JP2011003329A - Polymer heating element - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a polymer heating element having superior heat transfer, without impairing the comfort at it use.SOLUTION: The polymer heating element includes a pair of electrodes 4a, 4b held between a base side electrical insulation base material 2 and a cover side electrical insulation base material 3 and a polymer resistor 5, arranged between the electrodes 4a, 4b with PTC characteristics, wherein a heat insulating material is used for at least one of the base-side electrical insulation base material 2 and the cover-side electrical insulation substrate 3. Thus, the heat generated by the polymer heating element 5 can be transferred efficiently, whereby the polymer heating element can also be made high in energy-saving and friendly to environment.

Description

  The present invention relates to a polymer heating element using Joule heat of a polymer resistor.

  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 a combination of a conductive material and a resin, a temperature control circuit becomes unnecessary, and the number of parts can be reduced. Known as.

  Specifically, as shown in FIGS. 7 and 8, the conductive ink composition is obtained by printing or applying on a base material 101 having a function as a casing structure such as a ceramic or an insulating metal plate. And a resistor 103 obtained by printing or applying a resistor ink composition at a position where power is supplied by the electrode 102, and a heating element 105 from a cover material 104 covering the electrode 102 and the resistor 103. Was forming.

  The electrode 102 and the resistor 103 are isolated from the outside by the base material 101 and the cover material 104 to increase long-term reliability.

  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). Moreover, what added the flexible function by comprising these heat generating bodies using a polymer film or a fibrous flexible material is also seen (for example, refer patent document 2, 3).

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

  In a conventional heating element, a general woven fabric or non-woven fabric is frequently 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 for 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 more and more in the future, it is necessary to select a material considering further comfort and heat transfer.

  In particular, when it is assumed that energy conservation is fully taken into consideration, it is necessary to select materials that efficiently transmit heat from the heating element to the outside. Sufficient examination has not been made.

On the other hand, many materials for realizing energy saving have appeared from the viewpoint of consideration for 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 conventional problems is provided with a pair of electrodes sandwiched between a base-side electrically insulating substrate and a cover-side electrically insulating substrate, and between these electrodes. A polymer resistor having PTC characteristics, and a heat insulating material is used for at least one of the base-side electrically insulating substrate and the cover-side electrically insulating substrate.

  This makes it possible to efficiently transfer the heat generated from the polymer heating element, providing energy saving and environmentally friendly products.

  The polymer heating element of the present invention uses an electrically insulating base material that exhibits heat retention as an outer skin material, and the polymer heating element can be used either in direct contact with the human body or the like, or in the case of no direct contact with the human body. Heat can be transferred efficiently with little loss, and energy-saving performance can be improved.

Plan view of polymer heating element according to Embodiment 1 XY sectional view of FIG. Plan view of polymer heating element in Embodiment 2 XY cross section of FIG. Plan view of polymer heating element according to Embodiment 3 XY sectional view of FIG. Plan view of conventional polymer heating element XY sectional view of FIG.

  The present invention includes a base-side electrically insulating substrate and a pair of electrodes sandwiched between the cover-side electrically insulating substrate, and a polymer resistor having PTC characteristics disposed between the electrodes, The heat insulating material is used for at least one of the side electrical insulating base and the cover side electrical insulating base, and it is possible to efficiently transmit the heat generated from the polymer heating element. We can provide environmentally friendly products.

  The heat insulation material means a material whose heat insulation performance is improved by improving the shape and function of the material.

  In general, heat-insulating materials are often used as a role to make it difficult for heat from the human body to escape, but when these heat-insulating materials are used for the skin material of polymer heating elements, they are more comfortable than when not using them. It is excellent in lightness, lightweight, can efficiently transfer heat from the polymer heating element without impairing the texture, and the heat retaining function of the material even after the power supply to the heating element is cut off This makes it possible to maintain a comfortable warmth for a long time, which can greatly contribute to energy saving.

  By using a material with improved heat retention in this way, it is possible to efficiently transfer heat to the heat sink without wasting heat generated from the polymer heating element.

