WO2015133217A1

WO2015133217A1 - Heating device and heated toilet seat

Info

Publication number: WO2015133217A1
Application number: PCT/JP2015/053254
Authority: WO
Inventors: 昌哉中山
Original assignee: 富士フイルム株式会社
Priority date: 2014-03-05
Filing date: 2015-02-05
Publication date: 2015-09-11
Also published as: JPWO2015133217A1; JP6259069B2

Abstract

Provided are a heating device and a heated toilet seat having little heating unevenness. The seat comprises a structure and, disposed on the structure surface, a sheet film heater having metal thin wires in mesh form. The structure surface is provided with a curved region whereof the radius of curvature is 50 mm or shorter, and a plurality of curved surfaces and/or flat surfaces separated by the curved region. An insulation part adapted to the curved region of the structure divides the sheet film heater into a plurality of portions, which are respectively disposed on the plurality of curved surfaces or flat surfaces. Each of the plurality of portions of the sheet film heater is supplied with power independently.

Description

Heater and heated toilet seat

The present invention relates to a heating appliance and a heating toilet seat configured by arranging a heat generating surface on the surface of a structure having a three-dimensional curved surface.

2. Description of the Related Art Conventionally, a heated toilet seat that is installed in a Western-style toilet and generates heat on a seating surface on which a user is seated has been used. In Patent Document 1 and Patent Document 2, a planar film heater made of a metal mesh conductive film is three-dimensionally formed. There is disclosed a heating toilet seat that is formed by processing and arranging it on a seating surface of a toilet seat that is a structure having a three-dimensional curved surface.

JP 2013-59501 A JP 2013-66595 A

In the heated toilet seats described in Patent Document 1 and Patent Document 2, an annular central region on the surface of the toilet seat, which is considered to be a seating surface having a large contact area with the user's skin when the user is seated, is composed of a planar film heater. Areas where toilet seat heaters were arranged but were not considered seating surfaces of toilet seats, for example, outer peripheral areas, inner peripheral areas, and rear areas of the toilet seat surface outside the central area are planar film heaters Did not place.
Therefore, when sitting, it is considered that the user's skin is in contact with these areas where the sheet film heater is not disposed, and if the sheet film heater is not disposed for these areas, the heating toilet seat There was a problem that the role could not be fulfilled sufficiently.

For this reason, as shown in FIGS. 11, 12A and 12B, a heating toilet seat in which sheet film heaters are arranged in the outer peripheral region, the inner peripheral region, and the rear region beyond the bent region of the toilet seat is considered. be able to. Here, FIG. 11 is a schematic plan view showing a heated toilet seat as a reference example composed of a toilet seat 111 and a planar film heater 112 arranged on the surface of the toilet seat 111, and FIG. 11 is a cross-sectional view when the heating toilet seat shown in FIG. 11 is cut along the line AA, and FIG. 12B is a cross-sectional view when the heating toilet seat shown in FIG. 11 is cut along the line BB.

According to the researches of the present inventors, in order to arrange the sheet film heater in the area where the sheet film heater of the conventional heating toilet seat is not arranged, the sheet film heater 112 is replaced with the toilet seat 111 having the bent portion 113. When the toilet seat surface is three-dimensionally molded and arranged, the stretch ratio of the film locally increases at the bent portion 113 as shown in FIGS. 12 (A) and 12 (B). For this reason, it has been found that the bent portion 113 has a problem that the metal mesh is disconnected due to the stretching of the film. As described above, when the metal mesh is disconnected, there is a problem in that the uniformity of heat generation in the heating toilet seat is deteriorated.

An object of the present invention is to solve the above-described problems and provide a heating appliance and a heating toilet seat with less heat generation unevenness.

In order to solve the above-described problems, the present invention provides a heating apparatus including a structure and a planar film heater having a mesh-like fine metal wire disposed on the surface of the structure, wherein the surface of the structure has a curvature. The planar film heater corresponds to the bending region of the structure, comprising a bending region having a radius of 50 mm or less and a plurality of curved surfaces and / or planes having a curvature radius larger than 50 mm divided by the bending region. Provided is a heating appliance which is divided into a plurality of parts by an insulating portion and arranged on a plurality of curved surfaces and / or planes.

Further, when the curvature radius of the bent region is 40 mm or less, it is more preferable to apply the present invention.

Moreover, it is preferable that the plurality of portions of the sheet film heater are independently supplied with electric power.
Furthermore, it is preferable that a heat generation control unit for controlling heat generation of the sheet film heater is further provided, and the heat generation control unit controls a plurality of portions of the sheet film heater independently of each other.

Further, it is preferable that the heat generation control unit supplies power according to the surface area of the plurality of portions of the planar film heater.

Further, it is preferable that the insulating portion is formed by breaking a mesh-like fine metal wire with a predetermined width.

Further, the width of the insulating part is preferably 0.1 mm or more and 10 mm or less.

Further, the mesh-like fine metal wire is preferably composed of fine metal particles and a binder.

Further, the present invention is a heating toilet seat comprising a toilet seat and a planar film heater having a mesh-like thin metal wire disposed on the surface of the toilet seat, wherein the surface of the toilet seat has a bent region with a radius of curvature of 50 mm or less. The planar film heater includes an inner peripheral region having a radius of curvature greater than 50 mm divided by the bent region, a central region, an outer peripheral region, and a back region. The planar film heater has an inner periphery formed by an insulating portion corresponding to the bent region of the toilet seat. A heating toilet seat is provided that is divided into an inner peripheral area, a central area, an outer peripheral area, and a back area of the toilet seat by being divided into a central part, a central part, an outer peripheral part, and a back part.

It is more preferable to apply the present invention when the radius of curvature of the bent region is 40 mm or less.

