JP4277729B2 - Planar heating element - Google Patents

Description

  The present invention relates to a planar heating element that is flexible and can be mounted on an arbitrary curved surface, and relates to a car seat heater, a handle heater, and the like mainly used in vehicles.

  Conventionally, in the heat generating part of this type of planar heating element, a base polymer and a conductive material such as carbon black, metal powder, and graphite are dispersed in a solvent. (For example, see Patent Documents 1, 2, and 3).

  4A is a plan view of a conventional sheet heating element having PTC characteristics, FIG. 4B is a cross-sectional view taken along line xy of FIG. 4A, and FIG. FIG. As shown in FIGS. 4A and 4B, a pair of comb-shaped electrodes 51 and 52 obtained by printing and drying a conductive paste on an electrically insulating base material 50 such as a polyester sheet, and the like, A polymer resistor 53 obtained by printing and drying polymer resistor ink is provided at a position where power is supplied, and the comb-shaped electrodes 51 and 52 and the polymer resistor are covered with a covering 54 made of the same material as the base material 50. 53 is configured to be covered and protected. When a polyester film is used as the base material 50 and the covering material 54, for example, a polyethylene-based heat-fusible resin 55 is bonded to the covering material 54 in advance, and the base material 50 and the covering material 54 are pressed by heating. Are bonded via a heat-fusible resin 55. As a result, the comb-shaped electrodes 51 and 52 and the polymer resistor 53 are isolated from the outside world and given long-term reliability. As a means for pressurization at the time of heating, a schematic configuration sectional view when the covering material 54 is pasted is shown in FIG. 5, but a laminator 58 composed of two heating rolls 56 and 57 is generally used.

The PTC characteristic is a resistance temperature characteristic in which the resistance value increases as the temperature rises, and when the temperature reaches a certain temperature, the resistance value rapidly increases (takes the initial letter of English Positive Temperature Coefficient, which means that the resistance has a positive temperature coefficient) The polymer resistor 53 having PTC characteristics can provide a planar heating element having a self-temperature adjusting function.
Japanese Patent Laid-Open No. 56-13689 JP-A-6-96843 JP-A-8-120182

  However, in the conventional configuration, the electrode and the resistor printed on the electrically insulating base material 50 such as a polyester sheet are protected by the same electrically insulating coating material 54, and the material of the base material 50 and the coating material 54 is used. In addition, depending on the thickness of the heater, there is a problem that it lacks flexibility, and a feeling of sitting when used in a car seat heater and a feeling of touch when used in a handle heater are impaired.

  In addition, when the shape is planar and a force is applied to a part of the surface, the force is deformed to the whole and depending on the shape of the deformation, the amount of deformation increases as it goes to the end. As a result, creases or the like are generated on a part of the surface, and there is a concern that cracks or the like are generated in the printed electrodes and resistors on the folds and the durability is deteriorated.

  Furthermore, since it is composed of an electrically insulating base material 50 and a covering material 54 such as a polyester sheet that is planar and has no air permeability, it is used for a car seat heater or a handle heater. There was a problem that the humidity was easily confined and the seating feeling and touch feeling were impaired when used for a long time.

SUMMARY OF THE INVENTION The present invention solves the above-described conventional problems, and has an object to provide flexibility in shape to improve a feeling of use such as a seating feeling and to improve reliability such as durability.

  In order to solve the above problems, a planar heating element of the present invention includes an electrically insulating substrate, an electrode formed on the electrically insulating substrate, a polymer resistor fed by the electrode, an electrode, and a high electrode. In a planar heating element comprising a molecular resistor covering a covering material disposed in close contact with an electrically insulating substrate, a plurality of through holes are arranged so as to provide flexibility at appropriate positions of the planar heating element. The configuration is as follows.

  With the above-described configuration, a plurality of through holes are provided at appropriate positions of the planar heating element. Therefore, the planar heating element can be easily deformed and when a force is applied to a part of the planar heating element, A plurality of through-holes arranged in the proper position makes it easy to deform in the vicinity, imparts flexibility, and prevents the force from reaching the whole. Folding or the like does not occur in part, and air permeability is imparted by a plurality of through holes arranged at appropriate positions of the planar heating element.

