Ceiling film electric heater, room heating system containing ceiling film electric heater, production method of ceiling film electric heater and device for manufacturing bed of ceiling film electric heater

FIELD: heating.

SUBSTANCE: invention can be used for heating domestic and industrial rooms, as well as for manufacturing such electric heaters. Ceiling film electric heater includes resistive radiating element having in plan view a meander shape and arranged between two layers of electric insulating films. Resistive radiating element is equipped with outputs to be connected to electric mains. Parallel strips of resistive radiating element are connected in series by means of their L-shaped bending towards the next strip transversely on one and the other side. Edges of upper and lower electric insulating layers are connected be means of tape with self-adhesive base. According to invention, room heating system includes heat insulator representing a foam heat-insulating material with reflecting layer. Outputs of resistive radiating element of ceiling film electric heater are connected via control and protection devices to power network. Device for manufacturing the bed of ceiling film electric heater includes uncoiler for strips of resistive radiating element, uncoilers of upper and lower layers of electric insulating films, device for supply of tape with self-adhesive base, laminating machine with thermal shafts and winding shafts of the ready bed, which are installed in one process line.

EFFECT: low production cost and possible use in large-scale production.

16 cl, 9 dwg

The invention relates to the field of special requests and can be used for heating of domestic and industrial premises. The invention concerns a method and device for manufacturing thin film heaters in large scale production.

Famous film heater (patent RF №2088047, CL NW 3/18, NV 3/36, publ. 20.08.1997, containing two sheets (layer) flexible insulating films between which is placed resistive radiating element having a plan meander shape, made of an amorphous alloy of metals, or transition metals and metalloids. The thickness of the resistive emitting element is minimized. Resistive emitting element provided with leads for mounting to a power source or to another connected in parallel to the heater. The edges of the heater covered with tape.

A disadvantage of the known technical solution is the implementation of resistive radiating element in the form of strips, are sequentially connected by a jumper that determines the complexity of the production technology and the increase in time of the production of a single heater. Bonding the edges of the heater tape also increases production time of the heater.

Besides the use as a resistive radiant ale the NTA amorphous alloy metals or transition metals metalloids makes the heater costly.

In addition, the lack of heater is small thickness of the insulating films that do not provide protection from mechanical damage resistance emitting element.

As a prototype of the selected film heater (RF patent No. 57070, CL NW 3/14, publ. 27.09.2006, containing two sheets (layer) flexible insulating films between which is placed resistive emitting element, laid continuously and having a plan meander shape. Resistive radiating element is made of precision conductive material. To the resistive radiating element attached leads for connection to the mains.

Use as resistive emitting element precision conductive material makes electrical heater costly.

In addition, the lack of film heater is the inability to implement its large-scale production in connection with the performance of a resistive element in the form of a continuous winding of conductive material.

The task, which directed the present technical solution is the creation of a film heater having a low cost, which can be carried out continuously in large scale industries.

The task is ceiling film heater made in the form of two layers of insulating films between which is placed resistive radiating element having a plan meander shape and is provided with leads for connection to the mains, is achieved by the fact that the resistive radiating element made in the form of parallel strips connected in series by g-shaped bend in the direction of the next strip alternately with one and with the other hand.

In addition, this object is achieved in that ceiling film heater made in the form of two layers of insulating films between which is placed resistive radiating element having a plan meander shape and is provided with leads for connection to the mains, as the material for the resistive emitting element according to the invention used metal with a resistivity of ρ=7,0-8,5 µohm·m

The edges of the upper and lower insulating layers ceiling film heater are connected by a ribbon with self-adhesive base on the inside.

Series connection of resistive strips radiating element by means of a g-shaped buckle with the formation of a meander shape, and the connecting edges of the upper and lower insulating layers on the inner side of the tape with self-adhesive bases is th simplifies the manufacturing technology ceiling film heater by reducing the number of transactions and determines the possibility of its production in large scale industry, that, in turn, leads to the reduction of production cost of one ceiling film heater.

