JP4655255B2

JP4655255B2 - Planar heater and manufacturing method thereof

Info

Publication number: JP4655255B2
Application number: JP2001077359A
Authority: JP
Inventors: 剛三浦; 達也大崎; 宏之坪井; 真吾田中; 一行平山
Original assignee: Toto Ltd
Current assignee: Toto Ltd
Priority date: 2000-09-29
Filing date: 2001-03-19
Publication date: 2011-03-23
Anticipated expiration: 2021-03-19
Also published as: JP2002175870A

Description

【０００１】
【発明の属する技術分野】
本発明は、面状発熱体と、面状発熱体に密着して面状発熱体を被覆する絶縁層とを備える面状ヒータとその製造方法に関するものである。
【０００２】
【従来の技術】
面状発熱体と、面状発熱体に密着して面状発熱体を被覆する絶縁層とを備える面状ヒータが、各種暖房装置に使用されている。
【０００３】
【発明が解決しようとする課題】
面状ヒータは自立性を有さないので、支持体に貼着して使用される。支持体の湾曲表面に面状ヒータを貼着すると、面状ヒータに皺ができ、面状発熱体が折れ曲がって面状ヒータの性能が低下する。
面状ヒータは一般に薄膜状の面状発熱体と薄膜状の絶縁層とを積層し加熱プレスすることにより製造される。両者を積層し加熱プレスする際に、薄膜状の絶縁層が面状発熱体に一度に全面密着するので、両者の境界面にエア溜まりが発生し、面状ヒータの性能が低下する。
本発明は上記問題に鑑みてなされたものであり、支持体の湾曲表面に貼着しても皺ができ難く、面状発熱体と絶縁層との間にエア溜まりが無い面状ヒータと、その製造方法とを提供することを目的とする。
【０００４】
【課題を解決するための手段】
上記課題を解決するために、本発明においては、面状発熱体と、面状発熱体に密着して面状発熱体を被覆する絶縁層とを備え、支持体の湾曲表面に貼着される面状ヒータであって、絶縁層表面に凹凸が形成されており、貼着の際に延伸する絶縁層表面部位の凹凸の配列方向が、延伸方向に対して傾斜していることを特徴とする面状ヒータを提供する。
絶縁層表面に凹凸を有する面状ヒータを、支持体の湾曲表面に貼着すると、凹凸が変形して絶縁層表面が伸縮し、面状ヒータは支持体の湾曲表面に追随して変形する。従って、面状ヒータには皺はできず、面状ヒータの性能は低下しない。絶縁層表面の凹凸は、凹凸を形成した金型を用いて積層体を加熱プレスする、凹凸を形成した型板を被成形体と金型との間に挟んで積層体を加熱プレスする等の方法により形成される。この場合、金型、型板の凹凸の凸部に対峙する絶縁層の部位が、凹部に対峙する絶縁層の部位よりも先に面状発熱体に押圧されるので、絶縁層は面状発熱体に一度に全面密着しない。従って、両者の境界面にエア溜まりは形成されず、エア溜まりの存在による面状ヒータの性能低下は起こらない。
貼着の際に延伸する絶縁層表面部位の凹凸の配列方向が、延伸方向に対して傾斜していれば、凹凸は延伸方向へ容易に伸びるので、面状ヒータは支持体の湾曲表面に追随することができる。
【０００５】
本発明の好ましい態様においては、絶縁層表面の部位によって凹凸の寸法が異なる。
凹凸の寸法が変わると絶縁層表面の伸縮性が変わる。従って、支持体の湾曲表面の曲率が部位によって異なる場合、絶縁層表面の凹凸の寸法を、当該凹凸が対峙する湾曲表面の曲率に応じて適正に異ならせることにより、曲率が部位によって異なる支持体の湾曲表面に、面状ヒータを追随させることができる。
【０００６】
本発明の好ましい態様においては、人体に対峙する絶縁層表面の凹凸の凸部の面積が、人体に対峙しない絶縁層表面の凹凸の凸部の面積よりも小さい。
人体に接触する暖房装置に、本発明の面状ヒータを使用する場合、人体に対峙する絶縁層表面の凹凸の凸部の面積を、人体に対峙しない絶縁層表面の凹凸の凸部の面積よりも小さくすることにより、暖房装置の人体に接触する部位の加熱を防止し、火傷を防止することができる。
【０００７】
本発明の好ましい態様においては、面状ヒータの絶縁層表面に電装部品の敷設に十分な広さの平坦部が形成されている。
面状ヒータの絶縁層表面に温度検出素子等の電装部品を敷設する場合がある。面状ヒータの絶縁層表面に電装部品の敷設に十分な広さの平坦部が形成されていれば、電装部品の敷設を容易に行うことができる。
【０００８】
本発明の好ましい態様においては、絶縁層表面の凹凸の深さと、凹凸が対峙する湾曲表面の曲率との間に、正の相関が在る。
本発明の好ましい態様においては、絶縁層表面の凹凸の配設密度と、凹凸が対峙する湾曲表面の曲率との間に、正の相関が在る。
絶縁層表面の凹凸の深さが増加し、或いは凹凸の配設密度が増加すると、絶縁層表面の伸縮性が増加する。従って、上記何れかの面状ヒータを支持体の湾曲表面に貼着する場合、絶縁層表面の凹凸の深さと凹凸が対峙する湾曲表面の曲率との間に正の相関が在り、或いは絶縁層表面の凹凸の配設密度と凹凸が対峙する湾曲表面の曲率との間に正の相関が在れば、貼着に際して大きな曲率で湾曲すべき部位では絶縁層表面が大きく伸縮できるので、面状ヒータは支持体の湾曲表面に追随することができる。
本発明の好ましい態様においては、絶縁層表面の凹凸の巾と、凹凸が対峙する湾曲表面の曲率との間に、負の相関が在る。
絶縁層表面の凹凸の巾が減少すると、絶縁層表面の伸縮性が増加する。従って、上記何れかの面状ヒータを支持体の湾曲表面に貼着する場合、絶縁層表面の凹凸の巾と凹凸が対峙する湾曲表面の曲率との間に負の相関が在れば、貼着に際して大きな曲率で湾曲すべき部位では絶縁層表面が大きく伸縮できるので、面状ヒータは支持体の湾曲表面に追随することができる。
【０００９】
本発明の好ましい態様においては、貼着後に凹に湾曲する絶縁層表面部位における凹凸の凹部の面積が、貼着後に凸に湾曲する絶縁層表面部位の凹凸の凹部の面積よりも広い。
【００１０】
凹凸の凹部の面積が増加すると、絶縁層表面の縮性が増加する。従って、貼着後に凹に湾曲する絶縁層表面部位における凹凸の凹部の面積が、貼着後に凸に湾曲する絶縁層表面部位の凹凸の凹部の面積よりも広ければ、面状ヒータは支持体の湾曲表面に追随することができる。
【００１１】
本発明の好ましい態様においては、貼着の際に延伸する絶縁層表面部位の延伸方向と、絶縁層の易延伸方向とが一致する。
【００１２】
絶縁層の延伸性が非等方である場合、面状ヒータの貼着の際に延伸する絶縁層表面部位の延伸方向と、絶縁層の易延伸方向とが一致すれば、絶縁層表面は容易に延伸するので、面状ヒータは支持体の湾曲面に容易に追随することができる。
【００１３】
本発明においては、上記何れかの面状ヒータを備えることを特徴とする暖房便座装置を提供する。
【００１４】
本発明に係る面状ヒータは、湾曲した便座の下面に貼着するのに適している。従って、本発明に係る面状ヒータは暖房便座に使用可能である。
【００１５】
【発明の実施の形態】
本発明の実施例に係る面状ヒータを説明する。
図１に示すように、面状ヒータ１は、導電性繊維混抄紙２と、導電性繊維混抄紙２の両端に取り付けられた１対の金属箔電極３と、これらをサンドイッチ状に挟んで被覆する絶縁樹脂層４とを備えている。絶縁層４の表面には、凹凸５が形成されている。
面状ヒータ１は、図２に示すように、金属箔電極３が取り付けられた導電性繊維混抄紙２を、ホットメルトやエチレンビニルアセテートコポリマー（ＥＶＡ）等の熱可塑性樹脂から成る接着層４ａが積層されたポリエチレンテレフタレート（ＰＥＴ）やポリエチレン（ＰＥ）等から成る絶縁樹脂層４でサンドイッチ状に挟んで積層体を形成し、予め凹凸形状を形成した金型内で前記積層体を積層方向に加圧加熱することにより、製造される。導電性繊維混抄紙２と絶縁層４との圧着と凹凸５の形成とが同時に行われ、面状ヒータ１が効率良く生産される。
自立できない面状ヒータ１は、図３に示すように、支持体である便座６の湾曲した裏面に貼着され、便座６と協働して暖房便座７を構成している。
【００１６】
図３から分かるように、便座6裏面の湾曲部６ａにおいて、湾曲部６ａに貼着される絶縁層４表面の凹凸５が拡大して絶縁層４表面が伸び、反対側の湾曲部６ａに貼着されない絶縁層４表面の凹凸５が縮小して絶縁層４表面が縮むことにより、面状ヒータ１は便座６裏面の湾曲部６ａに追随して、湾曲部６ａ密着することができる。従って、面状ヒータ１には皺は発生せず、皺による導電性繊維混抄紙２の極端な屈曲は発生せず、面状ヒータ１の性能は低下しない。
図３から分かるように、面状ヒータ１においては、便座６裏面の曲率の大きな部位６ａに対峙する凹凸５の面積、深さを、便座６裏面の曲率の小さな部位６ｂに対峙する凹凸５の面積、深さよりも大きくしている。寸法の大きな凹凸５が形成された絶縁層４表面は、寸法の小さな凹凸５が形成された絶縁層４表面に比べて伸縮性が大きいので、便座６裏面の曲率の大きな部位６ａに対峙する絶縁層４表面は大きく伸縮でき、便座６裏面の曲率の小さな部位に対峙する絶縁層４表面は小さく伸縮できる。従って、面状ヒータ１は、部位によって曲率が異なる便座６裏面の湾曲に追随して、当該裏面に密着することができる。従って、面状ヒータ１を暖房便座６の裏面に貼着する際に、面状ヒータ１には皺は発生せず、導電性繊維混抄紙２は極端に屈曲せず、面状ヒータ１の性能は低下しない。
図３に示すように、絶縁層４表面に平坦部４ｂを形成すれば、サーミスタ等の電装部品８を絶縁層４表面に容易に敷設することができ、暖房便座７の利便性が向上する。
【００１７】
以上本発明の実施例を説明したが、本発明は上記実施例に限定されない。
面状発熱体１の使用目的に応じて、非導電性繊維混抄紙２の片面のみを絶縁層４で被覆しても良い。
金型に凹凸を形成するのに代えて、テフロン、シリコン等の樹脂製の凹凸指示材により凹凸５を形成しても良い。
