JP7413343B2 - Method for manufacturing carbon nanotube devices - Google Patents

Description

The present invention relates to a method for manufacturing carbon nanotube devices.

[Reference to related applications]
This application claims the benefit of priority from Japanese patent application JP2019-029258 filed on February 21, 2019, and the entire disclosure of that application is incorporated into this application.

In recent years, it has been proposed to mold a plurality of carbon nanotubes into various shapes and use them in various products such as heaters and sensors. For example, JP-A No. 2010-257971 (Document 1) and JP-A No. 2010-034056 (Document 2) disclose planar heat sources using carbon nanotubes. The planar heat sources of Documents 1 and 2 include a heating element in which a predetermined number (for example, 100 layers) of carbon nanotube films are laminated, and two electrodes connected to both ends of the heating element. Further, in the surface heat source of Document 2, it is disclosed that two electrodes are formed of a carbon nanotube film laminate, and that the heating element and the two electrodes are directly bonded to each other due to the adhesive properties of the carbon nanotubes.

By the way, in the surface heat sources of Documents 1 and 2, due to variations in the density of carbon nanotubes (so-called fiber density) in each carbon nanotube film to be stacked, even when carbon nanotube films with the same number of layers are stacked, Variations occur in the resistance of the heating element. For this reason, it is difficult to manufacture a surface heat source with a desired resistance. Furthermore, it is difficult to increase the area of the planar heat source.

The present invention is directed to a method of manufacturing a carbon nanotube device comprising a pair of electrodes and a connection sheet portion that is a sheet-like carbon nanotube molded body that connects the pair of electrodes, and the carbon nanotube device has a desired resistance. The main purpose is to provide devices.

A method for manufacturing a carbon nanotube device according to a preferred embodiment of the present invention includes: a) a pair of electrodes at both ends of a connection region extending in the circumferential direction on the outer surface of a rotating body that is rotatable about a rotating shaft pointing in the axial direction; and b) winding the carbon nanotube sheet on the outer surface while passing over the pair of electrodes by rotating the rotating body by an initial winding number, and winding the carbon nanotube sheet around the rotating body. forming a cylindrical intermediate body in which nanotube sheets are laminated in the radial direction; c) cutting the cylindrical intermediate body outside the connection area in the circumferential direction; d) measuring the resistance between the pair of electrodes that are electrically connected by a laminated sheet-like carbon nanotube structure that extends in the circumferential direction; and d) the resistance measured in step c). If the initial measured resistance is larger than a predetermined target resistance, the rotating body is rotated to pass the carbon nanotube sheet over the pair of electrodes and wrap it around the outer surface of the carbon nanotube structure. laminating the carbon nanotube sheets on the body; and e) cutting the carbon nanotube sheets outside the connection area in the circumferential direction, thereby forming a connection sheet in the form of a laminated sheet that extends in the circumferential direction in the connection area. f) fixing both ends of the connection sheet part to the pair of electrodes. According to the present invention, a carbon nanotube device having desired resistance can be provided.

A method for manufacturing a carbon nanotube device according to another preferred embodiment of the present invention includes: a) disposing a pair of electrodes at positions separated in the circumferential direction on the outer surface of a rotating body that is rotatable about a rotating shaft pointing in the axial direction; and b) winding the carbon nanotube sheet on the outer surface while passing over the pair of electrodes by rotating the rotating body an initial number of windings, and winding the carbon nanotube sheet around the rotating body. c) measuring the resistance between the pair of electrodes; and d) the initial measured resistance being the resistance measured in step c). If the resistance is greater than a predetermined target resistance, the carbon nanotube sheet is wound onto the outer surface while passing over the pair of electrodes by rotating the rotating body, and the carbon nanotube sheet is wound onto the outer surface of the cylindrical intermediate body. and e) fixing the carbon nanotube sheet layer stacked on the pair of electrodes to the pair of electrodes. According to the present invention, a carbon nanotube device having desired resistance can be provided.

Preferably, in the step a), the pair of electrodes are arranged 180° apart in the circumferential direction. In the step e), a connection sheet portion extending in the circumferential direction between the pair of electrodes is formed by cutting the carbon nanotube sheet layer and the pair of electrodes at the center of each of the pair of electrodes; a step of fixing both ends of the connection sheet portion to the pair of electrodes, or removing the pair of electrodes and the cylindrical carbon nanotube sheet layer from the rotating body, and fixing the carbon nanotube sheet layer to the pair of electrodes; fixing and pressing the carbon nanotube sheet layer between the pair of electrodes in the thickness direction to form a planar shape, thereby forming a connection sheet portion that connects the pair of electrodes.

Preferably, the number of turns of the carbon nanotube sheet in step d) is determined based on the initial measured resistance and laminated resistance information indicating a relationship between the number of laminated carbon nanotube sheets and resistance.

A method for manufacturing a carbon nanotube device according to another preferred embodiment of the present invention includes: a) disposing a pair of electrodes at positions separated in the circumferential direction on the outer surface of a rotating body that is rotatable about a rotating shaft pointing in the axial direction; b) winding the carbon nanotube sheet onto the outer surface while passing over the pair of electrodes by rotating the rotating body while measuring the resistance between the pair of electrodes; , c) forming a carbon nanotube sheet layer stacked on the pair of electrodes by continuing the step b) until the resistance measured in the step b) reaches a predetermined resistance; d) fixing the carbon nanotube sheet layer to the pair of electrodes. According to the present invention, a carbon nanotube device having desired resistance can be provided.

Preferably, in the step a), the pair of electrodes are arranged 180° apart in the circumferential direction. In the step d), a connecting sheet portion extending in the circumferential direction between the pair of electrodes is formed by cutting the carbon nanotube sheet layer and the pair of electrodes at the center of each of the pair of electrodes; a step of fixing both ends of the connection sheet portion to the pair of electrodes, or removing the pair of electrodes and the cylindrical carbon nanotube sheet layer from the rotating body, and fixing the carbon nanotube sheet layer to the pair of electrodes; fixing and pressing the carbon nanotube sheet layer between the pair of electrodes in the thickness direction to form a planar shape, thereby forming a connection sheet portion that connects the pair of electrodes.

A method for manufacturing a carbon nanotube device according to another preferred embodiment of the present invention includes: a) a pair of electrodes at both ends of a connection region extending in the circumferential direction on the outer surface of a rotating body that is rotatable about a rotating shaft pointing in the axial direction; and arranging a pair of measurement electrodes at positions sandwiching the connecting region and the pair of electrodes on the circumferentially outer side of the pair of electrodes, and b) winding the rotating body for the initial number of turns. By rotating, the carbon nanotube sheet is wound around the outer surface while passing over the pair of electrodes and the pair of measurement electrodes, so that the carbon nanotube sheet is laminated in the radial direction around the rotating body. c) cutting the cylindrical intermediate outside the pair of measurement electrodes in the circumferential direction, and forming a cylindrical intermediate between the pair of measurement electrodes in the cylindrical intermediate; d) measuring the resistance between the pair of measurement electrodes that are electrically connected by a laminated sheet-like carbon nanotube structure that extends in the circumferential direction; and d) the resistance obtained in step c). If the initial measured resistance, which is the resistance between the pair of electrodes determined based on the measured value, is larger than a predetermined target resistance, the carbon nanotube sheet is moved over the pair of electrodes by rotating the rotating body. (e) wrapping the carbon nanotube sheet on the outer surface while passing through the carbon nanotube structure, and laminating the carbon nanotube sheet on the carbon nanotube structure; a step of forming a laminated sheet-shaped connection sheet portion extending in the circumferential direction in the connection region by cutting the carbon nanotube sheet; and f) a step of fixing both ends of the connection sheet portion to the pair of electrodes. Equipped with. According to the present invention, a carbon nanotube device having desired resistance can be provided.

A method for manufacturing a carbon nanotube device according to another preferred embodiment of the present invention includes: a) disposing a pair of electrodes at positions separated in the circumferential direction on the outer surface of a rotating body that is rotatable about a rotating shaft pointing in the axial direction; At the same time, a step of arranging a pair of measurement electrodes at positions separated in the circumferential direction; and b) rotating the rotating body by an initial number of windings, the carbon nanotube sheet is placed on the pair of electrodes and the measurement electrode is placed on the pair of measurement electrodes. c) forming a cylindrical intermediate body in which the carbon nanotube sheets are laminated in the radial direction around the rotating body; d) if the initial measured resistance, which is the resistance between the pair of electrodes determined based on the measured value obtained in step c), is greater than a predetermined target resistance; a step of winding the carbon nanotube sheet on the outer surface while passing over the pair of electrodes by rotating a rotating body, and laminating the carbon nanotube sheet on the cylindrical intermediate; e) and fixing a carbon nanotube sheet layer stacked on the pair of electrodes to the pair of electrodes. According to the present invention, a carbon nanotube device having desired resistance can be provided.

Preferably, in the step a), the pair of electrodes are arranged 180° apart in the circumferential direction. In the step e), a connection sheet portion extending in the circumferential direction between the pair of electrodes is formed by cutting the carbon nanotube sheet layer and the pair of electrodes at the center of each of the pair of electrodes; a step of fixing both ends of the connection sheet portion to the pair of electrodes, or removing the pair of electrodes and the cylindrical carbon nanotube sheet layer from the rotating body, and fixing the carbon nanotube sheet layer to the pair of electrodes; fixing and pressing the carbon nanotube sheet layer between the pair of electrodes in the thickness direction to form a planar shape, thereby forming a connection sheet portion that connects the pair of electrodes.

Preferably, the number of turns of the carbon nanotube sheet in step d) is determined based on the initial measured resistance and laminated resistance information indicating a relationship between the number of laminated carbon nanotube sheets and resistance.

A method for manufacturing a carbon nanotube device according to another preferred embodiment of the present invention includes: a) disposing a pair of electrodes at positions separated in the circumferential direction on the outer surface of a rotating body that is rotatable about a rotating shaft pointing in the axial direction; At the same time, a step of arranging a pair of measurement electrodes at positions separated in the circumferential direction; and b) rotating the rotating body while measuring the resistance between the pair of measurement electrodes, the carbon nanotube sheet is a step of winding it on the outer surface while passing over the pair of electrodes and a pair of measurement electrodes, and c) the distance between the pair of electrodes determined based on the measured value obtained in step b). d) forming a carbon nanotube sheet layer laminated on the pair of electrodes by continuing the step b) until the resistance of the carbon nanotube sheet layer reaches a predetermined resistance; and a step of fixing it to the electrode. According to the present invention, a carbon nanotube device having desired resistance can be provided.

Preferably, in the step a), the pair of electrodes are arranged 180° apart in the circumferential direction. In the step d), a connecting sheet portion extending in the circumferential direction between the pair of electrodes is formed by cutting the carbon nanotube sheet layer and the pair of electrodes at the center of each of the pair of electrodes; a step of fixing both ends of the connection sheet portion to the pair of electrodes, or removing the pair of electrodes and the cylindrical carbon nanotube sheet layer from the rotating body, and fixing the carbon nanotube sheet layer to the pair of electrodes; fixing and pressing the carbon nanotube sheet layer between the pair of electrodes in the thickness direction to form a planar shape, thereby forming a connection sheet portion that connects the pair of electrodes.

Preferably, an adhesive is applied on the pair of measurement electrodes between the step a) and the step b).

Preferably, the adhesive is a pasty rosin.

Preferably, before the step b), a target number of windings corresponding to the target resistance is determined based on laminated resistance information indicating a relationship between the number of laminated carbon nanotube sheets and resistance, and the initial number of windings is is set smaller than the target number of turns.

Preferably, an adhesive is applied to the carbon nanotube sheet wound around the rotating body.

Preferably, the adhesive includes a conductive additive.

The above objects and other objects, features, aspects and advantages will become apparent from the following detailed description of the invention with reference to the accompanying drawings.

FIG. 1 is a side view of a carbon nanotube heater according to one embodiment. FIG. 2 is a plan view of a carbon nanotube heater. FIG. 2 is a side view of the device manufacturing apparatus. FIG. 2 is a plan view of the device manufacturing apparatus. It is a figure which shows an example of laminated resistance information. FIG. 3 is a diagram showing a first example of the flow of manufacturing a carbon nanotube heater. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 2 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. It is a figure which shows the flow of fixing a connection sheet part to an electrode. FIG. 6 is a diagram showing how the connection sheet portion is fixed to the electrode. FIG. 6 is a diagram showing how the connection sheet portion is fixed to the electrode. FIG. 6 is a diagram showing how the connection sheet portion is fixed to the electrode. FIG. 6 is a diagram showing how the connection sheet portion is fixed to the electrode. FIG. 6 is a diagram showing how the connection sheet portion is fixed to the electrode. FIG. 7 is a diagram showing a second example of the flow of manufacturing a carbon nanotube heater. FIG. 2 is a side view of the device manufacturing apparatus. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 2 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 7 is a diagram showing a third example of the flow of manufacturing a carbon nanotube heater. FIG. 3 is a diagram showing a part of the flow of manufacturing a carbon nanotube heater. FIG. 2 is a plan view of the device manufacturing apparatus. It is a figure which shows the 4th example of the flow of manufacturing a carbon nanotube heater. FIG. 2 is a side view of the device manufacturing apparatus. FIG. 2 is a plan view of the device manufacturing apparatus. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. FIG. 3 is a diagram showing a carbon nanotube heater in the process of being manufactured. It is a figure which shows the 5th example of the flow of manufacturing a carbon nanotube heater. FIG. 2 is a side view of the device manufacturing apparatus. It is a figure which shows the 6th example of the flow of manufacturing a carbon nanotube heater. FIG. 2 is a plan view of the device manufacturing apparatus.

FIG. 1 is a side view showing a carbon nanotube heater 1 according to one embodiment of the present invention. FIG. 2 is a plan view showing the carbon nanotube heater 1. FIG. The carbon nanotube heater 1 is, for example, a relatively thin sheet-shaped heater used for heating an object. In the example shown in FIG. 2, the carbon nanotube heater 1 has a substantially rectangular band shape in plan view. In the following description, the left-right direction in FIG. 1 is also referred to as the "longitudinal direction", and the up-down direction in FIG. 1 is also simply referred to as the "up-down direction". Further, the vertical direction (that is, the direction perpendicular to the longitudinal direction) in FIG. 2 is also referred to as the "width direction." Note that the above-mentioned vertical direction does not have to match the actual weight direction.

The carbon nanotube heater 1 includes a carbon nanotube device 2, a housing section 31, and a heat radiation section 34. The carbon nanotube device 2, the housing section 31, and the heat dissipation section 34 each have, for example, a substantially rectangular band shape extending in the longitudinal direction in a plan view. Note that the shapes of the carbon nanotube heater 1, the carbon nanotube device 2, the housing section 31, and the heat dissipation section 34 in plan view do not necessarily have to be substantially rectangular shapes that are long in the longitudinal direction; It may be a substantially square shape with substantially the same width, or it may be a substantially rectangular shape that is long in the width direction.

The carbon nanotube device 2 is a substantially sheet-shaped heating element that generates heat when supplied with electric power. The term "sheet-like" as used herein refers to a shape that is thinner than its length and width, and may or may not have flexibility. Furthermore, the term "sheet-like" as used herein is a concept that also includes a shape called a film-like shape. The carbon nanotube device 2 includes a connection sheet section 21, a pair of electrodes 22, and a support sheet section 23. The pair of electrodes 22 are spaced apart from each other in the longitudinal direction. The connection sheet portion 21 and the support sheet portion 23 extend in the longitudinal direction from one electrode 22 to the other electrode 22 and connect the pair of electrodes 22 .

The connection sheet portion 21 is an electrically conductive sheet member. The connection sheet portion 21 is a flexible sheet-like carbon nanotube molded body formed of a large number of carbon nanotubes. Specifically, the connection sheet portion 21 is a laminated sheet-like carbon nanotube molded body in which a plurality of carbon nanotube sheets are laminated in the thickness direction. The number of layers of carbon nanotube sheets in the connection sheet portion 21 varies depending on the performance required of the carbon nanotube device 2, but is, for example, 10 to 100 layers, and in this embodiment is about 40 layers.

The shape of the connection sheet portion 21 in plan view is, for example, a substantially rectangular band shape extending in the longitudinal direction. The length in the longitudinal direction (hereinafter also simply referred to as "length") of the connection sheet portion 21 varies depending on the performance required of the carbon nanotube device 2, and is, for example, 10 mm to 1000 mm. The width in the width direction (hereinafter also simply referred to as "width") of the connection sheet portion 21 varies depending on the performance required of the carbon nanotube device 2, and is, for example, 10 mm to 1000 mm. Both longitudinal ends of the connection sheet portion 21 are fixed and electrically connected to a pair of electrodes 22, respectively. In other words, the connection sheet portion 21 extends in the longitudinal direction between the pair of electrodes 22 and spreads in the width direction. The length and width of the connection sheet portion 21 are, for example, 200 mm and 60 mm. Further, the length and width of the connection sheet portion 21 are, for example, 94 mm and 180 mm. Preferably, the connection sheet portion 21 has a substantially rectangular shape with a diagonal length of 200 mm or more.

Each of the pair of electrodes 22 is a substantially rectangular strip-shaped thin plate member extending in the width direction. Each electrode 22 is a metal foil made of copper (Cu) or the like, for example. The thickness of each electrode 22 is, for example, 20 μm to 300 μm, preferably 50 μm to 100 μm. In the example shown in FIG. 1, each electrode 22 is connected to the connection sheet section 21 by being folded in half and pressed with the end of the connection sheet section 21 sandwiched therebetween. In the carbon nanotube device 2, the pair of electrodes 22 are electrically connected by the connection sheet portion 21.

The support sheet portion 23 is a flexible insulating sheet member made of an insulator. The support sheet portion 23 is, for example, a mesh sheet formed of resin fibers such as polyester or fluororesin. Both longitudinal ends of the support sheet portion 23 are fixed to the upper surfaces of the pair of electrodes 22 with, for example, an adhesive. Note that the material and structure of the support sheet portion 23 may be variously changed.

