JP2006054131A - Electric resistive element - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a heater material which can be simply formed by cutting it in any shape. <P>SOLUTION: The electric resistive element comprises a conductive layer molded in a thin-plate or a sheet form by melting a mixed body of thermoplastic resin and conductive fine particles, and a flat electrode formed on both sides of the conductive layer. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a sheet-like or thin-plate-like, flexible electric resistor that operates at a low voltage much lower than 100 V, for example, 30 V or less, particularly a low-temperature heating heater (planar heating element). Can be used in a flat state, of course, can also be pasted according to the curved shape of the object to be heated, and it can also be cut to shapes such as various figures and characters to match the figure etc. A heater that generates heat is provided.

  For example, electric heaters for high-temperature heating are used for cooking devices such as water heater pots, pot-type cookers or plate heaters, health appliances such as foot heaters, and small baked cookers such as fish-yaki and bread-bakers Has been. In general, nichrome wire and sheathed heaters are most commonly used for this electric heater. In addition, a heater for low-temperature heat generation in which a metal foil is laminated on an insulating plate and etched into a predetermined pattern is used.

  Among these electric heaters, for example, in the case of a foot warmer that directly heats the human body, it is a low temperature of 40 ° C. or lower. Many of these heaters are designed to operate at 100V or 200V.

  In addition, large electric heaters are used for snow melting equipment on frozen roads and roofs, which include cable heaters, sheet heaters molded from thermoplastic resins, or metal foils laminated to electrical insulation sheets. In addition, an etching type planar heater or the like in which a pattern of a heat generating portion is formed by etching the metal thin foil is used. In addition, as a heater for a floor heating device, a planar heater using a thermoplastic resin having excellent low temperature characteristics and safety is used (see, for example, Patent Document 1).

  A thermoplastic resin is used as a material for the planar heater described in Patent Document 1. This thermoplastic resin is made of, for example, a thermoplastic resin such as polyethylene, propylene, ethylene / vinyl acetate copolymer (EVA), a saturated polyester alone, or a mixture thereof as a base material. As a body, about 5 to 25% of carbon fine powder is added to form a mixture, which is melted by an extruder and extruded into a sheet (thin plate), and two electrode wires are formed along both edges. Is provided. This surface heater has recently been widely used as a member for floor heating, because it can be manufactured continuously and efficiently, and the effect of automatically limiting the current ( This is because it has a PTC effect.

  Since this planar heater is made of thermoplastic resin, it is designed to operate at a relatively low temperature in which the heat generation range is around 20 ° C. to 40 ° C. and does not deteriorate. This planar heater has a unique characteristic that the coefficient of thermal expansion with respect to the temperature rise is large, and the electrical resistance suddenly increases accordingly. This characteristic is called “PTC characteristic”. When the temperature rises beyond a certain range due to the PTC characteristic, the current value is rapidly limited due to a rapid increase in the resistance value, and accordingly, the temperature rise is automatically suppressed. Because of this unique characteristic, there is no accident such as a fire due to overheating of the heater, and a safe heating device is configured.

  In addition, this sheet heater is made of thermoplastic resin, so it is inherently corrosion resistant. For example, it is used for animal (pig farming, poultry farming) and plant and tree cultivation, especially for fish farming. It can be effectively used to heat fry grown on fishing reefs.

  The method of manufacturing a heater by mixing a thermoplastic resin and carbon fine powder described in Patent Document 1 and extruding the mixture into a cylindrical sheet with an extruder is not very suitable for mass production. In particular, the operation of uniformly adjusting the thickness of the sheet is difficult due to the characteristics of the die, and it is difficult to change the width of the planar heater.

Therefore, the present inventor has invented an extrusion molding apparatus that has improved the drawbacks of the conventional extrusion apparatus, and has previously proposed this (see Patent Document 2).
Japanese Patent No. 1232594 (Japanese Patent Publication No. 55-31598) Patent No. 3466171 (Japanese Patent Laid-Open No. 2000-17226)

  The main application of the sheet heater (electric resistor) made of the thermoplastic resin is a component of a floor heating device. In the case of this planar heater, a general width is about 100 to 450 mm and the width is changed according to the calorific value and application, and electrode wires are arranged in parallel on both edges and integrated. It is a heater configured to flow a current between two electrode wires in a plane. An AC voltage of 100 V is normally supplied as a power source for the heater for floor heating.

  Recently, automobile seats, motorcycle occupant gloves, medical beds, and appliances that vaporize aroma oils in small increments have been proposed, but the requirements for heaters used in such low calorific value applications The following can be mentioned as:

  I. It should be able to be heated at a low voltage (for example, about 30V or less, especially about 12V) with virtually no electrical damage to the human body and almost no danger of fire or burns.

