JPH11214131A - Sheet heater and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To properly manufacture a length and shape of a surface heater element and to uniformize the thickness of the conductive coating material and distribution of temperature by sewing in plural metallic fibers on both ends of a sheet prepared by making the cloth impregnated with a conductive resin agent such carbon or the like, for an electrode. SOLUTION: In a surface heater element, the conductive fiber threads 3 such as a copper fine wire or the like are sewn in onto the cloth 1 impregnated with a conductive resin agent 2 at desired intervals by a multi-needle flat sewing machine to be used as an electrode. On this occasion, the desired interval is the length corresponding to the object applied with the sheet heating element, and the conductive fiber thread 3 is sewn in adjacent to a part to be cut to be used as the electrode. The sheet heating element of the desired length can be obtained by cutting the cloth from the part adjacent to the electrode. Then one side of the conductive fiber thread 3 brought out from the upper and lower edge parts are twisted to be used as a connection terminal 3a to a power source. The sheet heating element excluding a part of the connection terminal 3a, is sealed and accommodated by an insulating resin sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet heating element in which electrodes are formed on both sides of a sheet coated with a conductive resin agent, the sheet heating element having a size that can be freely manufactured, and the sheet heating element. It relates to a manufacturing method.

[0002]

2. Description of the Related Art A conventional example in which electrodes are formed on both sides of a sheet coated with a conductive resin material and a heating state is established by connecting a power source to the electrodes is disclosed in Japanese Utility Model Application No. 1-146336 (registered utility model). No. 2,527,796). this is,
As shown in FIG. 3, both ends of a cloth b composed of a cloth yarn serving as a planar heating element are formed by twisting a composite yarn a obtained by mixing a plurality of metal fiber single yarns and a plurality of cloth single yarns. As a warp or a weft so that the cloth thickness becomes substantially the same, we woven the necessary number to form the width of the electrodes at both ends of the cloth, and after weaving, the conductive paint c was applied to the entire surface of the cloth. Things.

[0003]

By the way, when using a planar heating element, for example, to heat a floor of a building, a frame is assembled on a floor plate, and a space is formed between the frames. A planar heating element is fitted into the heating element, and a finishing material is assembled on the heating element to provide floor heating. The dimensions of the frame differ between the conventional method and the 2 × 4 method. Therefore, in the case where electrodes are formed at both ends of a cloth having a predetermined length, such as a conventional sheet heating element, since there is no degree of freedom in dimension, at least the sheet heating element for a conventional method is used. And two types of planar heating elements for the 2 × 4 method.

[0004] As described above, since the conventional planar heating element has no degree of freedom in dimensions, the same applies even when the above-mentioned building is used for floor heating of a building. There was such a problem. Furthermore, there is a problem that it is impossible to obtain a bend in the electrode portion because the metal thread is used for the fabric structure.

[0005] Further, in a conventional planar heating element, a composite yarn twisted by mixing a plurality of single metal fiber yarns and a plurality of single fabric yarns is woven into a cloth, and thereafter, a conductive paint is formed. Therefore, even if a thin metal fiber yarn is used, since the metal fiber single yarn is inevitably thicker than the cloth yarn constituting the fabric, the electrode portion is thicker than the cloth portion.

When a conductive paint is applied to the entire surface,
At the boundary between the electrode part A and the cloth part B, the thickness of the conductive paint becomes thicker. Therefore, when connected to a power source, the temperature of the part where the conductive paint at the boundary C is thicker becomes higher, and the temperature of the entire surface becomes higher. There was also a problem that the distribution was not uniform.

An object of the present invention is to solve the above-mentioned problems. It is an object of the present invention to make it possible to appropriately manufacture the length and shape of a sheet heating element and to reduce the thickness of a conductive paint. It is an object of the present invention to provide a planar heating element capable of maintaining a uniform and uniform temperature distribution and a method of manufacturing the same.

[0008]

Means for Solving the Problems The sheet heating element of the present invention achieves the above-mentioned object, and the means is provided at both ends of a sheet in which a cloth is impregnated with a conductive resin agent such as carbon. An electrode is formed by sewing a plurality of metal fibers.

Further, the metal fiber is a copper wire,
It is desirable that the metal fibers be sewn with a multi-needle flat sewing machine. Note that one of the electrodes may be a metal fiber and the other may be a fabric thread.

