CN101578913A - Sheet heating element - Google Patents

Abstract

The sheet heating element according to the present invention comprises a substrate sheet made of an electrically insulative material and lines made of electrically conductive materials and arranged with a distance between them on the substrate sheet. The sheet heating element further comprises at least one PTC resistor sheet being in electrical contact with the lines and configured to heat up in a self-regulated manner in response to a supply of electricity from the lines. The at least one PTC resistor sheet may comprise a flame retardant agent and/or a liquid-resistant resin. The sheet heating element according to the present invention has excellent flexibility, durability, and reliability, as well as low manufacturing cost. When the sheet heating element of the present invention is used in a car seat heater or in a steering wheel heater, the passenger feels comfortable when seated thereon, and the driver feels comfortable when touching the steering wheel.

Description

Sheet heating element

Technical field

The present invention relates to a kind of heater element, particularly, the present invention relates to a kind of sheet heating element (sheet heating element) with good ptc characteristics.This sheet heating element has the characteristic of highly flexible, so that it can be installed on the surface of utensil of Any shape.

Background technology

Ptc characteristics is meant the characteristic that resistance increases thereupon when temperature raises.Sheet heating element with this ptc characteristics has the temp autocontrolled performance to its heat of launching.Up to now, in the generating component of this sheet heating element, use resistor.This resistor is formed by resistor ink, and this resistor ink has matrix polymer and the electric conducting material that is dispersed in the solvent.

This resistor ink is printed on the basis material that forms heater element.This China ink is dried, and is cured then, thereby forms chip resistor (for example, referring to patent documentation 1, patent documentation 2 and patent documentation 3).This resistor generates heat by conduct electricity.The electric conducting material that uses in this resistor typically is carbon black, metal dust, graphite etc.Typically crystalline resin is used as matrix polymer.The sheet heating element that is formed by these materials presents ptc characteristics.

Figure 1A is the plan view of the sheet heating element of the prior art of description in patent documentation 1.In order to illustrate, this figure has provided the transparent view that can see the internal structure of this heater element.Figure 1B is the cross sectional view along the intercepting of the line 1B-1B among Figure 1A.As shown in Figure 1A and Figure 1B, sheet heating element 10 is formed by substrate 11, electrode pair 12 and 13, polymer resistive device 14 and cladding material 15.Electrode 12 and 13 forms the pectination shape.Substrate 11 is the materials with electrical insulation characteristics, and it is formed by resin, for example, is polyester film.

Conducting resinl by printing such as elargol in substrate 11 makes its drying then, forms electrode 12,13.Polymer resistive device 14 forms with comb electrode 12,13 and electrically contacts, and by these electrode power supplies.Polymer resistive device 14 has ptc characteristics.Polymer resistive device 14 is formed by polymer resistive device China ink, and print the position that electrically contacts and drying should China ink forming with electrode 12 and 13 in substrate.Cladding material 15 is formed by the material with substrate 11 identical type, and by coated electrode 12 and 13 and polymer resistive device 14 protect them.

Polyester film is used as under the situation of substrate 11 and cladding material 15 therein, makes the hot-melt resin 16 such as modified polyethylene be adhered to cladding material 15 in advance.Then, when heating, substrate 11 and cladding material 15 are exerted pressure.Therefore, substrate 11 and cladding material 15 are engaged.Cladding material 15 and hot-melt resin 16 make electrode 12 and 13 and polymer resistive device 14 isolate with external environment condition.The reliability that therefore, can keep sheet heating element 10 for a long time.

Fig. 2 illustrates the cross-sectional of the structure of the equipment that applies cladding material 15.As shown in this Fig, the laminating machine 22 that is formed with two hot- rollings 20,21 is carried out hot compression.In this technology, substrate 11 and cladding material 15 are placed on the top of each other, and supply to laminating machine 22, wherein in substrate 11, be formed with electrode 12,13 and polymer resistive device 14 in advance, hot-melt resin 16 is applied on the cladding material 15 in advance.Utilize hot-rolling 20,21 hot compression substrates 11 and cladding material 15, thereby be formed as one unit sheet heating element 10.

The polymer resistive utensil of Xing Chenging has ptc characteristics by this way, and because temperature raises, and resistance value increases, when reaching specified temp, resistance value significantly increases.Because polymer resistive device 14 has ptc characteristics, sheet heating element 1010 has temp autocontrolled function.

Patent documentation 2 discloses a kind of PTC composition that is formed by amorphous polymer, crystalline polymer particle, conductive black, graphite and inorganic filler.This PTC composition is dispersed in the organic solvent, thereby makes China ink.Then, this China ink is printed on the resin molding with electrode, thereby makes the polymer resistive device.In addition, execution heat treatment is crosslinked to realize.On the polymer resistive device, deposit resin molding as protective layer, thereby finish sheet heating element.This sheet heating element of patent documentation 2 has and the identical PTC heat generation characteristic of sheet heating element in the patent documentation 1.

Fig. 3 is illustrated in the cross sectional view of the sheet heating element of another prior art of describing in the patent documentation 3.As shown in Figure 3, sheet heating element 30 has pliability substrate 31.By printing, depositing electrode 32 and 33 and polymer resistive device 34 successively in this pliability substrate 31.Then, on its top, form pliability cover layer 35.Substrate 31 has gas barrier (gas-barrier) characteristic and fire resistance characteristic.Substrate 31 comprises and comprises long stapled polyester non-textile (non-wovenfabric), and is engaged on the surface of this polyester non-textile such as the hot melt film of polyurethane-type.Can use liquid, for example polymer resistive device China ink floods substrate 31.

Cover layer 35 comprises the polyester non-textile, and is engaged on the surface of this polyester non-textile such as the hot melt film of polyester-type.Cover layer 35 also has gas barrier properties and fire resistance characteristic.Cover layer 35 is adhered to substrate 31, the integral body of coated electrode 32,33 and polymer resistive device 34.The sheet heating element 30 of patent documentation 3 is done as a wholely to be formed by six layers.This sheet heating element 30 of patent documentation 3 also have with patent documentation 1 in identical PTC heat generation characteristic.

In the sheet heating element 10 of the prior art of patent documentation 1 and patent documentation 2, use rigid material such as polyester film as substrate 11.In addition, the heater element 10 of prior art has the five-layer structure that forms of comb electrode 12 and 13, polymer resistive device 14, its cladding material 15 that is provided with adhesive phase by substrate 11, printing on it.Along with its thickness increases, sheet heating element 10 loses pliability.When using so flexible sheet heating element 10 of shortage as the seat heater, passenger's ride quality is by compromise.When using the flexible sheet heating element 10 of such shortage in steering wheel heater, the grasping comfort is by compromise.

Because heater element 10 be sheet, for example, when taking thereon as seat heater and passenger, power extends to whole heater element, heater element 10 its shapes of change.Typically, the closer to the edge of heater element 10, the value of deformation is big more.Thereby, on heater element, form gauffer unevenly.These gauffers will cause the crackle in comb electrode 12,13 and polymer resistive device 14.Therefore, think that such heater element has low durability.

The polyester sheet that uses in substrate 11 and cladding material 15 does not have gas permeability.Therefore, when using heater element 10 in the seat heater or in steering wheel heater, the liquid that passenger or driver discharge is assembled easily therein.Drive for a long time or take and become very uncomfortable.

On the other hand, under the situation of the sheet heating element 30 of patent documentation 3, electrode 32 and 33, polymer resistive device 34, substrate 31 and cover layer 35 are flexible, therefore, when being used for the seat heater or being used for steering wheel heater, take or the touch direction dish is comfortable.Yet,, have the low and high shortcoming of cost of the productive rate of manufacturing because sheet heating element 30 is formed by six layers.

Patent documentation 1: Japanese Patent Application Publication No.S56-13689

Patent documentation 2: Japanese Patent Application Publication No.H8-120182

Patent documentation 3: U.S. Patent No. 7049559

Summary of the invention

The invention solves these problems of prior art, and will provide sheet heating element as its purpose with good pliability, durability and reliability and low manufacturing cost.When using sheet heating element of the present invention in the seat heater or in steering wheel heater, the passenger feels comfortable when taking, and the driver feels comfortable when the touch direction dish.

Sheet heating element according to the present invention comprises: substrate sheet (substrate sheet), and it is made by electrical insulating material; And circuit, it is made by electric conducting material, and is set to have spacing on the described substrate sheet between described circuit.Described sheet heating element also comprises at least one PTC resistor sheet, and described PTC resistor sheet (resistor sheet) contacts with described line electricity and is configured in the self-regulation mode in response to supplying with from the electricity of described circuit and generating heat.

The thickness of described at least one PTC resistor sheet is the 20-200 micron, perhaps preferred 30-100 micron.

Described at least one PTC resistor sheet comprises resinous principle and electric conducting material.Described resinous principle comprise reaction resin (reactant resin) and with the crosslinked reactive resin of described reaction resin.Described electric conducting material comprises at least a in carbon black and the graphite.Described at least one PTC resistor sheet can be by hot melt electrically contacting with realization and described circuit.

