This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2019-094303, filed on May 20, 2019; the entire contents of which are incorporated herein by reference.
Embodiments described herein relate generally to a heater.
A heater that heats an object by radiant heat is known. Such a heater includes a bulb, a heating portion provided inside the bulb, a sealing portion provided in both end portions of the bulb, a thin film-shaped conductive portion provided inside the sealing portion, and an outer lead. One end of the outer lead inside the sealing portion is electrically connected to the conductive portion and the other end thereof is exposed from the sealing portion.
Here, the spectrum of the emitted light changes when the material of the heating portion changes. For example, in the case of a carbon heater including a heating portion including carbons, a peak occurs in the energy of emitted light at wavelengths of 2 μm to 4 μm. Since the peak of the water absorption spectrum is about 3 μm, an object having a high water content can be efficiently heated by using the carbon heater. However, the heating portion including carbons is not easily and directly connected to a conductive portion. For that reason, in the case of the carbon heater, a connection portion electrically connected to the end portion of the heating portion and an inner lead having one end electrically connected to the connection portion and the other end electrically connected to the conductive portion are provided.
Further, in recent years, higher power heaters are required. For that reason, the temperature of the connection portion and the inner lead tends to increase. Generally, the connection portion and the inner lead are connected to each other by welding, but when the temperature of the welded portion increase, a crack or the like easily occurs in the welded portion. When the crack or the like occurs in the welded portion, the inner lead is separated from the connection portion in some cases. For that reason, there is concern that the life of the heater is shortened.
Therefore, it is desired to develop a heater capable of extending its life.
A heater according to an embodiment includes: a tubular portion; a sealing portion which is provided in each of both end portions of the tubular portion; a conductive portion which is provided inside each sealing portion; a heating portion which is provided inside the tubular portion, extends along a tube axis of the tubular portion, and includes carbons; an inner lead which is provided in each sealing portion so that one end portion side is connected to the conductive portion and the other end portion side is exposed into the tubular portion; and a connection portion which is connected to each of both end portions of the heating portion inside the tubular portion. A bent portion is provided in an end portion opposite to the conductive portion in each inner lead. The bent portion is bent in a direction in which the sealing portions face each other and is provided inside a hole of the connection portion.
Hereinafter, embodiments will be illustrated with reference to the drawings. Additionally, in the drawings, the same reference numerals will be given to the same components and a detailed description thereof will be omitted appropriately.
A heater 1 according to the embodiment can heat an object or a space in which the object is placed. For example, the heater 1 can be used for drying ink or the like in a process of drying a printed matter or the like or for drying a paint or the like in a coating drying process. However, the application of the heater 1 according to the embodiment is not limited thereto.
As illustrated in
The bulb 10 can include a tubular portion 11, a sealing portion 12, and a protrusion portion 13. The bulb 10 can be obtained by integrally forming the tubular portion 11, the sealing portion 12, and the protrusion portion 13. The bulb 10 can be formed of, for example, quartz glass. In this case, the bulb 10 can be formed of, for example, transparent, that is, uncolored quartz glass. Additionally, the bulb 10 can be formed of uncolored quartz glass or can be formed of colored quartz glass.
The tubular portion 11 can have, for example, a cylindrical shape. The tubular portion 11 can have a form in which the entire length L (the length in the tube axis direction) is longer than the tube outer diameter D which is the outer diameter of the tubular portion 11. In this case, when the tube wall load of the inner wall of the tubular portion 11 increases too much, the temperature of the tubular portion 11 also increases too much. Accordingly, there is concern that the tubular portion 11 may be deformed or the durability of the tubular portion 11 may deteriorate. For that reason, the tube outer diameter D and the entire length L of the tubular portion 11 can be set appropriately so as not to exceed a predetermined tube wall load in response to the electric power of the heater 1.
Further, a reflection film can be provided on the outer peripheral surface of the tubular portion 11. If the reflection film is provided, it is possible to reflect light including infrared rays toward a direction in which an object is placed. For that reason, the irradiation efficiency can be improved. The reflection film can include, for example, gold, aluminum oxide, and the like.
