JP2010272267A - Polymer heating element - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a polymer heating element excellent in heat transfer performance, without impairing comfort at use. <P>SOLUTION: The polymer-heating element has a pair of electrodes 3 sandwiched by a base-side electrically insulating base material 2 and a cover-side electrically insulating base material 5, and a polymer resistive element 4, with PTC characteristics arranged between the pair of electrodes. At least either the base-side electrically insulating base material 2 or the cover-side electrically insulating base material 5 is formed of a high air-permeable raw material. Consequently, the polymer-heating element which can lessen heat-transmission loss and is superior in energy saving, with due consideration on environment being taken into can be provided. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a polymer heating element using Joule heat of a polymer resistor, and more particularly to a means for efficiently transferring heat of the heating element to the outside.

  2. Description of the Related Art Conventionally, as a heat generating portion of a planar heating element, a material obtained by dispersing a conductive material such as carbon black, metal powder, or graphite in a resin is known.

  In particular, when a PTC (Positive Temperature Coefficient) heating element that exhibits a self-temperature control function is used by combining a conductive material and a resin, there is an advantage that a temperature control circuit is not required and the number of parts can be reduced. Known as a device.

  As shown in FIGS. 7 and 8, these structures are obtained by printing or applying a conductive ink composition on a base material 100 having a function as a casing structure such as a ceramic or an insulating metal plate. And a resistor 102 obtained by printing or applying a resistor ink composition at a position to which power is supplied, and a heating element 104 with a cover material 103 covering the electrode 101 and the resistor 102. Was forming.

  Since the electrode 101 and the resistor 102 are isolated from the outside by the base material 100 and the cover material 103, long-term reliability is imparted.

  Examples of conventional polymer resistors formed by printing and used as heating elements include automotive door mirrors, washstand mirrors, floor heating appliances, etc. (for example, patent documents) 1).

  Furthermore, it can be seen that these heating elements are provided with a flexible function by using a polymer film or a fibrous flexible material (see, for example, Patent Documents 2 and 3).

JP 2002-371699 A JP 2003-109804 A JP 2005-174629 A

  In the conventional heating element, a general woven fabric or non-woven fabric is often used as a constituent material for expressing flexibility in consideration of the role and texture of protecting and covering the heating element. For example, when used in a seat heater or the like, a heating element covered with a woven fabric or a non-woven fabric often comes into contact with a human body via a cushion material or the like.

  However, since the application to the part that directly contacts the human body will increase in the future, a material considering further comfort and heat transfer properties is required.

In particular, it is necessary to select a material that efficiently transfers heat from the heating element to the outside when it is assumed that it will be used with sufficient consideration for energy saving, but currently the development of the heating element itself is the main focus. Sufficient examination about a member was not made | formed.

  On the other hand, there are many materials for realizing energy saving from the viewpoint of the global environment. Specifically, it relates to materials such as cool biz and warm biz, and various materials have been proposed.

  SUMMARY OF THE INVENTION In view of the above-mentioned problems of the conventional technology, the problem to be solved by the present invention is to provide a polymer heating element having excellent heat transfer performance without impairing comfort during use. In particular, it has been found that it becomes effective by examining the material and configuration of the skin material of the heater.

  The polymer heating element of the present invention for solving the above conventional problems includes a pair of electrodes sandwiched between a base-side electrically insulating substrate and a cover-side electrically insulating substrate, and a pair of electrodes. And a polymer resistor having PTC characteristics, and at least one of the base-side electrically insulating base and the cover-side electrically insulating base has a highly air-permeable material.

  The polymer heating element of the present invention is a polymer heating element having an electrically insulating base material having high air permeability as an outer skin material, and can transmit heat efficiently and comfortably when directly contacting a human body or the like. It can be done.

The top view of the polymer heating element in Embodiment 1 of this invention XY sectional view of FIG. Plan view of polymer heating element in Embodiment 2 of the present invention XY cross section of FIG. The top view of the polymer heating element in Embodiment 3 of this invention XY sectional view of FIG. Plan view of conventional polymer heating element XY sectional view of FIG.

  A first invention includes a pair of electrodes sandwiched between a base-side electrically insulating substrate and a cover-side electrically insulating substrate, and a polymer resistor having PTC characteristics disposed between the pair of electrodes, And at least one of the base-side electrically insulating substrate and the cover-side electrically insulating substrate has a highly breathable material, which makes it possible to reduce heat transfer loss and is excellent in energy saving and environment. Considerable polymer heating elements can be provided.

