JPS6394577A - Manufacture of panel heater - Google Patents

Abstract

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

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention relates to a method for producing a planar heating element that requires a hard surface, such as floor heating, panel heaters, and pump heaters.

2. Description of the Related Art Conventionally, this type of technology has been proposed, for example, in Japanese Patent Laid-Open No. 55-33701 and Japanese Patent Laid-Open No. 52-8196.

According to the former method, a linear heater is laid out in the desired circuit shape on the back side of an exterior metal plate, temporarily fixed in several places with adhesive tape, and then a heat insulating material is applied through a double-sided adhesive plastic film and these are integrated by heat pressing. It had become

According to the latter, at least one of a pair of upper and lower clamping plates that can be opened and closed is coated with a resin having a heating element, and a cover cloth is applied to one side of the heating plate through the coated resin, and a cover cloth is applied to the other side of the heating plate. Heat-generating wires that can be melted with the resin are provided and bonded together.

Problems to be Solved by the Invention However, in the former case, the 5-frame heater is temporarily fixed to the back surface of the exterior metal with adhesive tape, so the temporarily fixed linear heaters cross each other, causing This may damage the insulating coating of the heater, making it impossible to ensure electrical insulation or resulting in defective work, resulting in poor workability and poor mass productivity.

In addition, since the insulation material and the exterior metal plate are bonded using a plastic film that has adhesive properties on both sides, if heat cycles are performed for a long period of time, the adhesive interface will peel off, forming an air layer and causing local overheating. It becomes easy to use, and its durability and reliability are inferior.

In the latter case, during the heat-press bonding process in which one heating element is welded to the resin coated on the surface of a heat equalizing plate, the thick and rigid heat equalizing plate expands and warps during heating.

Since uneven pressure is applied to the heating wire, the heating wire may be crushed due to thermal deformation.9 For example, the insulation coating of the heating wire may be damaged and insulation may not be ensured, or the heating wire may not be able to maintain its insulation properties. When the heat equalizing plate was taken out from the heat and pressure bonding device, the resin coated on the heat equalizing plate and the welding layer of the heating wire were insufficiently welded due to the residual heat of the heat equalizing plate, so 9 heating wires were removed from the heat equalizing plate. It may peel off or the welding may be incomplete.

In addition, when integrating with a heat insulating material, if heat and pressure bonding is performed again, the heat generating wire 7 will be thermally deformed, making it impossible to ensure insulation as described above.

Therefore, adhesion that does not involve heating is required, resulting in a structure in which the heating element 9 is sandwiched between the heat insulating material and the heat equalizing element, and it cannot be used under compressive stress, resulting in disadvantages such as insufficient adhesion.

Means for Solving the Problems The present invention has been made to eliminate the above-mentioned drawbacks.
A cord-shaped heating element coated in advance with a heat-fusible coating made of a thermoplastic elastomer having a rubber hardness of 50 to 100 is brought into contact with the adhesive thin body and arranged in an appropriate shape, and the core is A heater unit is formed by thermally adhering the thin body and the covering body, and the heating element of this heater unit is made to face a heat equalizing body, and a thermally deformable heat insulating body is brought into contact with the thin body side, and the heater unit is formed. This is a book that heats and presses the heat equalizing body and the heat insulating body so that they are integrally bonded.

By doing this (,1)), the heater unit is interposed between the thermally deformable heat insulating body and the heat equalizing body, so even if the cord-shaped heating elements are bonded under heat and pressure, the nuclear cord-shaped heating elements do not cross each other. .

(2) Even when the heater unit and the heat equalizer are bonded together by heat and pressure, there is no cross between the heating elements, so that the insulating coating of the heating element does not undergo significant thermal deformation.

(c) Since the heater unit and the heat equalizing body can be completely bonded together, the heat generating body will not locally overheat even if it is energized for a long time.

Example Hereinafter, nine embodiments of the present invention will be described with reference to the drawings.

1 and 2 are a structural perspective view of a planar heating element according to an embodiment of the present invention, and a cross-sectional view of the main part before the heater unit and the heat equalizer are integrally bonded. In FIG. 9, 1 is a heat insulation The material is made of, for example, needle-punched felt material or urethane foam, which has the property of being thermally deformed by heat and pressure bonding.

2 is a cord-shaped heating element, and a metal resistance wire 4 is attached around the outer circumference of the core yarn 3.
A heat-fusible covering 5 made of a thermoplastic elastomer having a rubber hardness of 50 to 100 is provided on the outermost layer. 6 is an adhesive thin body that can be welded to the heat-fusible covering 5 by thermocompression bonding. Reference numeral 7 denotes a heater unit, which is constructed by welding and fixing a cord-shaped heating element 2, which has been previously arranged in a meandering manner on the adhesive thin body 6, to the surface of the adhesive thin body 6 by thermocompression bonding. Reference numeral 8 denotes a heat equalizing body, which is made of a steel plate or the like, which faces the cord-shaped heating element 2 side and is integrally bonded to the heat insulating body 1 and the heater unit 7 through the heat-adhesive thin body 6 by thermocompression bonding. It is.