凹凸５の形状は、円形でも良く、矩形でも良く、或いは他の任意の形状でも良い。
【００１８】
面状ヒータ１において、人体に対峙する絶縁層４表面、すなわち便座６の裏面に貼着される絶縁層４表面の凹凸５の凸部の面積を、人体に対峙しない絶縁層４表面、すなわち便座６の裏面に貼着されない絶縁層４表面の凹凸５の凸部の面積よりも小さくしても良い。係る構成により、暖房便座６の人体に接触する部位の加熱を防止し、便座利用者の火傷を防止することができる。
【００１９】
面状ヒータ１において、凹凸５の深さと、当該凹凸５が対峙する便座６裏面の曲率との間に、正の相関を持たせても良い。
面状ヒータ１において、凹凸５の配設密度と、当該凹凸５が対峙する便座６裏面の曲率との間に、正の相関を持たせても良い。
絶縁層４表面の凹凸５の深さが増加し、或いは凹凸５の配設密度が増加すると、絶縁層４表面の伸縮性が増加する。従って、面状ヒータ１を便座６の湾曲裏面に貼着する場合、絶縁層４表面の凹凸５の深さと凹凸５が対峙する湾曲裏面の曲率との間に正の相関が在り、或いは絶縁層４表面の凹凸５の配設密度と凹凸５が対峙する湾曲裏面の曲率との間に正の相関が在れば、貼着に際して大きな曲率で湾曲すべき部位では絶縁層４表面が大きく伸縮できるので、面状ヒータ１は便座６の湾曲裏面に追随して密着することができる。
【００２０】
面状ヒータ１において、凹凸５の巾と、当該凹凸５が対峙する便座６裏面の曲率との間に、負の相関を持たせても良い。
絶縁層４表面の凹凸５の巾が減少すると、絶縁層４表面の伸縮性が増加する。従って、面状ヒータ1を便座6の湾曲裏面に貼着する場合、絶縁層4表面の凹凸5の巾と凹凸5が対峙する湾曲裏面の曲率との間に負の相関が在れば、貼着に際して大きな曲率で湾曲すべき部位では絶縁層4表面が大きく伸縮できるので、面状ヒータ1は便座6の湾曲裏面に追随して密着することができる。
【００２１】
面状ヒータ１において、便座６の裏面に貼着後に凹に湾曲する絶縁層4表面部位４ｃの凹凸５の凹部の面積を、便座６の裏面に貼着後に凸に湾曲する絶縁層４表面部位４ｄの凹凸５の凹部の面積よりも広くしても良い。凹凸５の凹部の面積が増加すると、絶縁層４表面の縮性が増加する。従って、貼着後に凹に湾曲する絶縁層４表面部位４ｃにおける凹凸５の凹部の面積が、貼着後に凸に湾曲する絶縁層４表面部位４ｄの凹凸５の凹部の面積よりも広ければ、面状ヒータ１は便座６の湾曲裏面に追随して密着することができる。
【００２２】
面状ヒータ１において、便座６に貼着する際に延伸する絶縁層４表面部位４ｄの凹凸５の配列方向を、図３で白抜き矢印で示す延伸方向に対して、傾斜させても良い。図４に、格子状にエンボス加工を施した面状ヒータ１の、延伸方向と格子の配設方向との成す角αと、引っ張り応力と、伸びとの関係を、ＪＩＳ規格引っ張り試験に準じた引っ張り試験に基づいて調査した結果を示す。図４から、延伸方向が格子の配設方向に対して傾斜していると、延伸方向が格子の配設方向と平行である場合に比べて、伸びが大きいことが分かる。従って、便座６に貼着する際に延伸する絶縁層４表面部位４ｄの凹凸５の配列方向を、図３で白抜き矢印で示す延伸方向に対して、傾斜させることにより、絶縁層４表面部位４ｄの延伸量を増加させることができ、面状ヒータ１を便座６の湾曲裏面追随させて密着させることができる。
【００２３】
面状ヒータ１において、便座６に貼着する際に延伸する絶縁層４表面部位４ｄの延伸方向（図３で白抜き矢印で示す）と、表面部位４ｄを含む絶縁層４の易延伸方向とを一致させても良い。
図５に、ポリエチレンフィルムの、延伸方向とのロール巻き取り方向との成す角βと、引っ張り応力と、伸びとの関係をＪＩＳ規格引っ張り試験に準じた引っ張り試験に基づいて調査した結果を示す。図５から、延伸方向がポリエチレンフィルムのロール巻き取り方向と一致する場合に、伸びが大きいことが分かる。ロールに巻き取ったポリエチレンフィルムのように、易延伸性が非等方である素材を絶縁層４として使用する場合には、便座６に貼着する際に延伸する絶縁層４表面部位４ｄの延伸方向と、表面部位４ｄを含む絶縁層４の易延伸方向とを一致させることにより、絶縁層４表面部位４ｄの延伸量を増加させることができ、面状ヒータ１を暖房便座６の湾曲裏面に追随させて密着させることができる。
【００２４】
面状ヒータ１は、便座６の湾曲裏面に貼着して暖房便座７を構成するのに適しているが、便座６に限らず種々の湾曲面に貼着可能であり、暖房便座７に限らず種々の暖房器具を構成可能である。
【００２５】
【発明の効果】
上記説明から分かるように、絶縁層表面に凹凸を有する面状ヒータを、支持体の湾曲表面に貼着すると、凹凸が変形して絶縁層表面が伸縮し、面状ヒータは支持体の湾曲表面に追随して変形する。従って、面状ヒータには皺はできず、面状ヒータの性能は低下しない。従って、本発明により、支持体の湾曲表面に貼着しても皺ができにくい面状ヒータが提供される。絶縁層表面の凹凸は、凹凸を形成した金型を用いて積層体を加熱プレスする、凹凸を形成した型板を被成形体と金型との間に挟んで積層体を加熱プレスする等の方法により形成される。この場合、金型、型板の凹凸の凸部に対峙する絶縁層の部位が、凹部に対峙する絶縁層の部位よりも先に面状発熱体に押圧されるので、絶縁層は面状発熱体に一度に全面密着しない。従って、両者の境界面にエア溜まりは形成されず、エア溜まりの存在による面状ヒータの性能低下は起こらない。
貼着の際に延伸する絶縁層表面部位の凹凸の配列方向が、延伸方向に対して傾斜していれば、凹凸は延伸方向へ容易に伸びるので、面状ヒータは支持体の湾曲表面に追随することができる。
【図面の簡単な説明】
【図１】本発明の実施例に係る面状ヒータの断面図である。
【図２】図１の面状ヒータの製造過程での断面図である。
【図３】図１の面状ヒータが湾曲裏面に貼着された便座の断面図である。
【図４】面状ヒータの延伸方向と伸びとの関係を示す図である。（ａ）は絶縁層表面に形成した格子状凹部の配設方向と引っ張り方向との成す角度αを説明する図であり、（ｂ）は引っ張り試験結果を示す線図である。
【図５】エチレンフィルムの延伸方向と伸びとの関係を示す図である。（ａ）はエチレンフィルムのロール方向と引っ張り方向との成す角度βを説明する図であり、（ｂ）は引っ張り試験結果を示す線図である。
【符号の説明】
１面状ヒータ
２導電性繊維混抄紙
３金属箔電極
４絶縁層
５凹凸
６便座
７暖房便座[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a planar heater including a planar heating element and an insulating layer that is in close contact with the planar heating element and covers the planar heating element, and a manufacturing method thereof.
[0002]
[Prior art]
A planar heater including a planar heating element and an insulating layer that is in close contact with the planar heating element and covers the planar heating element is used in various heating devices.
[0003]
[Problems to be solved by the invention]
Since the planar heater does not have a self-supporting property, it is used by being attached to a support. When a planar heater is attached to the curved surface of the support, the planar heater is wrinkled, the planar heating element is bent, and the performance of the planar heater is degraded.
A planar heater is generally manufactured by laminating a thin film-shaped heating element and a thin-film insulating layer and heating and pressing. When the two layers are laminated and heated and pressed, the thin-film insulating layer adheres to the planar heating element all at once, so that air is trapped at the boundary surface between them, and the performance of the planar heater is degraded.
The present invention has been made in view of the above problems, a sheet heater that does not easily wrinkle even when pasted on the curved surface of a support, and has no air accumulation between the sheet heating element and the insulating layer, It is an object of the present invention to provide a manufacturing method thereof.
[0004]
[Means for Solving the Problems]