In addition, it is preferable that power is independently supplied to the central portion, the inner peripheral portion, the outer peripheral portion, and the rear portion of the planar film heater.
Furthermore, it is preferable to further include a heat generation control unit that controls the heat generation of the sheet film heater, and the heat generation control unit controls the central part, the inner peripheral part, the outer peripheral part, and the rear part of the sheet film heater independently. .

Further, it is preferable that the heat generation control unit supplies power in accordance with the respective surface areas of the central part, the inner peripheral part, the outer peripheral part, and the rear part of the planar film heater.

It is preferable that the insulating portion of the planar film heater is formed by breaking a mesh-shaped metal fine wire with a predetermined width.

According to the present invention, the heat generation unevenness caused by the disconnection can be prevented by preliminarily setting the insulating region in the portion where the disconnection is likely to occur during the three-dimensional forming process, and the range of conditions for the three-dimensional forming process Can be applied to more complex structures.

It is a typical top view which shows the whole structure of a heating toilet seat provided with the heating toilet seat which concerns on one Embodiment of this invention in the state which decomposed | disassembled the heating toilet seat. (A) is an AA cross-sectional view of the heating toilet seat shown in FIG. 1, and (B) is a BB cross-sectional view of the heating toilet seat shown in FIG. (A) And (B) is an expanded sectional view which shows an example of the detailed structure of the predetermined area | region in the cross section of the heating toilet seat shown to FIG. 2 (A), respectively. (A) to (C) are schematic views respectively showing examples of insulating regions of the planar film heater in the heating toilet seat shown in FIG. It is a flowchart which shows the 1st manufacturing method of the heating toilet seat of this invention. FIG. 6A is a cross-sectional view in which a molding die for vacuum forming the planar film heater is partially omitted, and FIG. 6B is a sectional view showing that the planar film heater is attached to the molding die. It is sectional drawing which shows the state pressed. It is sectional drawing which abbreviate | omits and shows the state which installed the planar film heater in the metal mold | die for injection molding. It is a flowchart which shows the 2nd manufacturing method of the heating toilet seat of this invention. It is a flowchart which shows the 3rd manufacturing method of the heating toilet seat of this invention. (A) is a schematic diagram which shows the whole structure of the sheet | seat film heater used for the Example of this invention, (B) is a model which shows the whole structure of the sheet | seat film heater used for the comparative example of this invention. FIG. It is a schematic diagram which shows the whole structure of the heating toilet seat which has the planar film heater as a reference example. (A) is an AA sectional view of the heating toilet seat shown in FIG. 11, and (B) is a BB sectional view of the heating toilet seat shown in FIG.

A heating appliance and a heating toilet seat according to the present invention will be described in detail below based on preferred embodiments shown in the accompanying drawings.
FIG. 1 is a schematic plan view showing an entire configuration of a heating toilet seat device including a heating toilet seat, which is a representative example of a heating appliance according to an embodiment of the present invention, in a state in which the heating toilet seat is disassembled. 2A is a cross-sectional view of the heating toilet seat shown in FIG. 1 taken along line AA, and FIG. 2B is a cross-sectional view of the heating toilet seat shown in FIG. 1 taken along line BB.
Below, although the heating toilet seat is demonstrated as a typical example about the heating appliance which concerns on this invention, of course, this invention is not necessarily limited to this.

The heating toilet seat device has a heating toilet seat 1 and a main body 2, and the heating toilet seat 1 includes a toilet seat 11 and a sheet film heater 12 disposed on a toilet seat surface 12 a of the toilet seat 11. In FIG. 1, the toilet seat 11 and the sheet film heater 12 that are originally formed as an integral part are shown in an exploded manner for easy understanding.

The toilet seat 11 includes a toilet seat surface 12a configured by a curved surface, a flat surface, or a combination of a curved surface and a flat surface. For example, the toilet seat 11 has an annular outer shape as a whole and is installed in a Western-style toilet to support a user's sitting posture. . In addition to the toilet seat surface 12a, the toilet seat 11 includes a toilet seat back surface (not shown) that supports the toilet seat 11 facing the edge of the Western-style toilet when the user is seated.
In the illustrated example, the toilet seat 11 has a U-shaped (arch) shape in which one side of a rectangle (rectangular shape) is curved outwardly, for example, a semicircular shape, and a curved portion is a seating side. The rectangular structure is arranged on the back side, and has a similar annular toilet seat surface 12a.

The toilet seat surface 12 a of the toilet seat 11 has a bent region 13. The bending region 13 is defined by a portion having a radius of curvature of 50 mm or less. The radius of curvature of the bent region 13 is 50 mm or less, and can be appropriately designed depending on the material of the planar film heater 12 to be used and molding process conditions. A preferable radius of curvature of the bent region 13 is 40 mm or less. However, when the planar film heater 12 to be used is excellent in molding processability, the radius of curvature of the bent region 13 can be set to 20 mm, 10 mm, and 5 mm. The smaller the radius of curvature, the higher the possibility of disconnection, so the effect of the present invention becomes more prominent.

As shown in FIGS. 1, 2A and 2B, the bending region 13 is a region where the radius of curvature is 50 mm or less on the toilet seat surface 12a configured by a curved surface, a plane, or a combination of a curved surface and a plane. In addition, as described later, the toilet seat surface 12a is formed in the outer peripheral region 14a, the central region 15a, the inner peripheral region 16a, and the back region 17a having curved surfaces and / or planes larger than the curvature radius 50 mm by the bent region 13 as described later. Divided.

In the illustrated example, specifically, the toilet seat surface 12a has two U-shapes that are formed as a bent region 13 in parallel or substantially parallel to both sides along an annular surface shape in a U-shaped portion on the front side.

Bending regions

13a and 13b and one linear bending region 13c in the rectangular portion on the back side are provided. The bent region 13 of the toilet seat surface 12a of the toilet seat 11 in the present invention is not limited to 13a, 13b and 13c in the illustrated example, and has a radius of curvature of 50 mm or less formed on the toilet seat surface 12a of the toilet seat 11. Anything can be used.