A gas can be filed into the internal space of the tubular portion 11. The gas can be filled so that heat generated in the heating portion 20 is not easily transferred to the tubular portion 11. For that reason, the gas is desirably a gas having low thermal conductivity. The gas may be, for example, one kind of argon (Ar), xenon (Xe), krypton (Kr), and neon (Ne) or a mixed gas obtained by the combination of a plurality of kinds of gases.
A pressure (sealing pressure) of a gas at 25° C. in the internal space of the tubular portion 11 can be set to, for example, a pressure range from 0.6 bar (60 kPa) to 0.9 bar (90 kPa). Here, a pressure (sealing pressure) of a gas at 25° C. in the internal space of the tubular portion 11 can be obtained by a standard state (standard ambient temperature and pressure (SATP): temperature 25° C., 1 bar) of the gas.
The sealing portion 12 can be provided in each of both end portions of the tubular portion 11 in the tube axis direction. When the sealing portion 12 is provided in both ends of the tubular portion 11, the internal space of the tubular portion 11 can be sealed airtightly. For example, the pair of sealing portions 12 can be formed by pressing both end portions of the heated tubular portion 11. For example, the pair of sealing portions 12 can be formed by using a pinch seal method or a shrink seal method. When the sealing portion 12 is formed by using the pinch seal method, the plate-shaped sealing portion 12 illustrated in
The protrusion portion 13 can be provided on the outer surface of the tubular portion 11. The protrusion portion 13 can be provided in order to exhaust the internal space of the tubular portion 11 or introduce the above-described gas into the internal space of the tubular portion 11 at the time of manufacturing the heater 1. The protrusion portion 13 can be formed by burning off a tube formed of quartz glass after an exhaust and a gas are introduced.
The heating portion 20 can include carbon. The heating portion 20 can be formed in, for example, a spiral shape. The heating portion 20 can be formed, for example, by spirally winding a strip-shaped mesh structure including carbon or a linear body including carbon fibers. The general shape of the heating portion 20 can be, for example, a cylindrical shape. The heating portion 20 can be provided in the internal space of the tubular portion 11. The heating portion 20 can be formed so as to extend along the tube axis of the tubular portion 11 in the center region of the tubular portion 11. The heating portion 20 can generate heat and emit light including infrared rays when energized. Additionally, the heating portion 20 may be, for example, a tubular mesh structure including carbon fibers, a stripe-shaped body including carbon, a linear body including carbon, or the like. The heating portion 20 illustrated in
Both end portions of the heating portion 20 can extend along the tube axis of the tubular portion 11. Each of both end portions of the heating portion 20 is connected to the connection portion 60 in the internal space of the tubular portion 11. Further, the heating portion 20 can be pulled when both end portions of the heating portion 20 are connected to the connection portion 60. In this way, it is possible to suppress the heating portion 20 from contacting the inner wall of the tubular portion 11.
One conductive portion 30 can be provided in one sealing portion 12. The conductive portion 30 can be provided inside the sealing portion 12. The planar shape of the conductive portion 30 can be a square. The conductive portion 30 can have a thin film shape. The conductive portion 30 can be formed by, for example, a molybdenum foil.
One outer lead 40 can be provided in one conductive portion 30. One outer lead 40 illustrated in
A power-supply or the like provided outside the heater 1 can be electrically connected to the outer lead 40. For example, the outer lead 40 can be connected to a connector, a harness, or the like and the outer lead 40 can be electrically connected to a power-supply or the like through a cable provided in the connector, the harness, or the like.
When the heating portion 20 includes carbon, a peak occurs in the energy of emitted light at wavelengths of 2 μm to 4 μm. Since the peak of the absorption spectrum of water is around 3 μm, an object having a high water content can be efficiently heated by using the heating portion 20 including carbon. However, in the case of the heating portion 20 including carbon, the heating portion 20 is not easily and directly connected to the conductive portion 30. For that reason, the heater 1 is provided with the inner lead 50 and the connection portion 60.