In order to solve the above-described problems, the present invention includes a planar heating element and an insulating layer that is in close contact with the planar heating element and covers the planar heating element, and is adhered to the curved surface of the support. The planar heater has irregularities formed on the surface of the insulating layer, and the arrangement direction of the irregularities on the surface portion of the insulating layer that is stretched during sticking is inclined with respect to the stretching direction. A planar heater is provided.
When a planar heater having irregularities on the surface of the insulating layer is attached to the curved surface of the support, the irregularities are deformed and the surface of the insulating layer expands and contracts, and the planar heater follows the curved surface of the support and deforms. Therefore, the sheet heater cannot be wrinkled and the performance of the sheet heater does not deteriorate. As for the unevenness on the surface of the insulating layer, the laminate is heated and pressed using a mold having irregularities, and the laminate is heated and pressed by sandwiching a mold plate on which the unevenness is formed between the molded body and the mold. Formed by the method. In this case, the portion of the insulating layer that faces the convex and concave portions of the mold and the template is pressed by the planar heating element before the portion of the insulating layer that faces the concave portion. Does not adhere to the body all at once. Therefore, an air reservoir is not formed at the boundary surface between the two, and the performance of the planar heater does not deteriorate due to the presence of the air reservoir.
If the arrangement direction of the irregularities on the surface portion of the insulating layer that is stretched at the time of sticking is inclined with respect to the stretching direction, the irregularities easily extend in the stretching direction, so the planar heater follows the curved surface of the support. can do.
[0005]
In the preferable aspect of this invention, the dimension of an unevenness | corrugation changes with the site | parts of an insulating layer surface.
When the size of the unevenness changes, the elasticity of the insulating layer surface changes. Therefore, when the curvature of the curved surface of the support differs depending on the part, the support having a different curvature depending on the part by appropriately varying the size of the unevenness on the surface of the insulating layer according to the curvature of the curved surface on which the unevenness faces. A planar heater can be made to follow the curved surface.
[0006]
In a preferred embodiment of the present invention, the area of the uneven protrusion on the surface of the insulating layer facing the human body is smaller than the area of the uneven protrusion on the surface of the insulating layer not facing the human body.
When the planar heater of the present invention is used for the heating device that contacts the human body, the area of the uneven protrusion on the surface of the insulating layer that faces the human body is larger than the area of the uneven protrusion on the surface of the insulating layer that does not face the human body. By reducing the size of the heater, it is possible to prevent heating of a portion of the heating device that contacts the human body and prevent burns.
[0007]
In a preferred aspect of the present invention, a flat portion having a sufficient width for laying electrical components is formed on the surface of the insulating layer of the planar heater.
In some cases, electrical components such as temperature detection elements are laid on the surface of the insulating layer of the planar heater. If a flat portion having a sufficient width for laying the electrical component is formed on the insulating layer surface of the planar heater, the electrical component can be laid easily.
[0008]
In a preferred embodiment of the present invention, there is a positive correlation between the depth of the unevenness on the surface of the insulating layer and the curvature of the curved surface where the unevenness faces.
In a preferred embodiment of the present invention, there is a positive correlation between the arrangement density of the unevenness on the surface of the insulating layer and the curvature of the curved surface where the unevenness faces.
