WO2011001953A1 - Cord-like heater and planar heater - Google Patents

Cord-like heater and planar heater Download PDF

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Publication number
WO2011001953A1
WO2011001953A1 PCT/JP2010/061007 JP2010061007W WO2011001953A1 WO 2011001953 A1 WO2011001953 A1 WO 2011001953A1 JP 2010061007 W JP2010061007 W JP 2010061007W WO 2011001953 A1 WO2011001953 A1 WO 2011001953A1
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WO
WIPO (PCT)
Prior art keywords
heater
cord
heat
wire
flame
Prior art date
Application number
PCT/JP2010/061007
Other languages
French (fr)
Japanese (ja)
Inventor
基行 大場
雅嗣 斎藤
康浩 長谷
典男 池ヶ谷
大介 漆畑
Original Assignee
株式会社クラベ
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Application filed by 株式会社クラベ filed Critical 株式会社クラベ
Priority to JP2011520920A priority Critical patent/JP5916385B2/en
Publication of WO2011001953A1 publication Critical patent/WO2011001953A1/en

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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/34—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/56—Heating or ventilating devices
    • B60N2/5678—Heating or ventilating devices characterised by electrical systems
    • B60N2/5685—Resistance
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/40—Heating elements having the shape of rods or tubes
    • H05B3/54—Heating elements having the shape of rods or tubes flexible
    • H05B3/56—Heating cables
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/002—Heaters using a particular layout for the resistive material or resistive elements
    • H05B2203/003—Heaters using a particular layout for the resistive material or resistive elements using serpentine layout
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/017—Manufacturing methods or apparatus for heaters
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/026—Heaters specially adapted for floor heating
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/029—Heaters specially adapted for seat warmers

Definitions

  • the present invention relates to a cord-like heater that can be suitably used for an electric blanket, an electric carpet, a car seat heater, and the like, and a sheet-like heater using the cord-like heater, and more particularly, to a thing that can cope with an application that requires flame retardancy. .
  • Cord heaters used for electric blankets, electric carpets, car seat heaters, etc. are generally known to have a configuration in which a heater wire is spirally wound around a core wire and an outer cover is covered with an insulating layer from above. ing.
  • the heater wire is made of a copper wire, a nickel chrome alloy wire or the like that is aligned or twisted. Further, a heat-sealed portion is formed on the outer periphery of the heating wire, and the heat-bonded portion is adhered to a base material such as a nonwoven fabric or an aluminum foil (for example, Patent Document 1, Patent Document 2, Patent Document). 3 etc.).
  • Patent Document 4 has been filed by the applicant.
  • Polyethylene resin is mainly used as the heat fusion part of the cord heater.
  • this polyethylene resin is a flammable material, in the unlikely event that abnormal heating occurs due to disconnection of the heating wire, or there is ignition from the outside, the heat fusion part may burn There is.
  • combustion is prevented by using a flame retardant material on the side of the substrate or covering the outer periphery of the heating wire with a flame retardant insulator layer, but for more certainty, It is also necessary to improve flame retardancy on the side of the heat-sealed portion of the cord heater.
  • Patent Documents 2 and 3 it is described that a flame retardant that does not generate halogen is blended in a polyethylene resin and used for a cord-like heater, but this material is used only for insulation coating, No mention is made of the flame retardancy of the heat-sealed part.
  • the heat-fusible resin material that is normally used is easily combustible, even with such cord-like heaters according to Patent Documents 2 and 3, even if the insulation coating is flame-retardant, There is a risk that the flame propagates on the surface and the combustion part expands.
  • the present invention has been made in order to solve such problems of the prior art, and an object of the present invention is to provide a cord-shaped heater that can be used for applications that require flame retardancy, and a surface shape using the same. It is to provide a heater.
  • a cord-like heater according to claim 1 of the present invention is a cord-like heater having a heating wire and a heat fusion part formed on the outer periphery of the heating wire,
  • the conductor wire is wound around the core wire and the outer periphery thereof is covered with an insulating coating, or the conductor wire covered with the insulating coating is aligned or twisted.