The planar heating element of the present invention has a structure in which a plurality of through-holes are disposed at appropriate positions, can be easily deformed, is provided with flexibility, and has a seating feeling when used in a car seat heater, and a handle heater. together it is possible to improve the usability such as hand feeling when used in deformation when a force is applied that is Ino Do If及until the entire surface of the folds deformation amount caused by expansion Generation | occurrence | production can be prevented and reliability, such as durability, can be improved now. In addition, air permeability is imparted, and it is possible to prevent the accumulation of humidity, and further, it is possible to improve the feeling of use such as a seating feeling when used for a car seat heater and a touch feeling when used for a handle heater. It becomes like this.

The present invention relates to an electrically insulating substrate, an electrode formed on the electrically insulating substrate, a polymer resistor fed by the electrode, and covering the electrode and the polymer resistor so as to be in close contact with the electrically insulating substrate. In the sheet heating element provided with the covering material disposed in the manner described above, a plurality of through holes are disposed so as to provide flexibility at appropriate positions of the sheet heating element.

  And since it has a configuration in which a plurality of through holes are arranged so as to impart flexibility to the appropriate position of the planar heating element, it can be easily deformed, and when a force is applied to a part of the planar heating element, A plurality of through-holes arranged at appropriate positions of the planar heating element makes it easy to deform in the vicinity thereof, imparts flexibility, and is used for a seating feeling when used for a car seat heater, and a handle heater. It becomes possible to improve a feeling of use such as a touch feeling. In addition, the force applied to the planar heating element does not reach the entire surface, deformation due to the force extends to the entire surface, and no creases or the like are generated on a part of the surface. Generation of wrinkles can be prevented, and reliability such as durability can be improved.

  Furthermore, air permeability is provided by a plurality of through-holes arranged at appropriate positions of the planar heating element, and it is possible to prevent the accumulation of humidity. Furthermore, it is used for a seating feeling when used in a car seat heater, and for a handle heater. It is possible to improve the feeling of use, such as the feeling of touch when it is given.

In the present invention, the plurality of through holes are arranged so as to be located at a predetermined distance or more away from an electrode formed on an electrically insulating substrate and a polymer resistor fed by the electrode.

  The plurality of through holes are disposed so as to be spaced apart from the electrode and the polymer resistor by a predetermined distance or more, so structurally, the end of the through hole is disengaged, the position is shifted during die cutting, etc. It is possible to prevent the exposure of the electrodes and polymer resistors that are likely to occur in the case of a margin, and the electrodes and polymer resistors are located sufficiently far from the end of the through hole, and are in close contact with the electrically insulating substrate. It is protected by the covering material that is installed and is shielded from the outside air, and it can prevent problems such as contamination degradation due to moisture and foreign matter and short-circuiting due to electrode migration, and more stable and durable performance. Can be improved.

According to the present invention, the electrodes formed on the electrically insulating substrate are arranged so that the main electrodes face each other, and each main electrode is alternately arranged with a comb-shaped branch electrode, and the plurality of through-holes are arranged. The hole has a shape of a plurality of small holes or long holes, and is arranged in parallel to the branch electrode starting from the end of the branch electrode.

  Since the through hole is arranged in parallel to the branch electrode starting from the end of the branch electrode, the electrode can be used effectively for heat generation without being interrupted, and the heat generation area is kept as wide as possible. However, a through hole can be provided, an increase in watt density caused by providing the through hole can be suppressed, and reliability can be improved. In addition, since the branch electrode is thinner than the main electrode, it is easy to cause cracks and other deterioration due to deformation caused by the force applied to the planar heating element, but the force applied to the planar heating element is applied to the branch electrode. In contrast, the through-holes arranged in parallel are blocked, and the force does not extend over the entire through-hole, and the deformation due to the force extends to the entire branch electrode, causing folds and the like. Will be able to improve reliability.

