JP2001110555A - Mesh heater - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mesh heater which can be adhered onto a complicated curved surface assuring heat generation in a constant amount. SOLUTION: The heater element wire 20 is composed of the heater element fiber 20a having uniform diameter of 0.02-0.12 mm, coated with enamel paint 20b. The mash heater 2 having weaving pitch of 0.5-5 mm, is formed by tricot weaving of plural heater element wires 20 to weave loop continuously and plane shape to warp direction. Alternatively, the mesh heater 2 may be formed by tricot weaving of plural 1st heater element wires 200 composed of heater element fibers and the 2nd heater element wires 20 composed of heater element fiber 20a coated with enamel paint 20b, as the 1st heater element wires 200 are not crossing each other.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reticulated heater, and more particularly to a reticulated heater used for a steering wheel or a seat of an automobile or an elbow portion of a complicated pipe.

[0002]

2. Description of the Related Art It has been proposed that a handle be provided with a heater because, when a driver gets into a car and grips the handle in a cold winter in a cold region, the hand may freeze on the handle due to moisture on the skin of the hand. Such a heater for a handle is required to raise the temperature in a short time and to provide comfort that does not cause a sense of discomfort in the grip of the handle. Therefore, for example, a mesh heater is placed on the handle to satisfy these conditions. Becomes possible.

[0003]

However, in the case where the heater wires are knitted in a mesh shape, the heater wires are likely to rise at the intersections of the heater wires, so that the heater wires are raised on the skin for covering the heater. There is a possibility that the electrical stability may be lost.

It is conceivable to arrange the heater at the center of the cross section of the handle member to solve such a problem. However, even if a heater having a large amount of heat is used, it takes time to raise the temperature due to a delay in heat conduction. Would.

The present invention has been made in order to solve such a conventional problem, and provides a net-shaped heater which can be brought into close contact with a complicated curved surface and which can obtain a constant calorific value. The purpose is to:

[0006]

According to the present invention, there is provided a mesh heater having a wire diameter of 0.02 to 0.12 mm.
And a plurality of heater wires in which the enamel wire coating is coated on the heater bare wire having a single wire diameter are formed by tricot knitting which is continuously and planarly spelled in a loop (vertical) direction, The stitch pitch of this tricot is 0.5 to 5 mm
Which has a mesh heating element.

[0007] According to the reticulated heater of the present invention thus configured, since it is formed by tricot knitting,
Because of its high elasticity and flexibility, it can be adhered even to a complicated curved surface, and since the enamel wire paint is surely insulated at the intersection of the heater wires, the resistance value Can be stabilized. As a result, a stable and constant calorific value can be obtained.

[0008] The reticulated heater of the present invention has a wire diameter of 0.1 mm.
A plurality of first heater wires each consisting of only a bare heater wire having a single diameter of 02 to 0.12 mm and a plurality of second heaters each consisting of a bare heater wire coated with an enamel wire paint The strands are formed in a tricot stitch that spells in a continuous and planar manner in the direction through the loop (warp), and the first heater strands are formed so as not to intersect, and the stitch pitch of the tricot stitch is 0.5 to It has a mesh heating element of 5 mm.

According to the reticulated heater of the present invention configured as described above, since it is formed by tricot knitting,
Since it is rich in elasticity and flexible, it can be adhered even to a complicated curved surface, and the second heater element is woven so that the first heater element does not cross each other. Since the insulation can be reliably achieved with the enamel wire coating, the resistance value can be stabilized. As a result, a stable and constant calorific value can be obtained.

[0010] The mesh heater of the present invention has a wire diameter of 0.1 mm.
A plurality of bare heater wires having a single wire diameter of 02 to 0.12 mm are formed by tricot knitting which is continuously and planarly spelled in the (vertical) direction via a loop, and the stitch pitch of the tricot knitting is A plurality of bare heater wires each having a mesh heating element of 0.5 to 5 mm and formed of the mesh heating element by tricot knitting are subjected to insulation treatment.

[0011] According to the reticulated heater of the present invention thus configured, since it is formed by tricot knitting,
Because of its high elasticity and flexibility, it can be adhered even to complicated curved surfaces. In addition, the insulation treatment is applied to the plurality of bare wires forming the mesh heating element. , The resistance value can be stabilized. As a result, a stable and constant calorific value can be obtained.

Further, in the reticulated heater of the present invention, the bare heater wire is preferably a copper alloy wire containing silver. This makes it possible to obtain a tensile strength that is twice or three times that of the soft copper wire, so that the wire can be thin and highly flexible.

