JPH09306645A - Sheet heating device - Google Patents

Abstract

(57) [PROBLEMS] To provide an electric type surface heating device that ensures waterproofness and is efficient. SOLUTION: A tape-shaped heater module H whose waterproof property is ensured by insulatingly covering a PTC element heating element with a resin is fitted in a recess R formed in a surface heat transfer plate 5. A heat insulating material plate 6 is arranged below the recess R, and a support plate 7 is bonded to the lower surface thereof. The exposed surfaces of the heater module H and the surface heat transfer plate 5 are flush with each other and serve as a working surface for heating the floor material 3 of the bathroom. The heat generated from the exposed surface of the heater module H is directly applied to the flooring material 3, and the heat generated from the side surface and the bottom surface of the heater module H propagates through the surface heat transfer plate 5 and the flooring material 3 is exposed from the exposed surface 5s. Given to.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet heating device mainly used for floor heating, and more particularly to a sheet heating device preferably used for heating a floor of a bathroom.

[0002]

2. Description of the Related Art There are various heating systems for bathrooms,
For example, a warm air type and a floor heating type are generally used. However, it is reported that the warm air type blows warm air to a wet body, and even if it is warm air, it deprives the latent heat of vaporization from the surface of the body and causes discomfort to the user. ing. Therefore, the floor heating type is preferable as the heating mechanism for the bathroom.

Floor heating devices for bathrooms include one that circulates hot water through a pipe embedded inside the floor, one that heats the floor surface by attaching an electric sheet heating element to the back surface of the floor, and the like. There is. However, in the method of circulating hot water, a large-scale heating facility such as a boiler is required to make hot water that circulates through a pipe. In some cases, such equipment is always available in extremely cold regions, but in other areas, preparing for general households is
It is not easy in terms of installation space and cost. Therefore, the electric floor heating system, which can be easily processed and whose utility is easily available, is remarkably popular.

In the electric floor heating apparatus currently in use, for example, a sheet heating element in which carbon is mixed with resin is attached to the lower surface of the floor material, or a sheet heating element similar to the sheet heating element is used. It is constructed by pasting a plate-shaped heater, which is embedded, on the lower surface of the floor material (see Japanese Utility Model Laid-Open No. 61-130818). There is also an example in which a tube heater similar to that used in an electric carpet is embedded in a floor material to form a bathroom floor with a heater function.

[0005]

Among the above-mentioned electric floor heating devices, the one using a tube heater has a drawback that the step of embedding the tube heater in the floor material is difficult work, resulting in high cost. It has not spread. On the other hand, the one using the sheet heating element is relatively popular because it does not have the above problem.

However, the sheet heating element itself is poor in waterproofness. Therefore, a short circuit may occur due to dew condensation. Further, when used in the bathroom, it is important to ensure waterproofness because water may come into contact with the planar heating element to cause a short circuit due to water splash or the like in addition to dew condensation.
In some cases, a cover is attached to the sheet heating element to ensure waterproofness. However, it is technically difficult to completely seal the sheet heating element, which may eventually increase the cost.

Therefore, an object of the present invention is to solve the above-mentioned technical problems and to provide an electric type sheet-like heat generating device in which waterproofness is secured. Another object of the present invention is to provide a planar heating device capable of efficiently heating an object to be heated.

[0008]

In order to achieve the above object, the invention according to claim 1 has a structure having a heat transfer surface heat transfer layer which is to be placed facing an object to be heated, and the above surface. A planar heat generating device comprising: a heater module which is attached in close contact with a heat transfer layer and which is formed into a tape shape by insulatingly coating a positive temperature coefficient thermistor element with a resin.

According to the above construction, since the heater module formed in a tape shape by insulatingly coating the PTC thermistor element with resin is used, the heater module itself has excellent waterproofness. . for that reason,
When this sheet heating device is used for heating around water, it can have high reliability. Moreover, since the heater module is arranged in close contact with the surface heat transfer layer of a plate-shaped or block-shaped structure, for example, the heat generated from the heater module is transferred to the heater module via the surface heat transfer layer. It also propagates well to areas that are not. Therefore, the heat generated from the heater module can be efficiently dissipated from the entire surface of the planar heating device, so that the object to be heated can be efficiently heated.