The toilet seat surface 12a of the toilet seat 11 includes an outer peripheral region 14a, a central region 15a, an inner peripheral region 16a, and a back region 17a that are divided by a bent region 13 formed on the toilet seat surface 12a. In the present invention, each region of the toilet seat surface 12a may be any region as long as it is separated by the bent region 13, and of course is not limited to the illustrated example.
In the illustrated example, specifically, the toilet seat surface 12a includes two U-shaped outer peripheral regions 14a formed on the outer side of the outer bent region 13a by two U-shaped

bent regions

13a and 13b on the front side. A U-shaped central region 15a, which is formed between the

bent regions

13a and 13b and normally corresponds to a seating surface, an inner bent region 13b, and an annular inner peripheral region 16a and a bent region 13b formed inside the bent region 13b. It is divided into a rectangular rear region 17a formed on the outer side (back side). Here, the outer peripheral region 14a, the central region 15a, the inner peripheral region 16a, and the back surface region 17a are configured by curved surfaces or planes having a radius of curvature larger than that of the bent region 13 (13a, 13b, and 13c). In the present invention, it is appropriate that the outer peripheral region 14a, the central region 15a, the inner peripheral region 16a, and the back surface region 17a have a radius of curvature exceeding 50 mm.

That is, in the toilet seat surface 12a, of the toilet seat surface 12a divided by the bent regions 13 (13a, 13b, and 13c), the outer peripheral region 14a is the outermost region of the toilet seat surface 12a in the annular toilet seat 11, and the central region 15a is a region surrounded by the outer peripheral region 14a, the inner peripheral region 16a and the back region 17a on the toilet seat surface 12a, and the inner peripheral region 16a is the innermost region on the toilet seat surface 12a of the annular toilet seat 11. The back area 17a is an area located substantially on the back of the user when the user is seated on the toilet seat 11.

The heating toilet seat is formed by three-dimensionally molding the planar film heater 12 along the toilet seat surface 12a, and supplies predetermined power to the planar film heater 12 through an electrode (not shown). This generates heat and fulfills the function of the heater.

In the illustrated example, specifically, the planar film heater 12 has a similar shape covering the entire toilet seat surface 12a, and corresponds to the bent region 13 (13a, 13b and 13c) of the toilet seat surface 12a. It is formed between the U-shaped outer peripheral portion 14 and the two insulating

portions

18a and 18b formed outside the outer insulating portion 18a by the insulating portion 18 (18a, 18b and 18c) having the shape of A U-shaped central portion 15 serving as a surface, an inner insulating portion 18b on the inner side, an annular inner peripheral portion 16 formed on the inner side of the insulating portion 18c, and a rectangular rear surface portion formed on the outer side (back side) of the insulating portion 18b. It is divided into 17. Here, the outer peripheral portion 14, the central portion 15, the inner peripheral portion 16 and the back surface portion 17 of the sheet film heater 12 cover the outer peripheral region 14a, the central region 15a, the inner peripheral region 16a and the back surface region 17a of the toilet seat surface 12a, respectively. Each having a similar shape. In the present invention, the insulating part 18 and each part of the sheet film heater 12 may be in accordance with the bent region 13 and the bent region 13 of the toilet seat surface 12a, and are not limited to the illustrated example. .

The main body 2 includes an operation unit 21, a human body detection sensor 22, a temperature sensor 23, a heater driving unit (power supply unit) 24, a seating sensor 25, and a heat generation control unit 26. The human body detection sensor 22, the temperature sensor 23, the heater driving unit (power supply unit) 24, and the seating sensor 25 are connected to the heat generation control unit 26, and the heater driving unit (power supply unit) 24 is connected to the sheet film heater 12. Each of the outer peripheral portion 14, the central portion 15, the inner peripheral portion 16 and the back surface portion 17 is connected.

With reference to FIG. 2 (A) and (B), the heating toilet seat 1 of this invention is demonstrated in detail.
2A shows an outer peripheral region 14a of the toilet seat surface 12a and an outer peripheral portion 14, a central region 15a of the sheet film heater 12 when the heating toilet seat 1 shown in FIG. 1 is cut along the line AA. FIG. 2B is a cross-sectional view showing a cross section of the central portion 15, the inner peripheral region 16a, and the inner peripheral portion 16, and FIG. 2B is a sectional view of the heated toilet seat 1 shown in FIG. It is sectional drawing which shows the cross section of the inner peripheral area | region 16a and the inner peripheral part 16, and the back surface area | region 17a and the back surface part 17 at the time of doing.

2A and 2B, the outer peripheral portion 14 of the sheet film heater 12 is disposed on the outer peripheral region 14a of the toilet seat surface 12a, and the central portion 15 is disposed on the central region 15a. The portion 16 is disposed on the inner peripheral region 16a, the back surface portion 17 is disposed on the back surface region 17a, and each of these portions is electrically insulated by an insulating portion 18 disposed on the bent region 13. Moreover, the outer peripheral part 14, the center part 15, the inner peripheral part 16, and the back part 17 have an electrode which is not illustrated, respectively, a voltage is applied through the electrode which is not illustrated, and electric power supply is made independently.