To a significant reduction in the cost of electric heater and a significant expansion of the range of the applied metals results use as resistive emitting element of any metal with a resistivity of ρ=7,0-8,5 µohm·m

The device ceiling film heater is illustrated by drawings on which is shown: figure 1 - General view of the ceiling of a film heater, 2 - ceiling film heater (the cross-section of the canvas).

Ceiling film heater contains the top 1 and bottom 2 of the insulating film made of a polymeric material, between which is placed resistive emitting element 3. Resistive emitting element 3 is designed in the form of parallel strips connected in series with the education plan meander shape. The edge of the previous strip is bent to an l-shape in side of the next strip, as a rule, on the whole of its width, the other end which, in turn, to an l-shape bent towards the subsequent band. The strips are connected by spot welding. Serially connected resistive strip radiating element 3 is occupied by 15-70% canvas ceiling film heater. To anim the resistive strips radiating element 3 is soldered conclusions 4 for connection to the mains. Edge of the top 1 and bottom 2 of the insulating film electric heater connected to the inner side of the tape with self-adhesive base 5.

The thickness of each layer insulating films 1 and 2 in the range of 125-250 microns depending on the requirements of the heater.

The increase in the thickness of the insulating films 1 and 2, which additionally protects the heater from the breakdown electric current in case of overload the network and from mechanical damage resistance emitting element 3.

Conducted experiments have shown that the power density of the electric heater is in the range of 70-250 W/m²while working current flowing through the resistive radiating element 3, does not exceed 1A. Operating temperature on the surface of the heater when the air temperature in the heated room +20°C is in the range of +30...+70°C.

The current value within 1 And flowing through the resistive radiating element 3, creates an electromagnetic field, not exceeding the earth's magnetic field and not having a harmful effect on people.

Known heating device is an infrared radiation (RF patent No. 2075837, CL NW 3/30, publ. 20.03.1997,) containing composite tape (ceiling film heater), consisting of resistive radiant, electrical insulation is reflective (reflector) layer. Composite tape are connected by transverse slats so that in the horizontal plane to form a heating device meander shape. The transverse plate, in turn, attached to the walls of the heated premises, for example, springs. Under a solar device has a horizontal roof, made of permeable to infrared radiation material that serves as a decoration, a heating device. Conclusions a heating device connected to a power source through a step-down transformer.

The disadvantage of heating devices is the presence of useless infrared radiation on the ceiling the ceiling of the room.

Mounting a heating device and below the fixed horizontal overlap at some distance from the ceiling reduces the spatial volume of the room and greatly reduces the possibility of decoration.

In addition, the lack of heating devices is the difficulty and complexity of installation of the structure due to the presence of a large number of structural elements (products) and the inconvenience of the method of their attachment to the walls of the room. When difficult step forms the ceiling installation design difficult.

Known heating device is not automatically to maintain the temperature at about graveman the room.

The problem to which the invention is directed, is to raise the efficiency ceiling film heater for heating (space heating), the implementation automatically maintain the temperature of the air at the specified level.

Also object of the invention is to simplify the design heating device and its installation.

In a heating system of the room containing ceiling film heater with reflector (reflective layer) and insulated on both sides resistive radiating element having a plan meander shape, connected by means of pins to the power supply according to the invention a reflective layer (insulator) made independent and fixed on the ceiling surface of the heated premises, which has a ceiling film heater.

In addition, the solution of this problem is achieved in that in the heating system of the room containing ceiling film heater with reflector (reflective layer) and insulated on both sides resistive radiating element having a plan meander shape, connected by means of pins to the power supply according to the invention a reflective layer (insulator) made in the form of foamed deploytool is the dominant material with a reflective surface, as the use of a Mylar film or aluminum foil.

The reflective surface of the heat insulator is made rough.

Conclusions resistive radiant heater element soldered to the extreme bands, connected by means of the control and protection: air thermostat, logic relays and protective cutout device to the mains.

Placing the insulation on the ceiling surface reduces useless heating of the ceiling to a minimum and increases the reflection of radiation upward from the heater.

Reduced heating of the ceiling and increase the reflectivity of the heat insulator is also due to perform heat insulation of foamed heat insulating material with a smooth reflective surface.

Fastening of insulation and ceiling film heater one above the other in a specified way slightly reduces the spatial volume of the room and allows them the decoration of any building elements except metal and mirrored surfaces.