Described at least one PTC resistor sheet has scope in the resistivity between 0.0011 Ω m and 0.0078 Ω m between 0.0007 Ω m and the 0.016 Ω m or preferably.

Described at least one PTC resistor sheet comprises fire retardant.Described fire retardant comprises fire retardant based on phosphorus, based on the fire retardant of nitrogen, fire retardant, inorganic combustion inhibitor and at least a based in the fire retardant of halogen based on siloxanes (silicone).Described fire retardant with more than the 5 weight %, preferably 10-30 weight % or optimally the content of 15-25 weight % be included in described at least one PTC resistor sheet.Owing to comprise fire retardant, at least one during described at least one PTC resistor sheet meets the following conditions:

(a) when with an end of described at least one the PTC resistor sheet of bluster burning and when extinguishing described bluster after 60 seconds, even described at least one PTC resistor sheet is burnt, described at least one PTC resistor sheet does not burn yet;

(b) when with an end of described at least one the PTC resistor sheet of bluster burning, described at least one PTC resistor sheet catches fire and was no more than for 60 seconds, but flame extinguishes in 2 inches; Perhaps

(c) when with an end of described at least one the PTC resistor sheet of bluster burning, even described at least one PTC resistor sheet catches fire, in 1/2 inch thick zone, distance surface, flame does not spread with the speed more than the 4 inch per minute clocks yet.

Described at least one PTC resistor sheet comprises anti-liquid resin.Described anti-liquid resin comprises ethylene/vinyl alcohol copolymer, thermoplastic polyester, polyamide, acrylic resin or ionomer (ionomer) or their combination.Described anti-liquid resin is with more than the 10 weight %, preferably 10-70 weight % or optimally the content of 30-50 weight % be included in described at least one PTC resistor sheet.

Described circuit is stitched on the described substrate sheet.The diameter of described circuit is equal to or less than 1mm, or preferably is equal to or less than 0.5mm, and its resistivity (Ω/m) that is equal to or less than 1.The electric conducting material that forms described circuit can be the copper or the copper-silver alloy of copper, tin plating.Described circuit is with the spacing setting of about 70-150mm.

Described at least one PTC resistor sheet presents the elasticity higher than substrate sheet, and under less than the load of 7kgf extensible extent greater than 5%.

Described substrate sheet is made by the non-weaving or the textile that form from the polyester fiber with the pin perforation.Described sheet heating element also comprises emulsion sheet (cover sheet), and described emulsion sheet is made by electrical insulating material, and cooperates to surround described circuit and described at least one PTC resistor sheet with described substrate sheet.Described emulsion sheet is made by the non-weaving or the textile that form from polyester fiber.In described substrate sheet and the described emulsion sheet at least one comprises fire retardant.

In sheet heating element according to the present invention, described circuit can be arranged between described at least one PTC resistor sheet and the described substrate sheet.In replacement scheme, described at least one PTC resistor sheet is arranged between described circuit and the described substrate sheet.

Also comprise anti-liquid film according to sheet heating element of the present invention.Described anti-liquid film can comprise ethylene/vinyl alcohol copolymer, thermoplastic polyester, polyamide, acrylic resin or ionomer or their combination.The thickness of described anti-liquid film is the 5-100 micron, perhaps is preferably the 10-50 micron.Described anti-liquid film is arranged between described at least one PTC resistor sheet and the described substrate sheet.Described anti-liquid film can comprise fire retardant.

In the described circuit at least one extends in the waveform mode.Described circuit so is set, so as more than two circuits to each power supply in described at least one PTC resistor sheet.

Also can comprise conducting film according to sheet heating element of the present invention, described conducting film is arranged between described circuit and described at least one PTC resistor sheet, and allows described circuit to slide thereon.Described conducting film is made by oildag or the resin compound that comprises graphite.

Described at least one PTC resistor sheet comprises non-weaving or the textile with PTC resistor material dipping.

Sheet heating element according to the present invention also comprises the coverlay of being made by thermoplastic elastomer (s).Described coverlay can be by making based on the thermoplastic elastomer (s) of polyolefinic thermoplastic elastomer (s), styrene-based or based on the thermoplastic elastomer (s) of urethanes or their combination.

In described substrate sheet and described at least one PTC resistor sheet at least one can be formed with a plurality of slits (slit) or a plurality of breach (notch).

Description of drawings

Figure 1A is the transparent flat view of the sheet heating element of prior art.

Figure 1B is the cross sectional view at the sheet heating element shown in Figure 1A.

Fig. 2 is the cross-sectional of example of structure of manufacturing equipment of the sheet heating element of prior art.

Fig. 3 is the cross sectional view of the sheet heating element of another prior art.

Fig. 4 A is the plan view of the sheet heating element of embodiments of the invention 1.

Fig. 4 B is the cross sectional view at the sheet heating element shown in Fig. 4 A.

Fig. 4 C is a cross sectional view of revising embodiment at first of the sheet heating element shown in Fig. 4 A.

Fig. 4 D is a cross sectional view of revising embodiment at second of the sheet heating element shown in Fig. 4 A.

Fig. 5 A is the transparent transverse views that the sheet heating element of embodiments of the invention 1 is attached to the seat on it.

Fig. 5 B is the transparent front view that is shown in the seat of Fig. 5 A.

Fig. 6 A and Fig. 6 B are the figure of the embodiment 1 of the polymer resistive device that uses in the present invention.

Fig. 6 C and Fig. 6 D are the figure of the embodiment 2 of the polymer resistive device that uses in the present invention.

Fig. 7 A is the plan view of the sheet heating element of embodiments of the invention 2.

Fig. 7 B is the cross sectional view at the sheet heating element shown in Fig. 7 A.

Fig. 7 C is a cross sectional view of revising embodiment at first of the sheet heating element shown in Fig. 7 A.

Fig. 7 D is a cross sectional view of revising embodiment at second of the sheet heating element shown in Fig. 7 A.

Fig. 8 A is the plan view of the sheet heating element of embodiments of the invention 3.

Fig. 8 B is the cross sectional view at the sheet heating element shown in Fig. 8 A.

Fig. 8 C is a cross sectional view of revising embodiment at first of the sheet heating element shown in Fig. 8 A.

Fig. 8 D is a cross sectional view of revising embodiment at second of the sheet heating element shown in Fig. 8 A.

Fig. 9 A is the plan view of the sheet heating element of embodiments of the invention 4.

Fig. 9 B is the cross sectional view at the sheet heating element shown in Fig. 9 A.

Fig. 9 C is a cross sectional view of revising embodiment at first of the sheet heating element shown in Fig. 9 A.

Fig. 9 D is a cross sectional view of revising embodiment at second of the sheet heating element shown in Fig. 9 A.

Figure 10 A is the plan view of the sheet heating element of embodiments of the invention 5.

Figure 10 B is the cross sectional view at the sheet heating element shown in Figure 10 A.

Figure 10 C is a cross sectional view of revising embodiment at first of the sheet heating element shown in Figure 10 A.

Figure 10 D is a cross sectional view of revising embodiment at second of the sheet heating element shown in Figure 10 A.

Figure 11 A is the plan view of the sheet heating element of embodiments of the invention 6.

Figure 11 B is the cross sectional view at the sheet heating element shown in Figure 11 A.

Figure 11 C is a cross sectional view of revising embodiment at first of the sheet heating element shown in Figure 11 A.

Figure 11 D is a cross sectional view of revising embodiment at second of the sheet heating element shown in Figure 11 A.

Figure 12 A is the plan view of the sheet heating element of embodiments of the invention 7.

Figure 12 B is the cross sectional view at the sheet heating element shown in Figure 12 A.

Figure 12 C is a cross sectional view of revising embodiment at first of the sheet heating element shown in Figure 12 A.

Figure 13 A is the plan view of the sheet heating element of embodiments of the invention 8.

Figure 13 B is the cross sectional view at the sheet heating element shown in Figure 13 A.

Figure 13 C is a cross sectional view of revising embodiment at first of the sheet heating element shown in Figure 13 A.

Figure 13 D is a cross sectional view of revising embodiment at second of the sheet heating element shown in Figure 13 A.

Figure 14 A is the plan view of the sheet heating element of embodiments of the invention 9.

Figure 14 B is the cross sectional view at the sheet heating element shown in Figure 14 A.

Figure 14 C is a cross sectional view of revising embodiment at first of the sheet heating element shown in Figure 14 A.

Figure 14 D is a cross sectional view of revising embodiment at second of the sheet heating element shown in Figure 14 A.

Embodiment

Below, embodiments of the invention are described with reference to the accompanying drawings.It should be noted that and the invention is not restricted to these embodiment.And, can suitably make up the structure specific to each embodiment.

The embodiment 1 of sheet heating element

Below an embodiment of the sheet heating element of above-mentioned polymer resistive device is used in explanation.Fig. 4 A is the plan view of the embodiment 1 of sheet heating element of the present invention, and Fig. 4 B is the cross sectional view along the sheet heating element of Fig. 4 A of line 4B-4B intercepting.