Further, in the mesh heater of the present invention, electrodes are connected to both ends of the mesh heating element in the longitudinal (vertical) direction in a state where the electrodes are spaced apart, and the electrodes are made of a conductive tape and a conductive tape. It is preferable to use a conductive adhesive which is fixed to the front and back of the network heating element. As a result, the reticulated heating element can be formed as a parallel circuit, so that the resistance value is extremely stable.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A preferred embodiment of a mesh heater according to the present invention will be described below with reference to the drawings.

FIGS. 1A and 1B show a reticulated heater according to the present invention.
As shown in FIG. 2, a plurality of heater wires 2 each having a single heater diameter of a heater bare wire 20a coated with an enamel wire coating material 20b.
0 is a mesh heating element 2 formed by tricot knitting
have. Here, the tricot knitting means a knitting method in which the spell is continuously and planarly spelled in the direction V through the loop (vertically).

The heater bare wire 20a of the heater wire 20 used for the mesh heating element 2 is made of a copper alloy containing 1% or more of nickel or an alloy wire which is resistant to corrosion such as a nichrome wire and whose resistance value is easily controlled. If the volume resistivity is 1 to 100 times, preferably 2 to 20 times that of pure copper, workability is improved. The wire diameter of such a bare heater wire 20a is 0.02 to 0.12 mm, preferably 0.06 to 0.12 mm.
If it is 0.08 mm, both strength and flexibility can be achieved.

The diameter of the bare heater wire 20a is set to 0.02.
When the thickness is set to 0.04 mm, a copper alloy wire containing silver is preferable because the tensile strength is weak with the above materials. Depending on the silver content, the copper alloy wire containing silver can have a tensile strength that is two to three times that of the annealed copper wire. It can be made substantially the same as the wire diameter of the alloy wire of 0.05 to 0.07 mm. Therefore, a thinner and more flexible bare wire 20a can be provided, so that the stretchability and flexibility of the mesh heater can be further improved.

The enamel wire coating 20b is applied to the bare heater wire 20a and baked to form an insulating film. As the enamel wire coating 20b, a coating mainly containing polyvinyl acetal, polyurethane, polyamide imide, polyimide or the like is preferable. Enamel wire coating mainly composed of polyvinyl acetal or polyurethane has heat resistance of 100 to 150 ° C,
Since soldering can be performed without peeling off the film,
The reliability is improved, and the electrodes can be formed in a short time. In addition, the enamel wire coating mainly composed of polyamideimide or polyimide has high heat resistance and good abrasion resistance, so that tricot knitting is easy. According to such an enamel wire coating, an insulating property can be ensured by an extremely thin uniform film.
In the case of a metal conductor of mm, the minimum coating thickness is 0.003 mm with JIS Class 3 enameled wire, so the outer diameter of the heater wire does not become unnecessarily thick, and it can withstand severe mechanical bending during braiding It is possible to select a wide range of heat-resistant clades as required, and it is possible to select from 105 to 240 ° C. in UL standard except for special ones.

It is also conceivable to use paper winding, silk winding, or a thermoplastic resin such as polyethylene or vinyl chloride as the insulating film of the bare heater wire. However, in the case of paper winding or silk winding, the surface has poor slipperiness. Therefore, it becomes an obstacle such as fraying or disconnection at the time of knitting, and the outer diameter is enlarged. Also, in the case of thermoplastic resin, the slipperiness of the surface becomes worse, so that tricot knitting cannot be performed.
Since the thickness of the insulating film is much larger than that of the paint for enameled wire, the heat transfer efficiency is reduced.

When the stitch pitch when forming such a heater element wire 20 by tricot knitting is 0.5 to 5 mm, preferably 1 to 3 mm, all of the uniformity of heat generation, workability and economy are satisfied. it can. For example, when the vertical pitch VP is 1 mm and the apex angle α of the first stitch is 60 °,
Actual sutra (vertical) for 4 squares in one square (vertical)
Assuming that the length of the heater wire 20 is four squares of the length of the virtual warp heater wire in the warp direction V (FIG. 1A),

[0021]

(Equation 1)

## EQU1 ## Accordingly, since the heater bare wires 20a of the heater wires 20 are all in non-contact at intersections (hereinafter, referred to as “intersections”), the simple measurement length of 3.
The resistance value is 46 times.