When the depth of the unevenness on the surface of the insulating layer increases or the arrangement density of the unevenness increases, the stretchability of the surface of the insulating layer increases. Therefore, when any one of the above planar heaters is attached to the curved surface of the support, there is a positive correlation between the depth of the irregularities on the surface of the insulating layer and the curvature of the curved surface where the irregularities face each other, or the insulating layer If there is a positive correlation between the arrangement density of the surface irregularities and the curvature of the curved surface where the irregularities face each other, the surface of the insulating layer can be greatly expanded and contracted at the site to be curved with a large curvature when sticking. The heater can follow the curved surface of the support.
In a preferred embodiment of the present invention, there is a negative correlation between the width of the unevenness on the surface of the insulating layer and the curvature of the curved surface where the unevenness faces.
When the width of the unevenness on the surface of the insulating layer decreases, the elasticity of the surface of the insulating layer increases. Therefore, when any one of the above planar heaters is attached to the curved surface of the support, if there is a negative correlation between the width of the irregularities on the surface of the insulating layer and the curvature of the curved surface where the irregularities are opposed, Since the surface of the insulating layer can be greatly expanded and contracted at a portion that should be bent with a large curvature at the time of wearing, the planar heater can follow the curved surface of the support.
[0009]
In a preferred embodiment of the present invention, the area of the concave / convex concave portion in the insulating layer surface portion that curves concavely after pasting is wider than the area of the concave / convex concave portion in the insulating layer surface portion curved convexly after pasting.
[0010]
When the area of the concave and convex portions increases, the shrinkability of the insulating layer surface increases. Accordingly, if the area of the concave and convex recesses in the insulating layer surface portion that curves concavely after pasting is larger than the area of the concave and convex portions in the insulating layer surface portion that curves convex after pasting, the planar heater It can follow curved surfaces.
[0011]
In the preferable aspect of this invention, the extending | stretching direction of the insulating layer surface site | part extended | stretched in the case of sticking corresponds with the easy extending | stretching direction of an insulating layer.
[0012]
When the stretchability of the insulating layer is anisotropic, the surface of the insulating layer is easy if the stretching direction of the insulating layer surface portion that is stretched when the planar heater is attached matches the easy stretching direction of the insulating layer. Therefore, the planar heater can easily follow the curved surface of the support.
[0013]
The present invention provides a heating toilet seat device comprising any one of the above-described planar heaters.
[0014]
The planar heater according to the present invention is suitable for adhering to the lower surface of a curved toilet seat. Therefore, the planar heater according to the present invention can be used for a heating toilet seat.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
A planar heater according to an embodiment of the present invention will be described.
As shown in FIG. 1, the planar heater 1 is composed of a conductive fiber mixed paper 2, a pair of metal foil electrodes 3 attached to both ends of the conductive fiber mixed paper 2, and sandwiching them in a sandwich shape. The insulating resin layer 4 is provided. Concavities and convexities 5 are formed on the surface of the insulating layer 4.