In the carbon nanotube device 2, a large number of carbon nanotubes forming the connection sheet portion 21 extend, for example, substantially parallel to the longitudinal direction. The large number of carbon nanotubes may extend in a direction oblique to the longitudinal direction. The large number of carbon nanotubes may extend in substantially the same direction, or may extend in different directions.

In the carbon nanotube device 2 illustrated in FIG. 1, a large number of carbon nanotubes are adhered to each other with an adhesive mainly composed of an aqueous solution of polyvinyl alcohol (PVA), and are further adhered to the lower surface of the support sheet portion 23. . The adhesive may be an epoxy, acrylic, or silicone rubber adhesive. The adhesive preferably includes conductive additives. The conductive additive material is, for example, fine metal particles such as silver (Ag), graphene (specifically, powder obtained by crushing sheet-like graphene), milled fiber, or carbon nanotube powder. The diameter of the conductive additive is preferably 10 μm or less, more preferably less than 1 μm. Note that the adhesive does not need to contain a conductive additive.

The accommodating portion 31 is an exterior member that accommodates (that is, covers) and fixes the entire carbon nanotube device 2 therein. The housing portion 31 is a flexible, insulating sheet-like member. The accommodating portion 31 is made of, for example, resin or an elastic polymer material.

In the example shown in FIGS. 1 and 2, the housing section 31 includes a lower member 32 and an upper member 33. The lower member 32 supports and covers the carbon nanotube device 2 from below. The upper member 33 covers the carbon nanotube device 2 from above by being fixed on the upper surface of the lower member 32 with the carbon nanotube device 2 therebetween. In other words, the carbon nanotube device 2 is sealed by the lower member 32 and the upper member 33. The lower member 32 is formed, for example, by applying a film of silicone resin onto a release paper and curing it. The upper member 33 is formed, for example, by applying a film of silicone resin onto the lower member 32 and curing it. Alternatively, the lower member 32 and/or the upper member 33 may be a laminate film in which an adhesive layer is provided on the surface of a resin film, a silicone sheet, or the like.

The carbon nanotube heater 1 further includes a pair of terminals (not shown). The pair of terminals are electrically connected to the pair of electrodes 22 inside the housing portion 31, respectively. Further, the pair of terminals extends from the pair of electrodes 22 to the outside of the housing portion 31 through the housing portion 31 . Power is supplied to the carbon nanotube device 2 through the pair of terminals. As a result, the carbon nanotube device 2 generates heat.

In the carbon nanotube heater 1, the accommodating portion 31 does not necessarily need to accommodate the entire carbon nanotube device 2 therein, but only needs to accommodate at least the entire connection sheet portion 21 therein. In other words, in the carbon nanotube heater 1, a part or the entirety of each electrode 22 may be exposed to the outside from the housing portion 31. In this case, the pair of terminals described above may be omitted, and the electric wires may be directly connected to the pair of electrodes 22 exposed from the housing portion 31.

The heat dissipation section 34 is a sheet-like (ie, film-like or thin plate-like) member provided on the outer surface of the housing section 31 . In the example shown in FIG. 1, the heat dissipation section 34 is provided on the upper surface (that is, the upper main surface) of the housing section 31. The heat radiation part 34 is, for example, a sheet-like member made of metal such as metal foil fixed to the upper surface of the housing part 31 with an adhesive or the like. For example, aluminum (Al) or copper can be used as the metal. The heat dissipation section 34 may be, for example, a metal thin film formed on the upper surface of the housing section 31 by vapor deposition or the like. The heat dissipation section 34 extends along the main surface of the connection sheet section 21 and substantially parallel to the main surface. The heat dissipation portion 34 overlaps substantially the entirety of the connection sheet portion 21 in a direction perpendicular to the main surface of the connection sheet portion 21 . In other words, the heat dissipation section 34 covers substantially the entire connection sheet section 21 in plan view. The upper surface of the heat radiating section 34 (that is, the main surface on the opposite side from the accommodating section 31) is a heat radiating surface that equalizes and radiates the heat from the connection sheet section 21 of the carbon nanotube device 2.

The carbon nanotube heater 1 is provided with a temperature sensor 36 that measures the temperature of the heat radiation section 34. In the example shown in FIGS. 1 and 2, the temperature sensor 36 is provided at the periphery of the heat radiation section 34. The mounting position of the temperature sensor 36 on the heat radiation section 34 may be changed in various ways. As the temperature sensor 36, for example, an electric resistance temperature detector, a thermocouple, or a thermistor can be used. In the carbon nanotube heater 1, temperature control and overheating prevention of the carbon nanotube heater 1 are performed based on the output from the temperature sensor 36 (ie, temperature measurement value, etc.). Further, in the carbon nanotube heater 1, temperature control and overheating prevention of the carbon nanotube heater 1 may be performed using a thermostat. In this case, a portion built into the thermostat that changes depending on the temperature (for example, a bimetal in the case of a bimetal type thermostat) corresponds to the temperature sensor.

Next, manufacturing of the carbon nanotube heater 1 will be explained. FIG. 3 is a side view showing the configuration of the device manufacturing apparatus 4 for manufacturing the carbon nanotube device 2. As shown in FIG. FIG. 4 is a plan view showing the device manufacturing apparatus 4. As shown in FIG. In FIG. 3, the carbon nanotube sheet 94 and each electrode 22 are drawn thicker than they actually are in order to facilitate understanding of the figure. Further, each electrode 22 is marked with parallel diagonal lines. In FIG. 4, illustration of a part of the configuration of the device manufacturing apparatus 4 is omitted to facilitate understanding of the figure.

The device manufacturing apparatus 4 includes a substrate holding section 41 , a rotating body 42 , a rotating mechanism 43 , an adhesive application section 44 , a pressing roller 45 , and a control section 46 . In FIG. 3, the substrate holding part 41 is located at the upper left of the rotation axis J1 of the rotating body 42. As shown in FIG. The adhesive applying section 44 and the pressing roller 45 are located at the upper right of the rotation axis J1.

The substrate holder 41 contacts the lower surface of a substrate 92 on which a carbon nanotube array 91, which is a collection of many carbon nanotubes, is erected, and holds the substrate 92 from below. The substrate 92 is, for example, a flat thin plate member. The substrate 92 is, for example, a silicon substrate or a stainless steel substrate provided with a silicon dioxide film on its surface. Note that the substrate 92 may be a flexible elongated thin plate member. In this case, it is preferable that the device manufacturing apparatus 4 is provided with a recovery section (for example, a recovery roller and a motor) that winds up the portion of the substrate 92 from which the carbon nanotube array 91 has been peeled off.

The carbon nanotube array 91 is grown in a predetermined orientation direction (in this embodiment, approximately It is formed by growing a large number of vertically oriented carbon nanotubes on a substrate 92. Formation of carbon nanotube array 91 may be performed by various other methods.

The thickness of the carbon nanotube array 91 (that is, the length in the vertical direction of the carbon nanotubes included in the carbon nanotube array 91) is, for example, 50 μm to 1000 μm. In this embodiment, the thickness of carbon nanotube array 91 is 50 μm to 500 μm. The thickness of the carbon nanotube array 91 is measured using, for example, a scanning electron microscope (SEM) (manufactured by JEOL Ltd.) or a non-contact film thickness meter (manufactured by Keyence Corporation).

In the carbon nanotube array 91, for example, there are 10 ⁹ to 10 ¹¹ carbon nanotubes per 1 cm ² . The distance between adjacent carbon nanotubes is, for example, 100 nm to 200 nm. The outer diameter of each carbon nanotube is, for example, 10 nm to 30 nm. Each carbon nanotube is, for example, a multi-walled carbon nanotube with 5 to 10 layers. Each carbon nanotube may be a multi-walled carbon nanotube with 4 or less layers or 11 or more layers, or may be a single-walled carbon nanotube.

The bulk density of the carbon nanotube array 91 is, for example, 10 mg/cm ³ to 60 mg/cm ³ . Preferably, the bulk density of the carbon nanotube array 91 is 20 mg/cm ³ to 50 mg/cm ³ . The bulk density of the carbon nanotube array 91 is determined by dividing the mass (ie, basis weight) of the carbon nanotube array 91 per unit area by the thickness of the carbon nanotube array 91.

The rotating body 42 is a substantially cylindrical or substantially cylindrical member centered on a rotation axis J1 that faces in a direction perpendicular to the plane of the paper in FIG. 3 (hereinafter also referred to as the "axial direction"). The outer surface of the rotating body 42 is a substantially cylindrical surface extending parallel to the axial direction. The axial direction is a direction corresponding to the width direction of the carbon nanotube device 2, so it is also referred to as the "width direction." An insulating sheet member 230 (for example, a mesh sheet made of polyester fiber), which is to become the support sheet portion 23 of the carbon nanotube heater 1, is removably attached to the outer surface of the rotating body 42. The insulating sheet member 230 covers, for example, the outer peripheral surface of the rotating body 42 over the entire circumference in the circumferential direction (hereinafter also simply referred to as the "circumferential direction") centered on the rotating shaft J1.

A pair of electrodes are arranged on the outer surface of the rotating body 42. A plurality of pairs of electrodes may be arranged on the outer surface of the rotating body 42. In this embodiment, three pairs of electrodes are arranged on the outer surface of the rotating body 42 and are detachably attached to the outer surface of the rotating body 42 via an insulating sheet member 230. In the following description, two electrodes of the first electrode pair are designated with the symbol 22a, two electrodes of the second electrode pair are designated with the symbol 22b, and two electrodes of the third electrode pair are designated with the symbol 22c. attach Further, when the electrodes 22a, 22b, and 22c are not distinguished from each other, they are referred to as electrodes 22 as described above. In the device manufacturing apparatus 4, as will be described later, connection sheet portions 21 are formed between the three pairs of electrodes 22, and three carbon nanotube devices 2 are formed.

In the following description, a region extending in the circumferential direction between the two electrodes 22a of the first electrode pair and a region extending in the circumferential direction between the two electrodes 22b of the second electrode pair on the outer surface of the rotating body 42 will be described. The extending region and the region extending in the circumferential direction between the two electrodes 22c of the third electrode pair are each referred to as a "connection region 421." Among the three connection regions 421, a pair of electrodes 22a are arranged at both circumferential ends of the connection region 421 located on the left side of the rotation axis J1 in FIG. Further, a pair of electrodes 22b are arranged at both circumferential ends of the connection region 421 located at the lower right of the rotation axis J1. A pair of electrodes 22c are arranged at both circumferential ends of the connection region 421 located at the upper right of the rotation axis J1.

The rotating body 42 is rotatable about the rotating shaft J1 by a rotating mechanism 43. In the example shown in FIG. 3, the rotating body 42 rotates clockwise in the figure. The rotation mechanism 43 is, for example, an electric motor connected to the rotating body 42. As the rotating body 42 is rotated by the rotation mechanism 43, the carbon nanotube array 91 on the substrate 92 is pulled out in a direction from the left side to the right side in FIG. A carbon nanotube sheet 94 is formed that extends to . The width of the carbon nanotube sheet 94 in the width direction is approximately the same as the width of the carbon nanotube array 91 in the width direction. In the example shown in FIG. 4, the carbon nanotube sheet 94 has a substantially rectangular shape. The carbon nanotube sheet 94 drawn out from the carbon nanotube array 91 is wound onto the outer surface of the rotating body 42 while passing over the three pairs of electrodes 22 . As a result, the carbon nanotube sheets 94 are stacked on the outer surface of the rotating body 42 in a radial direction (hereinafter also simply referred to as "radial direction") centered on the rotation axis J1.

The carbon nanotube sheet 94 is a sheet-like carbon nanotube molded body formed of a plurality of carbon nanotubes. Specifically, the carbon nanotube sheet 94 is a sheet-like molded body (also called a web-like molded body) in which a plurality of carbon nanotube single fibers drawn out from the carbon nanotube array 91 in the drawing direction are arranged in the width direction and connected to each other. ). A carbon nanotube single yarn is a linear carbon nanotube molded body in which a plurality of carbon nanotubes are continuously connected in the longitudinal direction by van den Waals force or the like.

The adhesive applying section 44 is arranged at a position facing the outer surface of the rotating body 42 in the radial direction. The adhesive applying unit 44 applies the above-mentioned adhesive (preferably an adhesive containing a conductive additive) to the carbon nanotube sheet 94 wound on the outer surface of the rotating body 42 . The adhesive application unit 44 is, for example, a spray nozzle that sprays adhesive toward the carbon nanotube sheet 94 on the rotating body 42 . Alternatively, the adhesive applying unit 44 may be a coater that applies adhesive in contact with or in close proximity to the carbon nanotube sheet 94 on the rotating body 42 .

The pressing roller 45 is a substantially cylindrical or substantially cylindrical member centered on the rotation axis J2 that faces in the axial direction (that is, the width direction), and is rotatable about the rotation axis J2. The width of the pressing roller 45 in the width direction is larger than the width of the carbon nanotube sheet 94 in the width direction. The pressing roller 45 is located on the front side in the rotational direction of the rotating body 42 (that is, on the downstream side in the winding direction of the carbon nanotube sheet 94) with respect to the adhesive applying section 44, and faces the outer surface of the rotating body 42 in the radial direction. . The pressing roller 45 is pressed toward the rotating body 42 by a pressing mechanism (for example, an electric cylinder or an air cylinder) not shown, so that the carbon nanotube sheet 94 coated with adhesive is applied to the outer surface of the rotating body 42. Aim and press. As a result, the carbon nanotube sheet 94 is compacted onto the insulating sheet member 230 attached to the outer surface of the rotating body 42 . The radial distance between the rotating shaft J1 of the rotating body 42 and the rotating shaft J2 of the pressing roller 45 can be adjusted by the above-described pressing mechanism, and can also be adjusted while the rotating body 42 is rotating.

The control unit 46 is a normal computer system including a processor, memory, input/output unit, bus, and the like. A bus is a signal circuit that connects the processor, memory, and input/output units. The memory stores programs and various information. The processor executes various processes (for example, numerical calculations, etc.) using the memory and the like according to programs stored in the memory. The input/output unit receives input from the operator and outputs a signal to other components (for example, the rotation mechanism 43). Each function of the control unit 46 (for example, a storage unit and a calculation unit) is realized by the computer system performing processing based on a predetermined program. The control unit 46 may be, for example, a programmable logic controller (PLC), a circuit board, or the like. Note that in FIG. 4, illustration of the control unit 46 is omitted.

The storage unit of the control unit 46 stores in advance laminated resistance information indicating the relationship between the number of laminated carbon nanotube sheets 94 and the resistance of the laminated body for a laminated body in which carbon nanotube sheets 94 are laminated in the thickness direction. Stored. The laminated resistance information is obtained in advance through experiments or the like before the carbon nanotube heater 1 is manufactured. The laminate resistance information may include the resistance itself of the laminate, or may include a predetermined parameter that determines the resistance of the laminate.

In this embodiment, the laminated resistance information indicates the relationship between the number of laminated carbon nanotube sheets 94 and the resistance per unit length in the longitudinal direction of the laminated body. As shown in FIG. 5, the resistance per unit length of the laminate gradually decreases as the number of stacked carbon nanotube sheets 94 increases. In addition, when the resistance per unit length changes as the length in the longitudinal direction of the laminate changes (for example, when the resistance per unit length gradually decreases as the length in the longitudinal direction of the laminate increases) ), laminated resistance information corresponding to each length of the laminated body is stored in the storage section of the control section 46.

Next, a first example of the flow of manufacturing the carbon nanotube heater 1 will be described with reference to FIG. 6. 7 to 15 are diagrams showing the carbon nanotube heater 1 in the process of being manufactured.

When the carbon nanotube heater 1 is manufactured, first, a target resistance that is preset as the resistance of the carbon nanotube device 2 is input into the control section 46 by an operator. The target resistance is, for example, 1Ω to 100Ω, and in this embodiment is 20Ω. Subsequently, the calculation unit of the control unit 46 determines the number of laminated carbon nanotube sheets 94 corresponding to the target resistance (that is, the number of windings around the rotating body 42, hereinafter referred to as the “target number of windings”). Determined based on resistance information. Specifically, for example, laminated resistance information corresponding to a preset length of the connection sheet portion 21 is selected. Then, in the laminated resistance information, the resistance per unit length corresponding to the value obtained by dividing the target resistance by the length of the connection sheet portion 21 is calculated, and the number of laminated layers corresponding to the resistance per unit length is determined. It is calculated as a number of times. When determining the resistance per unit length, it is preferable that the contact resistance between the connection sheet portion 21 and the electrode 22 be taken into consideration.

As mentioned above, in the carbon nanotube sheet 94, there may be variations in the density of carbon nanotubes (so-called fiber density), so even if the carbon nanotube sheet 94 is wound the target number of times, the carbon nanotube The resistance of device 2 is not necessarily equal to the target resistance. Therefore, in the manufacturing method illustrated in FIG. 6, based on the target number of turns, the calculation unit sets an initial number of turns smaller than the target number of turns (step S11). The initial number of turns is a predetermined number of turns (for example, 1 to 20 turns, preferably 1 to 9 turns) less than the target number of turns.

Subsequently, as shown in FIGS. 3 and 4, an insulating sheet member 230 is attached to the outer surface of the rotating body 42, and three pairs of electrodes 22 are attached to the insulating sheet member 230. Each pair of electrodes 22 is arranged at both ends of the above-mentioned connection region 421 on the outer surface of the rotating body 42 (step S12). A conductive paste is applied to the upper main surface of each electrode 22 (that is, the upper surface opposite to the lower surface, which is the main surface facing the outer surface of the rotating body 42). The conductive paste is, for example, a low melting point solder, a metal paste, or a conductive adhesive. The conductive adhesive is, for example, an adhesive containing the above-mentioned conductive additive. Note that step S12 may be performed in parallel with step S11, or may be performed before step S11.

