JPH046149Y2 - - Google Patents

Description

[Detailed explanation of the invention] (Industrial application field) This invention relates to planar heaters such as heated toilet seats and panel heaters. To provide a planar heater that does not cause wire breakage in the body, can reduce the amount of carbon fiber used and the electric power required for heating, and can also prevent electric shock.

(Prior art and its problems) Conventionally, there have been planar heaters constructed by mixing carbon powder or carbon fibers into a plate-shaped synthetic resin molded body, such as Utility Model Publication No. 41-10783 "Heating Element". ,
Special Publication No. 49-19073 "Insulated Conductor Assembly Made of Conductive Polymer Core", Publication No. 35-5038 "Variable Resistor", Publication No. 39-22077 "Insulated Heater Wire"
is specifically exemplified.

In Japanese Utility Model Publication No. 41-10783, a "heating element" which is a tube body filled with a heating substance such as carbon, iron powder, alloy powder, etc. to create a vacuum inside and electrodes provided at both ends is specially described. Publication No. 49-19073 describes a technology in which a conductive polymer core filled with dispersed conductive particles is coated with a polymer insulator.
Publication No. 5038 describes a technology in which rubber is coated around a conductive wire made of a stretchable material such as conductive rubber or plastic, while Publication No. 39-22077 describes a technology in which a conductive wire made of a stretchable material such as conductive rubber or plastic is coated with rubber. Each of these techniques discloses a technique in which a heater core wire made of mixed strands is coated with heat-resistant insulating plastic.

However, when a "sheet heater" is obtained by molding a "heating element" loaded with a heating substance made of carbon or the like as described in Utility Model Publication No. 41-10783, the "heating substance" spreads throughout the molded body. Because it is uniformly dispersed, the exothermic substance is contained not only on the surface of the sheet heater that requires heating, but also on the back side of the sheet heater that does not require heating, and the exothermic substance on the back side is also energized. As a result, the amount of heat-generating substances used and the electricity required for heating became larger than necessary, resulting in an uneconomical problem.

Also, Utility Model Publication No. 39-22077 "Insulated Heater Wire"
In this technology, the heater core wire is constructed from a mixed stranded wire of multiple metal resistance wires and conductive fibers, but this technology is suitable for use in insulation coated heater wires for electric futons, electric blankets, etc. However, when used as a bent heating element like a planar heater, the metal resistance wire is likely to break due to thermal shock, and if the metal resistance wire breaks, the electrical continuity of only the conductive fibers will occur. However, there was a problem that an effective heating effect could not be obtained in a concentrated manner.

Furthermore, Japanese Utility Model Publication No. 35-5038 "Variable Resistor" and Japanese Patent Publication No. 49-19073 "Insulated Conductor Assembly Made of Conductive Polymer Core" both contain carbon powder, metal powder, or other materials in rubber or polymer insulators. This technology is filled with conductive particles such as carbon powder, but if the amount of conductive particles such as carbon powder is increased, the heating element becomes less flexible, making it difficult to deform into a bent state like a "sheet heater". There was a problem.

(Means for solving the problem) In this invention, a heating wire is constructed by filling a flexible synthetic resin tube with carbon fibers and carbon powder while maintaining a gap between them, and this heating wire is shaped like a plate. The above problem is solved by providing a planar heater that is embedded integrally in a synthetic resin molded body.

(Example) An embodiment of this invention will be described based on the drawings.

FIG. 1 is a diagram illustrating a heated toilet seat, which is a type of planar heater, according to an embodiment of this invention, and numeral 1 in the figure indicates the heated toilet seat.

The heated toilet seat 1 has a heat generating wire 3 embedded in a plate-shaped synthetic resin molded body 2.

The plate-shaped synthetic resin molded body 2 is made of ABS resin (acrylonitrile-butadiene-styrene copolymer resin),
Thermoplastic resins such as polystyrene resin and polyester resin are preferably used, and thermosetting resins can also be used instead.

As shown in FIG. 2, the heating wire 3 is constructed by filling a flexible synthetic resin tube 4 with carbon fibers 5 and carbon powder 6 as emitting materials with a gap maintained between them.