As a result of application in a heating system of the room thermostat automatic control temperature of the air, increasing its consumer properties and protection is istemi from possible overloads the network.

The installation of a heating system of the premises is made from ready-made structural components (ceiling film heater, the heat insulator, controls, and protection), requiring only fixing inside the heated room, the electrical connection between the self and the connection to the mains, which leads to its low complexity and allows you to install a heating system in areas with multi-level ceiling.

Figure 3 presents a General view of the heating system of the premises.

The heating system of the premises made in the form of ceiling film heater 6, the heat insulator 7, which is a layer of foamed insulating material 8 with the reflecting surface 9, the control devices (air thermostat 10) and protection (not shown) and power supply wires 11 connecting the resistive emitting element 3 ceiling film heater 6 and the power source through the control device 10 and protection.

On the ceiling surface of the room by, for example, a universal mounting elements 12 attached heat insulator 7, performing the function of a reflector of infrared (heat) radiation, generated ceiling film heater 6, and exceptions useless heating of the ceiling. Eploits the EOS 7 is executed, for example, in the form of isolon which is foamed heat insulating material 8 with reflective Mylar coating 9. Reflective coating 9 can also be made for example of aluminum foil. Reflective coating 9 has a smooth surface for superior reflection and scattering of infrared radiation generated ceiling film heater 6, into the room.

To obtain the greatest efficiency emission ceiling film heater 6 inside the heat insulator 7 covers the entire ceiling surface of the heated premises. The minimum thickness of the heat insulator 3 mm.

On the heat insulator 7 is fastened by, for example, a universal mounting elements 12 ceiling film heater 6, the mounting is carried out in parts, not containing resistive strips radiating element 3, to prevent damage to the conductive layer.

The coverage area of the ceiling surface of the heater is determined by the observed five-day minimum temperature. Than the temperature of the air in the street below, the large area of the ceiling surface is covered with a heater.

Resistive emitting element 3 ceiling film heater 6 is connected to the mains through an air thermostat 10, RA is displaced on a vertical surface at a distance of 1-1 .5 m from the floor level of the room. As a rule, as a vertical surface is the inner wall of the heated premises. thermostat 10 is mounted so as to exclude the influence of draughts, direct sunlight and influence of thermal field (radiation) bordering objects. To eliminate the influence on thermostat 10 contiguous items it is mounted on a heat insulator, similar to those described above. The controller 10 performs a control function of the temperature of the air in the room.

Film heater 6 and the heat insulator 7, mounted on the ceiling of the room can be closed construction and decoration of a thickness not exceeding 20 mm except for metallic materials and materials with a mirror surface.

The heating system of the premises is made with the option of working from a network of permanent and AC current in the range from 12 to 380 C.

The heating system of the premises is as follows:

The controller 10 sets the level of temperature that must be maintained by the system in the room. In the case of lowering the temperature of air by 1°C the temperature controller 10 directly or via magnetic contacts closes a circuit supplying ceiling film heater 6. On ceiling film heater 6 is energized, it starts radiation is the substance of infrared heat flow. The flow is distributed into the room, causing heating of the floor and objects in the room, they, in turn, being heated in contact with air increases its temperature. When the temperature of the air at a height of 1-1 .5 m from the floor level more than 1°C, recorded by the controller 10, the controller 10 closes the electrical circuit and infrared radiation electric heater 6 is stopped. The floor structure during operation of the electric heater 6 accumulates enough heat for long maintain the temperature of the air at the specified level.

Maximum efficiency ceiling film heater 6 provides when it is mounted on a horizontal ceiling surface, as when it is placed on the vertical surface of the heater 6 works as a convector, carrying out the heating of the air in the upper part of the room.

A known method of manufacturing a flat resistive heater (patent RF №2052907, CL NW 3/34, publ. 20.01.1996,), in which the resistive ribbon zig-zag resistive element of accomplishment in it of the slots with the subsequent cutting edges so that the resistive element had in terms meander shape. Resistive zigzag element connected with sousage with the upper and lower layers of the insulating film, with similar slits.