Moreover, as shown in FIG. 3 (A), the bonding cross section of the outer peripheral portion 14 and the outer peripheral region 14a, the central portion 15 and the central region 15a, the inner peripheral portion 16 and the inner peripheral region 16a, and the back portion 17 and the rear region 17a A sheet film heater 12 having a support 31 formed of a plastic film, a plastic plate, and the like, and a mesh-like fine metal wire (metal mesh) 32 provided on the support 31 is interposed between the toilet seat 11 via an adhesive 33. It is preferable that it is comprised by affixing on the toilet seat surface 12a. The support 31 has a thickness of 20 μm to 200 μm, and is preferably PET or PC from the viewpoint of forming processing.
Further, the planar film heater 12 has a plurality of openings 34 surrounded by fine metal wires 32 in a mesh shape. For this reason, the adhesive 33 bonds the toilet seat 11 and the planar film heater 12 by entering the plurality of openings 34 of the planar film heater 12. The height of the mesh-like fine metal wire is preferably 0.1 μm to 2 μm in consideration of the resistance value and the ease with which the adhesive 33 can enter the opening 34. In addition, the line | wire width of the mesh-shaped metal fine wire 32 is 0.5 micrometer or more and 100 micrometers or less, and 2 micrometers or more and 50 micrometers or less are more preferable. The mesh shape of the metal fine metal wire 32 can take various polygonal shapes such as a square, a rectangle, a rhombus, and a regular hexagon, but a square and a rhombus are preferable. The mesh arrangement method includes a regular mesh in which polygonal meshes are regularly arranged and a random mesh in which meshes of various shapes are irregularly arranged. In the case of a regular mesh, the mesh pitch is, for example, 10 μm or more and 5000 μm or less, and preferably 100 μm or more and 500 μm or less.

The mesh-shaped fine metal wire 32 is preferably composed of fine metal particles and a binder. By including the binder, the mesh-like fine metal wire 32 is easily bent and the bending resistance is improved. As the metal fine particles, silver fine particles are preferable from the viewpoint of stability of the resistance value. As the binder, known ones can be used as appropriate, and for example, gelatin and polyvinyl alcohol (PVA) described in JP2013-12604A can be used. Among them, a combination of developed silver fine particles obtained by exposure and development of silver halide fine particles and gelatin is preferable.

Further, as shown in the adhesion cross section of FIG. 3B, the planar film heater 12 is made of a conductive material such as ITO, silver nanowire, carbon nanotube, and polymer conductive material in each of the plurality of openings 34. The thermal material 35 may be arranged. By disposing the heat transfer material 35 in the opening 34, the heat generation speed warming property of the planar film heater 12 can be improved.

Further, the insulating portion 18 of the planar film heater 12 shown in FIG. 1 and FIGS. 2A and 2B is formed by breaking the mesh-shaped metal fine wire 32 over a predetermined width. The width of the insulating portion 18 needs to be 0.1 mm or more, preferably 0.1 mm or more and 10 mm or less, more preferably 0.2 mm or more and 2.0 mm or less. By setting to this range, both insulation and visibility can be achieved.

FIGS. 4A to 4C are schematic views respectively showing the structure of the mesh-like fine metal wires (metal mesh) 32 of the insulating portion 18.
In FIG. 4A, the metal mesh is completely removed from the insulating portion 18, and since the metal mesh does not exist in the insulating portion 18, the insulating portion 18 has a better insulating property than the other portions. There is a possibility that it will be easily visible and visible.
FIG. 4B is a diagram in which the metal mesh is disconnected at the boundary portions at both ends of the insulating portion 18 in the insulating portion 18, and the metal mesh is also present in the insulating portion 18. Even if it is inconspicuous and difficult to see, the insulation may be slightly poor. In FIG. 4B, the preferred length of the disconnection is 15 μm to 100 μm.
FIG. 4C shows the insulating part 18 in which the metal mesh inside the insulating part 18 is disconnected, which has good insulation, and the insulating part 18 also has a broken metal mesh. Because it exists, it does not stand out even when compared with other parts, and is hardly visible. In FIG. 4C, the preferred length of the disconnection is 10 μm to 50 μm. Moreover, since the disconnection location provided in the metal mesh inside is arrange | positioned at random, since disconnection is more difficult to visually recognize, it is more preferable.

1 is composed of various buttons, dials, and the like, and outputs instructions from the user to the heat generation control unit 26. The human body detection sensor 22 detects that the user has entered a toilet or the like where the heating toilet seat 1 is installed, and is configured by, for example, an infrared sensor. The human body detection sensor 22 detects that the user is in the vicinity of the heating toilet seat 1, and issues a heating instruction for the planar film heater 12 to the heat generation control unit 26.

The temperature sensor 23 detects the temperature of the toilet seat surface 12 a and the planar film heater 12 of the toilet seat 11 and outputs a temperature signal having temperature information to the heat generation control unit 26. The temperature sensor 23 may be connected to each of the outer peripheral portion 14, the central portion 15, the inner peripheral portion 16 and the back surface portion 17 of the planar film heater 12, and each temperature may be measured individually.
Based on an instruction from the heat generation control unit 26, the heater driving unit 24 applies voltage to the outer peripheral portion 14, the central portion 15, the inner peripheral portion 16, and the back surface portion 17 of the planar film heater 12 via electrodes (not shown). Is applied to cause the planar film heater 12 to generate heat.

The seating sensor 25 is composed of a load sensor, an infrared sensor, or the like, and detects that the user is seated on the heating toilet seat 1 and outputs a seating signal to that effect to the heat generation control unit 26.
The heat generation control unit 26 controls the whole heating toilet seat device by controlling each part of the main body unit 2 and drives the heater based on instructions from the user through the operation unit 21 and signals from various sensors. Heat generation control and temperature control of each part of the sheet film heater 12 through the part 24 are performed.

Here, the manufacturing method of the heating toilet seat which concerns on this Embodiment is demonstrated. As a method for manufacturing the heating toilet seat, there are three manufacturing methods (first manufacturing method to third manufacturing method) as shown in FIGS.
The first to third manufacturing methods of the heating toilet seat according to the present invention will be described below.

