JP2835077B2 - Foil for planar resistor, method of manufacturing the same, and method of manufacturing thin sheet heater using the same - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a thin-sheet heater used for wall heating, floor heating, panel heater, and the like, and a foil for a planar resistor used for the heater. The present invention relates to an excellent foil for a planar resistor and a method for producing the same, and a method for producing a thin leaf heater which is excellent in productivity and can be produced at low cost.

(Prior Art) A method of manufacturing a sheet resistor used as a resistor of a thin-sheet heater and a method of applying the sheet resistor to a thin-sheet heater are roughly classified into the following two methods.

(1) A method of uniformly depositing a resistance material such as tin oxide serving as a heating resistor on a surface of an insulating plate such as glass or resin in a desired circuit shape such as a meandering shape or a spiral shape.

(2) A resistive sheet foil of 100 μm or less made of nichrome, stainless steel, iron, nickel, or the like to be a heating resistor is processed into a desired circuit shape to form a sheet resistor, which is formed on the surface of glass or resin. How to stick to.

After the heating resistor is deposited or fixed, an insulating plate is further superposed on the surface of the heating resistor as necessary, so that the heating resistor is sandwiched between the insulating plates.

Among them, in the method (1), the heating resistor cannot be deposited to a uniform thickness, and it is difficult to form a thin-film heater that uniformly generates heat over the entire surface. Therefore, in recent years, thin sheet heaters using a planar resistor as a heating element, such as those formed by the method (2), have been widely used.

The method of processing the resistive sheet foil into a desired circuit shape to form a sheet resistor includes a method of manually processing the resistive sheet foil using scissors or a cutter, and a method such as laser machining or electric discharge machining. As described in JP-A-63-37588, there are a method of punching using a high-precision fitting die, a method of chemical etching, and the like.

(Problems to be Solved by the Invention) The manual processing and the thermal processing described above have poor productivity and are not suitable for mass production. In chemical etching, there is a problem that the production cost is high because the productivity is low and a large amount of expensive chemicals are used. In addition, the method using a fitting die requires time and a large production cost for the production of the die, and thus is not suitable for production of a small number of lots.

Furthermore, in the above-mentioned processing method, the processed planar resistor is separated from the original foil, so that there is a problem that it is difficult to handle in a subsequent step.

An object of the present invention is to solve the above-mentioned problems and to provide a foil for a planar resistor having excellent handling and a method for producing the same, and a method for producing a thin-sheet heater which is excellent in productivity and can be produced at low cost. It is in.

(Means for Solving the Problems) In order to solve the above problems, the present invention has taken the following measures.

(1) The sheet resistor foil is formed by forming a sheet resistor having a desired shape formed by cutting a resistive sheet or the like into a resistive sheet around the contour of the sheet resistor. It was configured to be connected with a foil and a bridge.

(2) The foil for a planar resistor having the configuration of the above (1) is erected on a contour of a desired planar resistor of the resistive planar foil, leaving portions of the contour shape. It was manufactured by inserting a blade using a Thomson mold.

(3) A step of manufacturing a sheet resistor foil using the thin sheet heater in the same manner as in (2) above, and placing the sheet resistor foil at a predetermined position on the insulating plate, The manufacturing is performed by a process of separating the unnecessary portion of the foil while holding down the foil for the planar resistor so that the body portion does not move, and a process of bonding the planar resistor to the insulating plate using an adhesive.

(4) using a thin sheet heater to produce a sheet resistor foil in the same manner as in (2), separating an unnecessary portion of the foil around the sheet resistor, and moving the insulating plate, Bonding the sheet resistor at a predetermined position on the insulating plate.

(5) A step of manufacturing a sheet heater foil using the thin sheet heater in the same manner as in (2) above, bonding the sheet resistor to a predetermined position on the insulating plate, and then removing unnecessary portions of the foil. It is manufactured by the separating step.

(Operation) In the foil for a planar resistor having the configuration (1), the planar resistor and other peripheral portions are not separated even after cutting, so that the handling of the planar resistor is facilitated.

According to the manufacturing method of (2), the foil for a planar resistor having the configuration of (1) can be manufactured easily and inexpensively.

According to the manufacturing methods of (3) to (5), the planar resistor can be easily fixed to the insulating plate.
The productivity of the thin sheet heater is improved, and a thin sheet heater that can be manufactured at low cost can be provided.

(Example) Hereinafter, the present invention will be described in detail with reference to the drawings.

FIG. 1 is a plan view of one embodiment of a mold (Thomson type) used for manufacturing the sheet resistor foil of the present invention,
A blade 1 is set up on the surface of the plywood 2 in accordance with a shape in which the blade is inserted (blade insertion). In Fig. 1, A
As shown as part B, part B is provided with a concave portion or a portion where a blade is not raised.

FIG. 2 is an enlarged cross-sectional view of the periphery of a portion A where the blade is not raised. In the present embodiment, two concave portions 6 are formed at various positions of the blade. As will be described later in detail, the recess 6
Even if the blade is cut into the resistive sheet foil depending on the mold, the part that becomes the sheet resistor and the surrounding resistive sheet foil do not separate and can be easily separated as necessary. Are provided to connect each of them via a connection such as a perforation.

Therefore, if the connection between the part to be the resistive sheet foil and the other parts can be maintained so that the above requirements are satisfied even after cutting, if the part can be maintained, Any shape, size, and formation position may be used. Instead of forming a concave portion on the blade as described above, a gap may be provided.