The disadvantage of the method of manufacturing a resistive heater is the impossibility of its application in large-scale industry, in addition, the labor-intensive method.

Moreover, in the process of forming the resistive layer remains significant amount of scrap conductive material.

As the prototype accepted way of the following description of the device film heater (patent RF №2088047, CL NW 3/18, NV 3/36, publ. 20.08.1997 g), which consists in forming a resistive emitting element performing it in the form of parallel strips connected in series between a jumper with education in terms of meander shape; attaching findings to extreme resistive strips radiating element for connection to a power source and connection with both sides of the resistive emitting element insulating films. The edges of the heater should be patched with tape.

The disadvantage of this method is the single-piece manufacture of the heater, which causes the high complexity of its manufacture and inappropriate use in large scale production.

The task of the invention is to develop a method of production ceiling film heater with a simplified those is a technology of forming a resistive emitting element, used in large scale industries.

The task in the way that the production ceiling film heater comprising in combination two layers of insulating films and placed between the resistive emitting element made in the form of parallel, evenly distributed bands is achieved by the fact that the resistive strip radiating element serially connected by the l-shaped bending their ends in the side of the next strip alternately with one and the other side.

In addition, this object is achieved in that the pre-insulating film and placed between the resistive radiating element in the form of parallel strips connected continuously with the formation of a cloth heater, which further cut into pieces corresponding to the length of the produced electric heater.

Edges connect the heater tape with self-adhesive base on the inside.

Method for the production of ceiling film heater can be used for the manufacture of electric heater consisting of five layers, by adding at the connection layers emitting layer, made in the form of aluminum foil, and an additional layer of insulating film.

A method of manufacturing a continuous p the pilot ceiling film heater, with its subsequent cutting into pieces, appropriate given the length of the heater, and the connection of resistive strips radiating element simplifies the manufacturing technology of film heaters, reduces the production time of a single heater, which leads to its application in large-scale industry.

The method allows to produce a film heater of any length without a corresponding cost pereosnastku.

The method of manufacturing a ceiling film heater according to the invention is illustrated by drawings: figure 4 - leaf ceiling film heater sealed with tape with self-adhesive backing; figure 5 and 6 connection of resistive strips radiating element; figure 7 is a part of the finished ceiling film heater.

A continuous resistive radiating element 3, which are strips of the same width, placed at equal distances from each other, attached on both sides of two continuous insulating films 1 and 2 of the polymeric material. Connection continuous layers: resistive emitting element 3 and the two insulating films 1 and 2 is produced in the process of lamination. Before lamination layers at equal intervals of time between the upper insulating film 1 and the cut is stepnum emitting element 3 is placed piece of tape with self-adhesive base 5. So get the cloth heater, through equal areas containing soldered tape with self-adhesive base 5 (figure 4), the length of the sections of fabric heater corresponds to the length of the heater 6. The width of the cut tape with self-adhesive base 5 define double the total value of the width of the resistive strip radiating element 3 and the distance between two resistive strips radiating element 3. Continuous laminated layers is wound under tension in the roll of the finished canvas.

For the further production of continuous cloth ceiling film heater cut in the middle of the tape with self-adhesive base 5. The edges of the obtained semi-finished product of the electric heater 6 are bent in the width soldered ribbon with self-adhesive base 5. The edge of the previous strip resistive emitting element 3 l-shape bend in the side of the next strip to complete their crossing, the other end which, in turn, to an l-shape bend towards the subsequent band to complete their crossing. Junction lanes weld spot welding is carried out at the molecular level (Fig.6). In this connection, all connected in series to the resistive strip radiating element 3 in the plan must have a meander shape. The extra portion of the band is cut. To KRA is the resistive strips radiating element 3 you solder tin solder the pins 4. With self-adhesive bases of tape 5 remove the protective coating and the adhesive tape 5 surface together with the upper insulating layer 1 is glued to the lower insulating layer 2 of the electric heater 6, closing and isolating the junction of the resistive strips radiating element 3 and the supply wires 4.

