JPH0654708B2 - Surface heating element - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial field of application) The present invention provides a heating element, a temperature sensor for temperature detection, and an electrode to be electrically connected to the heating element and the temperature sensor collectively by an ordinary weaving means. It can be woven, has flexibility,
In addition, the present invention relates to a structure of a surface heating element that allows continuous and consistent weaving without feeling unevenness.

(Prior Art) A surface heating element manufactured by conventional weaving generally has a heating element and an electrode woven therein, and a temperature sensor (a linear sensor that detects the temperature of the heating element becomes linear. Since it cannot be woven at the same time, it is attached to the surface heating element in a later process, and it takes a lot of man-hours and the surface heating element itself has a thick structure to eliminate the feeling of stiffness due to the temperature sensor. In addition to being heavy, it has the drawbacks of high cost and reduced heating efficiency.

From such a point, as disclosed in Japanese Utility Model Application Laid-Open No. 54-159449, a surface heating element has been proposed in which a heat-sensitive wire serving as a temperature sensor is woven during the weaving process.

In the above-mentioned known technique, a flexible structure is formed by arranging electrodes, in which a plurality of conductive wires are woven, at opposite end portions of a woven fabric so as to face each other, applying a conductive coating to the woven fabric, and covering the whole with an insulating coating. In the surface heating element having, the heat-sensitive wire covered with an insulating material is woven at a constant interval together with the conductive wire when the woven cloth is woven.

(Problems to be Solved by the Invention) What is disclosed in the above publication is that the heat-sensitive wire has glass fiber or the like as a core, and a bimetal fine wire is wound around the core, and further, the outer periphery is made of flexible rubber or plastic. It is shown that a yarn which can be woven is formed by being covered with an insulator, and the yarn is woven as a weft yarn and / or a warp yarn.

Since the above-mentioned heat-sensitive wire is obviously the outer shape of the insulator, it is necessary to remove the covering member to make electrical contact when connecting to the resistance detection circuit. Only the content that it will be integrated into the temperature control is described, the detailed structure is unknown, there is no speculation about specific means, it is lacking in practicality, and it will be a completed device Has the drawback that it still requires complicated processing steps.

Therefore, in the present invention, the temperature sensor can be woven in the same manner as the insulating thread in the process of weaving, and the temperature sensor is electrically connected to the flexible electrode provided in the inner layer of the woven material separately from the heating element. The purpose of this is to provide a surface heating element that allows all the steps to be performed all at once and can be continuously and consistently woven. Thus, it is possible to finish it into a thin sheet with great flexibility, and further It is an object of the invention to facilitate the assembling with a controller and play a part in popularizing a product suitable for practical use.

(Means for Solving the Problems) In order to achieve the above object sufficiently, the specific invention of claim 1 is such that the conductive wire (2) for the heating element alternates with the insulating thread (1). Alternatively, several thin tape-shaped temperature sensors (3) are interposed between the insulating threads (1) and conductive wires (2) are arranged.
On the other hand, a plurality of conductive yarns (5) are arranged next to each other in a warp group consisting of a plurality of warp yarns arranged at wide intervals of a large number and a large number of insulating yarns (4) woven into this warp group. A heating element electrode (6) and a sensor electrode (7) that have electrodes formed by weaving them into the warp group, and these electrodes are at a predetermined distance from each other (6) and (7). Electrodes that are separated by existing
The temperature sensor (3) sandwiches the heat-sensitive resin film (9), and the one side surface is narrower than the film. Conductive film (10)
The other side has a triple layer structure in which conductive tapes (11) each having the same width and a resistance equal to or higher than that of the conductive wire (2) are attached to the other side surface, and the heating element electrode (6) And dual-purpose electrode (8)
Each conductive thread (5) is woven into the warp group without contacting the conductive tape (11) and the conductive film (10), while the conductive thread of the sensor electrode (7) (5) and a plurality of insulating yarns (4) before and after it are woven, a conductive texture (5) and several insulating yarns (4) before and after the temperature sensor (3)
And a part of the insulating thread (1) dispersed, the conductive film (1
0) and the conductive tape (11) is woven without touching, and the remaining insulating thread
(4) is formed into a double-layer hollow weave having the conductive wire (2) and the other woven layer (13) woven into the remaining insulating yarn (1), and both woven layers (12) , (13) with a thin insulating sheet (14) interposed.

