Infrared heating wire capable of changing power

Abstract

An infrared heating wire capable of changing power comprises a carbon fiber core beam, metal winding wires are uniformly and spirally wound on the outer surface of the carbon fiber core beam at equal intervals, an intermediate material layer wraps the outer surfaces of the metal winding wires, outer-layer winding wires are uniformly and spirally wound on the outer surface of the intermediate material layer, and an insulating outer layer wraps the outer surfaces of the outer-layer winding wires. The spiral winding direction of the metal winding wire is opposite to the spiral winding direction of the outer layer winding wire. According to the utility model, the defects in the prior art are overcome, and the effect of randomly adjusting the power per unit length of the whole infrared heating wire can be realized. Besides, a plurality of parallel high-strength chemical fibers are arranged on the outer surface of the carbon fiber core bundle, so that the regularity of the whole wire core can be effectively guaranteed, the consistency of the sectional area of the whole wire core can be effectively guaranteed, and the requirement of a production mold is met.

Description

Technical Field

[0001] This utility model relates to the field of heating wire technology, specifically to an infrared heating wire with variable power. Background Technology

[0002] Among existing heating elements, heating wires are widely used in heating products due to their lightweight and compact design. Carbon fiber heating wires are a high-tech product distinct from traditional heating wires such as metal wires and halogen wires, boasting superior performance characteristics including long service life, high electrothermal conversion efficiency, far-infrared radiation, and health and environmental friendliness. The heating element of this wire is made of carbon fiber felt and carbon fiber filaments, offering advantages such as large power margin, high temperature resistance, strong high-heat capacity, long service life, and adjustable power. Therefore, it has wide applications in heating, far-infrared health care, baking, heat preservation, and moisture protection.

[0003] Existing carbon fiber heating wires consist of a heating conductor and an outer insulating jacket. The heating conductor is composed of multiple bundles of carbon fibers. The insulating jacket is made of polyethylene or polyvinyl chloride, or fluoroplastics or silicone rubber. However, the length of existing carbon fiber cables is limited by their resistance values. For example, commonly used 1K carbon fiber filaments have a resistance of approximately 290 ohms per meter; 3K carbon fiber filaments have a resistance of approximately 145 ohms per meter; 6K carbon fiber filaments have a resistance of approximately 70 ohms per meter; 12K carbon fiber filaments have a resistance of approximately 35 ohms per meter; and 24K carbon fiber filaments have a resistance of approximately 17 ohms per meter. Therefore, existing carbon fiber heating wires, due to their low power per unit, cannot meet actual heating needs. This necessitates connecting multiple units of carbon fiber heating wires in parallel, resulting in excessively large cross-sectional areas, increased production difficulty, compromised insulation, and reduced product lifespan and safety. Furthermore, since the resistivity per meter of carbon fiber precursor is constant, it is impossible to arbitrarily adjust the resistivity per unit length of carbon fiber core bundle (i.e., the resistivity per meter of carbon fiber core bundle) according to actual needs, and consequently, it is impossible to arbitrarily adjust the power per unit length of the entire infrared heating wire. Utility Model Content

[0004] To address the shortcomings of existing technologies, this invention provides an infrared heating wire with adjustable power, overcoming the deficiencies of existing technologies. It allows for arbitrary adjustment of the resistance of the entire infrared heating wire according to the designed resistance value, thereby achieving the effect of arbitrary adjustment of the entire infrared heating wire.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] An infrared heating wire with variable power includes a carbon fiber core bundle, on the outer surface of which metal wires are uniformly spirally wound at equal intervals, the outer surface of which is covered with an intermediate material layer, the outer surface of which is uniformly spirally wound with an outer layer of wires, and the outer surface of which is covered with an insulating outer layer.

[0007] The spiral winding direction of the metal wire is opposite to the spiral winding direction of the outer wire.

[0008] Preferably, the carbon fiber core bundle is parallel in the middle and contains metal wire bundles.

[0009] Preferably, the intermediate material layer is an NTC material layer, and the outer winding layer is a PTC material layer; the NTC material layer is used for electrical connection with the control circuit, and the NTC temperature sensing layer is used for detecting the temperature information of the PTC material layer and the carbon fiber core bundle, and transmitting the temperature information of the carbon fiber core bundle to the control circuit; the PTC material layer is electrically connected to the control circuit and transmits the temperature information to the control circuit so as to control the power through the control circuit, thereby controlling the heating temperature of the carbon fiber core bundle.

[0010] Preferably, the metal wire is a circular alloy wire structure or a flat alloy wire structure.

