JP3052319U - Planar heating element - Google Patents

Abstract

(57) [Problem] To provide a planar heating element having a high degree of freedom in dimension selection, a uniform thickness of a conductive resin coating, and a uniform temperature distribution. A planar heating element formed by sewing a plurality of fine metal wires (4, 5) along opposite opposite edges of a resin-coated sheet (2) formed by applying a conductive resin agent to a cloth (1). The plurality of thin metal wires at each edge are sewn and hooked to the plurality of first thin metal wires 4 extending in a direction along the edges at a small interval from each other. It comprises a second metal wire 5 attached in a zigzag manner in a transverse direction extending between the metal wires of the first metal wire. A plurality of thin metal wires provided at each edge are used as the current-carrying electrodes 6.

Description

[Detailed description of the invention]

[0001]

[Technical field to which the invention belongs]

 The present invention relates to a planar heating element which is formed by applying a plurality of thin metal wires along opposite opposite edges of a resin-coated sheet formed by applying a conductive resin agent to a cloth to form a current-carrying electrode.

[0002]

[Prior Art and Problems to be Solved by the Invention]

 2. Description of the Related Art A planar heating element in which current-carrying electrodes are provided along opposite opposite edges of a resin-coated sheet formed by applying a conductive resin agent to a cloth, and the electrodes are connected to a power source is conventionally known. An example is shown in the specification of Utility Model Registration No. 2527796 (issued on March 5, 1997). In this example, a composite yarn formed by twisting a plurality of fine metal wires and a plurality of single fabric yarns is used, and each of the plurality of thin yarns is formed along each of both end edges of the fabric as a material of the resin-coated sheet. The composite yarn of the book is woven together with the fabric yarn as warp or weft, and after weaving, a conductive heating agent is applied to the entire surface of the cloth including the pair of electrodes to form a sheet heating element. .

[0003] However, for example, when a planar heating element is used to heat the floor of a building, a frame is provided on a floor plate, and the planar heating element is fitted between the frames, and is placed on the frame. Although a floor heating device is completed by providing a finishing material, there is a problem that the dimensions of the framework are different due to a difference in the construction method of the building (eg, the conventional method and the 2 × 4 method). Therefore, when the composite yarns for electrodes are integrally woven at the opposite end edges of the cloth whose dimensions are predetermined, as in the above-mentioned known planar heating element, there is no degree of freedom in the dimensions, and the method depends on the difference in the construction method. Fabrics of different dimensions must be woven. This is the same even when a planar heating element is not used for floor heating of a building, and it is inevitable to produce many types and small quantities, which causes a cost increase.

[0004] On the other hand, in the known planar heating element, a composite resin yarn is integrally woven to form a fabric, and then a conductive resin agent is applied. Since the thickness of the portion is large, the thickness of the applied conductive resin material is larger than that of the non-electrode portion. Therefore, when the sheet heating element is energized through the electrodes, the temperature of the portion where the conductive resin material has a large thickness (that is, the electrode region) becomes higher than that of other parts, and the entire sheet heating element is heated. There is a problem that the temperature distribution becomes uneven.

[0005] Thus, an object of the present invention is to provide a planar heating element having a high degree of freedom in selecting dimensions, a uniform thickness of a conductive resin material coating, and a uniform temperature distribution.

[0006]

[Means for Solving the Problems]

 The purpose of this is to sew a plurality of thin metal wires along opposite edges of a resin-coated sheet made by applying a conductive resin agent to a cloth, and to form a plurality of metal wires at each edge of the resin-coated sheet. A plurality of first thin metal wires extending in a direction along the edge at a small interval from each other, and sewn on the first thin metal wires, and each thin metal wire of the first thin metal wire; Provided is a planar heating element comprising a second thin metal wire attached in a zigzag manner in a transverse direction extending between the plurality of thin metal wires, and the plurality of thin metal wires provided at each end edge are used as a current-carrying electrode. Achieved by: It is preferable that the resin-coated sheet formed by applying the conductive resin agent is impregnated with the resin agent penetrating into the fabric. Peeling is unlikely to occur. The metal thin wire is preferably made of copper or a copper alloy having good conductivity. Each of the thin metal wires may be a single wire, or may be a stranded wire formed by combining a plurality of thin metal wires. In addition, in order to sew a plurality of thin metal wires along both edges of the resin-coated sheet, it is preferable to use a multi-needle flat sewing machine.

The planar heating element of the present invention includes a step of manufacturing a resin-coated sheet by applying a conductive resin agent to a cloth of a predetermined size, and a step of forming a resin-coated sheet along opposite opposite edges of the resin-coated sheet. And a step of sewing several thin metal wires. In the normal case, it is preferable to simultaneously produce a plurality of sheet heating elements from a single resin-coated sheet, which can increase the productivity and is economical. In this method, a set of a plurality of thin metal wires is sewn in parallel with a large area of cloth at appropriate intervals and cut into a plurality of sheet heating elements as a unit having one to two sets of thin metal wires. Get it. Hereinafter, preferred embodiments of the present invention will be described.

[0008]

[Embodiment of the invention]

 The structure of the planar heating element of the present invention will be clarified by describing the manufacturing process. FIG. 1 shows a rectangular woven fabric 1 as a material. The woven fabric 1 includes a warp yarn 1a and a weft yarn 1b. The length of the woven fabric 1 can be set arbitrarily.

FIG. 2 shows a resin-coated sheet 2 obtained by applying a conductive resin agent to the entire front and back surfaces of a woven fabric 1. In the drawing, reference numeral 3 denotes a conductive resin coating layer.