At least one inner lead 50 can be provided in one conductive portion 30. One inner lead 50 illustrated in
Further, a bent portion 50a can be provided in the end portion opposite to the conductive portion 30 in the inner lead 50 (see
The inner lead 50 can include, for example, molybdenum or the like. The inner lead 50 is connected to the conductive portion 30 inside the sealing portion 12. For example, the inner lead 50 can be laser-welded or resistance-welded to the conductive portion 30.
The connection portion 60 can be provided in the internal space of the tubular portion 11. One connection portion 60 can be connected to each of both end portions of the heating portion 20. That is, the connection portion 60 is connected to the heating portion 20 and the inner lead 50. In addition, the connection between the connection portion 60 and the heating portion 20 and the connection between the connection portion 60 and the inner lead 50 will be described in detail later.
The connection portion 60 can be formed of a material having heat resistance and conductivity. The connection portion 60 can include, for example, metal such as nickel or nickel alloy.
As illustrated in
At the time of connecting the inner lead 150 and the heating portion 20 to the connection portion 160, first, as illustrated in
Next, an end portion of the heating portion 20 is inserted into a hole 160g.
Next, as illustrated in
In this way, the heating portion 20 is connected to the connection portion 160.
Further, the vicinity of the end portion of the inner lead 150 is welded to the surface of the base portion 160a.
Next, as illustrated in
Subsequently, the holding portion 160e and the holding portion 160f are welded to each other.
In this way, the inner lead 150 is connected to the connection portion 160.
Here, in recent years, higher power heaters are required. For example, the heater 1 having power density of 4.5 W (watt)/mm (millimeter) or more is desirable and the heater 1 having power density of 5 W/mm or more is further desirable.
Incidentally, when the power density is 4.5 W/mm, the temperature of the connection portion 160 and the inner lead 150 is about 480° C. in some cases. When the temperature of the connection portion 160 and the inner lead 150 is about 480° C., a crack easily occurs in a portion in which the inner lead 150 and the base portion 160a are welded to each other. As described above, when both end portions of the heating portion 20 are held by the connection portion 160, the heating portion 20 is pulled. For that reason, when a crack occurs in the welded portion, the connection portion 160 is pulled by the heating portion 20 and the inner lead 150 is separated from the connection portion 160 in some cases. For that reason, there is concern that the life of the heater is shortened although the heating portion 20 and the like are not abnormal.
As illustrated in
The base portion 60a can have a plate shape. The base portion 60a can include a convex portion 60a1 which protrudes from one surface. At least one convex portion 60a1 can be provided. The convex portion 60a1 can be provided in the vicinity of the end portion on the side of the holding portion 60d in the base portion 60a. The convex portion 60a1 can extend in a direction in which the holding portion 60c and the holding portion 60d face each other. The convex portion 60a1 can be formed by, for example, a press-molding method or the like.
Further, the base portion 60a can include a hole 60h which penetrates in the thickness direction. The hole 60h can be provided in the vicinity of the end portion opposite to the installation side of the convex portion 60a1 in the base portion 60a. The hole 60h can be formed by, for example, a press-molding method or the like. The number of the holes 60h can be the same as the number of the inner leads 50. The diameter dimension of the hole 60h can be slightly larger than the thickness of the inner lead 50. The bent portion 50a of the inner lead 50 can be inserted into the hole 60h.
The holding portion 60b can be provided in the end portion in a direction intersecting the arrangement direction of the convex portion 60a1 and the hole 60h in the base portion 60a. The holding portion 60c can be provided in the end portion opposite to the installation side of the holding portion 60b in the base portion 60a. The holding portion 60c can be provided at a position facing the holding portion 60b. The holding portions 60b and 60c can be provided in the vicinity of an end portion on the installation side of the convex portion 60a1 in the base portion 60a. Each of the holding portions 60b and 60c can have a plate shape and protrude from the end portion of the base portion 60a.
The holding portion 60d can be provided in the end portion on the installation side of the convex portion 60a1 in the base portion 60a in a direction intersecting a direction in which the holding portion 60b faces the holding portion 60c. The holding portion 60d can have a plate shape and protrude from the end portion of the base portion 60a. The holding portion 60d can include a hole 60g penetrating in the thickness direction. The hole 60g can be provided in the end portion on the side of the base portion 60a in the holding portion 60d. A part of the hole 60g can be provided in the base portion 60a. The diameter dimension of the hole 60g can be slightly larger than the thickness of the end portion of the heating portion 20. The end portion of the heating portion 20 can be inserted into the hole 60g.