As shown in FIG. 2, the sheet heater 1 includes a conductive fiber mixed paper 2 having a metal foil electrode 3 attached thereto, and an adhesive layer 4a made of a thermoplastic resin such as hot melt or ethylene vinyl acetate copolymer (EVA). A laminated body is formed by sandwiching sandwiched layers of insulating resin layers 4 made of laminated polyethylene terephthalate (PET), polyethylene (PE), etc., and the laminated body is added in the laminating direction in a mold having a concavo-convex shape. Manufactured by pressure heating. The conductive fiber mixed paper 2 and the insulating layer 4 are pressed together and the unevenness 5 is formed at the same time, and the planar heater 1 is efficiently produced.
As shown in FIG. 3, the planar heater 1 that cannot stand by itself is attached to the curved back surface of the toilet seat 6 that is a support, and constitutes a heated toilet seat 7 in cooperation with the toilet seat 6.
[0016]
As can be seen from FIG. 3, in the curved portion 6a on the back surface of the toilet seat 6, the unevenness 5 on the surface of the insulating layer 4 adhered to the curved portion 6a expands and the surface of the insulating layer 4 extends, and is adhered to the curved portion 6a on the opposite side. When the unevenness 5 on the surface of the insulating layer 4 that is not worn is reduced and the surface of the insulating layer 4 is contracted, the planar heater 1 can follow the curved portion 6a on the back surface of the toilet seat 6 and adhere to the curved portion 6a. Therefore, wrinkles are not generated in the sheet heater 1, and the conductive fiber mixed paper 2 is not bent significantly by wrinkles, and the performance of the sheet heater 1 is not deteriorated.
As can be seen from FIG. 3, in the planar heater 1, the area and depth of the unevenness 5 facing the portion 6 a having a large curvature on the back surface of the toilet seat 6 is set to the depth of the unevenness 5 facing the portion 6 b having a small curvature on the back surface of the toilet seat 6. It is larger than the area and depth. Since the surface of the insulating layer 4 on which the unevenness 5 having large dimensions is formed is more stretchable than the surface of the insulating layer 4 on which the unevenness 5 having small dimensions is formed, insulation against the portion 6a having a large curvature on the back surface of the toilet seat 6 is provided. The surface of the layer 4 can be expanded and contracted greatly, and the surface of the insulating layer 4 facing the portion having a small curvature on the back surface of the toilet seat 6 can be expanded and contracted small. Therefore, the planar heater 1 can closely adhere to the back surface following the curvature of the back surface of the toilet seat 6 having a different curvature depending on the part. Therefore, when the sheet heater 1 is attached to the back surface of the heating toilet seat 6, no wrinkles are generated in the sheet heater 1, and the conductive fiber mixed paper 2 is not extremely bent, and the performance of the sheet heater 1. Will not drop.
As shown in FIG. 3, if the flat portion 4 b is formed on the surface of the insulating layer 4, the electrical component 8 such as a thermistor can be easily laid on the surface of the insulating layer 4, and the convenience of the heating toilet seat 7 is improved.
[0017]
As mentioned above, although the Example of this invention was described, this invention is not limited to the said Example.
Depending on the intended use of the sheet heating element 1, only one side of the non-conductive fiber mixed paper 2 may be covered with the insulating layer 4.
Instead of forming the unevenness on the mold, the unevenness 5 may be formed by a resin unevenness indicator such as Teflon or silicon.
The shape of the unevenness 5 may be circular, rectangular, or any other shape.
[0018]
In the planar heater 1, the surface of the insulating layer 4 facing the human body, that is, the surface of the insulating layer 4 adhered to the back surface of the toilet seat 6 is the surface of the insulating layer 4 not facing the human body, that is, the toilet seat. 6 may be smaller than the area of the protrusions of the irregularities 5 on the surface of the insulating layer 4 that is not attached to the back surface. With such a configuration, it is possible to prevent heating of the portion of the heating toilet seat 6 that contacts the human body, and to prevent burns of the toilet seat user.
[0019]
In the planar heater 1, a positive correlation may be provided between the depth of the unevenness 5 and the curvature of the back surface of the toilet seat 6 facing the unevenness 5.