According to the present invention, the electrodes formed on the electrically insulating substrate are arranged so that the main electrodes face each other, and each main electrode is alternately arranged with a comb-shaped branch electrode, and the plurality of through-holes are arranged. The hole is formed into a plurality of small holes or long hole slits, and is arranged in parallel to the branch electrode in a range approximately half of the branch electrode starting from the end of the branch electrode, and adjacent through holes are in a staggered position. Thus, it is set as the structure arrange | positioned alternately alternately.

Since the through holes are arranged in parallel to the branch electrodes starting from the ends of the branch electrodes, the above-described reliability improvement effect can be obtained, and adjacent through holes are approximately half of the branch electrodes. Since the staggered positions are alternately arranged in a range of, for example, even if the through-hole area is the same, double the number of through-holes can be dispersed, and the through-holes that reduce the heat generation area can be dispersed. The area can be reduced as much as possible, and the structure can be more easily deformed. In other words, by dispersing the through holes, the vicinity of the closer through holes can be easily deformed regardless of which part of the planar heating element is applied, the flexibility is increased, and the adjacent through holes are staggered. Therefore, the force applied to the planar heating element does not reach the entire area with a small area of the through hole, and the reliability can be further improved.

Moreover, this invention is set as the structure located so that the said through-hole might be enclosed only in either one of the electrodes formed on the electrically insulating base material.

  And since the through hole is positioned so as to be surrounded only by one of the electrodes, the end of the electrode is exposed at two or more places at the end of the through hole due to the unraveling or misalignment of the end of the through hole. Even so, since they have the same polarity, current does not flow, and problems such as a short circuit due to migration can be prevented.

In the present invention, the electrodes formed on the electrically insulating substrate are arranged so that the main electrodes are opposed to each other, and each main electrode is alternately provided with comb-shaped branch electrodes. A portion wider than the other portions is provided in the portion, and a plurality of small holes or long-hole slit-shaped through holes are disposed in the wide portion of the branch electrode.

  And since a part wider than the other part is provided in a part of the branch electrode and the through hole is disposed in the wide part of the branch electrode, the periphery of the through hole is located between the same poles. The same effect as in claim 5 can be obtained, and even if two or more end portions of the electrode are exposed at the end portion of the through hole due to the disengagement or misalignment of the end portion of the through hole, the same polarity is obtained. , Current does not flow, and problems such as short circuit due to migration can be prevented.

Further, according to the present invention, the through-hole is positioned so as to be sandwiched between only one of the electrodes formed on the electrically insulating substrate, and the adjacent through-holes or the electrodes surrounding all the through-holes have the same polarity. It is comprised so that it may become.

  And since the electrodes surrounding the adjacent through holes or all the through holes have the same polarity, the electrodes at the end of the adjacent through holes should be removed due to the disengagement or misalignment of the end of the through hole. Even if the end portion of the electrode is exposed, it has the same polarity, so that current does not flow, and problems such as a short circuit due to migration can be prevented.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, this invention is not limited by this embodiment.

(Embodiment 1)
1 and 2 are schematic configuration diagrams of a planar heating element according to Embodiment 1 of the present invention, FIG. 1 is a plan view, and FIG. 2 is a cross-sectional view taken along line xy in FIG.

  In FIG. 1, a planar heating element 1 includes a pair of electrodes 3 formed by printing and drying a silver paste on a thin electrical insulating base material 2 such as a polyester film laminated on a polyester nonwoven fabric 2a, and an electrode 3 The polymer resistor 4 formed by printing and drying the polymer resistor ink so as to overlap is formed. Then, a thin-walled electrically insulating overcoat such as a polyester film in which an adhesive resin layer 5 such as an acrylic adhesive having adhesiveness with the electrode 3, the polymer resistor 4, and the electrically insulating substrate 2 is formed in advance. The covering material 6 laminated with the coating material is bonded together.