Further, in the related invention of claim 2, the conductive wire (2) for the heating element is arranged alternately or every several wires with respect to the insulating thread (1), and the narrow tape-shaped temperature sensor (3) is the insulating thread. (1) A plurality of warp yarns arranged between the conductive wires (2) with a wide interval between the conductive wires (2) and a large number of insulating yarns woven into the warp yarn group ( In (4), a heating element electrode (6) and a sensor electrode (7) formed by weaving a plurality of conductive threads (5) into the warp group are arranged so that both electrodes (6) and (7) are close to each other. However, each of the electrodes (6) or (7) is composed of a weft group having a set of four electrodes which are arranged so as to be separated at a predetermined interval, and the temperature sensor (3) is a thermosensitive resin film ( Both electrodes (6), which are close to each other, have a triple-layer structure in which conductive films (10) having a width narrower than that of the film (9) are pasted on both sides of the film (9).
Conductive yarn (5) in (7) and multiple insulating yarns before and after it
The woven structure part in which (4) is woven is the conductive wire (5) of the heating element electrode (6) and part of the insulating thread (4) as the conductive wire (2) and part of the insulating thread (1). One of the weaving layers (13) woven with respect to each other, the conductive thread (5) of the sensor electrode (7) and the remaining insulating thread (4) are connected to the temperature sensor (3) and the remaining insulating thread (1). Against
One of the two sensor electrodes (7) (7)
The conductive thread (5) and the remaining insulating thread (4) of the temperature sensor (3) should be in contact with the conductive film (10) on one side of the temperature sensor (3) and the conductive film (10) on the opposite side of the temperature sensor (3). However, the conductive thread (5) and the remaining insulating thread (4) of the other sensor electrode (7) contact the conductive film (10) on the opposite side of the temperature sensor (3), and the temperature sensor (3) A double-layer hollow weave having the other conductive layer (12) woven without coming into contact with the conductive film (10) on one side, and between the two conductive layers (12) and (13). Thin insulation sheet (1
It is characterized in that it is configured by interposing 4).

(Function) In the present invention, the insulating yarn (1), the conductive wire (2), and the temperature sensor (3) are used as warp yarns, and the insulating yarn (4) and the conductive yarn (5) are provided as weft yarns, and plain weave, twill weave and the like are provided. Each electrode (6) which does not cause any electrical interference between each other by performing the weaving of the double bag weave, especially in the electrode part, by the process of weaving the double bag weave combination only, (7) Weaving and conductive wire
(2), temperature sensor (3) can now be connected.

Therefore, when connecting to the controller,
It suffices to connect a conductor to the ear end of (6), (7), and (8).

Further, the temperature sensor (3) has a thin and narrow triple-layer tape structure, so that selective connection with the electrodes is possible.

Further, according to the invention of claim 1, since the combined electrode (8) is formed, the number of electrodes in the surface heating element is small and the number of bag-weaving portions is also small. Therefore, the weaving process is simplified and the improvement of the production efficiency is achieved. Will be fulfilled.

On the other hand, in the invention of claim 2, since the heating element and the temperature sensor have their own electrodes (6) and (7) respectively, the same weaving pattern may be repeated. It is possible to design the circuit under the best conditions for each.

Note that the heating element electrode (6) and the sensor electrode (7) that are close to each other may be provided so as to overlap with each other with the insulating sheet (14) interposed, but they are arranged so as to have an appropriate interval therebetween. In this case, the surface heating element is finished thinner, and the insulating sheet (14)
Is preferable in that it is less likely to receive external stress and leads to improvement in strength reliability.

(Example) Hereinafter, an example of the present invention is described based on an accompanying drawing.

