JPH11339936A - Flat molded heater - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a flat molded heater which is excellent in waterproofness, has good heat efficiency, is lightweight, and can be easily assembled by fixing heaters to a heat insulating material molded in advance, and sealing the heat insulating material into a molded main body with an injection molding resin. SOLUTION: Heater grooves 3 are provided on one face of a heat insulating material 2 molded in advance into a shape similar to the internal shape of a resin molded main body 1, and heaters 4 are fixed in them by a metal foil 6 such as an aluminum foil. The heat insulating material 2 is inserted into the resin molded main body 1 so that the face provided with the heater grooves 3 is faced to the inner face of the main body 1. A resin is injection-molded from the opposite side to the face provided with the heater grooves 3, it is integrally connected to the main body 1 to form a resin layer 5, and the opening face of the main body 1 is closed. A foamable resin is preferably used for the heat insulating material 2, and a resin compatible with the resin molded main body 1 and the heat insulating material 2 is preferably used for the resin layer 5.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a planar heater formed body such as a panel heater, a kotatsu heat source, and a heating toilet seat, and more particularly, has excellent waterproofness against water, etc., good thermal efficiency, and is lightweight and easy to assemble. The present invention relates to a flat sheet heater formed body.

[0002]

2. Description of the Related Art Conventionally, in a sheet heater molded body, for example, a heating toilet seat, as shown in FIG. 2, after a sheet heater 11 is attached to the inner surface of a toilet seat body 12, the toilet seat body 12 is closed with a bottom plate 13. Was used. In this case, the bottom plate 13 is fixed to the toilet seat body 12 by heat sealing, bonding with an adhesive, or the like. However, sufficient fixing cannot be performed, and a small gap remains in the fixing portion 14, from which water enters the inside. Since there is a problem in waterproofness due to infiltration, the work of attaching the sheet heater 11 to the inner surface of the toilet seat body 12 and fixing the bottom plate 13 to the toilet seat body 12 are performed manually,
There has been a problem that assembling is troublesome and inefficient. Furthermore, during use, there was a problem that the sheet heater 11 was easily peeled off from the back surface of the toilet seat body 12 due to an external collision.

On the other hand, as shown in FIG. 3, a fitting groove 15 for fitting a heater 11 ′ is provided on the back surface of the toilet seat body 12, and after fitting the heater 11 ′ into the fitting groove 15, Japanese Patent Application Laid-Open No. Sho 62-117516 proposes that a resin insulating layer 13 'having a predetermined thickness for covering the heater 11' is formed integrally with the toilet seat body 12.

However, in such a planar heater molded body, since there is no space between the heater 11 'and the resin insulating layer 13', that is, there is no air layer, heat from the heater 11 'is generated only by the toilet seat body 12. And it is transmitted to the resin insulating layer 13 ', and the thermal efficiency is poor.

Further, the resin for forming the resin insulating layer 13 'is injected at a high temperature and a high pressure and comes into contact with the heater 11', so that the insulating coating of the heater (for example, silicone resin) is melted and broken. Also, there is a problem that insulation failure occurs.

On the other hand, in the heating toilet seat shown in FIG. 2, it is also known that a heat insulating layer is formed by filling a space S formed between the toilet seat main body 12 and the bottom plate 13 with a foamed resin. JP-A-63-271879).

However, in this heating toilet seat, since the seat body 12 and the bottom plate 13 are not completely fixed, the bottom plate 13 comes off due to an increase in the internal pressure in the space S when the foamed resin is injected and filled. There is a problem, and further, since the pressure in the space S increases, the resin does not foam sufficiently,
There is a disadvantage that a satisfactory heat insulating effect cannot be obtained.
In addition, since the foamed resin is injected at a high temperature and a high pressure, the insulation coating (for example, a silicone resin) of the heater is melted and broken to cause insulation failure, or the heater attached to the inner surface of the toilet seat body 12 is peeled off and the heater is removed. There is also a problem that the position cannot be fixed.