  B. It must be flexible and can easily cope with curved surfaces as well as flat surfaces.

  C. It can be a heater that can be heated according to the shape and application of the heated part such as a round shape, a ring shape, a heart shape or a glove hand shape as well as a simple shape usually used such as a rectangle or a strip. .

  D. Open an opening with a predetermined shape or size in a part that does not require heating, or a predetermined part of a flat plate, regularly open a large number of windows in a grid pattern, or heat a complicated part Or, it is possible to easily manufacture a heater in which a portion that does not generate heat is formed.

  The present invention is a thin sheet-like electric resistor, specifically an electric heater. And, for example, even if pasted to the curved surface of a cylindrical body or an object to be heated, or appropriately cut to the required size or shape, the electric resistor for sheet-like heaters for low voltage can be “heated to that shape” Is intended to provide.

  In the present invention, a mixture of a thermoplastic resin and conductive fine powder melted and formed into a flat plate or sheet is referred to as a “conductive layer”, and a flat plate is formed on both sides of the conductive layer. A structure in which electrodes are bonded to each other so as to be energized between the two electrodes (in the thickness direction of the sheet) is referred to as an “electric resistor”, that is, a planar heater.

  In order to achieve the above object, an electric resistor operating at a low voltage according to the present invention, that is, a planar heater and its application product are configured as follows.

  1) The invention of claim 1 comprises a conductive layer formed by melting a mixture of thermoplastic resin and conductive fine powder into a thin plate or sheet, and planar electrodes formed on both sides of the conductive layer. It is an electrical resistor.

  This electric resistor constitutes a thin electric heater, is thin, can be cut with scissors or a cutter knife, and can be used for different applications from conventional heaters.

  2) In the invention of claim 2, the thickness of the conductive layer is much thinner than the length and width, and when a current is passed between the two planar electrodes, a current flows in the thickness direction of the conductive layer, It has the property of generating heat over the entire area of the electric resistor, and is an electric resistor that generates heat even when it is cut and the area or shape is changed. Can be used for applications.

  3) The invention of claim 3 is characterized in that the thickness of the electric resistor is 2 mm instead of 0.2 mm. Unlike an ordinary heater, this electric resistor generates heat by flowing a current in its thickness direction. In addition, the conventional heater is a planar direction.

  The heater according to the present invention has a thin thickness of 0.2 to 2.0 mm, is cuttable, flexible, and excellent in workability.

  4) The invention of claim 4 uses a conductive paste as an adhesive means between the planar electrode and the conductive layer, and can be easily cut and formed in accordance with the shape of the object. Can be attached according to the shape.

5) The invention of claim 5 comprises a conductive layer formed by melting a mixture of a thermoplastic resin and conductive fine powder into a flat or sheet shape, and planar electrodes formed on both sides of the conductive layer. In the electric resistor, assuming that the thickness of the electric resistor is 0.2 mm to 2 mm,
Voltage indicia rack is an AC of a low voltage below 30 V, further power consumption 500 W / m ² or less, preferably 100~250W / m ^2.

  The electric resistor, that is, the heater according to the present invention is for low voltage operation, and therefore, the heat generation amount is relatively small, and there is a possibility that the application is limited.

  6) The invention of claim 6 is an electric resistor comprising a conductive layer formed in the shape of a flat plate or a sheet and a flat electrode provided on both surfaces of the conductive layer, wherein the flat electrode is a thin metal plate or a metal foil. It is characterized by being.

  7) The invention of claim 7 is characterized in that the flat electrode is constituted by a knitted fabric knitted with a thin metal wire, or a knitted fabric using a thin metal wire and a heat-resistant fiber.

  When a thin metal plate or metal foil is used as an electrode, the degree of adhesion with the conductive layer becomes a problem. Therefore, in the present invention, when a knitted fabric of a thin metal wire is used as an electrode, the adhesiveness by biting into the conductive layer is very good. For example, even if the sheet is bent, there is no risk of poor conduction. Moreover, the property which can endure some expansion-contraction with respect to an electrical resistor can be given.

  8) The invention according to claim 8 is that the planar electrode on the other surface is not a single sheet but is formed in a small size and an arbitrary shape and size with respect to the area of the planar electrode arranged on one side of the conductive layer. Has been. Moreover, these electrodes are formed with a preliminary interval so as not to be electrically connected to each other.

  Therefore, a large number of small heaters can be appropriately manufactured by cutting and separating individually using this preliminary interval.

  9) According to the invention of claim 9, a ceramic layer that emits far-infrared rays according to the heat generation of the conductive layer, preferably a ceramic layer having a two-layer structure, is formed on the outer surface of the planar electrode disposed on the heated object side. It is characterized by.