Sheet heating element 40 comprises dielectric base 41, the first line electrode 42A, the second line electrode 42B and polymer resistive device 44.Line electrode 42A, 42B are collectively referred to as line electrode 42 sometimes.With line 43 line electrode 42 is sewn onto on the dielectric base 41.Form hot sticky agglomeration compound resistor 44 on the top of this structure with film.

Make sheet heating element 40 in the following manner.At first, left and right symmetrically is provided with line electrode 42A, 42B on dielectric base 41.Next, with line 43 line electrode 42A, 42B partly are sewn onto on the dielectric base 41.Then, for example, use T mould extruding machine (T-die extruder), on dielectric base 41 with polymer resistive device 44 extrusion film forming.Afterwards, with laminating machine welding (melt-adhere) polymer resistive device 44 and it is attached on the dielectric base 41.

Thickness to polymer resistive device 44 is not particularly limited, and still, during intensity when considering pliability, material cost, suitable resistance value and applying load, the thickness of 20-200 micron is suitable, the thickness of preferred 30-100 micron.

After polymer resistive device 44 being fused on line electrode 42 and the dielectric base 41, to the core perforation of sheet heating element.The perforated position of core is not limited to the position shown in the figure.Have such situation, wherein the perforation to core is that this depends on application in other positions.For fear of perforation, must adjust the wiring figure of line electrode 42.

For example, in the seat heater, use above-mentioned sheet heating element 40.In this case, as shown in Figure 5A and 5B, on the backrest 51 that sheet heating element 40 is attached on the seat part 50 and is provided with in mode from seat part 50 protuberances.Seat part 50 and backrest 51 have seat basis material 52 and cover the cover for seat 53 of seat basis material 52.Seat basis material 52 is formed by the flexible material such as urethane pad, and changes its shape when applying load by the people who takes, and recovers its original shape when load removes.Set up sheet heating element 40 to seat basis material 52 and dielectric base 41 towards the mode of cover for seat 53 with polymer resistive device 44 sides.

Because sheet heating element 40 has ptc characteristics, therefore, because the temperature fast rise, the energy that expends seldom.There is not the heater element of ptc characteristics that extra temperature controller must be arranged.This extra temperature controller is controlled heating temp by turning on and off electric current.Especially, when heater element has the circuit heat ray, there are a plurality of low-temperature sections between the online ray hot in nature.In order to reduce these low-temperature sections as much as possible, under the situation of the heater element that does not have ptc characteristics, heating temp is increased to about 80 ℃ during connection.Thus, there is not the heater element of ptc characteristics must be set at the interior degree of depth place of seat apart from cover for seat 53 certain distances.

Comparatively speaking, under the situation of the sheet heating element 40 with ptc characteristics, heating temp is controlled in 40 ℃-45 ℃ the scope automatically.Because heating temp remains lowlyer in such sheet heating element 40, it can be set near cover for seat 53.In addition, because heater element is arranged near the cover for seat 53, it can send heat to take passenger fast.And,, can reduce energy consumption because the heating temp maintenance is lower.

Next further specify the detailed structure of sheet heating element 43 of the present invention.Fig. 6 A-Fig. 6 D is illustrated in the example of the polymer resistive device 44 that uses in the sheet heating element of the present invention.Fig. 6 A and Fig. 6 B illustrate the polymer resistive device 44 of the graininess conductor of use such as carbon black.Fig. 6 C and Fig. 6 D illustrate the polymer resistive device that uses the fiber conductor.Fig. 6 A and 6C illustrate the internal structure of polymer resistive device 44 at room temperature, and Fig. 6 C and 6D illustrate when the internal structure of temperature when the state shown in Fig. 6 A and the 6B raises.

Polymer resistive device 44 shown in Fig. 6 A and Fig. 6 B has the graininess conductor 60 such as carbon black.Graininess conductor 60 forms some contact in resinous principle 62, thereby forms conductive path.When applying electric current between electrode 42A and 42B, electric current flows through graininess conductor 60, thus 44 heating of polymer resistive device.Along with 44 heating of polymer resistive device, resinous principle 62 expansions.Thus, as shown in Fig. 6 B, the electric pathway that is produced by graininess conductor 60 is cut off.As a result, the resistivity of polymer resistive device 44 significantly increases.

Polymer resistive device 44 shown in Fig. 6 C and Fig. 6 D uses fiber conductor 61 as conductor.These fiber conductors 61 are positioned at resinous principle 62 and vertically go up on the top of each other.When between electrode 42A and 42B, applying electric current, this also heating of polymer resistive device 44, and along with its heating, the resistivity of polymer resistive device 44 significantly increases.

The fiber conducting polymer that the example of fiber conductor 61 comprises the conductive ceramic fibers made by the titanium oxide that mixes with antimony of tin plating, form based on the glass fibre that is formed with the metal-plated of conductive layer on conductivity ceramics antenna, copper or the aluminum metal fiber of potassium titanate, its surface, carbon fiber, carbon nano-tube or by polyaniline etc.And, can use thin slice (flake) conductor to come alternative fiber conductor 61.The example of slice conductor comprises sheet metal or the flake graphite such as the ceramic sheet of the splitting that is formed with conductive layer in its surface, copper or aluminium etc.

Above-mentioned conductor can use or mix two or more uses separately, suitably selects this conductor according to desirable ptc characteristics.

By mixing present ptc characteristics reaction resin and with this reaction resin reactive activity resin, form the resinous principle 62 of polymer resistive device 44.Reaction resin is preferably the modified poly ethylene with carboxyl.Reactive resin is preferably the modified poly ethylene with epoxy radicals.By they are mixed, the carbonyl in the reaction resin and the oxidation bonding of the epoxy radicals in the reactive resin, thereby the polymer resistive device within it portion have cross-linked structure.

Only compared by the situation that reaction resin forms with resinous principle 62 wherein, because this cross-linked structure, the temperature characterisitic and the fusion temperature characteristic of the thermal expansion ratio of polymer resistive device 44 are more stable.Because reactive resin and reaction resin are because of the firm bonding of cross-linked structure, even cooling off repeatedly and heating and cause under the condition of thermal expansion repeatedly and thermal contraction, the polymer resistive device also keeps the temperature characterisitic and the fusion temperature characteristic of thermal expansion ratio, thereby suppresses the As time goes on temperature characterisitic of thermal expansion ratio and the variation of fusion temperature characteristic.In other words, even As time goes on, polymer resistive device 44 still keeps the temperature characterisitic of constant thermal expansion ratio and constant fusion temperature characteristic.

Except by the oxygen, can also this cross-linking reaction take place by nitrogen.If by mix the reactive resin that comprises functional group with oxygen at least or nitrogen and have can with the reaction resin of the functional group of this functional group reactions, cross-linking reaction then takes place.Provide the example except above-mentioned epoxy radicals and carbonyl of the functional group of the functional group of reactive resin and reaction resin below.

Except carbonyl, the example of the functional group of reaction resin comprises that (in additionpolymerization) epoxy radicals, carboxyl, ester group, hydroxyl, amino, vinyl, maleic anhydride base, Yi of addition polymerization are Ji oxazolinyl.Except epoxy radicals, the example Bao Kuo oxazolinyl and the maleic anhydride base of the functional group of reactive resin.

Because the seat heater need heating under 40-50 ℃ low relatively heating temp, therefore, the reaction resin that presents ptc characteristics can be preferably the olefin resin of low-melting modification, for example ethylene, ethylene/ethyl acrylate copolymer, ethylene/methacrylic acid methyl terpolymer, ethylene/methacrylic acid, ethylene/butylacrylate copolymer or other ester type ethylene copolymers.

Not necessarily need by stirring hybrid reaction resin and reactive resin to prepare resinous principle 62.Even use reaction resin itself, also can present ptc characteristics.Therefore, ptc characteristics changes to a certain extent if allow as time passes, then can use reaction resin itself.When using reaction resin itself, come the suitably kind of choice reaction resin according to desirable ptc characteristics value.

In the above description, make the reaction of reactive resin and reaction resin, so that the reaction resin of resinous principle 62 has cross-linked structure.Yet, can use the crosslinking agent different with reactive resin.And, can also not use reactive resin, but, in reaction resin, form cross-linked structure by with electron beam radioreaction resin.In this case, can use reaction resin with above-mentioned functional group.

Because polymer resistive device 44 is flexible membranes, when sheet heating element 40 was applied external force, polymer resistive device 44 stretched in the mode identical with dielectric base 41 and changes its shape.Polymer resistive device 44 should be identical with the pliability of dielectric base 41, and is perhaps more pliable and tougher than dielectric base 41.If polymer resistive device 44 is identical or more pliable and tougher than dielectric base 41 with the pliability of dielectric base 41, then the durability of polymer resistive device 44 and reliability improve, this be because, dielectric base 41 has the mechanical strength bigger than polymer resistive device 44, and when applying external force, dielectric base 41 is used for the stretching or the alteration of form of limit polymerization thing resistor 44.

