JPH06318491A - Manufacture of flat heater element - Google Patents

Abstract

PURPOSE:To make a slit disperse and absorb the distortion stress by the thermal effect of the metal foil of a uniform heater sheet and a thermosensitive heater wire, prevent the deformation of a flat heater element, and improve the quality by providing a plurality of slits on the uniform heater sheet. CONSTITUTION:A uniform heater sheet having thermally fused layers on both surfaces of a metal foil is superposed from above on a wiring board having a thermosensitive heater wire H arranged thereon, heated and pressurized by thermal press to mutually adhere them, and a flat heating element is manufactured. In the longitudinal direction of the wiring pattern of the thermosensitive heater wire H, a plurality of slits 13 are made on the whole surface in the state crossing H and never crossing H. Thus, the distortion stress by the difference between the thermal expansion of the metal oil of the uniform heater sheet C and the thermal contraction of the thermosensitive heater wire H at thermal press can be dispersed to and absorbed by the slits 13 to prevent the deflection and wrinkling of the uniform heater sheet.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet heating element used for a wide area heater, such as an electric carpet, and a method for manufacturing the sheet heating element.

[0002]

2. Description of the Related Art Conventionally, as shown in FIG. 3, in a wide area heater such as an electric carpet, a heat-fusible resin such as low density polyethylene is formed on both sides of a metal foil such as an aluminum foil. A heat-sensitive heating wire H having a heat-fusible resin layer, such as low-density polyethylene, formed on the outermost layer surface of the heat-soaking sheet C on which a film is adhered is wired in a predetermined pattern and heated.
It is generally known that a surface material A and a back surface material B are attached to both surfaces of the material after the material is pressed and integrally molded. In this type of sheet heating element, as shown in FIG. 4, a heat-sensitive heating wire H is wired in a predetermined pattern on a heat equalizing sheet in which heat-fusible resin layers 1 are formed on both sides of a metal foil 2. Therefore, there is an advantage that the heat generation temperature is uniform over the entire surface and the temperature control operation is stable. More specifically, as shown in FIG. 5, the heat-sensitive heating wire used for the planar heating element is formed by winding a heating wire 4 made of a copper alloy or the like in a spiral shape on a winding core 3 made of polyester fiber, and then forming a soft resin. The layer 5 is covered by extrusion molding, the temperature detecting electrodes 6 of a copper alloy are spirally wound around the outer peripheral surface of the layer 5 at equal intervals, and then a polyester tape or the like is wound to form a separation layer 7, and then a soft PV is formed.
The insulating layer 8 made of C is coated, and the thermal bonding layer 9 made of low-density polyethylene is applied to the outermost surface of the insulating layer 8.

[0003]

However, in the conventional sheet heating element, when the surface material A and the back surface material B are adhered to both sides of the electric carpet as shown in FIG. While the metal foil 2 of the heat-uniformizing sheet C is expanded by thermal expansion, the heat-sensitive heating wire H is extruded, so that the heat-shrinking action is caused by heating, and the surface material A and the back surface material B are also thermally shrunk. Therefore, mainly the heat-sensitive heating wire H in the metal foil 2 of the soaking sheet C is used.
There is a problem in that a large "deflection" and a large "wrinkle" are generated in the direction intersecting the wiring direction, which makes the sitting comfort uncomfortable and the appearance is poor. Furthermore, when an electric carpet is used, it may be in a partially heat-insulated state, and the temperature of the sheet heating element may rise to 80 to 90 ° C. Due to the thermal expansion of the foil 2 and the thermal contraction of the heat-sensitive heating wire H, similarly large "deflection" and large "wrinkle" may occur.

The present invention has been proposed in view of the above points, and an object of the present invention is to completely prevent large "deflection" and large "wrinkle" occurring in the metal foil of the heat-soaking sheet, and It is an object of the present invention to provide a method for manufacturing a planar heating element that does not cause deformation of a heat-sensitive heating wire, does not cause defective bonding, and can shorten the bonding time.

[0005]

In order to achieve the above object, the present invention provides a soaking sheet, a wiring board having a heat-fusible resin layer on at least one surface of a metal foil, and this wiring board. In a method for manufacturing a planar heating element in which heat-sensitive heating wires wired in a predetermined wiring pattern are arranged, and these are heat-pressed and welded in a state of being overlapped with each other, slack that occurs in the heat-uniformizing sheet during hot pressing As a means of absorbing wrinkles,
A plurality of slits are provided in the heat equalizing sheet so as to intersect with the longitudinal direction of the wiring pattern of the heat-sensitive heating wire.

