JP2001357963A - Plane electric heating unit having features in insulating layer - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a plane electric heating unit that is made thin in total thickness and is not vitiated in mechanical strength, and enabled to suppress leakage current, and that has excellent sound insulating characteristics when used as a flooring material and is superior in thermal diffusion to the adjoining panels. SOLUTION: The plane heating unit comprises a laminate of plane electric heating elements on a metal base body through an insulating layer made of a resin seat having gaps.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electric heating element incorporated in a heating floor material, and more particularly to an electric heating element characterized by a structure of an insulating layer.

[0002]

2. Description of the Related Art Positive Temperature Coefficient
oefficient, hereinafter referred to as “PTC”. A surface heating element using a composite material in which conductive particles having characteristics are dispersed in a resin is known. This surface heating element is made by attaching a metal foil or a metal plate as a heat equalizing plate or processing a sheet laminated with metal foil into a tube shape in order to achieve a uniform temperature on the heating surface. The body was put in.

[0003] Further, in the case where the ground is taken from the heat equalizing plate laminated on the surface heating element, a resin sheet is used in order to suppress the current leaking from the surface heating element to the heat equalizing plate to 1 mA or less, which is a technical standard for electric appliances. It is necessary to have a structure of laminating between the surface heating element and the soaking plate, so that the surface heating unit is thick.

[0004] On the other hand, in the case of houses, the height to the ceiling tends to be as large as possible in view of the comfort of the living space.
Electric heating panels for floor heating, which is one of the applications of the surface heating unit, are also being reduced in thickness from 15 mm to 12 mm.

[0005] In order to make the surface heating unit thinner, Japanese Patent Application Laid-Open No. 5-89952 discloses a surface heating unit having a structure in which a conductor and an electrode are covered with a thin insulating layer.

On the other hand, in order to prevent the transmission of sound to downstairs in apartments and the like, slits are vertically and horizontally formed on the back surface of the plywood of the floor material, and these are combined with a plurality of soft materials to achieve high sound insulation performance. The structure obtained is adopted.

[0007]

A conventional surface heating unit having a heat equalizing plate and a ground has a structure in which a resin sheet or the like is laminated between a surface heating element and a heat equalizing plate in order to suppress leakage current. The total thickness was increased, and the rigidity of the entire sheet was increased.

[0008] Further, as the floor material is thinned, it is necessary to reduce the thickness of the electrically heated floor heating panel without impairing the mechanical strength.
It was necessary to reduce the total thickness of the surface heating unit, which conflicted with keeping the leakage current value low.

Further, in the case of incorporating an electrically heated floor heating in a soundproof floor material directly attached to a concrete slab such as a condominium floor, the rigidity of the surface heating unit should be as low as possible in order to increase the level of shielding sound transmission downstairs. In a surface heating unit with a soaking plate and ground,
This was contrary to the increase in rigidity.

[0010] When a surface heating unit having a heat equalizing plate is incorporated into an electric heating panel, a structure in which the heat equalizing plate cannot be expanded, such as a joint portion with an adjacent panel, is compared with a heat generating portion.
The temperature tended to be lower.

The problem to be solved by the present invention is that the total thickness can be reduced, without impairing the mechanical strength.
An object of the present invention is to provide an electric heating surface heat generating unit which can suppress a leakage current value and is excellent in soundproofing when used as a flooring material and also excellent in heat diffusion between adjacent panels.

[0012]

In order to solve the above-mentioned problems, the present invention provides (I) an electric heating surface heating unit in which an electric heating surface heating element is laminated on a metal base via an insulating layer. Provided is an electric heating surface heating unit in which a layer is a resin sheet having voids.

In order to solve the above problems, the present invention has a structure in which (II) a resin sheet having voids is bonded to a metal substrate and / or a surface heating element via a soft adhesive material. An electric heating surface heating unit according to the above (I) is provided.

In order to solve the above problems, the present invention provides (III) a structure in which a resin sheet having voids is partially adhered, adhered or fused to a metal substrate and / or a surface heating element. An electric heating surface heating unit according to the above (I) is provided.

In order to solve the above-mentioned problems, the present invention provides (IV) a method of bonding, adhering or fusing a peripheral portion of an electric heating surface heating unit, and bonding, adhering or adhering an area within 50% of the entire surface. An electric heating surface heating unit according to the above (III) is provided.

In order to solve the above-mentioned problems, the present invention provides (V) the above-mentioned (I) to (I) wherein a ground is provided on a metal base.
V) A cyano-electric heating surface heating unit according to any one of the above items is provided.