If use polymer resistive device 44 in the seat heater, for polymer resistive device 44, comprising fire retardant can be more favourable.The seat heater must satisfy the flammability standards of U.S. FMVSS 302.Particularly, it must satisfy in the following condition any one:

(1) when with an end of bluster burning polymer resistive device 44 and when extinguishing this bluster after 60 seconds, even polymer resistive device 44 is burnt, this polymer resistive device 44 itself does not burn yet.

(2) when with an end of bluster burning polymer resistive device 44, polymer resistive device 44 catches fire and was no more than for 60 seconds, but flame extinguishes in 2 inches.

(3) when with an end of bluster burning polymer resistive device 44, even polymer resistive device 44 catches fire, in 1/2 inch thick zone, distance surface, flame does not spread with the speed more than the 4 inch per minute clocks.

Incombustibility is defined as follows.With 60 seconds an of end of bluster burning sample.When extinguishing this flame after 60 seconds, even residual on this sample have a residue that is burnt, this sample does not burn yet.Self-gravitation is meant that sample catches fire and was no more than for 60 seconds, and the part of being burnt is in 2 inches.

Fire retardant can for: based on the fire retardant of phosphorus, for example ammonium phosphate or tricresyl phosphate; Based on nitrogen compound, for example melamine, guanidine or dicyandiamidines; Or based on the compound of siloxanes; Or the combination of these fire retardants.Can use such as the inorganic combustion inhibitor of magnesium oxide or antimony trioxide or such as based on bromine or based on the fire retardant based on halogen of the compound of chlorine.

If fire retardant at room temperature is a liquid, perhaps have such fusing point, so that it melts under mixing temperature, advantageous particularly then.Can by use based on phosphorus, based on ammonia or at least a based in the compound of siloxanes, improve the pliability of polymer resistive device 44, thereby improve the mechanical robustness and the pliability of sheet heating element.

The amount of following definite fire retardant that is added.If there is fire retardant seldom, the incombustibility variation can not satisfy any in the above-mentioned condition of incombustibility.Given this, the amount with respect to polymer resistive device 44 of the fire retardant that is added should be more than the 5 weight %.Yet, when the amount of fire retardant increases, resinous principle 62 be included in wherein conductor 60 or the balanced composition variation between the conductor 61, the resistivity increase of polymer resistive device 44, thereby ptc characteristics variation.Given this, the amount with respect to polymer resistive device 44 of the fire retardant that is added is preferably 10-30 weight %, and optimum is 15-25 weight %.

It is favourable adding anti-liquid resin in polymer resistive device 44, thereby makes polymer resistive device 44 have anti-fluidity.Anti-fluidity prevents polymer resistive device 44 owing to contact and deterioration with the aqueous chemical thing, these aqueous chemical things are, for example comprise engine oil, such as the polar oil of brake oil and other oily inorganic oils or such as the low molecular weight solvent of diluent and other organic solvents.

When polymer resistive device 44 contacted with the aforesaid liquid chemicals, the resinous principle 62 that comprises a large amount of noncrystalline resins is expansion and change in volume easily, so that the conductive path of conductor is cut off, and resistance increases.This phenomenon is equal to the volume (or ptc characteristics) that is caused by heat and changes.When polymer resistive device 44 contacts with the aforesaid liquid chemicals,, can not recover the initial electrical resistivity value even after the liquid dried.Even resistivity value recovers, recover also to want spended time.

In order to make polymer resistive device 44 have anti-fluidity, in polymer resistive device 44, add the anti-liquid resin of highly crystalline, so that resinous principle 62 and conductor 60,61 partly are chemically bonded on this anti-liquid resin.As a result, even polymer resistive device 44 contacts with the aforesaid liquid chemicals, also can suppress the expansion of resinous principle 62.

Anti-liquid resin comprises and is selected from least a in ethylene/vinyl alcohol copolymer, thermoplastic polyester, polyamide, acrylic resin or the ionomer, perhaps can use the combination of these anti-liquid resins.These anti-liquid resins not only make polymer resistive device 44 have anti-fluidity, and they play a part also to prevent that the pliability of resinous principle 62 from reducing.In other words, these anti-liquid resins keep the pliability of polymer resistive device 44.

The amount of the anti-liquid resin that is added is preferably more than the 10 weight % with respect to the resinous principle in the polymer resistive device 44 62.Thereby the anti-fluidity of polymer resistive device 44 improves.Yet when existence is prevented the liquid resin in a large number, polymer resistive device 44 itself will harden, and its pliability will reduce.And conductor will be captured in the anti-liquid resin, even conductive path also almost can not be cut off when temperature raises, thereby ptc characteristics will finally reduce.Therefore, for the pliability that keeps the polymer resistive device and keep favourable ptc characteristics, the amount of anti-liquid resin is preferably in the scope of 10-70 weight %, and is optimum in the scope of 30-50 weight %.

Carry out following test, to investigate the effect of above-mentioned anti-liquid resin.At first, preparation does not comprise the polymer resistive device 44 of anti-liquid resin, and preparation comprises a plurality of polymer resistive devices 44 of different anti-liquid resins (50 weight %) respectively.The aforesaid liquid chemicals are dripped on these polymer resistive devices 44, and they were shelved 24 hours.These polymer resistive devices 44 were applied electric current after 24 hours, they were at room temperature shelved 24 hours.Before test and measure the resistivity value of these polymer resistive devices afterwards.The polymer resistive device 44 of finding not comprise anti-liquid resin demonstrate with test before compare and improved 200-300 resistivity doubly.

Comparatively speaking, comprise in the polymer resistive device 44 of anti-liquid resin, and compare resistivity before the test and increased and be not more than 1.5-3 doubly at all.This test shows is added the expansion that anti-liquid resin can suppress to form the resinous principle 62 of polymer resistive device 44 in polymer resistive device 44, this expansion causes by contacting with aqueous chemical thing such as organic solvent or beverage.In other words, by in polymer resistive device 44, adding anti-liquid resin, can make the resistivity of polymer resistive device 44 stable, and sheet heating element can have high-caliber durability.

In two row, a pair of line electrode 42A, the 42B that faces with each other and be provided with is being set on the longitudinal direction of sheet heating element 40.Polymer resistive device 44 so is set, so that cover this respectively on line electrode 42A, the 42B.When from line electrode 42A, 42B during to polymer resistive device 44 power supply, electric current flows to polymer resistive device 44, thus 44 heatings of polymer resistive device.

Utilize polyester line 43, use quilting machine that line electrode 42 is sewn onto on the dielectric base 41.Thus, line electrode 42 is invested on the dielectric base 41 securely, makes it and change its shape along with dielectric base 41 change shapes, thereby improves the Mechanical Reliability of sheet heating element.

Line electrode 42 by metallic conductor line at least and/or wherein the stranded metallic conductor line that twists together of metallic conductor line form.The metallic conductor wire material can be the copper or the copper-silver alloy of copper, tin plating.From the viewpoint of mechanical strength, favourable when using copper-silver alloy, this is because it has high tensile strength.Particularly, twist together, form line electrode 42 by the copper-silver alloy line that has 0.05 micron diameter with 19.

The resistance of line electrode 42 should be low as far as possible, and should be very little along the voltage drop of line electrode 42.Like this resistance of selection wire electrode 42 is so that the voltage of the voltage that sheet heating element is applied is reduced to below the 1V.In other words, the resistivity of line electrode 42 is 1 Ω/be favourable below the m.If the diameter of line electrode 42 is big, it forms projection, the loss of the comfort when causing taking thereon in sheet heating element 44.Therefore, diameter should be below the 1mm, and feels more comfortable in order to take thereon, wishes that diameter is below the 0.5mm.

Distance between line electrode 42A, the 42B should be in the scope of about 70-150mm.For practicality, the distance between line electrode 42A, the 42B should be about 100mm.If distance between electrodes is less than about 70mm, when the people is sitting on the sheet heating element 44 and buttocks when being pressed on the line electrode 42, might load and flexural force can make line electrode 42 fractures or impaired.On the other hand, if distance between electrodes greater than 150mm, then the resistivity of polymer resistive device 44 must be reduced to low-down level, makes to be difficult to make the useful polymer resistive device 44 with ptc characteristics.

If the distance between line electrode 42A, the 42B is 70mm, because the film thickness of polymer resistive device 44 is the 20-200 micron as mentioned above, be preferably the 30-100 micron, the resistivity of polymer resistive device 44 should be preferably about 0.0023-0.0078 Ω/m in the scope of about 0.0016-0.016 Ω/m.In addition, if the distance between line electrode 42A, the 42B is 100mm, then the resistivity of polymer resistive device 44 should be preferably about 0.0016-0.0055 Ω/m in the scope of about 0.0011-0.011 Ω/m.And if the distance between line electrode 42A, the 42B is 150mm, then the resistivity of polymer resistive device 44 should be preferably about 0.0011-0.0036 Ω/m in the scope of about 0.0007-0.007 Ω/m.

It should be noted that in this embodiment, use line electrode as electrode, but the invention is not restricted to this, also can use metal foil electrode or the electrode film made by the silk screen printing of silver paste etc.

