JP6060421B2 - Heating element, method for manufacturing the same, and heater - Google Patents
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- JP6060421B2 JP6060421B2 JP2013034113A JP2013034113A JP6060421B2 JP 6060421 B2 JP6060421 B2 JP 6060421B2 JP 2013034113 A JP2013034113 A JP 2013034113A JP 2013034113 A JP2013034113 A JP 2013034113A JP 6060421 B2 JP6060421 B2 JP 6060421B2
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- 238000010438 heat treatment Methods 0.000 title claims description 202
- 238000004519 manufacturing process Methods 0.000 title claims description 11
- 238000000034 method Methods 0.000 title description 6
- 238000004804 winding Methods 0.000 claims description 55
- 239000011162 core material Substances 0.000 claims description 25
- 238000007906 compression Methods 0.000 claims description 14
- 230000006835 compression Effects 0.000 claims description 13
- 238000005520 cutting process Methods 0.000 claims description 5
- 230000020169 heat generation Effects 0.000 description 8
- 239000002184 metal Substances 0.000 description 8
- 229910052751 metal Inorganic materials 0.000 description 8
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 239000000463 material Substances 0.000 description 5
- 230000001105 regulatory effect Effects 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 238000002474 experimental method Methods 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 229910001120 nichrome Inorganic materials 0.000 description 3
- 238000004904 shortening Methods 0.000 description 3
- 238000005452 bending Methods 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- 238000009529 body temperature measurement Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
Description
本発明は、発熱体、その製造方法、及び、加熱器に関する。 The present invention relates to a heating element, a manufacturing method thereof, and a heater.
従来、加熱器として種々の形態のものが知られているが、その一つとして、コイル状電熱線からなる発熱体を通電加熱することにより加熱を行う加熱器が知られている。このようなコイル状電熱線からなる発熱体を用いる加熱器も種々存在するが、例えば、特許文献１に開示されているようなものが知られている。 Conventionally, various types of heaters are known, and one of them is a heater that heats a heating element made of a coiled heating wire by energization heating. There are various heaters using such a heating element composed of a coiled heating wire. For example, the one disclosed in Patent Document 1 is known.
この特許文献１に開示されている加熱器は、図１５の概略構成断面図に示すように、花巻状に巻回されたコイル状電熱線からなる発熱体１００と、当該発熱体１００の内部空間に挿入される絶縁性材料からなる芯材１０１と、芯材１０１に発熱体をセットすることにより構成される構造物を被覆する管状のガラス管１０２等とを備えている。芯材１０１は中空状に形成されており、発熱体１００の端部に接続する導線を芯材内部に配置できるように構成されている。また、このような構成の加熱器の一方端には、空気を供給する装置が接続されており、供給された空気を加熱して加熱器の他方端からホットエアーを吹き出すことができるように構成されている。 As shown in the schematic configuration cross-sectional view of FIG. 15, the heater disclosed in Patent Document 1 includes a heating element 100 formed of a coiled heating wire wound in a flower winding shape, and an internal space of the heating element 100. A core material 101 made of an insulating material, and a tubular glass tube 102 that covers a structure formed by setting a heating element on the core material 101. The core material 101 is formed in a hollow shape, and is configured such that a conducting wire connected to the end of the heating element 100 can be disposed inside the core material. Further, a device for supplying air is connected to one end of the heater having such a configuration, and the supplied air is heated so that hot air can be blown out from the other end of the heater. Has been.
上述の特許文献１に開示されている加熱器は、花巻状のコイル状電熱線を有していることから、通常の丸巻きとして形成されたコイル状電熱線を備える加熱器よりも優れた発熱特性を有しているものであり、丸巻き状のコイル状電熱線を備える加熱器よりも小型化が可能なものである。しかしながら、更なる小型化、特に、コイル状電熱線の長さ方向の短縮が求められている。コイル状電熱線の長さ方向の短縮を行うためには、例えば、花巻コイル状電熱線に薄い絶縁被膜（主成分：アルミナ、被膜厚さ：１μｍ）を設け、巻きのピッチ間を密着させることにより可能であるが、このような場合、電熱線の径と、巻き数との関係により、おのずとコイル状電熱線の長さ方向の短縮に限界がある。 Since the heater disclosed in Patent Document 1 described above has a flower-shaped coiled heating wire, the heat generation is superior to a heater provided with a coiled heating wire formed as a normal round winding. It has characteristics and can be made smaller than a heater provided with a round coiled heating wire. However, further miniaturization, particularly shortening of the length of the coiled heating wire is required. In order to shorten the length of the coiled heating wire, for example, a thin insulating film (main component: alumina, film thickness: 1 μm) is provided on the flower-wound coiled heating wire, and the pitch of the windings is closely adhered. However, in such a case, there is a limit in shortening the length of the coiled heating wire due to the relationship between the diameter of the heating wire and the number of turns.
また、コイル状電熱線の長さ方向の短縮を行う他の方法としては、例えば、花巻コイル状電熱線の巻き径を大きくして、巻き数を少なくすることが考えられるが、このような方策では、巻き数の減少を伴うため、絶縁被膜に加わる電圧が上昇し絶縁被膜の絶縁耐圧を超える恐れがあり、安定した製品を得ることは難しいという問題があった。また、このような方策を採用した場合、コイル状電熱線の長さを短縮することはできるが、コイル状電熱線の外径が増大することとなり、コイル状電熱線の小型化要求を必ずしも満たしているとはいえないという問題もある。 Further, as another method for shortening the length of the coiled heating wire, for example, it is conceivable to increase the winding diameter of the flower winding coiled heating wire to reduce the number of turns. However, since the number of windings is reduced, the voltage applied to the insulating film increases and may exceed the withstand voltage of the insulating film, and it is difficult to obtain a stable product. In addition, when such a measure is adopted, the length of the coiled heating wire can be shortened, but the outer diameter of the coiled heating wire is increased, and the requirement for downsizing the coiled heating wire is not always satisfied. There is also a problem that it cannot be said.
