WO2002058435A1

WO2002058435A1 - Refractory incombustible surface control heater and method of producing the same

Info

Publication number: WO2002058435A1
Application number: PCT/JP2001/000320
Authority: WO
Inventors: Akitoshi Niibe
Original assignee: Techno Giken Co., Ltd
Priority date: 2001-01-19
Filing date: 2001-01-19
Publication date: 2002-07-25

Abstract

A low-melting-point soft resin layer (4) is bonded to a resistor (2). An incombustible paper conductor (3) is attached to the upper surface of the soft resin layer (4). Opposite edges of the resistor (2) are provided with electrode strips (9, 9) and terminals (10, 10), the terminals (10, 10) being connected to a controller (6). The conductor (3) is formed as by printing conductive ink on one surface of an incombustible paper sheet (12), and a leak current sensing terminal (11) which is contact-compressed into the conductor (3) is connected to the terminal of the controller (6) through a lead wire. When the resistor (2) reaches abnormal temperatures, the soft resin layer (4) melts, so that the conductor (3) and the resistor (2) contact each other, resulting in a leak current, which is sensed, thereby cutting off the power supply.

Description

Specification

Fireproof non-combustible surface control heating element and method of manufacturing the same

TECHNICAL FIELD The present invention relates to a layered structure comprising a heating resistor in which a harmless soft low-melting resin is adhered to a flexible surface or a sheet resistor in a vacuum state on the front and back surfaces of the resistor, and a control body. is there. When the temperature of the control element becomes abnormal and the temperature of the local area is about to deteriorate, the control unit detects the leakage current flowing when the low-melting-point resin melts and the non-combustible conductor provided on one side comes into contact with the resistance element, and shuts off the power. The resistance change temperature of the resistor is low and the low melting point resin melts within the range of 80 ° C to 110 ° C, and the non-flammable conductor detects it and shuts off the current. The present invention relates to a planar control heating element. BACKGROUND ART Conventionally, a flexible carbon heating element having a PVC sheath has been known. This type of heating element is used, for example, for bedding and snow melting on the roof. Bedding with S-shaped Nichrome wires and floor heating panels with Nichrome wires are also used in various areas. Heating elements that use metal foil as a heat source are also used, but metal heating elements have high energy consumption, and there are many problems in safety and durability among those announced. I do.

It is known that a heating element is made by forming a film plate from silicon resin containing carbon particles.This type of heating element has a non-uniform distribution of carbon and a distribution of a generated temperature through a device. . Also known is a planar heating element in which carbon particles and a rubber-based resin are mixed with a synthetic weft, a carbon solution is applied and dried, and the heat-generating weft and the synthetic weft are alternately woven with the warp and covered with a PVC sheath. Have been.

However, since the synthetic heat-generating yarn has a carbon solution attached to the periphery of the yarn in the form of a film, the heating element device of the mixture of the carbon particles and the resin breaks when it is bent or subjected to force or load. In some cases. In any of the above, there is no contact failure between the electrode band and the heat generating portion, but the device is not provided with a non-combustible device at a local abnormal temperature of the surface or the planar heating element, and may be short-circuited at the abnormal temperature with deterioration.

In order to eliminate such an accident, U.S. Pat.No.5.679.2.777 was approved by the inventor of the present patent application, but this feature is that the carbon sheet resistor can be used at an abnormal temperature even in a local area. When deteriorated and short-circuited, the PVC sheet on the front and back surfaces of the resistor carbonized, and the thin metal wire provided on one side of the PVC sheet made a fire-resistant heating element that senses leakage current and shuts off the power. . Further, in Japanese Patent Application Laid-Open No. 9-128332262, an auxiliary vinyl chloride film is provided on one side of a surface heating element to which a polyvinyl chloride sheet is adhered, on the front and back surfaces of a pressure-sensitive sheet surface resistor. There is a patent for a controlled heating element that integrates a vinyl chloride film coated with a carbon liquid onto a vinyl chloride film, with a configuration in which the conductor on the surface of the bon is in contact. However, these two patents were found to have significant flaws.

