JP3437163B2 - Planar heating element using thin metal foil - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a planar heating element having a self-temperature control function for various uses.

[0002]

2. Description of the Related Art Heretofore, a sheet heating element using a thin metal foil having a self-temperature control function for various purposes has been proposed.

This sheet heating element is heated by being energized,
The area to which the planar heating element is attached is heated.

By the way, this sheet heating element is manufactured by the following manufacturing method.

A thin stainless steel foil 11 is adhered on a PET film 13 via an ester-based adhesive 12 (FIG. 1), and a protective pattern 14 with an etching resist is applied on the foil 11 in a desired pattern ( 2), followed by ferric chloride solution to corrode the part where the protective print 14 does not exist (FIG. 3), the protective print 14 is removed with sodium hydroxide solution or the like (FIG. 4), and an epoxy system or the like is further applied. Insulation film 13 coated with thermoplastic adhesive 12 is melt-bonded with a heat press machine (Fig. 5) and used for processing such as soldering 15, crimping connector and welding to thin metal foil 11 of terminal 11A. Connect the electric wire 16 (shown in the case of soldering in FIG. 6), fill the terminal portion 11A with an insulating resin 17 such as silicon or epoxy, and attach it to any place on the heater (planar heating element). Thermostat 18
An electric wire 16 is connected in series to the above to manufacture a planar heating element (Fig. 7,
(Figure 8).

[0006]

As a result of various studies, the applicant has confirmed that the above conventional structure has the following drawbacks. Since the thermostat is attached on the heater,
It requires space for the attached part and wiring cost. The detected temperature varies depending on the environment around the thermostat and the bonding position. If the thermostat comes off, temperature control will not work and an accident such as overheating will occur.

An object of the present invention is to provide a sheet heating element using a thin metal foil having a self-temperature control function, which solves the above-mentioned drawbacks of the conventional structure.

[0008]

The gist of the present invention will be described with reference to the accompanying drawings.

A thin metal foil 1 which generates heat when energized is covered with an insulating film 3 as an exterior material via an adhesive agent 2, and an electric wire 6 is connected to a terminal portion 1A of the thin metal foil 1. Is a heater portion 1B for detecting the temperature of the thin metal foil 1.
In a planar heating element using a metal thin foil in which a thermostat 8 for detecting the temperature of is connected in series, the temperature detecting heater portion 1B is connected to the terminal portion 1A for connecting the electric wire 6 to the metal thin foil 1. The thermostat 8 is arranged at a position close to each other, the thermostat 8 is arranged at a position close to the terminal 1A, and the electric wire 6 portion connected to the terminal 1A and the thermostat 8 are filled with an insulating resin 7 by injection molding. Sheet-like heat generation using a thin metal foil, characterized in that the terminal portion 1A including the thermostat 8 and the electric wire 6 is covered and integrated so as to have improved mechanical strength, insulating property and waterproof property. It is related to the body.

Further, in the formation pattern of the thin metal foil 1,
The sheet heating element using the thin metal foil according to claim 1, wherein a dedicated portion serving as the temperature detecting heater portion 1B is provided.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION A preferred embodiment of the present invention (how to carry out the invention) will be briefly described with reference to the drawings and showing its function and effect.

A dummy heater portion 1B is provided on the terminal portion 1A (for example, when the thin metal foil 1 is formed into a predetermined pattern by etching, a dedicated portion for the temperature detecting heater portion 1A is formed), and a thermostat is formed thereon. After bonding 8 together, the thermostat 8 and the thin metal foil 1 are connected to the terminal portion 1.
In A, the thermostat 8, the wiring material (electric wire 6), and the entire terminal connecting portion are connected in series with the electric wire 6 in a single molding, and the insulating resin 7 is filled and covered to protect the small and lightweight self-temperature control function. A heating element having is manufactured.

That is, the thermostat 8 detects the temperature of the temperature detecting heater portion 1B formed in the vicinity of the terminal portion 1A, so that the temperature of the entire heater can be maintained at a constant temperature, and the filling of the insulating resin 7 is performed by injection molding. By doing so, it is possible to improve the insulating property, waterproof property, and mechanical strength of the terminal portion 1A (connection portion) including the thermostat 8 and the electric wire 6 and uniformly form the same.

Further, since the thermostat 8 is incorporated and integrated in the terminal portion 1A, it leads to the mechanical protection of the wiring portion and the electrical reliability is improved. Furthermore, since the thermostat is not attached to the heater surface, the space can be effectively used and temperature unevenness can be prevented.