また、コイル状電熱線を構成する電熱線の径を小さくして、電熱線の展開長さを短くすればコイル状電熱線（発熱体）の小型化は可能であるが、この方策の場合、巻き数の減少による絶縁耐圧の問題と、発熱体の有効表面積の低下により表面負荷が大きくなるという問題がある、これは、同じ熱風温度でも発熱体温度がより高温になることを意味し、発熱体（当該発熱体を用いる加熱器）の寿命が大幅に短くなってしまうという問題がある。 In addition, if the diameter of the heating wire constituting the coiled heating wire is reduced and the length of the heating wire is shortened, the coiled heating wire (heating element) can be reduced in size. There is a problem of withstand voltage due to a decrease in the number of windings and a problem that the surface load increases due to a decrease in the effective surface area of the heating element. This means that the heating element temperature becomes higher even at the same hot air temperature. There is a problem that the life of the body (the heater using the heating element) is significantly shortened.
本発明は、このような問題を解決するためになされたものであって、従来よりも小型の発熱体、その製造方法、及び当該発熱体を用いた加熱器を提供することを目的とする。 The present invention has been made to solve such a problem, and an object of the present invention is to provide a heating element that is smaller than the conventional one, a manufacturing method thereof, and a heater using the heating element.
本発明の上記目的は、コイル状電熱線からなる発熱体であって、前記コイル状電熱線は、非円形に複数回巻かれた花巻状に形成されており、前記コイル状電熱線の軸線に沿って螺旋状に配設される隣り合う電熱線同士の接触部において、前記コイル状電熱線の軸線に沿う方向に屈曲する屈曲部を備えることを特徴とする発熱体により達成される。 The object of the present invention is a heating element composed of a coiled heating wire, wherein the coiled heating wire is formed in a flower winding shape that is wound non-circularly a plurality of times, and is formed on the axis of the coiled heating wire. This is achieved by a heating element comprising a bent portion that bends in a direction along the axis of the coiled heating wire at a contact portion between adjacent heating wires that are spirally arranged.
また、本発明の上記目的は、発熱体の製造方法であって、長尺状の電熱線を花巻状に巻回し、花巻コイルを形成する花巻ステップと、前記花巻ステップにより形成された前記花巻コイルを所定長さに切断する切断ステップと、切断された前記花巻コイルの両端部を前記花巻コイルの軸線方向に沿って圧縮することによって、前記花巻コイルの軸線に沿って螺旋状に配設される隣り合う電熱線同士の接触部において、前記花巻コイルの軸線に沿う方向に屈曲する屈曲部を形成する圧縮ステップとを備える発熱体の製造方法により達成される。 The above-mentioned object of the present invention is a method for manufacturing a heating element, in which a long heating wire is wound into a flower winding shape to form a flower winding coil, and the flower winding coil formed by the flower winding step. A cutting step of cutting the coiled coil into a predetermined length, and compressing both ends of the cut coiled coil along the axial direction of the coiled coil so as to be spirally disposed along the axis of the coiled coil. This is achieved by a heating element manufacturing method comprising a compression step for forming a bent portion that bends in a direction along the axis of the flower winding coil at a contact portion between adjacent heating wires.
また、本発明の上記目的は、コイル状電熱線からなる発熱体を有する加熱器であって、前記コイル状電熱線は、非円形に複数回巻かれた花巻状に形成されており、前記コイル状電熱線の軸線に沿って螺旋状に配設される隣り合う電熱線同士の接触部において、前記コイル状電熱線の軸線に沿う方向に屈曲する屈曲部を備えることを特徴とする加熱器により達成される。 Another object of the present invention is a heater having a heating element composed of a coil-shaped heating wire, wherein the coil-shaped heating wire is formed in a non-circular shape that is wound in a flower shape. A heater comprising a bent portion that bends in a direction along the axis of the coiled heating wire at a contact portion between adjacent heating wires arranged spirally along the axis of the heating wire. Achieved.
また、この加熱器において、前記コイル状電熱線の内部空間に挿入される芯材と、前記コイル状電熱線を被覆する管状体とを更に備えることが好ましい。 Moreover, it is preferable that this heater further includes a core member inserted into the internal space of the coiled heating wire and a tubular body that covers the coiled heating wire.
また、前記管状体の一方の端部側から前記管状体の内部に空気を供給する空気供給手段を備えることが好ましい。 Moreover, it is preferable to provide an air supply means for supplying air into the inside of the tubular body from one end side of the tubular body.
本発明によれば、従来よりも小型の発熱体、その製造方法、及び当該発熱体を用いた加熱器を提供することができる。 According to the present invention, it is possible to provide a heating element that is smaller than the conventional one, a method for manufacturing the same, and a heater using the heating element.
以下、本発明の実施形態について添付図面を参照して説明する。図１は、本発明の一実施形態にかかる加熱器１を示す概略構成断面図である。この加熱器１は、図１に示すように、略円柱形状の棒状の芯材２と、芯材２の外周面上に配置される発熱体３と、管状体４とを備えている。芯材２、発熱体３、及び管状体４により構成される構造物は、その一方端に設けられる固定具５を介して一体的に組み立てられている。 Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 1 is a schematic cross-sectional view showing a heater 1 according to an embodiment of the present invention. As shown in FIG. 1, the heater 1 includes a substantially cylindrical rod-shaped core material 2, a heating element 3 disposed on the outer peripheral surface of the core material 2, and a tubular body 4. The structure constituted by the core member 2, the heating element 3, and the tubular body 4 is integrally assembled through a fixture 5 provided at one end thereof.