As shown in FIGS. 2A and 2B,
Assuming that the mesh heating element 2 is a rectangle having a width of 55 mm and a length of 1.25 m, and 29 warp element wires 20 are arranged in the width direction, the weft (horizontal) pitch HP is:

[0024]

(Equation 2)

Since the intersection of the bare heater wire 20a of the warped heater wire 20 is completely non-contact, one of the wires is 1.25.
It becomes 29 parallel circuits with mx3.46 times the heater wires 20. Here, the wire diameter of the heater wire 20 is 0.0
If it is assumed that a copper alloy wire having a volume resistivity of 6 mm and a volume resistivity of 54 Ω / m is used, the resistance R of the mesh heating element 2 is as follows.

[0026]

(Equation 3)

So that

[0028]

(Equation 4)

## EQU1 ## Therefore, since all the intersections of the heater bare wires 20a of the heater wires 20 used for the mesh heating element 2 are not in contact, the maximum resistance value is about 8Ω.

This indicates that the resistance value of the mesh heating element 2 can be stabilized.

In the preferred embodiment of the reticulated heater according to the present invention, the reticulated heating element 2 is formed only by the plurality of heater wires 20 in which the heater bare wire 20a is covered with the enamel paint 20b. However, the present invention is not limited to this. A plurality of first heater wires 200 composed of only the heater bare wires, and a plurality of second heater wires 20 composed of the plurality of heater bare wires 20a coated with the enamel paint 20b, The reticulated heating element 2 formed by tricot knitting that spells continuously and planarly in a direction (vertically) through a loop may be used.

In this case, the first heater wires 200 are braided so as not to cross each other. Thus, the insulation between the heater wires can be reliably insulated by the enamel wire paint, so that the resistance value of the mesh heating element 2 can be stabilized. Further, the first heater wire 200 and the second heater wire 20 are alternately woven, and the like.
First heater wire 2 consisting only of inexpensive heater bare wire
If the ratio of 00 is increased, the cost can be reduced in mass production.

Further, as a preferred embodiment of the reticulated heater of the present invention, the reticulated heating element 2 in which a plurality of heater bare wires 200 are previously formed by tricot knitting may be subjected to insulation treatment.

As such an insulation treatment, formation of an oxide film by heating or application of an insulating paint or insulating oil can be considered. When the oxide film formed by heating is, for example, a copper alloy containing 1% or more of nickel, the heater bare wire 200 is used in advance.
Can be formed by connecting an electrode to the mesh-shaped heating element 2 formed by tricot knitting, setting the heating temperature to 200 ° C., and heating for 1 hour. The insulating paint is applied by applying an insulating paint such as a urethane paint, an acrylic paint, an epoxy paint, or a fluororesin paint to the mesh heating element 2 in which the heater bare wire 200 is formed by tricot knitting in advance, and baking the coating. Is formed. In the application of the insulating oil, a film is formed by applying a small amount of an insulating oil such as silicone oil. In any case, processing must be performed so that the flexibility of the mesh heating element 2 is not significantly impaired.

As described above, if all the intersections of the bare heater wire 200 of the mesh heating element 2 are in contact, the pitch VP
Is 1 mm, the basic length VP is 1 × cos ⁻¹ 3
Since there are three 0-degree long bare heater wires 200 equally in each section mass, it can be modeled as a simple parallel circuit as shown in FIG. As a result, the resistance R of the mesh heating element 2 becomes

[0036]

(Equation 5)

[0037]

(Equation 6)

## EQU4 ## This indicates that the resistance value of the mesh heating element 2 can be stabilized.

When a hard wire that has not been annealed is used as the material of the heater bare wire 200, the heater bare wire 200 is more likely to float at the intersection. Will approach you.
Conversely, when a well annealed soft wire is used, the number of contact points of the bare heater wire 200 at the intersection increases, so that the resistance value approaches the minimum resistance value.

As described above, if the plurality of heater wires 20 and the bare heater wires 200 are regularly spelled so that the loops are continuous in the longitudinal direction, the influence of local breaks and intersections is reduced. Since the mesh heater 1 with high elasticity can be provided, the heater wire 20 or the bare heater wire 200 does not float at the intersection of the heater wire 20 and the bare heater wire 200.