  The electrode 3 is provided with wide main electrodes 3a and 3b so as to face each other, and a plurality of comb-shaped branch electrodes 3c and 3d are alternately provided from the respective main electrodes 3a and 3b, and overlap each other. By supplying power from the branch electrodes 3c and 3d to the polymer resistor 4 arranged as described above, a current flows through the polymer resistor 4 to generate heat. This polymer resistor 4 has PTC characteristics, and when the temperature rises, the resistance value of the polymer resistor 4 rises and has a self-temperature adjusting function so as to reach a predetermined temperature, so temperature control is unnecessary. Thus, it has a function as a highly safe planar heating element.

  In addition, an elongated slit-shaped through-hole 7 is arranged in a range approximately half of the branch electrodes 3c and 3d in parallel with the branch electrodes 3c and 3d starting from the end portions of the branch electrodes 3c and 3d. A portion 3e having a width wider than other portions is provided in a part of the branch electrodes 3c and 3d so as to surround the through-hole 7, and the through-hole 7 is located at a predetermined distance or more away from the electrode 3 and the polymer resistor 4. The through holes 7 adjacent to each other are alternately arranged so as to be staggered.

  Here, since the plurality of through holes 7 are arranged at appropriate positions of the planar heating element 1, it can be easily deformed, and when a force is applied to a part of the planar heating element 1, the planar heating element When a plurality of through-holes 7 arranged at appropriate positions in the body 1 are easily deformed in the vicinity thereof, and are provided with flexibility, when used for a car seat heater or when used for a handle heater It is possible to improve the feeling of use such as the feeling of touch. Further, the force applied to the planar heating element 1 does not reach the whole, the deformation due to the force does not reach the entire part, and no crease or the like occurs in a part of the surface, and the deformation amount is increased. Occurrence of creases can be prevented, and reliability such as durability can be improved.

  Further, the plurality of through-holes 7 disposed at appropriate positions of the planar heating element 1 can provide air permeability and prevent accumulation of humidity. Further, the seating feeling when used in a car seat heater, the handle heater It is possible to improve the feeling of use such as the feeling of touch when used in the above.

  The plurality of through-holes 7 are disposed so as to be spaced apart from the electrode 3 and the polymer resistor 4 by a predetermined distance or more. The exposure of the electrode 3 and the polymer resistor 4 that are likely to occur due to misalignment of the electrode 3 can be prevented with a margin, and the electrode 3 and the polymer resistor 4 are located sufficiently apart from the end of the through hole 7. It is protected by the electrically insulating base material 2 and the covering material 6 disposed in close contact therewith and is configured to be shielded from the outside air, such as contamination deterioration due to moisture and foreign matter, short-circuiting due to migration of the electrode 3, etc. Problems can be prevented, and the stability and durability of performance can be improved.

  Further, since the through-hole 7 is arranged in parallel to the branch electrode starting from the ends of the branch electrodes 3c, 3d, the branch electrodes 3c, 3d can be effectively used for heat generation without being interrupted. The through hole 7 can be provided while keeping the heat generation area as wide as possible, and the increase in watt density caused by providing the through hole 7 can be suppressed, and the reliability can be improved. Further, the branch electrodes 3c and 3d are thinner than the main electrode, so that deterioration such as cracks is likely to occur due to deformation caused by the force applied to the planar heating element 1, but the force applied to the planar heating element 1 Is blocked by the through-holes 7 arranged in parallel to the branch electrodes 3c and 3d, and the force does not extend over the entire through-hole 7, and deformation due to the force is large throughout. No folds or the like occur in the branch electrodes 3c and 3d, and the reliability can be improved.

  Further, since the adjacent through holes 7 are arranged so as to be in a staggered position in a range approximately half of the branch electrodes 3c and 3d, for example, even if the through holes 7 have the same area, the double number of through holes 7 are formed. The area of the through-hole 7 that can be dispersed and reduces the heat generation area can be reduced as much as possible, and can be configured to be more easily deformed. That is, by dispersing the through-holes 7, the vicinity of the closer through-hole 7 can be easily deformed regardless of which part of the planar heating element 1 is applied, and the flexibility is increased. Since the holes 7 are arranged so as to be in a staggered position, the force applied to the planar heating element 1 does not reach the entire area with a small area of the through-holes 7, and the reliability can be further improved. become.