芯材２は、内部が中空となる管体状に構成されており、絶縁材料から形成されている。この芯材２を形成する材料としては、例えば、アルミナ(Al2O3) 等のセラミック材料を挙げることができる。また、この芯材２には、コイル状電熱線からなる発熱体３が外周に配置されることになるが、かかる発熱体３の位置決め行う規制部材２１を設けるのが好ましい。規制部材２１は、芯材２の両端部に配置され、各規制部材２１の間に発熱体３が配置されるように構成される。規制部材２１は、図２に示すように、金属材料から形成したリング状部材２１ａの軸部にコイル状部材２１ｂの中空軸部を挿通させることにより、コイル状部材２１ｂがリング状部材２１ａを被覆するように構成されている（リング状部材２１ａの軸部の表面をコイル状部材２１ｂが被覆するように構成されている）。コイル状部材２１ｂで被覆されたリング状部材２１ａにより芯材２の外周部を挟み込むことにより、規制部材２１を芯材２に設置する。また、コイル状部材２１ｂにおける互いに隣接する線材間には、図２に示すように、隙間が形成されるように構成されている。 The core material 2 is configured in a tubular shape having a hollow inside, and is formed of an insulating material. Examples of the material for forming the core material 2 include ceramic materials such as alumina (Al2O3). The core member 2 is provided with a heating element 3 made of a coiled heating wire on the outer periphery, but it is preferable to provide a regulating member 21 for positioning the heating element 3. The regulating member 21 is arranged at both ends of the core member 2, and the heating element 3 is arranged between the regulating members 21. As shown in FIG. 2, the regulating member 21 is formed by inserting the hollow shaft portion of the coil-shaped member 21b through the shaft portion of the ring-shaped member 21a formed of a metal material, so that the coil-shaped member 21b covers the ring-shaped member 21a. (The coil-shaped member 21b is configured to cover the surface of the shaft portion of the ring-shaped member 21a). The regulating member 21 is installed on the core 2 by sandwiching the outer periphery of the core 2 with the ring-shaped member 21a covered with the coil-shaped member 21b. Moreover, as shown in FIG. 2, it is comprised so that a clearance gap may be formed between the mutually adjacent wire materials in the coil-shaped member 21b.
発熱体３は、コイル状電熱線により構成されており、当該コイル状電熱線は、非円形に複数回巻かれた花巻状に形成されている。電熱線としては、例えばニクロム線の表面に、薄い絶縁被膜を形成した線材を利用することができる。この電熱線としては、例えば、その直径が０．１５ｍｍ〜２．０ｍｍの範囲のものを採用することが好ましい。なお、ニクロム線の代わりに、コイル状電熱線からなる発熱体３として従来から使用されている電熱線（例えば、タングステン線、カンタル線等）を利用することができる。また、電熱線表面に形成される絶縁被膜は、例えばアルミナ等のセラミックス材料により形成されている。 The heating element 3 is configured by a coiled heating wire, and the coiled heating wire is formed in a flower winding shape that is wound non-circularly a plurality of times. As the heating wire, for example, a wire material in which a thin insulating film is formed on the surface of a nichrome wire can be used. As this heating wire, for example, it is preferable to adopt a wire having a diameter in the range of 0.15 mm to 2.0 mm. In addition, the heating wire (for example, a tungsten wire, a cantal wire, etc.) conventionally used as the heat generating body 3 which consists of a coil-shaped heating wire can be utilized instead of a nichrome wire. The insulating coating formed on the surface of the heating wire is made of a ceramic material such as alumina.
この発熱体３（コイル状電熱線）の両端部には、外部の電源装置（図示せず）に接続する導線がそれぞれ接続している。当該発熱体３の一方の端部に接続する導線は、上述の芯材２の内部に通され、発熱体３の他方の端部側に引き廻され、外部の電源装置に接続できるように構成されている。なお、電源装置には、発熱体３に供給する電力量を調節する調節部が設けられており、発熱体３の温度を適宜変更可能となるように構成されている。 Conductive wires connected to an external power supply device (not shown) are connected to both ends of the heating element 3 (coiled heating wire). A conducting wire connected to one end of the heating element 3 is passed through the inside of the core member 2 and routed to the other end of the heating element 3 so that it can be connected to an external power supply device. Has been. Note that the power supply device is provided with an adjustment unit that adjusts the amount of power supplied to the heating element 3, and is configured so that the temperature of the heating element 3 can be appropriately changed.
また、発熱体３（コイル状電熱線）は、上述のように花巻状に巻回されて構成されている。電熱線を、花巻状に形成したコイル状電熱線とするためには、従来からの種々の方法を採用することができる。例えば、特開平６−７２６３３号公報や、特開２００７−２２７２９号公報に開示されている装置や方法により、花巻状のコイル状電熱線を形成することが可能である。花巻状のコイル状電熱線の形態としては、電熱線を非円形に複数回巻かれた形態であれば特に限定されず、種々の形態を採用することができる。例えば、図１におけるＡ−Ａ断面を示す図３に示すように、略Ｕ字形状（或いは略Ｖ字形状）に径方向外側に膨出するような形態として、花巻状のコイル状電熱線を構成してもよい。 In addition, the heating element 3 (coiled heating wire) is configured to be wound in a flower winding shape as described above. In order to make the heating wire into a coiled heating wire formed in the shape of a flower winding, various conventional methods can be employed. For example, it is possible to form a coiled coiled heating wire by the apparatus and method disclosed in Japanese Patent Laid-Open No. 6-72633 and Japanese Patent Laid-Open No. 2007-22729. The form of the flower winding coiled heating wire is not particularly limited as long as the heating wire is wound a plurality of times in a non-circular shape, and various forms can be adopted. For example, as shown in FIG. 3 showing the AA cross section in FIG. It may be configured.