[0008]

SUMMARY OF THE INVENTION Accordingly, the present invention solves the above-mentioned problems of the prior art, is excellent in waterproofness, has good thermal efficiency, is lightweight, and can be securely and easily assembled. An object of the present invention is to provide a planar heater molded body.

[0009]

Means for Solving the Problems The inventors of the present invention have made intensive studies to solve the above-mentioned problems, and as a result, have fixed a heater to a pre-molded heat insulating material and used the heat-insulating material as an injection molded resin. Thus, the present invention was completed, with the idea of encapsulating the molded body in a molded body.

That is, according to the present invention, (1) a heater heater is formed in a planar heater resin molded body whose one surface is open to a shape similar to the internal shape of the body, and the heater is fitted to one surface thereof. A heat insulating material having a groove and having a heater fitted in the heater fitting groove is inserted with the surface provided with the heater fitting groove facing the inner surface of the main body, and a heater fitting groove of the heat insulating material is provided. And (2) the heater is inserted into the fitting groove by a metal foil, wherein the open surface of the main body is integrally closed by injection-molding a resin from the opposite side of the main surface. The sheet heater according to (1), wherein the sheet heater is fixed, and (3) the sheet heater according to (1) or (2), wherein the heat insulating material is made of a foamed resin. It is a heater molded body.

[0011]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a longitudinal sectional view showing an example of the planar heater molded body of the present invention. In a planar heater resin molded body main body 1 having one surface opened, a shape similar to the internal shape of the main body 1 is formed. A preformed heat insulating material 2 is inserted. On one surface of the heat insulating material 2, a heater fitting groove 3 is provided, into which a heater 4 is fitted. The heat insulating material 2 is inserted so that the surface provided with the heater fitting groove 3 faces the inner surface of the main body 1.

A resin is injection-molded from the side of the heat insulating material 2 opposite to the surface on which the heater fitting groove 3 is provided, and is integrally joined with the main body 1 to form a resin layer 5 so that the open surface of the main body 1 is formed. Block.

The material, size, and shape of the sheet heater resin molded body 1 can be arbitrarily selected according to its use, but the thickness is preferably about 2 to 6 mm. As the heater 4, a generally used silicone rubber-coated heater having a diameter of about 1 to 4 mm, a fluorine resin-coated heater, or the like is used. Any material can be used as the heat insulating material 2 as long as it has heat insulating properties, but a foamed resin is preferably used because of its light weight. Such foamed resins include polypropylene, polystyrene, polyurethane,
Various foamed resins such as polyester and polyamide can be used.

As the resin layer 5 formed by injection molding, the resin layer 5 is completely bonded to the resin molded body 1 to obtain sufficient waterproofness. It is preferable that the resin has a certainty.

The thickness of the resin layer 5 is substantially equal to that of the resin molded body 1.
Is the value obtained by subtracting the thickness of the heat insulating material 2 from the depth of the resin molded body. However, in order to save the amount of the injection molding resin to be used, to obtain a lightweight and sufficient mechanical strength, the same as the resin molded body 1 is obtained. Thickness (2
mm to 6 mm).

On one surface of the heat insulating material 2, a heater fitting groove 3 is provided in advance, and a heater 4 is fitted and fixed in the groove 3. In order to obtain a uniform temperature distribution, In order to securely fix the heater 4 and the heater 4 in the heater fitting groove 3 of the heat insulating material 2, a metal foil 5 is adhered to the surface of the heat insulating material 2 where the heater fitting groove 3 is provided with an adhesive material or the like. It is preferable that the opening of the opening 3 is closed and the heat from the heater 4 is uniformly transmitted to the entire heating surface of the resin molded body 1. As such a metal foil, an aluminum foil or the like is suitably used.