  • the landing portion is made of a flame retardant polymer composition, and the cord-like heater has flame retardant properties that pass the UL1581 horizontal combustion test.
  • a cord-like heater according to claim 2 is the cord-like heater according to claim 1, wherein the flame-retardant polymer composition comprises an olefin resin and a flame retardant.
  • the cord-like heater according to claim 3 is the cord-like heater according to claim 2, wherein the flame-retardant polymer composition is measured according to JIS-K7210 method A at a temperature of 200 ° C. and a load of 2.16 kg. a melt flow rate of the object is characterized in that it is 5.0 cm 3/10 minutes or more.
  • a corded heater according to claim 4 is the corded heater according to claim 2 or 3, wherein the olefin resin is an ethylene-unsaturated ester copolymer.
  • a cord-like heater according to claim 5 is the cord-like heater according to any one of claims 1 to 4, wherein the heating wire is formed by aligning or twisting conductor wires covered with an insulating film, It is characterized by being wound on a core wire.
  • a sheet heater according to claim 6 is characterized in that the cord heater according to any one of claims 1 to 5 is disposed on a base material.
  • a sheet heater according to claim 7 is the sheet heater according to claim 6, wherein the base material is FMVSS No. It consists of what has the flame retardance which passes the combustion test of 302 automotive inner-layer material.
  • the sheet heater according to claim 8 is the sheet heater according to claim 7, characterized in that the substrate is made of a nonwoven fabric.
  • the sheet heater according to claim 9 is the sheet heater according to claim 6, wherein the non-woven fabric is composed of a heat-fusible fiber and a flame-retardant fiber that does not contribute to the heat-sealing.
  • the sheet heater according to claim 10 is the sheet heater according to claim 9, wherein the non-woven fabric is mixed with 70% or more of the flame-retardant fiber and 5% or more of the heat-fusible fiber. It is characterized by being mixed.
  • the sheet heater according to claim 11 is the sheet heater according to any one of claims 8 to 10, wherein the heat fusion part of the cord heater surrounds the fibers constituting the nonwoven fabric. The cord heater and the base material are adhered to each other.
  • the sheet heater according to claim 12 is the sheet heater according to claim 9 or 10, wherein the heat-fusible fiber has a core-sheath structure and surrounds the core part.
  • the sheath part and the heat fusion part of the cord heater are fused and integrated with each other.
  • a cord-like heater having a heating wire and a heat fusion part formed on the outer periphery of the heating wire, wherein the heating wire has a conductor wire on the core wire. It is wound and the outer periphery is coated with an insulating coating, or a conductor wire coated with an insulating coating is aligned or twisted, and the cord heater is used in the UL 1581 horizontal combustion test. It has the flame retardance to pass.
  • a planar heater according to a fourteenth aspect is characterized in that the cord-shaped heater according to the thirteenth aspect is disposed on a base material.
  • the heat fusion part is made of a flame retardant polymer composition
  • the cord-like heater passes the UL1581 horizontal combustion test. Since it has flame retardancy, it can be used for applications that require flame retardancy.
  • the flame retardant polymer composition is composed of an olefin resin and a flame retardant, the above effect can be further ensured.
  • the flame flow rate of the flame retardant polymer composition measured by the method A of JIS-K7210 at a temperature of 200 ° C. and a load of 2.16 kg is 5.
  • the said effect can be made more reliable.
  • the cord-like heater according to claim 4 since the olefin-based resin is an ethylene-unsaturated ester copolymer, the above effect can be further ensured.
  • the heating wire is formed by arranging or twisting conductor wires covered with an insulating film and wound on the core wire. The effects as described above can be obtained.
  • the planar heater according to claim 6 since the cord-like heater according to any one of claims 1 to 5 is disposed on the base material, it is used for an application that requires flame retardancy. Can do.
  • the base material has FMVSS No. Since it consists of what has the flame retardance which passes the combustion test of 302 automotive inner-layer material, the said effect can be made more reliable.
  • the substrate is made of a nonwoven fabric, and the above-described effects can be achieved even in such a configuration. Further, according to the planar heater according to the ninth aspect, since the nonwoven fabric is composed of the heat-fusible fiber and the flame-retardant fiber that does not contribute to the heat-sealing, the above effect can be further enhanced.