In the planar heater 1, a positive correlation may be provided between the arrangement density of the unevenness 5 and the curvature of the back surface of the toilet seat 6 facing the unevenness 5.
When the depth of the unevenness 5 on the surface of the insulating layer 4 increases or the arrangement density of the unevenness 5 increases, the stretchability of the surface of the insulating layer 4 increases. Therefore, when the planar heater 1 is attached to the curved back surface of the toilet seat 6, there is a positive correlation between the depth of the unevenness 5 on the surface of the insulating layer 4 and the curvature of the curved back surface where the unevenness 5 faces, or the insulating layer If there is a positive correlation between the arrangement density of the irregularities 5 on the four surfaces and the curvature of the curved back surface where the irregularities 5 face each other, the surface of the insulating layer 4 can be greatly expanded and contracted at a portion that should be curved with a large curvature upon sticking. Therefore, the planar heater 1 can follow and adhere to the curved back surface of the toilet seat 6.
[0020]
In the planar heater 1, a negative correlation may be provided between the width of the unevenness 5 and the curvature of the back surface of the toilet seat 6 that the unevenness 5 faces.
When the width of the unevenness 5 on the surface of the insulating layer 4 decreases, the stretchability of the surface of the insulating layer 4 increases. Therefore, when the planar heater 1 is attached to the curved back surface of the toilet seat 6, if there is a negative correlation between the width of the uneven surface 5 on the surface of the insulating layer 4 and the curvature of the curved back surface where the uneven surface 5 faces, Since the surface of the insulating layer 4 can be greatly expanded and contracted at a portion to be bent with a large curvature when worn, the planar heater 1 can follow the curved back surface of the toilet seat 6 and closely adhere to it.
[0021]
In the planar heater 1, the surface area of the insulating layer 4 that is concavely curved after being attached to the back surface of the toilet seat 6 is the surface area of the insulating layer 4 that is convexly curved after being attached to the back surface of the toilet seat 6. You may make it larger than the area of the recessed part of the unevenness | corrugation 5 of 4d. When the area of the recesses of the unevenness 5 increases, the shrinkage of the surface of the insulating layer 4 increases. Therefore, if the area of the concave portion of the uneven portion 5 in the surface portion 4c of the insulating layer 4 curved concavely after pasting is wider than the area of the concave portion of the surface portion 4d of the insulating layer 4 curved convexly after pasting, the surface The shaped heater 1 can follow the curved back surface of the toilet seat 6 and adhere to it.
[0022]
In the planar heater 1, the arrangement direction of the unevenness 5 of the surface portion 4 d of the insulating layer 4 that extends when the sheet heater 6 is attached to the toilet seat 6 may be inclined with respect to the extending direction indicated by the white arrow in FIG. 3. In FIG. 4, the relationship between the angle α formed by the stretching direction and the grid arrangement direction, the tensile stress, and the elongation of the sheet heater 1 embossed in a grid shape conforms to the JIS standard tensile test. The result of investigation based on the tensile test is shown. It can be seen from FIG. 4 that when the stretching direction is inclined with respect to the grid arrangement direction, the elongation is larger than when the stretching direction is parallel to the grid arrangement direction. Therefore, by inclining the arrangement direction of the unevenness 5 of the surface portion 4d of the insulating layer 4 that extends when sticking to the toilet seat 6 with respect to the extending direction indicated by the white arrow in FIG. The stretch amount of 4d can be increased, and the planar heater 1 can be brought into close contact with the curved back surface of the toilet seat 6.
[0023]
In the planar heater 1, the extending direction of the surface portion 4d of the insulating layer 4 that is stretched when sticking to the toilet seat 6 (indicated by a white arrow in FIG. 3), and the easy extending direction of the insulating layer 4 including the surface portion 4d May be matched.