Further, in order to solve the above-mentioned problems, the present invention provides (VI) any one of the above items (I) to (V), wherein the electric heating surface heating element is a conductive polymer having a positive temperature coefficient characteristic. An electric heating surface heating unit according to the item is provided.

Further, in order to solve the above-mentioned problems, the present invention provides an electric heating panel comprising the electric heating unit according to any one of the above (I) to (VI) as a constituent element.

[0019]

BEST MODE FOR CARRYING OUT THE INVENTION In an electric heating unit according to the present invention, a metal plate is provided with functions of soaking and grounding, and
In order to reduce the total thickness and reduce the rigidity of the surface heating unit, a resin sheet having voids is used as an insulating layer provided between the heat equalizing plate and the surface heating element. Examples of the resin sheet having voids include a resin cross sheet, a nonwoven fabric, and a resin mesh.

When bonding the resin sheet having a gap to the heat equalizing plate and the surface heating element, the resin sheet having the gap follows the bending in consideration of distortion of the resin sheet having the gap when the surface heating unit is bent. It is preferable to adopt a method of forming a structure in which bonding is performed via a soft material that can be performed, or a method of partially bonding, sticking, or fusing.

As a method of attaching the ground to the resin sheet having a gap, a hole smaller than the fastening diameter is formed in a portion where there is no conductive sheet, and the R-shaped sleeve is fixed through a rivet from the heat equalizing plate side together with the component having the electric wire attached thereto. Method. This makes it possible to reliably ground the thin surface heating unit.

By laminating a resin sheet having voids on the floor surface side from the surface heating element, heat is prevented from being transmitted directly to the surface floor material, thereby diffusing the heat to the peripheral portion of the panel. In addition, it is possible to achieve a uniform temperature on the floor surface.

In order to prevent the resin sheet layer having voids from being separated from the layer between the heat equalizing plate and the surface heating element at the stage of product processing or the like, the peripheral portion of the surface heating unit should be within 10 mm from the end. It is preferable that the resin sheet layer having the voids, the heat equalizing plate, and the surface heating element are integrated with each other by bonding or fusing at a spot a range of 50% and a range of 50% or less within the surface.

The electric heating element used in the electric heating element of the present invention is obtained by covering a conductive sheet provided with electrodes with a cover material and insulating the conductive sheet. And a sheet obtained by dispersing a conductive powder or the like into a sheet.

Examples of the thermoplastic resin used here include polyolefin resins, polystyrene resins, polyamide resins, polyester resins, ionomer resins, and the like. Among these, acid-modified resins and ionomer resins are preferable in that they have adhesiveness to electrodes made of metal or the like, such as acid-modified polyethylene, acid-modified polypropylene, and acid-modified ethylene ethyl acrylate copolymer. Acid-modified polyolefin resins and ionomer resins are particularly preferred.

As the conductive powder, carbon black,
Graphite; metal powders such as copper powder and stainless steel powder; conductive fibers such as carbon short fiber, stainless steel short fiber and brass short fiber; metal oxides such as tin oxide and zinc oxide; and conductive whiskers. Among them, carbon black is preferred.

For example, when carbon black is used as the conductive powder, the mixing ratio of the thermoplastic resin and the conductive powder is preferably in the range of 10 to 45 parts by weight of carbon black with respect to 100 parts by weight of the thermoplastic resin.

As a method for producing the conductive sheet, for example, a kneading machine such as a Henschel mixer, a Banbury mixer, a kneader or an extruder is used to knead a thermoplastic resin and a conductive powder into a conductive resin. Is prepared by dispersing the compound, forming the compound into a film or sheet by calendering or melt extrusion, and cutting the compound. The thickness of the film or sheet thus obtained is preferably in the range of 50 to 500 μm.

As the material of the metal substrate used in the electric heating unit of the present invention, for example, aluminum, copper,
Examples of the metal substrate used in the electric heating unit according to the present invention include an aluminum film or sheet having excellent thermal conductivity and having been subjected to surface oxidation processing.

Next, various embodiments of the electric heating unit according to the present invention will be described with reference to the drawings.