Next, the operation of this embodiment will be described.

A heat-fusible coating (hereinafter referred to as
A cord-shaped heating element (hereinafter referred to as 1
A heating element) 2 is disposed in a meandering manner on an adhesive thin body 6 (hereinafter referred to as a thin body), and the covering body 5 and the thin body 6 are bonded together by heating to form a heater unit 7.

Next, heat insulator 1. The heater unit 7 and the heat equalizer 8 are stacked one on top of the other so as to be located on the side of the heat generating body 2 of the heater unit, and are bonded together by heating and pressing from the heat insulating body 1 side to form a nine-sided heat generating body.

At this time, the covering 5 does not lose its rubber elasticity even though it is pressurized in a temperature range of 130 to 180 DEG C., and therefore returns to a shape close to its original shape after the pressure is removed.

Here, if the hardness of the covering body 5 is 50 or less, although the rubber elasticity is improved, it becomes too soft and deforms too much due to compressive stress during hot press bonding, resulting in a decrease in moldability.

Moreover, when the hardness is 100 or more, the restoring property due to rubber elasticity decreases, and permanent deformation occurs as it is when hot and press-bonded.

Therefore, in order to prevent the covering 5 from deforming, a rubber hardness of 50 to 100, more preferably 60 to 85, is suitable.

Next, since the covering body 5 is easily welded to the olefin-based thin body 6, the heating element 2 can be easily welded to the thin body 6 by simply arranging it meanderingly on the thin body 6 and bonding it by thermocompression.
9 heating elements 2 will not cross each other since they are each completely fixed.

Therefore, even under compressive stress during the integral bonding process in which the covering 5 faces the heat equalizing body 8 without causing thermal deformation and is bonded by heat and pressure, the heating element 2 can maintain sufficient insulation properties. Ensure the thickness of the exposed part.

Furthermore, during heat compression bonding, the heat insulator 1 deforms and fills the gap between the heat generating element 2 and the thin body 6 so as not to form an air layer between them, so that the heat generating element 2 and the thin body 6 are uniformly heated. The heater unit 7 and the heat equalizer 8 are bonded together only after they come into contact with the body 8. Therefore, the thin body 6 is.

Even a thin adhesive film of 50 to 150 μm has high adhesive strength.

By the way, the T peel strength is 3.0 to 4.5 K9725 m
The width of m width is that of the present invention. α5~2. OK
9/25 Becomes ttan width.

Effects of the Invention As detailed above, the present invention has the following advantages: (a) Since the cord-shaped heating elements are made into a heater unit, the cord-shaped heating elements do not cross each other during the manufacturing process. 7. Work efficiency can be improved and mass production is excellent.

[Yes]) Since the heater unit is integrated with a heat insulating body and a heat equalizing body, there is no formation of a local air layer around the heating element, and there is no need to worry about local overheating of the heating element in the air layer. It has excellent durability and reliability.

(c) Since the outermost layer of the cord-shaped heating element is made of a thermoplastic elastomer with rubber elasticity, it does not undergo significant thermal deformation even under the compressive stress of heat-pressing. Since it can be used under stress, the heating element can be completely bonded and fixed.

[Brief explanation of the drawing]

1 and 2 are a structural perspective view and a sectional view before integral bonding of a planar heating element showing an embodiment of the present invention. 1... Heat insulator, 2... Cord-shaped heating element. 5... Heat-fusible covering body, 6... Adhesive thin body. 7... Heater unit, 8... Soaking body.

Claims (1)

[Claims] A cord-shaped heating element (2) coated with a heat-fusible coating (5) made of a thermoplastic elastomer having a rubber hardness of 50 to 100 on the outermost side is arranged in an appropriate shape, and the arranged cord is An adhesive thin body (6) made of a film is brought into contact with the cord-shaped heating element (2), and the cord-shaped heating element (
After forming a heater unit (7) by bonding the heat-fusible covering (5) of 2) and the adhesive thin body (6) by heating, the cord-shaped heating element ( 2)
facing the heat equalizing body (8), and also bringing a thermally deformable heat insulating body (1) into contact with the adhesive thin body (6) side constituting the heater unit (7), and applying heat and pressure bonding. The heater unit (7) is connected to the heat equalizer (8) and the heat insulator (
1) A method for producing a planar heating element, characterized in that it is integrally bonded to the heating element.