When step S11 and step S12 are completed, the rotation mechanism 43 is controlled by the control unit 46, and the rotating body 42 is rotated by the above-mentioned initial number of windings. As a result, the carbon nanotube sheet 94 drawn out from the carbon nanotube array 91 is wound around the outer surface of the rotating body 42 while passing over the three pairs of electrodes 22a, 22b, and 22c. In other words, the carbon nanotube sheets 94 are stacked between each of the three pairs of electrodes 22a, 22b, and 22c.

At this time, an adhesive containing the above-mentioned conductive additive is applied from the adhesive applying section 44 to the carbon nanotube sheet 94 wound around the rotating body 42 . The adhesive is, for example, a PVA aqueous solution containing 0.1% to 10% by weight (preferably 1% to 5% by weight) of PVA. By applying the adhesive to the carbon nanotube sheet 94, the carbon nanotubes constituting the carbon nanotube sheet 94 aggregate. That is, the adhesive is also an aggregating agent that aggregates carbon nanotubes. Further, the carbon nanotube sheet 94 wound around the rotating body 42 is pressed toward the outer surface of the rotating body 42 by the pressing roller 45 and compacted onto the insulating sheet member 230 on the outer surface.

In the device manufacturing apparatus 4, as shown in FIG. 7, a cylindrical intermediate body 51 is formed in which carbon nanotube sheets 94 are laminated in the radial direction around the rotating body 42 by a number of layers equal to the initial number of turns (step S13). ). In FIG. 7, only two electrodes 22a of the first electrode pair among the three pairs of electrodes 22 are shown. Hereinafter, a method for manufacturing the pair of electrodes 22a and the carbon nanotube device 2 including the pair of electrodes 22a will be described. Note that the same applies to the manufacture of the carbon nanotube device 2 each including a pair of electrodes 22b and a pair of electrodes 22c. For convenience of illustration, the number of stacked carbon nanotube sheets 94 shown in FIG. 7 is smaller than the actual number of stacked layers.

FIG. 8 shows that the electrode 22a is provided at the lower left end of the upper electrode 22a in FIG. FIG. 4 is a view seen from the tangential direction of the outer surface of the rotating body 42 in a position where the rotating body 42 is in a position shown in FIG. The electrode 22a includes a plurality of convex portions 222 erected upward from the upper main surface 221 of the electrode 22a at one end in the longitudinal direction shown in FIG. The carbon nanotube sheet 94 wound on the outer surface of the rotating body 42 contacts the electrode 22a along the upper ends of the plurality of convex portions 222 at the one end of the electrode 22a. Moreover, the carbon nanotube sheet 94 contacts the upper main surface 221 of the electrode 22a at a portion other than the one end of the electrode 22a. The same applies to the lower electrode 22a in FIG.

When the initial number of turns of the carbon nanotube sheet 94 is completed, the rotation mechanism 43 is stopped. Then, as shown in FIG. 9, the cylindrical intermediate body 51 is cut outside the connection region 421 in the circumferential direction. Specifically, the cylindrical intermediate body 51 is cut at the outside of the pair of electrodes 22a (that is, at two cutting positions on the opposite side of the connection region 421 with each electrode 22a in between). In this embodiment, the specific cutting positions are between circumferentially adjacent electrodes 22a and 22b, between electrodes 22a and 22c, and between electrodes 22b and 22c. be. The cylindrical intermediate body 51 is cut by, for example, a cutting blade 47 such as a cutter. Note that the cutting of the cylindrical intermediate body 51 may be performed on the pair of electrodes 22a.

Subsequently, as shown in FIG. 10, the resistance between the pair of electrodes 22a is measured (step S14). Both longitudinal ends of a laminated sheet-like carbon nanotube structure 52, which is a portion of the cylindrical intermediate body 51 extending in the circumferential direction in the connection region 421, are in contact with the pair of electrodes 22a. The ends of the carbon nanotube structures 52 are temporarily fixed to the electrodes 22a using the above-described conductive paste and an adhesive applied from the adhesive applying section 44. Thereby, the pair of electrodes 22a are electrically connected by the carbon nanotube structure 52. The resistance is measured, for example, by an operator using a resistance measuring device 48 such as a tester. Alternatively, the resistance measuring device 48 may be provided in the device manufacturing apparatus 4, and the resistance measurement in step S14 may be automatically performed after the end of step S13.

The resistance measured in step S14 (hereinafter referred to as "initial measured resistance") is sent to the control unit 46 (see FIG. 3). The initial measured resistance is greater than or equal to the target resistance described above. When the initial measured resistance is approximately equal to the target resistance, winding of the carbon nanotube sheet 94 is completed.

If the initial measured resistance is larger than the target resistance, the calculation unit of the control unit 46 determines the necessary resistance for the resistance of the carbon nanotube device 2 to be approximately equal to the target resistance, based on the initial measured resistance and the above-mentioned laminated resistance information. The number of additional turns of the carbon nanotube sheet 94 (hereinafter referred to as the "additional number of turns") is determined (step S15). Specifically, the resistance per unit length corresponding to the value obtained by dividing the initial measured resistance by the length of the connection sheet portion 21 is calculated, and the number of laminated layers (initial number of turns) corresponding to the resistance per unit length is calculated. ) and the target number of turns is determined as the additional number of turns.

When the number of additional windings is determined, the rotation mechanism 43 is driven by the control unit 46, and the rotating body 42 is rotated by the number of additional windings. As a result, similarly to step S13, the carbon nanotube sheet 94 drawn out from the carbon nanotube array 91 is wound around the outer surface of the rotating body 42 while passing over the three pairs of electrodes 22a, 22b, and 22c. In the device manufacturing apparatus 4, a carbon nanotube sheet 94 is stacked on the carbon nanotube structure 52 between each of the three pairs of electrodes 22a, 22b, and 22c, as shown in FIG. 11 (step S16).

Also in step S16, the adhesive containing the above-mentioned conductive additive is applied from the adhesive applying unit 44 to the carbon nanotube sheet 94 wound around the rotating body 42. Further, the carbon nanotube sheet 94 wound around the rotating body 42 is pressed toward the outer surface of the rotating body 42 by the pressing roller 45 and compacted onto the carbon nanotube structure 52 .

When the additional number of windings of the carbon nanotube sheet 94 is completed, the rotation mechanism 43 is stopped. Then, as shown in FIG. 12, the carbon nanotube sheet 94 on the carbon nanotube structure 52 is formed at two cuts on the outside of the pair of electrodes 22a in the circumferential direction (that is, on the opposite side to the connection area 421 with each electrode 22a in between). position). A specific cutting position is, for example, a position overlapping in the radial direction with the end of each electrode 22a opposite to the end where the plurality of convex portions 222 (see FIG. 8) are provided. As a result, the connection sheet portion 21 in the form of a laminated sheet extending in the circumferential direction is formed in the connection region 421 (step S17). In step S17, when cutting the carbon nanotube sheet 94, the insulating sheet member 230 is also cut. As a result, a support sheet portion 23 extending in the circumferential direction is formed in the connection region 421. The cutting of the carbon nanotube sheet 94 and the insulating sheet member 230 is performed by, for example, the cutting blade 47, such as a cutter similar to step S14.

When step S17 is completed, the pair of electrodes 22a, the connection sheet part 21, and the support sheet part 23 are removed from the rotating body 42, and both ends of the connection sheet part 21 in the longitudinal direction are fixed to the pair of electrodes 22a. , the carbon nanotube device 2 is formed (step S18). Specifically, as shown in FIG. 13, the pair of electrodes 22a, the connection sheet part 21, and the support sheet are temporarily fixed on the upper main surface 221 of the electrode 22a. The section 23 is removed from the rotating body 42. FIG. 13 is an enlarged side view showing a portion near one electrode 22a (the same applies to FIG. 14). In the state shown in FIG. 13, each electrode 22a is heated. This facilitates deformation of the electrode 22a. The electrode 22a is heated, for example, by irradiating the electrode 22a with a laser.

Thereafter, each electrode 22a is folded in half along a folding line 223 substantially perpendicular to the longitudinal direction, as shown in FIG. As a result, the longitudinal ends of the connection sheet portion 21 are held between the electrodes 22a from both the upper and lower sides in the figure. The plurality of convex portions 222 provided at one longitudinal end of the electrode 22a penetrate the longitudinal end of the connection sheet portion 21 in the thickness direction, and extend through the other longitudinal end of the electrode 22a. come into contact with. Then, the plurality of convex parts 222 are pressed by the other end and bent to approach the one end of the electrode 22a, thereby connecting the end of the connection sheet part 21 to the one end of the electrode 22a. fixed between.

In the electrode 22a, the conductive paste applied in step S12 is cured, thereby strengthening the fixation between the connection sheet portion 21 and the electrode 22a. In addition, if low melting point solder is applied to the electrode 22a in step S12, when the electrode 22a is folded in half in step S18, the electrode 22a is heated and then cooled, so that the low melting point solder is applied to the electrode 22a. is cured, and the fixation between the connection sheet portion 21 and the electrode 22a is strengthened. Note that in step S18, the fixation between the connection sheet portion 21 and the electrode 22a may be further strengthened by mechanically fixing the portions on both sides of the folding line 223 of the folded electrode 22a with a stapler or the like. good. Alternatively, the electrode 22a that has been folded in half may be further folded (for example, folded into a spiral shape) to further strengthen the fixation between the connection sheet portion 21 and the electrode 22a.

Once the carbon nanotube device 2 is formed, as shown in FIG. 15, the carbon nanotube device 2 is placed on the lower member 32 of the accommodating part 31, which is made by applying a film of silicone resin on a release paper 35 and hardening it. placed. Then, the upper member 33 of the accommodating portion 31 is formed by applying a film of silicone resin onto the lower member 32 and the carbon nanotube device 2 and curing it. Thereby, as shown in FIG. 3, the carbon nanotube device 2 is housed inside the housing section 31, and the carbon nanotube heater 1 is formed (step S19).

It was confirmed that by supplying a voltage of 40 V to the carbon nanotube heater 1 manufactured by this manufacturing method, the temperature was raised from room temperature (approximately 20° C.) to approximately 25° C. to 100° C. in 5 minutes. The temperature was obtained by sandwiching the carbon nanotube heater 1 between aluminum panels having a thickness of 3 mm and measuring the temperature of the surface of the aluminum panel with a thermometer. Note that the supply voltage, heating rate, reached temperature, etc. can be changed in various ways by changing the watt density (W/cm ² ) of the carbon nanotube device 2.

In manufacturing the carbon nanotube heater 1 described above, a carbon nanotube sheet 94 is pulled out from a carbon nanotube array 91, which is a collection of carbon nanotubes erected in a predetermined orientation direction, and wound around the outer surface of the rotating body 42. However, it is not limited to this. For example, the carbon nanotube sheet 94 may be formed in advance by a carbon nanotube sheet manufacturing apparatus different from the device manufacturing apparatus 4, and may be wound in advance around a supply roll provided in the device manufacturing apparatus 4. In this case, as the rotating body 42 of the device manufacturing apparatus 4 rotates, the supply roll also rotates, and the carbon nanotube sheet 94 is fed out from the supply roll. The carbon nanotube sheet 94 in the carbon nanotube sheet manufacturing apparatus described above may be manufactured by various methods. For example, the carbon nanotube sheet 94 may be formed by being pulled out from the carbon nanotube array as described above, or may be formed by tilting the carbon nanotube array in a predetermined direction using a pressing tool or the like. Alternatively, the carbon nanotube sheet 94 may be formed by dispersing carbon nanotubes in a network of sheet-like fibers using a wet papermaking method, an impregnation method, or the like. The carbon nanotube sheet 94 may also be formed by weaving carbon nanotube wires. The same applies to other manufacturing methods of the carbon nanotube heater 1 that will be described later.

As described above, the carbon nanotube device 2 includes a pair of electrodes 22 and a connection sheet portion 21 that is a sheet-shaped carbon nanotube molded body that connects the pair of electrodes 22. The first manufacturing method of the carbon nanotube device 2 includes a step of arranging a pair of electrodes 22 (step S12), a step of forming a cylindrical intermediate body 51 (step S13), and measuring the resistance between the pair of electrodes 22. (step S14), a step of stacking the carbon nanotube sheets 94 (step S16), a step of forming the connection sheet portion 21 (step S17), and fixing both ends of the connection sheet portion 21 to a pair of electrodes 22. (step S18).

In step S12, a pair of electrodes 22 are arranged at both ends of a connection region 421 extending in the circumferential direction on the outer surface of the rotating body 42 that is rotatable about the rotation axis J1 pointing in the axial direction. In step S13, by rotating the rotating body 42 by the initial number of turns, the carbon nanotube sheet 94 is wound onto the outer surface of the rotating body 42 while passing over the pair of electrodes 22. As a result, a cylindrical intermediate body 51 in which carbon nanotube sheets 94 are laminated in the radial direction around the rotating body 42 is formed.

In step S14, the cylindrical intermediate body 51 is cut outside the connection region 421 in the circumferential direction. Then, the resistance between the pair of electrodes 22 electrically connected by the laminated sheet-like carbon nanotube structure 52 is measured. The carbon nanotube structure 52 is a portion of the cylindrical intermediate body 51 that extends in the circumferential direction in the connection region 421 . In step S16, if the initial measured resistance, which is the resistance measured in step S14, is larger than the predetermined target resistance, the rotating body 42 is rotated to cause the carbon nanotube sheet 94 to pass over the pair of electrodes 22. It is wound on the outer surface of the rotating body 42. As a result, the carbon nanotube sheet 94 is stacked on the carbon nanotube structure 52. In step S17, the carbon nanotube sheet 94 is cut outside the connection region 421 in the circumferential direction, thereby forming the connection sheet portion 21 in the form of a laminated sheet extending in the circumferential direction in the connection region 421.

By manufacturing the carbon nanotube device 2 using this manufacturing method, the influence of variations in the density of carbon nanotubes in the carbon nanotube sheet 94 can be suppressed, and carbon having a desired resistance (that is, resistance approximately equal to the target resistance) can be produced. A nanotube device 2 can be provided. Moreover, the carbon nanotube device 2 can be easily manufactured by the above manufacturing method.

As described above, it is preferable that the first manufacturing method of the carbon nanotube device 2 further includes a step of setting the initial number of windings (step S11) before step S13. In step S11, the target number of windings corresponding to the target resistance is determined based on the laminated resistance information indicating the relationship between the number of laminated carbon nanotube sheets 94 and the resistance. The initial number of turns is set to be smaller than the target number of turns. Thereby, when forming the cylindrical intermediate body 51 in step S13, it is possible to prevent or suppress excessive stacking of the carbon nanotube sheets 94. As a result, the resistance of the carbon nanotube device 2 can be brought close to the target resistance with high accuracy. The same applies to the fourth manufacturing method of the carbon nanotube device 2, which will be described later.

Preferably, the number of windings of the carbon nanotube sheet 94 (i.e., the number of additional windings) in step S16 is determined based on the initial measured resistance and laminated resistance information indicating the relationship between the number of laminated carbon nanotube sheets 94 and the resistance. (Step S15). Thereby, the number of stacked carbon nanotube sheets 94 to be stacked in step S16 can be determined with high accuracy. As a result, the resistance of the carbon nanotube device 2 can be brought close to the target resistance with high accuracy. The same applies to the fourth manufacturing method of the carbon nanotube device 2.

As described above, in the first manufacturing method of the carbon nanotube device 2, it is preferable that an adhesive is applied to the carbon nanotube sheet 94 wound around the rotating body 42. Thereby, the strength of the connection sheet portion 21 can be increased. As a result, damage to the connection sheet portion 21 (for example, cracking of the connection sheet portion 21 in the width direction, or falling off of carbon nanotubes from the connection sheet portion 21, etc.) can be suppressed. More preferably, the adhesive includes a conductive additive. Thereby, the electrical conductivity of the connection sheet portion 21 can be increased. As a result, the resistance of the carbon nanotube device 2 can be brought closer to the target resistance while reducing the number of stacked carbon nanotube sheets 94 in the connection sheet portion 21. Therefore, the weight of the carbon nanotube heater 1 can be reduced.

As described above, the carbon nanotube heater 1 preferably includes the carbon nanotube device 2, the housing section 31, and the heat radiation section 34. The carbon nanotube device 2 is a heating element that generates heat when electric power is supplied. The accommodating portion 31 accommodates the connection sheet portion 21 of the carbon nanotube device 2 therein. Thereby, damage to the connection sheet portion 21 can be further suppressed. Further, since the housing section 31 has flexibility, the degree of freedom in selecting the installation location of the carbon nanotube heater 1 can be improved. The heat radiation part 34 is provided on the outer surface of the housing part 31, equalizes the heat from the carbon nanotube device 2, and radiates the heat from the heat radiation surface. Thereby, it is possible to improve the uniformity of heating in each part to be heated by the carbon nanotube heater 1.

Preferably, the housing section 31 is a sheet-like member that extends along the main surface of the connection sheet section 21, and the heat dissipation section 34 extends parallel to the main surface of the connection sheet section 21 on the storage section 31, and It overlaps with the entire connecting sheet portion 21 in the direction perpendicular to the main surface of the portion 21 . Thereby, temperature non-uniformity in the connection sheet portion 21 can be suitably suppressed. Specifically, since heat is less likely to escape from the center of the connection sheet section 21 than from the periphery of the connection sheet section 21, the temperature at the center of the carbon nanotube heater 1 tends to be higher than the temperature at the periphery. However, the heat dissipation section 34 makes it easier for heat to be transferred from the center of the connection sheet section 21 to the periphery, thereby improving the uniformity of temperature distribution throughout the carbon nanotube heater 1 and the connection sheet section 21. can do.

As described above, the connection sheet portion 21 has a rectangular shape that extends between the pair of electrodes 22, and the diagonal length of the connection sheet portion 21 is preferably 200 mm or more. When the length of the diagonal line of the connection sheet portion 21 is 200 mm or more, the temperature difference between the center portion and the peripheral portion of the connection sheet portion 21 becomes relatively large. Specifically, the temperature difference is, for example, 10° C. or more. Therefore, as described above, the structure of the carbon nanotube heater 1 that can improve the uniformity of the temperature distribution of the connection sheet portion 21 is particularly suitable for a carbon nanotube heater with a relatively large temperature difference.