As shown in FIG. 4, electrodes 3 are connected to both ends 2a, 2b in the longitudinal direction V of the mesh heating element 2 formed by tricot knitting. The electrodes 3 cover the entire widths of both ends 2a and 2b of the mesh heating element 2 in the meridional direction V in order to make the mesh heating element 2 electrically stable. As shown in FIG. 5, such an electrode 3 is composed of a conductive tape 31 and a conductive adhesive 32 for fixing the conductive tape 31 to the front and back of the mesh heating element 2. Is a copper foil tape, aluminum mylar tape, etc. having a thickness of about 30 μm, which is resistant to rust and has a proper electric capacity. The conductive adhesive 32 is composed of silicone rubber based adhesive and conductive carbon. Each of them is preferable. Thereby, the mesh heating element 2 can be formed as a parallel circuit, so that the resistance value is extremely stabilized. Lead wires 4 and 4 are connected to the ends of these two electrodes 3 and 3, respectively.
Are fixed, and these lead wires 4, 4 are thermostat 5
It is connected to the.

A twisted wire such as a braided wire may be attached to both ends 2a and 2b in the longitudinal direction V of the mesh heating element 2, and the contact intersection may be locally soldered.
In this way, if the amount of solder is small and the stitch is large, the flexibility of the mesh heating element 2 is not impaired.

Such a net heater is usually knitted by a warp knitting machine.

[0044]

As described above, according to the reticulated heater of the present invention, since it is formed by tricot knitting, it has high elasticity and flexibility, so that it can adhere to complicated curved surfaces. Since the heaters are insulated with an insulator so that the bare wires do not cross each other, or the mesh heating element itself formed only of the heater bare wires is covered with the insulator, the resistance value is increased. Can be stabilized, and a stable and constant calorific value can be obtained. As a result, even when used for a steering wheel or a seat of an automobile, the temperature can be raised in a short time because it is electrically stable, and in particular, in the steering wheel of an automobile, the heater wire does not float at the intersection of the heater wires. In addition, the heater wire does not protrude on the skin for covering the heater. Also, it can be used for the elbow section of complicated piping, etc., and can raise the temperature in a short time, which is useful for ensuring the fluidity of water in severe winter.

[Brief description of the drawings]

FIGS. 1A and 1B are diagrams showing a preferred embodiment of a mesh heater according to the present invention, wherein FIG. 1A is a tricot knitting pattern diagram, and FIG.

FIGS. 2A and 2B are explanatory diagrams of a mesh heater according to the present invention, in which FIG. 2A shows a size and FIG. 2B shows a parallel circuit.

FIG. 3 is an explanatory diagram showing a state of a heater element wire when all intersections of a mesh heating element used in the mesh heater of the present invention are in contact with each other.

FIG. 4 is an overall configuration diagram of a mesh heater according to the present invention.

FIG. 5 is a partial cross-sectional view showing a fixed state of a mesh heating element and an electrode of the mesh heater of the present invention.

[Explanation of symbols]

 1, a mesh heater 2, a mesh heating element 2a, 2b, both ends of a mesh heating element 3, an electrode 31, a conductive tape 32 ···························································································································································································································································. Heater bare wire, first heater element wire VP ..... Merit pitch (stitch pitch) HP ..... Weft pitch (stitch pitch)

Claims (5)

[Claims] A plurality of heater wires each having a wire diameter of 0.02 to 0.12 mm and a single wire diameter coated with an enamel wire paint on a bare heater wire are formed through a loop. A) a mesh-shaped heater having a mesh-shaped heating element formed by tricot knitting spelled continuously and planarly in a direction, and the stitch pitch of the tricot knitting is 0.5 to 5 mm. 2. A plurality of first heater wires each having only a bare heater wire having a wire diameter of 0.02 to 0.12 mm and having a single wire diameter, and said first heater wire being coated with an enamel wire paint. A plurality of second heater wires composed of heater bare wires are formed by tricot knitting which is spelled continuously and planarly in a looping (vertical) direction so that the first heater wires do not cross each other. The stitch pitch of this tricot is 0.5 to 5 mm
A reticulated heater comprising a reticulated heating element. 3. A tricot knit in which a plurality of bare heater wires having a wire diameter of 0.02 to 0.12 mm and a single wire diameter are spelled continuously and in a plane through a loop in a vertical direction. Formed, the stitch pitch of this tricot stitch is 0.5 to 5 mm
Wherein the plurality of bare wires in which the mesh heating elements are formed by tricot knitting are subjected to insulation treatment. 4. The reticulated heater according to claim 1, wherein the bare heater wire is a copper alloy wire containing silver. 5. An electrode is connected to both ends of the mesh heating element in the longitudinal direction so as to be separated from each other, and the electrode is formed of a conductive tape and the conductive tape. 5. The reticulated heater according to claim 1, wherein the reticulated heater comprises a conductive adhesive adhered to the front and back of the heating element.