The non-textile that is formed by the polyester fiber that uses the pecker perforation can be used for dielectric base 41.Also can use the textile that forms by polyester fiber.This dielectric base 41 makes sheet heating element 44 have pliability.If the external force of applying, sheet heating element 44 can easily change its shape.Therefore, if it is used in the seat heater, the comfort of taking thereon improves.Sheet heating element has the extension characteristics identical with the cover for seat material.Particularly, under the load below the 7kgf, its maximum extension 5%.

As mentioned above, line electrode 42 is stitched on the dielectric base 41.Owing to sew up, in dielectric base 41, form pin hole, but above-mentioned non-textile or textile can prevent that crackle from launching from pin hole.

The non-textile or the textile of polyester fiber have air permeability and good, and when as seat heater or steering wheel heater, moisture can not assembled.Thus,, also can keep initial comfort thereon even take for a long time or grasping, and as snug as a bug in a rug.And because the sound of passenger not sending as being sitting in paper on when taking, even the sheet heating element 40 of portion's placement within it, seat does not lose its comfort yet.

And, wish by having incombustibility with above-mentioned fire retardant varnished insulation substrate 42.The amount with respect to dielectric base 41 of fire retardant should be more than the 5 weight %.Yet when the amount of the fire retardant that is added increased, the manufacturing cost of sheet heating element 40 improved.In addition, the physical characteristic variation of dielectric base 41.Given this, the amount with respect to dielectric base 41 of the fire retardant that is added is preferably 10-30 weight %, and optimum is 15-25 weight %.

Sheet heating element also can have the anti-liquid film 45 of the type shown in Fig. 4 C.Anti-liquid film 45 adheres on the dielectric base 41.Make the sheet heating element 40 shown in Fig. 4 C as follows.At first, for example, use the T mould, on dielectric base 41,, form anti-liquid film 45 with the form of the film anti-liquid resin of extruding out.Then, line electrode 42A, 42B are arranged on the anti-liquid film 45, and are sewn onto on dielectric base 41 and the anti-liquid film 45 with line 43.Then, use the extrusion of T mould, on anti-liquid film 45 with the form of the film polymer resistive device 44 of extruding out.Polymer resistive device 44 is prevented liquid film 45 with line electrode 42 hot sticky being attached to.

So set up sheet heating element 40, so that dielectric base 41 will contact the wherein permeable position of liquid compound.Thus, even the aqueous chemical thing is penetrated into dielectric base 41, it also is subjected to the protection of anti-liquid film 45, thereby chemicals can not arrive polymer resistive device 44.In other words, anti-liquid film 45 prevents contacting between chemicals and the polymer resistive device 44.If sheet heating element has anti-liquid film 45, then polymer resistive device 44 does not need to have anti-liquid characteristic.

The material of anti-liquid film 45 can be ethylene/vinyl alcohol copolymer, thermoplastic polyester, polyamide, acrylic resin or ionomer, and they can be used alone or in combination.

From the flexible angle of sheet heating element 40, anti-liquid film 45 should be very thin, but in order to obtain anti-fluidity, thickness should be in the scope of 5-100 micron.According to making productivity ratio and cost, the thickness of 10-50 micron is optimum.

In addition, can in anti-liquid film 45, add above-mentioned fire retardant.The amount with respect to anti-liquid film 45 of the fire retardant that is added is preferably 10-30 weight %, and optimum is 15-25 weight %.

And sheet heating element can have second dielectric base 46 of the type shown in Fig. 4 D.Make the sheet heating element of Fig. 4 D as follows.At first, left and right symmetrically is provided with line electrode 42A, 42B on first dielectric base 41, and with line 43 line electrode 42A, 42B partly is sewn to respectively on first dielectric base 41.Then, use the extrusion of T mould, on second dielectric base 46, form polymer resistive device 44 with the extrusion membrane.Then, use equipment, first dielectric base 41 and second dielectric base 46 are bonded together, contact so that line electrode 42 forms with polymer resistive device 44 by heat bonding such as laminating machine.

With forming second dielectric base 46 with first dielectric base, 41 identical materials and specification.Can flood second dielectric base 46 with above-mentioned fire retardant.The amount with respect to dielectric base 46 of the fire retardant that is added is necessary for more than the 5 weight %, is preferably 10-30 weight %, and optimum is 15-25 weight %.

Because the both sides of sheet heating element 40 are covered by first dielectric base 41 and second dielectric base 46 respectively, sheet heating element 40 buffering effects own strengthen.Thus, if be used for the seat heater, comfort strengthens when taking thereon.In addition, second dielectric base, 46 protection polymer resistive devices 44 are not collided and are swiped.

In addition, when using heater element in vehicle heater or under such as the condition of the constant external force that heater element is stood be made of slip, second dielectric base 46 prevents the wearing and tearing and the damage of polymer resistive device 44.Because polymer resistive device 44 is covered fully by two dielectric base, the electrical insulation characteristics of sheet heating element improves.

And the heater element 40 shown in Fig. 4 C can have second dielectric base 46.

The embodiment 2 of sheet heating element

Fig. 7 A is the plan view of the sheet heating element 70 of embodiments of the invention 2, and Fig. 7 B is the cross sectional view of the line 7B-7B intercepting in Fig. 7 A.The difference of the structure of this structure and embodiment 1 (referring to Fig. 4 A) is, with wavy line line electrode 71 is set on dielectric base 41.

As shown in Figure 7A, line electrode 71 is arranged on the dielectric base 41 with wavy line, and is set up by line 43.According to this structure, when sheet heating element 70 was applied external force, because line electrode 71 with the wavy line setting, has admissible error (leeway) with regard to length, so they easily changed shape in response to tension force, stretching and bending.Therefore, wavy line electrode 71 has the mechanical strength with respect to external force that is better than the line electrode 42 that is provided with straight line as shown in Fig. 4 A.

In addition, in the zone of wavy line electrode 71 processes, the voltage that polymer resistive device 44 is applied becomes evenly, and the distribution of the heating temp of polymer resistive device 44 becomes even.

And sheet heating element 70 can have at the anti-liquid film 45 described in the embodiment 1 (referring to Fig. 7 C).Use line 43, on the dielectric base 41 wavy line electrode 71 is being sewn onto on the anti-liquid film 45.

In addition, sheet heating element can have in second dielectric base 46 (referring to Fig. 7 D) described in the embodiment 1.The sheet heating element 70 that is covered by second dielectric base 46 shown in Fig. 7 D also can have the anti-liquid film shown in Fig. 7 C.

The embodiment 3 of sheet heating element

Fig. 8 A is the plan view of the sheet heating element of embodiments of the invention 3, and Fig. 8 B is the cross sectional view of the line 8B-8B intercepting in Fig. 8 A.The difference of the structure of this structure and embodiment 1 (referring to Fig. 4 A) is, between the online electrode pair 42 boost line electrode 81 is set.In other words, boost line electrode 81 is arranged on line electrode between 42, and with the situation of line electrode 42 in the same manner, use the line of making by polyester fiber etc. 82, be sewn onto on the dielectric base 41 by quilting machine.

In the structure shown in Fig. 4 A, polymer resistive device 44 tends to heating unevenly between line electrode 42, and the increase of that part of resistivity, makes electromotive force concentrate on the there.If continue this state, to compare with other parts, that part of temperature of polymer resistive device 44 raises more, causes known hot line (hot-line) phenomenon.By boost line electrode 81 is set as among Fig. 8 A, become evenly at whole polymer resistive device 44 built-in potentials, even thereby heating temp becomes.Therefore, can prevent from the part of polymer resistive device 44, to take place the hot line phenomenon.

It should be noted that with line electrode 42 similarly, boost line electrode 81 is formed by metallic conductor or stranded metallic conductor.

In Fig. 8 A and 8B, two boost line electrodes 81 are set between the online electrode pair 42.But the quantity of boost line electrode 81 is not limited thereto, and can determine this quantity according to the size of polymer resistive device 44, distance and needed heat distribution between the line electrode 42.

In Fig. 8 A, boost line electrode 81 is set to be basically parallel to line electrode to 42.But its setting is not limited thereto, and can also with zigzag (zig-zag) configuration boost line electrode 81 be set between the online electrode pair 42.

And, can as the line electrode 71 of the embodiment shown in Fig. 7 A and 7B 2, boost line electrode 81 be set with contoured configuration.Certainly, can combined waveform line electrode 71 and waveform boost line electrode 81.

Sheet heating element 80 can have at the anti-liquid film 45 described in the embodiment 1 (referring to Fig. 8 C). Use line 43,82, line electrode 42 and boost line electrode 81 are sewn onto on the anti-liquid film 45 and on the dielectric base 41.

In addition, sheet heating element 80 can have in second dielectric base 46 (referring to Fig. 8 D) described in the embodiment 1.This configuration also can have second dielectric base shown in the anti-liquid film shown in Fig. 8 C and Fig. 8 D.

The embodiment 4 of sheet heating element

Fig. 9 A is the plan view of the sheet heating element 90 of embodiments of the invention 4.Fig. 9 B is the cross sectional view of the line 9B-9B intercepting in Fig. 9 A.The difference of the structure of this structure and embodiment 1 (referring to Fig. 4 A) is, by insert polymer resistive device 44 between dielectric base 41 and line electrode 42, polymer resistive device 44 is set.