Note that when the length, width, and diagonal length of the connection sheet portion 21 are 200 mm, 60 mm, and 209 mm, and the temperature at the center of the connection sheet portion 21 is raised to approximately 92°C, the center of the connection sheet portion 21 The temperature difference between the area and the periphery was about 14°C. Furthermore, when the length, width, and diagonal length of the connection sheet portion 21 are 94 mm, 180 mm, and 203 mm, and the temperature at the center of the connection sheet portion 21 is raised to approximately 92° C., the center of the connection sheet portion 21 The temperature difference between the area and the periphery was about 23°C. On the other hand, when the length, width, and diagonal length of the connection sheet part 21 are 62 mm, 145 mm, and 158 mm, and the temperature at the center of the connection sheet part 21 is raised to about 92°C, the center of the connection sheet part 21 The temperature difference between the area and the periphery was about 9°C.

As described above, it is preferable that the carbon nanotube heater 1 further includes a temperature sensor 36 that measures the temperature of the heat radiation section 34. As described above, since the temperature uniformity of the carbon nanotube heater 1 is improved by the heat dissipation section 34, it is possible to suppress the occurrence of a difference in measured temperature depending on the mounting position of the temperature sensor 36. As a result, the degree of freedom in the mounting position of the temperature sensor 36 is improved, and the temperature of the carbon nanotube heater 1 can be measured with high accuracy. Furthermore, even if an abnormality such as overheating occurs at a location away from the temperature sensor 36, the abnormality can be detected with high accuracy.

As described above, the first manufacturing method of the carbon nanotube device 2 includes the step of forming the connection sheet portion 21 (step S17) and the step of fixing both ends of the connection sheet portion 21 to the pair of electrodes 22 (step S18). ) and. In step S17, the carbon nanotube sheets 94 are laminated between the pair of electrodes 22, thereby forming a connection sheet portion 21 in the form of a laminated sheet extending in the longitudinal direction between the pair of electrodes 22. Each electrode 22 of the pair of electrodes 22 is plate-shaped. In step S18, each electrode 22 is folded with the end of the connection sheet portion 21 in between. By manufacturing the carbon nanotube device 2 using this manufacturing method, the contact resistance between the connection sheet portion 21 and the electrode 22 can be reduced.

As described above, in the first manufacturing method, in the state before step S18, each electrode 22 has a plurality of protrusions erected from the main surface 221 of each electrode 22 at one end in the longitudinal direction. 222 is preferable. Then, in step S18, each electrode 22 is folded in half along the folding line 223 perpendicular to the longitudinal direction to sandwich the end of the connection sheet part 21, and the plurality of convex parts 222 are arranged at the ends of the connection sheet part 21. It is preferable to penetrate through the section and contact the other end of each electrode 22 in the longitudinal direction. Thereby, the contact resistance between the connection sheet portion 21 and the electrode 22 can be further reduced.

As described above, in the first manufacturing method, it is preferable that a conductive paste is applied on the main surface 221 of each electrode 22 before step S18. Thereby, the contact resistance between the connection sheet portion 21 and the electrode 22 can be further reduced.

As described above, in the first manufacturing method, each electrode 22 is preferably heated in step S18. This makes it easier for the electrode 22 to deform along the connection sheet portion 21, so that more suitable contact between the electrode 22 and the connection sheet portion 21 can be achieved. As a result, the contact resistance between the connection sheet portion 21 and the electrode 22 can be further reduced.

In manufacturing the carbon nanotube device 2, the fixing of the connection sheet portion 21 to the electrode 22 (step S18) does not necessarily have to be done by folding the electrode 22 as described above. The connection sheet portion 21 may be fixed to the electrode 22 by covering the end of the sheet portion 21 with metal foil and joining the metal foil to the electrode 22. Further, the connection sheet portion 21 may be fixed to the electrode 22 by other fixing methods other than those described above.

Hereinafter, as an example of the other fixing method, fixing of the connection sheet portion 21 to the electrode 22 using a conductive connection tool will be described with reference to FIGS. 16 to 21. FIG. 16 is a diagram showing the flow of fixing the connection sheet portion 21 to the electrode 22. 17 to 21 are diagrams showing the vicinity of the end of the connection sheet portion 21. FIG.

The connection aid has a material and shape that has better bonding characteristics to the electrode 22 than the connection sheet portion 21. Good bonding characteristics mean, for example, that the bonding strength is high when welded to the electrode 22 using low melting point solder or the like, and the contact resistance with the electrode 22 is low. The connection aid is made of metal such as copper, for example.

In the fixing method using a connecting tool, first, as shown in FIG. 17, a slit 211 parallel to the longitudinal direction is formed at the end of the connecting sheet portion 21 corresponding to each electrode 22 by laser irradiation or the like. . Thereby, the end of the connection sheet portion 21 is divided into a plurality of end elements 212 arranged in the width direction. The width of the end element 212 is, for example, between 10 mm and 50 mm. Subsequently, by bundling each of the plurality of end elements 212, a plurality of linear end portions 213 are formed as shown in FIG. 18 (Step S181). The linear end portion 213 is formed, for example, by twisting and converging the end element 212 with fingers. Note that when forming the plurality of linear end portions 213, it is not always necessary to form slits by laser irradiation or the like. For example, the linear end portion 213 may be formed by pinching and twisting a portion of the end portion in the width direction with fingers at the end portion of the connection sheet portion 21 where no slit is formed.

Next, the plurality of linear ends 213 are each held by a plurality of connection tools (step S182). In the example shown in FIG. 19, the connection aid 24a is a plate-like member. In step S182, the connection aid 24a is folded in half in the direction of the arrow along folding lines substantially parallel to the longitudinal direction, and the linear end 213 is folded in half from the side (i.e., from one side in the width direction). Pinch and secure.

In the example shown in FIG. 20, the connection aid 24b is a plate-like member having a through hole 241 in the center. In step S182, the linear end portion 213 is inserted into the through hole 241 of the connection aid 24 and then bent at a predetermined angle (for example, approximately 90°) with respect to the longitudinal direction. This prevents the linear end portion 213 from coming out of the through hole 241. The connecting tool 24b is folded in half in the direction of the arrow along a folding line that is substantially parallel to the width direction and passes above the through hole 241, and is fixed by sandwiching the linear end portion 213 protruding from the through hole 241. .

In the example shown in FIG. 21, the connection aid 24c is a cylindrical member (for example, a cylindrical member). In step S182, the linear end portion 213 is inserted into the radially inner side of the connecting tool 24c. By being compressed in the radial direction, the connecting tool 24c is fixed by sandwiching the linear end portion 213 located inside. The connection aid 24c may be a square tubular member. In the following description, the connection aids 24a to 24c will be collectively referred to as the connection aid 24 when there is no need to distinguish them.

When step S182 is completed, the plurality of connection tools 24 are joined to the electrodes 22 (step S183). The connection tool 24 is joined to the electrode 22 using, for example, low melting point solder. The joining may be performed by other methods. Further, if the width of the connecting sheet portion 21 is relatively small, the end portion of the connecting sheet portion 21 is not divided in step S181, and the entire end portion of the connecting sheet portion 21 is bundled into one line. A shaped end 213 may be formed.

As explained above, in the examples shown in FIGS. 16 to 21, the step (step S18) of fixing both ends of the connection sheet portion 21 to the pair of electrodes 22 corresponds to each electrode 22 of the pair of electrodes 22. A step of bundling the ends of the connection sheet portion 21 to form a linear end portion 213 (step S181), and forming a conductive connection aid 24 that has better bonding characteristics with the pair of electrodes 22 than the connection sheet portion 21. The method includes a step of holding the linear end portion 213 between the two electrodes (step S182), and a step of joining the connecting tool 24 to each electrode 22 (step S183). Thereby, the contact resistance between the connection sheet portion 21 and the electrode 22 can be reduced.

In the preferred example shown in FIG. 19, the connection aid 24a is a plate-like member. In step S182, the connecting aid 24a is folded while sandwiching the linear end portion 213 from the sides, thereby fixing the linear end portion 213. Thereby, the end portion of the connection sheet portion 21 can be easily and firmly fixed to the connection aid 24a.

In the preferred example shown in FIG. 20, the connection aid 24b is a plate-like member having a through hole 241. As shown in FIG. In step S182, the linear end portion 213 is inserted into the through hole 241 of the connection tool 24b. Furthermore, the connecting aid 24b is folded across the linear end 213 protruding from the through hole 241, thereby fixing the linear end 213. Thereby, the end portion of the connection sheet portion 21 can be easily and firmly fixed to the connection aid 24b.

In the preferred example shown in FIG. 21, the connection aid 24c is a cylindrical member. In step S182, the linear end portion 213 is inserted inside the connecting tool 24c, and the connecting tool 24c is compressed in the radial direction, thereby fixing the linear end portion 213. Thereby, the end portion of the connection sheet portion 21 can be easily and firmly fixed to the connection aid 24c.

As described above, in a preferred example of steps S181 to S183, in step S181, the end of the connection sheet portion 21 is divided into a plurality of end elements 212 lined up in the width direction, and each of the plurality of end elements 212 is bundled. As a result, a plurality of linear end portions 213 are formed. Subsequently, in step S182, the plurality of linear ends 213 are each held by the plurality of connection tools 24. Then, in step S183, a plurality of connection tools 24 are joined to each electrode 22. Thereby, even if the width of the connection sheet part 21 is wide, the connection sheet part 21 and the electrode 22 can be suitably joined.

Next, a second example of the flow of manufacturing the carbon nanotube heater 1 will be described with reference to FIG. 22. In the manufacturing method illustrated in FIG. 22, the arrangement of the pair of electrodes 22 in step S32 is different from the arrangement of the pair of electrodes 22 in step S12 of FIG. Furthermore, unlike steps S14 and S17 in FIG. 6, the carbon nanotube sheet 94 is not cut during the resistance measurement in step S34 and the formation of the connection sheet portion 21 in step S39. Steps S31 to S40 in FIG. 22 will be specifically explained below. Note that steps S31, S33, S35 to S36, and S40 in FIG. 22 are substantially the same as steps S11, S13, S15 to S16, and S19 in FIG. 6, so the explanation will be simplified. Further, the structures of the housing section 31 and the heat radiation section 34 of the carbon nanotube heater 1 are substantially the same as those in the first example.

In the method for manufacturing the carbon nanotube heater 1 according to the second example, first, similarly to step S11, in the calculation unit of the control unit 46, the target number of windings corresponding to the target resistance of the carbon nanotube heater 1 is determined based on the laminated resistance information. Based on the target number of turns, an initial number of turns smaller than the target number of turns is set (step S31).

Subsequently, an insulating sheet member 230 is attached to the outer surface of the rotating body 42, and a pair of electrodes 22 is attached onto the insulating sheet member 230. As shown in FIG. 23, the pair of electrodes 22 are arranged at positions 180° apart in the circumferential direction (step S32). The conductive paste is applied to the upper main surface of each electrode 22 (that is, the upper surface opposite to the lower surface, which is the main surface facing the outer surface of the rotating body 42), as in step S12. . Note that step S32 may be performed in parallel with step S31 or may be performed before step S31.

When step S31 and step S32 are completed, similarly to step S13, the rotating body 42 is rotated by the above-mentioned initial winding number, and the carbon nanotube sheet 94 pulled out from the carbon nanotube array 91 passes over the pair of electrodes 22. and is wound on the outer surface of the rotating body 42. As a result, a cylindrical intermediate body 51 is formed in which carbon nanotube sheets 94 are laminated in the radial direction around the rotating body 42 by a number of layers equal to the initial number of turns (step S33).

In step S33, in the same manner as described above, an adhesive containing the above-mentioned conductive additive is applied from the adhesive applying section 44 to the carbon nanotube sheet 94 wound around the rotating body 42. Further, the carbon nanotube sheet 94 wound around the rotating body 42 is pressed toward the outer surface of the rotating body 42 by the pressing roller 45 and compacted onto the insulating sheet member 230 on the outer surface.

When step S33 ends, the resistance between the pair of electrodes 22 is measured (step S34). As described above, the cylindrical intermediate body 51 is not cut in step S34. The initial measured resistance measured in step S34 is greater than or equal to the above-mentioned target resistance. When the initial measured resistance is approximately equal to the target resistance, winding of the carbon nanotube sheet 94 is completed.

If the initial measured resistance is larger than the target resistance, the calculation unit of the control unit 46 determines the additional number of turns of the carbon nanotube sheet 94 based on the initial measured resistance and the above-mentioned laminated resistance information, as in step S15. (Step S35).

When the number of additional windings is determined, the rotating body 42 is rotated by the number of additional windings as in step S16, and the carbon nanotube sheet 94 pulled out from the carbon nanotube array 91 rotates while passing over the pair of electrodes 22. It is wrapped around the outer surface of body 42. Thereby, the carbon nanotube sheet 94 is laminated on the cylindrical intermediate body 51, and a carbon nanotube sheet layer is formed (step S36). Also in step S36, the adhesive containing the above-mentioned conductive additive is applied from the adhesive applying unit 44 to the carbon nanotube sheet 94 wound around the rotating body 42. Further, the carbon nanotube sheet 94 wound around the rotating body 42 is pressed by the pressing roller 45 toward the outer surface of the rotating body 42 and compacted onto the cylindrical intermediate body 51 .

When step S36 is completed, as shown in FIG. 24, the pair of electrodes 22 and the cylindrical carbon nanotube sheet layer 53 laminated on the pair of electrodes 22 are removed from the rotating body 42 together with the insulating sheet member 230. (Step S37).

When step S37 ends, the carbon nanotube sheet layer 53 is fixed to the pair of electrodes 22 (step S38). Specifically, the electrode 22 is heated while the carbon nanotube sheet layer 53 is temporarily fixed on the electrode 22, and as shown in FIG. Ru. As a result, a part of the carbon nanotube sheet layer 53 (that is, a part that is temporarily fixed on the electrode 22 and is scheduled to become the longitudinal end of the connection sheet part 21) is removed by the electrode 22 as shown in the figure. is held from both the top and bottom sides. The plurality of convex portions 222 provided at one longitudinal end of the electrode 22 penetrate the carbon nanotube sheet layer 53 in the thickness direction and contact the other longitudinal end of the electrode 22 . Then, the plurality of convex parts 222 are pressed by the other end and bent to approach the one end of the electrode 22, thereby placing the carbon nanotube sheet layer 53 between the one end of the electrode 22 and the other end. Fixed to.

In the electrode 22, the conductive paste applied in step S32 is cured, thereby strengthening the fixation between the carbon nanotube sheet layer 53 and the electrode 22. Further, in step S32, if low melting point solder is applied to the electrode 22, when the electrode 22 is folded in half in step S38, the electrode 22 is heated and then cooled, so that the low melting point solder is applied to the electrode 22. is cured, and the fixation between the carbon nanotube sheet layer 53 and the electrode 22 is strengthened. In addition, in step S38, by mechanically fixing the portions on both sides of the folding line 223 of the electrode 22 folded in half using a stapler or the like, the fixation between the carbon nanotube sheet layer 53 and the electrode 22 is further strengthened. Good too. Alternatively, the fixation between the carbon nanotube sheet layer 53 and the electrode 22 may be further strengthened by further folding the electrode 22 that has been folded in half (for example, folding it into a spiral shape).

When step S38 is completed, the cylindrical carbon nanotube sheet layer 53 between the pair of electrodes 22 is pressed together with the insulating sheet member 230 in the thickness direction to form a planar shape. In other words, the carbon nanotube sheet layer 53 between the pair of electrodes 22 is crushed in the thickness direction. As a result, as shown in FIG. 26, the connection sheet portion 21 and support sheet portion 23 that connect the pair of electrodes 22 are formed, and the formation of the carbon nanotube device 2 is completed (step S39). In the example shown in FIG. 26, the connection sheet portions 21 are provided both above and below the support sheet portion 23 with the support sheet portion 23 interposed therebetween.

Once the carbon nanotube device 2 is formed, the carbon nanotube device 2 is housed inside the housing section 31 similarly to step S19. As a result, the carbon nanotube heater 1 (see FIG. 1) is formed (step S40).

As explained above, the second manufacturing method of the carbon nanotube device 2 includes the step of arranging the pair of electrodes 22 (step S32), the step of forming the cylindrical intermediate body 51 (step S33), and the step of arranging the pair of electrodes 22 (step S32). A step of measuring the resistance between the electrodes 22 (step S34), a step of laminating the carbon nanotube sheets 94 (step S36), and fixing the carbon nanotube sheet layer 53 laminated on the pair of electrodes 22 to the pair of electrodes 22. (step S38).

In step S32, a pair of electrodes 22 are arranged at positions separated in the circumferential direction on the outer surface of the rotating body 42 that is rotatable about the rotation axis J1 facing in the axial direction. In step S33, by rotating the rotating body 42 by the initial number of turns, the carbon nanotube sheet 94 is wound onto the outer surface of the rotating body 42 while passing over the pair of electrodes 22. As a result, a cylindrical intermediate body 51 in which carbon nanotube sheets 94 are laminated in the radial direction around the rotating body 42 is formed.

In step S36, if the initial measured resistance, which is the resistance measured in step S34, is larger than the predetermined target resistance, the carbon nanotube sheet 94 is passed over the pair of electrodes 22 by rotating the rotating body 42. It is wound on the outer surface of the rotating body 42. Thereby, the carbon nanotube sheet 94 is laminated on the cylindrical intermediate body 51.

By manufacturing the carbon nanotube device 2 using this manufacturing method, the influence of variations in the density of carbon nanotubes in the carbon nanotube sheet 94 can be suppressed, and carbon having a desired resistance (that is, resistance approximately equal to the target resistance) can be produced. A nanotube device 2 can be provided. Moreover, the carbon nanotube device 2 can be easily manufactured by the above manufacturing method.

