JPS62274592A - Heater unit - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

Detailed Description of the Invention 3. Detailed Description of the Invention Industrial Application Field The present invention is a bondable cord-shaped heating wire arranged in a meandering manner, which is used in electric carpets, thermal cloaks, panel heaters, etc. Regarding the heater unit.

Conventional technology Conventionally, heater units in which cord-shaped heating wires are arranged in a meandering manner are disclosed in Japanese Patent Publication No. 59-30407 and Japanese Utility Model Publication No. 58-336.
It is disclosed in Publication No. 67, and a representative example thereof will be explained in detail with reference to FIG. The whole is covered with an insulating jacket 22 of soft vinyl chloride, and the outermost shell is made of a crystalline resin such as polyethylene or vinyl acetate.

The heating wire 24 is made of soft polyvinyl chloride, which has a negative temperature coefficient between a pair of electrodes, and is coated with a fusible coating layer 23 made of polypropylene or the like, with 1 to 3 weight percent of quaternary ammonium salt added thereto. The whole is covered with an insulating jacket 22 made of soft polyvinyl chloride, and the outermost shell is covered with a fusible coating layer 23 made of a crystalline resin such as polyethylene, vinyl acetate, polypropylene, etc. Temperature detection line +-25I/'i meandering heating line 21
and a fusible coating layer 23.2 at the contact surface with the temperature sensor 824.
3. A crystalline resin such as polyethylene, vinyl acetate, polypropylene, etc., which has the function of temporarily fixing by thermocompression bonding and the function of intervening as a planar warming device, for example, between the cloak fabric and the outer fabric and then bonding and bonding them together by thermocompression bonding. The thickness consists of 0.
It is an adhesive film of 1 to 0.2wn. Fusible coating layer 2
3 is provided to temporarily fix the meandering cord-shaped heating wires 21 and temperature detection wires 24 to the surface of the adhesive film 25, so it is necessary to use a crystalline resin of the same type as the adhesive film 25. When the adhesive film 25 and the fusible coating layer 23 are melted together and cooled, a heater unit is formed.

Problems to be solved by the invention Japanese Patent Publication No. 59-30407 and Utility Model Publication No. 58-336
According to the heater unit disclosed in Publication No. 69, the cord-shaped heat generation 'a21 and temperature detection wire 24 arranged in a meandering manner are fused and fixed at the contact surface with the adhesive film 25, so that a plurality of It is possible to serpentinely arrange and fuse and fix cord-like objects at the same time in a fully automatic manner, making it excellent for mass production, and by interposing the thus obtained heater unit between the outer material and the cloak material and thermo-compression bonding, the structure can be reduced. Regardless of the material used, a reliable bond can be obtained, and the manufacturing method is a revolutionary method.Many excellent performance and inexpensive planar heating devices have been manufactured using this method for many years, and its industrial effects have been great. There was something.

However, conventional heater units have the following problems, and improvements have been desired.

fl) In order to simultaneously weld the fusible coating layer 23 and the adhesive film 25 by thermocompression bonding in a short time,
A high temperature of 0.00°C is required, but at this temperature, the insulating jacket 21 made of vinyl chloride will be thermally deformed even with slight pressure variations, making it impossible to secure the insulation distance, so the solution is to thicken the insulating jacket 21 and Since the process has to be carried out at a low temperature of ~150°C for more than 5 seconds, further improvement in mass productivity cannot be achieved.

(2) Since the fusible coating layer 23 is made of a crystalline resin, it becomes hard and loses flexibility when the temperature is low in winter, and its outer diameter increases, reducing the workability of meandering casting.

(3) When the heater unit is interposed between the cloak fabric and the outer fabric and bonded by thermocompression, the adhesive film 25 and the fusible coating layer 23 are melted, and the end portions of the heating wire 21 and the temperature detection wire 24 are also bonded to form an electrical component. Since it is difficult to attach, it is necessary to prevent heat from being applied to these terminal parts, which may result in the adhesive film 25 at the terminal part not bonding the cloak material and the outer material, or the adhesive strength may be insufficient, resulting in a shortened durable life. Reliability was poor.