Next, a method for manufacturing the planar heater molded article of the present invention will be described. In FIG. 1, first, a heat insulating material 2 which is molded into a shape similar to the internal shape of a resin molded body 1 and has a heater fitting groove 3 in a predetermined pattern on one surface thereof is formed. A heater 4 fitted with the heater 4 is prepared in advance. In this case, in order to secure the heater 4 more securely and make the temperature distribution more uniform, the heat insulating material 2
It is a preferred embodiment to attach the metal foil 5 to the surface provided with the heater fitting groove 3 with an adhesive or the like.

Next, the heat insulating material 2 is inserted into the resin molded body 1 having one surface opened such that the surface provided with the heater fitting groove 3 faces the inner surface of the main body 1. afterwards,
The resin molded body 1 in which the heat insulating material 2 is inserted is set in an injection molding machine, and the resin layer is formed from the opposite side of the surface of the heat insulating material 2 where the heater fitting groove 3 is provided, that is, from the open surface of the resin molded body 1. 5 is injected to form a resin layer 5 integrally joined with the main body 1, and the open surface of the main body 1 is closed.

Finally, the surface is polished until the joining surface between the resin molded body 1 and the resin layer 5 becomes completely flat. The planar heater molded article of the present invention can be used for various uses such as a panel heater, a kotatsu, and a heating toilet seat.

[0020]

According to the planar heater molded article of the present invention, since the resin molded article main body 1 and the resin 5 are integrally joined by injection molding, it is possible to prevent water from entering from the joint. No, it is excellent in waterproofness.

Further, since the heat insulating material 2 prevents unnecessary heat dissipation to the side opposite to the heating side, the thermal efficiency is good. Further, a heat insulating material formed in advance into a shape similar to the internal shape of the resin molded body 1, having a heater fitting groove 3 on one surface thereof, and a heater 4 fitted and fixed in the heater fitting groove 3. Since No. 2 is used, problems such as defective foaming and breakage of the joint portion in the conventional injection of the foamed resin do not occur at all, and the heater does not peel off due to impact or the like.

In addition, the resin forming the resin layer 5 is:
Since the injection is performed from the side opposite to the surface on which the heater fitting groove 3 of the heat insulating material 2 is provided, the heater 4 fitted in the heater fitting groove 3 is not directly affected, and the insulation of the heater 4 is not affected. No melting breakage of the coating or peeling of the heater occurs at all.

Further, since the heater is fitted into the heater fitting groove 3 of the preformed heat insulating material 2 and inserted into the resin molded body 1, the resin layer 5 is formed by injection molding.
Reliable and easy assembly.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view showing an example of a sheet heater molded body of the present invention.

FIG. 2 is a longitudinal sectional view showing an example of a conventional planar heater.

FIG. 3 is a longitudinal sectional view showing another example of the conventional planar heater.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 resin molded body 2 heat insulating material 3 heater fitting groove 4 heater 5 resin layer 6 metal foil

 ────────────────────────────────────────────────── ─── Continued on the front page (72) Inventor Mitsuhiro Hayami 5-1-1 Koiehonmachi, Tokoname-shi, Aichi Prefecture Inax Corporation (72) Inventor Yoshio Matsuda 5-1-1 Koiehonmachi, Tokoname-shi, Aichi Co., Ltd. Inside Inax

Claims (3)

[Claims] 1. A heater resin molded body main body having an open surface on one side thereof, which is formed in advance into a shape similar to the internal shape of the main body, a heater fitting groove on one surface thereof, and A heat insulating material in which a heater is fitted in the heater fitting groove is inserted with the surface provided with the heater fitting groove facing the inner surface of the main body, and the heat insulating material is inserted from the side opposite to the surface provided with the heater fitting groove. A planar heater molded body, wherein an open surface of the main body is integrally closed by injection molding of a resin. 2. The planar heater molded body according to claim 1, wherein the heater is fixed in the fitting groove by a metal foil. 3. The planar heater formed body according to claim 1, wherein the heat insulating material is made of a foamed resin.