  This ceramic layer has a function of actively extracting heat energy generated by the heater, which is an electric resistor, to the ceramic layer side and emitting it as far infrared rays. This ceramic layer has a two-layer structure in which the underlying layer (first layer) has a central wavelength of radiant energy (short wavelength) such as titanium oxide, and the upper layer (second layer) is oxidized. The maximum effect can be achieved by arranging a material having a central wavelength of radiant energy (long wavelength) in a lower temperature range than the wavelength such as aluminum.

  10) The invention of claim 10 is characterized in that an electric resistor is laminated on a heat insulating layer such as foamed resin, and the electric resistor side is used as a heating surface.

  According to the present invention, if the dashboard of an automobile is formed with a heat insulating layer such as a foamed resin, and the electric resistor is further directed to the windshield surface, the windshield surface is heated by the radiant heat generated from this to act as a defroster. Can be made.

  In addition, by forming a heat insulating duct made of a synthetic resin foam formed on the inner surface of the electrical resistor, air is heated while passing through the duct, and this air is used for heating. You can also

  11) The invention of claim 11 is characterized in that the electric resistor, that is, the electric heater is wrapped and protected by a soft insulating layer, and is housed in a heat insulating member for heating a part of the human body. It is a human body warming tool. This human body warming tool and a stuffed toy for children can be used as a heating tool, or applied to a heating seat such as a driver's seat of an automobile.

  12) The invention of claim 12 is applicable to the heat retaining member for gloves, chair cushions, waistcoats used outdoors, and the like.

  The material of the electric resistor according to the present invention, that is, the electric heater, has a three-layer structure including a conductive layer made of a thermoplastic resin manufactured by a known method and flat electrodes arranged on both sides thereof. . A major feature is that the current flow in the surface direction in the conventional planar heater is changed to a flow in the thickness direction.

  As a result, this sheet heater is capable of functioning satisfactorily as a heater even if the sheet is cut into a predetermined shape by cutting a synthetic resin sheet with scissors or a cutter knife. . Moreover, the conductive layer between the two plate-like electrodes has a characteristic of generating heat in accordance with its shape.

  This planar heater is essentially flexible and elastic because it uses a thermoplastic resin as a basic material, and can be molded according to the object to be heated using this characteristic. Moreover, it is possible to use it by slitting in a ribbon shape, or by making holes in a lattice shape in a planar shape to make a heater, or by forming a hole having an arbitrary shape and size.

  Also, use this sheet heater by laminating it on other plate materials such as heat insulating material such as foamed resin plate, or by putting it inside a stuffed toy, bed or sheet. Can do.

  The planar heater having this special structure is electrically safe because it operates at a low voltage because the distance between the electrodes is short. In addition, for example, when a needle, nail, knife, or the like is passed through this planar heater, there is a characteristic that the conductive layer melts locally only at that part and the power is cut off, and there is an accident such as local heat generation due to short circuit. Absent.

  Furthermore, a planar heater having a conductive layer made of the thermoplastic resin of the present invention as a main material as a central member does not flow linearly like a heater using a conventional heating wire, and has a thickness between electrodes. Since the current flows in the right direction, a strong current does not flow, so that electromagnetic waves that affect the human body are hardly generated.

  In addition, by adding a small amount of foaming agent to the conductive layer and forming it as a foam with a low foaming rate (if the foaming rate is too high, current flow is affected), it is possible to make a planar heater with a cushion. It is.

  The thermoplastic resin (main raw material) forming the main body of the conductive layer is polyethylene, propylene, ethylene, vinyl acetate copolymer (EVA), a saturated polyester alone or a mixture thereof.

  Further, the conductive fine powder (subsidiary raw material) is one kind selected from harness black, graphite, ketjen black or acetylene black, or a mixture thereof.

  And the addition amount of this electroconductive fine powder is 5 to 25 weight% with respect to the said thermoplastic resin, Preferably it is about 10 to 20 weight%, It is characterized by the above-mentioned.

  The electrical resistor according to the present invention is sheet-like and flexible. Therefore, it is possible to draw by making use of this characteristic, and using this drawing characteristic, for example, it is sufficiently possible to heat the bathtub electrically by fitting it onto the outer surface of the bathtub of a Western style bath. Therefore, it can be applied to a heating means such as a bathtub or a heat retaining means.

  By using this formability to form a pot shape with a conical wall surface and keeping the bottom of the flower pot warm by this, for example, a rooftop plant can be heated at a low voltage. In particular, it is troublesome in managing the electricity on the roof, and there are dangers such as electric leakage and electric shock. Therefore, by using a heater that operates at a low voltage, it is easy to manage rooftop plant fish with a large temperature difference in winter.

  The conductive layer constituting the main part of the electric resistor of the present invention is sheet-like, thin, flexible, and can be handled in the same manner as a rubber sheet. The calorific value is the same.

  Again, the electrical resistor of the present invention, i.e., the planar heater, has the following important characteristics.

  a. Excellent workability.