(4) The fusible coating layer 26 has the function of joining the outer material and the cloak material after being incorporated into the sheet heating device, so it has excellent mechanical durability. The heat generation 1s21 and the temperature detection wire 24 and the surrounding fibers melted and became hard, making it difficult to fold with a planar heating device that requires folding. It had a Japanese feel and was inferior in terms of usability.

Means for Solving the Problems The present invention solves the conventional drawbacks by adding ethylene to the outermost shell.
An insulating jacket made of a thermoplastic elastomer consisting of a composition of at least one resin component of propylene and at least one rubber component such as ethylene propylene, styrene, phthadiene, acrylonitrile, etc., and having a rubber hardness of 5Q to 100. Cord-shaped heating wires covered by extrusion processing are arranged in a meandering manner, and a polyolefin adhesive film having a melting point of 100 to 148°C and mainly composed of polyethylene is placed on the cord-shaped heating wires, which are coated by extrusion processing. The heater unit was obtained by welding and fixing the contact portion with the outer cover by thermocompression bonding.

an insulating jacket of thermoplastic elastomer coated on the outermost working shell;
By welding and fixing the contact portion with a polyolefin adhesive film having a melting point of 00 to 148°C by thermocompression bonding, the following effects can be expected.

m The resin components such as ethylene and propylene of the insulating jacket and the adhesive film are welded and fixed by thermocompression bonding even at temperatures of 130 to 150℃, and the rubber component has elasticity and restores itself, minimizing thermal deformation during thermocompression bonding. I can do it to a limit.

(2) The thermoplastic nystomer of the insulating jacket remains flexible even at low temperatures, allowing the cord-shaped heating element to be made thinner.

(3) The thermoplastic elastomer of the insulating jacket does not melt and adhere to surrounding fibers even if it is interposed between the outer material or the mat material and is thermocompressed, making it easier to process the terminals of heating wires and temperature sensing wires.

(4) Even if heat-generating wires or temperature-sensing wires are interposed between the outer material and the matte material and bonded by thermocompression, the insulating outer covering is made of thermoplastic elastomer, so it does not melt with the fibers of the matte material and maintains its flexibility. Hold.

Example An embodiment of the present invention will be described in detail below with reference to the drawings.

FIG. 1 shows a cross-sectional view of the essential parts of the heater unit of the present invention, in which 1 is a thermoplastic elastomer, such as polypropylene resin, which has a rubber hardness of 85Q and is coated on the outermost shell of the heating wire 2 by extrusion processing. and an ethylene propylene rubber component, and 3 is a polyolefin resin having a melting point of, for example, 115° C., which is placed on the meandering heating wire and welded to the insulating jacket by thermocompression bonding. It is a polyethylene adhesive film.

FIG. 2 shows another embodiment of the present invention, 1
a is an insulating jacket of thermoplastic elastomer made of an ethylene propylene resin component and an ethylene propylene rubber component having a rubber hardness of 55 and coated on the outermost shell of the cord-shaped heating wire 2a by extrusion processing.

3a is a heat-uniforming plate 4 made of metal, for example, by laminating a polyolefin resin made of polyethylene with a main melting point of 115°C and 8% by weight of ethylene ethyl acrylate on both sides of aluminum foil with a thickness of 15μ. The adhesive film 3a is welded and fixed by thermocompression bonding to the insulating jacket 1a provided on the outermost shell of the heating wire 2a arranged in a meandering manner.

FIG. 3 shows a heater unit 20 according to another embodiment of the present invention, in which 1b is made of rubber having a hardness of 70 which has been twisted by extrusion on the outermost shell of the cord-shaped heating wire 2b and the temperature sensor 1m. 3b is an insulating jacket made of a thermoplastic nidistomer having the characteristics of, for example, a resin component of polyethylene and polypropylene and a rubber component of ethylene propylene; 3b is a composition in which polyolefin, for example, polyethylene with a melting point of 125° C. and vinyl acetate are added in an amount of 5% by weight; It is an adhesive film consisting of.