FIG. 5 shows the results of investigating the relationship between the angle β formed between the stretching direction and the roll winding direction of the polyethylene film, the tensile stress, and the elongation based on a tensile test according to the JIS standard tensile test. FIG. 5 shows that the elongation is large when the stretching direction coincides with the roll winding direction of the polyethylene film. When a material that is anisotropic easily stretched, such as a polyethylene film wound around a roll, is used as the insulating layer 4, the stretching of the surface portion 4 d of the insulating layer 4 that is stretched when sticking to the toilet seat 6 is performed. By making the direction and the easy extending direction of the insulating layer 4 including the surface portion 4 d coincide with each other, the amount of extension of the insulating layer 4 surface portion 4 d can be increased, and the planar heater 1 is placed on the curved back surface of the heating toilet seat 6. It can be made to follow and adhere.
[0024]
Although the planar heater 1 is suitable for adhering to the curved back surface of the toilet seat 6 to form the heating toilet seat 7, it can be applied to various curved surfaces as well as the toilet seat 6, and is limited to the heating toilet seat 7. Various heaters can be configured.
[0025]
【The invention's effect】
As can be seen from the above description, when a planar heater having irregularities on the surface of the insulating layer is attached to the curved surface of the support, the irregularities are deformed and the insulating layer surface expands and contracts, and the planar heater becomes a curved surface of the support. Deform to follow. Therefore, the sheet heater cannot be wrinkled and the performance of the sheet heater does not deteriorate. Therefore, according to the present invention, there is provided a planar heater that is unlikely to wrinkle even if it is attached to a curved surface of a support. As for the unevenness on the surface of the insulating layer, the laminated body is heated and pressed using a mold having unevenness, the laminated body is sandwiched between the molded body and the mold, and the laminated body is heated and pressed. Formed by the method. In this case, the portion of the insulating layer that faces the convex and concave portions of the mold and the template is pressed by the planar heating element before the portion of the insulating layer that faces the concave portion. Does not adhere to the body all at once. Therefore, an air reservoir is not formed at the boundary surface between the two, and the performance of the planar heater does not deteriorate due to the presence of the air reservoir.
If the arrangement direction of the irregularities on the surface portion of the insulating layer that is stretched at the time of sticking is inclined with respect to the stretching direction, the irregularities easily extend in the stretching direction, so the planar heater follows the curved surface of the support. can do.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a planar heater according to an embodiment of the present invention.
2 is a cross-sectional view of the planar heater of FIG. 1 in the manufacturing process.
3 is a cross-sectional view of a toilet seat in which the planar heater of FIG. 1 is attached to a curved back surface.
FIG. 4 is a diagram showing the relationship between the stretching direction and elongation of a planar heater. (A) is a figure explaining angle (alpha) which the arrangement | positioning direction of the grid | lattice-shaped recessed part formed in the insulating layer surface and the tension | pulling direction comprise, (b) is a diagram which shows a tension test result.
FIG. 5 is a diagram showing the relationship between the stretching direction and elongation of an ethylene film. (A) is a figure explaining angle (beta) which the roll direction and tension | pulling direction of an ethylene film comprise, (b) is a diagram which shows a tension test result.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Sheet heater 2 Conductive fiber mixed paper 3 Metal foil electrode 4 Insulating layer 5 Concavity and convexity 6 Toilet seat 7 Heating toilet seat