[0006]

By providing a plurality of slits in the heat equalizing sheet, the strain stress due to the difference between the thermal expansion of the metal foil 2 of the heat equalizing sheet C and the heat absorption of the heat-sensitive heating wire H is dispersed / absorbed in the slits 13, and the heat equalizing is performed. Large "deflection" and large "wrinkles" do not occur on the sheet.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the drawings. Figure 1
Is an explanatory perspective view showing an embodiment of the present invention, in which:
D is a wiring board made of plywood or rubber, H is a heat-sensitive heating wire,
E is a support pin that supports the heat-sensitive heating wire H along the wiring pattern. The wiring board D has a passage of a predetermined wiring pattern formed therein, and support pins E1 to E12 of the heat-sensitive heating wire H are provided at the bending points of the passage so as to project from both ends of the heat-sensitive heating wire H. A pair of support pins E0 and E1 for holding
3 is provided.

Next, a method of manufacturing the sheet heating element will be described.
One end of the heat-sensitive heating wire is held between a pair of support pins E0 provided at one corner of the wiring board D, and the heat-sensitive heating wire H is hooked on the support pins E1 to E12 sequentially provided along the passage. The wiring is formed so that the tip end portion is supported by the other pair of support pins E13. Next, from the upper side of the wiring board D on which the heat-sensitive heating wires H are wired, the metal foil 2
The sheet-like heat generating element is manufactured by superposing the soaking sheet C having the heat-sealing layer 1 adhered on both sides thereof and adhering the sheet by heating and pressurizing with a hot press. As shown in FIG. 2, in the planar heating element configured in this manner, a portion of the soaking sheet C facing the heat-sensitive heat generating wire H wired on the wiring board D intersects with the heat-sensitive heat generating wire H and Multiple slits 1 without crossing
3 is drilled on almost the entire surface.

When a trial production of an electric carpet is carried out using this sheet heating element, the strain stress due to the difference between the thermal expansion of the metal foil 2 of the heat equalizing sheet C and the thermal contraction of the heat-sensitive heating wire H is dispersed and absorbed in the slit 13. As a result, the soaking sheet does not have a large "deflection" or a large "wrinkle".

As a method of forming the slit 13 in the soaking sheet C, a method of previously providing the slit 13 in the soaking sheet C, a cutter blade or the like provided in the wiring board D and slitting the soaking sheet C at the same time as the heat pressing There is a method of molding 13 or a method of providing slits 13 with a cutter or the like only in a portion where there is no heat-sensitive heating wire H after the planar heating element is completed.

Slits 13 provided on the heat equalizing sheet C
Also effectively disperses and absorbs strain stress when the front surface material A and the back surface material B are bonded to the planar heating element. further,
The electric carpet using this planar heating element has an effect of facilitating folding.

Although the present invention has been described so far only when it is used for an electric carpet, it is not limited to the electric carpet. Further, not only the planar heating element in which the heat-sensitive heating line is wired, but also the planar heating element in which a plurality of lines such as a temperature detection line are simultaneously wired are similarly effective.

[0013]

As described above, according to the method for manufacturing the sheet heating element of the present invention, as a means for absorbing the slack wrinkles generated in the soaking sheet during hot pressing or after completion of the sheet heating element. Since the heat equalizing sheet is provided with slits, it can completely prevent large "bends" and large "wrinkles" that occur in the metal foil of the heat equalizing sheet, and there is no deformation of the heat-sensitive heating wire, which may cause defective adhesion. Moreover, the bonding time can be shortened.

[Brief description of drawings]

FIG. 1 is an internal perspective view showing an embodiment of the present invention.

FIG. 2 is an overall plan view showing an embodiment of the present invention.

FIG. 3 is an explanatory sectional view showing an example of a conventional electric carpet.

FIG. 4 is a sectional view showing an example of a conventional sheet heating element.

FIG. 5 is a developed perspective view showing a heat-sensitive heating wire in a conventional sheet heating element.

[Explanation of symbols]

 A surface material B back surface material C heat spreader sheet D wiring board H heat-sensitive heating wire 13 slit

Claims (1)

[Claims] 1. A heat equalizing sheet in which a heat-fusible resin layer is provided on at least one surface of a metal foil, a wiring board, and heat-sensitive heating wires arranged in a predetermined wiring pattern on the wiring board. In the method for manufacturing a planar heating element in which these are stacked and heated and welded by welding, as a means for absorbing slack wrinkles generated in the soaking sheet during hot pressing,
A method for manufacturing a planar heating element, comprising: using a plurality of slits provided in the heat equalizing sheet so as to intersect with a longitudinal direction of a wiring pattern of a heat-sensitive heating wire.