FIG. 1 is a schematic organization diagram of weaving according to an embodiment of the invention of claim 1, wherein a warp group and a weft group are woven in a plain weave in most of the sheet form, and the warp group is a polyethylene flat. Conductive wires (2) for heating elements, which are thin and thin tape-shaped and are made of a composite material of tetrafluoroethylene resin and conductive carbon, are alternately or alternately placed on the insulating thread (1) such as yarn. A narrow tape-shaped temperature sensor (3) is arranged between the insulating threads (1) and (1), and there is a wide gap between the conductive wires (2). And a plurality of them are arranged.
(2) and the temperature sensor (3) instead of the conductive wire (2) for every 10 wires so that one conductive wire (2) is arranged every two insulating threads (1). Examples include those arranged.

The temperature sensor (3) is in the form of a narrow tape having a triple-layer structure as shown in the enlarged sectional view of FIG.
A heat-sensitive resin film (9) of a narrow tape, for example, a nylon film having a width of 5 mm and a thickness of 0.2 mm is sandwiched, and a conductive film (10) having a width narrower than that of the film (9) on one side, for example, a width. 2m
A metal foil made of aluminum or copper with a thickness of 0.1 mm and a thickness of 0.1 mm is attached so that the width centers are aligned, and the surface on the other side is also narrow and has a resistance equal to or higher than that of the conductive wire (2). A conductive tape (11), for example, a tetrafluoroethylene resin-conductive carbon composite tape having a width of 2 mm and a thickness of several tens of microns is adhered so that the width centers thereof are aligned to form a three-layer structure tape.

The conductive film (10) was replaced with a conductive tape (1
It is also possible to use the same tape as in 1).

The temperature sensor (3) having such a structure is highly flexible and easy to be woven, and has a volume resistivity (Ω · cm) of, for example, 407 at 20 ° C and 35 at 50 ° C.
And has a temperature-resistance characteristic that changes in inverse proportion to the temperature.

Next, regarding the weft yarn group, the insulating yarn (1) woven into the warp yarn group is mainly composed of, for example, a polyethylene flat yarn, and in the insulating yarn (1), a plurality of conductive yarns (5), for example, core yarns are used. Band-shaped electrodes (6) made by weaving copper foil yarns obtained by spirally winding copper foils side by side into the warp group,
(7) and (8) have 3 strips per unit area of heating element, and when the warp group is cut into a predetermined length to form one to three mats, one side of the warp group is cut. There are two rows of electrodes, one for the heating element (6) and one for the sensor (7), which are close to each other at a position close to the edge, and have a single row at the position near the other cutting edge. It has electrodes (8).

Among these electrodes (6), (7), (8), the heating element electrode (6) and the shared electrode (8) are the insulating yarn (1), the conductive wire (2) and the temperature of the warp group. By interlacing the sensor (3) with a series of twills, for example, each conductive wire (2) and each temperature sensor
The contact is made with the conductive tape (11) of (3) and not with the conductive film (10).

In this case, since the entire surface of the conductive wire (2) is a conductive portion, it is easy to make contact with each other by simply entangling the conductive threads (5), while the temperature sensor forming a triple layer tape ( For 3), the weaving pattern of the conductive yarn (5) which is a weft yarn is set from the fact that the arrangement mode of the sensor (3) and the surface on which the conductive tape (11) is present are determined in advance. As a result, it is an easy means to scan the conductive thread (5) so that it contacts the conductive tape (11) and does not contact the conductive film (10). Figure,
It is shown in FIGS. 5 and 6.

Next, regarding the sensor electrode (7), as is clear from the nature, it is required that the conductive wire (2) is electrically disconnected and the temperature sensor (3) is electrically connected. Therefore, weaving of this part requires a special form.

Therefore, as shown in Fig. 7, the sensor electrode (7)
The textured part in which the plurality of conductive yarns (5) that form the above and the plurality of insulating yarns (4) before and after that are woven together are formed into a double-layer hollow weave as a whole, and the insulating yarn (1 )
Of the dispersed parts, for example, half of the insulating thread (1) and the temperature sensor (3) that fly every other pair are used as the first group, and the remaining half of the insulating thread (1) and the conductive wire (2 ) And the second group, while
On the weft side, the conductive yarn (5) and several insulating yarns (4) arranged in front of and behind it are not included in the first group.
The remaining insulating yarns (4) to be lined up in front of and behind the group are made into the second group, and the warp first group and the weft first group and the warp second group and the weft second group are entangled and woven. .