  Since the electric resistor according to the present invention is formed of a sheet using a thermoplastic resin as a base material and flat electrodes are disposed on both sides thereof to form a thin plate-like three-layer structure, the thermoplastic resin layer between the electrodes Is the heating element itself, and therefore the electric resistor can be grasped as a fine resistor or a collection of heating elements.

As a result, the sheet can be cut into small pieces, or cut in accordance with various shapes such as characters. Moreover, it can heat as a porous sheet which opened many small holes, allowing a liquid and gas to pass through. (Even if cut into any shape, heat can be generated by supplying power between the flat electrodes arranged on both sides of the conductive layer.)
b. It can be used for many purposes.

  For example, a sheet-like electric resistor, that is, a sheet heater is cut and used as a strip shape, or it is formed into a spiral shape by forming it into a spiral shape, or a special heater wound in a spiral shape. be able to.

  As a large device, it is attached along the outer surface of the object to be heated, such as a bathtub, to heat the bathtub itself, or as an industrial application, it is applied to the heated air passage part of the dashboard of an automobile to heat the air. It can be used as a defroster or as a heating duct.

  In addition, if the radius of curvature is small and the heater is simply bent, wrinkles may occur or it may be difficult to apply it to the curved surface accurately. It can open and give the necessary bending to the planar heater itself with increased flexibility.

  In a normal heater, it is impossible to easily cut the shape once determined and change it to an appropriate heater.

  In the present invention, a thermoplastic resin is used as a main raw material, a predetermined amount of a conductive material is added thereto, mixed, melted, discharged from a base having a slit-like opening, and molded into a conductive sheet (conductive layer). In addition, a thin sheet metal or metal foil is laminated on both sides of this conductive sheet as a planar electrode so that it can be energized, and a heater for low voltage is formed by energizing between these two planar electrodes. is doing.

  The conductive sheet, which is a heating material of the heater, is thin, and the conductive sheet generates heat by flowing current in the thickness direction and generates heat in a planar manner. With this unique function, the conductive material sheet can be cut to change the area, or a heater having a shape or pattern adapted to the object to be heated can be obtained.

  In other words, since the conventional heating device or heater uses a nichrome wire or a metal foil is etched to form a heat generation pattern, it must be designed from the beginning according to the object to be heated. On the other hand, the present invention, as described above, can be attached to the object to be heated by cutting it into a required shape and size as in the case of using a thick adhesive tape. It can be used for different purposes than the other heaters.

  Next, embodiments of the present invention will be described with reference to the drawings.

[Example 1]
A. Manufacture of conductive sheet
a) Material 1: A thermoplastic resin (polyethylene, polypropylene, ethylene / vinyl acetate copolymer (EVA), nylon, polyvinyl chloride (PVC) alone or a mixture thereof can be used as a main raw material.

  In this example, a mixture of 40% polypropylene (weight), 40% polyethylene and 10% EVA was used as the thermoplastic resin.

  b) A mixture of 30% Ketchen Black and 70% graphite was used as the conductive material as the material 2 and the auxiliary material, and 13% (by weight) of the material 1 was added.

  c) Molding method: a normal synthetic resin extruder and a structure described in Japanese Patent No. 3466171 (Japanese Patent Laid-Open No. 2003-17226: Patent Document 2), two sheets are extruded simultaneously at the top and bottom, and electrodes are formed on both sides. A high-capacity planar heating element manufacturing apparatus was used in which wires were placed and further pressed in the softened state of these sheets to adhere to one sheet.

  In the molding apparatus, the first-stage (upper-stage) resin path was closed and the supply of the two electrode wires was stopped, and one conductive sheet was continuously molded from the lower slit.

Four types of sheets with different thicknesses of 0.5, 1.0, 1.5, and 2.0 mm are extruded by finely adjusting the interval over the entire length of the slit of the die, with the discharge width of the die being 180 mm. Then, this was immersed in cooling water at about 15 ° C. to form a conductive sheet (conductive layer).
B. Production of Planar Heater FIG. 1 is an enlarged sectional view showing the conductive sheet 1 obtained as described above. Among these four types of conductive sheets 1, one having a thickness of 1.0 mm was selected, and cut into a square of 200 mm × 200 mm in length and width to obtain an electric resistance sheet 1a.

  Then, a copper foil having a thickness of 0.05 mm is used as an electrode material, and the both sides of the electric resistance sheet 1a are flattened by conductive paste 4 “trade name: Byron” (for hot melt adhesive use) manufactured by Toyobo Co. The electrodes 2 and 3 were bonded by heating to produce a planar heater material 5 having a three-layer structure. In addition, although this copper foil can use the thing of the range of 0.05-0.15 mm, The thickness is determined by the relationship with the thickness of a conductive layer.

  The planar heater material 5 is designed to operate at a low voltage (for example, a battery of 12V, an AC power supply of 30V or less). Further, as the conductive paste 4, those containing a solvent are highly likely to deteriorate with time, so it is preferable to use an adhesive that does not contain this solvent.