In the case of manufacturing a sheet resistor for a thin leaf heater using a mold having such a configuration, first, a sheet foil is placed on a mold and pressed, and a desired sheet resistance is applied to the sheet foil. Perform cutting of the body shape.

At this time, as described above, since the blade 1 is provided with a portion where the blade is not set up in some places, even after the blade is inserted, the portion which becomes the planar resistor is not separated from the other portion by the bridge. The connected and bladed sheet foil is still substantially in a single foil state. Therefore, handling of the sheet resistor becomes easy.

When the cutting is completed, the sheet-like foil is fixed to the surface of an insulating plate such as a mica plate, an alumina plate, a synthetic resin insulating film or the like.

(1) Place the bladed sheet foil at a predetermined position on the insulating plate, hold the sheet resistor portion so as not to move, and cut off unnecessary portions of the surrounding foil, and place on the insulating plate. In a state where only the planar resistor is placed at a predetermined position. After all unnecessary parts of the foil are cut off, the sheet resistor is bonded to the insulating plate using an adhesive.

(2) Place the bladed sheet foil on a flat plate, and cut off unnecessary portions of the foil around the sheet resistor on the flat plate. On the other hand, an adhesive is applied to at least a portion of the main surface of the insulating plate to which the planar resistor is adhered, and then the insulating plate is placed so that the planar resistor is located at a predetermined position on the main surface. A method in which the planar resistor is bonded to a predetermined position on the insulating plate by being superposed on a flat plate.

(3) An adhesive is applied to at least a part of the sheet resistor of the cut sheet foil or at least a part of the main surface of the insulating plate to which the sheet resistor is bonded, and the sheet foil cut into the blade is cut. And the insulating plate. Then, a method of cutting off unnecessary portions of the foil while the adhesive does not cure.

The adhesive used at this time is preferably a polyorganosiloxysan resin, an inorganic adhesive, a polyimide heat-resistant organic adhesive, or the like.

When the bonding of the planar resistor to the insulating plate is completed as described above, an insulating plate is further laminated on the surface according to the application, and a pasten terminal or the like serving as an electrode is further connected to complete the thin leaf heater. I do.

FIG. 3 is a sectional view of the thin-film heater manufactured as described above. The sheet resistor 3 is sandwiched between two sheet resistors 4-1 and 4-2 together with the adhesive 5. Structure.

According to this embodiment, even after the blade is cut, the sheet resistor and the other parts are connected by the bridge, so that they are not separated, and can be easily separated as necessary. The thin-film heater can be manufactured with excellent productivity and at low cost.

(Effects of the Invention) As is clear from the above description, according to the present invention, the planar resistor and other parts do not separate even after cutting, so that handling of the planar resistor becomes easy.

Furthermore, if a thin-sheet heater is manufactured by using a sheet-like resistor foil having a bladed structure, the sheet-like resistor can be easily fixed to an insulating plate. The property can be improved and it can be manufactured at low cost. A thin-film heater can be provided.

[Brief description of the drawings]

FIG. 1 is a plan view of an embodiment of a big die used for manufacturing a foil for a planar resistor according to the present invention, FIG. 2 is an enlarged sectional view around a portion A in FIG. 1, and FIG. It is sectional drawing of a heater. DESCRIPTION OF SYMBOLS 1 ... Blade, 2 ... Plywood, 3 ... Planar resistor, 4-1, 4-2 ... Insulating plate, 5 ... Adhesive

Claims (6)

(57) [Claims] 1. A foil for a planar resistor, characterized in that a blade is cut along a contour of a portion to be a planar resistor except for some portions thereof. 2. A method for producing a foil for a sheet resistor, comprising: forming a resistive sheet foil on a Thomson mold having a blade formed along a contour of a desired sheet resistor shape, leaving a part thereof in place. Is placed and pressed, and a blade is cut into the resistive sheet foil along the contour of the sheet resistor shape, leaving a place there. . 3. A method of manufacturing a thin-film heater using a sheet resistor processed into a desired circuit shape as a heating element, wherein the sheet resistor is left along a contour of a portion to be the sheet resistor. Place the sheet resistor foil with the blade in place at a predetermined position on the insulating plate, and hold the sheet resistor foil so that the sheet resistor portion does not move, A method for manufacturing a thin-film heater, comprising: a step of cutting off the periphery of the sheet-like resistor portion along the periphery; and a step of bonding the sheet-like resistor to an insulating plate using an adhesive. 4. A method for manufacturing a thin-film heater using a sheet-like resistor processed into a desired circuit shape as a heating element, wherein a part of the sheet-like resistor is left along a contour of a portion to be the sheet-like resistor. A step of placing the foil for a planar resistor having a blade placed on a flat plate and cutting off the periphery of the planar resistor portion along the contour, an insulating plate having a main surface coated with an adhesive, Laminating the insulating plate on the flat plate and bonding the planar resistor to a predetermined position on the insulating plate so that the planar resistor is located at a predetermined position on the main surface. A method of manufacturing a thin-sheet heater. 5. A method for manufacturing a thin-film heater using a sheet-like resistor processed into a desired circuit shape as a heating element, wherein a part of the sheet-like resistor is left along a contour of a portion to be the sheet-like resistor. Bonding the foil for a planar resistor having a blade to a predetermined position on an insulating plate, and then cutting off the periphery of the planar resistor along the contour. Manufacturing method. 6. A thin-film heater according to claim 3, wherein an insulating plate is further laminated on the planar resistor, following the step described in any one of claims 3 to 5. Production method.