The method can be applied to the production ceiling film heater comprising five layers. The making of the film heater containing additional insulated emitting layer, made for example in the form of aluminum foil, is performed in the following way: make the connection by laminating five layers are as follows: between the top and middle layers insulating film include a resistive radiating element made in the form of parallel strips, and respectively between the middle and bottom layers - emitting layer, made for example in the form of aluminum foil. Tape with self-adhesive base are soldered between the upper insulating layer and the resistive radiating element. Further, the technology of manufacturing electric heater similar to the above.

A known machine for the continuous manufacture of a flexible electric heating elements (patent RF №2116890, CL B29D 9/00, VS 65/02, VS 65/64, publ. 10.8.1998,), consists of decoiler for the conductive strips (strips of resistive emitting element), decoilers upper and lower layers of the insulating films, the drive of the welding stand with heated rollers and a pressing mechanism (termovalle laminator) and means of reception of finished products (the winding shaft, the finished paintings). Uncoiler for conductive tape is attached to the frame of the axial element with installed bearing units. External cartridge bearings halted spring petals. On bearing assemblies mounted sleeve wound with coils of conductive strips (strips of a resistive element).

The drawback of the unit is the design complexity of decoiler for conductive tapes.

The challenge which seeks technical solution is to simplify the construction of the coil to the conductive strips (strips of a resistive element).

In addition, the task is to use the unit for the production of ceiling film heater in accordance with the above-described method.

The solution of this problem is achieved as follows.

Device for cloth production ceiling film heater, which consists of decoiler for resistive strips radiating element decoilers upper and lower layers of the insulating films, laminator with termovalle shaft and winding the finished canvas is further provided with a feeder tape with self-adhesive base established between the uncoiler and the laminator.

In addition, the solution of the problem in the coil of resistive strips radiating element representing a frame with a fixed axial element containing bearing assemblies with impaled on them coils with resistive bands radiating element, is achieved in that the coil is installed with alternating direction of unwinding.

Axial element made in the form of a shaft, both ends are spring-loaded.

Device for cloth production ceiling film heater may include at least two additional coil layers.

To simplify the design of decoiler for resistive strips radiating element is due to the exclusion of podpruzhineny bearings.

The introduction of feeder tape with self-adhesive base in the device for manufacturing the blade ceiling film heater allows it to be used in the above method.

The unwinding of the coils in opposite directions increases as the tension resistive strips radiating element when laminating.

Introduction to the design updat the enforcement decoilers allows to obtain a laminated fabric heater consisting of more than three layers.

The essence of the technical solution is illustrated by drawings, showing: Fig - General view of the device for cloth production ceiling film heater Fig.9 - uncoiler for resistive strips radiating element (top view).

Device for cloth production ceiling film heater 6 is installed in one process line uncoiler for resistive strips radiating element 13, decoilers top 14 and bottom 15 of layers of insulating films. The feeder tape with self-adhesive base (not shown) installed prior to thermoflow laminator 16 and after decoilers layers of the insulating films 14 and 15. The winding shaft of the finished blade 17 is located after thermoflow laminator 16. Termovalle laminator 16 connects the layers of the heater 6 is supplied from the uncoiler 13, 14 and 15, in one canvas.

Uncoiler for resistive strips radiating element 13 comprises a frame 18 mounted on it axial element - shaft 19. On the shaft 19 mounted bearing units (not shown)which are mounted coil 20 wound with strips of resistive emitting element 3. The shaft 19 is halted spring elements - couplings 21 installed at both sides of the Ala 19. A spring-loaded sleeve 21 provides the necessary friction when unwinding coils 20 with resistive bands radiating element 3. Coil 20 mounted on the shaft 19 so that when unwinding the strips of resistive element 3 each even-numbered coil is rotated clockwise, and each odd-numbered counterclockwise or Vice versa. Such placing of the coils 20 provides the necessary tension resistive strips radiating element 3 when the lamination layers of the electric heater 6.

Device for cloth production ceiling film heater 6 is as follows.