FIG. 1 shows a conceptual diagram of a sheet-like insulating material obtained by knitting a resin into a cloth. Flat tapes 1 obtained by folding and stacking film-shaped resin are arranged in parallel, and similar tapes 2 are woven at right angles to each other,
It is a resin cross sheet as shown in FIG. By knitting the superposed flat tapes in a cross shape, an appropriate air layer can be included in the insulating layer, it can be thinner than a resin sheet, and it is knitted in a cross shape against bending Can follow the bending, and does not increase the rigidity. Further, the knitting in a cross shape has the effect of preventing interlayer destruction due to tension in the vertical direction.

FIG. 2 shows the relationship between the total thickness and the leakage current due to the difference in the structure of the insulating layer. From this figure, it can be seen that a sheet (resin cloth sheet) in which a flat tape formed by laminating resin films in a cross shape (resin cloth sheet) has a smaller thickness and a lower leakage current value than a resin sheet.
This is thought to be due to the presence of an appropriate air layer in the resin cross sheet. Similar results can be obtained when a nonwoven fabric or a resin mesh is used.

FIG. 3 shows a conceptual diagram of the surface heating unit. The surface heating unit has a configuration in which a resin cross sheet 5 is attached to a surface heating element in which a conductive sheet 4 having lead wires 7 is covered with a cover material 3 from above the cover material, and a heat equalizing plate 6 is further attached. is there. The bonding between the cover member 3 and the cross sheet 5 and between the cross sheet 5 and the heat equalizing plate 6 may be performed by using a soft material or partially bonding the cloth so as not to hinder the movement of the cloth when bent. And Further, since the heat equalizing plate 6 is provided on the floor surface side, heat can be diffused to the peripheral portion of the panel by the resin cross sheet.

FIG. 4 is a cross-sectional view of the ground mounting portion. A hole having substantially the same diameter as the R-shaped sleeve 9 with the lead wire 10 is formed in a laminated sheet of the surface heating element 11, the resin cross sheet 5, and the heat equalizing plate 6 and fixed with the fixing rivets 8. The fixing rivet 8 and the heat equalizing plate 6 are fastened in a state of complete contact. In FIG. 4, the shape of the fixing rivet is the same as that of the heat equalizing plate, but a rivet having a semi-circular shape may be used.

FIG. 5 shows another conceptual diagram of the surface heating unit. This surface heating unit has a configuration in which a surface heating element 11, a resin cross sheet 5 and a soaking plate 6 are bonded to each other, and a peripheral portion of the resin cross sheet 5 is formed into a sheet 12 containing no air layer by thermocompression bonding. . The sheet portion 12, the surface heating element 11, and the heat equalizing plate 6 have a structure in which delamination is not caused by pressure bonding. The same structure can be obtained even if the resin cloth sheet 5 is replaced with a resin sheet containing other voids.

[0036]

The present invention will be described in more detail with reference to the following examples.

<Example 1> An electrically insulating film composed of a polyethylene terephthalate film having a total thickness of 0.1 mm and an olefin-based adhesive resin film was placed on the olefin-based adhesive resin side with 115 mm between electrodes and 800 mm in length.
A sheet-like semiconductive resin body (conductive sheet) molded to have a resistance value of 525Ω in an atmosphere of 0 ° C. is arranged, and a pair of twisted wire electrodes is arranged in parallel on each edge thereof on each side. Further, an electrically insulating film was arranged thereon such that the inner layer composed of the olefin-based adhesive resin film was located below, and the resultant was overlaid by thermocompression bonding to obtain an electrically heated surface heating element.

Next, the shape shown in FIG.
A sheet-like insulating material was prepared by knitting a flat tape obtained by folding and laminating a polyethylene resin film having a thickness of about 0.2 mm and a thickness of about 0.2 mm in a cross shape.

A sheet-like insulating material was adhered to the surface of the previously prepared electric heating element, and an aluminum soaking plate having a thickness of 0.1 mm was adhered to obtain a surface heating unit. At this time, the adhesive between the electrically insulating film and the sheet-shaped insulating material constituting the surface of the electrically heated surface heating element and between the electrically insulating film and the soaking plate are made by an adhesive “Super X” manufactured by Cemedine. Was applied to and adhered to a fiber having a diameter of 0.5 mm at intervals of 5 mm.

<Example 2> In Example 1, the surface heat generation was performed in the same manner as in Example 1 except that the adhesive was not applied in the form of spots but applied to the periphery of the resin-made cloth sheet with a width of 3 mm. Got a unit.