Claims

面状発熱体と、面状発熱体に密着して面状発熱体を被覆する絶縁層とを備え、支持体の湾曲表面に貼着される面状ヒータであって、絶縁層表面に凹凸が形成されており、貼着の際に延伸する絶縁層表面部位の凹凸の配列方向が、延伸方向に対して傾斜していることを特徴とする面状ヒータ。A planar heater that includes a planar heating element and an insulating layer that is in close contact with the planar heating element and covers the planar heating element, and is attached to the curved surface of the support, wherein the insulating layer surface has irregularities. A planar heater , wherein the arrangement direction of the irregularities on the surface portion of the insulating layer that is formed and is stretched during sticking is inclined with respect to the stretching direction .

絶縁層表面の部位によって凹凸の寸法が異なることを特徴とする請求項１に記載の面状ヒータ。 The planar heater according to claim 1, wherein the size of the unevenness varies depending on a portion of the surface of the insulating layer.

人体に対峙する絶縁層表面の凹凸の凸部の面積が、人体に対峙しない絶縁層表面の凹凸の凸部の面積よりも小さいことを特徴とする請求項１又は２に記載の面状ヒータ。 3. The planar heater according to claim 1, wherein an area of the uneven protrusion on the surface of the insulating layer facing the human body is smaller than an area of the uneven protrusion on the surface of the insulating layer not facing the human body.

絶縁層表面に電装部品の敷設に十分な広さの平坦部が形成されていることを特徴とする請求項１乃至３の何れか１項に記載の面状ヒータ。 The planar heater according to any one of claims 1 to 3, wherein a flat portion having a sufficient width for laying electrical parts is formed on the surface of the insulating layer.

絶縁層表面の凹凸の深さと、凹凸が対峙する湾曲表面の曲率との間に、正の相関が在ることを特徴とする請求項１乃至４何れか１項に記載の面状ヒータ。5. The planar heater according to claim 1 , wherein a positive correlation exists between the depth of the unevenness on the surface of the insulating layer and the curvature of the curved surface on which the unevenness faces. 6.

絶縁層表面の凹凸の配設密度と、凹凸が対峙する湾曲表面の曲率との間に、正の相関が在ることを特徴とする請求項１乃至４何れか１項に記載の面状ヒータ。The planar heater according to any one of claims 1 to 4, wherein there is a positive correlation between the arrangement density of the unevenness on the surface of the insulating layer and the curvature of the curved surface where the unevenness faces. .

絶縁層表面の凹凸の巾と、凹凸が対峙する湾曲表面の曲率との間に、負の相関が在ることを特徴とする請求項１乃至４何れか１項に記載の面状ヒータ。5. The planar heater according to claim 1, wherein a negative correlation exists between the width of the unevenness on the surface of the insulating layer and the curvature of the curved surface on which the unevenness faces.

貼着後に凹に湾曲する絶縁層表面部位の凹凸の凹部の面積が、貼着後に凸に湾曲する絶縁層表面部位の凹凸の凹部の面積よりも広いことを特徴とする請求項１乃至４何れか１項に記載の面状ヒータ。The area of the concave / convex concave portion on the surface portion of the insulating layer that curves concavely after pasting is wider than the area of the concave / convex concave portion on the surface portion of the insulating layer curved convexly after pasting. The planar heater of Claim 1.

貼着の際に延伸する絶縁層表面部位の延伸方向と、絶縁層の易延伸方向とが一致することを特徴とする請求項１乃至４何れか１項に記載の面状ヒータ。 The planar heater according to any one of claims 1 to 4, wherein an extending direction of a surface portion of the insulating layer that is extended at the time of sticking coincides with an easy extending direction of the insulating layer .

請求項１乃至９の何れか１項に記載の面状ヒータを備えることを特徴とする暖房便座装置。 A heating toilet seat device comprising the planar heater according to any one of claims 1 to 9 .