Preferably, in step S32, the pair of electrodes 22 are arranged 180 degrees apart in the circumferential direction. Furthermore, in the step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22, the pair of electrodes 22 and the cylindrical carbon nanotube sheet layer 53 are removed from the rotating body 42, and the carbon nanotube sheet layer 53 is fixed to the pair of electrodes 22. Then, the carbon nanotube sheet layer 53 between the pair of electrodes 22 is pressed in the thickness direction to make it planar, thereby forming the connection sheet portion 21 that connects the pair of electrodes 22 (steps S37 to S39). Equipped with. Thereby, the carbon nanotube device 2 can be easily formed. Further, the number of stacked carbon nanotube sheets in the connection sheet portion 21 can be easily increased.

As described above, the second manufacturing method of the carbon nanotube device 2 preferably further includes a step of setting the initial number of windings (step S31) before step S33, similarly to the first manufacturing method. In step S31, the target number of windings corresponding to the target resistance is determined based on the laminated resistance information indicating the relationship between the number of laminated carbon nanotube sheets 94 and the resistance. The initial number of turns is set to be smaller than the target number of turns. Thereby, when forming the cylindrical intermediate body 51 in step S33, it is possible to prevent or suppress excessive stacking of the carbon nanotube sheets 94. As a result, the resistance of the carbon nanotube device 2 can be brought close to the target resistance with high accuracy. The same applies to the fifth manufacturing method of the carbon nanotube device 2, which will be described later.

Preferably, the number of turns of the carbon nanotube sheet 94 in step S36 is determined based on the initial measured resistance and laminated resistance information indicating the relationship between the number of laminated carbon nanotube sheets 94 and the resistance, as in the first manufacturing method. (Step S35). This makes it possible to accurately determine the number of carbon nanotube sheets 94 to be stacked in step S36. As a result, the resistance of the carbon nanotube device 2 can be brought close to the target resistance with high accuracy. The same applies to the fifth manufacturing method of the carbon nanotube device 2.

As described above, in the second manufacturing method of the carbon nanotube device 2, it is preferable that an adhesive is applied to the carbon nanotube sheet 94 wound around the rotating body 42, similarly to the first manufacturing method. . Thereby, the strength of the connection sheet portion 21 can be increased. As a result, damage to the connection sheet portion 21 (for example, cracking of the connection sheet portion 21 in the width direction, or falling off of carbon nanotubes from the connection sheet portion 21, etc.) can be suppressed. More preferably, the adhesive includes a conductive additive. Thereby, the electrical conductivity of the connection sheet portion 21 can be increased. As a result, the resistance of the carbon nanotube device 2 can be brought closer to the target resistance while reducing the number of stacked carbon nanotube sheets 94 in the connection sheet portion 21. Therefore, the weight of the carbon nanotube heater 1 can be reduced. The same applies to the third to sixth manufacturing methods of the carbon nanotube device 2.

As mentioned above, it is preferable that the carbon nanotube heater 1 includes the above-described carbon nanotube device 2, the housing section 31, and the heat radiation section 34. The carbon nanotube device 2 is a heating element that generates heat when electric power is supplied. The accommodating portion 31 accommodates the connection sheet portion 21 of the carbon nanotube device 2 therein. Thereby, damage to the connection sheet portion 21 can be further suppressed. Further, since the housing section 31 has flexibility, the degree of freedom in selecting the installation location of the carbon nanotube heater 1 can be improved. The heat radiation part 34 is provided on the outer surface of the housing part 31, equalizes the heat from the carbon nanotube device 2, and radiates the heat from the heat radiation surface. Thereby, it is possible to improve the uniformity of heating in each part to be heated by the carbon nanotube heater 1.

As described above, the second manufacturing method of the carbon nanotube device 2 includes the step of forming the connection sheet portion 21 (step S39) and the step of fixing both ends of the connection sheet portion 21 to the pair of electrodes 22 (step S38). ) and. In step S39, the carbon nanotube sheets 94 are laminated between the pair of electrodes 22, thereby forming the connection sheet portion 21 in the form of a laminated sheet extending in the longitudinal direction between the pair of electrodes 22. Each electrode 22 of the pair of electrodes 22 is plate-shaped. In step S38, each electrode 22 is folded with the end of the connection sheet portion 21 in between. By manufacturing the carbon nanotube device 2 using this manufacturing method, the contact resistance between the connection sheet portion 21 and the electrode 22 can be reduced.

As described above, in the second manufacturing method, similarly to the first manufacturing method, in the state before step S38, each electrode 22 has a main surface at one end in the longitudinal direction. It is preferable to include a plurality of protrusions 222 standing from 221. Then, in step S38, each electrode 22 is folded in half along the folding line 223 perpendicular to the longitudinal direction to sandwich the end of the connection sheet part 21, and the plurality of convex parts 222 are arranged at the ends of the connection sheet part 21. It is preferable to penetrate through the section and contact the other end of each electrode 22 in the longitudinal direction. The end portion of the connection sheet portion 21 is a part of the carbon nanotube sheet layer 53 that is to become the connection sheet portion 21. Thereby, the contact resistance between the connection sheet portion 21 and the electrode 22 can be further reduced.

As described above, in the second manufacturing method, as in the first manufacturing method, it is preferable that a conductive paste is applied on the main surface 221 of each electrode 22 before step S38. Thereby, the contact resistance between the connection sheet portion 21 and the electrode 22 can be further reduced.

As described above, in the second manufacturing method, each electrode 22 is preferably heated in step S38, similarly to the first manufacturing method. This makes it easier for the electrode 22 to deform along the carbon nanotube sheet layer 53 that is to become the connection sheet portion 21, so that more suitable contact between the electrode 22 and the connection sheet portion 21 can be achieved. As a result, the contact resistance between the connection sheet portion 21 and the electrode 22 can be further reduced.

Next, a third example of the flow of manufacturing the carbon nanotube heater 1 will be described with reference to FIGS. 27 and 28. In the manufacturing method illustrated in FIGS. 27 and 28, the resistance between the pair of electrodes 22 is continuously measured from the start of winding the carbon nanotube sheet 94. For this reason, as shown in FIG. 29, a resistance measuring device 48 is provided in the device manufacturing apparatus 4 shown in FIG. connected to. Note that the structures of the accommodating part 31 and the heat dissipating part 34 are substantially the same as those in the first and second manufacturing methods.

In the method for manufacturing the carbon nanotube heater 1 according to the third example, first, as in step S32, an insulating sheet member 230 is attached to the outer surface of the rotating body 42, and a pair of electrodes 22 are placed on the insulating sheet member 230. can be installed. As shown in FIG. 29, the pair of electrodes 22 are arranged at positions 180° apart in the circumferential direction (step S51). The conductive paste is applied to the upper main surface of each electrode 22 (that is, the upper surface opposite to the lower surface, which is the main surface facing the outer surface of the rotating body 42), as in step S32. .

Subsequently, by rotating the rotating body 42, the carbon nanotube sheet 94 drawn out from the carbon nanotube array 91 is wound onto the outer surface of the rotating body 42 while passing over the pair of electrodes 22 (step S52). In step S52, similarly to step S33, an adhesive containing the above-mentioned conductive additive is applied from the adhesive applying unit 44 (see FIG. 23) to the carbon nanotube sheet 94 wound around the rotating body 42. be done. Further, the carbon nanotube sheet 94 wound around the rotating body 42 is pressed toward the outer surface of the rotating body 42 by a pressing roller 45 (see FIG. 23), and is compressed onto the insulating sheet member 230 on the outer surface. be done.

In step S52, the winding of the carbon nanotube sheet 94 is performed in parallel with continuous measurement of the resistance between the pair of electrodes 22 by the resistance measuring device 48. Then, step S52 is continued until the resistance measured by the resistance measuring device 48 reaches a predetermined target resistance, thereby forming a cylindrical carbon nanotube sheet layer 53 stacked on the pair of electrodes 22. (Step S53).

When steps S52 to S53 are completed, similarly to steps S37 to S39, the pair of electrodes 22 and the cylindrical carbon nanotube sheet layer 53 laminated on the pair of electrodes 22 are transferred to the rotating body together with the insulating sheet member 230. 42 (step S54), and the carbon nanotube sheet layer 53 is fixed to the pair of electrodes 22 (step S55). Then, the cylindrical carbon nanotube sheet layer 53 between the pair of electrodes 22 is pressed in the thickness direction together with the insulating sheet member 230 to form a planar shape. As a result, the connection sheet portion 21 and support sheet portion 23 that connect the pair of electrodes 22 are formed, and the formation of the carbon nanotube device 2 is completed (step S56).

In the third manufacturing method, steps S61 to S62 may be performed instead of steps S54 to S56. In this case, the carbon nanotube sheet layer 53, the pair of electrodes 22, and the insulating sheet member 230 are cut approximately at the longitudinal center of each of the pair of electrodes 22. As a result, two connection sheet portions 21 extending in the circumferential direction between the pair of electrodes 22 (each divided into two) are formed (step S61). Then, both ends of each connection sheet portion 21 are fixed to a pair of electrodes 22 (divided into two), thereby forming two carbon nanotube devices 2 (step S62).

The connection sheet portion 21 may be fixed in step S62 by, for example, folding the electrode 22 with the end of the connection sheet portion 21 in between, as shown in FIGS. 13 and 14. In this case, it is preferable that the plurality of convex portions 222 of the electrode 22 be provided at both longitudinal ends of the electrode 22 before cutting. Alternatively, the connection sheet portion 21 may be fixed in step S62 using connection aids 24a to 24c, as shown in FIGS. 19 to 21.

Once the carbon nanotube device 2 is formed, the carbon nanotube device 2 is housed inside the housing section 31 similarly to step S40. As a result, the carbon nanotube heater 1 (see FIG. 1) is formed (step S57).

As explained above, the third manufacturing method of the carbon nanotube device 2 includes the step of arranging the pair of electrodes 22 (step S51) and the winding of the carbon nanotube sheet 94 while measuring the resistance between the pair of electrodes 22. The carbon nanotube sheet layer 53 is rotated (step S52), the carbon nanotube sheet layer 53 is formed (step S53), and the carbon nanotube sheet layer 53 is fixed to the pair of electrodes 22 (step S55).

In step S51, a pair of electrodes 22 are arranged at positions separated in the circumferential direction on the outer surface of the rotating body 42 that is rotatable about the rotation axis J1 facing in the axial direction. In step S52, by rotating the rotating body 42, the carbon nanotube sheet 94 is wound around the outer surface of the rotating body 42 while passing over the pair of electrodes 22. In step S53, carbon nanotube sheets are stacked on the pair of electrodes 22 by continuing step S52 until the resistance measured in step S52 reaches a predetermined resistance (that is, a resistance approximately equal to the target resistance). Form layer 53.

By manufacturing the carbon nanotube device 2 using this manufacturing method, the influence of variations in the density of carbon nanotubes in the carbon nanotube sheet 94 can be suppressed, and carbon having a desired resistance (that is, resistance approximately equal to the target resistance) can be produced. A nanotube device 2 can be provided.

Preferably, in step S51, the pair of electrodes 22 are arranged 180 degrees apart in the circumferential direction. Further, the step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22 includes a step of implementing steps S54 to S56 or steps S61 to S62.

In steps S54 to S56, after step S53 is completed, the pair of electrodes 22 and the cylindrical carbon nanotube sheet layer 53 are removed from the rotating body 42, and the carbon nanotube sheet layer 53 is fixed to the pair of electrodes 22. Then, the carbon nanotube sheet layer 53 between the pair of electrodes 22 is pressed in the thickness direction to form a planar shape, thereby forming the connection sheet portion 21 that connects the pair of electrodes 22. Thereby, the carbon nanotube device 2 can be easily manufactured. Further, the number of stacked carbon nanotube sheets in the connection sheet portion 21 can be easily increased.

In steps S61 to S62, the carbon nanotube sheet layer 53 and the pair of electrodes 22 are cut at the center of each of the pair of electrodes 22, thereby forming a connecting sheet portion 21 extending in the circumferential direction between the pair of electrodes 22. Ru. Both ends of the connection sheet portion 21 are fixed to a pair of electrodes 22 . Thereby, the carbon nanotube device 2 can be easily manufactured. If the electrode 22 after cutting is called an electrode piece, in steps S61 and S62, two sets of connection sheet parts 21 extending in the circumferential direction are formed between a pair of electrode pieces, and both ends of each connection sheet part 21 are connected to a pair of electrode pieces. By being fixed to the electrode piece, two carbon nanotube devices 2 having substantially the same shape are manufactured. Note that in step S61, the pair of electrodes 22 may be used to manufacture one carbon nanotube device 2 without being cut. The same applies to the sixth manufacturing method of carbon nanotube device 2, which will be described later.

As described above, in the third manufacturing method of the carbon nanotube device 2, an adhesive is applied to the carbon nanotube sheet 94 wound around the rotating body 42, similarly to the first and second manufacturing methods. It is preferable. Thereby, the strength of the connection sheet portion 21 can be increased. As a result, damage to the connection sheet portion 21 (for example, cracking of the connection sheet portion 21 in the width direction, or falling off of carbon nanotubes from the connection sheet portion 21, etc.) can be suppressed. More preferably, the adhesive includes a conductive additive. Thereby, the electrical conductivity of the connection sheet portion 21 can be increased. As a result, the resistance of the carbon nanotube device 2 can be brought closer to the target resistance while reducing the number of stacked carbon nanotube sheets 94 in the connection sheet portion 21. Therefore, the weight of the carbon nanotube heater 1 can be reduced.

As mentioned above, it is preferable that the carbon nanotube heater 1 includes the above-described carbon nanotube device 2, the housing section 31, and the heat radiation section 34. The carbon nanotube device 2 is a heating element that generates heat when electric power is supplied. The accommodating portion 31 accommodates the connection sheet portion 21 of the carbon nanotube device 2 therein. Thereby, damage to the connection sheet portion 21 can be further suppressed. Further, since the housing section 31 has flexibility, the degree of freedom in selecting the installation location of the carbon nanotube heater 1 can be improved. The heat radiation part 34 is provided on the outer surface of the housing part 31, equalizes the heat from the carbon nanotube device 2, and radiates the heat from the heat radiation surface. Thereby, it is possible to improve the uniformity of heating in each part to be heated by the carbon nanotube heater 1.

In the third manufacturing method of the carbon nanotube device 2, the pair of electrodes 22 do not necessarily need to be arranged at positions 180° apart in the circumferential direction. For example, the circumferential angle between the pair of electrodes 22 may be 120° on one side and 240° on the other. In this case, in the step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22, the above steps S61 to S62 (see FIG. 28) are performed. Thereby, two carbon nanotube devices 2 having different lengths of connection sheet portions 21 can be formed in parallel.

When the angle in the circumferential direction between the pair of electrodes 22 is not 180°, in the resistance measurement in step S52, a parallel circuit is synthesized between one side and the other side of the pair of electrodes 22 in the carbon nanotube sheet layer 53. Resistance is measured by resistance measuring device 48 . Then, using the length ratio of the one side portion and the other side portion of the carbon nanotube sheet layer 53 (that is, the resistance ratio), the resistance of the one side portion and the other side are calculated from the above composite resistance. The resistance at the location (that is, each resistance between the pair of electrodes 22) is determined by a known calculation method.

In the third manufacturing method of the carbon nanotube device 2, a plurality of pairs of electrodes 22 may be arranged on the outer surface of the rotating body 42 in step S51. The angles between the plurality of pairs of electrodes 22 may be the same or different. In this case, in the resistance measurement in step S52, the combined resistance of the parallel circuit between the two electrodes 22 selected from the plurality of pairs of electrodes 22 is measured, and the combined resistance of the parallel circuit between the two electrodes 22 is measured. The resistance between each pair of electrodes 22 is determined from the combined resistance using the ratio of the lengths of the carbon nanotube sheet layers 53 between them. Further, in the step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22, the above-described steps S61 to S62 (see FIG. 28) are performed for each pair of electrodes 22. Thereby, a plurality of carbon nanotube devices 2 can be formed in parallel.

In the second manufacturing method of the carbon nanotube device 2 described above, steps S61 to S62 shown in FIG. 28 may be performed instead of steps S37 to S39 (see FIG. 22), similarly to the third manufacturing method. . In other words, in the second manufacturing method, the step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22 includes the step of implementing steps S37 to S39 or steps S61 to S62. In steps S61 to S62, as described above, by cutting the carbon nanotube sheet layer 53 and the pair of electrodes 22 at the center of each of the pair of electrodes 22, a connecting sheet extending in the circumferential direction between the pair of electrodes 22 is formed. A portion 21 is formed. Both ends of the connection sheet portion 21 are fixed to a pair of electrodes 22 . Thereby, the carbon nanotube device 2 can be easily formed. Specifically, two sets of connection sheet parts 21 extending in the circumferential direction are formed between a pair of electrode pieces, and both ends of each connection sheet part 21 are fixed to the pair of electrode pieces, so that two sets of substantially the same shape are formed. One carbon nanotube device 2 is manufactured. The same applies to the fifth manufacturing method of the carbon nanotube device 2, which will be described later.

In the second manufacturing method of the carbon nanotube device 2, similarly to the third manufacturing method, the pair of electrodes 22 do not necessarily need to be arranged at positions 180° apart in the circumferential direction. For example, the angle in the circumferential direction between the pair of electrodes 22 may be 120° on one side and 240° on the other. In this case, in the resistance measurement in step S34, the combined resistance of the above-mentioned parallel circuit is measured, and the resistance between the pair of electrodes 22 is determined from the combined resistance. Further, in the step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22, the above-mentioned steps S61 to S62 (see FIG. 28) are performed. Thereby, two carbon nanotube devices 2 having different lengths of connection sheet portions 21 can be formed in parallel.

In the second manufacturing method of the carbon nanotube device 2, similarly to the third manufacturing method, a plurality of pairs of electrodes 22 may be arranged on the outer surface of the rotating body 42 in step S51. The angles between the plurality of pairs of electrodes 22 may be the same or different. In this case, in the resistance measurement in step S52, for two electrodes 22 selected from a plurality of pairs of electrodes 22, the combined resistance of the parallel circuit between the two electrodes 22 is measured, and from the combined resistance, the combined resistance of each pair of electrodes 22 is measured. The resistance between the pair of electrodes 22 is determined. Further, in the step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22, the above-described steps S61 to S62 (see FIG. 28) are performed for each pair of electrodes 22. Thereby, a plurality of carbon nanotube devices 2 can be formed in parallel.