また、発熱体３（コイル状電熱線）は、隣り合う電熱線同士が接触するように構成されている。また、従来からある花巻状のコイル状電熱線において、隣り合う電熱線同士が接触するように構成した場合、図４の模式側面図に示すように、隣り合う電熱線３１，３１同士には、コイル状電熱線の軸線に沿って螺旋状に配置される接触部３２が形成されることとなるが、本発明に係る発熱体３（コイル状電熱線）は、図５の模式側面図に示すように、螺旋状に配置される接触部３２において、コイル状電熱線の軸線に沿う方向に略く字状或いは湾曲状に屈曲する屈曲部３３が形成されており、当該屈曲部３３において、隣り合う電熱線同士が互いに接触する構造となっている。なお、接触部３２は、電熱線３１の一巻きごとにズレた位置となるように構成されており、一巻きごとの各接触部３２がコイル状電熱線の軸線方向に沿って一直線上に配置されないようにコイル状電熱線を構成する。 Moreover, the heat generating body 3 (coiled heating wire) is comprised so that adjacent heating wires may contact. Moreover, in the conventional coiled heating wire in the shape of a coil, when the adjacent heating wires are configured to contact each other, as shown in the schematic side view of FIG. Although the contact part 32 arrange | positioned spirally along the axis line of a coiled heating wire will be formed, the heat generating body 3 (coiled heating wire) which concerns on this invention is shown to the schematic side view of FIG. Thus, in the contact portion 32 arranged in a spiral shape, a bent portion 33 that is bent in a substantially letter shape or a curved shape is formed in a direction along the axis of the coiled heating wire. Matching heating wires are in contact with each other. In addition, the contact part 32 is comprised so that it may become a position shifted for every winding of the heating wire 31, and each contact part 32 for every winding is arrange | positioned on the straight line along the axial direction of a coiled heating wire. The coiled heating wire is configured so as not to be.
このような構造を有する発熱体３（コイル状電熱線）は、例えば、図６に示すように、長尺状の電熱線３１を花巻状に巻回して花巻コイルＺを形成（花巻ステップ；図６（ａ））した後、当該花巻コイルＺを所定長さに切断し（切断ステップ；図６（ｂ）、切断された花巻コイルＺを筒状体５０の内部に収納し（図６（ｃ））、花巻コイルＺの両端部を花巻コイルＺの中央部に向けて花巻コイルＺの軸線方向に沿って圧縮することによって、花巻コイルＺの軸線に沿って螺旋状に配設される隣り合う電熱線３１，３１同士の接触部３２において、花巻コイルＺの軸線に沿う方向に屈曲する屈曲部３３を形成すること（圧縮ステップ；図６（ｃ））により製造することができる。ここで、花巻コイルＺの軸線方向に沿って圧縮する際の圧縮力は、例えば、花巻コイルＺを構成する電熱線の材料や電熱線径、巻き数等に応じて適宜設定すればよいが、例えば、１００Ｎ〜５００Ｎの範囲で設定することができる。 For example, as shown in FIG. 6, the heating element 3 (coiled heating wire) having such a structure is formed by winding a long heating wire 31 into a flower winding shape to form a flower winding coil Z (flower winding step; FIG. 6 (a)), the flower winding coil Z is cut into a predetermined length (cutting step; FIG. 6 (b)), and the cut flower winding coil Z is stored inside the cylindrical body 50 (FIG. 6 (c). )), By compressing both ends of the flower-wound coil Z toward the center of the flower-wound coil Z along the axial direction of the flower-wound coil Z, adjacent to each other arranged spirally along the axis of the flower-wound coil Z In the contact part 32 of the heating wires 31 and 31, it can manufacture by forming the bending part 33 bent in the direction along the axis line of the flower winding coil Z (compression step; FIG.6 (c)). The compression force when compressing along the axial direction of the flower winding coil Z is For example, the material and the heating wire diameter of the heating wire constituting the Hanamaki coil Z, may be appropriately determined in accordance with the number of turns or the like, for example, can be set in the range of 100N～500N.
また、管状体４は、芯材２の外周を被覆するように発熱体３の内部空間に芯材２を挿入した構造物を更に被覆するための部材である。この管状体４としては、例えば、石英ガラス管や、セラミックス管、金属管、石英ガラス管の外周を金属管で被覆した複合管等、種々の管体を使用することができる。本実施形態においては、管状体４として、石英ガラス管４１の外周を金属管４２で被覆した複合管を用いている。 The tubular body 4 is a member for further covering a structure in which the core material 2 is inserted into the internal space of the heating element 3 so as to cover the outer periphery of the core material 2. As the tubular body 4, various tubular bodies such as a quartz glass tube, a ceramic tube, a metal tube, and a composite tube in which the outer periphery of the quartz glass tube is covered with a metal tube can be used. In the present embodiment, a composite tube in which the outer periphery of the quartz glass tube 41 is covered with a metal tube 42 is used as the tubular body 4.