  In addition, a portion 3e having a width wider than the other portions is provided in a part of the branch electrodes 3c and 3d, and the through hole 7 is provided in the wide portion 3e of the branch electrodes 3c and 3d. 7 is located between the same poles. Even if two or more electrode ends are exposed at the end of the through-hole 7 due to the end of the through-hole 7 being disconnected or misaligned, Since it is a pole, current does not flow and problems such as a short circuit due to migration can be prevented.

(Embodiment 2)
FIG. 3 is a plan view showing a schematic configuration diagram of the planar heating element 1 according to the second embodiment of the present invention.

  In FIG. 3, this Embodiment 2 arrange | positions so that all the through-holes 7 may be surrounded by the electrode 3 of the same polarity by changing the printing pattern of the electrode 3 on the electrically insulating base material 2 and the polymer resistor 4. The configuration is different from that of the first embodiment, and the same parts are denoted by the same reference numerals and only different parts will be described.

  That is, a part of the branch electrodes 3c and 3d is provided with a substantially hexagonal part 3f which is wider than the other parts, and the hexagonal parts 3f are staggered to reduce the distance between the branch electrodes 3c and 3d. A through hole 7 having an elongated slit shape is disposed in a wide hexagonal portion 3f of the branch electrodes 3c and 3d, and the through hole 7 is formed of the electrode 3 and the polymer. Arranged so as to be located at a predetermined distance or more away from the resistor 4 part, and further, the through hole 7 is positioned so as to be sandwiched only by one of the electrodes formed on the electrically insulating substrate 2, The electrodes surrounding all the through holes 7 are configured to have the same polarity.

  Then, a part of the branch electrodes 3c and 3d is provided with a substantially hexagonal part 3f which is wider than the other branch electrodes 3c and 3d, and the through hole 7 is provided in the substantially hexagonal part 3f which is wide. Therefore, since the periphery of the through hole 7 is located between the same poles, the same effect as in the first embodiment can be obtained, and by any chance the end of the through hole 7 is disengaged or misaligned. Even if two or more end portions of the branch electrodes 3c and 3d are exposed at the end portions, they have the same polarity, so that current does not flow, and problems such as a short circuit due to migration can be prevented.

  In addition, since the distance between the branch electrodes 3c and 3d is positioned so as to be substantially constant, by providing a wide substantially hexagonal portion 3f in a part of the branch electrodes 3c and 3d, the area of the heat generating portion is reduced. There is no reduction in uselessness, and further, there is less restriction on the position of the portion, that is, the portion where the through hole 7 is provided.

  And since the substantially hexagonal part 3f surrounding each of all the through holes 7 is configured to have the same polarity, the adjacent through holes 7 may be caused by the unraveling or misalignment of the end portions of the through holes 7. Even if the end portions of the branch electrodes 3c and 3d are exposed at the end portion, the current is not flowed because of the same polarity, and problems such as a short circuit due to migration can be prevented.

  In the first embodiment, the through hole 7 has a long slit shape. However, this may be formed by connecting a plurality of small holes. In the second embodiment, a part of the branch electrodes 3c and 3d is formed. In the above description, the substantially hexagonal portion 3f that is wider than the other portions is provided. However, this may be other shapes such as a circle or an ellipse. Further, it is not always necessary that the distance between the branch electrodes 3c and 3d is substantially constant, and a wide and substantially hexagonal portion provided in the branch electrodes 3c and 3d surrounding all the through holes 7 is provided. Although the configuration has been described so that 3f has the same polarity, it is sufficient that the adjacent through-holes 7 have the same polarity, and the configuration of each other part is within the range that achieves the object of the present invention. May be anything.