  As an index for knowing the heat retaining property of the material, “Under certain conditions, it is necessary for the temperature not to decrease when wearing the fabric on the basis of the amount of heat (A) necessary to prevent the temperature from dropping without wearing the fabric. The heat retention rate ((A−B) / A × 100) may be defined in some cases, but in the present invention, it is used as a coating material for a polymer heating element. Quantitative definition is not performed because the amount of heat A and amount of heat B varies depending on the surrounding material and atmosphere. However, if the heat retention performance is improved when using the materials shown below, they are retained. We will define

  In other words, specifically, materials that generate heat, such as materials that have achieved lightweight heat retention due to hollow structures and ultra-fine materials, heat storage and heat retention materials, far-infrared radiation materials, materials that absorb heat and absorb heat, or phase conversion A temperature-adjustable material using a substance can be used.

  As a lightweight heat-retaining material, for example, it can be formed of a polyester hollow fiber and have a soft texture.

  As the heat storage and heat retaining material, for example, a fiber kneaded with zirconium carbide, as a far-infrared radiation material, for example, a fiber kneaded with ceramics in polyester, and as a hygroscopic heat generating material, for example, acrylic fiber, polyester fiber A material that includes at least one of them may be a material obtained by processing a microcapsule encapsulating a phase change material into a woven or knitted fabric as a temperature adjusting material.

  If at least one of the base-side electrically insulating substrate and the cover-side electrically insulating substrate has a multilayer structure of a heat insulating material layer and an insulating film layer, a method for producing a polymer resistor material, for example, a printing method, Regardless of the extrusion method, it can be used as an insulating substrate, and a polymer heating element excellent in flexibility, comfort, and energy saving can be provided.

  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 is disposed on a base-side electrically insulating base 2 and a cover-side electrically insulating base 3 between a pair of electrodes 4 and 4b and these electrodes 4a and 4b. And it is the structure which pinched | interposed the polymer resistor 5 which has the connected PTC characteristic.

  The base-side electrically insulating substrate 2 and the cover-side electrically insulating substrate 3 used Toray's trade name “Sebon Samron” as a lightweight heat insulating material. This material is made in advance by making a fiber composed of two components and making it into a woven or knitted fabric, so that it is hollowed by melting one of the components, and has a light weight and a soft texture.

  Here, the manufacturing procedure will be described. The polymer resistor 5 is disposed on one side surface of the base-side electrically insulating substrate 2 by heat fusion, and then the electrodes 4 and 4b are disposed on both sides of the polymer resistor 5. The cover-side electrically insulating base material 3 is finally heat-sealed to form the polymer heating element 1.

  The electrodes 4 and 4b are obtained by twisting 19 tin-plated copper wires having a diameter of 0.06 mm. Note that lead wires for supplying power to the electrodes 4 and 4b are omitted.

The polymer resistor 5 is prepared by kneading with the following materials and procedures and then heat-sealing into a sheet on the base-side electrically insulating substrate 2 by calendaring.

  That is, as crystalline resin, ethylene / methyl methacrylate copolymer [trade name “ACRIFT CM5021”, melting point 67 ° C., manufactured by Sumitomo Chemical Co., Ltd.] 30 parts, ethylene / methacrylic acid copolymer [trade name 30 parts of “Nucleel N1560”, melting point 90 ° C., manufactured by Mitsui DuPont Polychemical Co., Ltd.) and ethylene / methacrylic acid copolymer metal coordination product [trade name “Himiran 1702”, melting point 90 ° C., Mitsui DuPont Polychemica Co., Ltd.] 40 parts.

  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” as two types of conductors) Primary particle size 21 nm, manufactured by Degussa) 25% by weight, graphite [trade name “GR15”, scaly graphite, manufactured by Nippon Graphite Co., Ltd.] 18% by weight, flame retardant [trade name “Reophos RDP”, phosphorus A kneaded product A was prepared with 20 wt% of acid ester liquid flame retardant, manufactured by Ajinomoto Co., Inc.

  Next, as the elastomer, styrene-based thermoplastic elastomer [trade name “Tuftec M1943”], Asahi Kasei Engineering Co., Ltd. 40% by weight, carbon black [trade name “# 10B”, primary particle size 75 nm, Mitsubishi Chemical Stock] 45 wt%, tungsten carbide [Izawa Metal Co., Ltd.] 13 wt%, and as a melt tension improver, an alkyl methacrylate / alkyl acrylate copolymer and a tetrafluoroethylene copolymer A kneaded product B was prepared from 2% by weight of the mixture [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 5 was produced.