Cord-shaped heating wire 2 with adhesive film 3b arranged in a meandering manner
b and above the temperature detection wire 6, and are welded and fixed by thermocompression bonding at the contact portion with the insulating jacket 1b.

Fig. 4 shows a structural diagram of the heating wire 2 used in the heater unit shown in Fig. 1, and 7 is a heat-resistant core yarn such as polyester, which is wound around the outer circumference of the 8-strand core yarn 7. The heating element wire 1 is made of a copper alloy and is an insulating jacket made of a thermoplastic nidistomer which is formed by extrusion covering the outer periphery of the core thread 7 and the heating element wire 8.

FIG. 5 shows a structural diagram of the heating wire 2b used in FIG. 3, where 9 is a core yarn made of polyester or heat-resistant polyamide, and 10 is a copper or copper alloy wound around the outer circumference of the core yarn 9. 11 is a fuse layer made of polyamide resin which is coated around the outer periphery of the core yarn 9 and the heat generating strand 10 by extrusion processing; 12 is a fuse layer 2 made of copper wound around the outer periphery of the fuse layer 11; The secondary conductor 1b is the fuse layer 11 and the secondary conductor 1.
It is a thermoplastic nidistomer formed by extrusion coating the outer periphery of the heating wire 2b, and when the heating wire 2b reaches an abnormal temperature, the heath layer 11 melts and the heating element wire 10 and the secondary conductor 12 are heated.
This causes a short circuit between the two and a safety circuit (not shown) provided in the control circuit is operated to cut off the current flowing through the heating element wire 10.

FIG. 6 shows a structural diagram of the temperature detection wire 6 used in FIG. 3, in which 13 is a core thread made of polyester or heat-resistant polyamide, and 14 is a copper wire wound around the outer circumference of the core thread 13. 15 is a heat-sensitive layer made of polyvinyl chloride having a negative impedance and 1 to 5% quaternary ammonium salt, which is coated around the outer circumference of the core thread 13 and the internal electrode 14 by extrusion processing; 16 is a heat-sensitive layer; an external electrode wrapped around the outer circumference of layer 15;

17 is a shielding layer made of a heat-resistant film that prevents additives such as plasticizers from migrating to the outside of the heat-sensitive layer 15, 1 br/'i
It is an insulating jacket made of thermoplastic nilastomer that is coated around the outer circumference of the closed layer 17 by extrusion processing, and this temperature detection wire 6 detects temperature changes in the impedance of the heat sensitive layer 15 between the internal electrode 14 and the external electrode 16. It has a characteristic that a control circuit (not shown) can control the heating current of the heating wire 5 by detecting the current.

FIG. 7 is a sectional view of a main part of the heater unit 20 shown in FIG. 6 incorporated into a planar heating device, and 18 is a needle-punched fiber of miscellaneous wool, acrylic, polyester, polypropylene, nylon, etc. A mat fabric made of felt obtained by processing, 19 is an outer fabric made of needle-punched polyester fibers, and when a heater unit 20 is interposed between the mat fabric 18 and the outer fabric 19 and bonded by thermocompression, a heating wire 2b and temperature detection are generated. The wire 6 is buried in the matte material 18 and the adhesive film 6 is melted to form the matte material 18 and the outer material 1.
9 is joined.

Next, the operation of the above configuration will be explained in detail.

Either ethylene or propylene in the outermost shell.
An insulating jacket (1), (1a), (1b) of a thermoplastic nidistomer made of a composition of 10,000 resin components and at least one rubber component such as ethylene propylene, styrene, butadiene, acrylonitrile, etc. is coated by extrusion processing. cord-shaped heating wires (2), (2a).

(2b) are arranged in a meandering manner, and the heating wires (2), (2a),
Adhesive film (3), (3a) of polyolefin resin having a main melting point between 100 and 148°C on the upper surface of (2b)
, (3b) is placed to create a heater unit,
Insulating jacket (1), (1a), (1b) and adhesive film (3), (3a) even in a short time of 3-5 seconds and at a low welding temperature of 160-150°C.