First, in the first manufacturing method, in step S1 of FIG. 5, the planar film heater 50 is loaded with a load of 5 to 235 kg / cm ² (more preferably 30 to 200 kg / cm ² , more preferably 50 to 200 kg / cm ² ). Molding under the following conditions. Specifically, as shown in FIG. 6 (A), the planar film heater 50 is vacuum-formed into a curved surface shape in accordance with the shape of the seating surface of the toilet seat 11. In this case, the toilet seat 11 is vacuum-molded using a molding die 74 having substantially the same dimensions as the injection molding die 72 (see FIG. 7) used for injection molding. In FIGS. 6A, 6B, and 7, the shape of the mold is exaggerated. As shown in FIG. 6A, when the toilet seat 11 has, for example, a three-dimensional curved surface, the molding die 74 has a similar curved surface, in this case, an inverted curved surface, and a large number of suction holes 76. Is formed. For example, when a concave curved surface is formed on the toilet seat 11, a convex curved surface 78 is formed on the molding die 74, and the convex curved surface 78 fits into the concave curved surface of the toilet seat 11. It has become a relationship.

Then, the vacuum film forming of the planar film heater 50 using the molding die 74 is performed after preheating the planar film heater 50 to 110 to 300 ° C., as shown in FIG. 6 (A). As shown in FIG. 2, the sheet film heater 50 is pressed against the convex curved surface 78 of the molding die 74, and is evacuated from the molding die 74 through the suction hole 76, and a load is applied from the sheet film heater 50 side. It can be carried out by applying an air pressure of 5 to 235 kg / cm ² . By this vacuum forming, the planar film heater 50 having a curved surface shape along the shape of the toilet seat surface 12a of the toilet seat 11 is completed.

After that, in step S2 of FIG. 5, the molded sheet film heater 50 is attached to the toilet seat surface 12a of the toilet seat 11 using, for example, an adhesive 62, and the sheet film heater 50 (sheet film heater 12) becomes. The attached toilet seat 11, that is, the heating toilet seat 1 is completed.

Next, the second manufacturing method is a manufacturing method using insert molding. In step S101 of FIG. 8, as in step S1 of the first manufacturing method, the planar film heater 50 is loaded with a load of 5 to 235 kg / cm ^2. Molding under the following conditions.

Then, in step S102, as shown in FIG. 7, the post-molded planar film heater 50 is placed in the injection mold 72. At this time, among the cavities 80 formed in the injection mold 72, the mesh-like metal wires 32 or the protective layer on the mesh-like metal wires 32 is formed on the cavity surface 80a forming the toilet seat surface 12a of the toilet seat 11. Install in contact.

Thereafter, in step S103, molten resin is injected into the cavity 80 of the injection mold 72 and cured to complete the toilet seat 11 in which the sheet film heater 50 is integrally formed on the toilet seat surface 12a. . In this case, the toilet seat surface 12a of the toilet seat 11 and the conductive film 63 are in direct contact or face each other through a protective layer.

Further, the third manufacturing method is a manufacturing method using insert molding as in the second manufacturing method. First, in step S201 of FIG. 9, the planar film heater before molding is formed on the injection molding die 72. It differs in that 50 is installed.

Thereafter, in step S202, molten resin is injected into the cavity 80 of the injection mold 72 and cured, thereby completing the heating toilet seat in which the sheet film heater 50 is integrally formed on the toilet seat surface 12a of the toilet seat 11. . In this injection molding (insert molding), it is preferable to adjust the molten resin injection pressure and the like so that the planar film heater 50 is molded under a load of 5 to 235 kg / cm ² .

In the 1st manufacturing method, the process of sticking the metal foil sheet | seat which was conventionally required to the toilet seat 11, and the process of sticking a cord-like heater on a metal foil sheet with an adhesive tape can be skipped, for example, one time sticking In the process, the planar film heater 50 (planar film heater 12) can be installed on the toilet seat surface 12a of the toilet seat 11.
In the second manufacturing method, when the toilet seat 11 is produced by injection molding of molten resin, the toilet seat 11 in which the planar film heater 50 is integrally molded can be obtained by insert molding the planar film heater 50. Therefore, the process of attaching the planar film heater 50 (planar film heater 12) can be omitted, and the manufacturing process of the heating toilet seat can be simplified.
In the third manufacturing method, since the molding process of the planar film heater 50 before injection molding can be omitted, the manufacturing process of the heating toilet seat can be greatly simplified.

Next, an example of the operation of the heating toilet seat apparatus shown in FIG. 1 will be briefly described focusing on the sheet film heater 12 of the heating toilet seat 1.
When the user enters the toilet in which the heated toilet seat device is installed, the human body detection sensor 22 of the main body 2 detects the user's entry and outputs a signal to that effect to the heat generation control unit 26. The heat generation control unit 26 issues a heating instruction for the sheet film heater 12 to the heater driving unit 24 based on the temperature of the heating toilet seat 1 detected by the temperature sensor 23. The heater driving unit 24 applies a predetermined voltage to each part of the sheet film heater 12 based on an instruction from the heat generation control unit 26 to cause the sheet film heater 12 to generate heat.

For example, the heat generation control unit 26 controls the heater driving unit 24 based on an instruction from the user through the operation unit 21 to adjust the temperature of the sheet film heater 12. Alternatively, the heat generation control unit 26 may give a heating instruction to the heater driving unit 24 of the sheet film heater 12 after receiving a signal from the seating sensor 25.
Further, when the user is not entering the toilet, the heat generation control unit 26 controls the heater driving unit 24 based on the temperature signal from the temperature sensor 23 so that the sheet film heater 12 is kept at a predetermined standby temperature. You may control so that it may.

Further, since the sheet film heater 12 is divided into an outer peripheral part 14, a central part 15, an inner peripheral part 16 and a back part 17, the heat generation control part 26 controls the temperature of each part based on a user instruction. It may be adjusted individually. Further, for example, the heat generation control unit 26 may perform control so as to supply power through the heater driving unit 24 according to the surface areas of the outer peripheral portion 14, the central portion 15, the inner peripheral portion 16, and the back surface portion 17.