Next, a fourth example of the flow of manufacturing the carbon nanotube heater 1 will be described with reference to FIG. 30. The fourth manufacturing method is similar to the first manufacturing method described above, except that a measurement electrode other than electrode 22 is used, as will be described later. When the carbon nanotube heater 1 is manufactured by the fourth manufacturing method, first, the target resistance of the carbon nanotube device 2 is inputted to the control section 46 shown in FIG. 31, as in step S11 (see FIG. 6), The target number of turns of the carbon nanotube sheet 94 corresponding to the target resistance is determined based on the laminated resistance information. Then, based on the target number of turns, an initial number of turns is set which is smaller than the target number of turns by a predetermined number of turns (step S71).

Subsequently, in the device manufacturing apparatus 4 shown in FIGS. 31 and 32, the insulating sheet member 230 is attached to the outer surface of the rotating body 42, similarly to step S12. Then, three pairs of electrodes 22a, 22b, 22c and three pairs of measurement electrodes 25a, 25b, 25c are attached on the insulating sheet member 230 (step S72). The shapes of the electrodes 22a, 22b, 22c are the same as those described above. The pair of electrodes 22a, the pair of electrodes 22b, and the pair of electrodes 22c are arranged at both ends of the connection region 421, respectively. The measurement electrodes 25a, 25b, and 25c are, for example, approximately belt-shaped and extend approximately parallel to the rotation axis J1 of the rotating body 42.

A pair of measurement electrodes 25a are arranged at positions separated in the circumferential direction. The same applies to the pair of measurement electrodes 25b and the pair of measurement electrodes 25c. In the example shown in FIGS. 31 and 32, the pair of measurement electrodes 25a are located at the connection area 421 between the pair of electrodes 22a on the circumferential outer side of the pair of electrodes 22a, and at a position sandwiching the pair of electrodes 22a therebetween. will be placed in Preferably, the pair of measurement electrodes 25a are arranged close to the pair of electrodes 22a. The pair of measurement electrodes 25b are arranged on the circumferentially outer sides of the pair of electrodes 22b, in the connection region 421 between the pair of electrodes 22b, and at positions sandwiching the pair of electrodes 22b therebetween. Preferably, the pair of measurement electrodes 25b are arranged close to the pair of electrodes 22b. The pair of measurement electrodes 25c are arranged on the circumferential outer side of the pair of electrodes 22c, in a connection region 421 between the pair of electrodes 22c, and at a position sandwiching the pair of electrodes 22c therebetween. Preferably, the pair of measurement electrodes 25c are arranged close to the pair of electrodes 22c. In the following description, the electrodes 22a, 22b, and 22c are also collectively referred to as "electrodes 22" as described above. Moreover, the measurement electrodes 25a, 25b, and 25c are also collectively referred to as "measurement electrodes 25." In step S72, the arrangement of the electrodes 22 and the arrangement of the measurement electrodes 25 may be performed first or may be performed in parallel.

A conductive paste (eg, an adhesive containing conductive additives) is applied onto each electrode 22, as described above. An adhesive is applied onto each measurement electrode 25. The adhesive is preferably an insulating paste. As the insulating paste, preferably, paste-like rosin (for example, powdered rosin dissolved in a solvent such as alcohol) is used. Note that step S72 may be performed in parallel with step S71, or may be performed before step S71.

When step S71 and step S72 are completed, the rotating body 42 is rotated by the above-mentioned initial number of windings, similarly to step S13. As a result, the carbon nanotube sheet 94 pulled out from the carbon nanotube array 91 passes over the three pairs of electrodes 22a, 22b, 22c and the three pairs of measurement electrodes 25a, 25b, 25c, and then onto the outer surface of the rotating body 42. is wound around. In other words, the carbon nanotube sheets 94 are stacked between each of the three pairs of electrodes 22a, 22b, and 22c.

As described above, an adhesive containing a conductive additive is applied to the carbon nanotube sheet 94 wound around the rotating body 42 by the adhesive applying unit 44 . As a result, the carbon nanotubes constituting the carbon nanotube sheet 94 aggregate. Further, the carbon nanotube sheet 94 wound around the rotating body 42 is pressed toward the outer surface of the rotating body 42 by the pressing roller 45 and compacted onto the insulating sheet member 230 on the outer surface.

In the device manufacturing apparatus 4, as shown in FIG. 33, a cylindrical intermediate body 51 is formed in which carbon nanotube sheets 94 are laminated in the radial direction around the rotating body 42 by a number of layers equal to the initial number of turns (step S73). ). In FIG. 33, among the three pairs of electrodes 22 and the three pairs of measurement electrodes 25, one pair of electrodes 22a and one pair of measurement electrodes 25a are shown. In the following, a method for manufacturing the carbon nanotube device 2 will be described, focusing on the carbon nanotube device 2 including the pair of electrodes 22a. Note that the same applies to the manufacture of the carbon nanotube device 2 each including a pair of electrodes 22b and a pair of electrodes 22c. For convenience of illustration, the number of stacked carbon nanotube sheets 94 shown in FIG. 33 is smaller than the actual number of stacked layers.

When the initial number of turns of the carbon nanotube sheet 94 is completed, the rotation mechanism 43 is stopped. Then, as shown in FIG. 34, the cylindrical intermediate body 51 is cut at two cutting positions outside the pair of measurement electrodes 25a in the circumferential direction. Specifically, the cylindrical intermediate body 51 is cut at a cutting position opposite to the connection region 421 of the electrode 22a and the measurement electrode 25a. In this embodiment, the specific cutting positions are between circumferentially adjacent measurement electrodes 25a and 25b, between measurement electrodes 25a and 25c, and between measurement electrodes 25a and 25c. 25b and the measurement electrode 25c. The cylindrical intermediate body 51 is cut by, for example, a cutting blade 47 such as a cutter.

Subsequently, as shown in FIG. 35, the resistance between the pair of measurement electrodes 25a is measured (step S74). Both longitudinal ends of a laminated sheet-like carbon nanotube structure 52, which is a portion of the cylindrical intermediate body 51 that extends in the circumferential direction between the pair of measurement electrodes 25a, are in contact with the pair of measurement electrodes 25a. are doing. The end of the carbon nanotube structure 52 is temporarily fixed to the measurement electrode 25a with the above-mentioned adhesive (for example, paste-like rosin) and an adhesive applied from the adhesive application section 44. Thereby, the pair of measurement electrodes 25a are electrically connected by the carbon nanotube structure 52. In addition, the adhesive permeates into the gaps between the many carbon nanotubes that constitute the carbon nanotube structure 52 and pulls the carbon nanotube structure 52 onto the measurement electrode 25a. Reduce contact resistance between The resistance is measured, for example, by an operator using a resistance measuring device 48 such as a tester. Alternatively, the resistance measuring device 48 may be provided in the device manufacturing apparatus 4, and the resistance measurement in step S74 may be automatically performed after step S73 is completed.

The measured value obtained in step S74 is sent to the control section 46 (see FIG. 31). The control unit 46 determines the initial measured resistance, which is the resistance between the pair of electrodes 22a, based on the measured value. The initial measurement resistance is obtained, for example, by multiplying the measured value by the ratio of the distance in the circumferential direction between the pair of electrodes 22a to the distance in the circumferential direction between the pair of measurement electrodes 25a. Furthermore, in cases such as when the distance between the electrode 22a and the measurement electrode 25a is small, the above measurement value may be used as the initial measurement resistance. The initial measured resistance is greater than or equal to the target resistance described above. When the initial measured resistance is approximately equal to the target resistance, winding of the carbon nanotube sheet 94 is completed.

If the initial measured resistance is larger than the target resistance, similarly to step S15, the calculation unit of the control unit 46 determines that the resistance of the carbon nanotube device 2 is approximately equal to the target resistance based on the initial measured resistance and the laminated resistance information described above. The number of additional windings of the carbon nanotube sheet 94 required to achieve equality is determined (step S75).

When the number of additional windings is determined, the rotation mechanism 43 is controlled by the control unit 46, and the rotating body 42 is rotated by the number of additional windings. As a result, the carbon nanotube sheet 94 passes over the three pairs of electrodes 22a, 22b, 22c and the three pairs of measurement electrodes 25a, 25b, 25c and onto the outer surface of the rotating body 42, similarly to step S73. rolled around. In the device manufacturing apparatus 4, a carbon nanotube sheet 94 is stacked on the carbon nanotube structure 52 between each of the three pairs of electrodes 22a, 22b, and 22c, as shown in FIG. 36 (step S76). Also in step S76, the adhesive containing the above-mentioned conductive additive is applied from the adhesive applying unit 44 to the carbon nanotube sheet 94 wound around the rotating body 42. Further, the carbon nanotube sheet 94 wound around the rotating body 42 is pressed toward the outer surface of the rotating body 42 by the pressing roller 45 and compacted onto the carbon nanotube structure 52 . Note that in step S75, the additional number of windings may be determined by the operator based on the measured value obtained in step S74. Further, in step S76, the rotation mechanism 43 may be operated by the operator, and the rotating body 42 may be rotated by the additional number of windings.

When the additional number of windings of the carbon nanotube sheet 94 is completed, the rotation mechanism 43 is stopped. Then, as shown in FIG. 37, the carbon nanotube sheet 94 on the carbon nanotube structure 52 is cut at a cutting position between the circumferentially adjacent electrode 22a and the measurement electrode 25a. The carbon nanotube sheet 94 may be cut on the electrode 22a. In other words, the carbon nanotube sheet 94 is cut at two cutting positions located outside the connection region 421 in the circumferential direction and inside the pair of measurement electrodes 25a. As a result, the connection sheet portion 21 in the form of a laminated sheet extending in the circumferential direction is formed in the connection region 421 (step S77). In step S77, when cutting the carbon nanotube sheet 94, the insulating sheet member 230 (see FIGS. 31 and 32) is also cut. As a result, a support sheet portion 23 extending in the circumferential direction is formed in the connection region 421. The carbon nanotube sheet 94 and the insulating sheet member 230 are cut by, for example, the cutting blade 47, such as a cutter similar to step S74.

When step S77 ends, the pair of electrodes 22a, the connection sheet part 21, and the support sheet part 23 are removed from the rotating body 42, and both longitudinal ends of the connection sheet part 21 are connected to the pair of electrodes 22a, as in step S18. The carbon nanotube device 2 is formed by fixing to the carbon nanotube (step S78). Then, similarly to step S19, the carbon nanotube device 2 is housed inside the housing section 31, and the carbon nanotube heater 1 is formed (step S79).

Note that the number of electrodes 22 and measurement electrodes 25 arranged on the outer surface of the rotating body 42 is not limited to three pairs, and may be one pair, two pairs, or four or more pairs.

As explained above, the fourth manufacturing method of the carbon nanotube device 2 includes the step of arranging the pair of electrodes 22 and the pair of measurement electrodes 25 (step S72), and the step of arranging the cylindrical intermediate body 51. a step of forming (step S73), a step of measuring the resistance between the pair of measurement electrodes 25 (step S74), a step of stacking the carbon nanotube sheets 94 (step S76), and a step of forming the connection sheet portion 21. (Step S77), and a step of fixing both ends of the connection sheet portion 21 to a pair of electrodes 22 (Step S78).

In step S72, a pair of electrodes 22 are arranged at both ends of the connection region 421 extending in the circumferential direction on the outer surface of the rotating body 42 which is rotatable about the rotation axis J1 pointing in the axial direction. Further, the pair of measurement electrodes 25 are arranged on the circumferential outer side of the pair of electrodes 22 at positions sandwiching the connection region 421 and the pair of electrodes 22 therebetween. In step S73, by rotating the rotating body 42 by the initial number of turns, the carbon nanotube sheet 94 is wound onto the outer surface of the rotating body 42 while passing over the pair of electrodes 22 and the pair of measurement electrodes 25. Ru. As a result, a cylindrical intermediate body 51 in which carbon nanotube sheets 94 are laminated in the radial direction around the rotating body 42 is formed.

In step S74, the cylindrical intermediate body 51 is cut outside the pair of measurement electrodes 25 in the circumferential direction. Then, the resistance between the pair of measurement electrodes 25 electrically connected by the laminated sheet-like carbon nanotube structure 52 is measured. The carbon nanotube structure 52 is a portion of the cylindrical intermediate body 51 that extends in the circumferential direction between the pair of measurement electrodes 25 . In step S76, if the initial measured resistance, which is the resistance between the pair of electrodes 22 determined based on the measured value obtained in step S74, is larger than the predetermined target resistance, by rotating the rotating body 42, A carbon nanotube sheet 94 is wound onto the outer surface of the rotating body 42 while passing over the pair of electrodes 22 . As a result, the carbon nanotube sheet 94 is stacked on the carbon nanotube structure 52. In step S77, the carbon nanotube sheet 94 is cut outside the connection region 421 in the circumferential direction and inside the pair of measurement electrodes 25, so that a connection sheet portion in the form of a laminated sheet extending in the circumferential direction in the connection region 421 is cut. 21 is formed.

By manufacturing the carbon nanotube device 2 using this manufacturing method, as in the first manufacturing method described above, the influence of variations in the density of carbon nanotubes in the carbon nanotube sheet 94 can be suppressed, and desired resistance (i.e., A carbon nanotube device 2 having a resistance approximately equal to the target resistance can be provided. Moreover, the carbon nanotube device 2 can be easily manufactured by the above manufacturing method. As mentioned above, it is preferable that the pair of measurement electrodes 25 be arranged close to the pair of electrodes 22. Thereby, the resistance between the pair of electrodes 22 can be determined with higher accuracy.

As described above, in the fourth manufacturing method, it is preferable that an adhesive is applied on the pair of measurement electrodes 25 between step S72 and step S73. Thereby, the carbon nanotube structure 52 and the measurement electrode 25 can be suitably brought into contact with each other, and the contact resistance between the carbon nanotube structure 52 and the measurement electrode 25 can be reduced. As a result, the accuracy of resistance measurement in step S74 can be improved. Moreover, it is more preferable that the adhesive is a paste-like rosin. Thereby, the contact resistance can be further suitably reduced. In addition, in the fourth manufacturing method, powdered rosin may be applied to the measurement electrode 25, and a solvent such as alcohol may be sprayed in a post-process, so that the rosin dissolves in the solvent and becomes a paste. The same applies to the fifth and sixth manufacturing methods of the carbon nanotube device 2, which will be described later.

As described above, in the fourth manufacturing method of the carbon nanotube device 2, the resistance measurement is performed using the measurement electrode 25 that is different from the electrode 22 that constitutes the carbon nanotube device 2, so the configuration related to the resistance measurement is The degree of freedom in design (for example, the shape and arrangement of the measurement electrode 25) can be improved. Furthermore, as described above, since the measurement electrode 25 is not included in the carbon nanotube device 2, the above-mentioned rosin etc. can be applied to the measurement electrode 25 without considering the influence on the quality and life of the carbon nanotube device 2. contact resistance can be reduced by adding The same applies to the fifth and sixth manufacturing methods of the carbon nanotube device 2.

Next, a fifth example of the flow of manufacturing the carbon nanotube heater 1 will be described with reference to FIG. 38. The fifth manufacturing method is similar to the second manufacturing method described above, except that a measurement electrode other than electrode 22 is used, as will be described later. In the fifth manufacturing method of the carbon nanotube device 2, first, similarly to step S31 (see FIG. 22), the target number of windings corresponding to the target resistance of the carbon nanotube heater 1 is determined based on the laminated resistance information, and the target number of turns is determined based on the laminated resistance information. Based on the number of turns, an initial number of turns smaller than the target number of turns is set (step S81).

Subsequently, as shown in FIG. 39, in the device manufacturing apparatus 4, an insulating sheet member 230 is attached to the outer surface of the rotating body 42, and a pair of electrodes 22 and a pair of measurement electrodes are mounted on the insulating sheet member 230. Electrode 25 is attached (step S82). The pair of electrodes 22 are arranged 180° apart in the circumferential direction. A pair of measurement electrodes 25 are also arranged at positions 180° apart in the circumferential direction. Note that the angle in the circumferential direction between the pair of measurement electrodes 25 does not necessarily have to be 180°. As illustrated in FIG. 39, the pair of measurement electrodes 25 are preferably arranged close to the pair of electrodes 22. As in step S32, the conductive paste is applied onto each electrode 22. Further, similarly to step S72, the above-mentioned adhesive (for example, paste-like rosin) is applied onto each measurement electrode 25. Note that step S82 may be performed in parallel with step S81, or may be performed before step S81.

When step S81 and step S82 are completed, similarly to step S33, the rotating body 42 is rotated by the above-mentioned initial number of windings, and the carbon nanotube sheet 94 pulled out from the carbon nanotube array 91 is placed on the pair of electrodes 22 and on the pair of electrodes 22. It is wound around the outer surface of the rotating body 42 while passing over the measurement electrode 25 . As a result, a cylindrical intermediate body 51 is formed in which carbon nanotube sheets 94 are laminated in the radial direction around the rotating body 42 by a number of layers equal to the initial number of turns (step S83).

In step S83, in the same manner as described above, an adhesive containing the above-mentioned conductive additive is applied from the adhesive applying section 44 to the carbon nanotube sheet 94 wound around the rotating body 42. Further, the carbon nanotube sheet 94 wound around the rotating body 42 is pressed toward the outer surface of the rotating body 42 by the pressing roller 45 and compacted onto the insulating sheet member 230 on the outer surface.