また、本発明に係る加熱器１は、管状体４の内部に空気を供給する空気供給手段（図示せず）を更に備えている。当該空気供給手段は、管状体４の一方の端部４ａ側から当該管状体４の内部に空気を供給できるように構成されている。空気供給手段としては、例えば、吸引ポンプを備える本体部と、吸引ポンプにより吸引した空気を管状体４の内部に導く空気パイプ６と、当該空気パイプ６から管状体４に排出される空気量を適宜変更するために吸引ポンプの作動をコントロールする制御部とを備えるように構成されている。空気を管状体４に導く空気パイプ６の先端は、図１における固定具５に接続されており、供給された空気は、固定具５の内部を介して管状体４の一方の端部４ａに導かれて管状体４内部に導入され、管状体４内部に配置される発熱体３によって加熱され、管状体４の他方の端部４ｂから加熱された状態となって吹き出すこととなる。なお、芯材２に配置される規制部材２１は、上述のように、互いに隣接する線材間に隙間が形成されるコイル状部材２１ｂの中空軸部にリング状部材２１ａを挿入するようにして構成されているため、管状体４の内部に導かれた空気が、コイル状部材２１ｂを構成する互いに隣接する線材間の隙間を通過して流れるため、空気が管状体４内部で詰まることなくスムーズに流れることができる。 The heater 1 according to the present invention further includes air supply means (not shown) for supplying air into the tubular body 4. The air supply means is configured to be able to supply air into the tubular body 4 from the one end 4 a side of the tubular body 4. As the air supply means, for example, a main body provided with a suction pump, an air pipe 6 for guiding the air sucked by the suction pump to the inside of the tubular body 4, and the amount of air discharged from the air pipe 6 to the tubular body 4 And a controller that controls the operation of the suction pump in order to change as appropriate. The tip of the air pipe 6 that guides air to the tubular body 4 is connected to the fixture 5 in FIG. 1, and the supplied air passes through the inside of the fixture 5 to one end 4 a of the tubular body 4. It is guided and introduced into the tubular body 4, heated by the heating element 3 disposed inside the tubular body 4, and blown out from the other end 4 b of the tubular body 4 in a heated state. The restricting member 21 disposed on the core member 2 is configured such that the ring-like member 21a is inserted into the hollow shaft portion of the coil-like member 21b in which a gap is formed between adjacent wire members as described above. Therefore, the air guided to the inside of the tubular body 4 flows through the gaps between the adjacent wires constituting the coiled member 21b, so that the air is smoothly blocked without clogging inside the tubular body 4. Can flow.
また、本発明に係る加熱器１においては、管状体４の内部に、温度計測用の熱電対等の温度センサーを配設するように構成してもよい。温度センサーは、単数でも複数でもよいが、発熱体３の中央部及び端部付近の温度を計測できるように複数配設するように構成することが好ましい。 Moreover, in the heater 1 which concerns on this invention, you may comprise so that temperature sensors, such as a thermocouple for temperature measurement, may be arrange | positioned inside the tubular body 4. FIG. The temperature sensor may be a single temperature sensor or a plurality of temperature sensors, but it is preferable that a plurality of temperature sensors are arranged so as to measure the temperature near the center and end of the heating element 3.
上記のように構成された加熱器１においては、用いられる発熱体３として、非円形に複数回巻かれた花巻状のコイル状電熱線を使用しており、当該花巻状のコイル状電熱線は、コイル状電熱線の軸線に沿って螺旋状に配設される隣り合う電熱線同士の接触部３２において、コイル状電熱線の軸線に沿う方向に屈曲する屈曲部３３を備えるように構成されている。このような構成により、コイルの巻き径や巻き数を減じることなく、コイル状電熱線の長さ（軸方向長さ）を短くすることが可能となり、発熱体３や加熱器１の小型化を図ることが可能となる。 In the heater 1 configured as described above, as the heating element 3 to be used, a coiled coiled heating wire wound in a non-circular shape is used, and the coiled coiled heating wire is The contact portion 32 between adjacent heating wires arranged spirally along the axis of the coiled heating wire is configured to include a bent portion 33 that bends in the direction along the axis of the coiled heating wire. Yes. With such a configuration, it becomes possible to shorten the length of the coiled heating wire (length in the axial direction) without reducing the coil winding diameter and the number of windings, thereby reducing the size of the heating element 3 and the heater 1. It becomes possible to plan.
また、本発明に係る加熱器１は、空気供給手段を介して空気が管状体４の内部に供給され、熱風として外部に吹き出す構造を有している。このような加熱器１の場合、供給される空気の供給圧力によって、管状体４内部における発熱体３は、強い風圧を受けることとなる。従来の花巻状のコイル状電熱線により発熱体を構成した場合には、高温により軟化した電熱線が風圧により不均一な圧縮を受けて、発熱密度の不均一が発生する恐れがあった。更に、発熱体の温度が最も高くなる熱風出口側（管状体４の他方の端部側）が最も圧縮されるので、この部分が更に高温となり、発熱体（加熱器）の寿命を大幅に縮めてしまうという問題があった。これに対し、本発明に係る発熱体３においては、従来からある花巻状のコイル状電極線をその軸方向に圧縮することによって、隣り合う電熱線３１，３１同士が接触する接触部３２においてコイル状電熱線の軸線に沿う方向に略く字状に屈曲する屈曲部３３を形成し、当該屈曲部３３において、隣り合う電熱線同士が互いに接触（密接）した構造を有するように構成しているため、風圧による圧縮変形がほとんど発生せず、発熱密度の不均一が発生することを効果的に防止し、発熱密度の均一化を図ることが可能となる。つまり、本発明に係る発熱体３及び加熱器１は、小型化が可能となることに加え、耐風圧体力も大幅に向上し、大風量に耐えることができ、更にはこれにより、発熱体３（加熱器１）の長寿命化を図ることが可能となる。また、発熱密度が均一化できることにより発熱体３の熱ロスを少なくでき、加熱器１の熱効率向上にも寄与する。また。発熱密度が不均一であった従来の発熱体の場合、耐久性の観点から、最高熱風温度を８５０度程度に設定していたが、発熱密度を均一化できる本発明の発熱体３の場合、発熱密度を増大させて最高熱風温度を５０度程度高めることが可能となる。 Moreover, the heater 1 according to the present invention has a structure in which air is supplied into the tubular body 4 through the air supply means and blown out as hot air. In the case of such a heater 1, the heating element 3 inside the tubular body 4 receives a strong wind pressure due to the supply pressure of the supplied air. In the case where the heating element is configured by a conventional coiled coil-shaped heating wire, the heating wire softened due to high temperature may be subjected to non-uniform compression by wind pressure, which may cause non-uniform heat generation density. Furthermore, since the hot air outlet side (the other end side of the tubular body 4) where the temperature of the heating element becomes the highest is compressed most, this part is further heated, and the life of the heating element (heater) is greatly shortened. There was a problem that. On the other hand, in the heating element 3 according to the present invention, by compressing a conventional coiled coil-shaped electrode wire in the axial direction, a coil is formed at the contact portion 32 where the adjacent heating wires 31 contact each other. A bent portion 33 that is bent substantially in a letter shape in the direction along the axis of the heating wire is formed, and the bent portion 33 has a structure in which adjacent heating wires are in contact with each other (closely). Therefore, almost no compressive deformation due to wind pressure occurs, and it is possible to effectively prevent the occurrence of non-uniform heat generation density and to make the heat generation density uniform. In other words, the heating element 3 and the heater 1 according to the present invention can be downsized, and the wind-resistant body force can be greatly improved and can withstand a large amount of air. It becomes possible to extend the life of (heater 1). Further, since the heat generation density can be made uniform, the heat loss of the heating element 3 can be reduced, which contributes to the improvement of the thermal efficiency of the heater 1. Also. In the case of the conventional heating element in which the heat generation density is not uniform, the maximum hot air temperature was set to about 850 degrees from the viewpoint of durability, but in the case of the heating element 3 of the present invention that can make the heat generation density uniform, The maximum hot air temperature can be increased by about 50 degrees by increasing the heat generation density.
また、従来からある花巻状のコイル状電極線においては、隣り合う電極線同士における接触形態が点接触となるため、コイル状電極線を持ち上げたり、台等の上に載置する際に、点接触部分が摺れたり、当該点接触部分に予期せぬ圧力が加わったりして、絶縁被膜が剥がれやすいという問題があった。これに対し、本発明に係る発熱体３は、上述のように、従来からある花巻状のコイル状電極線をその軸方向に圧縮することによって、隣り合う電熱線同士が接触する接触部３２においてコイル状電熱線の軸線に沿う方向に略く字状に屈曲する屈曲部３３を形成し、当該屈曲部３３において、隣り合う電熱線同士が互いに接触（密接）した構造を有しているため、隣り合う電極線同士の接触部分における電極線は、互いに押し潰された形状とあっている。つまり、隣り合う電極線同士の接触形態は、面接触の形態を有することになる。これにより、隣り合う電極線同士の接触圧力が低く保たれることになり、接触部分が摺れたり、予期せぬ圧力が加わったとしても、電熱線の表面に形成される絶縁被膜が剥がれにくくなり、発熱体３の扱いが大幅に容易となる。 Further, in the conventional coiled coiled electrode wire, the contact form between adjacent electrode wires is point contact, so when the coiled electrode wire is lifted or placed on a stand or the like, There is a problem that the contact portion is slid or an unexpected pressure is applied to the point contact portion, and the insulating coating is easily peeled off. On the other hand, as described above, the heating element 3 according to the present invention compresses the conventional coiled coil-shaped electrode wire in the axial direction thereof, thereby bringing the adjacent heating wires into contact with each other at the contact portion 32. Since the bent portion 33 that is bent in a substantially square shape in the direction along the axis of the coiled heating wire is formed, and the adjacent heating wires are in contact with each other (closely) in the bent portion 33, The electrode lines at the contact portion between adjacent electrode lines have a shape that is crushed. That is, the contact form between adjacent electrode lines has a form of surface contact. As a result, the contact pressure between adjacent electrode wires is kept low, and even if the contact portion is slid or an unexpected pressure is applied, the insulating coating formed on the surface of the heating wire is difficult to peel off. Thus, handling of the heating element 3 is greatly facilitated.
また、本発明の発明者は、実際に本発明に係る発熱体３（コイル状電熱線）を製作し、従来からある発熱体（コイル状電熱線）と比較する実験を行ったので、以下、実験結果について説明する。 In addition, the inventors of the present invention actually manufactured the heating element 3 (coiled heating wire) according to the present invention and conducted an experiment for comparison with a conventional heating element (coiled heating wire). The experimental results will be described.
まず、表面に１μｍの厚みの絶縁被膜を形成した線径が０．３５ｍｍのニクロム線（電熱線）を用い、外径が８ｍｍ、全長が６６ｍｍの花巻コイルを２つ製作した。一方をサンプルＡとし、他方をサンプルＢとする。一方のサンプルＡに係る花巻コイルに対して、２００Ｎの力で花巻コイルの軸線方向に沿って圧縮し、本発明に係る屈曲部３３を有する発熱体３（コイル状電熱線）を作成した。他方のサンプルＢに係る花巻コイルに対しては、圧縮を行わず、従来からある発熱体とした。これらサンプルＡ及びサンプルＢの画像を図７に示す。また、図８にサンプルＡ及びサンプルＢの要部拡大画像を示す。図７及び図８においては、上側に配置される発熱体がサンプルＡに係るものであり、下側に配置される発熱体がサンプルＢに係るものである。 First, two flower winding coils having an outer diameter of 8 mm and a total length of 66 mm were manufactured using a nichrome wire (electric heating wire) having a wire diameter of 0.35 mm and having an insulating film having a thickness of 1 μm formed on the surface. One is sample A and the other is sample B. The heating coil 3 (coiled heating wire) having the bent portion 33 according to the present invention was created by compressing the flower winding coil according to one sample A along the axial direction of the flower winding coil with a force of 200 N. The flower winding coil according to the other sample B was not compressed, and a conventional heating element was used. The images of Sample A and Sample B are shown in FIG. Moreover, the principal part enlarged image of the sample A and the sample B is shown in FIG. 7 and 8, the heating element arranged on the upper side is related to the sample A, and the heating element arranged on the lower side is related to the sample B.