  The thickness of the electrical resistance sheet 5 (electrical resistance body) is such that there is no concern that electrical insulation problems such as electrical shorting will occur when used as a heater, and that the conductive sheet 1 is connected when wiring is connected to electrodes. Considering that no thermal damage is caused, the thickness of the thinnest sheet is limited to 0.2 mm, and the thick one is limited to 2.0 mm. It is in the range of 5 to 1.0 mm.

  Further, the thickness of the electric resistance sheet 5 is limited to 2 mm in order to keep the flexibility sufficiently without losing the flexibility. If it is thicker than the upper limit, the flexibility becomes poor and the function as a flexible heater is lowered. Further, if this electric resistance sheet is forcibly bent with a small radius, peeling occurs due to the difference in elongation between the electric resistance sheet 1a and the electrodes 2 and 3, so 2 mm was made the upper limit.

  However, a material in which a large number of holes are formed in the planar heater material 5 is flexible even if it is thick to some extent, and the thickness can be changed within a range in which the function as a low voltage heater is not lost.

Next, the planar heater material 5 processed as described above was cut into a square having a length and width of 200 mm. The peripheral portions of the electrodes 2 and 3 laminated on the upper and lower surfaces of the electric resistance sheet 1a constituting the planar heater material 5 are arranged so as not to be electrically contacted by a method such as delicate grinder polishing, and the polished surface A sheet heater material 5 having no danger of electrical short-circuit was applied by applying a paint having heat resistance and electrical insulation as required. The standard heating value of the planar heater material 5 was 150 W / m ² .

  If the conductive sheet is as thin as 0.4 mm or less, for example, there is a possibility that both the electrodes 2 and 3 are quite close to each other and an electrical problem may occur. Therefore, in order to avoid such a state, the portion where the electrical resistance sheet 1a is exposed by reducing the size of the other electrode with respect to the size of one plate-like electrode, that is, the “short circuit distance” is set. It is better to adopt a longer structure.

  When wires were connected to the electrodes 2 and 3 on both sides of the planar heater material 5 produced as described above, and a 12 V battery was connected thereto, heat was generated at about 35 to 45 ° C. within a short time. From this experiment, it was found that a planar heater operating at a low voltage of 30 V or less was completed.

[Example 2]
FIG. 3 shows a deformed heater 6 in which the planar heater material 5 manufactured in the manner shown in FIG. 2 is cut into a heart shape, and its peripheral portion is polished to ensure electrical insulation. A simple heater cannot be manufactured easily.)

The electric resistance sheet 1a constituting the heater 6 had a thickness of 1.0 mm and an area of about 25 cm ² . When a 20V battery was connected between the electric wires 7a and 7b connected to the electrodes 2 and 3 on both surfaces of the electric resistance sheet 1a, heat was gently generated at about 35 to 45 ° C.

  The small heater 6 can be used for, for example, a heating tool for heating an infant's body at a low temperature by putting it in a stuffed animal preferred by the infant. In this case, when the heater 6 is hard and has a sense of incongruity as a stuffed animal, it is preferable to punch out a small hole in the heater 6 and use it with increased flexibility.

  FIG. 13 shows an electric resistor, that is, a sheet heater 60 cut to a predetermined size using the sheet heater material 5 shown in FIG. 1, and the sheet heater 60 has a large number of protrusions. This is used when the object is heated by being applied to the surface of a certain object, and a large number of holes 61, 62, 63 are opened in the heater 60 so that the protrusion protrudes or penetrates.

  The heater having such a shape can achieve the purpose only by using the electric resistor according to the present invention. A paper pattern that matches the surface shape of the object to be heated is prepared and this paper pattern is used. Necessary parts can be covered with a heater and heated. Surprisingly, in the case of this heater 60, even if the cut 64 is formed, it does not have any influence on the heat generating action. In an extreme case, the heater 60 can be further cut into small pieces and used as a heater.

  In addition, when using the heater 6 shown in FIG. 3 as a heater, it accommodates in the flexible bag made from a plastic with electrical insulation and water resistance, and seals to ensure watertightness and electrical safety. Furthermore, it is preferable to provide a towel cloth on the surface that comes in contact with the skin to ensure hygiene and safety (the same applies to the heater in FIG. 13).

Example 3
FIG. 4 shows a sheet heater having a width enough to wrap the peripheral surface of the pipe 10 on the insulating layer 10a of polyester film formed on the surface of the aluminum pipe 10 (thickness 2 mm, diameter 26 mm, length 500 mm). 11 shows a pipe heater 12 wound with 11. Reference numeral 14a denotes a lower electrode connecting portion on the electrode 3 side, and 14b denotes an upper electrode connecting portion on the electrode 2 side.