[0011] Preferably, the outer layer of winding wire is a circular alloy wire structure or a flat alloy wire structure.

[0012] Preferably, the outer surface of the carbon fiber core bundle is parallel and has high-strength chemical fiber filaments.

[0013] Preferably, the outer surface of the core is spirally and tightly wound with high-strength chemical fiber strands.

[0014] Preferably, the intermediate material layer is a temperature protection layer, and the material of the intermediate material layer is one of polyvinyl chloride, polyethylene, polytetrafluoroethylene, polypropylene, and nylon.

[0015] Preferably, the carbon fiber core bundle includes multiple carbon fiber heating wires, and adjacent carbon fiber heating wires are arranged side by side in parallel.

[0016] Preferably, the number of carbon fiber heating wires is 1K-48K.

[0017] This invention provides an infrared heating wire with adjustable power. It offers the following advantages: by spirally winding metal wires at equal intervals around the outer surface of the carbon fiber core bundle according to actual needs, the resistance per meter of the core can be adjusted by changing the spiral spacing of the metal wires, thus ensuring that the resistance per meter of the core can be adjusted to any desired value. Consequently, the resistance of the entire infrared heating wire can be arbitrarily adjusted according to the designed resistance value, achieving the effect of arbitrary adjustment of the entire infrared heating wire.

[0018] Furthermore, compared to a complete wire core formed entirely from carbon fiber core bundles, this invention effectively reduces the cross-sectional area of ​​the entire wire core by winding low-resistance metal wires around the outer surface of the carbon fiber core bundle. Therefore, for the same resistance value, the cross-sectional area of ​​the infrared heating wire of this invention can be smaller. This also effectively avoids the problems of increased cost and interference with the normal use of heating products caused by excessively thick carbon fiber core bundles. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in this utility model or the prior art, the accompanying drawings used in the description of the prior art will be briefly introduced below.

[0020] Figure 1 A schematic diagram of the structure of this utility model;

[0021] Figure 2 A schematic diagram of the cross-sectional structure of this utility model;

[0022] Explanation of the labels in the diagram:

[0023] 1. Carbon fiber core bundle; 2. Metal winding; 3. Intermediate material layer; 4. Outer winding; 5. Insulating outer layer; 6. Chemical fiber filament; 7. Chemical fiber winding; 8. Metal wire bundle. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings.

[0025] Example 1, as Figures 1 to 2 As shown, an infrared heating wire with variable power can be used in heating devices, such as electric blankets, electric blankets, pet blankets, heated boots, localized human body heating products, and other heat preservation and heating products.

[0026] The infrared heating wire includes a carbon fiber core bundle 1, with metal wires 2 evenly spirally wound on the outer surface of the carbon fiber core bundle 1 at equal intervals. The outer surface of the metal wires 2 is covered with an intermediate material layer 3. The outer surface of the intermediate material layer 3 is evenly spirally wound with an outer layer wire 4. The outer surface of the outer layer wire 4 is covered with an insulating outer layer 5.

[0027] The spiral winding direction of the metal wire 2 is opposite to that of the outer layer wire 4. By having the metal wire 2 and the outer layer wire 4 wound in opposite directions, the heating wire gains better permeability. The two opposite winding methods create different, relatively point-like contact areas between the metal wire 2 and the outer layer wire 4. This helps to offset the influence of external forces to a certain extent and improve the stability of the heating wire.

[0028] In this embodiment, by spirally winding metal wires 2 at equal intervals around the outer surface of the carbon fiber core bundle 1 according to actual needs, the resistance per unit length of the core can be adjusted by changing the spiral spacing of the metal wires 2, thus ensuring that the resistance per unit length of the core can be adjusted to any value as required. This achieves the effect of arbitrarily adjusting the power per unit length of the entire infrared heating wire.

[0029] Furthermore, compared to a complete wire core formed entirely from carbon fiber core bundle 1, this invention effectively reduces the cross-sectional area of ​​the entire wire core by winding a low-resistance metal wire 2 around the outer surface of the carbon fiber core bundle 1. Therefore, for the same resistance value, the cross-sectional area of ​​the infrared heating wire of this invention can be smaller. This also effectively avoids the problem of increased cost and disruption to normal heating product use caused by an excessively thick carbon fiber core bundle 1.