The two patented sheet resistors include a cloth in which electrode bands are woven together with a woven cloth on both sides of a cotton woven cloth, and a carbon liquid obtained by mixing a urethane-based coagulant and carbon powder with a solvent. It is a dry resistor. The same is true for rubber-based coagulants, but one of the defects is that the temperature at which this type of resistor changes resistance is within the range of 80 ° C to 110 ° C, and deteriorates when the temperature exceeds 120 ° C. It will be carbonized and shorted immediately. Two of the defects are in the PVC skin. The melting point of PVC is 160 ° C, which is the structure of the patent. While the PVC sheet is carbonized and the good conductor senses the leakage current, the carbon resistor is short-circuited widely and used for bedding etc. In this case, discoloration or burning of cotton occurs. U.S. Patent No.5.679.2777 states that PVC insulation sheets claim a melting point below ignition, e.g. more than 100 ° C to 150 ° C, but there is a problem with the melting point . The three defects are the harmful plasticizer in the PVC sheet, the plasticizer diverges at a temperature of 50 ° C, the electrical insulation decreases, and the heat is generated in a bent state for a long time. Cracks occur. The four defects are that the heating element of the PVC sheath is non-combustible garbage and generates harmful dioxin when burned. OBJECTS AND SUMMARY OF THE INVENTION It is an object of the present invention to provide a harmless refractory non-combustible surface control heating element that overcomes the shortcomings of conventional editorials. It is a further object of the present invention to provide a non-toxic heating element which has a flexible surface heating element, a uniform heat distribution, is safe, and which burns completely with high heat. The mixed residual resistor of polyurethane or rubber-based resin and carbon particles in cotton woven fabric is impregnated with cotton yarn, so that it can be bent or locally loaded and has high power heat conversion efficiency.

However, the deficiencies of this type of resistor are that the initial resistance changes at abnormal temperatures, and when used at elevated temperatures for extended periods of time, it deteriorates and carbonizes. An object of the present invention is to produce a heating element configured to solve the defect by making use of the features. Another object of the present invention is to provide a flexible heating element mainly composed of a harmless resin and having a structure in which a harmless fireproof and nonflammable good conductor and a heating element are integrated. A further object of the present invention is to provide a structure in which a flexible carbon surface heating element is used for floor heating to cut off a cigarette fire with a refractory material, even if there is a mistake in electric processing, but there is no fire accident by shutting off the power supply. It is an object.

In addition, it is a heating element that does not change its resistance even when it is put on a table or piano, and its purpose is to be able to adapt to home heating elements or beddings such as beds.

DISCLOSURE OF THE INVENTION The present invention relates to a surface obtained by impregnating and drying a resistance solution obtained by mixing carbon particles and a rubber or polyurethane resin with a deoxylane solvent on a cloth in which electrode bands are woven on both sides of a 100% cotton satin woven cloth. A heating layer made by laminating a harmless soft low-melting resin that melts within 80 ° C to 110 ° C in a vacuum state on the front and back surfaces of the resistor, and a heat-resistant, insulating and waterproof colored resin on the lower surface To form a heating element surface. In addition, as a good conductor for fire resistance and leakage current sensing, printed on a single side of non-combustible paper with pulp mixed with inorganic aluminum hydroxide or magnesium silicate non-combustible agent, mixed with carbon particles and PET resin with solvent on one side. A non-combustible paper good conductor or aluminum foil PET film or good conductive material is used as a control body. A good conductor of non-combustible paper has a configuration in which the leakage current sensing terminal is in good contact with a part of the good conducting surface, and a non-toxic soft low-melting resin is laminated and provided as a waterproof protection for the non-combustible paper. Is laminated with a heat-resistant waterproof colored resin to form a good conductor of fire-resistant and non-combustible paper.

As a configuration having flexibility, the method of bonding the heating element surface and the control body is such that the leakage current sensing terminal can be contacted, and only the heating element surface and the control body surface are bonded or thermocompressed on both sides to be integrated. Flexible non-combustible control heating element. The electrical cut-off configuration is an abnormal heat in which the initial resistance of the resistor changes, that is, the harmless soft low-melting resin melts even at a local temperature within a temperature range of 80 ° C to 110 ° C, and the resistor is connected to the resistor. When the non-combustible paper good conductor comes into contact, the leakage current is conducted to the entire surface of the non-combustible paper good conductor at a short time, and the leakage current flows to the leakage current sensing terminal provided at one end and to the lead wire, and from the lead wire to the controller. A switch disposed in the internal power supply path opens to provide the safest fireproof nonflammable control heating element that shuts off the supply of electric power to the heating element.