  The electrodes 4a and 4b are arranged in such a manner that a wide pair (electrically positive side and negative side) so as to oppose each other on the outer side in the longitudinal direction of the base-side electrically insulating substrate 2 and the cover-side electrically insulating substrate 3 It is arrange | positioned along with this, and this is made to heat | fever by sending an electric current through the polymer resistor 5. FIG.

  In the present embodiment, the polymer resistor 5 has a PTC characteristic, 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 comes to have a function as a highly safe polymer heating element 1.

  In addition, although the lightweight heat insulation material was used for both the base side electrically insulating base material 2 and the cover side electrically insulating base material 3, it is not necessarily specified to this, for example, it arrange | positions in one side which contacts a human body. Even in such a case, the polymer heating element 1 with less heat loss and good flexibility and texture will be obtained.

  It was found that the energy saving performance of about 5% was exhibited when compared with the case where a woven fabric having the same thickness not considering the normal heat retention was used as the base material.

(Embodiment 2)
3 and 4, the polymer heating element 11 is disposed on the base-side electrically insulating substrate 12 and the cover-side electrically insulating substrate 13 so as to be connected to the pair of electrodes 14a and 14b and these electrodes 14a and 14b. In addition, the polymer resistor 15 having the connected PTC characteristic is sandwiched.

The electrodes 14a and 14b are set in a comb-like shape in which a plurality of sub-electrodes are alternately branched in the opposite direction from the main electrode portion.

  The base-side electrically insulating substrate 12 and the cover-side electrically insulating substrate 13 were made of a two-layer structure of a heat retaining material layer and an insulating film layer.

  As the heat insulating material layer, the product name “Thermotron” of Unitika Co., Ltd. was used for both the base-side electrically insulating substrate 12 and the cover-side electrically insulating substrate 13.

  This material also has a function of reflecting heat generated from the human body, and exhibits excellent heat retention performance in combination with heat from the heating element.

  As an insulating film layer, it was created using an inflation method, and an olefin-based thermoplastic resin (a resin containing PP softening material exhibiting excellent compatibility with PP) and heat resistance are developed. An olefin-based adhesive resin (including an ethylene component including a maleic anhydride component) that provides good contact characteristics between a thermoplastic resin (polymerized TPO obtained by directly reacting ethylene and propylene) and an electrode or a resistor. Resin), a film composed of a total of three types of resin blends, and a film thickness of 60-70 microns after lamination is obtained by heat-sealing to one side of the heat retaining material. A base-side electrically insulating substrate 12 and a cover-side electrically insulating substrate 13 were obtained.

  In FIG. 4, the portion corresponding to the heat insulating material layer is indicated by a white frame line and the portion corresponding to the insulating film layer is indicated by a thick black line so that the two-layer structure can be understood.

  A pair of electrodes 14a, 14b is printed on the base-side electrically insulating substrate 12 by printing / drying, and a polymer resistor is formed by printing / drying PTC resistor ink at a position where power is supplied by these electrodes 14a, 14b. 15 was produced.

  The polymer resistor 15 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 13 was bonded to the electrodes 14a and 14b and the polymer resistor 15 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 13 have a heat insulating material layer and an insulating film layer. For example, even when the polymer heating element 11 is arranged on one side in contact with the human body, the polymer heating element 11 with less heat loss and good flexibility and texture will be obtained.

  It was found that energy saving performance of about 6% was exhibited when compared with the case of using a base material composed of a fiber material layer and an insulating film layer having the same thickness that does not take into account normal heat retention.

(Embodiment 3)
5 and 6, a polymer heating element 21 is disposed on a base-side electrically insulating base material 22 and a cover-side electrically insulating base material 23 and connected to a pair of electrodes 24a, 24b and these electrodes 24a, 24b. In addition, the polymer resistor 25 having the connected PTC characteristic is sandwiched.