According to a second aspect of the present invention, the surface heat transfer layer is formed with a recess for embedding the heater module, and at least a part of the surface of the heater module is exposed in the recess. The planar heating device according to claim 1, wherein the planar heating device is buried in a state of being embedded. With this configuration, since the heater module is embedded in the recess formed in the surface heat transfer layer, heat generated from the surface other than the exposed surface of the heater module can be efficiently transferred to the surface heat transfer layer.

According to a third aspect of the present invention, the heater module is embedded in the recess so that the exposed surface of the surface heat transfer layer and the exposed surface of the heater module are flush with each other. The sheet heating device according to claim 2. According to this configuration, since the exposed surfaces of the surface heat transfer layer and the heater module are flush with each other, the surface heat transfer layer and the heater module can be brought into close contact with the planar surface of the object to be heated. Thereby, the object to be heated can be efficiently heated.

According to a fourth aspect of the present invention, there is provided the planar heating device according to any one of the first to third aspects, which is arranged in contact with the lower surface of the floor material of the bathroom.
According to this structure, the sheet heating device is installed on the lower surface of the floor material of the bathroom. At this time, there is no possibility of short-circuiting the heater module due to the influence of dew condensation or water splash, and the floor heating of the bathroom can be performed extremely efficiently.

[0013]

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a cross-sectional view showing a usage state of a planar heating device according to an embodiment of the present invention. The sheet heating device 1 can be used, for example, for floor heating in a unit bath. Specifically, it is adhered to the lower surface of the floor material 3 connected to the bathtub 2,
The planar heating device 1 is arranged. The floor material 3 forms the floor of the washing area.

FIG. 2 is an exploded perspective view of the sheet heating device 1, and FIG. 3 is an enlarged sectional view showing the intermediate portion omitted. The planar heating device 1 includes a plurality of (six in this embodiment) heater modules H1 to H6 (hereinafter, collectively referred to as "heater module H") formed in a tape shape having a rectangular cross section in parallel. It has a structure 10. The planar heating device 1 further includes a plurality of recesses R (six in this embodiment) for burying the heater module H.
A surface heat transfer plate 5 made of aluminum in which 1 to R6 are formed in parallel, a heat insulating material plate 6 adhered to the back surface of the surface heat transfer plate 5 without a gap, and aluminum bonded to the back surface of the heat insulating material plate 6. And a holding plate 7 made of steel. The surface heat transfer plate 5 is fixed to the surface of the heat insulating material plate 6 with an adhesive to form a plate-like structure,
Further, the heater modules H1 to H6 are fitted into the recesses R1 to R6 of the surface heat transfer plate 5 (hereinafter, referred to as “recesses R” when collectively referred to), and finally, the holding plate 7 is attached to the heat insulating material plate 6. The planar heating device 1 is completed by sticking it to the back surface with an adhesive.

As shown in FIG. 3, the surface heat transfer plate 5
The recess R is formed in a linear groove shape and has a rectangular cross section. A tape-shaped heater module H is fitted in the recess R without any gap. Further, when the heater module H is fitted into the recess R, the surface Hs of the heater module H facing the floor material 3 and the exposed surface 5s of the surface heat transfer plate 5 are flush with each other, and the floor material 3 is It acts as a heating surface. Therefore, the heat generated from the surface Hs of the heater module H is directly transferred to the floor material 3. Further, the heat generated from the rear surface (the surface facing the bottom surface of the recess R) Hus and the side surface Hls (the surface facing the rising surface of the recess R) of the heater module H propagates through the surface heat transfer plate 5 and is transferred to the surface. The exposed surface 5 s of the heating plate 5 is transferred to the floor material 3.