The following sheet heating element 90 of making embodiment 4.At first, on dielectric base 41 heat lamination polymer resistive device 44 as film.Then, line electrode 42 is arranged on the polymer resistive device 44, and is sewn on the dielectric base 41 by quilting machine.Line electrode 42 and polymer resistive device 44 are carried out the hot compression processing, thereby line electrode 42 is adhered to polymer resistive device 44.Because line electrode 42 on polymer resistive device 44, can easily be checked the position that is provided with of line electrode 42.When the core of dielectric base 41 is perforated with the raising pliability, can avoid perforation reliably to line electrode 42.

In addition, owing to line electrode 42 is stitched on the dielectric base 41, and polymer resistive device 44 has been attached on the dielectric base 41, therefore, the bigger degree of freedom is arranged when line electrode 42 is set.By making the technology that polymer resistive device 44 is attached on the dielectric base 41 be shared technology, after this shared technology, can be provided with suture electrode 42 having various heating figures, thereby can easily make various sheet heating element 90 with various.

And, in this embodiment, the boost line electrode 81 shown in Fig. 8 A can also be set.

In this embodiment, hot sticky leeched line electrode 42 and polymer resistive device 44.But the invention is not restricted to this.Can also adhere to line electrode 42 and polymer resistive device 44 by using electroconductive binder.Can also be by they are forced together simply with the mode electric connection line electrode 42 and the polymer resistive device 44 of Mechanical Contact.

Sheet heating element 90 also can have at the anti-liquid film 45 described in the embodiment 1 (referring to Fig. 9 C).Heat lamination polymer resistive device 44 by polymer resistive device 44 and anti-liquid film 45, is sewn onto line electrode 42 on the dielectric base 41 then as film on anti-liquid film 45.

Sheet heating element 90 also can have in second dielectric base 46 (referring to Fig. 9 D) described in the embodiment 1.In addition, the sheet heating element shown in Fig. 9 D 90 can have the anti-liquid film shown in Fig. 9 C between the compression polymer resistor 44 and first dielectric base 41.

The embodiment 5 of sheet heating element

Figure 10 A is the plan view of the sheet heating element 100 of embodiments of the invention 5.Figure 10 B is the cross sectional view of the line 10B-10B intercepting in Figure 10 A.The difference of the structure of this structure and embodiment 4 (referring to Fig. 9 A) is, conductive strips (conductive strip) 101 are set between polymer resistive device 44 and line electrode 42, and line electrode 42 can slide on these conductive strips 101.

The following sheet heating element 100 of making embodiment 5.Heat lamination polymer resistive device 44 is as film on dielectric base 41.Afterwards, conductive strips 101 are installed on this polymer resistive device 44.Then, line electrode 42 is arranged on the conductive strips 101 and with quilting machine line electrode 42 is sewn onto on the dielectric base 41 by conductive strips 101 and polymer resistive device 44.Line electrode 42 and polymer resistive device 44 are carried out the hot compression processing, thereby polymer resistive device 44 is adhered to line electrode 42 securely.

For example, by the film of making from the oildag of drying or by the film of making from the resin compound that comprises graphite, form conductive strips 101.When on polymer resistive device 44 conductive strips 101 being installed, these films are pressed onto polymer resistive device 44 by thermosphere or are printed onto on the polymer resistive device 44.

Because line electrode 42 can slide on conductive strips 101, has further improved the pliability of sheet heating element 100.Because conductive strips 101 have good conductivity, therefore by conductive strips 101 electric connection line electrode 42 and polymer resistive device 44 more reliably.

It should be noted that in this embodiment, can also additionally be arranged on the boost line electrode 81 described in the embodiment 3 (referring to Fig. 8 A).And, can also conductive strips 101 be set for boost line electrode 81.

In this embodiment, conductive strips 101 are installed on polymer resistive device 44 after adhering to polymer resistive device 44 on the dielectric base 41.Can in advance conductive strips 101 be attached on the polymer resistive device 44.

Hot sticky leeched line electrode 42 and polymer resistive device 44.But the invention is not restricted to this.Can also adhere to line electrode 42 and polymer resistive device 44 by using electroconductive binder.Can also be by they are forced together simply with the mode electric connection line electrode 42 and the polymer resistive device 44 of Mechanical Contact.

Sheet heating element 100 also can have at the anti-liquid film 45 described in the embodiment 1 (referring to Figure 10 C).Heat lamination polymer resistive device 44 is as film on anti-liquid film 45.Then conductive strips 101 are installed on the polymer resistive device 44.By conductive strips 101, polymer resistive device 44 and anti-liquid film 45, line electrode 42 is sewn onto on the dielectric base 41.

Sheet heating element 100 can have second dielectric base 46, shown in Figure 10 D.Heat lamination polymer resistive device 44 is as film on second dielectric base 46.Conductive strips 101 are installed on polymer resistive device 44 then.On the other hand, line electrode 42 is stitched on first dielectric base 41.Afterwards, second dielectric base 46 is engaged with first dielectric base 41, thereby line electrode 42 contact, and forms the unit with conductive strips 101 formation by the hot compression processing.

The embodiment 6 of sheet heating element

Figure 11 A is the plan view of the sheet heating element 110 of embodiments of the invention 6.Figure 11 B is the cross sectional view of the line 11B-11B intercepting in Figure 11 A.The difference of the structure of this structure and embodiment 4 (referring to Fig. 9 A) is, polymer resistive device 111 is set, replace polymeric resistor 44.By flooding netted non-textile or textile, make polymer resistive device 111 with the polymer resistive device.

The following sheet heating element 110 of making embodiment 6.By in such as the liquid of solvent, disperseing and being blended in the polymer resistive device described in the embodiment 1-5, make China ink.By such as print, smear, method such as immersion, flood netted non-textile or textile with this China ink, make its drying then, thereby make polymer resistive device 111.Netted non-textile or textile have a plurality of apertures between fiber, and the resin resistor is penetrated in these holes.

Next, line electrode 42 is set on polymer resistive device 111, and it is sewn onto on the dielectric base 41 with quilting machine.By heat lamination this polymer resistive device 111 is adhered to dielectric base 41 then.Line electrode 42 and polymer resistive device 111 are carried out the hot compression processing, thereby polymer resistive device 44 is adhered to line electrode 42 securely.

In this structure, because polymer resistive device 111 is formed by netted non-textile or textile with a plurality of holes, it presents high suppleness, and this is because under the external force that is applied to it, it can easily change shape.

Because the polymer resistive device is maintained in the hole in non-textile or the textile, polymer resistive device 111 by tight adhesion on dielectric base 41, thereby improve the mechanical strength of polymer resistive device 111.

It should be noted that in this embodiment, flood netted non-textile or textile with black type polymer resistive device.Can also carry out the hot compression processing to netted non-textile or textile, to flood non-textile or textile with membranous type or sheet type polymer resistive device.

In addition, in this embodiment, hot sticky leeched line electrode 42 and polymer resistive device 111.But the invention is not restricted to this.Can also adhere to line electrode 42 and polymer resistive device 111 by using electroconductive binder.Can also be by they are forced together simply with the mode electric connection line electrode 42 and the polymer resistive device 111 of Mechanical Contact.

And, in this embodiment, can also be arranged on the boost line electrode 81 described in the embodiment 3 (referring to Fig. 8 A).

Sheet heating element 110 also can have at the anti-liquid film 45 described in the embodiment 1 (referring to Figure 11 C).By lamination mucoadhesive polymers resistor 111 and anti-liquid film 45.

Sheet heating element 110 can have second dielectric base 46, shown in Figure 11 D.Flood netted non-weaving or textile with the polymer resistive modulator material, form polymer resistive device 111.By the heat lamination polymer attached resistor 111 and second dielectric base 46.By machine line electrode 42 is sewn onto on first dielectric base 41.By the hot compression processing first and second dielectric base 41,46 are engaged with first dielectric base 41,111 formation contact with the polymer resistive device thereby line electrode 42 is with line electrode 42.

Second dielectric base 46 can be set to the sheet heating element 110 shown in Figure 11 C.

The embodiment 7 of sheet heating element

Figure 12 A is the plan view of the sheet heating element 120 of embodiments of the invention 7.Figure 12 B is the cross sectional view of the line 12B-12B intercepting in Figure 12 A.The difference of the structure of this structure and embodiment 1 (referring to Fig. 4 A) is, cover layer 121 further is set on polymer resistive device 44.

Cover layer 121 is formed by the material with electrical insulation characteristics.Using heat lamination polymer resistive device 44 to be laminated to after line electrode 42 has been attached on the dielectric base 41 on it, also set up cover layer 121, with overlie polymer resistor 44 by heat lamination.

Cover layer 121 has the combination based on the thermoplastic elastomer (s) of polyolefinic thermoplastic elastomer (s), styrene-based or these elastomeric materials that use based on the thermoplastic elastomer (s) of urethanes or as key component of itself using as its key component.Thermoplastic elastomer (s) makes sheet heating element 120 have pliability.