[0015]

Embodiments of the present invention will be described with reference to the drawings.

As shown in FIGS. 1 to 6 shown as a conventional example, a thin stainless steel foil 1 is attached to a polyethylene terephthalate (PET) resin film 3 via an ester adhesive 2 and the foil 1 Protective printing 4 with an etching resist is applied in a desired pattern on top of it, and then a portion without protective printing 4 is corroded with a ferric chloride solution, and protective printing 4 is removed with a sodium hydroxide solution or the like. An insulating film 3 coated with a thermoplastic adhesive 2 such as an epoxy resin is melt-bonded by a heat press machine to form a terminal portion 1A.
Solder to the thin metal foil 1 (where the electric wire 6 is connected) 5,
Crimping connector, and the wire 6 at a processing method such as welding to connect (not in the case of solder 9 with).

In addition, a dedicated portion (dummy pattern) to be the temperature detecting heater portion 1B is provided in advance in the vicinity of the terminal portion 1A as a formation pattern of the thin metal foil 1, and the thermostat 8 is attached directly above the temperature detecting heater portion 1B. Then, the thermostat 8 and the portion where the electric wire 6 is connected to the terminal portion 1A by soldering (terminal portion 1A) are filled with the insulating resin 7 by injection molding. That is, the entire terminal connecting portion including the thermostat 8 and the wiring material (electric wire 6) is integrally molded with the insulating resin 7 such as vinyl chloride to cover and protect the sheet heating element. (FIGS. 9 and 10) The present embodiment having the above-mentioned configuration has the following features. The thermostat 8 detects and controls the temperature of the temperature detecting heater portion 1B formed in the terminal portion 1A (in the vicinity), so that the temperature of the entire heater can be maintained at a constant temperature. By filling the insulating resin 7 by injection molding, the terminal portion 1A
The insulation, waterproofness, and mechanical strength of can be improved and it can be formed uniformly. By incorporating the thermostat 8 and the entire wiring portion into the terminal portion 1A and integrally molding the resin portion with the resin coating, the wiring portion is mechanically protected, and the electrical reliability is improved. Since the thermostat 8 is integrated in the resin coating of the terminal portion 1A, the thermostat 8 that has conventionally been attached externally
Is unnecessary, space can be used effectively, and temperature unevenness can be prevented.

[0018]

According to the present invention because configured as described above, easy and a planar heating element using thin metal foil having a self temperature control function with excellent electrical reliability and temperature reliability in a space-saving
It can be easily manufactured and provided.

[Brief description of drawings]

FIG. 1 is an explanatory diagram of a manufacturing process 1 of a conventional example (this example).

FIG. 2 is an explanatory diagram of a manufacturing process 2 of a conventional example (this example).

FIG. 3 is an explanatory diagram of a manufacturing process 3 of a conventional example (this example).

FIG. 4 is an explanatory diagram of manufacturing process 4 in a conventional example (this example).

FIG. 5 is an explanatory diagram of manufacturing process 5 in a conventional example (this example).

FIG. 6 is an explanatory diagram of manufacturing process 6 in a conventional example (this example).

FIG. 7 is an explanatory diagram of manufacturing process 7 of a conventional example.

FIG. 8 is an overhead view of a conventional product.

FIG. 9 is an explanatory diagram of a manufacturing process of this example.

FIG. 10 is an overhead view of the product of this embodiment.

[Explanation of symbols]

1 thin metal foil 1A terminal 1B Temperature detection heater 2 adhesive 3 insulating film 6 electric wires 7 Insulating resin 8 thermostat

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Claims (2)

(57) [Claims] 1. A thin metal foil, which generates heat when energized, is covered with an insulating film as an exterior material via an adhesive, and an electric wire is connected to a terminal portion of the thin metal foil. In a planar heating element using a metal thin foil in which a thermostat for detecting the temperature of a thin foil temperature detecting heater portion is connected in series, the temperature detecting heater portion is used to connect the electric wire to the metal thin foil. Arranged at a position close to the terminal portion, the thermostat is arranged at a position close to the terminal portion, and the electric wire portion connected to the terminal portion and the thermostat are filled and covered with an insulating resin by injection molding.
A sheet heating element using a thin metal foil, characterized in that the terminal portion including the thermostat and the electric wire is integrated to improve mechanical strength, insulation and waterproofness. 2. The sheet heating element using the thin metal foil according to claim 1, wherein a dedicated portion to be the heater portion for temperature detection is provided on the formation pattern of the thin metal foil.