An adhesive may be used to fix the heater module H to the recess R, but in order to efficiently transfer the heat generated from the heater module H to the surface heat transfer plate 5, both of them are used. Bonding is preferably achieved only by mating. Further, it is more preferable to enhance the thermal coupling between the recess R and the surface of the heater module H by using a conductive resin such as silicone resin.

Falling edge portions 5a and 5b are formed on both sides of the surface heat transfer plate 5 so as to fall along the side surfaces of the heat insulating material plate 6. The falling edge portions 5a and 5b secure a large contact area with the surface heat transfer plate 5 of the adjacent sheet heat generating devices 1 to eliminate insufficient heating in the area between the sheet heating devices 1 adjacent to each other. It is useful. FIG. 4 is a diagram showing the configuration of the tape-shaped heater module H, and FIG.
FIG. 5 is a transverse cross-sectional view as seen from a section line V-V of FIG. This heater module H is a PTC (Posi
A plurality of PTC element heating elements 12 made of a ceramic semiconductor having a tive temperature coefficient are provided. The plurality of PTC element heating elements 12 are connected in parallel with each other between the pair of conductive wires 31 and 32 arranged along the longitudinal direction of the heater module H with a certain interval. The heating unit including the PTC element heating element 12 and the conductive wires 31 and 32 is sealed in the covering member 4 made of an insulating resin, and FIG. 4 shows a state in which a part of the covering member 4 is cut away. It is shown. One end of each of the conductive wires 31 and 32 is drawn out of the covering member 4 on one end side of the covering member 4.

At the tip of the heater module H, a case 5 is attached.
0 is attached. The case 50 is filled with an insulating resin (for example, silicon resin),
The conductive wire 31, which is exposed at the tip of the covering member 4,
32 is sealed to ensure waterproofness. Figure 6 shows PT
FIG. 6 is a perspective view showing a combined structure of a C element heating element 12 and conductive wires 31 and 32. The PTC element heating element 12 is formed in a rectangular parallelepiped, and is connected to the conductive wires 31 and 32 by the conductive metal terminal 8. More specifically, the metal terminal 8 includes four heating element gripping portions 33 for gripping the ends of the PTC element heating element 12, and a pair of electric wire gripping portions 34 for gripping the conductive wires 31 and 32. have.

An electrode 17 is formed on the end of the PTC element heating element 12 at a portion contacting the heating element grip 33. Therefore, the PTC element heating element 12 is sandwiched between the pair of electrodes 17, and the current flows uniformly over the entire volume of the heating element. The electric wire grip portion 34 of the metal terminal 8 is joined to the conductive wires 31 and 32 by the solder 11. Further, the heating element grip portion 33 and the electrode 17 are bonded to each other by adhering or soldering with a conductive adhesive tape or an adhesive material.

The PTC element heating element 12 is made of a material having a PTC characteristic, for example, a ceramic semiconductor whose main raw material is barium titanate, and has a room temperature to a Curie temperature T.
Although it has a low resistance up to c (rapid change temperature), it has a characteristic that the resistance value sharply increases when the Curie temperature Tc is exceeded. Due to this characteristic, when a voltage is applied to the PTC element heating element 12 at a temperature below the Curie temperature Tc, the resistance value is small at the beginning because of the low temperature, and a large current flows. Thereby, the temperature rises sharply. When the temperature exceeds the Curie temperature Tc, the resistance value sharply increases, the current value decreases, and the heat generation amount decreases. Therefore, the temperature does not rise above a certain temperature, and is stabilized at a certain temperature. That is, the PTC element heating element 12 has a self-temperature control function.

