Woven resistor unit and its manufacturing process

FIELD: electrothermy, electric heaters such as fiber-plastic ones for medicine, agriculture, liquid and gaseous media heating devices for various industries.

SUBSTANCE: proposed woven resistor unit has electricity conducting and heat liberating threads disposed in parallel with power electrodes made of tinsel threads and separated from them by insulating threads; uniformly distributed perpendicular to electricity conducting and heat liberating threads and tinsel threads of power electrodes throughout resistor unit length are additional and current-distributing electrodes made of tinsel threads. Manufacture of woven resistor unit involves cutting of resistor unit blank of desired geometry from current-conducting fabric followed by cutting peripheral zones of all current distributing electrodes and some of peripheral zones of additional electrodes in pack of insulating threads contacting power electrodes on one end and pack of electricity conducting and heat liberating threads, on other end; peripheral zones of additional electrodes are cut out of alternating sides of pack of electricity conducting and heat liberating threads for switching circuit of desired resistor unit; terminal current conductors made, for instance, from copper foil run over with tin and provided with power cord are attached to edges of power and additional electrodes of resistor unit.

EFFECT: enhanced electric safety and reliability of woven resistor unit.

2 cl, 7 dwg

 

The invention relates to the field of special requests and can be used in the manufacture of electric heaters, for example, of fiberglass, which are widely used in everyday life, medicine, celosamente and devices for heating liquids and gases used in various industries.

Known woven resistive element, in which the warp and the weft is made of electrically conductive and electroconductive yarns laid by rotation in one direction of the fabric, and the electrodes are located along the base (U.S. patent No. 3349359, CL N 05 3/34, 1967).

Also known woven resistive element, electroconductive filaments which are made of a complex of cotton fibers, with a volumetric ratio of electroconductive yarns to the conductive warp threads is 1:1-1:1.5, and the volumetric ratio of the electrically conductive warp and weft threads is 1:1.5 to 1:10 (RF patent No. 2046552, CL N 05 3/36, 1995).

In the above invention solves the problem of reducing the shrinkage of a resistive element in the process of production and operation of electric heaters.

A similar problem is solved in a flexible electric heater (patent USSR No. 1794284, CL N 05 3/38, 1993), containing a resistive element in the form of conductive fabric, the weft and the base of which is made of electrically conductive heat-generating threads, electrop vodnykh threads and metallic tinsel, United in the electrodes, which are placed along the edges of the resistive element and bypass the integrated conductive polymer strands.

The main disadvantage of the above-mentioned resistive elements is that when the breakage of the conductive thread (bundle of fibers), placed between the electrodes, there will be a redistribution of the electric current between neighboring conductive threads, i.e. electrically conductive threads that are located parallel to the electrodes, electric current in place of the cliff will be redistributed to the neighboring conductive thread from education for some time, new breaks, but on adjacent threads. The described process will be irreversible in nature, involving all new electrically conductive threads, until the failure of the resistive element.

The closest analogue, selected as a prototype, is the invention according to the patent USSR No. 1794284.

The main task is the development of such woven resistive element, which would rule out the above disadvantages, and its textile structure regulate the required technical parameters of electric heaters for use in various industries.

The technical result that can be obtained from the use of the invention is the appreciation is the electrical safety and reliability woven resistive element.

The main problem is solved and the technical result is achieved due to the fact that the woven resistive element, electroconductive filaments which are made of a complex of cotton fibers, with a volumetric ratio of electroconductive yarns to the conductive warp threads is 1:1-1:1.5, and the volumetric ratio of the electrically conductive warp and weft threads is 1:1.5 to 1:10, according to the invention consists of electrically conductive filaments that are parallel to the power electrodes of tinsel threads and posted them electroconductive threads and perpendicular to the conductive thread and tinsel strands of the power electrodes along the length of the resistive element evenly distributed additional electrodes and power distribution made of tinsel threads.

Also according to the invention of the conductive tissue cutting a workpiece of a resistive element of a given geometry, the array of electroconductive yarns in contact with one side of the power electrodes, and on the other side with an array of electrically conductive filaments, cut down the peripheral zones of all power distribution and part of the peripheral areas of additional electrodes, and a peripheral zone of the additional electrodes are cut down with the alternation with one or the other side of the array of electrically conductive threads with the formation of switching the schema specified resistive element, and the ending of the power and the additional electrode resistive element is fixed terminal leads, for example, copper foil, tin tin, with the power cord.

Distinctive features are essential, because each of them separately and together is aimed at solving the problem and achieving a new technical result.

Woven resistive element consisting of electrically conductive filaments, electroconductive yarns and tinsel threads with the longitudinal and transverse switching scheme, will provide a low temperature gradient on the heated surface and high technology in the process of refining the product.

Switching woven resistive element by cutting the peripheral zones of the additional electrodes interleaved with one, then with the other hand and cutting the peripheral zones of the current distribution of the electrodes on both sides of the array of electrically conductive threads will allow the use of a resistive element to any value of the supply voltage and to improve its operational reliability.