In this case, when the weft first group is woven into the warp first group, the temperature sensor (3) is in contact with the surface side where the conductive film (10) is present, and is not in contact with the surface side where the conductive tape (11) is present. like,
It is a requirement that the conductive yarn (5) and the insulating yarn (4) are scanned, and other weaving conditions may adopt ordinary plain weaving or twill weaving means. The other weave layer (13) is formed by weaving the second group of the other weave layers (12), and this portion has a double-layer bag weave structure.

In addition, in each of the electrodes (6), (7), (8), several insulating yarns (4) arranged in front of and behind them are replaced with polyethylene flat yarns, for example, fine yarns such as staple fiber spun yarns. It is preferable to use it as a reinforcing yarn row layer for fixing the position of the conductive yarn (5) forming each electrode so that the bundle of the conductive yarn (5) does not move or shift.

As described above, most of the single weave parts and the sensor electrode (7)
It is possible to continuously weave the existing double weaving section using a loom, and, in the step immediately following the weaving step, perform double-layer bag weaving by manual work or mechanized automatic work. Between the two woven layers (12) and (13) formed, a thin insulating sheet (1
By inserting 4) from the side, a continuous woven surface heating element is obtained.

The surface heating unit is formed by cutting the surface heating element in the weaving direction between the location where both electrodes (6) and (7) are present close to each other and the location where the dual-purpose electrode (8) is present. Thus, as shown in FIG. 3, the heating element electrode (6) and the combined use electrode (8)
For and, a plurality of conductive wires (2) and a plurality of conductive tapes (11) having resistance are connected in parallel,
With respect to (7) and the combined-use electrode (8), a high-resistivity thermosensitive resin film (9) is provided via each conductive film (10) and each conductive tape (11).
Since a plurality of are connected in parallel, the heat generating circuit and the temperature detecting circuit can be woven so that there is no electrical interference between them.

Next, FIG. 2 is a schematic structure diagram of weaving according to the embodiment of the invention of claim 2, and the constituent elements in the warp group and the weft group are basically the same as those in the example shown in FIG. However, in one unit of the surface heating element, the number of electrodes in the example shown in FIG. 1 is three, whereas in this example, there are a total of four, one pair for each two, and a double layer bag. Weaving point and temperature sensor
There is a difference in the structure of (3).

First, the temperature sensor (3) has a triple-layer structure, and a conductive film (1
0) is attached with the width centers aligned, and the conductive film (10) may be a conductor having a resistance of zero or a conductor having a resistance equal to or higher than that of the low resistance conductive wire (2).

On the other hand, regarding the four-row electrode, the heating element electrode (6) and the sensor electrode (7) have a structure in which they are in close proximity to each other and are separated by a predetermined distance. There is a tissue part in which conductive threads (5) that form electrodes and electrodes (6) and (7) that are close to each other and are formed as a set, and a plurality of insulating threads (4) that are lined up between them and before and after are interwoven. Is formed as a double-layered hollow weave as a whole, and on the warp side, half the insulating thread (1) and the temperature sensor (3) are used as in the example shown in FIG.
And the first group, the other half of the insulation thread (1) and conductive wire (2)
On the other hand, on the weft side, on the other hand, the conductive thread (5) forming the sensor electrode (7) and several insulating threads (4) arranged before and after it are not included in the first group. , Also, electrodes for heating element
The conductive yarn (5) forming (6) and several insulating yarns (4) arranged in front of and behind it are included in the second group, and the remaining insulating yarns
Divide (4) appropriately into two groups, and divide into the first group and the second group,
The first warp group and the first weft group, and the second warp group and the second weft group are entangled and woven.