On the uncoiler device skewer rolls consumables. Coil 20 wound with strips of resistive emitting element 3 is placed on bearing assemblies decoiler for resistive strips radiating element 13. Before turning on the laminator strip resistive emitting element 3 and the insulating films 1 and 2 are fixed between termovalle laminator 16. After you turn the laminator termovalle 16 begin to tighten layers, connecting them. After a certain period of time between the upper insulating film 1 and the resistive strips radiating element 3 is fed cut the tape with self-adhesive base 5 using the feeder tape with self-adhesive basis is Oh. Thus, after the lamination is obtained continuous three-layer fabric with sealed through equal areas of the tape with self-adhesive base 5. Ready continuous cloth wound on the winding shaft, the finished fabric 17.

Device for the production of the leaf electric heater can be used to obtain a film heater, comprising more than three layers. For example, if a film heater includes a resistive radiating element made in the form of parallel strips, and the emitting layer, made for example in the form of aluminum foil separated and insulated by layers of insulating films, tape with self-adhesive base, soldered between the upper insulating layer and the resistive strips radiating element. To obtain this film heater additional emitting layer and an additional insulating layer is wound on a reel mounted on additional decoilers set to thermoflow laminator. The device works on the same technology.

The technical result provided by a set of objects of the invention, consists in the following:

- cost reduction due to the possibility of use as a resistive emitting element of any steel metal,ease of installation, the heating system of the premises, the simplification of manufacturing technology;

- the possibility of large scale production, achieved by obtaining method of continuous manufacture of ceiling film heater, a simplification of the serial connection of the resistive strips radiating element.

1. Ceiling film heater containing resistive radiating element, placed between two layers of flexible insulating film having a plan meander shape and is provided with leads for connection to the mains or other heater, characterized in that the resistive radiating element made in the form of parallel strips connected in series by G-shaped bend in the direction of the next strip alternately with one and with the other hand.

2. Ceiling film heater according to claim 1, characterized in that the edges of the upper and lower insulating layers are connected by a ribbon.

3. Ceiling film heater according to claim 2, characterized in that the tape is self-adhesive base.

4. The heating system of the room containing ceiling film heater with a heat insulator and insulated from both sides of the resistive radiating element having a plan meander shape and is connected by pins to the power outlet is different is connected with the fact, that the heat insulator is made independent and fixed on the ceiling surface of the heated premises, which has a ceiling film heater.

5. The system of heating according to claim 4, characterized in that the conclusions resistive emitting element ceiling film heater is connected through the control and protection to the mains.

6. The heating system of the room containing ceiling film heater with a heat insulator and insulated from both sides of the resistive radiating element having a plan meander shape and is connected by pins to the power network, wherein the heat insulator is made in the form of a foamed heat insulating material with a reflective surface, which is used Mylar film or aluminum foil.

7. The heating system of the premises according to claim 6, characterized in that the reflecting surface of the heat insulator is made rough.

8. Method for the production of ceiling film heater, which consists in the connection of at least two layers of insulating films and placed between the resistive emitting element made in the form of parallel evenly distributed strips, wherein the strips of resistive radiant the element serially connected by the l-shaped bending their ends in the side of the next strip alternately with one and the other side.

9. Method for the production of ceiling film heater of claim 8, wherein the resistive strip radiating element connected by point welding.

10. Method for the production of ceiling film heater of claim 8, wherein the edge heater connect the tape with self-adhesive base on the inside.

11. Method for the production of ceiling film heater of claim 10, wherein the tape has a self-adhesive base.

12. Method for the production of ceiling film heater of claim 8, wherein when the connection layers add emitting layer, made in the form of aluminum foil, and an extra layer of insulating film.

13. Device for cloth production ceiling film heater, which consists of decoiler for resistive strips radiating element, decoilers upper and lower layers of insulating films, laminator with termovalle shaft and winding the finished fabric, characterized in that it is provided with a feeder belt mounted between the uncoiler layers and laminating machine.

14. Device for cloth production ceiling film heater according to item 13, characterized in that it contains at least two additional razmityu the indicator layer.

15. Uncoiler for resistive strips radiating element consisting of a frame fixed thereto an axial element containing bearing assemblies with impaled on them coils wound with strips of resistive emitting element, characterized in that the coil is installed with alternating direction of unwinding.

16. Uncoiler for strips of a resistive element according to item 15, wherein the axial element is designed as a shaft, spring loaded on both ends.