In the heating toilet seat according to the present invention, unevenness in heat generation caused by disconnection can be prevented by previously setting an insulating region at a location where disconnection is likely to occur during three-dimensional molding.
In addition, the heating appliance according to the present invention is not limited to the above-described heating toilet seat, and the range of conditions for the three-dimensional molding process is widened by preliminarily setting an insulating region at a place where disconnection is likely to occur during the three-dimensional molding process. It can be adapted to more complex shapes.

In the embodiment of the present invention, the toilet seat is described as being annular, but of course, it is not applied only to the annular toilet seat and can be applied to all known toilet seat shapes. For example, it can be applied to a U-shaped toilet seat instead of an annular shape.
Furthermore, in the embodiment of the present invention, the planar film heater has been described as being adhered to the surface of the toilet seat. In addition, the present invention may be applied to at least a part of a bent portion having a radius of curvature of 50 mm or less, and even if not applied to all locations, it is within the scope of the present invention.
In addition, the heating appliance of the present invention is not limited to the above-described heating toilet seat, and may be, for example, a seat or a handle of an automobile or a bicycle.
As mentioned above, although the heating appliance and heating toilet seat of this invention were demonstrated in detail, this invention is not limited to the said embodiment, In the range which does not deviate from the summary of this invention, various improvement and change are performed. Also good.

The heating appliance and heating toilet seat according to the present invention will be specifically described based on examples.
The heating toilet seats of Examples and Comparative Examples according to the present invention were manufactured, durability tests were performed on the manufactured heating toilet seats, and heat generation distribution was evaluated before and after the durability test.
[Example 1]
First, a planar film heater 50 shown in FIG. This planar film heater 50 has a bent region 13 (13a, 13b, 13c) [of the bent region 13 in which the electrical insulating portion 64 (64a, 64b, 64b) has a radius of curvature of the toilet seat 11 shown in FIG. The maximum radius of curvature was 38 mm. ] And is divided into

regions

66a, 66b, 66c, and 66d by the electrical insulating portion 64. In each of the

regions

66a, 66b, 66c, and 66d, an electrode 56 for supplying heater power is provided.
The planar film heater 50 was produced as follows in the same manner as Sample C described in Japanese Patent Application Laid-Open No. 2013-59501.

<Method for Manufacturing Sheet Film Heater 50>
[Preparation of emulsion]
・ 1 liquid:
750 mL of water
20g phthalated gelatin
Sodium chloride 3g
1,3-Dimethylimidazolidine-2-thione 20mg
Sodium benzenethiosulfonate 10mg
Citric acid 0.7g
・ Two liquids:
300 mL water
150 g silver nitrate
・ Three liquids:
300 mL water
Sodium chloride 38g
Potassium bromide 32g
Hexachloroiridium (III) potassium (0.005% KCl 20% aqueous solution) 5 mL
Ammonium hexachlororhodate (0.001% NaCl 20% aqueous solution) 7 mL
Potassium hexachloroiridium (III) (0.005% KCl 2
0% aqueous solution) and ammonium hexachlororhodate (0.001% NaCl 20% aqueous solution) were prepared by dissolving the respective complex powders in KCl 20% aqueous solution and NaCl 20% aqueous solution and heating at 40 ° C. for 120 minutes.

To 1 liquid maintained at 38 ° C. and pH 4.5, 90% of the 2 and 3 liquids were simultaneously added over 20 minutes with stirring to form 0.16 μm core particles. Subsequently, the following 4th and 5th liquids were added over 8 minutes, and the remaining 10% of the 2nd and 3rd liquids were added over 2 minutes to grow to 0.21 μm. Further, 0.15 g of potassium iodide was added and ripened for 5 minutes to complete grain formation.
・ 4 liquids:
100mL water
Silver nitrate 50g
・ 5 liquids:
100mL water
Sodium chloride 13g
Potassium bromide 11g
Yellow blood salt 5mg
Then, it washed with water by the flocculation method according to a conventional method. Specifically, the temperature was lowered to 35 ° C., and the pH was lowered using sulfuric acid until the silver halide precipitated (the pH was in the range of 3.6 ± 0.2). Next, about 3 liters of the supernatant was removed (first water washing). Further, 3 liters of distilled water was added, and sulfuric acid was added until the silver halide settled. Again, 3 liters of the supernatant was removed (second water wash). The same operation as the second water washing was further repeated once (third water washing) to complete the water washing / desalting process. The emulsion after washing and desalting was adjusted to pH 6.4 and pAg 7.5, 100 mg of 1,3,3a, 7-tetraazaindene as a stabilizer, and Proxel as a preservative (trade name, manufactured by ICICo., Ltd.) 100 mg was added. Finally, a silver iodochlorobromide cubic grain emulsion containing 70 mol% of silver chloride and 0.08 mol% of silver iodide and having an average grain diameter of 0.22 μm and a coefficient of variation of 9% was obtained. The final emulsion was pH = 6.4, pAg = 7.5, conductivity = 4000 μS / cm, density = 1.4 × 10 ³ kg / m ³ , and viscosity = 20 mPa · s.

[Preparation of emulsion layer coating solution]
The following compound (Cpd-1) 8.0 × 10 ⁻⁴ mol / mol Ag, 1,3,3a, 7-tetraazaindene 1.2 × 10 ⁻⁴ mol / mol Ag was added to the above emulsion and mixed well. . Next, the following compound (Cpd-2) was added as necessary to adjust the swelling ratio, and the coating solution pH was adjusted to 5.6 using citric acid.

[Support]
As the support 52, a PET film having a thickness of 100 μm subjected to corona discharge treatment on both surfaces and subjected to surface hydrophilization treatment was used.

[Preparation of photosensitive film]
Corona discharge treated PET film described above and applied so that the emulsion layer coating solution Ag7.8g / ^{m 2,} gelatin 1.0 g / ^{m 2.}
The resulting photosensitive film had an emulsion layer silver / binder volume ratio (silver / GEL ratio (vol)) of 1/1.