In this case, when the weft first group is woven into the warp first group, on the other hand, for example, the left side in FIG. 4 is brought into contact with the conductive film (10) on one side of each temperature sensor (3). , Conductive thread (5) so as not to contact the conductive film (10) on the opposite side,
It is necessary to scan the insulating thread (4). On the other hand, for example, in the case of the right side in FIG. 4, one side is in contact with the conductive film (10) on the opposite side of each temperature sensor (3). It is necessary to scan the yarns (4) and (5) so that they do not come into contact with the conductive film (10), and for other weaving conditions, ordinary plain weave or twill weave means may be adopted. Thus, one weave layer (12) is formed by weaving the first group, and another weave layer (13) is formed by weaving the second group, and this portion becomes a double layer bag weave structure (Fig. 8 and (See FIG. 9).

The point that the insulating sheet (14) is inserted between both the weaving layers (12) and (13) of this bag-weaving structure is the same as the example shown in FIG.

Thus, as shown in FIG. 4, the opposing heating element electrodes
For (6) and (6), a plurality of conductive wires (2) are connected in parallel, while for the opposing sensor electrodes (7) and (7), each conductive film (10) is connected. ) Through high resistance thermosensitive resin film
Since a plurality of (9) are connected in parallel, the heat generating circuit and the temperature detecting circuit can be woven so that they are electrically independent from each other.

Each surface heating element described above, the temperature sensor (3) is disposed in a distributed manner, because the heating element consisting of the conductive wire (2) detects the average temperature when heat is generated as a resistance change, The temperature sensor (3) can be used as a temperature detecting element to automatically and stably perform constant control of the temperature of the heating element.

(Advantages of the Invention) The present invention forms a temperature sensor (3) in the form of a thin and thin triple-layered flexible tape and simultaneously weaves it at the time of weaving the surface heating element, so that an uneven feeling is obtained. As a result, the final finished product of the surface heating element can be formed into a thin structure without any element, and as a result, an inexpensive and sufficiently high heating performance can be obtained.

Furthermore, when the electrodes (6), (7) and (8) are formed by weaving the conductive thread (5), the temperature sensor (3) separates the conductive portions on both sides of the thermosensitive resin film (9). Since it has a structure, it is possible to select the conductive part on any surface by weaving and make it contact with the conductive thread (5). Moreover, this electrode forming part is made into a double layer bag weave and the insulating sheet (1
By interposing 4), it becomes possible to insulate the electrodes from the conductive wire (2) and the temperature sensor (3) and cross them.
Therefore, it is possible to independently form the heating element circuit and the temperature detection circuit so as not to cause interference, while processing the heating section, the temperature detection section, and the electrode section collectively in the weaving process.

The present invention also provides continuous production of long products by weaving,
It is possible to obtain a completed surface heating element of the required size simply by cutting a predetermined part in the weaving width direction and inserting the insulating sheet (14) into the bag weaving part, which has never been possible before. It is noted that this is an epoch-making excellent effect in that the productivity improvement by continuous weaving can be solved.

Further, according to claim 1, since the heating element and the temperature sensor (3) are provided with the dual-purpose electrodes (8), the number of electrodes is small, and the number of bag-weaving portions is also small, which simplifies the weaving process. It is also possible to obtain low cost products with good productivity.

Further, according to claim 2, the heating element and the temperature sensor (3) have their own electrodes (6) and (7) respectively, and since the same weaving pattern can be repeated, weaving is performed in an orderly manner. Not only is it expected that the quality will be improved, but there are no restrictions on the temperature sensor and the heating element, and it is possible to design the circuit under the best conditions.

[Brief description of drawings]

FIGS. 1 and 2 are partially omitted weaving design diagrams according to the respective embodiments of the present invention, FIGS. 3 and 4 are conceptual structural diagrams corresponding to FIGS. 1 and 2, and FIG. FIGS. 7 to 7 are organization charts showing enlarged cross sections along line VV, VI-VI and VII-VII in FIG. 3, and FIGS. 8 and 9 are VIII in FIG.
-VIII and IX-IX line enlarged sectional view organization chart, No. 10
The drawing is an enlarged sectional view showing the temperature sensor in FIGS. 1 and 2. (1) …… Insulation thread, (2) …… Conductive wire, (3) …… Temperature sensor, (4) …… Insulation thread, (5) …… Conductive thread, (6) …… Heating element electrode, (7) …… Sensor electrode, (8) …… Common electrode, (9) …… Heat sensitive resin film, (10) …… Conductive film, (11) …… Conductive tape, (12), (13)… … Woven layer, (14) …… Insulation sheet.