  • the nonwoven fabric is mixed with 70% or more of the flame-retardant fiber and 5% or more of the heat-fusible fiber. It can be made more reliable.
  • the cord-shaped heater and the base material are bonded together by the heat-sealed portion of the cord-shaped heater surrounding the fibers constituting the nonwoven fabric. Since it is comprised, the said effect can be made more reliable.
  • the heat-fusible fiber has a core-sheath structure and surrounds the core portion, and the heat-sealed portion of the cord-shaped heater and the sheath portion.
  • cord-like heater according to claim 13 since it has flame retardancy that passes the UL1581 horizontal combustion test, it can be used for applications that require flame retardancy. Further, according to the planar heater according to claim 14, since the cord-like heater according to claim 13 is disposed on the base material, it can be used for an application requiring flame retardancy.
  • FIG. 5 is a diagram illustrating the embodiment 1-1 according to the present invention and is a diagram illustrating a configuration of a hot press type heater manufacturing apparatus.
  • FIG. 5 is a diagram showing the embodiment 1-1 according to the present invention, and is a partial perspective view showing a state in which cord-like heaters are arranged in a predetermined pattern shape.
  • FIG. 1-1 by this invention and is a top view which shows the structure of a planar heater.
  • FIG. 5 is a diagram showing the embodiment 1-1 according to the present invention, and is a perspective view showing a part of the state in which the planar heater is embedded in the vehicle seat. It is a figure which shows Embodiment 1-2 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater. It is a figure which shows Embodiment 1-3 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater. It is a figure which shows Embodiment 2 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater.
  • Embodiment 3-1 it is a figure which shows Embodiment 3-1 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater. It is a figure which shows Embodiment 3-2 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater. It is a figure which shows Embodiment 4 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater.
  • the adhesion state of the base material and the cord-shaped heater is enlarged 45 times.
  • Embodiment 1 of the present invention (Embodiment 1-1 to Embodiment 1-3) will be described with reference to FIG. 1 to FIG. 7. These embodiments use the present invention as a planar heater. The example which assumes application to the seat heater for vehicles is shown.
  • Embodiment 1-1 will be described with reference to FIGS.
  • the configuration of the cord-like heater 10 in this embodiment will be described.
  • the cord-like heater 10 in the present embodiment is configured as shown in FIG. First, there is a heater core 3 made of an aromatic polyamide fiber bundle having an outer diameter of about 0.2 mm, and a tin-plated hard tin-containing copper alloy wire (TH-SNCC) having an element wire diameter of 0.08 mm is provided on the outer periphery of the heater core 3. -3), which is formed by aligning six conductor wires 5a (only three of them are shown in FIG. 1) is wound spirally at a pitch of about 0.7 mm. .
  • TH-SNCC tin-plated hard tin-containing copper alloy wire
  • a tetrafluoroethylene-hexafluoropropylene copolymer (FEP) as an insulator layer 7 is extruded with a thickness of about 0.15 mm.
  • the heating wire 1 is formed by covering. Further, the outer periphery of the heating wire 1 is further extruded and coated with a polyethylene resin containing a flame retardant as the heat-sealing portion 9 to a thickness of 0.2 mm.
  • the cord-shaped heater 10 has such a configuration, and its finished outer diameter is 1.1 mm.
  • the heater core 3 is effective when considering flexibility and tensile strength.
  • this cord-shaped heater 1 has a flame retardance which passes the UL1581 horizontal combustion test (2008, 4th edition) alone. “UL” is a safety standard created by Underwriters Laboratories Inc., USA.
  • the base material 11 in this example is a non-woven fabric in which 10% heat-fusible fiber having a core-sheath structure having low melting point polyester as a sheath component and 90% flame-retardant fiber made of flame-retardant polyester fiber are mixed. (A basis weight is 100 g / m 2 and a thickness is 0.6 mm). Such a base material 11 is formed into a desired shape by a known method such as die cutting.
  • FIG. 2 is a diagram showing a configuration of a hot press type heater manufacturing apparatus 13 for bonding and fixing the cord-like heater 10 on the base material 11.