Cover layer 121 protection sheet heating elements 120 are not collided and are swiped, and this collision and scraping can damage sheet heating elements 120.

In addition, when heater element being used for the seat heater or during such as the condition of the constant external force that heater element is stood be made of slip, cover layer 121 prevents the wearing and tearing of polymer resistive device 44, so sheet heating element 120 can not lose its heating function.

And because sheet heating element 120 is isolated by electricity, even sheet heating element 120 is applied high voltage, it also is safe.

Cover layer 121 should so be set, so that cover whole polymer resistive device 44.Yet, consider pliability, the preferred cover layer that approaches that uses is as cover layer 121.

Sheet heating element 120 also can have at the anti-liquid film 45 described in the embodiment 1 (referring to Figure 12 C).Anti-liquid film 45 is pressed onto on the dielectric base 41 by thermosphere.By anti-liquid film 45 line electrode 42 is sewn onto on the dielectric base 41.After on polymer resistive device 44 thermospheres being pressed onto anti-liquid film 45, heat lamination cover layer 121.

The embodiment 8 of sheet heating element

Figure 13 A is the plan view of the sheet heating element 130 of embodiments of the invention 8.Figure 13 B is the cross sectional view of the line 13B-13B intercepting in Figure 13 A.The difference of the structure of this structure and embodiment 1 (referring to Fig. 4 A) is that dielectric base 41 and/or polymer resistive device 44 have a plurality of slits 131 at least.

The sheet heating element 130 of following manufacturing embodiment 8.At first, with among the embodiment 1 similarly, line electrode 42 is provided with and is sewn on the dielectric base 41.Use the extrusion of T mould molded, with polymer resistive device 44 extrusion film forming or thin slices, and with the polymer resistive device 44 hot sticky dielectric base 41 that are attached to.In that the core of dielectric base 41 is bored a hole with after forming long and narrow hole, use the Thomson punch, in polymer resistive device 44 and dielectric base 41, to form a plurality of slits 131.

Position with the perforation of Thomson punch is not limited to the position shown in the figure.Shape according to the cover for seat 53 of seat can be provided with perforation in the position except the position shown in the figure.In this case, be necessary to adjust the wiring figure of line electrode 42.

In addition, line electrode 42 and polymer resistive device 44 can be affixed on the dielectric base 41, on this dielectric base 41, be formed with slit 131 by the perforation of Thomson punch.In replacement scheme, polymer resistive device 44 can be attached to separator (separator), for example on polypropylene or the processing release paper (not shown).Then, by before being affixed on the dielectric base 41, boring a hole, in polymer resistive device 44, form slit 131.In the previous case, only in dielectric base 41, form slit 131, and under latter event, only in polymer resistive device 44, form slit 131.

Because form a plurality of slits 131 in the sheet heating element 130 of this embodiment, sheet heating element 130 can easily change shape in response to external force, thereby when taking, strengthen comfort thereon.Can think that also the long and narrow hole that forms is used to make sheet heating element 130 to have pliability in the core of dielectric base 41.Yet long and narrow hole is for sheet heating element 130 being affixed on the seat and be provided with, rather than in order to make sheet heating element 130 have pliability setting.Therefore, differentiation long and narrow hole and slit 131 must used.

It should be noted that the slit 131 that can also on the sheet heating element of embodiment 1-7, form this embodiment.

Sheet heating element 130 also can have at the anti-liquid film 45 described in the embodiment 1 (referring to Figure 13 C).At first, with among the embodiment 1 similarly, by anti-liquid film 45 line electrode 42 is sewn onto on the dielectric base 41.Use the extrusion of T mould molded, with polymer resistive device 44 extrusion film forming, and with polymer resistive device 44 hot sticky line electrode 42 and the anti-liquid films 45 of being attached to.After core perforation to dielectric base 41, use the Thomson punch, between line electrode 42, to form slit 131, pass from polymer resistive device 44 and arrive dielectric base 41.

Sheet heating element 130 can have second dielectric base 46, shown in Figure 13 D.At first, line electrode 42 is sewn onto on first dielectric base 41.On the other hand, use the extrusion of T mould molded, with polymer resistive device 44 extrusion film forming or thin slices, and with polymer resistive device 44 hot sticky second dielectric base 46 that are attached to.Handle that by hot compression first and second dielectric base 41,46 are engaged, thereby line electrode 42 forms each other with polymer resistive device 44 and contacts.After core perforation to first dielectric base 41 and second dielectric base 46, use the Thomson punch, pass the slit 131 of first dielectric base 41, polymer resistive device 44 and second dielectric base 46 with formation.

Can form slit 131 in advance by using the Thomson punch to 41,46 perforation of first and second dielectric base.In replacement scheme, polymer resistive device 44 can be attached to separator, for example on polypropylene or the processing release paper (not shown), and forms slit 131 by perforation in polymer resistive device 44.In the previous case, only in dielectric base 41,46, form slit 131, and under latter event, only in polymer resistive device 44, form slit 131.

The embodiment 9 of sheet heating element

Figure 14 A is the plan view of the sheet heating element 140 of embodiments of the invention 9, and Figure 14 B is the cross sectional view of the line 14B-14B intercepting in Figure 14 A.The difference of the structure of this structure and embodiment 8 (referring to Figure 13 A) is, a plurality of breach 141 are set, and substitutes slit 131.

The following sheet heating element 140 of making embodiment 9.At first, polymer resistive device 44 is affixed to separator, for example on polypropylene or the processing release paper (not shown), and to 44 perforation of polymer resistive device to form breach 141.Next,, use heat lamination, polymer resistive device 44 is affixed on the dielectric base 41, wherein on this dielectric base 41, be sewed with wavy line electrode 71 after polymer resistive device 44 is removed separator.

Because by breach 141, polymer resistive device 44 easily changes shape in response to external force, therefore when taking thereon, comfort strengthens.

And, can on dielectric base 41, form similar breach 141.In this case, these breach 141 play above-mentioned effect effectively, make can further strengthen comfort thereon when taking.

Can also in the sheet heating element of embodiment 1-7, form the breach 141 of this embodiment.

Sheet heating element also can have at the anti-liquid film 45 described in the embodiment 1 (referring to Figure 14 C).At first, by anti-liquid film 45 wavy line electrode 71 is sewn onto on the dielectric base 41.Polymer resistive device 44 is attached to separator, for example on polypropylene or the processing release paper (not shown), and is perforated to form breach 141 in polymer resistive device 44.After removing separator, use heat-laminator, polymer resistive device 44 is affixed on the anti-liquid film 45.

Sheet heating element 140 can have second dielectric base 46, shown in Figure 14 D.At first, polymer resistive device 44 is attached to separator, for example on polypropylene or the processing release paper (not shown), and is perforated to form breach 141 in polymer resistive device 44.After being pressed onto polymer resistive device 44 thermospheres on second dielectric base 46, remove separator.On the other hand, on first dielectric base 41 with waveform suture electrode 42.Then, use hot press, handle that by hot compression first and second dielectric base are engaged, thereby line electrode 42 contacts with 44 formation of polymer resistive device, forms the unit.

Sheet heating element 140 shown in Figure 14 C can have second dielectric base 46.

Industrial usability

Sheet heating element of the present invention has simple structure, good ptc characteristics, and has Easily change the pliability of shape in response to external force. Because this sheet heating element can be affixed to Have on the surface of utensil of complex surface shape, so it can be used for seat heater or side In dish warmer, and can be for the application such as the floor thermoelectric heating device that needs heating. And, because good manufacturing productivity ratio and low cost has wide range of applications.

Claims (62)

1. sheet heating element comprises:

Substrate sheet, it is made by electrical insulating material;

Circuit, it is made by electric conducting material, and is set to have spacing on the described substrate sheet between described circuit; And

At least one PTC resistor sheet, it contacts with described line electricity and is configured in the self-regulation mode in response to supplying with from the electricity of described circuit and generating heat.

2. according to the sheet heating element of claim 1, the thickness of wherein said at least one PTC resistor sheet is the 20-200 micron.

3. according to the sheet heating element of claim 1, the thickness of wherein said at least one PTC resistor sheet is the 30-100 micron.

4. according to the sheet heating element of claim 1, wherein said at least one PTC resistor sheet comprises resinous principle and electric conducting material.

5. according to the sheet heating element of claim 4, wherein said resinous principle comprise reaction resin and with the crosslinked reactive resin of described reaction resin.

6. according to the sheet heating element of claim 4, wherein said electric conducting material comprises at least a in carbon black and the graphite.

7. according to the sheet heating element of claim 1, wherein said at least one PTC resistor sheet can be by hot melt electrically contacting with realization and described circuit.

8. according to the sheet heating element of claim 1, wherein said at least one PTC resistor sheet has the resistivity of scope between 0.0007 Ω m and 0.016 Ω m.

9. according to the sheet heating element of claim 1, wherein said at least one PTC resistor sheet has the resistivity of scope between 0.0011 Ω m and 0.0078 Ω m.

10. according to the sheet heating element of claim 1, wherein said at least one PTC resistor sheet comprises fire retardant.

