Metal working – Method of mechanical manufacture – Electrical device making
Reexamination Certificate
1999-10-18
2001-06-05
Huson, Gregory L. (Department: 3729)
Metal working
Method of mechanical manufacture
Electrical device making
Reexamination Certificate
active
06240624
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for manufacturing a heating element having a coating layer of catalyst or the like, and electronic dust collector using said heating element, and an air conditioner provided therewith. Especially, the invention relates to a technique for forming a ceramic catalyst layer on a sheathed heater simply and at low cost.
2. Description of the Prior Art
Hitherto, there has been known, as an example of a heating element provided with a coating layer such as a catalyst, as shown for example in Japanese Laid-open Patent Publication No. HEI 9-61042, one made by coating a surface of a glass tube heater (sheathed heater) self-containing an electric resistor with a catalyst coating layer. Further, there is known, as shown for example in Japanese Laid-open Patent Publication No. HEI 8-41655, one made by providing an aluminized steel, coating the surface thereof with a glass coating, firing, and further forming a catalyst coating layer on its surface.
By the way, the coating of a catalyst or the like in the heating element is formed through a baking treatment in a high temperature furnace. The sheathed heater as a heater material is made by filing an electric resistor line, magnesium oxide, etc. in a metal tube, and sealing both ends of the metal tube. Accordingly, the glass sealed port parts require to be immune from thermal destruction. Thus, according to the conventional method of manufacturing the heating element for forming a catalyst coated layer on the metal tube surface of the sheathed heater, there has been practiced, prior to sealing with glass the metal tube of the sheathed heater, to provide the metal tube surface with a catalyst or the like by baking, followed by inserting a filler in the metal tube and then providing glass sealing. Also, in the one made by using a metal tube of a piece independent from the metal tube of the sheathed heater, a metal tube of a separate piece is put in a furnace, a catalyst coated layer is fired on the tube surface, and a metal tube provided with firing of the catalyst layer is fixed to the metal tube of the sheathed heater by caulking.
However, in case of the method for manufacturing the heating element with a catalyst layer as described above, a baking treatment using a high temperature furnace is required for forming a catalyst layer, for which purpose a large scale equipment is required, and there is a problem of difficulty to manufacture a heating element simply at a low cost. Furthermore, in the method of forming a catalyst layer directly on the surface of the metal tube of the sheathed heater, the completed sheathed heater cannot be used, because of which the manufacturing steps are increased, leading to a cost increase.
SUMMARY OF THE INVENTION
The present invention has been made to dissolve the problems mentioned above, and its object is to manufacture a heating element in which the baking treatment using a furnace is unnecessary; breakage of the glass seals of the heater material by the high temperature seizure in furnace can be evaded; to form a coating layer such as a catalyst direct on the heater material easily at a low cost. Furthermore, the object is to provide an electronic dust collector using the heating element manufactured under the method for manufacturing the heating element and an air conditioner equipped with said electronic dust collector.
In order to attain the above object, the present invention provides a method for manufacturing a heating element made by forming a coating layer of catalyst or the like on the surface of a heater element, comprising: a step of coating the surface of a heater material with a low temperature curing type heat resistant inorganic adhesive; a step of depositing a substance forming a coating layer such as a catalyst on the heat resistant inorganic adhesive; and a step of energizing said heater material to self-generate heat, heating to cure said heat resistant inorganic adhesive with said heating, thereby fixing the coating layer of catalyst or the like on the heater material.
In this manufacturing method, the heater material is energized under the condition where a coating layer such as a catalyst is adhered to the heat resistant inorganic adhesive applied to the surface of the heater material, and by the self-exothermic heat the low temperature curing type heat resistant inorganic adhesive is cured under heat, thereby fixing the catalyst layer onto the heater material by baking. Since the catalyst layer is baked to fix to the heater material, a high temperature baking in furnace becomes unnecessary, the equipment can be simplified, and manufacturing at low cost is possible.
As a heater material, there can be used a sheathed heater made by inserting an electric heating line in a metal tube and sealing with glass both ends of said metal tube. In the present invention method, because the baking in furnace is unnecessary, it becomes possible to form a catalyst layer in a simple manner on a metal tube of a sheathed heater without causing damage to the glass sealed port of the sheathed heater.
It is desirable for the above coating layer with a catalyst or the like to be at least one containing zeolite.
The present invention is also characterized by using a heating element as a dust collection electrode for collecting dust contained in air by using a discharge effect.
Also, the present invention covers an air conditioner characterized by arraying an electronic dust collector in an air passage in the conditioner.
REFERENCES:
patent: 3330034 (1967-07-01), Price
patent: 3812580 (1974-05-01), Drugmand
patent: 4034330 (1977-07-01), Goto
patent: 4326122 (1982-04-01), McCulloch
patent: 4551619 (1985-11-01), Lefebvre
patent: 5134772 (1992-08-01), McQueen
patent: 0013034 (1979-01-01), None
patent: 8-41655 (1996-02-01), None
patent: 9-61042 (1997-03-01), None
Funai Electric Co. Ltd.
Huson Gregory L.
Morrison Law Firm
Smith Sean
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