[Exposure and development processing]
Next, a grid-like photomask line / space = 290 μm / 10 μm (pitch: 300 μm) that can give a developed silver image of line / space = 10 μm / 290 μm to the above-mentioned photosensitive film, the space is a grid, and the mesh shape and electrical It exposed using the parallel light which used the high pressure mercury lamp as the light source through the photomask which has the pattern shape of the shape where the shape of the insulation part 64 united. Here, the shape of the electrical insulating portion 64 (64a, 64b, 64c) corresponds to the shape of the bent region 13 (13a, 13b, 13c) of the toilet seat surface 12a of the toilet seat 11 shown in FIG. At this time, exposure for forming an electrode, that is, strip-shaped exposure with a constant width along one side was also performed. Then, the process including the process of fixing, washing with water, and drying was performed.

(Developer composition)
The following compounds are contained in 1 liter of developer.
Hydroquinone 15g / L
Sodium sulfite 30g / L
Potassium carbonate 40g / L
Ethylenediamine ・ tetraacetic acid 2g / L
Potassium bromide 3g / L
Polyethylene glycol 2000 1g / L
Potassium hydroxide 4g / L
Adjust to pH 10.5 (fixing solution composition)
The following compounds are contained in 1 liter of the fixing solution.
300 ml of ammonium thiosulfate (75%)
Ammonium sulfite monohydrate 25g / L
1,3-Diaminopropane ・ tetraacetic acid 8g / L
Acetic acid 5g / L
Ammonia water (27%) 1g / L
Potassium iodide 2g / L
Adjust to pH 6.2

Through the above steps, a planar film heater 50 having mesh-like fine metal wires made of developed silver and gelatin was obtained. The thickness of the fine metal wire is 0.2 μm, the width of the fine metal wire is 10 μm, the mesh shape is square, and the pitch is 300 μm. Further, the surface resistance value of the sheet film heater 50 is 25 ohm / sq. Met.

As shown in FIG. 10 (A), the sheet film heater 50 was cut out in accordance with the shape of the toilet seat 11 shown in FIG.
The sheet film heater 50 of Sample 1 obtained in this way is formed and processed into the shape of the toilet seat 11 shown in FIG. 1, and the electrically insulating portions 64 (64 a, 64 b, 64 c) of the sheet film heater 50 are formed on the toilet seat 11. The heating toilet seat of Example 1 was manufactured so as to correspond to the bent region 13 (13a, 13b, 13c) of the toilet seat surface 12a.

Next, in the exposure process for the photosensitive film of Example 1, as shown in FIG. 10B, an electrically insulating portion 84 (not corresponding to the bent region 13 (13a, 13b, 13c) of the toilet seat 11 shown in FIG. 84a, 84b, and 84c) are exposed to light using a mask having a pattern shape in which the shapes are combined, and then developed to obtain a planar film heater. Further, the shape of the toilet seat 11 shown in FIG. Sample A was cut out according to the above.

The sheet film heater of Sample A was molded into the shape of the toilet seat 11 and placed on the toilet seat 11 shown in FIG. 1 to produce a heating toilet seat of Comparative Example 1.
The planar film heater of Sample A is divided into

regions

86a, 86b, 86c, and 86d by an electrically insulating portion 84 as shown in FIG. In each of the

regions

86a, 86b, 86c, and 86d, an electrode 56 for supplying heater power is provided.
In addition, the electrical insulation part 84 (84a, 84b, 84c) is not arrange | positioned so as to correspond to the bending area | region 13 (13a, 13b, 13c) used as the curvature radius of the toilet seat 11 shown in FIG.

In addition, the cross-sectional shape of the insulating part of the planar film heater of Example 1 and Comparative Example 1 is as shown in FIG. 4A, and the width of the insulating part of the planar film heater before molding is 1 mm. It is said. Moreover, what used the sample 2 which comprised the insulation part of Example 1 as shown in the above-mentioned FIG.4 (B) is set as Example 2, and the insulation part of Example 1 is shown in the above-mentioned FIG.4 (C). A sample 3 having the above-described configuration was used as Example 3. Moreover, in Example 3, the length of the disconnection of the metal mesh in the insulating part of the planar film heater before forming was set to 15 μm.

The molding conditions for molding the planar film heater used in Examples 1 to 3 and Comparative Example 1 were as follows. The planar film heater was molded at a molding temperature of 80 ° C., a load of 50 kg / cm ² , and a stretching rate of 110%. Matched the shape of the mold. Then, the sheet film heater after molding was bonded to the toilet seat surface of the toilet seat with an adhesive (OCA: Optical Clear Adhesive), and the heated toilet seats of Examples 1 to 3 and Comparative Example 1 were manufactured.
The heating toilet seat is individually connected to a heater driving unit (power supply unit) for each region through the electrode 56, and the heater driving unit is individually controlled by the heat generation control unit.

In the durability test, an infrared thermography device InfRec R300SR (Nippon Avionics) was used to determine the initial heat distribution before rubbing the surface of the heated toilet seat with cloth and the heat distribution after rubbing the surface of the heated toilet seat 100 times with cloth (heat distribution after the durability test). ). In the measurement of the initial heat generation distribution, adjustment was made by the heat generation control unit in order to make the heat generation distribution uniform. However, the measurement of the heat generation distribution after the endurance test was performed when the initial heat generation distribution was measured. The adjustment was performed by the heat generation control unit.
The measured heat generation distribution was evaluated as A to D as follows. Table 1 below summarizes the results.
A: Temperature distribution is within ± 2 ° C (good)
B: Temperature distribution exceeds ± 2 ° C and within ± 5 ° C (no problem)
C: Temperature distribution exceeds ± 5 ° C and within ± 10 ° C (somewhat problematic)
D: Does not generate heat (problems)

As shown in Table 1, in Comparative Example 1, the evaluation of the initial heat generation distribution was A at the initial stage before the endurance test, but the evaluation of the heat generation distribution was C after the endurance test. In Examples 1 to 3 according to the present invention, the evaluation of the initial heat generation distribution before the endurance test was A, and the heat generation distribution evaluation B or higher was maintained even after the endurance test. In Example 1, as in Example 3, the evaluation of the heat generation distribution is all A, but since the appearance of the insulating portion is conspicuous, Example 3 is most preferable.