(3b) can be welded and fixed by thermocompression bonding. That is, unlike the conventional fusible coating layer 23 using a crystalline resin, which cannot be welded unless everything is melted, the insulating outer coating (1) using a thermoplastic elastomer of the present invention,
(1a) and (Ib) are composed of a resin component and a rubber component, so even if they are bonded under heat and pressure, only the resin component of the composition of ethylene or propylene near the surface layer melts, resulting in an adhesive film (3).
, (3a), and (3b), it can be sufficiently welded to form a heater unit even at a low temperature of 130 to 150°C.

The hardness of thermoplastic elastomer is 50 to 100 in terms of rubber hardness.
The reason for limiting this is as follows.

The rate of thermal deformation of the insulating jackets (1), (Ia), and (1b) during thermocompression bonding or the rate of deformation due to the load during use largely depends on the rubber hardness, as shown in FIG. Practically speaking, this type of insulator is molded by extrusion coating to a thickness of 0.5 to 1.0 mm, but in consideration of variations in molding conditions and legal restrictions, the initial thickness must be 50 mm or more. It is undesirable for the rubber to deform to 50% due to these conditions.
It is preferable to set it to 100. In other words, if the hardness is less than 50, the rubber component will increase, which will not only reduce extrusion processability, but also cause poor adhesion after molding, and will become too soft and easily deform due to mechanical compression, which will affect the properties of the insulating layer. If the rubber hardness exceeds 100, the elasticity will decrease, which will reduce the flexibility of the heating wire, resulting in poor meandering wiring and bending properties, as well as poor thermal bonding when making the heater unit. The hardness of the thermoplastic elastomer is 50 to 100. Even more preferably, as shown in FIG. 9, the deformation rate is 30% or less.
The insulating jacket (1) of the present invention has a rubber hardness of 0 to 85, (ia
) and (1b).

Next, the role played by the components of the thermoplastic elastomer in forming the heater unit will be explained in detail.

The resin components of ethylene and propylene, which are components of thermoplastic elastomer, are adhesive films (3) and (3a).

It has the effect of welding with the polyolefin resin which is the component (3b) by thermocompression bonding, and has the effect of welding ethylene propylene, styrene,
Rubber components such as acrylonitrile and butadiene can restore the original shape after deformation during thermocompression bonding.

It acts to restore its original shape to mechanical compression.

Therefore, ethylene propylene rubber and styrene rubber have good affinity with the resin components of ethylene and propylene.

Components such as acrylonitrile rubber and butadiene rubber are suitable. Although this type of composition may be a mixture of each component, for example, a mixture of a resin component consisting of a copolymer of ethylene and propylene and a rubber component is stable, and immediately The mixture composition with is heat resistant,
Rubber elastic.

It is the most suitable in terms of moldability, adhesion, etc.

The reason for using polyolefin resin for the adhesive films (3), (3a), and (3b) is that it can be easily welded and fixed to the thermoplastic elastomer insulating jacket (1), (1a), and (1b) by thermocompression bonding. , It has a thickness of 0.1 to 0.2 mm and is sturdy enough to be used as a heater unit, and it can be easily bonded together even at low temperatures when sandwiched between other members and thermocompressed.

Furthermore, the cost of materials is low. The reason why the melting point of polyolefin resin is set to 100-148℃ is 100
If it is lower than 148°C, the heat resistance will be poor, and if it is higher than 148°C, the thermocompression bonding temperature when making the heater unit will be too high, causing significant deformation of the insulating jackets (1), (1a), and (1b), which is undesirable. This is because there is no

As detailed above, the cord-shaped heating wires (2), (2a)
.

The outermost shell of (2b) is an insulating jacket made of thermoplastic nidistomer (
1), (Ia), and (1b)' are coated by extrusion processing and arranged in a serpentine shape, and polyolefin resin adhesive films (3), (3a), and (3b) are placed on the upper surface. By fixing their contact surfaces by thermocompression bonding to obtain a heater unit, a ninth-order effect can be expected.