When step S83 ends, the resistance between the pair of measurement electrodes 25 is measured (step S84). In step S84, the cylindrical intermediate body 51 is not cut. The measured value obtained in step S84 is sent to the control section 46. The control unit 46 determines the initial measured resistance, which is the resistance between the pair of electrodes 22, based on the measured value. As described above, when the angle in the circumferential direction between the pair of electrodes 22 and the angle in the circumferential direction between the pair of measurement electrodes 25 are both 180°, the above measured value is taken as the initial measured resistance. Further, if the angle in the circumferential direction between the pair of measurement electrodes 25 is not 180°, the combined resistance of the parallel circuit described above is measured in substantially the same manner as in steps S34 and S52 described above, and the combined resistance of the pair of measurement electrodes 25 is measured from the combined resistance. The resistance between the electrodes 25 is determined. Then, by multiplying the resistance between the pair of measurement electrodes 25 by the ratio of the circumferential distance between the pair of electrodes 22 to the circumferential distance between the pair of measurement electrodes 25, the initial measurement resistance is determined. is required. The initial measured resistance is greater than or equal to the target resistance described above. When the initial measured resistance is approximately equal to the target resistance, winding of the carbon nanotube sheet 94 is completed.

If the initial measured resistance is larger than the target resistance, the number of additional windings of the carbon nanotube sheet 94 is determined based on the initial measured resistance and the above laminated resistance information (step S85), similar to step S35.

When the number of additional windings is determined, similarly to step S36, the rotating body 42 is rotated by the number of additional windings, and the carbon nanotube sheet 94 pulled out from the carbon nanotube array 91 is placed on the pair of electrodes 22 and on the pair of measurement It is wound onto the outer surface of the rotating body 42 while passing over the electrode 25 . As a result, the carbon nanotube sheet 94 is stacked on the cylindrical intermediate body 51, and a carbon nanotube sheet layer is formed (step S86). Also in step S86, the adhesive containing the above-mentioned conductive additive is applied from the adhesive applying unit 44 to the carbon nanotube sheet 94 wound around the rotating body 42. Further, the carbon nanotube sheet 94 wound around the rotating body 42 is pressed by the pressing roller 45 toward the outer surface of the rotating body 42 and compacted onto the cylindrical intermediate body 51 .

When step S86 is completed, the pair of measurement electrodes 25 are removed from the rotating body 42. Then, similarly to step S37, the pair of electrodes 22 and the cylindrical carbon nanotube sheet layer 53 laminated on the pair of electrodes 22 (see FIG. 24) are removed from the rotating body 42 together with the insulating sheet member 230. (step S87).

When step S87 ends, the carbon nanotube sheet layer 53 is fixed to the pair of electrodes 22 (step S88), similarly to step S38. Then, similarly to step S39, the cylindrical carbon nanotube sheet layer 53 between the pair of electrodes 22 is pressed in the thickness direction together with the insulating sheet member 230 to form a planar shape. In other words, the carbon nanotube sheet layer 53 between the pair of electrodes 22 is crushed in the thickness direction. As a result, the connection sheet portion 21 and support sheet portion 23 that connect the pair of electrodes 22 are formed, and the formation of the carbon nanotube device 2 is completed (step S89). Thereafter, similarly to step S40, the carbon nanotube device 2 is housed inside the housing section 31. As a result, the carbon nanotube heater 1 (see FIG. 1) is formed (step S90).

As explained above, the fifth manufacturing method of the carbon nanotube device 2 includes the step of arranging the pair of electrodes 22 and the pair of measurement electrodes 25 (step S82), and forming the cylindrical intermediate body 51. (step S83), a step of measuring the resistance between the pair of measurement electrodes 25 (step S84), a step of laminating the carbon nanotube sheets 94 (step S86), and a step of laminating the carbon nanotube sheets 94 on the pair of electrodes 22. The method includes a step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22 (step S88).

In step S82, a pair of electrodes 22 are arranged at positions separated in the circumferential direction on the outer surface of the rotating body 42 which is rotatable about the rotation axis J1 facing in the axial direction, and a pair of electrodes 22 are arranged at positions separated in the circumferential direction. measurement electrodes 25 are arranged. In step S83, by rotating the rotating body 42 by the initial number of turns, the carbon nanotube sheet 94 is wound onto the outer surface of the rotating body 42 while passing over the pair of electrodes 22 and the pair of measurement electrodes 25. Ru. As a result, a cylindrical intermediate body 51 in which carbon nanotube sheets 94 are laminated in the radial direction around the rotating body 42 is formed.

In step S86, if the initial measured resistance, which is the resistance measured in step S84, is larger than the predetermined target resistance, the rotating body 42 is rotated to cause the carbon nanotube sheet 94 to pass over the pair of electrodes 22. It is wound on the outer surface of the rotating body 42. Thereby, the carbon nanotube sheet 94 is laminated on the cylindrical intermediate body 51.

By manufacturing the carbon nanotube device 2 using this manufacturing method, as in the second manufacturing method described above, the influence of variations in the density of carbon nanotubes in the carbon nanotube sheet 94 can be suppressed, and desired resistance (i.e., A carbon nanotube device 2 having a resistance approximately equal to the target resistance can be provided. Moreover, the carbon nanotube device 2 can be easily manufactured by the above manufacturing method. The pair of measurement electrodes 25 are preferably arranged close to the pair of electrodes 22, as described above. Thereby, the resistance between the pair of electrodes 22 can be determined with higher accuracy.

Preferably, in step S82, the pair of electrodes 22 are arranged 180 degrees apart in the circumferential direction. Furthermore, in the step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22, the pair of electrodes 22 and the cylindrical carbon nanotube sheet layer 53 are removed from the rotating body 42, and the carbon nanotube sheet layer 53 is fixed to the pair of electrodes 22. Then, the carbon nanotube sheet layer 53 between the pair of electrodes 22 is pressed in the thickness direction to make it planar, thereby forming the connection sheet portion 21 that connects the pair of electrodes 22 (steps S87 to S89). Equipped with. Thereby, the carbon nanotube device 2 can be easily formed. Further, the number of stacked carbon nanotube sheets in the connection sheet portion 21 can be easily increased.

In the fifth manufacturing method of the carbon nanotube device 2 described above, steps S61 to S62 shown in FIG. 28 may be performed instead of steps S87 to S89 (see FIG. 38), similarly to the second manufacturing method. . In other words, in the fifth manufacturing method, the step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22 includes the step of implementing steps S87 to S89 or steps S61 to S62. In steps S61 to S62, as described above, by cutting the carbon nanotube sheet layer 53 and the pair of electrodes 22 at the center of each of the pair of electrodes 22, a connecting sheet extending in the circumferential direction between the pair of electrodes 22 is formed. A portion 21 is formed. Both ends of the connection sheet portion 21 are fixed to a pair of electrodes 22 . Thereby, the carbon nanotube device 2 can be easily formed.

In the fifth manufacturing method of the carbon nanotube device 2, similarly to the second manufacturing method, the pair of electrodes 22 do not necessarily need to be arranged at positions 180° apart in the circumferential direction. In this case, in the resistance measurement in step S84, the resistances on one side and the other side of the pair of electrodes 22 are determined, respectively, based on the measured value of the resistance between the pair of measurement electrodes 25 described above. Further, in the step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22, the above-mentioned steps S61 to S62 (see FIG. 28) are performed. Thereby, two carbon nanotube devices 2 having different lengths of connection sheet portions 21 can be formed in parallel. The same applies to the sixth manufacturing method of carbon nanotube device 2, which will be described later.

In the fifth manufacturing method of the carbon nanotube device 2, similarly to the second manufacturing method, multiple pairs of electrodes 22 may be arranged on the outer surface of the rotating body 42 in step S81. The angles between the plurality of pairs of electrodes 22 may be the same or different. In this case, in the resistance measurement in step S84, the resistance between the pair of electrodes 22 in each group is determined based on the measured value of the resistance between the pair of measurement electrodes 25 described above. Further, in the step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22, the above-described steps S61 to S62 (see FIG. 28) are performed for each pair of electrodes 22. Thereby, a plurality of carbon nanotube devices 2 can be formed in parallel. The same applies to the sixth manufacturing method of the carbon nanotube device 2.

Next, a sixth example of the flow of manufacturing the carbon nanotube heater 1 will be described with reference to FIG. 40. The sixth manufacturing method is similar to the third manufacturing method described above, except that a measurement electrode other than electrode 22 is used, as will be described later. In the sixth manufacturing method of the carbon nanotube device 2, first, in the device manufacturing apparatus 4 shown in FIG. 22 and a pair of measurement electrodes 25 are attached (step S101). The pair of electrodes 22 are arranged 180° apart in the circumferential direction. A pair of measurement electrodes 25 are also arranged at positions 180° apart in the circumferential direction. Note that the angle in the circumferential direction between the pair of measurement electrodes 25 does not necessarily have to be 180°. As illustrated in FIG. 41, the pair of measurement electrodes 25 are preferably arranged close to the pair of electrodes 22. As in step S51, the conductive paste is applied onto each electrode 22. Further, similarly to step S72, the above-mentioned adhesive (for example, paste-like rosin) is applied onto each measurement electrode 25.

Subsequently, as in step S52, by rotating the rotating body 42, the carbon nanotube sheet 94 pulled out from the carbon nanotube array 91 passes over the pair of electrodes 22 and the pair of measurement electrodes 25. It is wound onto the outer surface of the rotating body 42 (step S102). In step S102, similarly to step S52, an adhesive containing the above-mentioned conductive additive is applied from the adhesive applying unit 44 (see FIG. 39) to the carbon nanotube sheet 94 wound around the rotating body 42. be done. Further, the carbon nanotube sheet 94 wound around the rotating body 42 is pressed toward the outer surface of the rotating body 42 by a pressing roller 45 (see FIG. 39), and is compressed onto the insulating sheet member 230 on the outer surface. be done.

In step S102, the winding of the carbon nanotube sheet 94 is performed in parallel with continuous measurement of the resistance between the pair of measurement electrodes 25 by the resistance measurement device 48. Then, based on the measured values obtained by the resistance measuring device 48, the resistance between the pair of electrodes 22 is continuously determined. The method of determining the resistance between the pair of electrodes 22 from the measured value of the resistance between the pair of measurement electrodes 25 is the same as in step S84 described above. Then, step S102 is continued until the resistance between the pair of electrodes 22 reaches a predetermined target resistance, thereby forming a cylindrical carbon nanotube sheet layer 53 stacked on the pair of electrodes 22 (step S103).

When steps S102 to S103 are completed, the pair of measurement electrodes 25 is removed from the rotating body 42, similarly to steps S87 to S89. Further, the pair of electrodes 22 and the cylindrical carbon nanotube sheet layer 53 laminated on the pair of electrodes 22 are removed from the rotating body 42 together with the insulating sheet member 230 (step S104), and the carbon nanotube sheet layer 53 is removed from the rotating body 42 together with the insulating sheet member 230. is fixed to the pair of electrodes 22 (step S105). Then, the cylindrical carbon nanotube sheet layer 53 between the pair of electrodes 22 is pressed in the thickness direction together with the insulating sheet member 230 to form a planar shape. As a result, the connection sheet portion 21 and support sheet portion 23 that connect the pair of electrodes 22 are formed, and the formation of the carbon nanotube device 2 is completed (step S106).

In the sixth manufacturing method, steps S61 to S62 shown in FIG. 28 may be performed instead of steps S104 to S106. In this case, as described above, the carbon nanotube sheet layer 53, the pair of electrodes 22, and the insulating sheet member 230 are cut approximately at the longitudinal center of each of the pair of electrodes 22. Thereby, two connection sheet parts 21 extending in the circumferential direction between the pair of electrodes 22 are formed (step S61). Then, both ends of each connection sheet portion 21 are fixed to a pair of electrodes 22, thereby forming two carbon nanotube devices 2 (step S62).

Once the carbon nanotube device 2 is formed, the carbon nanotube device 2 is housed inside the housing section 31 similarly to step S57. As a result, the carbon nanotube heater 1 (see FIG. 1) is formed (step S107).

As explained above, the sixth manufacturing method of the carbon nanotube device 2 includes the step of arranging the pair of electrodes 22 and the pair of measurement electrodes 25 (step S101), and the step of arranging the pair of measurement electrodes 25. a step of winding the carbon nanotube sheet 94 while measuring the resistance of the carbon nanotube sheet 94 (step S102), a step of forming the carbon nanotube sheet layer 53 (step S103), and a step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22. (Step S105).

In step S101, a pair of electrodes 22 are arranged at positions separated in the circumferential direction on the outer surface of the rotating body 42 that is rotatable about the rotation axis J1 facing in the axial direction, and a pair of electrodes 22 are arranged at positions separated in the circumferential direction. electrode 25 is arranged. In step S102, by rotating the rotating body 42, the carbon nanotube sheet 94 is wound onto the outer surface of the rotating body 42 while passing over the pair of electrodes 22 and the pair of measurement electrodes 25. In step S103, step S102 is continued until the resistance between the pair of electrodes 22, which is determined based on the measured value obtained in step S102, reaches a predetermined resistance. A carbon nanotube sheet layer 53 is formed.

By manufacturing the carbon nanotube device 2 using this manufacturing method, similarly to the third manufacturing method described above, the influence of variations in the density of carbon nanotubes in the carbon nanotube sheet 94 can be suppressed, and desired resistance (i.e., A carbon nanotube device 2 having a resistance approximately equal to the target resistance can be provided. Moreover, the carbon nanotube device 2 can be easily manufactured by the above manufacturing method. The pair of measurement electrodes 25 are preferably arranged close to the pair of electrodes 22, as described above. Thereby, the resistance between the pair of electrodes 22 can be determined with higher accuracy.

Preferably, in step S101, the pair of electrodes 22 are arranged 180 degrees apart in the circumferential direction. Further, the step of fixing the carbon nanotube sheet layer 53 to the pair of electrodes 22 includes a step of implementing steps S104 to S106 or steps S61 to S62.

In steps S104 to S106, after step S103 is completed, the pair of electrodes 22 and the cylindrical carbon nanotube sheet layer 53 are removed from the rotating body 42, and the carbon nanotube sheet layer 53 is fixed to the pair of electrodes 22. Then, the carbon nanotube sheet layer 53 between the pair of electrodes 22 is pressed in the thickness direction to form a planar shape, thereby forming the connection sheet portion 21 that connects the pair of electrodes 22. Thereby, the carbon nanotube device 2 can be easily manufactured. Further, the number of stacked carbon nanotube sheets in the connection sheet portion 21 can be easily increased.

In steps S61 to S62, as described above, by cutting the carbon nanotube sheet layer 53 and the pair of electrodes 22 at the center of each of the pair of electrodes 22, a connecting sheet extending in the circumferential direction between the pair of electrodes 22 is formed. A section 21 is formed. Both ends of the connection sheet portion 21 are fixed to a pair of electrodes 22 . Thereby, the carbon nanotube device 2 can be easily manufactured.

Various modifications can be made to the above-described carbon nanotube device 2 and carbon nanotube heater 1, as well as the manufacturing method thereof.

For example, in the device manufacturing apparatus 4, the shape of the rotating body 42 does not necessarily have to be substantially cylindrical or substantially cylindrical, and may have various shapes. The rotating body 42 may be, for example, columnar or cylindrical with a rectangular or polygonal cross section, or may be flat. Further, for example, the electrode 22 disposed on the flat plate-shaped rotating body 42 and the carbon nanotube sheet 94 wound around the rotating body 42 are not removed from the rotating body 42 and are not removed from the rotating body 42 . It may also be used as a carbon nanotube device 2.

In the first, second, fourth, and fifth manufacturing methods, the setting of the initial number of windings of the carbon nanotube sheet 94, the determination of the additional number of windings, etc. are not necessarily performed by the control unit 46, but are performed by the operator. This may also be done manually.

In the first, second, fourth, and fifth manufacturing methods, it is not necessarily necessary to acquire laminated resistance information. In this case, the initial number of windings in steps S11, S31, S71, and S81 may be set in advance based on, for example, prior experiments. Further, in the first manufacturing method, cutting of the cylindrical intermediate body 51, measuring the resistance between the pair of electrodes 22 (step S14), and laminating the carbon nanotube sheets 94 (step S16) are repeated, and the Steps S17 to S19 are performed when the resistance between the electrodes 22 becomes approximately equal to the target resistance. The same applies to the fourth manufacturing method. In the second manufacturing method, the resistance measurement between the pair of electrodes 22 (step S34) and the stacking of the carbon nanotube sheets 94 (step S36) are repeated, and the resistance between the pair of electrodes 22 in step S34 reaches the target resistance. When the values are approximately equal, steps S37 to S40 are performed. The same applies to the fifth manufacturing method.

If the application of the conductive paste to the electrode 22 in the first manufacturing method is performed before the electrode 22 is bent in step S18, it is performed after the winding of the carbon nanotube sheet 94 in step S13. or may be performed in parallel with step S13. Alternatively, application of the conductive paste to the electrode 22 may be omitted. Furthermore, heating of the electrode 22 may also be omitted. The same applies to the second to sixth manufacturing methods.

The adhesive applied to the measurement electrode 25 in the fourth manufacturing method may be an insulating paste other than pasty rosin, or a conductive paste such as a conductive adhesive, as described above. It may be. Alternatively, application of the adhesive to the measurement electrode 25 may be omitted. The same applies to the fifth and sixth manufacturing methods.

In the first manufacturing method, when three or more electrodes 22 are arranged on the outer surface of the rotating body 42, any two of the three or more electrodes 22 are used as a pair of electrodes 22. A connection sheet portion 21 that is selected and connects the pair of electrodes 22 may be formed. Thereby, the length of the connection sheet portion 21 can be easily changed.

The structure of the device manufacturing apparatus 4 is not limited to that illustrated in FIGS. 3, 4, 23, 29, 31, 32, 39, and 41, and may be modified in various ways. For example, the adhesive applying section 44 and/or the pressing roller 45 may be omitted. Alternatively, instead of the pressing roller 45, a group of suction ports for adsorbing the carbon nanotube sheet 94 may be provided on the outer surface of the rotating body 42. The suction port group may be provided together with the pressing roller 45.