[0030] In this embodiment, the carbon fiber core bundle 1 includes multiple carbon fiber heating wires, with adjacent carbon fiber heating wires arranged parallel to each other. This allows the carbon fiber to generate far-infrared rays with wavelengths of 2μm-30μm when heated, producing a resonance phenomenon. This can promote an increase in cell temperature in the skin and subcutaneous tissue, causing heat transfer from the inside out, promoting and improving blood circulation, relieving fatigue, aiding in bodily function recovery, enhancing metabolism, and improving the body's immune function.

[0031] Example 2, as a further effective solution of Example 1, includes parallel metal wire bundles 8 in the middle of the carbon fiber core bundle 1. By arranging multiple low-resistance metal wire bundles 8 in a parallel manner in the middle of the carbon fiber core bundle 1, the cross-sectional area of ​​the infrared heating wire of this invention can be smaller for the same resistance compared to a whole wire core formed entirely from the carbon fiber core bundle 1. This ensures that, under the same power conditions, the length of the infrared heating wire of this invention can be longer, meeting the heating requirements.

[0032] In Example 3, as a further preferred embodiment of Example 1, the intermediate material layer 3 is an NTC material layer, and the outer winding 4 is a PTC material layer. The NTC material layer is used for electrical connection with the control circuit, and the NTC temperature sensing layer is used to detect the temperature information of the PTC material layer and the carbon fiber core bundle 1, and transmit the temperature information of the carbon fiber core bundle 1 to the control circuit; the PTC material layer is electrically connected to the control circuit and transmits the temperature information to the control circuit so that the power is controlled by the control circuit, thereby controlling the heating temperature of the carbon fiber core bundle 1.

[0033] By using an NTC material layer as the intermediate material layer 3, and considering that NTC is a semiconductor resistor with a negative temperature coefficient, its resistance decreases as temperature increases. At lower temperatures, the number of charge carriers (electrons and holes) in the NTC thermistor is relatively small, resulting in a higher resistance. As the temperature rises, the number of charge carriers increases, and the resistance decreases accordingly. When the heating wire temperature is too high, the resistance of the NTC material layer will decrease significantly, thereby changing the current or voltage in the circuit. This allows the NTC material layer to exhibit a significant resistance change with temperature variations, which can be used for temperature measurement and control. Furthermore, because NTC is sensitive to temperature changes, it can quickly reflect temperature changes. The NTC characteristic can also be used to protect against localized overheating of the product. The principle behind this protection is achieved by determining whether the voltage drop across the sampling resistor caused by a large leakage current or voltage generated by the NTC insulation material due to localized high temperatures reaches the high-level input of the control circuit (or microcontroller).

[0034] By using a PTC material layer as the outer winding wire 4, the PTC material exhibits a positive temperature coefficient, meaning its resistance increases with temperature. This characteristic causes the PTC material layer to have increased resistance and decreased current as temperature rises, automatically limiting the heating power and preventing overheating. Furthermore, due to the relatively small heat capacity of the PTC heating wire, it can quickly reach a stable operating state. After being powered on, the PTC heating wire heats up rapidly. Since the resistance of the PTC material mainly depends on its heating temperature and is less affected by power supply voltage fluctuations, using different power supply voltages will not significantly affect the operating temperature of the element as long as the applied voltage provides sufficient heat to the PTC element to reach its Curie point and exhibit PTC characteristics. This characteristic allows the PTC heating wire to maintain stable detection and control performance even in environments with unstable power supply voltages. Specifically, as the temperature of the PTC material layer rises, its resistance increases, and the sampling voltage decreases. When the voltage falls below the set reference voltage or current, the control circuit stops outputting trigger pulses upon detecting the low potential. Subsequently, the resistance of the PTC material layer gradually decreases, and the sampling voltage increases. When the sampling voltage increases, the control circuit detects a high potential, outputs trigger pulses, and resumes output. The control circuit cuts off the output as the resistance of the PTC heating layer increases and heats up as the resistance decreases, achieving constant temperature control through cyclical control.

[0035] In Example 4, as a further preferred embodiment of Example 1, the metal wire 2 is a circular alloy wire structure or a flat alloy wire structure. In this embodiment, a flat alloy wire structure is preferred, which increases the surface area of ​​the metal wire 2, thereby enabling the metal wire 2 to provide higher power density in a smaller volume, and also further increasing the mechanical strength of the metal wire 2.

[0036] In Example 5, as a further preferred embodiment of Example 1, the outer winding wire 4 is a circular alloy wire structure or a flat alloy wire structure. In this embodiment, a flat alloy wire structure is preferred, which increases the heating area of ​​the outer winding wire 4, further increases the mechanical strength and roundness of the outer winding wire 4, and also ensures that the outer winding wire 4 can be more tightly wound on the outer surface of the intermediate material layer 3.