  In this embodiment, the lower electrode 3 of the planar heater 11 is formed of a metal foil having a continuous plane. On the other hand, the upper electrode 2 is formed by opening the opening 13 to reduce the area of the electrode 2 so that the amount of heat generated in that portion is adjusted.

Since this cylindrical heating apparatus can accommodate an object to be heated inside the aluminum pipe 10, for example, the heating of foods such as cooked foods and confectionery, the heating body applied to parts such as stiff shoulders, the warming of chemicals, or liquid It can be used for various applications such as heating.
Example 4
FIG. 5A is a cross-sectional view of a planar heater 15 using a “mesh electrode” as a kind of planar electrode, and FIG.

  This planar heater 15 uses a conductive sheet 1b similar to that manufactured in Example 1 as a conductive layer, and mesh electrodes 2a and 2b (a thin metal wire having a diameter of about 10 μm) on both sides thereof. A certain metal net) is arranged. Then, this was sandwiched between two heating plates and heated to about the softening temperature (about 110 ° C.) of the conductive sheet 1b. When the conductive sheet 1b was heated to a predetermined temperature, the mesh electrodes 2a and 3a were immersed on both surfaces of the conductive sheet 1b in an embossed manner to ensure electrical contact.

  Since the planar heater 15 uses the mesh electrodes 2a and 3a as the planar electrodes, it was confirmed that the electrical connection between the conductive sheet 1b and the mesh electrodes 2a and 3a was good. Further, the heater 15 as a whole has flexibility due to the flexibility of the mesh electrodes 2a, 3a.

  Therefore, since it can be used by being deformed in accordance with the curved surface (curvature) of the surface or inner surface of various heated objects, it can be effectively used even when heating a heated object having a delicate curved surface. Furthermore, the stretchability and flexibility characteristics can be changed by selecting the thickness of the metal wire and the density of the net-like material, and by using a metal wire with a crimp. By changing the material and thickness of the metal wire, even a very flexible planar heater 15 can be easily manufactured.

Example 5
In FIG. 6, openings 17 patterned in various shapes are arranged on the surface of the conductive sheet 1 manufactured as shown in FIG. 1 (Example 1), for example, the planar electrode 2b made of the upper metal foil. In addition, a front view of a planar heater 16 (electric resistor) using a normal flat electrode 2b that does not form such an opening is shown in the lower electrode made of metal foil.

  In the case of the planar heater 16, the opening 17 is provided in accordance with the position of the heated object, the size of the heated part, and the heating location, and a power-saving low-voltage heater can be obtained.

Example 6
FIG. 7 shows a cross-sectional view of the heater 22 with a heat insulating material. This heater 22 is provided with a planar heater 20 (electric resistance sheet) provided with planar electrodes 2d and 3d on both surfaces of a conductive sheet 1c on the surface of a heat insulating layer 19 made of a heat insulating material such as a synthetic resin foam such as polyethylene. In addition, an “insulating heater 22” is configured by bonding an electrically insulating sheet 21 made of a synthetic resin with an adhesive portion 21a so as to cover the entire surface of the heater 20 by bonding.

Example 7
FIG. 8 shows a heater 22 with a heat insulating material manufactured in Example 6 (FIG. 7) along the inner surface of a duct 24 having a square cross section, which guides a gas (or a liquid in some cases) such as air. The apparatus which heats is shown. And in the part which bends this heater 22, the slit 25 is opened at a predetermined interval and formed easily.

  The planar heater according to the present invention is necessary as described above because the conductive sheet (electric resistance sheet) generates heat by energizing between the flat electrodes arranged on both sides of the conductive sheet. There is no electrical problem even if a slit is opened in the portion.

Example 8
FIG. 9 shows a planar heater in which the planar heater 15 having the mesh electrodes 2a and 3a shown in FIG. 5 (Embodiment 4) provided on both surfaces of the conductive sheet 1b is accommodated inside an electrically insulating bag body 15a. It is sectional drawing which shows the heating apparatus 27 which uses 26 by laminating | stacking (adhering) 26 to the surface of heat insulation layers 19 (heat insulation sheet), such as urethane foam resin. This heating device 27 can be used in the same manner as the heater 22 with a heat insulating material shown in FIG. 7 (Example 6).

  As shown in FIG. 9, the heating device 27 provided with the heat insulating layer 19 can be used, for example, for a flower or plant cultivation device or a water tank heating device in winter.

Example 9
FIG. 10 is an exploded perspective view of the planar heater material 30 according to the ninth embodiment.
The conductive sheet 1 manufactured in Example 1 (FIG. 1) is used, and the planar electrode 3 made entirely of copper foil is adhered to the back surface of the conductive sheet 1 in the same manner as in FIG. An electrode 2m made of copper foil having various shapes and sizes is bonded to the upper surface of the conductive sheet 1 with a conductive paste.