  As described above, according to the present invention, it is possible to obtain a planar heating element that is flexible and can be mounted on an arbitrary curved surface. Therefore, the present invention is mainly used for vehicles such as car seat heaters and handle heaters used for vehicles, and heating. It can also be applied to uses such as appliances and heating appliances.

The top view which shows the structure of the planar heating element in Embodiment 1 of this invention Schematic cross section of the same heating element The top view which shows the structure of the planar heating element in Embodiment 2 of this invention. (A) Plan view showing the configuration of a conventional heating element (b) Cross-sectional view of the heating element Schematic configuration diagram when pasting a conventional sheet heating element covering material

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Planar heating element 2 Electrically insulating base material 3 Electrode 3c, 3d Branch electrode 3e Wide part of branch electrode 3f Wide part of branch electrode and hexagonal part 4 Polymer resistor 5 Adhesive resin layer 6 Coating Material 7 Through hole

Claims (6)

An electrically insulating substrate, an electrode formed on the electrically insulating substrate, a polymer resistor fed by the electrode, and the electrode and the polymer resistor are disposed in close contact with the electrically insulating substrate. In the planar heating element provided with a covering material, in the planar heating element provided with a plurality of through holes so as to give flexibility to an appropriate position of the planar heating element,
The electrodes formed on the electrically insulating substrate are arranged so that the main electrodes are opposed to each other, and each main electrode is alternately arranged with a comb-shaped branch electrode, and the plurality of through holes have a plurality of through holes. It is a small hole or a long hole slit shape, is arranged in parallel to the branch electrode in the range of about half of the branch electrode starting from the end of the branch electrode, and the adjacent through holes are in a staggered position. The sheet heating elements are alternately arranged in a row . An electrically insulating substrate, an electrode formed on the electrically insulating substrate, a polymer resistor fed by the electrode, and the electrode and the polymer resistor are disposed in close contact with the electrically insulating substrate. In the planar heating element provided with a covering material, in the planar heating element provided with a plurality of through holes so as to give flexibility to an appropriate position of the planar heating element,
The through hole, the electrically insulating planar heating element is positioned so as to be surrounded only to either of the electrodes formed on the substrate. An electrically insulating substrate, an electrode formed on the electrically insulating substrate, a polymer resistor fed by the electrode, and the electrode and the polymer resistor are disposed in close contact with the electrically insulating substrate. In the planar heating element provided with a covering material, in the planar heating element provided with a plurality of through holes so as to give flexibility to an appropriate position of the planar heating element,
Together with the electrically insulating base electrode formed on the substrate is disposed opposite the main electrode, disposing the branch electrodes of the comb shape of each of the main electrodes alternately, the other part of the branch electrode A planar heating element provided with a portion wider than this portion and provided with a plurality of small holes or long-hole slit-shaped through holes in the wide portion of the branch electrode. An electrically insulating substrate, an electrode formed on the electrically insulating substrate, a polymer resistor fed by the electrode, and the electrode and the polymer resistor are disposed in close contact with the electrically insulating substrate. In the planar heating element provided with a covering material, in the planar heating element provided with a plurality of through holes so as to give flexibility to an appropriate position of the planar heating element,
The through holes, said position is allowed to be sandwiched only to either of the electrically insulating base electrode formed on material, such that the electrodes surrounding the through-holes or all of the through-hole proximate becomes the same polarity a planar heating element configured to. The plurality of through holes, either by electrically insulating base electrode and the electrode formed on the substrate is disposed so as to be positioned apart a predetermined distance or more from the polymer resistor powered claims 1-4 1 The sheet heating element according to item . The electrodes formed on the electrically insulating substrate are arranged so that the main electrodes are opposed to each other, and each main electrode is alternately arranged with comb-shaped branch electrodes, and the plurality of through holes are formed with a plurality of small holes. The planar heating element according to any one of claims 1 to 5 , wherein the sheet heating element is formed in a hole or long hole slit shape and is arranged in parallel to the branch electrode starting from an end of the branch electrode.

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