  The electrodes 24a and 24b are set in a comb-like shape in which a plurality of sub-electrodes are alternately branched in the opposite direction from the main electrode portion.

  Here, the base-side electrically insulating substrate 22 has a two-layer structure of a heat insulating material layer and an insulating film layer, and the cover-side electrically insulating substrate 23 has only an insulating film layer. Was used.

  As the heat-insulating material layer, the product name “Generamoneo” of Sumitomo 3M Co., Ltd. was used as a temperature control material.

  This material is a material obtained by processing a phase change material that easily changes into a solid and a liquid in a normal temperature range. Even when the outside air temperature changes, there is little temperature change near the material surface, and a comfortable warm feeling can be obtained.

  Further, the insulating film layer of the base-side electrically insulating substrate 22 and the insulating film layer of the cover-side electrically insulating substrate 23 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 direct reaction of ethylene and propylene), and electrodes and resistors. It is a film made of a kneaded product of an olefin-based adhesive resin (a resin containing an ethylene component containing a maleic anhydride component) that has good contact characteristics with a total of three types of resin blends. The film thickness was 50-60 microns, and the base-side electrically insulating substrate 22 was obtained by heat-sealing to one side of the heat retaining material.

  In FIG. 6, the portion corresponding to the heat insulating material layer is illustrated with a white frame line, and the portion corresponding to the insulating film layer is illustrated with a thick black line so that the two-layer structure can be understood.

  A pair of electrodes 24a and 24b is printed and dried on the base-side electrically insulating base 22 by a silver paste, and a polymer resistor is printed and dried by a PTC resistor ink at a position where power is supplied by the electrodes 24a and 24b. 25 was produced.

  The polymer resistor 25 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. A cover-side electrically insulating base material 23 made of an insulating film layer obtained by making an ink and made by the above-described method was bonded to the electrodes 24 a and 24 b and the polymer resistor 25.

  In the present polymer heating element 21, only the base-side electrically insulating base material 22 has a two-layer structure having a heat insulating material layer and an insulating film layer, and this surface is arranged so as to come into contact with the human body. As a result, it was found that the polymer heating element had little heat loss and good flexibility and texture.

  It was found that energy saving performance of about 8% was exhibited when compared with the case of using a base material composed of a fiber material layer and an insulating film layer having the same thickness that does not take into account normal heat retention.

  As described above, the polymer heating element according to the present invention can efficiently transmit heat with a small loss, can improve energy saving performance, and can be mounted on a heating heat source or the like of an automobile seat device. Is possible.

1,11,21 Polymer heating element 2,12,22 Base-side electrically insulating substrate 3,13,23 Cover-side electrically insulating substrate 4a, 4b, 14a, 14b, 24a, 24b Electrodes 5, 15, 25 Polymer resistor

Claims (9)

A base-side electrically insulating base and a pair of electrodes sandwiched between the cover-side electrically insulating base and a polymer resistor having a PTC characteristic disposed between the electrodes; A polymer heating element using a heat insulating material for at least one of a base material and a cover-side electrically insulating base material. The polymer heating element according to claim 1, wherein the heat retaining material includes at least one of a light weight heat retaining material, a heat generating material, and a temperature adjusting material. The polymer heating element according to claim 2, wherein the heat generating material includes at least one of a heat storage and heat retaining material, a far-infrared radiation material, or a moisture absorbing heat generating material. The polymer heating element according to claim 2, wherein the lightweight heat retaining material is made of a polyester hollow fiber. 4. The polymer heating element according to claim 3, wherein the heat storage and heat retaining material is made of a fiber kneaded with zirconium carbide. The polymer heating element according to claim 3, wherein the far-infrared radiation material is composed of a fiber obtained by kneading ceramics into polyester. The polymer heating element according to claim 3, wherein the moisture-absorbing heat-generating material includes at least one of acrylic fiber and polyester fiber. The polymer heating element according to claim 2, wherein the temperature adjustment material is made of a material obtained by processing a microcapsule enclosing a phase change material into a woven or knitted fabric. The polymer heating element according to claim 1, wherein at least one of the base-side electrically insulating substrate and the cover-side electrically insulating substrate has a multilayer structure of a heat insulating material layer and an insulating film layer.