  In the second invention, in particular, in the polymer heating element of the first invention, the highly breathable material exhibits temperature sensitivity, and the fiber network is closed in the low temperature state, but the humidity is high in the high temperature state. Since the mesh opens under the influence of temperature, it is not directly affected by the temperature factor, but it can exert its effect indirectly by increasing the temperature, and it is possible to maintain good air permeability especially at high temperatures. Is.

  In the third aspect of the invention, in particular, in the polymer heating element of the first or second aspect of the invention, the highly breathable material showing temperature sensitivity is formed of fibers combining rayon and acrylic, and has a soft texture. It is possible to provide a high-quality polymer heating element that can exhibit energy saving performance.

  In the fourth aspect of the invention, in particular, in the polymer heating element according to any one of the first to third aspects, the highly breathable material includes warp fibers and weft fibers made of different materials. The structure is easy to create a space, and high air permeability can be realized.

  According to a fifth aspect of the invention, in particular, in the polymer heating element of the fourth aspect of the invention, the highly breathable material comprising warp fibers and weft fibers, each made of different materials, comprises polyester fibers for the warps and surface for the weft By using a fiber made of cotton yarn having a concavo-convex shape, it is possible to easily create concavo-convex on the fiber surface. As a result, a space can be formed in the fabric by this structure, and high air permeability can be realized.

  In the sixth aspect of the invention, in particular, in the polymer heating element of any one of the first to fifth aspects, the highly breathable material includes hollow fibers, so that both weight reduction and comfort can be achieved. It becomes possible.

  According to a seventh aspect of the invention, in the polymer heating element of the sixth aspect of the invention, a highly breathable material made of hollow fibers is made of polyester cotton having a hollow shape, and a fabric having breathability and lightness is obtained. Can do.

  In the eighth invention, in particular, in the polymer heating element of any one of the first to seventh inventions, at least one of the base-side electrically insulating base and the cover-side electrically insulating base is highly air-permeable. It consists of a multilayer structure of a material layer and an insulating film layer, and can be used as an insulating base material regardless of the production method of polymer resistor material, for example, printing method or extrusion method. It is possible to provide a polymer heating element excellent in comfort and energy saving.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the present invention is not limited to the embodiments.

(Embodiment 1)
1 and 2, the polymer heating element 1 has a pair of electrodes 3 and 3 'and a polymer resistor 4 disposed on a base-side electrically insulating substrate 2, and these are covered with a cover-side electrically insulating substrate. 5 is covered.

  The base-side electrically insulating substrate 2 and the cover-side electrically insulating substrate 5 were the same type. In other words, a fiber made of a combination of Bemberg (a kind of rayon) and micro anti-pill acrylic (very thin acrylic) was used.

  Then, the polymer resistor 4 is disposed on one side of the base-side electrically insulating base material 2 by thermal fusion, and then the electrodes 3 and 3 ′ are thermally fused to the polymer resistor 4, and finally the cover-side electrical Insulating substrate 5 was heat-sealed to produce polymer heating element 1.

  The electrodes 3 and 3 ′ are obtained by twisting 19 tin-plated copper wires having a diameter of 0.06 mm. A lead wire for supplying power to the electrodes 3 and 3 'is omitted.

  The polymer resistor 4 was obtained by preparing a kneaded material using the following materials and procedures and then heat-sealing the base-side electrically insulating base material 2 into a sheet shape by calendering.

That is, the polymer resistor 4 includes, as a crystalline resin, 30 parts of an ethylene / methacrylic acid copolymer (trade name “Acrylift CM5021”, melting point 67 ° C., manufactured by Sumitomo Chemical Co., Ltd.), ethylene / methacrylic acid. 30 parts of copolymer (trade name “Nucleel N1560”, melting point 90 ° C., manufactured by Mitsui DuPont Polychemical Co., Ltd.), ethylene / methacrylic acid copolymer metal coordination product (trade name “Himiran 1702”, melting point 90 C., 40 parts by Mitsui DuPont Polychemica Co., Ltd.).

  35% by weight of this crystalline resin, 2% by weight of a reactive resin (trade name “Bond First 7B”, manufactured by Sumitomo Chemical Co., Ltd.), and carbon black (trade name “Printex L”, Primary particle size 21 nm, 25% by weight manufactured by Degussa), graphite (trade name “GR15”, scale-like graphite, manufactured by Nippon Graphite Co., Ltd.) 18% by weight, flame retardant (trade name “Reophos RDP”, phosphate ester A kneaded product A was prepared with 20% by weight of an aqueous liquid flame retardant (manufactured by Ajinomoto Co., Inc.).