  The electrode 2m has a shape necessary for the application, the electrode A constituting the electrode 2m is rectangular, the electrode B is square, the electrode C is circular, and the electrode D has a large number of openings. A lattice-shaped one having an opening d is shown. This planar heater material 30 is formed with a non-energized area F where the conductive sheet 1 is exposed around the electrodes A, B, C.

  When this planar heater material 30 is used, a large number of small planar heaters can be formed at once by cutting off the electrodes A, B, C,... . And the electric wire for electric power feeding is connected to the electrode of both surfaces. Further, if there is an electrical problem with the bare heater, it is housed in an electrically insulating bag and used in a state where the electric wire is drawn out.

Example 10
11 and 12 show the application of the present invention to a Western-style bathtub.
As shown in the figure, a surface heater 32 having the structure shown in FIG. 2 is molded and pasted on the outer surface of the bathtub 31, and the outer surface is covered with a heat insulating layer 33.

  The planar heater 32 is formed by laminating an electric resistance sheet (conductive layer) 1a and planar electrodes 2 and 3 on both sides thereof, and further, a ceramic layer 34 is formed on the surface of the electrode 2. An insulating layer 35 is laminated on the surface of the ceramic layer 34 to ensure safety.

  The ceramic layer 34 has a two-layer structure. A titanium oxide layer is formed on the electric resistance sheet 1a side, and an aluminum oxide layer is formed thereon by plasma spraying. The ceramic layer having this structure is generated from the electric resistance sheet 1a. Thermal energy (far infrared rays) is efficiently guided to the bathtub 31 side and can heat the water in the bathtub 31.

  Since the electric resistance sheet according to the present invention can be heated entirely by supplying power to the flat electrodes on both sides of the sheet, it can be easily applied to the above-mentioned applications. Can do it.

Example 11
(Application to other applications)
a) In the second embodiment shown in FIG. 3, the heart-shaped heater 6 is shown. However, if the application is a heating device for infants or children, it is suitable for various characters popular with infants and children. It is preferable to use after cutting or shaping. Of course, since it is difficult to use the heater 6 as it is, it is used in a state that is preferred by children by using necessary cushioning materials and heat insulating materials in combination, and those that have improved safety.

  b) Gloves for bike riders, for example, require heating especially in winter. In such a case, the planar heater material 5 (FIG. 2) is appropriately cut into a shape that can be incorporated in the glove, and a hole or a slit is formed as necessary, and the surface is flexible with electrical insulation and water resistance. A cover heater or the like is applied to form a hand-shaped heater.

  And this planar heater is arrange | positioned at the inner surface (especially back side) of a glove. Then, a battery is connected to this heater for heating. In addition, when one electrode is comprised with many small electrodes as shown in FIG. 10, the shape of this electrode is formed to match with a glove, and what was cut | disconnected according to the shape is used as a heater. be able to.

c) Application to automobile seats Especially for trucks that are driven over long distances, the buttocks get cold in winter. In addition, even ordinary cars require heating of the driver's seat in the winter. Although heaters used for such applications have already been proposed, there are only a few that are actually popular. The reason is that a wire-shaped heating element mainly composed of nichrome wire is used, so the heating range is local, a large area cannot be heated, and a cord-shaped heating element is used for the human body. This is because the use feeling is worsened by arranging them in adjacent portions. Furthermore, since the heating wire lacks elasticity, a special wiring shape that can eliminate this is required.

  When the planar heater made of the electric resistor according to the present invention is used for such an application, the structure is provided with expansion and contraction and flexibility. For example, a strip-shaped heater material using a planar electrode made of a mesh (preferably a mesh using a crimp yarn) is used, and this is housed in a cushion material and used in a cover.

  d) In the case of a character-shaped dakimakura for an infant, an appropriate number of thin strip-shaped planar heaters may be arranged on the pillow held by the infant and heated at a low temperature.

  In addition, in the case of a sheet-type heating device that is used on a bed in a hospital or a heating device that is used on the side of a quilt, it is necessary to give flexibility to the planar heater. For this purpose, it is preferable to select from the above-mentioned various planar heaters, and further to use a variety of flexibility imparting processing methods and structures to form a safe heating device without feeling uncomfortable.

It is sectional drawing of an electroconductive sheet (conductive layer). It is sectional drawing of the planar heater material which stuck metal foil on both surfaces of the electroconductive sheet (conductive layer). It is a perspective view of the heart-shaped heater which processed the said planar heater material. It is a perspective view of a pipe type heater. (A) is the cross section of the planar heater which uses a mesh electrode, (B) is the same top view. It is a top view of the planar heater which provided many cross-shaped openings in one electrode. It is sectional drawing of a planar heater with a heat insulating material. It is a perspective view of the heating duct formed with the planar heater with a heat insulating material. It is sectional drawing of a planar heater with a heat insulating material. It is a disassembled perspective view of the planar heater material which can manufacture many small heaters. It is principal part sectional drawing of a bathtub with a heater. FIG. 12 is a partially enlarged view of FIG. 11. It is a perspective view of the planar heater which opened many holes.

Explanation of symbols

1 conductive sheet (conductive layer) 1a electric resistance sheet
2, 3 Copper foil (plate electrode) 4 Conductive paste 5 Sheet heater material 7a, 7b Electric wire 10 Aluminum pipe 11 Sheet heater 10a Polyester film 12 Pipe heater 13 Opening 15, 16 Sheet heater 19 Heat insulation layer 20 Sheet shape Heater 21 Electrical insulation sheet 22 Heater with insulation

Claims (13)

An electric resistor comprising a conductive layer formed by melting a mixture of a thermoplastic resin and conductive fine powder into a thin plate or sheet and planar electrodes formed on both sides of the conductive layer. In an easily cutable electric resistor comprising a conductive layer formed by melting a mixture of a thermoplastic resin and conductive fine powder into a thin plate or sheet shape and planar electrodes formed on both sides of the conductive layer, The thickness of the conductive layer is much thinner than the length and width. When a current is passed between the two planar electrodes, a current flows in the thickness direction of the conductive layer and generates heat over the entire area of the electrical resistor. 2. The electric resistor according to claim 1, which has characteristics and generates heat on the entire surface even if the area or shape is changed by cutting. In an easily cutable electric resistor comprising a conductive layer formed by melting a mixture of a thermoplastic resin and conductive fine powder into a flat or sheet shape and planar electrodes formed on both sides of the conductive layer, 2. The electric resistor according to claim 1, wherein the thickness of the electric resistor is not 2 mm but 2 mm. In an electrical resistor comprising a conductive layer formed by melting a mixture of a thermoplastic resin and conductive fine powder into a flat or sheet shape, and planar electrodes formed on both sides of the conductive layer, the planar electrode and The conductive paste is used as an adhesive means between the conductive layer and can be easily cut, can be formed according to the shape of the object, and can be attached according to the shape of the object. Electrical resistor. An electric resistor comprising a conductive layer formed by melting a mixture of a thermoplastic resin and conductive fine powder into a flat or sheet shape and planar electrodes formed on both sides of the conductive layer. The electric resistor according to claim 1, wherein the electric resistor has a thickness of 0.2 mm to 2 mm, operates with an alternating current of a low voltage of 30 V or less, and further has a power consumption of 500 W / m ² or less. 6. The electric resistor comprising a conductive layer formed into a flat plate shape or a sheet shape and a flat electrode provided on both surfaces of the conductive layer, wherein the flat electrode is a thin metal plate or a metal foil. Electrical resistor. An electric resistor comprising a conductive layer formed into a flat or sheet shape and a planar electrode provided on both sides of the conductive layer, wherein the planar electrode is a knitted fabric woven from a thin metal wire or a thin metal wire and heat resistance 7. The electric resistor according to claim 1, wherein the electric resistor is made of a knitted fabric using fibers. In the electric resistor composed of the conductive layer formed in the flat plate shape or the sheet shape and the planar electrode formed on both surfaces of the conductive layer, the other planar electrode is small with respect to the area of one planar electrode, and Further, the electrodes are arranged in an arbitrary shape and size, and are arranged with a preliminary interval so that the electrodes are not electrically connected to each other, and can be separated individually using the preliminary interval. 8. The electrical resistor according to 7. An electric resistor comprising a conductive layer formed by melting a mixture of a thermoplastic resin and conductive fine powder into a flat or sheet shape, and planar electrodes formed on both sides of the conductive layer. The electrical resistor according to claim 1, wherein a ceramic layer that emits far-infrared rays is formed on an outer surface of the arranged planar electrode in accordance with heat generation of the conductive layer. An electric resistor comprising a conductive layer formed by melting a mixture of a thermoplastic resin and conductive fine powder into a flat or sheet shape, and planar electrodes formed on both sides of the conductive layer, and the electric resistor An electrical resistor, wherein a heat insulating layer is formed on one surface, and a surface opposite to the heat insulating layer is a heat radiating surface. An insulating layer was used to protect an electrical resistor composed of a conductive layer formed by melting a mixture of a thermoplastic resin and conductive fine powder into a flat or sheet shape and planar electrodes formed on both sides of the conductive layer. A human body warming tool characterized by being housed in a heat retaining member for heating a part of the human body. The warming tool according to claim 11, wherein the heat retaining member is a glove, a chair cushion, a waistcoat or the like. The electrical resistor according to claim 10, wherein the electrical resistor is disposed on a wall of a fluid guide member that allows air to pass through, using a composite material in which a heat insulating layer is laminated on one surface of the electrical resistor, a wall of a room in which air is heated, or the like.

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