According to another embodiment of the present invention, the configuration of the electrode terminal attached to the electrode band of the non-combustible control heating element includes two flat plates together with a lead wire insertion hole, one flat plate being a good conductive plate and one flat plate. Is an insulating plate including the protrusion.The insulation protrusion penetrates the good conductor of non-combustible paper, and the electrode terminal structure is provided by bending and fixing the tip of the protrusion through the protrusion insertion hole provided on the surface of the good conductive plate. . According to another embodiment of the present invention, two flat plates are provided from the axis of the lead wire insertion hole, and both of the two flat plates are provided with two stapler-type compression terminal insertion holes in each of the two flat plates, One flat plate surface shall be in good contact with a good conductor surface of non-combustible paper, and another flat plate surface shall be in contact with the colored resin surface on the upper surface, and shall have a leakage current sensing terminal structure fixed by a stapler type compression terminal. According to another embodiment of the present invention, when the carbon-based resistor reaches an abnormal temperature at which an initial resistance change occurs, that is, an abnormal temperature within a range of 80 ° C to 110 ° C, the carbon-based resistor is deposited on the front and back surfaces of the resistor. When the harmless soft resin with a low melting point dissolves to the extent of a needle hole even in the local area of the resin surface and comes into contact with the non-combustible paper good conductor surface on one side of the resistor, the leakage current of the resistor flows over the entire non-combustible paper good conductor. This leakage current is detected by the leakage current sensing terminal, which makes good contact with one end of a good conductor surface of non-combustible paper, and senses it with high sensitivity and conducts it to the lead wire.The rectifier and comparator inside the controller transmit the vitality signal through the terminal of the relay coil. As a result, the latching relay opens, shutting off the power supply to the heating element. As described above, a heating element with a fireproof and non-combustible surface control shall be used as a complete safety device, including a fire accident during machining of electrode strip terminals or lead wires.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view of a fireproof non-combustible surface control heating element according to an embodiment of the present invention. FIG. 2 is a cross-sectional view of the configuration of the fire-resistant non-combustible surface control heating element according to the embodiment of the present invention. FIG. 3 is a perspective view of the electrode band terminal diagram A and the leakage current sensing terminal diagram B of the present invention.

FIG. 4C is a sectional view C of connection of the heating element.

FIG. 4 is a system diagram of an electric control panel of a fireproof non-combustible surface control heating element. BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in more detail with reference to the accompanying drawings. 1 in FIG. 1 is a heating element for controlling a fire-resistant and non-combustible surface, and a soft resin having a low melting point of 4 · 4 is adhered to one or both sides of the resistor in a vacuum state. The non-combustible paper conductor (3) is mounted on the upper surface (4). Electrode strips 9 and 9 and terminals 10 and 10 are provided on both side edges of the resistor 2, and the terminals 10 and 10 are connected to the first terminal of the controller 6. The good conductor of No. 3 is printed on one side of the non-combustible paper 12, and the leakage current sensing terminal 11 squeezed on the good conducting surface of No. 3 is connected to the second terminal of the controller of No. 6. The details of the melting of the 4/4 resin or the 4/5 resin will cause leakage current to flow through the good conductor of 3 and shut off the power supply, which will be described later.

The configuration of the present invention uses a flexible and harmless material, and the second resistor has an initial resistance. When the temperature reaches an abnormal temperature that causes resistance change, the soft resin of 4 and 4 melts, and the leakage current that flows when the non-combustible paper good conductors 3 and 12 on the upper surface come into contact with the resistor 2 flows over the good conductor 3 ', The 11 leakage current sensing terminals and lead wires provided on the edge detect with high sensitivity. The fire resistance is made by mixing the inorganic fire retardant aluminum hydroxide or magnesium silicate into the non-combustible paper of No. 12 to make the fire resistant material that does not spread even in a cigarette fire.

The resistor 2 having flexibility and heat conversion efficiency is made of a 100% cotton yarn twill weave, and a plurality of electrode wires 8 made of a plurality of thin metal wires are woven into 10 electrode bands 9, and 9 is provided on both sides. The prepared cloth is impregnated with a carbon-containing liquid of a polyurethane-based coagulant and graphite powder, and dried to form the second resistor. This type of resistor 2 has an initial resistance that changes locally at an abnormal temperature of 80 ° C. to 11 ° C. or less.

In the control body of the present invention, the good conductor 3 is provided by printing a good ink obtained by mixing carbon particles and a PET resin with a solvent on one surface of the noncombustible paper 12. Further, the non-combustible paper 12 has fire resistance that does not spread even at a cigarette fire of 450 ° C. Fig. 2 shows the heating element surface composed of heat-resistant colored resin 5 on the lower surface of soft resin 4 and 4 with low melting point provided on the front and back surfaces of resistor 2 because of its flexibility, and the upper surface of soft resin 4 A flexible fire-resistant non-flammable surface control heating element 1 is bonded or thermo-compressed on both sides of the fire-resistant and non-flammable control body provided with a good conductor of non-combustible paper of 3 and a heat-resistant colored resin of 5 above. Are configured as shown in the sectional view of FIG.