11. according to the sheet heating element of claim 10, wherein said fire retardant comprises fire retardant based on phosphorus, based on the fire retardant of nitrogen, fire retardant, inorganic combustion inhibitor and at least a based in the fire retardant of halogen based on siloxanes.

12. according to the sheet heating element of claim 10, at least one during wherein said at least one PTC resistor sheet meets the following conditions:

(a) when with an end of described at least one the PTC resistor sheet of bluster burning and when extinguishing described bluster after 60 seconds, even described is burnt, described does not burn yet;

(b) when with an end of described at least one the PTC resistor sheet of bluster burning, described catches fire and was no more than for 60 seconds, but flame extinguishes in 2 inches; Perhaps

(c) when with an end of described at least one the PTC resistor sheet of bluster burning, even described catches fire, in the distance zone of surperficial 1/2 inch thickness, flame does not spread with the speed more than the 4 inch per minute clocks yet.

13. according to the sheet heating element of claim 10, wherein said fire retardant is included in described at least one PTC resistor sheet with the content more than the 5 weight %.

14. according to the sheet heating element of claim 10, wherein said fire retardant is included in described at least one PTC resistor sheet with the content of 10-30 weight %.

15. according to the sheet heating element of claim 10, wherein said fire retardant is included in described at least one PTC resistor sheet with the content of 15-25 weight %.

16. according to the sheet heating element of claim 1, wherein said at least one PTC resistor sheet comprises anti-liquid resin.

17. according to the sheet heating element of claim 16, wherein said anti-liquid resin is included in described at least one PTC resistor sheet with the content more than the 10 weight %.

18. according to the sheet heating element of claim 16, wherein said anti-liquid resin is included in described at least one PTC resistor sheet with the content of 10-70 weight %.

19. according to the sheet heating element of claim 16, wherein said anti-liquid resin is included in described at least one PTC resistor sheet with the content of 30-50 weight %.

20. according to the sheet heating element of claim 16, wherein said anti-liquid resin comprises at least a in ethylene/vinyl alcohol copolymer, thermoplastic polyester, polyamide, acrylic resin and the ionomer.

21. according to the sheet heating element of claim 1, wherein said at least one PTC resistor sheet generates heat between about 40 ℃ and about 45 ℃ in self-regulating mode.

22. according to the sheet heating element of claim 1, wherein said circuit is stitched on the described substrate sheet.

23. according to the sheet heating element of claim 1, the diameter of wherein said circuit is equal to or less than 1mm.

24. according to the sheet heating element of claim 1, the diameter of wherein said circuit is equal to or less than 0.5mm.

25. according to the sheet heating element of claim 1, the resistivity of wherein said circuit is equal to or less than 1 (Ω/m).

26. according to the sheet heating element of claim 1, the electric conducting material that wherein forms described circuit is any in the copper of copper, tin plating and the copper-silver alloy.

27. according to the sheet heating element of claim 1, wherein twist together, form described circuit by the copper-silver alloy line that has 0.05 micron diameter with 19.

28. according to the sheet heating element of claim 1, wherein said circuit is with the spacing setting of about 70-150mm.

29. according to the sheet heating element of claim 1, wherein said at least one PTC resistor sheet presents the flexible elasticity that is equal to or higher than described substrate sheet.

30. according to the sheet heating element of claim 1, wherein said at least one PTC resistor sheet under less than the load of 7kgf extensible extent greater than 5%.

31. according to the sheet heating element of claim 1, wherein said substrate sheet is made by the non-weaving or the textile that form from polyester fiber.

32., wherein use at described substrate sheet perforation according to the sheet heating element of claim 30.

33. according to the sheet heating element of claim 1, also comprise emulsion sheet, it is made by electrical insulating material, and cooperates to surround described circuit and described at least one PTC resistor sheet with described substrate sheet.

34. according to the sheet heating element of claim 33, wherein said emulsion sheet is made by the non-weaving or the textile that form from polyester fiber.

35. according to the sheet heating element of claim 33, at least one in wherein said substrate sheet and the described emulsion sheet comprises fire retardant.

36. according to the sheet heating element of claim 35, wherein said fire retardant comprises fire retardant based on phosphorus, based on the fire retardant of nitrogen, fire retardant, inorganic combustion inhibitor and at least a based in the fire retardant of halogen based on siloxanes.

37. according to the sheet heating element of claim 35, described at least one at least one in meeting the following conditions in wherein said substrate sheet and the described emulsion sheet:

(a) when in burn with bluster described substrate sheet and the described emulsion sheet described at least one an end and when extinguishing described bluster after 60 seconds, even described is burnt, described does not burn yet;

(b) when described at least one the end in burn with bluster described substrate sheet and the described emulsion sheet, described catches fire and was no more than for 60 seconds, but flame extinguishes in 2 inches; Perhaps

(c) when described at least one the end in burn with bluster described substrate sheet and the described emulsion sheet, even described catches fire, in 1/2 inch thick zone, distance surface, flame does not spread with the speed more than the 4 inch per minute clocks yet.

38. according to the sheet heating element of claim 35, wherein said fire retardant is included in described at least one in described substrate sheet and the described emulsion sheet with the content more than the 5 weight %.

39. according to the sheet heating element of claim 35, wherein said fire retardant is included in described at least one in described substrate sheet and the described emulsion sheet with the content of 10-30 weight %.

40. according to the sheet heating element of claim 35, wherein said fire retardant is included in described at least one in described substrate sheet and the described emulsion sheet with the content of 15-25 weight %.

41. according to the sheet heating element of claim 1, wherein said circuit is arranged between described at least one PTC resistor sheet and the described substrate sheet.

42., also comprise anti-liquid film according to the sheet heating element of claim 1.

43. according to the sheet heating element of claim 42, wherein said anti-liquid film comprises at least a in ethylene/vinyl alcohol copolymer, thermoplastic polyester, polyamide, acrylic resin and the ionomer.

44. according to the sheet heating element of claim 42, the thickness of wherein said anti-liquid film is the 5-100 micron.

45. according to the sheet heating element of claim 42, the thickness of wherein said anti-liquid film is the 10-50 micron.

46. according to the sheet heating element of claim 42, wherein said anti-liquid film is arranged between described at least one PTC resistor sheet and the described substrate sheet.

47. according to the sheet heating element of claim 42, wherein said anti-liquid film comprises fire retardant.

48. according to the sheet heating element of claim 47, wherein said fire retardant comprises fire retardant based on phosphorus, based on the fire retardant of nitrogen, fire retardant, inorganic combustion inhibitor and at least a based in the fire retardant of halogen based on siloxanes.

49. according to the sheet heating element of claim 47, at least one during wherein said anti-liquid film meets the following conditions:

(a) when an end of the described anti-liquid film that burns with bluster and when extinguishing described bluster after 60 seconds, even described substrate sheet is burnt, described anti-liquid film does not burn yet;

(b) when an end of the described anti-liquid film that burns with bluster, described anti-liquid film catches fire and was no more than for 60 seconds, but flame extinguishes in 2 inches; Perhaps

(c) when an end of the described anti-liquid film that burns with bluster, even described anti-liquid film catches fire, in 1/2 inch thick zone, distance surface, flame does not spread with the speed more than the 4 inch per minute clocks yet.

50. according to the sheet heating element of claim 47, wherein said fire retardant is included in the described anti-liquid film with the content more than the 5 weight %.

51. according to the sheet heating element of claim 47, wherein said fire retardant is included in the described anti-liquid film with the content of 10-30 weight %.

52. according to the sheet heating element of claim 47, wherein said fire retardant is included in the described anti-liquid film with the content of 15-25 weight %.

53. according to the sheet heating element of claim 1, at least one in the wherein said circuit extends in the waveform mode.

54. according to the sheet heating element of claim 1, described circuit is set so wherein, so as more than two circuits to each power supply in described at least one PTC resistor sheet.

55. according to the sheet heating element of claim 1, wherein said at least one PTC resistor sheet is arranged between described circuit and the described substrate sheet.

56. according to the sheet heating element of claim 1, also comprise conducting film, it is arranged between described circuit and described at least one PTC resistor sheet, and allows described circuit to slide thereon.

57. according to the sheet heating element of claim 56, wherein said conducting film is by oildag and comprise a kind of making in the resin compound of graphite.

58. according to the sheet heating element of claim 1, wherein said at least one PTC resistor sheet comprises non-textile or the textile with PTC resistor material dipping.

59., also comprise the coverlay of making by thermoplastic elastomer (s) according to the sheet heating element of claim 1.

60. according to the sheet heating element of claim 59, wherein said coverlay is by based on the thermoplastic elastomer (s) of polyolefinic thermoplastic elastomer (s), styrene-based with based at least a the making in the thermoplastic elastomer (s) of urethanes.

61. according to the sheet heating element of claim 1, at least one in wherein said substrate sheet and described at least one PTC resistor sheet is formed with a plurality of slits.

62. according to the sheet heating element of claim 1, at least one in wherein said substrate sheet and described at least one PTC resistor sheet is formed with a plurality of breach.

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