<Evaluation> The leakage current value of the surface heating unit obtained in Examples 1 and 2 was 0.1 mA or less as a result of measurement using a universal leakage current meter manufactured by Yokogawa Electric Corporation. L-50 was satisfied at ４4000 Hz.
The temperature distribution on the floor surface was within 5 ° C. as a result of measuring a plurality of arranged states using a thermography JTG-3210 manufactured by Nippon Kogaku.

[0042]

According to the surface heating unit of the present invention, a plastic sheet is used as an insulating layer when a soaking plate is provided on a plastic sheet-like surface heating element and the functions of soaking and grounding are satisfied. Thereby, the total thickness of the surface heating unit can be reduced.

Further, the surface heat generating unit of the present invention uses a soft material when attaching the surface heating element and the resin insulating sheet including the gap and the resin insulating sheet including the gap to the heat equalizing plate. By adopting the method of pasting,
When bending, the interlayer between resin sheets containing voids is distorted,
The rigidity of the surface heating unit itself can be increased without increasing the rigidity of the unit.

Furthermore, the surface heat generating unit of the present invention is provided with a ground, so that when the surface heat generating unit is incorporated in a non-metallic panel and used, even if an unexpected situation occurs in which a metal piece or the like pierces the panel, the electric power is generated. Can be shut off, so the safety is high.

Further, the surface heating unit of the present invention
By installing a metal plate, a resin sheet containing voids, and a surface heating element in this order from the floor surface side, when an electric heating panel installed on the surface floor material is installed, heat is diffused between adjacent panels, reducing heat unevenness can do.

[Brief description of the drawings]

FIG. 1 is a perspective view of a resin cross sheet as an example of a resin sheet having a void used as an insulating layer of the surface heat generating unit of the present invention.

FIG. 2 is a table showing the relationship between the type of material used for an insulating layer, its thickness, and a leakage current value.

FIG. 3 is a perspective view showing an example of the surface heating unit of the present invention.

FIG. 4 is a cross-sectional view of a ground attachment portion of the surface heating unit of the present invention.

FIG. 5 is a perspective view showing an example of the surface heating unit of the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Flat tape which folds and overlaps resin sheet 2 Flat tape which folds and overlaps resin sheet 3 Cover material 4 Conductive sheet 5 Resin cross sheet 6 Heat equalizing plate 7 Lead wire 8 Rivet 9 R type sleeve DESCRIPTION OF SYMBOLS 10 Ground wire 11 Surface heating element 12 Sheet part

[Procedure amendment]

[Submission date] June 23, 2000 (2000.6.2)
3)

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Claim 6

[Correction method] Change

[Correction contents]

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0016

[Correction method] Change

[Correction contents]

In order to solve the above-mentioned problems, the present invention provides (V) the above-mentioned (I) to (I) wherein a ground is provided on a metal base.
V) An electric heating surface heat generating unit according to any one of the above items is provided.

[Procedure amendment 3]

[Document name to be amended] Statement

[Correction target item name] 0017

[Correction method] Change

[Correction contents]

Further, according to the present invention, in order to solve the above problems, (VI) any one of the above items (I) to (V), wherein the electric heating surface heating element is a conductive sheet having a positive temperature coefficient characteristic. The present invention provides an electric heating surface heating unit according to (1).

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3K034 AA02 AA03 AA05 AA09 AA15 AA31 BB08 BB13 BC02 BC03 BC16 CA02 CA15 EA16 FA03 FA13 FA32 FA33 HA04 HA10 JA01 JA09 3L072 AA01 AB04 AC02 AD02 AD17 AE08

Claims (7)

[Claims] 1. An electric heating unit comprising a metal substrate and an electric heating element laminated on an insulating layer via an insulating layer, wherein the insulating layer is a resin sheet having voids. unit. 2. The electric heating surface heating unit according to claim 1, wherein the resin sheet having a void has a structure in which the resin sheet is bonded to a metal base and / or a surface heating element via a soft adhesive material. 3. The electric heating surface heating unit according to claim 1, wherein the resin sheet having voids has a structure in which the resin sheet is partially adhered, adhered or fused to a metal substrate and / or a surface heating element. 4. Adhering, adhering or fusing the peripheral portion of the electric heating surface heating unit, and reducing an area within 50% of the entire surface to
The heating unit according to claim 3, which is adhered, adhered or fused. 5. A metal substrate provided with a ground.
The electric heating surface heating unit according to any one of the above. 6. The heating unit according to claim 1, wherein the heating unit is a conductive polymer having a positive temperature coefficient characteristic. 7. An electric heating panel comprising the electric heating unit according to claim 1 as a constituent element.