  • the anchoring mechanism 17 includes a pin 19, and the pin 19 is inserted into a hole 21 drilled in the hot press jig 15 from below.
  • a retaining member 23 is attached to the upper portion of the pin 19 so as to be movable in the axial direction, and is always urged upward by a coil spring 25.
  • the cord-like heaters 10 are hooked on the locking members 23 of the plurality of locking mechanisms 17 and arranged in a predetermined pattern shape.
  • a press hot plate 27 is disposed above the plurality of locking mechanisms 17 so as to be movable up and down. That is, the cord-shaped heater 10 is arranged in a predetermined pattern shape while being hooked on the retaining members 23 of the plurality of retaining mechanisms 17, and the base material 11 is placed thereon. In this state, the press hot plate 27 is lowered to heat and press the cord-like heater 10 and the base material 11 at, for example, 230 ° C./5 seconds. As a result, the heat fusion part 9 on the cord-like heater 10 side and the heat-fusible fiber on the substrate 11 side are fused, and as a result, the cord-like heater 10 and the substrate 11 are bonded and fixed. It will be. It should be noted that the retaining members 23 of the plurality of retaining mechanisms 17 move downward against the urging force of the coil spring 25 during heating and pressurization due to the lowering of the press hot plate 27.
  • An adhesive layer may be formed or a double-sided tape may be attached to the surface of the substrate 11 where the cord heater 10 is not disposed. This is for fixing the planar heater 31 to the seat when it is attached to the seat.
  • a sheet heater 31 of a vehicle seat heater as shown in FIG. 4 can be obtained.
  • a cord 40 is connected to both ends of the cord heater 10 in the planar heater 31 and to the temperature control device 39, and the cord 40 is connected to the cord heater 10, the temperature control device 39, and the connector 35. Is connected. And it connects to the electric system of the vehicle which is not illustrated via this connector 35.
  • planar heater 31 which comprises the said structure is embedded and arrange
  • Embodiment 1-2 Next, Embodiment 1-2 will be described with reference to FIG. In the case of the embodiment 1-2, as shown in FIG. 6, a plurality of conductor strands 5a covered with an insulating coating 5b are twisted. Other configurations are the same as those of the embodiment 1-1, and the same parts are denoted by the same reference numerals and description thereof is omitted.
  • Embodiment 1-3 Next, Embodiment 1-3 will be described with reference to FIG. In the case of Embodiment 1-3, as shown in FIG. 7, a plurality of conductor strands 5a covered with an insulating coating 5b are aligned. Other configurations are the same as those of the embodiment 1-1, and the same parts are denoted by the same reference numerals and description thereof is omitted.
  • FIG. 8 is a schematic diagram.
  • the heating wire 1 is formed by aligning and spirally winding at a pitch of 1 mm.
  • the conductor wire 5a is covered with an insulating film 5b made of polyurethane with a thickness of about 0.005 mm.
  • a polyethylene resin containing a flame retardant as the heat fusion part 9 is extruded and coated with a thickness of 0.25 mm.
  • the cord-like heater 10 has such a configuration, and its finished outer diameter is 0.9 mm.
  • this cord-shaped heater 1 has a flame retardance which passes the UL1581 horizontal combustion test (2008, 4th edition) alone.
  • the configuration and manufacturing method of the substrate 11 and the like are the same as those in the first embodiment.
  • Embodiment 3 (Embodiment 3-1, Embodiment 3-2) of the present invention will be described with reference to FIG. 9 and FIG. Embodiment 3-1
  • the cord-like heater 10 in the present embodiment is configured as shown in FIG. FIG. 9 is a schematic diagram.
  • the heater core 3 made of an aromatic polyamide fiber bundle having an outer diameter of about 0.2 mm
  • seven conductor strands 5a made of a tin-copper alloy wire having a strand diameter of 0.08 mm (in FIG. Only five wires are shown.)
  • the heating wire 1 is formed by aligning and spirally winding at a pitch of 1 mm.