FIG. 7 is a plan view showing a structure for supplying power to the heater module H. At one end of each heater module H, the conductive wires 31 and 32 are drawn from the covering member 4 as described above. The crimp terminals 35, 3 are attached to the respective tips of the drawn-out portions of the conductive wires 31, 32.
6 are crimped respectively. These crimp terminals 35, 36
Are soldered and connected to a pair of parallel terminals 41 and 42 extending in a direction substantially orthogonal to the longitudinal direction of the heater module H and arranged in parallel. This parallel terminal 41, 4
Lead wire lead-out portions 91 and 92 of the power cord 9 are connected to the respective one ends of the cord 2 by crimp terminals 51 and 52, respectively. Therefore, when the power cord 9 is connected to a commercial AC power supply, power is supplied to the plurality of heater modules H in parallel. In the heater module H, since the plurality of PTC element heating elements 12 are connected in parallel to the conductive wires 31 and 32, after all, the plurality of PTC element heating elements 12 included in the planar heating device 1 have
The voltage from the commercial AC power supply will be applied in parallel.

8 and 9 are views showing an example of the sealing structure of the end portion of the heater module H. As shown in FIG. At the tip of the heater module H, as shown in FIG.
A case 50 including a lower case member 49 is covered, and the case 50 is filled with a silicone resin through a resin filling opening 47 formed between the upper case member 48 and the lower case member 49. ing. This allows
The conductive wires 31 and 32 exposed at the tip portion of the heater module H are resin-sealed to ensure waterproofness at the tip portion.

On the other hand, the base ends of the plurality of heater modules H are inserted in the case 60 as shown in FIG. That is, the case 60 includes an upper case member 58 and a lower case member 59, and an opening 57 for introducing the plurality of heater modules H into the internal space is formed between the pair of case members. As shown in FIG. 7, the case 60 further accommodates the above-mentioned parallel terminals 41 and 42, the tip of the power cord 9, and the lead wire drawing portions 91 and 92. Then, the silicone resin 55 is filled through the resin filling opening 56 formed between the pair of case members 58 and 59. Thus, the lead-out portions of the base ends of the conductive wires 31 and 32, the parallel terminals 41 and 42, and the lead wire lead-out portions 91 and 92 of the power cord 9 are resin-sealed in the case 60. , Waterproof is secured.

The structure for sealing the tip of the heater module H with the resin is not limited to the above-described one.
And the portions corresponding to 60 may be integrally molded with resin, or the exposed portions of the conductive wires 31 and 32 and the parallel terminals 41 and 42 may be covered with resin to achieve insulating coating without using a case. Good.

The sheet heating device 1 as described above can be produced, for example, as follows. That is,
First, the electrodes 17 are formed in the vicinity of both ends of the flat rectangular parallelepiped PTC element 12. For example, the electrode 17 can be formed by applying the silver paste for forming the ohmic contact electrode and then heating the PTC element heating element 12 at 120 ° C. for 30 minutes.

Next, the heating element grip 33 of the metal terminal 8 is electrically and mechanically connected to the electrode 17. Further, the metal terminal 8 is electrically and mechanically connected to the pair of conductive wires 31 and 32. Similarly, a plurality of PTC element heating elements 12 are connected to the conductive wires 31 and 32 at regular intervals to create a ladder-like continuous structure. By subjecting this structure to extrusion coating, a long structure insulatively coated with the coating member 4 is created. Then, by cutting this structure into a certain length, it is decomposed into a plurality of long structures.

The covering member 4 is removed in the vicinity of each one end of the plurality of disassembled structures to expose the pair of conductive wires 31 and 32. The crimp terminals 35 and 36 are crimped to the tips of the exposed portions of the pair of conductive wires 31 and 32. The other end of each of the disassembled structures is subjected to an insulating coating process as described with reference to FIG. In this way, a plurality of heater modules H are obtained.

Further, the crimp terminals 35 and 36 of the plurality of heater modules H are soldered to the parallel terminals 41 and 42,
One end of each of the parallel terminals 41 and 42 is connected to the power cord 9. Then, as described with reference to FIG. 9, the parallel structure 10 shown in FIG. 1 is obtained by performing the insulating coating process in the vicinity of the base end portion of the heater module H.