FIG. A of the third diagram shows the configuration of the terminals 10. 10 fixed to the ends of the electrode strips 9. The terminal structure is provided with two flat plates a and b from the lead wire insertion hole axis, the flat plate a has a projection, and the entire flat plate a is an insulating plate with insulating paint c to make insulation protrusion The flat plate b is a good conductive plate, is provided with an insertion hole d, and comes into contact with the lower electrode band 9 of the resistor 2. The two-sided terminals are fixed by bending the protruding tip of the insulated terminal of a through the flat hole d of b.

Figure B shows a leakage current sensing terminal structure with two flat plates from the lead wire insertion hole shaft.Each of the two flat plates has an insertion hole of e Make good contact with the good surface of good conductor 3. The flat plate on one side is brought into contact with the heat-resistant colored resin surface 5 on the upper surface of the non-combustible paper, and is squeezed and fixed between the insertion holes e and e with the stapler terminal f.

FIG. C is an example of an installation cross-sectional view of the electrode terminal 10 of FIG. A and the leakage current sensing terminal 11 of FIG. The structure of the heating element is as follows: After the terminal is squeezed, the heat-resistant colored resin 5 on the upper surface of the noncombustible paper and the soft resin 4 of the resistor 2 are thermocompression-bonded to form a fireproof nonflammable surface control heating element. In the controller circuit configuration of FIG. 4, one end of the AC source 13 is connected to the input of the reference voltage generator and the latching relay 27 by the ON / OFF switch 14. The output of the latching relay 27 is connected to the electromagnetic terminal 10 and one terminal of the heat sensing line A. The second terminal of the AC source of 1 3 has a reference voltage of 2 9 It is connected to the circuit and the temperature control device.

The 29 reference voltage generating circuit includes 15 rectifiers and 30 voltage regulators. The voltage adjustment output of the reference voltage generating circuit of 29 is used as the input of the residual effect rectifier circuit of 25. The output of the leakage current sensing terminal of the non-combustible paper conductor is connected to the second input of the residual effect rectifier circuit.

The soft resin (4) between the resistor (2) and the good conductor of non-combustible paper (3) prevents leakage current flow at a normal temperature of 80 ° C or less.

The 25 residual effect rectifier circuit has one of its inputs receiving the regulated reference voltage from the reference voltage generator circuit of 29, the rectifier of 16 and the comparator, and the non-combustible paper of 3 at other inputs. Includes output from good conductors. The outputs of the rectifier and 16 comparators are connected in parallel to 26 relay coils and 17 holding contactors of 26 relay coils.

The 20 temperature control device includes 23 control switches, and receives 13 power supply outputs at one of its inputs. The output of the control switch 23 is connected to the latching relay 27. The output of 27 latching relay is connected to the second terminal of resistor 2. 21 Rectifier receives input from A's heat sensing wire. The output of the 21 rectifier is connected to the second input of the 22 temperature comparator. The output of the 23 temperature comparator is used as a control output to the 23 control switch.

The mechanical contacts that normally open the 17 holding contacts of the relay and the normally closing contacts of the 27 latching relays ensure the coordinated impulses of all three sets of relay contacts. In normal operation, contact with 27 and 27 'latching relays is closed. When the ON / OFF switch 14 is closed, the power to the resistor 2 and the heat sensing line A is regulated by the control switch 23.

The 21 rectifier is sensitive to temperature-dependent changes in voltage and current caused by the temperature sensed by the heat sensing line of A, for use of the temperature-dependent voltage in the 22 temperature comparator.

If the temperature sensed by the heat sensing line of A is lower than the initial set value, the temperature comparator of 22 sends a vitality signal to the control switch of 23. This closes 23 control switches and uses power there through and through 27 latching relays to 2 resistors. And it enables the generation of heat in the second resistor. If the sensed temperature exceeds the second set point, the 22 temperature comparator removes the vitality signal from the 23 control switch and temporarily shuts off the heat frequency. If the sensed temperature is again below the initial set point, heat is restored. T JP01 / 00320

7

If the resistor (2) together with the good conductor of non-combustible paper (3) and the temperature controller (20) for maintaining the overall safe temperature of the current interrupt mechanism (4) become defective, the heating element (1) It becomes permanently unusable. One of the noted defects includes a few control switch defects in the ON state. This causes the heat in the second resistor to be unregulated. If any part of resistor 2 exceeds the melting temperature of the soft dissolvable sheet of 4, electrical contact will occur between the conductor in resistor 2 and the good conductor of non-combustible paper. The leakage current and voltage generated by the good non-combustible paper conductor are used for the output of the rectifier and the input of the rectifier and comparator in the residual effect rectifier circuit.