  • the conductor wires 5a Three of the seven conductor wires 5a are covered with an insulating film 5b made of polyurethane with a thickness of about 0.005 mm. The remaining four conductor wires 5a are not covered with an insulating film. The conductor strands 5a are aligned so that those covered with the insulating coating 5b and those not covered are alternately arranged.
  • a polyethylene resin containing a flame retardant as the heat fusion part 9 is extruded and coated with a thickness of 0.25 mm.
  • the cord-like heater 10 has such a configuration, and its finished outer diameter is 0.9 mm. Moreover, this cord-shaped heater 1 has a flame retardance which passes the UL1581 horizontal combustion test (2008, 4th edition) alone.
  • the configuration and manufacturing method of the substrate 11 and the like are the same as those in the first embodiment.
  • FIG. 10 is a schematic diagram.
  • the heating wire 1 is formed by aligning and spirally winding at a pitch of 1 mm.
  • the seven conductor wires 5a are covered with an insulating coating 5b made of polyurethane with a thickness of about 0.005 mm. The remaining one conductor wire 5a is not covered with an insulating film. The conductor strands 5a are aligned so that the uncoated ones are disposed among those coated with the insulating coating 5b.
  • a polyethylene resin containing a flame retardant as the heat fusion part 9 is extruded and coated with a thickness of 0.25 mm.
  • the cord-like heater 10 has such a configuration, and its finished outer diameter is 0.9 mm. Moreover, this cord-shaped heater 1 has a flame retardance which passes the UL1581 horizontal combustion test (2008, 4th edition) alone.
  • the configuration and manufacturing method of the substrate 11 and the like are the same as those in the first embodiment.
  • the cord-like heater 10 in the present embodiment is configured as shown in FIG. First, there is a heater core 3 made of an aromatic polyamide fiber bundle having an outer diameter of about 0.2 mm, and a tin-plated hard tin-containing copper alloy wire (TH-SNCC) having an element wire diameter of 0.08 mm is provided on the outer periphery of the heater core 3. -3), which is composed of six conductor wires 5a (only three of them are shown in FIG. 11) arranged in a spiral at a pitch of about 0.7 mm. Yes.
  • TH-SNCC tin-plated hard tin-containing copper alloy wire
  • a tetrafluoroethylene-hexafluoropropylene copolymer (FEP) as an insulator layer 7 is extruded with a thickness of about 0.15 mm.
  • the heating wire 1 is formed by covering. Further, the outer periphery of the heating wire 1 is further covered with a polyethylene resin not blended with a flame retardant as the heat fusion part 9 with a thickness of 0.1 mm and intermittently at intervals of 5 mm.
  • the cord-like heater 10 has such a configuration, and its finished outer diameter is 0.9 mm.
  • the cord-like heater 1 alone has flame retardancy that passes the UL1581 horizontal combustion test (2008, 4th edition).
  • the configuration and manufacturing method of the substrate 11 and the like are the same as those in the first embodiment.
  • FIG. 12 shows an electron micrograph of the vicinity of the heat fusion part 9 of the cord-like heater 10 according to the first embodiment. Also from this photograph, it can be confirmed that the heat fusion part 9 of the cord heater surrounds the fibers constituting the nonwoven fabric (base material 11).
  • the base material 11 is a non-woven fabric and contains heat-fusible fibers
  • the heat-fusible fibers have a core-sheath structure and the sheath portion has a low melting point, the state surrounding the core portion
  • the sheath part and the heat fusion part 9 of the cord heater are fused and integrated with each other.
  • the cord-like heater 10 and the base material 11 are more firmly bonded.
  • the present invention is not limited to Embodiments 1 to 4 described above.
  • various conventionally known cord-like heaters can be used.
  • the configuration of the heating wire 1 for example, as in the above-described Embodiment 1-1, a plurality of conductor wires 5a are twisted or aligned, and these are wound on the core wire 3 and insulated on the outer periphery thereof.
  • the one provided with the coating 7 see FIG. 1), the one obtained by twisting a plurality of conductor wires 5a covered with the insulating coating 5b as in the above-described Embodiment 1-2 (see FIG.
  • a plurality of conductor wires 5a covered with the insulating coating 5b are aligned (see FIG. 7), and the conductor element covered with the insulating coating 5b as in Embodiment 2 above.