  Next, as the elastomer, 40% by weight of a styrene thermoplastic elastomer (trade name “Tuftec M1943”, manufactured by Asahi Kasei Engineering Co., Ltd.), carbon black (trade name “# 10B”, primary particle diameter 75 nm, Mitsubishi Chemical Corporation) 45% by weight made by company) and 13% by weight tungsten carbide (made by Izawa Metal Co., Ltd.), and a mixture of an alkyl methacrylate / alkyl acrylate copolymer and a tetrafluoroethylene copolymer as a melt tension improver ( A kneaded product B was prepared from 2% by weight of a trade name “METABBRENE A3000” (manufactured by Mitsubishi Rayon Co., Ltd.).

  Then, an equal amount of the kneaded material A and the kneaded material B, 2% by weight of modified silicone oil as a release agent, and 2% by weight of an alkyl methacrylate / alkyl acrylate copolymer as a fluidity imparting agent are kneaded. Thus, a polymer resistor 4 was produced.

  The electrodes 3 and 3 ′ are arranged so that a pair (widely positive side and negative side) of the electrodes 3 and 3 ′ is opposed to each other along the outer side in the longitudinal direction of the planar heating element 1. Heat is generated by passing an electric current.

  In the present embodiment, the polymer resistor 4 has PTC characteristics, and when the temperature rises, the resistance value rises, and has a self-temperature adjusting function so as to reach a predetermined temperature, and temperature control is unnecessary. It has a function as the highly safe planar heating element 1.

  In this polymer heating element 1, both the base-side electrically insulating base material 2 and the cover-side electrically insulating base material 5 are made of a highly breathable material, and either surface is in contact with the human body. Even when arranged in such a manner, it has been found that the polymer heating element has little heat loss and good flexibility and texture.

  In addition, examples of the highly breathable material include a material exhibiting temperature sensitivity, a material composed of warp fibers and weft fibers each made of different fiber materials, and a material containing hollow fibers.

  Furthermore, it is preferable that the highly breathable material exhibits temperature sensitivity. As the material, a material in which the mesh of the fiber opens and closes and expands and contracts due to the influence of humidity can be used. For example, “Thermogear” fiber manufactured by Asahi Kasei Co., Ltd. can be mentioned. When the temperature is low, the fiber mesh is kept closed. However, when the temperature is high, the mesh is detected by detecting sweat and moisture. It uses the principle of opening.

  In the case where a temperature-sensitive material is used for the polymer heating element 1 of the present embodiment, the mesh of the material is opened by sensing sweat or moisture caused by heat generated from the human body according to the heat generation situation. As a result, the heat transfer efficiency can be improved because the air permeability between the polymer heating element 1 and the human body becomes good after a certain time has elapsed.

(Embodiment 2)
3 and 4 show the second embodiment. In the polymer heating element 11, a pair of comb-like electrodes 13 and 13 'and a polymer resistor 14 are arranged on a base-side electrically insulating substrate 12, These are configured by covering with a cover-side electrically insulating base material 15.

  The base-side electrically insulating substrate 12 and the cover-side electrically insulating substrate 15 were each made of a two-layer structure of highly breathable material layers 12a and 15a and insulating film layers 12b and 15b.

  As the highly breathable material layers 12a and 15a, both the base-side electrically insulating substrate 12 and the cover-side electrically insulating substrate 15 are made of polyester long fiber and Egyptian cotton as warp and a highly air-permeable gap on the surface as weft. We used “Samilan” yarn and Egyptian cotton.

  The insulating film layers 12b and 15b are formed by using an inflation method, and exhibit heat resistance with an olefin-based thermoplastic resin (a resin including a PP softening material having excellent compatibility with PP). Olefin-based adhesive resin (ethylene containing maleic anhydride component) with good contact characteristics between the thermoplastic resin (polymerized TPO obtained by direct reaction of ethylene and propylene) and the electrode and resistor Resin containing components), a film composed of a total of three types of resin blends, and a film thickness of 60-70 microns after lamination is obtained. One side of the highly breathable materials 12a, 15a It was heat-sealed.

  A pair of electrodes 13 was printed on the base-side electrically insulating substrate 12 by printing / drying silver paste, and a polymer resistor 14 was produced by printing / drying PTC resistor ink at a position where power was supplied by the electrodes 13.

  The polymer resistor 14 is manufactured to have an exothermic temperature of about 40 ° C., a combination of two types of ethylene vinyl acetate copolymers, kneaded and cross-linked carbon black, and acrylonitrile butyl rubber as a binder. The cover-side electrically insulating base material 15 was bonded to the electrode 13 and the polymer resistor 14 described above.