The device manufacturing apparatus 4 is provided with a swinging mechanism that swings the substrate holder 41 in the axial direction, and the carbon nanotube sheet 94 is pulled out from the carbon nanotube array 91 on the axially swinging substrate 92, and the carbon nanotube sheet 94 is pulled out in the width direction. A relatively large area connecting sheet portion 21 with a large width may be manufactured. As a result, even if there is a region in the carbon nanotube array 91 where the density of carbon nanotubes is lower than the surrounding area (hereinafter referred to as a "low-density region"), carbon nanotubes in the low-density region remain (i.e., Problems such as non-uniform density of the carbon nanotube sheet 94 due to the phenomenon that the carbon nanotube sheet 94 remains on the substrate 92 without being pulled out from the substrate 92 can be suppressed. This is because the relative rocking of the carbon nanotube sheet 94 with respect to the carbon nanotube array 91 acts on the pull-out position (i.e., the point at which the carbon nanotube sheet 94 is pulled out) in the carbon nanotube array 91 via the plurality of single carbon nanotube filaments. This is because, in the vicinity of the extraction position, the carbon nanotubes in the low-density region come into contact with the surrounding (in particular, axially adjacent) carbon nanotubes and are pulled out together.

In the above example, the carbon nanotube sheet 94 was described as being drawn out from the carbon nanotube array 91 standing upright on the substrate 92; Good too.

In the carbon nanotube device 2, the support sheet portion 23 may be omitted. Further, the plurality of convex portions 222 of the electrode 22 may also be omitted. In the carbon nanotube device 2, when the connection tool 24 is used, the shape of the connection tool 24 is not limited to the connection tools 24a to 24c shown in FIGS. 19 to 21, and may be modified in various ways.

In the carbon nanotube device 2, the fixing of the connection sheet part 21 and the electrode 22 does not necessarily require that the ends of the connection sheet part 21 be sandwiched between the folded electrodes 22, and it is not necessary to use the connection aid 24. do not have.

The size and shape of the connection sheet portion 21 of the carbon nanotube device 2 may be varied in accordance with the application. For example, the length of the diagonal line of the connection sheet portion 21 does not necessarily need to be 200 mm or more, and may be less than 200 mm. Further, the shape of the connection sheet portion 21 in plan view may be other than a substantially rectangular shape (for example, a trapezoid, etc.).

In the carbon nanotube heater 1, the heat radiation part 34 does not necessarily need to overlap the entire connection sheet part 21 in the vertical direction, and may overlap only a part of the connection sheet part 21, for example. In the carbon nanotube heater 1, a reflecting part that reflects heat from the carbon nanotube device 2 may be provided on the main surface of the housing part 31 on the opposite side from the heat dissipating part 34, and on the side surface. The reflective portion is, for example, a sheet-like member having a metal foil provided on the inner surface of a heat insulating sheet. Thereby, heat from the carbon nanotube device 2 can be efficiently collected in the heat radiating section 34. Alternatively, a film-like or thin plate-like member similar to that of the heat radiating portion 34 may be provided on the main surface and the side surface of the housing portion 31 opposite to the heat radiating portion 34 . Note that in the carbon nanotube heater 1, the heat radiation section 34 may be omitted. Furthermore, the temperature sensor 36 may also be omitted.

The accommodating portion 31 of the carbon nanotube heater 1 does not necessarily have to be flexible and may be a hard member.

In the carbon nanotube heater 1, two or more carbon nanotube devices 2 may be housed in the housing section 31. For example, in addition to the carbon nanotube device 2, the carbon nanotube heater 1 may further include another carbon nanotube device that has a similar structure to the carbon nanotube device 2 and is housed inside the housing section 31. . In this case, preferably, the other carbon nanotube device is arranged adjacent to the side of the carbon nanotube device 2, and the heat dissipation section 34 is arranged in a direction perpendicular to the main surface of the connection sheet section 21 of the carbon nanotube device 2. , the entire connection sheet portion 21 of the carbon nanotube device 2 and the entire connection sheet portion of the other carbon nanotube device overlap. Thereby, it is possible to improve temperature uniformity in the connection sheet portion of the plurality of carbon nanotube devices. Note that the carbon nanotube heater 1 may be provided with two heat radiating parts 34 that overlap with the carbon nanotube device 2 and the other carbon nanotube devices, respectively. Furthermore, in the carbon nanotube heater 1 including a plurality of carbon nanotube devices 2, the pair of electrodes 22 of the plurality of carbon nanotube devices 2 are shared, and power is supplied to the plurality of connection sheet parts 21 by the pair of common electrodes. Good too.

The shape of the carbon nanotube heater 1 may be changed in various ways depending on the application. For example, the shape of the carbon nanotube heater 1 in plan view may be other than a substantially rectangular shape. Further, the carbon nanotube heater 1 does not necessarily have to be a thin sheet-like heater, and may be a relatively thick member.

The carbon nanotube device 2 does not necessarily need to be used as a heat source for the carbon nanotube heater 1, and can be used for various purposes. For example, the carbon nanotube device 2 may be used as a thermostat or various sensors.

The configurations of the above embodiment and each modification may be combined as appropriate unless mutually contradictory.

Although the invention has been described and described in detail, the foregoing description is intended to be illustrative and not restrictive. Therefore, it can be said that many modifications and embodiments are possible without departing from the scope of the present invention.

1 Carbon nanotube heater 2 Carbon nanotube device 21 Connection sheet portion 22, 22a, 22b, 22c Electrode 24, 24a to 24c Connection tool 25, 25a, 25b, 25c Measuring electrode 31 Storage portion 34 Heat dissipation portion 42 Rotating body 51 Cylindrical Intermediate 52 Carbon nanotube structure 53 Carbon nanotube sheet layer 92 Substrate 94 Carbon nanotube sheet 212 End element 213 Linear end 221 Main surface (of electrode) 222 Convex portion 223 Folding line 241 Through hole (of connection tool) 421 Connection area J1 Rotating axis S11-S19, S31-S40, S51-S57, S61-S62, S71-S79, S81-S90, S101-S107, S181-S183 Step

Claims (17)

A method for manufacturing a carbon nanotube device, comprising: a pair of electrodes; and a connection sheet portion that is a sheet-like carbon nanotube molded body that connects the pair of electrodes,
a) arranging a pair of electrodes at both ends of a connection region extending in the circumferential direction on the outer surface of the rotating body rotatable about a rotation axis pointing in the axial direction;
b) By rotating the rotating body by the initial number of windings, the carbon nanotube sheet is wound on the outer surface while passing over the pair of electrodes, and the carbon nanotube sheet is radially oriented around the rotating body. forming a laminated cylindrical intermediate;
c) The cylindrical intermediate body is cut outside the connection area in the circumferential direction, and electricity is generated by the laminated sheet-like carbon nanotube structure that is the portion of the cylindrical intermediate body that extends in the circumferential direction in the connection area. measuring the resistance between the pair of electrodes that are connected to each other;
d) If the initial measured resistance, which is the resistance measured in step c) above, is larger than the predetermined target resistance, by rotating the rotating body, the carbon nanotube sheet is passed over the pair of electrodes. Wrapping the carbon nanotube sheet onto the outer surface and laminating the carbon nanotube sheet on the carbon nanotube structure;
e) cutting the carbon nanotube sheet outside the connection area in the circumferential direction to form a connection sheet portion in the form of a laminated sheet extending in the circumferential direction in the connection area;
f) fixing both ends of the connection sheet portion to the pair of electrodes;
A method for manufacturing a carbon nanotube device, comprising: A method for manufacturing a carbon nanotube device, comprising: a pair of electrodes; and a connection sheet portion that is a sheet-like carbon nanotube molded body that connects the pair of electrodes,
a) a step of arranging a pair of electrodes at positions separated in the circumferential direction on the outer surface of a rotating body that is rotatable around a rotating shaft pointing in the axial direction;
b) By rotating the rotating body by the initial number of windings, the carbon nanotube sheet is wound on the outer surface while passing over the pair of electrodes, and the carbon nanotube sheet is radially oriented around the rotating body. forming a laminated cylindrical intermediate;
c) measuring the resistance between the pair of electrodes;
d) If the initial measured resistance, which is the resistance measured in step c) above, is larger than the predetermined target resistance, the carbon nanotube sheet is passed over the pair of electrodes by rotating the rotating body. Wrapping on the outer surface and laminating the carbon nanotube sheet on the cylindrical intermediate body;
e) fixing the carbon nanotube sheet layer stacked on the pair of electrodes to the pair of electrodes;
A method for manufacturing a carbon nanotube device, comprising: A method for manufacturing a carbon nanotube device according to claim 2, comprising:
In the step a), the pair of electrodes are arranged 180° apart in the circumferential direction,
The step e) is
By cutting the carbon nanotube sheet layer and the pair of electrodes at the center of each of the pair of electrodes, a connection sheet portion extending in the circumferential direction between the pair of electrodes is formed, and both ends of the connection sheet portion are cut. fixing the part to the pair of electrodes, or
The pair of electrodes and the cylindrical carbon nanotube sheet layer are removed from the rotating body, the carbon nanotube sheet layer is fixed to the pair of electrodes, and the carbon nanotube sheet layer between the pair of electrodes is stretched in the thickness direction. forming a connection sheet portion connecting between the pair of electrodes by pressing it into a planar shape;
A method for manufacturing a carbon nanotube device, comprising: A method for manufacturing a carbon nanotube device according to any one of claims 1 to 3, comprising:
The number of windings of the carbon nanotube sheet in the step d) is
the initial measured resistance;
Laminated resistance information indicating a relationship between the number of laminated carbon nanotube sheets and resistance;
A method for manufacturing a carbon nanotube device, characterized in that the method is determined based on. A method for manufacturing a carbon nanotube device, comprising: a pair of electrodes; and a connection sheet portion that is a sheet-like carbon nanotube molded body that connects the pair of electrodes,
a) a step of arranging a pair of electrodes at positions separated in the circumferential direction on the outer surface of a rotating body that is rotatable around a rotating shaft pointing in the axial direction;
b) winding the carbon nanotube sheet onto the outer surface while passing over the pair of electrodes by rotating the rotating body while measuring the resistance between the pair of electrodes;
c) forming a carbon nanotube sheet layer stacked on the pair of electrodes by continuing the step b) until the resistance measured in the step b) reaches a predetermined resistance;
d) fixing the carbon nanotube sheet layer to the pair of electrodes;
A method for manufacturing a carbon nanotube device, comprising: A method for manufacturing a carbon nanotube device according to claim 5, comprising:
In the step a), the pair of electrodes are arranged 180° apart in the circumferential direction,
The step d) is:
By cutting the carbon nanotube sheet layer and the pair of electrodes at the center of each of the pair of electrodes, a connection sheet portion extending in the circumferential direction between the pair of electrodes is formed, and both ends of the connection sheet portion are cut. fixing the part to the pair of electrodes, or
The pair of electrodes and the cylindrical carbon nanotube sheet layer are removed from the rotating body, the carbon nanotube sheet layer is fixed to the pair of electrodes, and the carbon nanotube sheet layer between the pair of electrodes is stretched in the thickness direction. forming a connection sheet portion connecting between the pair of electrodes by pressing it into a planar shape;
A method for manufacturing a carbon nanotube device, comprising: A method for manufacturing a carbon nanotube device, comprising: a pair of electrodes; and a connection sheet portion that is a sheet-like carbon nanotube molded body that connects the pair of electrodes,
a) A pair of electrodes are disposed at both ends of a circumferentially extending connection area on the outer surface of a rotating body that is rotatable about a rotating shaft pointing in the axial direction, and the connection is made on the circumferentially outer side of the pair of electrodes. a step of arranging a pair of measurement electrodes at a position sandwiching the region and the pair of electrodes;
b) By rotating the rotating body by the initial number of windings, the carbon nanotube sheet is wound on the outer surface while passing over the pair of electrodes and the pair of measurement electrodes, and around the rotating body. forming a cylindrical intermediate body in which the carbon nanotube sheets are laminated in the radial direction;
c) A laminated sheet in which the cylindrical intermediate body is cut outside the pair of measurement electrodes in the circumferential direction, and the portion of the cylindrical intermediate body extends in the circumferential direction between the pair of measurement electrodes. a step of measuring the resistance between the pair of measurement electrodes electrically connected by a shaped carbon nanotube structure;
d) If the initial measured resistance, which is the resistance between the pair of electrodes determined based on the measured value obtained in step c), is larger than the predetermined target resistance, by rotating the rotating body, Winding a carbon nanotube sheet on the outer surface while passing over the pair of electrodes, and laminating the carbon nanotube sheet on the carbon nanotube structure;
e) cutting the carbon nanotube sheet outside the connection area in the circumferential direction and inside the pair of measurement electrodes to form a connection sheet portion in the form of a laminated sheet extending in the circumferential direction in the connection area; process and
f) fixing both ends of the connection sheet portion to the pair of electrodes;
A method for manufacturing a carbon nanotube device, comprising: A method for manufacturing a carbon nanotube device, comprising: a pair of electrodes; and a connection sheet portion that is a sheet-like carbon nanotube molded body that connects the pair of electrodes,
a) A pair of electrodes are arranged at positions separated in the circumferential direction on the outer surface of a rotating body that is rotatable around a rotating shaft facing in the axial direction, and a pair of measurement electrodes are arranged at positions separated in the circumferential direction. The process of
b) By rotating the rotating body by the initial number of windings, the carbon nanotube sheet is wound on the outer surface while passing over the pair of electrodes and the pair of measurement electrodes, and around the rotating body. forming a cylindrical intermediate body in which the carbon nanotube sheets are laminated in the radial direction;
c) measuring the resistance between the pair of measurement electrodes;
d) If the initial measured resistance, which is the resistance between the pair of electrodes determined based on the measured value obtained in step c), is larger than the predetermined target resistance, by rotating the rotating body, Winding the carbon nanotube sheet on the outer surface while passing over the pair of electrodes, and laminating the carbon nanotube sheet on the cylindrical intermediate body;
e) fixing the carbon nanotube sheet layer stacked on the pair of electrodes to the pair of electrodes;
A method for manufacturing a carbon nanotube device, comprising: A method for manufacturing a carbon nanotube device according to claim 8, comprising:
In the step a), the pair of electrodes are arranged 180° apart in the circumferential direction,
The step e) is
By cutting the carbon nanotube sheet layer and the pair of electrodes at the center of each of the pair of electrodes, a connection sheet portion extending in the circumferential direction between the pair of electrodes is formed, and both ends of the connection sheet portion are cut. fixing the part to the pair of electrodes, or
The pair of electrodes and the cylindrical carbon nanotube sheet layer are removed from the rotating body, the carbon nanotube sheet layer is fixed to the pair of electrodes, and the carbon nanotube sheet layer between the pair of electrodes is stretched in the thickness direction. forming a connection sheet portion connecting between the pair of electrodes by pressing it into a planar shape;
A method for manufacturing a carbon nanotube device, comprising: A method for manufacturing a carbon nanotube device according to any one of claims 7 to 9, comprising:
The number of windings of the carbon nanotube sheet in the step d) is
the initial measured resistance;
Laminated resistance information indicating a relationship between the number of laminated carbon nanotube sheets and resistance;
A method for manufacturing a carbon nanotube device, characterized in that the method is determined based on. A method for manufacturing a carbon nanotube device, comprising: a pair of electrodes; and a connection sheet portion that is a sheet-like carbon nanotube molded body that connects the pair of electrodes,
a) A pair of electrodes are arranged at positions separated in the circumferential direction on the outer surface of a rotating body that is rotatable around a rotating shaft facing in the axial direction, and a pair of measurement electrodes are arranged at positions separated in the circumferential direction. The process of
b) By rotating the rotating body while measuring the resistance between the pair of measurement electrodes, the carbon nanotube sheet is passed over the pair of electrodes and over the pair of measurement electrodes and onto the outer surface. The process of winding;
c) laminating on the pair of electrodes by continuing the step b) until the resistance between the pair of electrodes determined based on the measured value obtained in the step b) reaches a predetermined resistance; forming a carbon nanotube sheet layer;
d) fixing the carbon nanotube sheet layer to the pair of electrodes;
A method for manufacturing a carbon nanotube device, comprising: A method for manufacturing a carbon nanotube device according to claim 11, comprising:
In the step a), the pair of electrodes are arranged 180° apart in the circumferential direction,
The step d) is:
By cutting the carbon nanotube sheet layer and the pair of electrodes at the center of each of the pair of electrodes, a connection sheet portion extending in the circumferential direction between the pair of electrodes is formed, and both ends of the connection sheet portion are cut. fixing the part to the pair of electrodes, or
The pair of electrodes and the cylindrical carbon nanotube sheet layer are removed from the rotating body, the carbon nanotube sheet layer is fixed to the pair of electrodes, and the carbon nanotube sheet layer between the pair of electrodes is stretched in the thickness direction. forming a connection sheet portion connecting between the pair of electrodes by pressing it into a planar shape;
A method for manufacturing a carbon nanotube device, comprising: A method for manufacturing a carbon nanotube device according to any one of claims 7 to 12, comprising:
A method for manufacturing a carbon nanotube device, characterized in that an adhesive is applied on the pair of measurement electrodes between the step a) and the step b). A method for manufacturing a carbon nanotube device according to claim 13, comprising:
A method for manufacturing a carbon nanotube device, wherein the adhesive is a paste-like rosin. A method for manufacturing a carbon nanotube device according to any one of claims 1 to 4 and claims 7 to 10 ,
Before the step b), a target number of windings corresponding to the target resistance is determined based on laminated resistance information indicating a relationship between the number of laminated carbon nanotube sheets and the resistance;
A method of manufacturing a carbon nanotube device, wherein the initial number of turns is set to be smaller than the target number of turns. A method for manufacturing a carbon nanotube device according to any one of claims 1 to 15, comprising:
A method of manufacturing a carbon nanotube device, characterized in that an adhesive is applied to the carbon nanotube sheet wound around the rotating body. A method for manufacturing a carbon nanotube device according to claim 16, comprising:
A method for manufacturing a carbon nanotube device, wherein the adhesive contains a conductive additive.

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