圧縮することにより、花巻コイルの軸線に沿う方向に屈曲する屈曲部３３を形成したサンプルＡの全長は、４４ｍｍであり、従来からある発熱体（サンプルＢ）に対して、長さが６７％となった。つまり、従来からある発熱体（サンプルＢ）の略２／３の長さとなり、大幅に小型化されたことがわかる。 The total length of the sample A formed with the bent portion 33 that bends in the direction along the axis of the flower winding coil by compression is 44 mm, which is 67% of the length of the conventional heating element (sample B). became. In other words, the length of the conventional heating element (sample B) is about 2/3, and it can be seen that the size has been greatly reduced.
また、発熱体に係るサンプルＡ及びサンプルＢをそれぞれ本発明に係る加熱器１にセットし、エア流量、エア圧損、供給電圧、発熱体３温度、エアー入口側金属管温度の関係を確認し、両者の加熱性能を確認した。サンプルＡ及びサンプルＢをそれぞれ加熱器１にセットした状態を図９の画像に示す。図９において上側に配置されているのがサンプルＡをセットした加熱器であり、下側に配置されているのがサンプルＢをセットした加熱器である。なお、図９においては管状体４を取り外した状態を示している。加熱性能結果を図１０及び図１１に示す。図１０は、サンプルＡを用いた場合の結果であり、図１１は、サンプルＢを用いた場合の結果である。なお、エアー入口側金属管温度とは、管状体４を構成する金属管４２の一方の端部（空気供給手段の空気パイプ６が接続される側の端部）から１０ｍｍの位置での金属管の表面温度である。図１０及び図１１を比較すると、サンプルＡとサンプルＢとの間に性能上の差異がないことが分かる。むしろ、エア圧損（図１０及び図１１における下側のグラフを参照）に関しては、サンプルＡを用いた場合の方が減少しており、空気供給手段から供給される空気の管状体４内部における通過抵抗が減少し、より熱風を吹き出しやすい加熱器１を得ることができたことがわかる。 Moreover, the sample A and the sample B related to the heating element are set in the heater 1 according to the present invention, respectively, and the relationship between the air flow rate, the air pressure loss, the supply voltage, the heating element 3 temperature, and the air inlet side metal tube temperature is confirmed, Both heating performances were confirmed. The state where the sample A and the sample B are set in the heater 1 is shown in the image of FIG. In FIG. 9, the heater arranged with the sample A is arranged on the upper side, and the heater arranged with the sample B is arranged on the lower side. In addition, in FIG. 9, the state which removed the tubular body 4 is shown. The heating performance results are shown in FIGS. FIG. 10 shows the results when the sample A is used, and FIG. 11 shows the results when the sample B is used. The air inlet side metal tube temperature is a metal tube at a position 10 mm from one end of the metal tube 42 constituting the tubular body 4 (the end on the side to which the air pipe 6 of the air supply means is connected). Of the surface temperature. Comparing FIG. 10 and FIG. 11, it can be seen that there is no difference in performance between sample A and sample B. Rather, with respect to air pressure loss (see the lower graphs in FIGS. 10 and 11), the case where the sample A is used is reduced, and the passage of the air supplied from the air supply means inside the tubular body 4 is reduced. It turns out that resistance decreased and the heater 1 which can blow out hot air more easily was able to be obtained.
以上、本発明の一実施形態に係る発熱体３及び加熱器１について説明したが、本発明に係る発熱体３を備える加熱器１の具体的構成は、上記実施形態に限定されない。上記実施形態においては、本発明に係る発熱体３を、熱風を吹き出すことができる熱風ヒータ型の加熱器に適用しているが、コイル状電熱線からなる発熱体３を使用する種々の加熱器全般に対して適用することができる。例えば、本発明に係る発熱体３を電気ストーブにおける発熱体として用い、電気ストーブ型の加熱器１を構成してもよい。また、半田ごて（加熱器１）に用いられるコイル状の発熱体３として本発明に係る発熱体３を用い、当該半田ごてを構成してもよい。 Although the heating element 3 and the heater 1 according to one embodiment of the present invention have been described above, the specific configuration of the heater 1 including the heating element 3 according to the present invention is not limited to the above embodiment. In the said embodiment, although the heat generating body 3 which concerns on this invention is applied to the hot air heater type heater which can blow off hot air, the various heater which uses the heat generating body 3 which consists of a coiled heating wire. It can be applied to all. For example, the heating element 3 according to the present invention may be used as a heating element in an electric stove to constitute the electric stove type heater 1. Alternatively, the heating iron 3 according to the present invention may be used as the coil-like heating element 3 used in the soldering iron (heater 1) to constitute the soldering iron.
また、コイル状電熱線を形成する電熱線の断面形状としては、円形形状のものが一般的であるが、例えば、断面形状が四角形状や楕円形状、三角形状等種々の形状を有する電熱線を用いて本発明に係るコイル状電熱線（発熱体）を形成することができる。 In addition, the cross-sectional shape of the heating wire forming the coiled heating wire is generally a circular shape, but for example, heating wires having various shapes such as a square shape, an elliptical shape, and a triangular shape are used. It can be used to form a coiled heating wire (heating element) according to the present invention.