Claims (2)

[Claims] 1. A conductive tape (2) for a heating element is arranged alternately or every several wires with respect to an insulating thread (1), and a narrow tape-shaped temperature sensor (3) is provided between the insulating threads (1). A plurality of intervening warp yarns that are arranged with a wide space between the conductive wires (2) with a wide interval between them, and a large number of insulating yarns woven into this warp yarn group.
(4) has an electrode formed by weaving a plurality of conductive yarns (5) adjacent to each other in the warp group, and a heating element electrode (6) and a sensor electrode (7) that are close to each other. ), And a dual-purpose electrode that is separated from both electrodes (6) and (7) at a predetermined interval.
The temperature sensor (3) sandwiches the heat-sensitive resin film (9), and the one side surface is narrower than the film. Conductive film (10)
The other side has a triple layer structure in which conductive tapes (11) each having the same width and a resistance equal to or higher than that of the conductive wire (2) are attached to the other side surface, and the heating element electrode (6) And dual-purpose electrode (8)
Is that each conductive thread (5) contacts the conductive tape (11),
Woven structure in which the conductive thread (5) of the sensor electrode (7) and a plurality of insulating threads (4) before and after the conductive thread (5) are woven without being in contact with the conductive film (10). The part is composed of a conductive thread (5) and several insulating threads (4) before and after the temperature sensor.
(3) and a part of the dispersed insulating thread (1), the conductive film
One of the weaving layers (12) which is in contact with the conductive tape (11) but does not contact with the conductive tape (11) and the remaining insulating thread (4) are connected to the conductive wire (2) and the remaining portion. A double-layer hollow weave having the other woven layer (13) woven into the insulating thread (1) is formed, and a thin insulating sheet (14) is provided between the two woven layers (12) and (13). A surface heating element characterized in that it is made to interpose. 2. A conductive tape (2) for a heating element is arranged alternately or every several wires with respect to the insulating thread (1), and a narrow tape-shaped temperature sensor (3) is provided between the insulating threads (1). A plurality of intervening warp yarns that are arranged with a wide space between the conductive wires (2) with a wide interval between them, and a large number of insulating yarns woven into this warp yarn group.
In (4), a heating element electrode (6) and a sensor electrode (7) formed by weaving a plurality of conductive threads (5) into the warp group are used as a heating element electrode (6) and a sensor electrode. (7) are close to each other, and the electrodes for heating element (6), (6) and the electrodes for sensor (7), (7) are a set of four electrodes arranged so as to be separated from each other at a predetermined interval. The temperature sensor (3) is composed of a weft yarn group, and a triple conductive film (10) having a width narrower than that of the film (9) is sandwiched between the thermosensitive resin films (9). A heating element electrode (6) and a sensor electrode (7) that have a layered structure and are close to each other
The conductive thread (5) and a plurality of insulating threads (4) before and after it are woven to form a conductive thread of the heating element electrode (6).
One woven layer (1) obtained by weaving (5) and part of the insulating thread (4) into the conductive wire (2) and part of the dispersed insulating thread (1).
3), and the conductive thread (5) and the remaining insulating thread (4) of the two sensor electrodes (7) provided at a predetermined interval with respect to the temperature sensor (3) and the remaining insulating thread (1), Of the two sensor electrodes (7), the conductive thread (5) of one of the sensor electrodes (7) contacts the conductive film (10) on one side of the temperature sensor (3) and the other side of the temperature sensor (3) The conductive thread (5) of the other sensor electrode (7) contacts the conductive film (10) on the opposite side of the temperature sensor (3) without contacting the conductive film (10) of the temperature sensor (3). ) And a woven layer (12) of the other side which is woven without coming into contact with the conductive film (10) on one side of the conductive layer (10) and is formed into a double-layer bag weave, and both woven layers (1)
A surface heating element characterized in that a thin insulating sheet (14) is interposed between (2) and (13).