FIG. 3 shows a state in which fine metal wires for current-carrying electrodes are sewn to the resin-coated sheet 2. Each set of three electrodes, each of which is made of a thin metal wire 4, is arranged substantially in parallel at a predetermined interval. The three thin metal wires 4 of each set are also arranged in parallel with a small space therebetween. The thin metal wire 4 is a thin wire made of copper or copper alloy having a diameter of about 0.2 mm, and is sewn to the resin-coated sheet 2 using a multi-needle flat sewing machine (for example, Japanese Utility Model Laid-Open No. 6-46678). Here, the predetermined interval is a dimension according to an object to be used for the sheet heating element, and means, for example, a length suitable for floor heating according to a conventional construction method of a building or a 2 × 4 method. . In the example shown in FIG. 3, two sets of fine metal wires located at the center are cut close to each other at the center of the sewn portion.

FIG. 4 shows a state in which a thin metal wire 5 similar to the thin metal wire 4 is sewn in a zigzag form on each of the front and back surfaces of the resin-coated sheet 2 to which a plurality of sets of thin metal wires 4 are sewn. The metal wires 5 are zigzag-shaped so that all the seams of the metal wires 4 are in contact with each other. That is, at each seam, the fine metal wire 5 is attached by inserting between the fine metal wire 4 and the resin-coated sheet 2. Thus, a sheet heating element (FIG. 4) in which a plurality of sets of electrodes 6 are attached to the resin-coated sheet 2 is obtained. The sheet heating element is sequentially cut at a central position of a portion where two sets of electrodes 6 are closely sewn to obtain a large number of sheet heating elements. The sheet heating element obtained by the cutting is hermetically covered with the insulating resin sheets A and B as shown in FIG. 5, and the sheet heating element 8 as a final product is obtained.

In the planar heating element 8, the extended portions 7 of the thin metal wires 4 and 5 are used as connection terminals to a power supply.

In the above specific example, the metal thin wires 4 and 5 were used, but instead of these, three metal thin wires of the same type and four fabric yarns, which is a cotton yarn of 20 count and 1.75 twists, were twisted. A composite yarn having a diameter of about 1.0 mm may be used in total. In addition, although the thin metal wires 4 are sewn straight to the resin-coated sheet, when the shape of the resin-coated sheet is not a simple rectangle but has a curved side, a shape matching along the curved side is used. The metal wires 4 and 5 may be attached so as to form

[0014]

[Effect of the invention]

 As is clear from the above description, the sheet heating element of the present invention employs a structure in which fine metal wires are sewn to the resin-coated sheet after applying the conductive resin agent to the fabric. The thickness of the conductive resin agent coating layer is constant, and the temperature distribution over the entire surface of the planar heating element becomes uniform when current is applied. In addition, a thin metal wire is sewn to the resin-coated sheet after the conductive resin agent is applied to the fabric. By mounting a plurality of sets at predetermined intervals, a large number of sheet heating elements having desired dimensions can be obtained by cutting the sets at appropriate lengths, realizing high productivity and reducing costs. obtain. Further, in the planar heating element of the present invention, the plurality of thin metal wires at each edge of the resin-coated sheet are spaced apart from each other by a plurality of first thin metal wires extending in a direction along the edge. A second metal thin wire sewn on the first metal thin wire and attached in a zigzag manner in a transverse direction extending between the metal thin wires of the first metal thin wire. Even if a disconnection occurs at any of the above points, the plurality of first metal wires and the second metal wires in a zigzag arrangement complement each other, and a local increase in electrical resistance can be eliminated. Fever can be prevented.

[Brief description of the drawings]

FIG. 1 is a plan view and a cross-sectional view showing a rectangular woven fabric as a material of a planar heating element of the present invention.

FIG. 2 is a plan view and a cross-sectional view showing a resin-coated sheet obtained by applying a conductive resin agent to both front and back surfaces of the woven fabric shown in FIG.

FIG. 3 is a plan view and a cross-sectional view showing a resin-coated sheet formed by sewing fine metal wires for a current-carrying electrode.

FIG. 4 is a plan view of a sheet heating element formed by further sewing another thin metal wire for a current-carrying electrode on a resin-coated sheet.

FIG. 5 is a perspective view of the planar heating element of the present invention showing a state in which the planar heating element shown in FIG. 4 is covered with an insulating resin sheet.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Woven cloth 1a Warp yarn 1b Weft yarn 2 Resin coating sheet 3 Conductive resin coating layer 4 Fine metal wire 5 Fine metal wire 6 Electrode 7 Extended part (connection terminal) 8 Planar heating element

Claims (4)

[Utility model registration claims] 1. A resin-coated sheet formed by applying a conductive resin agent to a cloth, and a plurality of fine metal wires are sewn along opposite opposite edges of the resin-coated sheet. A plurality of first thin metal wires extending in a direction along the edge at a small interval from each other, and sewn to these first thin metal wires, and the first thin metal wires are It comprises a second metal thin wire attached in a zigzag form in the transverse direction straddling between each of the metal thin wires, wherein a plurality of the metal thin wires provided on each of the edges are used as a current-carrying electrode. Sheet heating element. 2. The sheet heating element according to claim 1, wherein the thin metal wire is made of a metal having good conductivity. 3. The sheet heating element according to claim 1, wherein the thin metal wire is made of copper or a copper alloy. 4. The planar shape according to claim 1, wherein each of the thin metal wires is a stranded wire formed by collectively forming a plurality of thin metal wires. Heating element.