また、本発明に係る発熱体を構成するコイル状電熱線としては、単数の電熱線を用いて花巻状に巻回して形成してもよく、或いは、複数（例えば、２本或いは３本）の電熱線を平行巻きにして花巻状のコイル状電極線を構成してもよい。 In addition, the coiled heating wire constituting the heating element according to the present invention may be formed by winding in a flower winding shape using a single heating wire, or a plurality (for example, two or three) of heating wires. A flower-coiled coiled electrode wire may be configured by parallel winding of heating wires.
また、本発明に係る発熱体３（コイル状電熱線）を製造する際に、花巻コイルＺの両端部を花巻コイルＺの中央部に向けて花巻コイルＺの軸線方向に沿って圧縮する手法について上述したが、この圧縮段階において、圧縮される花巻コイルＺを加熱しながら所定の圧縮を行うようにしてもよい。このように加熱しながら圧縮することにより、従来からある花巻コイル（圧縮前の花巻コイル）の長さの５０％〜５５％程度の長さとなるようにコイル状電熱線を構成することが可能となり、より一層の発熱体３の小型化が可能となる。加熱圧縮することにより作成した発熱体３の画像を図１２及び図１３に示す。図１２及び図１３において、上側に配置されるものが従来からある発熱体であり、下側に配置されるものが、加熱圧縮することにより作成した発熱体３である。また、図１３は、図１２の要部拡大画像である。また、加熱圧縮することにより作成した発熱体３を芯材にセットして構成した加熱器１（上側）、及び、従来からある発熱体を芯材にセットして構成した加熱器（下側）を示す画像を図１４に示す。ここで、圧縮時の加熱温度は、圧縮される花巻コイルの大きさや材質等によって種々変更されるものであるが、８００度〜１０００度の温度範囲を例示することができる。 In addition, when manufacturing the heating element 3 (coiled heating wire) according to the present invention, a method of compressing both ends of the flower winding coil Z toward the center of the flower winding coil Z along the axial direction of the flower winding coil Z. As described above, in this compression stage, a predetermined compression may be performed while heating the flower winding coil Z to be compressed. By compressing while heating in this way, it becomes possible to configure the coiled heating wire so that it is about 50% to 55% of the length of a conventional flower winding coil (flower winding coil before compression). Further, the heating element 3 can be further downsized. Images of the heating element 3 created by heat compression are shown in FIGS. In FIGS. 12 and 13, what is arranged on the upper side is a conventional heating element, and what is arranged on the lower side is a heating element 3 created by heating and compression. FIG. 13 is an enlarged view of the main part of FIG. Moreover, the heater 1 (upper side) comprised by setting the heat generating body 3 created by heat-compression to a core material, and the heater (lower side) comprised by setting the conventional heat generating body to a core material The image which shows is shown in FIG. Here, although the heating temperature at the time of compression is variously changed according to the size and material of the flower winding coil to be compressed, a temperature range of 800 degrees to 1000 degrees can be exemplified.
１ 加熱器
２ 芯材
２１ 規制部材
３ 発熱体
３１ 電熱線
３２ 接触部
３３ 屈曲部
４ 管状体
４１ 石英ガラス管
４２ 金属管
５ 固定具
６ 空気パイプ
Ｚ 花巻コイル
DESCRIPTION OF SYMBOLS 1 Heater 2 Core material 21 Control member 3 Heating element 31 Heating wire 32 Contact part 33 Bending part 4 Tubular body 41 Quartz glass tube 42 Metal tube 5 Fixture 6 Air pipe Z Hanamaki coil
Claims (5)
前記コイル状電熱線は、非円形に複数回巻かれた花巻状に形成されており、前記コイル状電熱線の軸線に沿って螺旋状に配設される隣り合う電熱線同士の接触部において、前記コイル状電熱線の軸線に沿う方向に屈曲する屈曲部を備えることを特徴とする発熱体。 A heating element comprising a coiled heating wire,
The coiled heating wire is formed in a non-circular shape that is wound in a plurality of turns, and in a contact portion between adjacent heating wires that are spirally disposed along the axis of the coiled heating wire, A heating element comprising a bent portion bent in a direction along the axis of the coiled heating wire.
長尺状の電熱線を花巻状に巻回し、花巻コイルを形成する花巻ステップと、
前記花巻ステップにより形成された前記花巻コイルを所定長さに切断する切断ステップと、
切断された前記花巻コイルの両端部を前記花巻コイルの軸線方向に沿って圧縮することによって、前記花巻コイルの軸線に沿って螺旋状に配設される隣り合う電熱線同士の接触部において、前記花巻コイルの軸線に沿う方向に屈曲する屈曲部を形成する圧縮ステップとを備える発熱体の製造方法。 A method of manufacturing a heating element,
A winding step of winding a long heating wire into a flower winding shape to form a flower winding coil;
A cutting step of cutting the flower winding coil formed by the flower winding step into a predetermined length;
By compressing both ends of the cut flower winding coil along the axial direction of the flower winding coil, in the contact portion between adjacent heating wires arranged spirally along the axis of the flower winding coil, A heating element manufacturing method comprising: a compression step that forms a bent portion that is bent in a direction along the axis of the flower winding coil.
前記コイル状電熱線は、非円形に複数回巻かれた花巻状に形成されており、前記コイル状電熱線の軸線に沿って螺旋状に配設される隣り合う電熱線同士の接触部において、前記コイル状電熱線の軸線に沿う方向に屈曲する屈曲部を備えることを特徴とする加熱器。 A heater having a heating element composed of a coiled heating wire,
The coiled heating wire is formed in a non-circular shape that is wound in a plurality of turns, and in a contact portion between adjacent heating wires that are spirally disposed along the axis of the coiled heating wire, A heater comprising a bent portion bent in a direction along an axis of the coiled heating wire.
The heater according to claim 4, further comprising air supply means for supplying air from one end side of the tubular body to the inside of the tubular body.
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