  The polymer heating element 11 has a two-layer structure in which both the base-side electrically insulating substrate 12 and the cover-side electrically insulating substrate 15 have high air permeability material layers 12a and 15a and insulating film layers 12b and 15b. However, the highly breathable material layers 12a and 15a are in contact with the outside, and even when either side is placed in contact with the human body, there is little heat loss and flexibility. It was found that the polymer heating element 11 with good texture was obtained.

(Embodiment 3)
5 and 6 show the third embodiment, in which the polymer heating element 21 has a pair of comb-like electrodes 23 and 23 'and a polymer resistor 24 arranged on a base-side electrically insulating substrate 22, These are configured by covering with a cover-side electrically insulating substrate 25.

  The base-side electrically insulating substrate 22 has a two-layer structure of a highly breathable material layer 22a and an insulating film layer 22b, and the cover-side electrically insulating substrate 25 has only an insulating film layer 25b. Was used.

  As the highly breathable material layer 22a, a material made of a yarn made by blending a hollow polyester fiber and a fine cotton was used.

The insulating film layer 22b of the base-side electrically insulating substrate 22 and the insulating film layer 25b of the cover-side electrically insulating substrate 25 are prepared using a sheet extrusion molding apparatus, and are made of an olefin-based thermoplastic resin (PP A resin containing PP softening material exhibiting excellent compatibility), a thermoplastic resin (polymerization type TPO obtained by directly reacting ethylene and propylene), and electrodes and resistors. A film made of a kneaded mixture of olefinic adhesive resins (resins containing an ethylene component including a maleic anhydride component) that have good contact characteristics with the resin, and a film composed of a total of three types of resin blends. The thickness of the film was 50-60 microns.

  In the base-side electrically insulating substrate 22, the insulating film layer 22b is heat-sealed to one side surface of the highly breathable material 22a.

  A pair of electrodes 23, 23 ′ is printed on the base-side electrically insulating substrate 22 by printing / drying, and a polymer is formed by printing / drying the PTC resistor ink at a position where power is supplied by these electrodes 23, 23 ′. The resistor 24 was produced.

  The polymer resistor 24 is manufactured to have an exothermic temperature of about 40 ° C., a combination of two types of ethylene vinyl acetate copolymers, kneaded and cross-linked carbon black, and acrylonitrile butyl rubber as a binder. The cover-side electrically insulating base material 25 made of the insulating film layer 25b obtained by the above-described method and bonded to the electrodes 23 and 23 'and the polymer resistor 24 was bonded.

  In the present polymer heating element 21, only the base-side electrically insulating base material 22 has a two-layer structure having a highly breathable material layer 22a and an insulating film layer 22b, and this surface is in contact with the human body. As a result of the arrangement, it was found that the polymer heating element had low heat loss and good flexibility and texture.

  As described above, according to the polymer heating element of the present invention, it is possible to conduct heat efficiently and comfortably when directly contacting a human body, etc., and realize high energy saving performance when applied to a heating appliance or the like. it can.

1,11,21 Polymer heating element 2,12,22 Base side electrically insulating substrate 3,13,23 Electrode 4,14,24 Polymer resistor 5,15,25 Cover side electrically insulating substrate 12a, 15a Highly breathable material layer 12b, 15b Insulating film layer

Claims (8)

A pair of electrodes sandwiched between a base-side electrically insulating substrate and a cover-side electrically insulating substrate; and a polymer resistor having a PTC characteristic disposed between the pair of electrodes. A polymer heating element in which at least one of a side electrically insulating base and the cover side electrically insulating base is made of a highly breathable material. The polymer heating element according to claim 1, wherein the highly breathable material has temperature sensitivity. 3. The polymer heating element according to claim 2, wherein the highly breathable material having temperature sensitivity is formed of a fiber combining rayon and acrylic. The polymer heating element according to any one of claims 1 to 3, wherein the highly breathable material is composed of warp and weft fibers made of different materials. The polymer heating element according to claim 4, wherein polyester fibers are used for the warp and fibers having an uneven shape on the surface are used for the weft. The polymer heating element according to claim 4, wherein the highly breathable material includes hollow fibers. 7. The polymer heating element according to claim 6, wherein the highly breathable material made of hollow fibers is made of polyester cotton having a hollow shape. The polymer heat generation according to any one of claims 1 to 7, wherein at least one of the base-side electrically insulating substrate and the cover-side electrically insulating substrate has a multilayer structure of a highly air-permeable material layer and an insulating film layer. body.