These distinctive essential features are new, because their use in the prior art, analogs and prototype not found, which allows to characterize the proposed technical solution suitable the e criterion of "novelty".

One set of new essential features with commonly known essential features that allow one to solve the problem and achieve new technical results, which allows to characterize a new technical solution significant differences compared with the prior art, analogs and prototype. A new technical solution is the result of experimental design development and creative contribution, obtained without the use of standard design solutions or any of the recommendations in its originality and content performance meets the criterion of "inventive step".

Figure 1 shows the blank of woven resistive element of electrically conductive filaments, electroconductive and tinsel strands. Figure 2 presents ready-to-use (commutated) woven resistive element. Figure 3 presents several possible variants (switching) woven resistive element.

Presented in figure 1 procurement woven resistive element includes conductive filaments 1 are parallel to power the electrodes 2 of tinsel threads and posted them electroconductive filaments 3 and perpendicular to the conductive threads 1 and tinsel strands of the power electrode 2 along the length of the workpiece resistive cell battery (included) is the uniformly distributed additional 4 and power distribution 5 electrodes, made of tinsel threads. As the electrically conductive yarn according to the invention are: conductive thread "Bicarbon-2M (TU 2282-057-00203996-98), conductive thread "CANS-p (TU 2282-049-00203996-99), carbon thread and any other threads with the linear resistivity of not more than 104Om/see as electroconductive yarns according to the invention are used: polyamide (nylon), cotton thread, thread, glass, and any other threads with insulating properties.

In accordance with the method of manufacture is presented in figure 2 woven resistive element of conductive tissue cutting a workpiece of a resistive element of a given geometry, the array of electroconductive yarns 3 in contact with one side of the power electrodes 2, and the other side with an array of conductive yarns 1, cut down the peripheral zone 7 all power distribution 5 and part of the peripheral zones 6 additional electrodes 4, and a peripheral zone 6 additional electrodes 4 are cut down with the alternation with one or the other side of the array of electrically conductive filaments 1 with the formation of the switching circuit specified resistive element, and the ending of the force 2 and 4 more electrodes of a resistive element is fixed terminal power supply circuit 8, for example, of copper foil, on agenoy tin, the power cord 9.

Figure 1 and additional power distribution electrodes shown a single position 4, 5, and 2 additional and current distribution of the electrodes shown in different positions 4 and 5. This is because in the structure of the conductive fabric of these electrodes runfunction, i.e. indistinguishable from each other. In the structure of a resistive element and additional current distribution of the electrodes on the functionality used for different purposes: additional electrodes are used to create a switching circuit that provides a voltage supply to an electrically conductive filament, and power distribution for the redistribution of the current in case of violation of the integrity of the conductive filament or bundle of filaments) on non-conductive threads to increase efficiency and operational reliability of a resistive element.

Figure 3 presents several possible embodiments of woven resistive element. On figa additional 4 and power distribution electrodes 5 a resistive element distributed with alternating 1+1, figb additional 4 and power distribution electrodes 5 a resistive element distributed with alternating 1+3, i.e. depending on the set of technical parameters (power, voltage, gabaritizmeri) the number of additional and current distribution of the electrodes of a resistive element may change. On FIGU additional 4 electrodes resistive element is uniformly distributed along its length (power distribution electrodes are absent). This scheme switching is most commonly used in the manufacture of a resistive element at low values of the supply voltage.

Tests designed woven resistive element, produced the pilot method showed positive results. Currently, woven resistive element has already found wide application in industry in the field of creation of fiberglass and flexible heaters and devices for heating based on them, operating in the harshest climates.

Thus, the proposed new technical solution in the specified essential features meets the criterion of "industrial applicability", i.e. the level of invention.

1. Woven resistive element, electroconductive filaments which are made of a complex of cotton fibers, with a volumetric ratio of electroconductive yarns and electrically conductive warp threads is 1:1÷1:1.5, and the volumetric ratio of the electrically conductive warp and weft threads is 1:1.5÷1:10, characterized in that it consists of electrically conductive filaments that are parallel to the power electrodes of tinsel threads and spaced from them is elektroprovodnyi threads and perpendicular to the conductive thread and tinsel strands of the power electrodes along the length of the resistive element evenly distributed and additional power distribution electrodes, made of tinsel threads.

2. A method of manufacturing a woven resistive element according to claim 1, characterized in that the conductive tissue cutting a workpiece of a resistive element of a given geometry, the array of electroconductive yarns in contact with one side of the power electrodes, and on the other side with an array of electrically conductive filaments, cut down the peripheral zones of all power distribution and part of the peripheral areas of additional electrodes, and a peripheral zone of the additional electrodes are cut down with the alternation with one or the other side of the array of electrically conductive threads with the formation of the switching circuit specified resistive element, and the ends of the power and the additional electrode resistive element is fixed terminal leads, such as from copper foil, tin tin, with the power cord.



 

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