In addition, the molding conditions of Examples 1 to 3 and Comparative Example 1 described above were changed, and moldings were performed under the molding conditions of a molding temperature of 110 ° C., a load of 50 kg / cm ² , and a stretch ratio of 140%. The same durability test as in Examples 1 to 3 and Comparative Example 1 was conducted as Comparative Example 2, and the heat generation distribution was evaluated before and after the durability test.
Table 2 below summarizes the results.

As shown in Table 2, in Comparative Example 2, the evaluation was D in both the initial heat distribution before the endurance test and the heat generation distribution after the endurance test, but in Examples 4 to 6 according to the present invention, the endurance test was performed. All of the previous evaluations of the initial heat generation distribution were A, and the evaluation of the heat generation distribution maintained B or more even after the endurance test. As in the case of Table 1, Example 4 is a heat generation distribution evaluation A as in Example 6, but Example 6 is the most preferable because the appearance of the insulating portion is conspicuous.

As described above, according to Examples 1 to 6 of the present invention, it can be understood that unevenness of heat generation caused by disconnection can be prevented by previously setting an insulating region in a portion where disconnection is likely to occur during three-dimensional forming.
From the above, the effect of the present invention is clear.

DESCRIPTION OF SYMBOLS 1 Heating toilet seat, 2 Main part, 11, 111 Toilet seat, 12, 50, 112 Planar film heater, 12a Toilet seat surface, 13 Bending area, 14 Outer peripheral part, 14a Outer peripheral area, 15 Central part, 15a Central area, 16 Inner circumference Part, 16a inner circumference area,
17 rear part, 17a rear region, 18, 64 electrical insulation part, 21 operation part,
22 Human Body Detection Sensor, 23 Temperature Sensor, 24 Heater Drive Unit (Power Supply Unit), 25 Seat Sensor, 26 Heat Generation Control Unit, 31 Support, 32 Mesh-shaped Metallic Wire, 33 Adhesive, 34 Opening, 35 Heat Transfer Material , 50 sheet film heater,
56 electrodes, 113 bends.

Claims

A heating appliance comprising a structure and a planar film heater having a mesh-like fine metal wire disposed on the surface of the structure,
The surface of the structure includes a bent region having a radius of curvature of 50 mm or less, a plurality of curved surfaces having a radius of curvature greater than 50 mm divided by the bent region, and / or a plane.
The heating apparatus according to claim 1, wherein the planar film heater is divided into a plurality of portions by an insulating portion corresponding to the bent region of the structure, and is arranged on each of the plurality of curved surfaces and / or planes.
The heating appliance according to claim 1, wherein a radius of curvature of the bent region is 40 mm or less.
The heating apparatus according to claim 1 or 2, wherein the plurality of portions of the planar film heater are independently supplied with electric power.
A heat generation control unit for controlling heat generation of the planar film heater;
The heating apparatus according to any one of claims 1 to 3, wherein the heat generation control unit independently controls the plurality of portions of the planar film heater.
The heating apparatus according to claim 4, wherein the heat generation control unit supplies power according to a surface area of the plurality of portions of the planar film heater.
The heating apparatus according to any one of claims 1 to 5, wherein the insulating portion is formed by disconnecting the mesh-like fine metal wires with a predetermined width.
The heating apparatus according to any one of claims 1 to 6, wherein a width of the insulating portion is 0.1 mm or more and 10 mm or less.
The heating apparatus according to any one of claims 1 to 7, wherein the mesh-shaped fine metal wire is composed of metal fine particles and a binder.
A heating toilet seat comprising a toilet seat and a planar film heater having a mesh-like fine metal wire disposed on the surface,
The surface of the toilet seat includes a bent region having a radius of curvature of 50 mm or less and an inner peripheral region, a central region, an outer peripheral region, and a back region having a radius of curvature greater than 50 mm divided by the bent region,
The sheet film heater is divided into an inner peripheral portion, a central portion, an outer peripheral portion, and a back portion by an insulating portion corresponding to the bent region of the toilet seat, and the inner peripheral region, the central region, and the outer peripheral portion of the toilet seat. A heating toilet seat, which is disposed in each of the region and the back region.
The heating toilet seat according to claim 9, wherein a radius of curvature of the bent region is 40 mm or less.
The heating toilet seat according to claim 9 or 10, wherein the central portion, the inner peripheral portion, the outer peripheral portion, and the rear portion of the sheet film heater are independently supplied with electric power.
A heat generation control unit for controlling heat generation of the planar film heater;
12. The heat generation control unit controls the central part, the inner peripheral part, the outer peripheral part, and the rear part of the sheet film heater independently of each other. Heated toilet seat as described in
The said heat generation control part supplies electric power according to each surface area of the said center part, the said inner peripheral part, the said outer peripheral part, and the said back part of the said planar film heater, It is characterized by the above-mentioned. Heated toilet seat.
The heating toilet seat according to any one of claims 9 to 13, wherein the insulating portion of the planar film heater is formed by disconnecting the fine metal wire in a predetermined width.
The heating toilet seat according to any one of claims 9 to 14, wherein a width of the insulating portion is 0.1 mm or more and 10 mm or less.
The heating toilet seat according to any one of claims 9 to 15, wherein the mesh-shaped fine metal wire is composed of metal fine particles and a binder.