Further, the holding portion 60d can be provided with at least one convex portion 60d1. The convex portion 60d1 can be formed by, for example, a press-molding method or the like. The convex portion 60d1 can protrude in a direction in which the convex portion 60a1 protrudes from the surface of the holding portion 60d. The convex portion 60d1 can extend in the extension direction of the convex portion 60a1. The convex portion 60d1 can be provided at a position not interfering with the convex portion 60a1 when the holding portion 60d is bent toward the base portion 60a.
The holding portion 60e can be provided in the end portion on the installation side of the holding portion 60b in the base portion 60a. The holding portion 60f can be provided in the end portion opposite to the installation side of the holding portion 60b in the base portion 60a. The holding portion 60f can be provided at a position facing the holding portion 60e. The holding portions 60e and 60f can be provided in the vicinity of the end portion on the installation side of the hole 60h in the base portion 60a. Each of the holding portions 60e and 60f can have a plate shape and protrude from the end portion of the base portion 60a.
At the time of connecting the inner lead 50 and the heating portion 20 to the connection portion 60, first, as illustrated in
Next, the end portion of the heating portion 20 is inserted into the hole 60g.
Next, as illustrated in
Subsequently, the holding portion 60d is bent toward the holding portions 60b and 60c and the holding portion 60d is welded to the holding portions 60b and 60c. For example, the holding portion 60d can be welded to the holding portions 60b and 60c by using a resistance-welding method.
In this way, the heating portion 20 can be connected to the connection portion 60.
Further, the bent portion 50a of the inner lead 50 is inserted into the hole 60h. Subsequently, the vicinity of the end portion on the side opposite to the conductive portion 30 in the inner lead 50 is welded to the base portion 60a. For example, the vicinity of the end portion of the inner lead 50 can be welded to the base portion 60a by using a laser-welding method or the like.
Next, as illustrated in
In this way, the inner lead 50 can be connected to the connection portion 60.
As described above, when the power density is 4.5 W/mm, the temperature of the connection portion 60 and the inner lead 50 becomes about 480° C. For that reason, a crack or the like easily occurs in a portion in which the inner lead 50 and the base portion 60a are welded to each other.
In the embodiment, the bent portion 50a of the inner lead 50 is provided inside the hole 60h. For that reason, since the bent portion 50a is caught on the inner wall of the hole 60h even when a crack occurs in the welded portion, it is possible to suppress the inner lead 50 from being separated from the connection portion 60. For that reason, it is possible to extend the life of the heater 1.
According to the knowledge of the inventor, it is possible to suppress the inner lead 50 from being separated from the connection portion 60 even when the power density becomes 5 W/mm or more and the temperature of the connection portion 60 and the inner lead 50 becomes 480° C. or more. For that reason, in the heater 1 according to the embodiment, higher power and longer life of the heater 1 can be achieved.
As illustrated in
If the groove 61a is provided, it is possible to suppress the movement of the position of the inner lead 50 when the bent portion 50a of the inner lead 50 is inserted into the hole 60h. For that reason, it is possible to improve the adhesion between the inner lead 50 and the base portion 60a when the inner lead 50 is pressed by the holding portions 60e and 60f.
Further, the welding between the inner lead 50 and the connection portion 61 (the base portion 60a) can be omitted. No crack occurs when there is no welding portion. Further, manufacturing cost can be decreased. In addition, the inner lead 50 and the connection portion 61 (the base portion 60a) may be welded to each other.
Further, in the description above, the groove 61a provided with the inner lead 50 has been illustrated, but a configuration may be employed in which a plurality of convex portions protruding from the surface of the base portion 60a is provided and the inner lead 50 is provided between the convex portion and the convex portion.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions. Moreover, above-mentioned embodiments can be combined mutually and can be carried out.
Number | Date | Country | Kind |
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2019-094303 | May 2019 | JP | national |