If the current leaks from the good non-combustible paper conductor, the rectifier and comparator in 16 receive the vitality signal through the terminals of 26 relay coil. The 26 relay coils then open the contacts that the 27 and 27 'latching relays normally close and close the 17 holding contacts. The holding contact of 17 maintains the vital voltage of the 26 relay coil even if the initial vital signal is removed. Opening of the latching relays 27 and 27 'ensures that heat generation is stopped Shuts off power to both ends of resistor 2

The melting point of the soft dissolvable sheet in 4 determines the temperature at which the current interruption function of 2 4 removes power from the 2 resistor. A suitable choice of material is for the abnormal temperature at which the resistor of 2 does not recover to the initial pile, that is, for melting temperatures within 80 ° (: ~ 110 ° C. The resistor of 2 This is a resistor made by impregnating a cotton cloth with a carbon-based resistance solution in which flexible carbon particles and a resin are mixed with a solvent, and then drying.

The initial resistance of the carbon-based resistor 2 changes locally even at an abnormal temperature of 80 ° C. to 110 ° C. or less. If the temperature rises above this level, it deteriorates and carbonizes, causing an electrical short. The present invention is composed of a harmless resin, and the soft resin on the front and back surfaces of the resistor (2) melts at a temperature within 80 ° C to 110 ° C, and comes into contact with the resistor (2) and a good conductor of non-combustible paper. The leakage current flowing through the rectifier and comparator of 16 receives the vitality signal through the terminals of the 26 relay coil, the latching relays of 27 and 27 'open, and the 2 Provided is a completely non-combustible fire-resistant non-combustible surface control heating element that shuts off electric power. Industrial applicability

As described above, the fire-resistant and non-combustible surface control heating element according to the present invention can be used for housing-related floor heating and bedding, rugs, baths, toilets, roof snow melting, and the like, as well as medical instruments, hospital beds, and the elderly. Applicable to heat retention and electrical potential therapy for nursing care equipment and infant beds. In addition, any of the heat insulation related to ships, drying equipment for seafood seaweed, etc., oil pipe cylindrical steel, tank insulation, etc. are all applicable to the field of application of heat insulation equipment for fireproof non-combustible surface control heating elements without electrical ignition accidents. .

Claims

Scope of Claim The present invention provides a flexible surface or planar resistor, in which a harmless soft low-melting resin is used for the front and back surfaces of the resistor, or a soft low-melting resin for the good conductor surface and a harmless heat-resistant resin for the back surface, A non-combustible surface controlled heating element characterized by a heating element in which resistors are bonded in a vacuum state and a layered structure composed of a control body. The control body of the present invention is a non-combustible paper obtained by printing and drying a good conductive ink mixed with carbon particles, a resin, and a solvent on one side of a non-combustible paper obtained by mixing pulp with inorganic aluminum hydroxide or magnesium silicate as a fire-resistant good conductor. A fire-resistant control body having a good conductor, a good conductor of a metal foil film, or another good conductor on one side or both sides of a resistance heating element. The layered structure of the present invention has a structure in which a single-sided good conductor is provided with a harmless heat-resistant resin laminated on the upper surface of the good conductor, or a double-sided good conductor is laminated with a harmless heat-resistant resin on the front and back surfaces of the good conductor for heat-resistant waterproof protection. A heat-resistant single-sided or double-sided heating element in which the layered structure is further bonded by bonding or thermocompression bonding only the resin surface on both side edges of the heating element and the resin surface on both side edges of the control body. In the electrode terminal structure of the non-combustible control heating element of the present invention, the lead wire insertion hole has two flat plates, one flat plate has a projection, and the flat plate surface and the projection are covered with an insulating material. The half flat plate shall be a good conductive plate and a projection insertion hole shall be provided.Fixed, the good conductive plate surface should be in contact with the electrode band surface, An electrode terminal structure that penetrates, passes through the insertion hole in the surface of the good conductor plate, and bends and fixes the tip of the projection. The leakage current sensing terminal of the present invention has two flat plates from the lead wire insertion hole shaft connected to the controller, and each of the two flat plates has a stapler-type compression terminal and a human hole. One flat plate is brought into contact with the good conductive surface, the half flat plate is placed on the heat-resistant resin surface on the good conductor, and the stapler type terminal is

Leakage current terminal structure that passes through two flat plate insertion holes and is squeezed and fixed. A method for manufacturing a refractory non-combustible surface control heating element, which is manufactured by combining the above claims.