[0037] Example 6, as a further preferred embodiment of Example 1, has high-strength chemical fiber filaments 6 parallel to the outer surface of the carbon fiber core bundle 1. Specifically, the high-strength chemical fiber filaments 6 can be aramid filaments, polyester filaments, etc. By merging multiple high-strength chemical fiber filaments 6 parallel to each other on the outer surface of the carbon fiber core bundle 1, the regularity of the entire core can be effectively guaranteed, and the consistency of the cross-sectional area of ​​the entire core can also be effectively guaranteed, so as to meet the requirements of the production mold.

[0038] Example 7, as a further preferred embodiment of Example 1, involves a high-strength chemical fiber winding 7 tightly spirally wound around the outer surface of the core. Specifically, the high-strength chemical fiber winding 7 can be made of aramid filaments, polyester filaments, etc. By winding the high-strength chemical fiber winding 7, the tightness and roundness of the entire core can be effectively improved.

[0039] Example 8, as a further preferred embodiment of Example 1, uses an intermediate material layer 3 as a temperature protection layer. The material of the intermediate material layer 3 is one of polyvinyl chloride, polyethylene, polytetrafluoroethylene, polypropylene, or nylon. By using a temperature protection layer as the intermediate material layer 3, the entire infrared heating wire can function as a protective wire. When the temperature of the carbon fiber core bundle 1 of the infrared heating wire is too high, the intermediate material layer 3 will melt due to the high temperature. This causes the outer winding filament 4 wrapped around the outer surface of the intermediate material layer 3 to come into contact with the metal winding filament 2 inside the intermediate material layer 3, resulting in an increase in external current and voltage. This, in turn, will melt the external temperature fuse, thereby achieving short-circuit protection.

[0040] Example 9, as a further preferred embodiment of Example 1, uses 1K-48K carbon fiber heating wires. The number of carbon fiber heating wires can change the resistance of the carbon fiber heating element; the more carbon fiber heating wires there are, the lower the resistance of the carbon fiber heating element.

[0041] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. An infrared heating wire with variable power, characterized in that: A carbon fiber core bundle (1) has metal wires (2) wound evenly and spirally on its outer surface. The metal wires (2) are covered with an intermediate material layer (3). The outer surface of the intermediate material layer (3) is evenly and spirally wound with an outer layer wires (4). The outer surface of the outer layer wires (4) is covered with an insulating outer layer (5). The spiral winding direction of the metal wire (2) is opposite to the spiral winding direction of the outer wire (4); The intermediate material layer (3) is an NTC material layer, and the outer winding (4) is a PTC material layer. The NTC material layer is used to be electrically connected to the control circuit. The NTC material layer is used to detect the temperature information of the carbon fiber core bundle (1). By judging that the NTC material layer has a large leakage current or voltage due to local high temperature, it can protect against local overheating. The PTC material layer is electrically connected to the control circuit and transmits the temperature information to the control circuit so that the power can be controlled by the control circuit, thereby controlling the heating temperature of the carbon fiber core bundle (1).

2. The infrared heating wire with variable power according to claim 1, characterized in that: The carbon fiber core bundle (1) is parallel in the middle and has metal wire bundles (8).

3. The infrared heating wire with variable power according to claim 1, characterized in that: The metal wire (2) is a circular alloy wire structure or a flat alloy wire structure.

4. The infrared heating wire with variable power according to claim 1, characterized in that: The outer layer winding (4) is a circular alloy wire structure or a flat alloy wire structure.

5. An infrared heating wire with variable power according to claim 1, characterized in that: The outer surface of the carbon fiber core bundle (1) is parallel and has high-strength chemical fiber filaments (6).

6. The infrared heating wire with variable power according to claim 1, characterized in that: The outer surface of the carbon fiber core bundle (1) is spirally and tightly wound with high-strength chemical fiber windings (7).

7. An infrared heating wire with variable power according to claim 1, characterized in that: The intermediate material layer (3) is a temperature protection layer, and the material of the intermediate material layer (3) is one of polyvinyl chloride, polyethylene, polytetrafluoroethylene, polypropylene, and nylon.

8. An infrared heating wire with variable power according to claim 1, characterized in that: The carbon fiber core bundle (1) includes multiple carbon fiber heating wires, and adjacent carbon fiber heating wires are arranged side by side in parallel.

9. An infrared heating wire with variable power according to claim 8, characterized in that: The number of carbon fiber heating wires is 1K-48K.

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