The surface heat transfer plate 5 is formed, for example, by bending and processing an aluminum plate. The surface heat transfer plate 5 is bonded to the heat insulating material plate 6, and the holding plate 7 is bonded to the back surface of the heat insulating material plate 6. Then, by further fitting the heater modules H into the recesses R of the surface heat transfer plate 5, the planar heating device 1 is completed. As described above, according to the planar heating device 1 of the present embodiment, the PTC element heating element 1
The heat generating unit in which 2 is connected to the conductive wires 31 and 32 is insulated and covered by the covering member 4, and the heater module H is constituted by this. Further, the front end and the base end of the heater module H are insulation-coated with the cases 50 and 60 and the silicone resin, and the heater module H can have high waterproof performance. Therefore, it is possible to have high reliability even in applications such as floor heating of a bathroom under conditions where dew condensation or short circuit due to direct contact with water is likely to occur.

Further, in this embodiment, the plurality of heater modules H are fitted in the plurality of recesses R formed in the surface heat transfer plate 5, and the exposed surface of the heater module H and the surface heat transfer are obtained. The exposed surface of the plate 5 is flush with the exposed surface of the plate 5 and serves as a working surface for applying heat to the object to be heated. Therefore, the heat generated from the surface of the heater module H is directly applied to the object to be heated as it is. Further, the heat generated from the side surface and the bottom surface of the heater module H propagates through the surface heat transfer plate 5 and is given to the object to be heated from the exposed surface. Thereby, the heat from all the surfaces of the heater module H can be efficiently transferred to the object to be heated, and the heating without waste becomes possible. Moreover, since the heat insulating material plate 6 is combined below the surface heat transfer plate 5, heat is not radiated to other than the working surface. This allows more efficient heating.

As described above, in the sheet heating device of this embodiment, since the heater module H, which is the heating portion, itself has excellent waterproofness, a problem arises in waterproofness even when heating a wide area. Never. Moreover, high heating efficiency can be achieved. Therefore, it can be used safely around the water as in a bathroom, and efficient heating is possible. Although this embodiment has been described above, it is needless to say that the present invention can take various embodiments other than the above-mentioned embodiment. For example, in the above-described embodiment, the surface heat transfer layer is formed by bending the aluminum plate. However, for example, the surface heat transfer layer may be formed by applying metal plating to the surface of the heat insulating material. You may In addition to aluminum,
Other metals such as iron, nickel, stainless steel, and duralumin, and substances other than metals such as AlN and Si ₃ N ₄ have high thermal conductivity, and thus can be used as materials for forming the surface heat transfer layer. it can.

Further, in the above embodiment, a plate-like structure in which the surface heat transfer plate 5 and the heat insulating material plate 6 are combined is used, but such a structure needs to be a plate-like one. Instead, it may be in the form of a block, for example. Further, the surface of the structure having the surface electrothermal layer does not need to be flat, and the surface shape of the structure may be determined according to the shape of the object to be heated. That is, for example, the surface of the structure having the surface heating layer may have a step or may be curved.

Further, in the above-described embodiment, an example in which the sheet heating device is used for floor heating of the bathroom has been described, but the sheet heating device of the present invention can be used for floor heating other than the bathroom. Needless to say. In addition, various design changes can be made within the scope of technical matters described in the claims.

[0034]

Next, a more specific example will be described.
A ladder-shaped structure in which PTC element heating elements were connected to a pair of conductive wires at 5 cm intervals was subjected to vinyl chloride extrusion insulation coating to obtain a long structure. The structure was cut every 750 millimeters in length. The width is 17 millimeters and the thickness is 4 millimeters. One coating of the fixed-size structure was processed to expose a part of the pair of conductive wires. The exposed conductive wires were respectively connected to the parallel terminals. In the fixed length structure, the cut surface on the side opposite to the parallel terminal is made of silicon resin (TSE392 manufactured by Toshiba Silicone
It was insulation-sealed with C), and the exposed portion of the conductive wire and the parallel terminal portion were also insulation-sealed with the same resin.

