generating part application of resin; The described heat generating part that has applied resin is carried out the step of sintering,

Described heat generating part is made of following part: towards many continuous separately length direction carbon fibers of length direction, and have at least on Width and turn back for 1 time and at least 1 Width carbon fiber that forms with the form braiding that intersects up and down along the continuous separately carbon fiber of described length direction.

2. the manufacture method that carbon is heater is characterized in that, comprising: with the step of heat generating part with the carbon fiber formation; Make described heat generating part contain the step of resin pickup; With impregnation the described heat generating part of resin carry out the step of sintering,

Described heat generating part is made of following part: towards many continuous separately length direction carbon fibers of length direction, and have at least on Width and turn back for 1 time and at least 1 Width carbon fiber that forms with the form braiding that intersects up and down along the continuous separately carbon fiber of described length direction.

3. the manufacture method that carbon is heater is characterized in that, comprising: the step that constitutes heat generating part by the prior carbon fiber that has applied resin; Described heat generating part is carried out the step of sintering,

Described heat generating part is made of following part: towards many continuous separately length direction carbon fibers of length direction, and have at least on Width and turn back for 1 time and at least 1 Width carbon fiber that forms with the form braiding that intersects up and down along the continuous separately carbon fiber of described length direction.

4. a carbon is heater, it is characterized in that, comprising: the heat generating part that is made of carbon fiber; To being connected the resin of reinforcement between carbon fiber and the carbon fiber,

Described heat generating part is carried out sintering to following part and is formed: towards many continuous separately length direction carbon fibers of length direction, and have at least on Width and turn back for 1 time and at least 1 Width carbon fiber that forms with the form braiding that intersects up and down along the continuous separately carbon fiber of described length direction.

5. a heater is characterized in that, having the described carbon of claim 4 is that heater is sealed in the structure in the glass tube.

6. heater as claimed in claim 5 is characterized in that, described to have the carbon fiber of turning back for 1 time on Width at least be the horizontal or oblique continuous carbon fiber that extends towards Width.

7. heater as claimed in claim 5 is characterized in that, described carbon is that heater forms tabular.

8. heater as claimed in claim 5 is characterized in that, described carbon is that heater is formed by multilayer laminated.

9. heater as claimed in claim 5 is characterized in that, described carbon is that heater is by constituting towards the thin carbon fiber of length direction extension and the thick carbon fiber that extends towards Width.

10. heater as claimed in claim 5 is characterized in that, described carbon is that heater is by constituting towards the thick carbon fiber of length direction extension and the thin carbon fiber that extends towards Width.

11. heater as claimed in claim 5 is characterized in that, described carbon is that a heater part is in the longitudinal direction intersected to form by many carbon fibers.

12. heater as claimed in claim 5 is characterized in that, forms thin plate by many carbon fibers, makes the flat board of the layered laminate that a plurality of described thin plates are overlapped, and will keep the described flat board of shape to carry out sintering by resin, forming described carbon is heater.

13. heater as claimed in claim 5 is characterized in that, resin is coated on the many carbon fibers in advance, the flat board of the overlapping layered laminate that forms of a plurality of thin plates that will be made of described many carbon fibers carries out sintering, and forming described carbon is heater.

14. heater as claimed in claim 5 is characterized in that, on the flat board of the layered laminate that the thin plate multi-disc that is made of many carbon fibers overlaps the coating or contain the laggard capable sintering of resin pickup, forming described carbon is heater.

15. heater as claimed in claim 5 is characterized in that, will be that to be arranged on described carbon be positions beyond the heater both ends for retaining member that heater keeps to the described carbon that extends towards length direction.

16. a heater is characterized in that, has the described heater of claim 5.

17. heater as claimed in claim 16, it is characterized in that, has heater, many carbon fibers of this heater comprise the length direction carbon fiber that extends towards length direction and at an end of Width along horizontal or obliquely have the Width carbon fiber of turning back for 1 time at least, make the side of turning back of the described carbon fiber that extends towards Width dispose above-mentioned heater in the above.

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