The method for producing a sheet heating element according to the present invention comprises the steps of producing a sheet in which cloth is impregnated with a conductive resin agent such as carbon, and forming a sheet of copper wire or the like which becomes an electrode at desired intervals of the sheet. The method comprises a step of sewing a plurality of metal fibers, and a step of cutting each pair of the plurality of formed electrodes.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for manufacturing a sheet heating element according to the present invention will be described with reference to the drawings. 1A and 1B show a manufacturing process, and FIG. 1A shows a plan view and a sectional view of a normal cloth 1 comprising a warp yarn 1a and a weft yarn 1b, and the length direction is freely set.
(b) is a plan view and a cross-sectional view showing a state in which the cloth 1 is coated with and impregnated with a conductive resin agent 2 such as a carbon-based resin.

(C) is a multi-needle flat stitch sewing machine which is used for a cloth 1 impregnated with a conductive resin material 2 and which is generally used for a cloth 1 such as a thin copper wire having a diameter of about 0.2 mm. FIG. 3A is a plan view of an electrode sewn by a conventional technique (for example, Japanese Utility Model Laid-Open No. 6-46678) and a cross-sectional view of a sewn portion.

[0013] Here, the term "desired intervals" refers to the length of the sheet heating element according to the object to be used.
The length is suitable for floor heating in the × 4 construction method, and a metal fiber single thread 3 is sewn adjacent to a location to be cut to form an electrode.

Then, a sheet-like heating element A having a desired length is obtained by cutting the portion where the electrodes are adjacent to each other. Next, one of the metal fiber single yarns 3 led out from the upper and lower ends is twisted to form a connection terminal 3a to a power supply. The sheet heating element A configured as described above is sealed and accommodated by the insulating resin sheet B except for the connection terminals 3a as shown in FIG.

In the above-described embodiment, a single metal fiber yarn 3 is used as an electrode and both the upper yarn and the lower yarn are used. It may be formed as a single yarn and the other as a fabric yarn.

As the electrode, a single composite yarn having a diameter of about 1.0 mm is used by mixing and twisting three metal fiber single yarns and four fabric single yarns, each of which is a cotton yarn having a count of 20 and a number of 1.75. You may. Further, in the above-described embodiment, the electrode portion is sewn in a straight line. However, when a curved product is manufactured, a sewing method according to the curve may be performed.

[0017]

According to the present invention, as described above, after the conductive resin agent is applied to the cloth and impregnated, the conductive fibers are sewn and the thickness of the conductive resin agent becomes constant.
The temperature distribution over the entire surface of the planar heating element is constant.

Further, since the conductive fiber yarn is sewn after the conductive resin agent is applied to the cloth and impregnated, the length suitable for the object to be used for the cloth impregnated with the long conductive resin agent is used. By sewing and cutting the conductive fiber thread every time, various types of planar heating elements having different lengths can be formed, and a curved electrode can be manufactured freely. This has the effect that various types of planar heating elements can be manufactured at low cost.

[Brief description of the drawings]

1A and 1B are a plan view and a cross-sectional view illustrating a manufacturing process of a sheet heating element of the present invention.

FIG. 2 is a perspective view showing a state in which a sheet heating element is wrapped with an insulating resin sheet.

FIG. 3 is a sectional view of a main part of a conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Cloth 2 Conductive resin agent 3 Conductive fiber yarn 3a Connection terminal

Claims (5)

[Claims] 1. A sheet heating element characterized in that a plurality of metal fibers are sewn at both ends of a sheet in which a cloth is impregnated with a conductive resin agent such as carbon to form electrodes. 2. The planar heating element according to claim 1, wherein said metal fiber is a copper wire. 3. The planar heating element according to claim 1, wherein said metal fibers are sewn by a multi-needle flat sewing machine. 4. The planar heating element according to claim 3, wherein one of the electrodes is a metal fiber and the other is a cloth thread. 5. A step of manufacturing a sheet in which a cloth is impregnated with a conductive resin agent such as carbon, and a step of sewing a plurality of metal fibers such as copper wires serving as electrodes at desired intervals of the sheet.
Cutting a pair of the plurality of formed electrodes.