For the synthetic resin tube 4, the thermoplastic resins listed above as those used for the plate-shaped synthetic resin molded body 2 are preferably used, but it is preferable to use the same material as that used for the plate-shaped synthetic resin molded body 2. is the most desirable.

The carbon fiber 5 may be either long (5 to 20 mm) or short (less than 5 mm), and may be pitch type,
Any polyacrylonitrile type is suitably used.

Such a heating wire 3 is a plate-shaped synthetic resin molded body 2
It may be completely buried in the inside, or it may be partially exposed and buried in the surface of the plate-shaped synthetic resin molded body 2.

In addition, 7 in the figure is a terminal connected to the end of the heat generating wire 3.

The structure of the heated toilet seat 1 according to an embodiment of this invention is as described above, and next, the optimum method for manufacturing the heated toilet seat 1 will be shown in the order of steps in FIGS. 3A to 3D.

As shown in FIG. 3A, the heating wire 3 is bent into an appropriate shape and placed in the mold 8.

The heating wire 3 is filled with carbon fibers 5 and carbon powder 6 filled therein with a gap maintained between them, and is freely bent and deformed as the carbon fibers 5 and the like flow.

Note that the heating wire 3 does not necessarily need to be placed inside the lower mold 9; molding can also be carried out by temporarily fixing it to the upper mold 10 or by stretching it between the upper mold 10 and the lower mold 9. It is.

As shown in FIG. 3B, while injecting synthetic resin molding material 11 in a hot molten state into the lower mold 9 from the injection nozzle 12, as shown in FIG. 3C, the lower mold 9 and the upper mold 1 with a shear edge are By meshing them, the pressure spreads the synthetic resin molding material 11 to every corner inside the mold 8.

As shown in FIG. 3D, the upper mold 10 is separated from the lower mold 9, and the heated toilet seat 1 inside the lower mold 9 is taken out.

Next, the usage condition of the heated toilet seat 1 according to an embodiment of this invention will be explained.

When the heating wire 3 is energized through the terminal 7, the carbon fibers 5 and the carbon powder 6 filled with a gap between them are sequentially energized through their mutual contact points, and due to their energizing resistance. The entire heating wire 3 generates heat.

Even if the plate-shaped synthetic resin molded body 2 of the heated toilet seat 1 partially cracks due to long-term use, only the synthetic resin tube 4 is exposed, but the carbon fibers 5 and carbon powder 6 are not exposed.

(Effects of the invention) In this invention, a heating wire is constructed by filling a flexible synthetic resin tube with carbon fibers and carbon powder with a gap between them, and this heating wire is formed into a plate-shaped synthetic resin molded material. Since it is a planar heater that is embedded integrally with the heater, it has the following effects.

That is, since carbon fibers and carbon powder are filled in the synthetic resin tube, which is a heat generating material, with a gap between them, the heat generating material is efficiently concentrated in the synthetic resin tube, and the carbon fibers and Since the heating wire can be bent and deformed freely due to the gaps between the carbon powders, a small amount of the heating material can be concentrated and placed in the area necessary for generating heat in the sheet heater without causing the heating element itself to break. , it is possible to reduce the amount of heat-generating materials required for heating, as well as the electricity required for heating.

[Brief explanation of the drawing]

Fig. 1 is a partially cutaway plan view of a heated toilet seat according to an embodiment of this invention, Fig. 2 is a sectional view of another example of a heating wire, and Figs. 3 A to D are moldings of a heated toilet seat according to this invention. It is an explanatory diagram of the law. 1... heated toilet seat, 2... plate-shaped synthetic resin molded body,
3... Heat generating wire, 4... Synthetic resin tube, 5...
...Carbon fiber, 6...Carbon powder.

Claims (1)

[Scope of utility model registration request] A heating wire is constructed by filling a flexible synthetic resin tube with carbon fibers and carbon powder while maintaining a gap between them, and this heating wire is embedded integrally in a plate-shaped synthetic resin molded body. heater.