A terminal for crimping the power cord was provided at one end of the parallel terminal, and the power cord was electrically and mechanically connected. The electric circuit of this connection portion was also insulated and coated with the same resin. The heater module portion of the parallel structure thus prepared was fitted into the recess of the surface heat transfer plate prepared by using an aluminum plate having a thickness of 1 mm, and further bonded with a silicone resin. The number of heater modules is six. On the surface of the surface heat transfer plate opposite to the heater module mounting surface, urethane foam as a heat insulating material is adhered, and further, the surface of the urethane foam opposite to the surface heat transfer plate is made flat. Shaved. This allows
A planar heating device having a thickness of 9 mm was obtained. Further, in order to increase the anisotropic bending strength, an aluminum plate having a thickness of 1 mm is bonded as a support plate to the surface of the urethane foam opposite to the surface heat transfer plate, and the total thickness is 10 mm.
It was a millimeter surface heating device.

It is confirmed that the sheet heating device thus obtained has excellent waterproofness and can heat a large area, and therefore is suitable for applications such as floor heating in a bathroom washing room. It was

[0037]

According to the invention described in claim 1, since the heater module itself has excellent waterproofness, it is possible to have high reliability even when heating around water. Further, since the heater module itself is waterproof, it is possible to configure the heater module so as to be in direct contact with the object to be heated, which enables efficient heating.

Further, since the heater module is arranged in close contact with the heat transfer surface heat transfer layer, the heat generated from the heater module can be efficiently applied to the object to be heated. According to the invention of claim 2, since the heater module is embedded in the recess formed in the surface heat transfer layer,
The heat generated from the surface other than the exposed surface of the heater module can be efficiently transferred to the surface heat transfer layer. Thereby, the object to be heated can be heated more efficiently.

According to the third aspect of the invention, since the exposed surfaces of the surface heat transfer layer and the heater module are flush with each other,
The surface heat transfer layer and the heater module can be brought into close contact with the flat surface of the object to be heated. Thereby, the object to be heated can be heated more efficiently. According to the invention as set forth in claim 4, since there is no possibility that the heater module is short-circuited by the influence of dew condensation or water splash, it is possible to provide a highly reliable and efficient electric floor heating apparatus for bathroom. .

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a usage state of a planar heating device according to an embodiment of the present invention.

FIG. 2 is an exploded perspective view of a planar heating device.

FIG. 3 is an enlarged cross-sectional view of a planar heating device.

FIG. 4 is a diagram for explaining the structure of a heater module.

5 is a cross-sectional view of the heater module taken along the section line VV in FIG.

FIG. 6 is a perspective view showing a combined structure of a PTC element heating element and a conductive wire.

FIG. 7 is a plan view showing a configuration for supplying power to the heater module.

FIG. 8 is a perspective view showing a sealing structure at the tip of the heater module.

FIG. 9 is a perspective view showing a sealing structure near a base end portion of a heater module.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Planar heating device 2 Bath 3 Floor material for washing room 4 Covering member 5 Surface heat transfer plate 6 Insulating material plate 7 Support plate 8 Metal terminal 10 Parallel structure 12 PTC element heating element 17 Electrode 31,32 Conductive wire H1 to H6 Heater Module R1-R6 recess

Claims (4)

[Claims] 1. A structure having a heat transfer surface heat transfer layer which is to be disposed so as to face an object to be heated, and a structure which is attached in close contact with the surface heat transfer layer and insulates a positive temperature coefficient thermistor element with resin. A planar heat generating device including a heater module formed in a tape shape by the above. 2. A recess for burying a heater module is formed in the surface heat transfer layer, and the heater module is buried in the recess with at least a part of the surface exposed. The planar heating device according to claim 1, wherein 3. The heater module is embedded in the recess so that the exposed surface of the surface heat transfer layer and the exposed surface of the heater module are flush with each other. The sheet heating device described. 4. The sheet heating device according to claim 1, wherein the sheet heating device is arranged in contact with a lower surface of a floor material of a bathroom.