(1) Resin components such as ethylene and propylene and 100
Adhesive film (3) of polyolefin resin mainly composed of polyethylene having a melting point of ~148°C.

(3a) and (3b) allow thermocompression bonding at 130 to 150° C. without causing significant thermal deformation of the insulating jacket.

(2) Since the rubber component of the thermoplastic elastomer has elasticity, it not only minimizes thermal deformation during thermocompression bonding, but also prevents permanent deformation even when mechanical stress or load is applied, resulting in an insulating jacket (1) , (1a) and (1b) can be ensured.

(3) Thermoplastic nidistomers have a small amount of crystalline components and are elastic even at low temperatures, so the heating element does not lose its flexibility even at low temperatures.

(4) Thermoplastic nystomer has a heater unit interposed between the outer material and the cloak material, and is integrally joined by thermocompression bonding.At a temperature of 160 to 160°C, it melts and does not adhere to surrounding materials by bath fusion, so it generates only 1 heat. Line (2).

(2a) and (2b) terminal processing becomes easier.

(5) If the heater unit is interposed between the outer fabric or the cloak fabric and is integrally bonded, it is an adhesive film (3).

Even if (3a) and (3b) are integrally bonded to the outer fabric and the cloak fabric, the thermoplastic elastomer insulating jacket (1) and (Ia)
.

(1b) does not weld to surrounding members, so the cord does not lose its flexibility.

Effects of the Invention As detailed above, according to the present invention, the following effects can be expected, and the industrial effects thereof are significant.

(1) The thermocompression bonding temperature of the thermoplastic elastomer insulating jacket and polyolefin resin adhesive film is 130 to 15
Since welding can be performed in a short time of 3 to 5 seconds and with a low rate of thermal deformation even at 0°C, a heater unit can be obtained with no risk of deterioration of insulation or electric shock.

Furthermore, mass productivity is 1.3 times greater than conventional methods.

(2) The insulating jacket made of thermoplastic nidistomer does not lose its flexibility even when the temperature is low in winter, so it is possible to prevent mistakes in the meandering arrangement of the 9 heating wires and improve workability by 1.2 times compared to the conventional method.

(3) When the heater unit of the present invention is interposed between the outer fabric and the cloak fabric and they are integrally bonded by thermocompression bonding, the adhesive film joins the outer fabric and the cloak fabric.

This is because the insulating jacket does not weld to surrounding components.

It is easy to attach electrical components to the end of the heating wire, and sufficient adhesive strength can be obtained to ensure reliability over a long life.

(4) Even if the thermoplastic elastomer insulating jacket is interposed between the outer material and the cloak material and is integrally joined, it does not become stiff because it does not weld to surrounding materials, and the cord hardly feels strange and is easy to fold. .

[Brief explanation of drawings]

1 to 3 are sectional views of essential parts of a heater unit showing an embodiment of the present invention, FIG. 4 is a structural diagram of a heating wire used in the embodiment of FIG. 1, and FIGS. Figure 3 is a structural diagram of the heating wire and temperature sensing liquid used, Figure 7 is a sectional view of the main part of a planar heating device to which the heater unit of the present invention is applied, and Figure 8 is a sectional view of the main part of a conventional heater unit. , FIG. 9 shows a characteristic diagram of the thermoplastic elastomer of the present invention.

Claims (1)

[Claims] The outermost shell is an insulating jacket made of thermoplastic elastomer (1), (1
Cord-shaped heating wires (2), (2a), and (2b) formed by covering a) and (1b) by extrusion processing are arranged in a meandering manner to produce polyolefin resin adhesive films (3) and (3a).
), (3b) are placed, and the adhesive films (3), (3
a), (3b) and insulating jacket (1), (1a), (1b)
In the heater unit, which is welded and fixed by thermocompression bonding,
The thermoplastic elastomer insulating jacket (1), (1a),
(1b) is at least one resin component of ethylene or propylene and at least one rubber component such as ethylene propylene, styrene, acrylonitrile, butadiene, etc.
What is claimed is: 1. A heater unit comprising a composition comprising: