JP2007273132A - Planer heating element - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a planer heating element with stabilized quality of which a connecting branch electrodes adjacent to a connection part have same polarity to form a long planer heating element and to eliminate risk of short-circuit and migration or the like. <P>SOLUTION: The connecting branch electrode 3e with a greater width than other part positioned on a connection part is arranged by superimposing and connecting rear parts of branch electrodes 3c, 3d and a part of a front part subsequently printed, and a joint part 4a of a polymer resistor 4 is arranged on the connecting branch electrode 3e. Thus, the risk of abnormal heat generation and migration or the like caused by the short-circuit between the connecting branch electrodes 7, 8 adjacent to the connection part is eliminated. Furthermore, risk of unsafety caused by a higher temperature than a predetermined temperature of the joint part 4a due to heat generated at the polymer resistor 4 is removed by arranging the joint part 4a of the polymer resistor 4 on the connecting branch electrode 3e. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a thin and long planar heating element configured to be easily disposed in a wide range as a heater that is disposed on a floor and warms the entire floor surface.

  Conventionally, in the heat generating part of this type of planar heating element, a base polymer and a conductive material such as carbon black, metal powder, and graphite are dispersed in a solvent. (For example, refer to Patent Documents 1, 2, and 3).

  6 is a plan view of a conventional sheet heating element having PTC characteristics, FIG. 7 is an enlarged plan view of the main part of FIG. 6, and FIG. 8 is a schematic sectional view of the sheet heating element when bonded together. . As shown in FIG. 6, the sheet heating element 50 has positive and negative widths obtained by printing and drying a conductive paste on the outer surface of the upper surface of the electrically insulating base material 51 such as a polyester sheet. The pair of main electrodes 52, 53 having a large width and a large number of narrow branch electrodes 52a, 53a alternately led toward the electrodes 53, 52 opposed to the main electrodes 52, 53, and power is supplied from the branch electrodes 52a, 53a In this way, a polymer resistor 54 obtained by printing and drying a polymer resistor ink is provided on the branch electrodes 52 a and 53 a and on the upper surface of the substrate 51, and the same material as the substrate 51 is coated. The material 55 covers and protects the main electrodes 52 and 53, the branch electrodes 52a and 53a, and the polymer resistor 54. The polymer resistor 54 is supplied with power from a large number of branch electrodes 52a and 53a to generate current and generate heat.

  When a polyester film is used as the base material 51 and the covering material 55, for example, a polyethylene-based heat-fusible resin (not shown) is bonded in advance to the covering material 55, and the pressure is applied while applying heat (heating time). Pressure), the base material 51 and the covering material 55 are joined via the heat-fusible resin. As a result, the main electrodes 52 and 53, the branch electrodes 52a and 53a, and the polymer resistor 54 are isolated from the outside world, and long-term reliability is imparted.

As a means for applying pressure at the time of heating, FIG. 8 shows a schematic cross-sectional view when the covering material 55 is bonded, but a laminator 58 composed of two heating rolls 56 and 57 rotating in the direction of the arrow is generally used. Is. The PTC characteristic is a resistance temperature characteristic in which the resistance value rises as the temperature rises, and when the temperature reaches a certain temperature, the resistance value increases abruptly. The polymer resistor 54 having PTC characteristics can provide a planar heating element having a self-temperature adjusting function.
Japanese Patent Laid-Open No. 56-13689 JP-A-6-96843 JP-A-8-120182

In the conventional sheet heating element 50, when a long one is to be produced, the printing plate becomes large. Therefore, a plate having a predetermined length is inevitably produced, and the printing end portions are overprinted and added. In such a case, the overlapping printing portion may vary in overlap, and the polymer resistor 54 in the overlapping portion may have a large film thickness, resulting in a low resistance value and a variation in heat generation temperature. In consideration of the fact that it becomes higher than the temperature and becomes unsafe, a method of electrically connecting a plurality of planar heating elements by superimposing only the main electrode has been taken. At this time, the branch electrodes adjacent to the connecting portion are alternately arranged so that they have different polarities, and there is a fear of abnormal heat generation or migration due to variation in overlap, and therefore, the space between the surface heating elements to be added is widened. There is a problem that the temperature is lowered because the portion does not generate heat.

  In view of the problems of the above-described conventional technology, the problem to be solved by the present invention is to form a long planar heating element so that the branch electrode adjacent to the connecting portion has the same polarity, such as a short circuit or migration. The object is to provide a planar heating element with a stable quality without worrying.

  In order to solve the above problems, an electrically insulating substrate, a pair of main electrodes formed by screen printing on the electrically insulating substrate and arranged to face each other, and alternately from each main electrode An electrode composed of a comb-shaped branch electrode disposed toward the opposing main electrode, a polymer resistor that is screen-printed over the electrode and that is supplied with heat from the electrode and generates heat, and the electrode and the polymer resistor A screen covering the electrode and the polymer resistor continuously by winding the roll-shaped electrical insulating substrate in a roll shape. In addition to the continuous screen printing method to be formed, at least the rear part of the main electrode for screen printing and a part of the front part of the next main electrode to be printed are overlapped and connected, and the branch electrode located at the connecting part is located behind the branch electrode And a portion of the front portion to be printed next is overlapped and connected to provide a connecting branch electrode wider than the other portions, and a joint portion of a polymer resistor is provided on the connecting branch electrode. As a configuration.

  In the above-described configuration, the rear part of the branch electrode positioned at the connection part and the part of the front part printed next are overlapped and connected to provide a connection branch electrode wider than the other part, and the connection branch Since the joint portion of the polymer resistor is arranged on the electrode, there is no worry about abnormal heat generation or migration due to short circuit between the branch electrodes adjacent to the connecting portion, and the polymer resistor is placed on the connecting branch electrode. By providing the joint portion, the polymer resistor does not generate heat at the joint portion, and there is no fear that the temperature becomes higher than a predetermined temperature and becomes unsafe. Therefore, the joint portion of the polymer resistor of the connecting portion may or may not overlap, and the end of the polymer resistor of the connecting portion may be provided on the connecting branch electrode. The degree of freedom in setting the printing of the resistor is increased, and the range of the non-heat generating portion of the connecting portion can be made as small as possible.

  The planar heating element of the present invention eliminates concerns about abnormal heat generation and migration due to short-circuiting between the branch electrodes adjacent to the connecting part, and does not cause heat generation of the polymer resistor at the joint part. Therefore, the range of the non-heat generating portion of the connecting portion can be made as small as possible, and a planar heating element with stable quality can be provided.

  The first invention is an electrically insulating base material, a pair of main electrodes formed by screen printing on the electrically insulating base material and arranged to face each other, and alternately facing each main electrode. An electrode composed of a comb-shaped branch electrode disposed toward the main electrode, screen-printed over the electrode, a polymer resistor that is supplied with heat from the electrode and generates heat, and covers the electrode and the polymer resistor, The screen printing includes forming a electrode and a polymer resistor continuously by screen printing while winding the roll-shaped electrical insulating substrate in a roll shape. In addition to the continuous screen printing method, at least the rear part of the main electrode for screen printing and the front part of the main electrode to be printed next are overlapped and connected, and the rear part of the branch electrode positioned next to the connecting part is next Print on By connecting overlapping portions of the front with arranging the wide connection branch electrode width than the other portion to be, it is constituted that were provided with joints of the polymer resistor on the connecting branch electrode.

Then, a rear part of the branch electrode positioned at the connection part and a part of the front part printed next are overlapped and connected to dispose a connection branch electrode wider than the other part, and on the connection branch electrode Since the joint part of the polymer resistor is provided, there is no worry of abnormal heat generation or migration due to short circuit between the branch electrodes adjacent to the connection part, and the connection part of the polymer resistor is provided on the connection branch electrode. By disposing, the polymer resistor does not generate heat at the joint, and there is no fear that it becomes higher than a predetermined temperature and becomes unsafe. Therefore, the joint portion of the polymer resistor of the connecting portion may or may not overlap, and the end of the polymer resistor of the connecting portion may be provided on the connecting branch electrode. The degree of freedom in setting the printing of the resistor is increased, and the range of the non-heat generating portion of the connecting portion can be made as small as possible.

  In particular, the second invention is arranged in the connecting portion of the first invention, and the rear and front portions of the branch electrode are overlapped and connected to each other, and the connecting branch electrode having a width wider than the other portions is disposed. The connecting portion of the polymer resistor is arranged on the connecting branch electrode, and the hollow portion where the electrode is not printed is arranged at the central portion of the connecting branch electrode.

  And in addition to the effect of 1st invention, since the hollow part which does not print an electrode is arrange | positioned in the center part of a connection branch electrode, the usage-amount of an expensive electrode can be reduced and it comprises at low cost. In addition, since a rotating circuit is formed, even if a part of the connection branch electrode is disconnected for some reason, power is supplied from the surroundings, so that the influence is reduced and the reliability is improved.

  In the third invention, in particular, the method of reducing the range of the non-heat generating portion of the connecting portion of the first invention as much as possible is performed by another method. On the electrically insulating substrate and the electrically insulating substrate, A pair of main electrodes formed by screen printing and arranged so as to face each other, electrodes composed of comb-shaped branch electrodes arranged alternately from each main electrode toward the opposite main electrodes, and the electrodes The screen printing includes a roll of screen printing, a polymer resistor that is supplied with heat from the electrode and generates heat, and a covering material that covers the electrode and the polymer resistor and is in close contact with the electrically insulating substrate. A continuous screen printing method in which an electrode and a polymer resistor are continuously formed by screen printing while winding the electrical insulating base material in a roll shape, A part of the front part of the main electrode to be printed is overlapped and connected, and the branch electrode adjacent to the connection part has the same polarity, and a high voltage is placed on the adjacent same-polarity branch electrode or between the same-polarity branch electrodes. The joint of the molecular resistor is provided.

  And by making the branch electrode adjacent to the connecting portion have the same polarity, there is no worry of abnormal heat generation or migration due to short circuit between the branch electrodes adjacent to the connecting portion, and on the adjacent same-polarity branch electrode, or By arranging the joint portion of the polymer resistor between the branch electrodes of the same polarity, the polymer resistor does not generate heat at the joint portion, and there is no fear that it becomes higher than a predetermined temperature and becomes unsafe. Therefore, the joint portion of the polymer resistor of the connecting portion may or may not overlap, and the connecting portion may be on the same polarity branch electrode adjacent to the connection portion or between the same polarity branch electrodes. Since there is only need for an end of the polymer resistor, the degree of freedom in setting the printing of the polymer resistor is increased, and the range of the non-heat-generating portion of the connecting portion formed between the same-polarity branch electrodes adjacent to the connecting portion is increased. It becomes possible to make it as small as possible. Further, the branch electrode adjacent to the connecting portion has the same configuration, so that the amount of expensive electrodes used can be reduced and the configuration can be reduced.

  In particular, the fourth aspect of the invention has a configuration in which a soaking means such as an aluminum tape is disposed on the upper surface of the covering material so as to cover the vicinity of the connecting portion of the first to third aspects of the invention.

  And, since the soaking means such as aluminum tape is arranged on the upper surface of the covering material so as to cover the vicinity of the connecting portion, the heat is transferred from the heat generating part before and after the connecting portion by the soaking means, and the connecting portion The temperature drop in the range of the non-heat generating part can be reduced.

The present invention is not limited to the present embodiment. Further, in the description of the present embodiment, the same reference numerals are given to the same configuration and the effects and the same description is not repeated.

(Embodiment 1)
1 to 3 are schematic configuration diagrams of a sheet heating element according to Embodiment 1 of the present invention. FIG. 1 is a perspective view of a main part, FIG. 2 is a plan view of the main part, and FIG. It is the process schematic at the time of printing.

  In FIG. 1, a sheet heating element 1 is a pair (electrically positive side and negative side) formed by printing and drying a silver paste on the upper surface of a thin roll-shaped electrically insulating substrate 2 such as a polyester film. An electrode 3 and a polymer resistor 4 as a polymer resistor formed by printing and drying a polymer resistor ink so as to overlap the electrode 3 are provided. A thin-walled polyester film or the like formed in advance with an adhesive resin layer (not shown) such as an acrylic adhesive having adhesiveness with the electrode 3, the polymer resistor 4, and the electrically insulating substrate 2. The sheet heating element 1 is formed by bonding the electrically insulating coating material 5 together.

  The electrode 3 has a pair of wide main electrodes 3a and 3b (corresponding to the positive side and the negative side of the DC power supply) so as to face each other along the outer side in the longitudinal direction of the planar heating element 1, A plurality of branch electrodes 3c and 3d are alternately led out from the respective main electrodes 3a and 3b toward the other main electrode to form a comb-like shape as a whole, and a polymer resistor disposed so as to overlap therewith 4 is supplied with power from a large number of branch electrodes 3c and 3d, a current flows through the polymer resistor 4 to generate heat.

  Here, as shown in FIG. 3, as the order of the processing steps, first, while winding the electrically insulating substrate 2 made of polyester film in a roll shape, the screen printing direction is set on the electrically insulating substrate 2. In a continuous screen printing method in which the electrode 3 and the polymer resistor 4 are continuously formed by screen printing in the same direction as the winding direction, a pair of electrodes 3 are formed by printing and drying of a silver paste, and overlap the electrodes 3 Thus, the polymer resistor 4 is formed by printing and drying the polymer resistor ink. And the electrode 3 and the polymer resistor 4 are formed by continuously laminating the roll-shaped electrically insulating base material 2 and the covering material 5 formed thereon, and a plurality of heating element main body parts are completed, The finished product is processed into a final product by post-processing (not shown) such as drawing out lead wires into a sheet and finishing it into a final product. It is arranged and used as a heater that warms the entire floor.

  Here, at least the rear portions of the main electrodes 3a and 3b for screen printing and the front portions of the main electrodes 3a and 3b to be printed next are overlapped and connected, and one branch electrode 3c located at this connecting portion is connected. The rear portion and the front portion to be printed next are overlapped and connected to provide a wider connecting branch electrode 3e than the other portions, and the polymer resistor 4 is joined to the connecting branch electrode 3e. Continuous printing is performed so that the portion 4a comes. Further, the connecting branch electrode 3e is provided with a hollow portion 3f where the electrode 3 is not printed at the center of the connecting branch electrode 3e so that the electrode thickness is thinner than the other branch electrodes 3c and 3d. A soaking means 6 such as an aluminum tape is disposed on the upper surface of the covering material 5 so as to cover the vicinity of the connecting portion.

  Then, the rear portions of the branch electrodes 3c and 3d located at the connection portion and the front portion to be printed next are overlapped and connected to provide a connection branch electrode 3e having a width wider than the other portions, and the connection Since the joint portion of the polymer resistor 4 is disposed on the branch electrode 3e, there is no need to worry about abnormal heat generation or migration due to a short circuit between the branch electrodes 3c and 3d adjacent to the connection portion, and the connection branch electrode 3e. By disposing the joint portion of the polymer resistor 4 on the top, the polymer resistor 4 does not generate heat at the joint portion, and there is no fear that it becomes higher than a predetermined temperature and unsafe. Therefore, the joint portion of the polymer resistor 4 at the connecting portion may or may not overlap, and the end of the polymer resistor 4 at the connecting portion may be provided on the connecting branch electrode 3e. The degree of freedom in setting the printing of the polymer resistor 4 is increased, and the range of the non-heat generating portion of the connecting portion can be made as small as possible.

  Further, since the hollow portion 3f where the electrode 3 is not printed is disposed at the central portion of the connection branch electrode 3e, the amount of the expensive electrode 3 used can be reduced, and it can be configured at low cost. In order to form a circuit, even if a part of the connecting branch electrode 3e is disconnected for some reason, power is supplied from the surroundings, so that the influence is reduced and the reliability is improved.

And since the soaking | uniform-heating means 6, such as an aluminum tape, is arrange | positioned on the upper surface of the coating | covering material 5 so that the connection part vicinity may be covered, it is made to heat-transfer by the soaking | uniform-heating means 6 from the heat-generation part before and behind a connection part. The temperature drop in the range of the non-heat generating part of the connecting part can be reduced.
(Embodiment 2)
4 is a perspective view of a main part of a sheet heating element according to Embodiment 2 of the present invention, and FIG. 5 is a plan view of the main part. In the present embodiment, the method of reducing the range of the non-heat generating portion of the connecting portion of the first embodiment as much as possible is performed by another method, and the configuration of the connecting portion for screen printing is the invention of the first embodiment. Only the different configurations are given the same numbers and only different configurations will be described.

  As shown in FIGS. 4 and 5, at least the rear portions of the main electrodes 3a and 3b for screen printing and the front portions of the main electrodes 3a and 3b to be printed next are overlapped and connected, and adjacent to the connecting portions. The connecting portion branch electrodes 7 and 8 have the same polarity, and the joint portion 4a of the polymer resistor 4 is disposed between the adjacent connecting portion branch electrodes 7 and 8 having the same polarity.

  Further, by making the connecting part branch electrodes 7 and 8 adjacent to the connecting part have the same polarity, there is no fear of abnormal heat generation or migration due to a short circuit between the connecting branch electrodes 7 and 8 adjacent to the connecting part. By disposing the joint 4a of the polymer resistor 4 between the connecting branch electrodes 7 and 8 having the same polarity, the polymer resistor 4 does not generate heat at the joint 4a and becomes higher than a predetermined temperature. No worries about becoming. Therefore, the joint portion 4a of the polymer resistor 4 at the connection portion may or may not overlap, and the connection branch electrodes 7 and 8 of the same polarity adjacent to the connection portion or the connection of the same polarity. Since it is only necessary to have the end of the polymer resistor 4 at the connecting portion between the branch electrodes 7 and 8, the degree of freedom in setting the printing of the polymer resistor 4 is increased, and the connecting branch electrode 7 of the same polarity adjacent to the connecting portion is provided. , The range of the non-heat generating part of the connecting part formed between 8 can be made as small as possible. Furthermore, it becomes a simple structure which makes the connection branch electrodes 7 and 8 adjacent to a connection part the same pole, the usage-amount of the expensive electrode 3 can be reduced, and it can comprise now at low cost.

  If the polymer resistor 4 located in the hollow portion 3f where the electrode 3 is not printed at the central portion of the connecting branch electrode 3e is also the portion corresponding to the hollow portion 3f where printing is not performed, the amount of use of the polymer resistor 4 is reduced. In addition, a through hole, a fixing means for the planar heating element, and the like can be provided in this portion. Further, the joint portion 4a of the polymer resistor 4 of the connecting portion may or may not overlap, and the configuration of each of the other portions is not limited as long as the object of the present invention is achieved. It may be.

  As described above, the planar heating element according to the present invention can be made of a thin and long planar heating element so that it can be easily disposed in a wide area, and is disposed on the floor. It can be used for heating heaters that heat the entire floor and other appliances that require heating in a wide area.

1 is a perspective view showing a main part of a sheet heating element according to Embodiment 1 of the present invention. The principal part top view of the planar heating element in the same Embodiment 1 Process schematic diagram at the time of printing of the same surface heating element in the first embodiment The principal part perspective view which shows the planar heating element in Embodiment 2 of this invention The principal part top view of the planar heating element in the same Embodiment 2 Plan view showing a conventional planar heating element The top view which expands and shows the principal part of the same planar heating element Schematic configuration diagram showing when the covering material 5 of the same planar heating element is bonded

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Planar heating element 2 Electrically insulating base material 3 Electrode 3a, 3b Main electrode 3c, 3d Branch electrode 3e Connection branch electrode 3f Connection branch electrode hollow part 4 Polymer resistor 5 Coating material 6 Heat equalization means

Claims (4)

An electrically insulating substrate, a pair of main electrodes formed on the electrically insulating substrate by screen printing and disposed so as to face each other, and each main electrode alternately arranged toward the opposite main electrode An electrode composed of a comb-shaped branch electrode, a polymer resistor that is screen-printed over the electrode, and that is supplied with heat from the electrode and generates heat; covers the electrode and the polymer resistor; and the electrically insulating substrate The screen printing is a continuous screen printing method in which an electrode and a polymer resistor are continuously formed by screen printing while winding a roll-shaped electrically insulating substrate in a roll shape. And at least a rear part of the main electrode for screen printing and a part of the front part of the main electrode to be printed next to each other, and the rear part of the branch electrode located in the connecting part and the front part to be printed next. One Linked by overlapping with disposing the wide connection branch electrode width than other portions, the planar heating element which is arranged a joint portion of the polymer resistor on the connecting branch electrode. A portion of the rear portion and the front portion of the branch electrode, which is located at the connection portion, is overlapped and connected, and a connection branch electrode having a width wider than that of the other portion is disposed, and a joint portion of the polymer resistor is provided on the connection branch electrode. The planar heating element according to claim 2, wherein a hollow portion where no electrode is printed is disposed at a central portion of the connecting branch electrode. An electrically insulating substrate, a pair of main electrodes formed on the electrically insulating substrate by screen printing and disposed so as to face each other, and each main electrode alternately arranged toward the opposite main electrode An electrode composed of a comb-shaped branch electrode, a polymer resistor that is screen-printed over the electrode, and that is supplied with heat from the electrode and generates heat; covers the electrode and the polymer resistor; and the electrically insulating substrate The screen printing is a continuous screen printing method in which an electrode and a polymer resistor are continuously formed by screen printing while winding a roll-shaped electrically insulating substrate in a roll shape. In addition, at least the rear part of the main electrode for screen printing and a part of the front part of the next main electrode to be printed are overlapped and connected, and the branch electrode adjacent to the connecting part has the same polarity. branch Electrode, or a planar heating element disposed the joints of the polymer resistor between the branch electrodes of the same polarity. The planar heating element according to any one of claims 1 to 3, wherein a soaking unit such as an aluminum tape is disposed on an upper surface of the covering material so as to cover the vicinity of the connecting portion.