  • a plurality of wires 5a are twisted or aligned, and the wires 5a are wound around the core wire 3 (see FIG. 8).
  • FIG. 9 only in the form (FIG. 9) where the conductor strands 5a covered with the insulating coating 5b and the conductor strands 5a not covered with the insulating coating 5b are alternately arranged. For example, as shown in FIG.
  • the core wire 3 for example, inorganic fibers such as glass fibers, polyester fibers such as polyethylene terephthalate, monofilaments of organic fibers such as aliphatic polyamide fibers, aromatic polyamide fibers, wholly aromatic polyester fibers, multifilaments, spans, or Examples thereof include fibers having a structure in which the fiber material or an organic polymer material constituting the fiber material is used as a core and a thermoplastic organic polymer material is coated on the periphery thereof. Further, if the core wire 3 has heat shrinkability and heat meltability, the core wire is melted and cut by contraction due to abnormal heating when the conductor wire 5a is disconnected, and the core wire 3 is wound.
  • inorganic fibers such as glass fibers, polyester fibers such as polyethylene terephthalate, monofilaments of organic fibers such as aliphatic polyamide fibers, aromatic polyamide fibers, wholly aromatic polyester fibers, multifilaments, spans, or Examples thereof include fibers having a structure in which the fiber material or an
  • the conductor strand 5a follows the operation of the core wire 3 and separates the ends of the disconnected conductor strand 5a. For this reason, the ends of the disconnected conductor wires do not come into contact with or leave from each other, and contact with a slight contact area such as point contact can be prevented, and abnormal heat generation can be prevented. Moreover, if the conductor strand 5a is the structure insulated by the insulating film 5b, the core wire 3 does not need to stick to an insulating material. For example, a stainless steel wire or a titanium alloy wire can be used. However, considering that the conductor wire 5a is disconnected, the core wire 3 is preferably an insulating material.
  • the conductor wire 5a a conventionally known wire can be used.
  • a copper alloy wire containing silver in which a copper solid solution and a copper silver eutectic are formed into a fiber shape can be used.
  • Various cross-sectional shapes can be used, and the cross-sectional shape is not limited to a generally used cross-sectional shape, and a so-called rectangular wire may be used.
  • the conductor wire 5 a is wound around the core wire 3, among them, it is preferable that the amount of spring back when the heating wire 1 is wound is small, and the restoration rate is 200% or less. .
  • a silver alloy copper alloy wire in which a copper solid solution and a copper silver eutectic are formed into a fiber shape is excellent in tensile strength and bending strength, but easily springs back when a heating wire is wound. For this reason, when the wire is wound around the core wire 3, it is not preferable because the conductor wire 5 a is easily lifted or the conductor wire 5 a is easily broken due to excessive winding tension, and twists are likely to occur after processing. In particular, when the conductor wire 5a is covered with the insulating coating 5b, the restoring force by the insulating coating 5b is also applied. Therefore, it is important to select a conductor wire 5a with a low restoration rate and cover the restoring force of the insulating coating 5b.
  • the measurement of the restoration rate defined in the present invention will be described in detail.
  • a conventionally known resin material or the like can be used as the insulating coating 5b covered with the conductor wire 5a.
  • resin material or the like can be used as the insulating coating 5b covered with the conductor wire 5a.
  • polyurethane resin, polyamide resin, polyimide resin, polyamideimide resin, polyesterimide resin, nylon resin, polyester Nylon resin, polyethylene resin, polyester resin, vinyl chloride resin, fluororesin, silicone resin and the like can be mentioned.
  • the conductor wires 5a can be fused together, so that the heating wire 1 does not vary during terminal processing such as connection with the connection terminal. It is preferable because it can improve the workability.
  • the material of the insulating coating 5b has good thermal decomposability. It is preferable that Further, fluororesins such as FEP, ETFE, and PFA are preferable because they are nonflammable and chemically stable. In particular, ETFE is preferable because it is excellent in mechanical strength and spark resistance.
  • the conductor strands 5a are aligned or twisted and wound on the core material 3, they are preferably aligned rather than twisted. This is because the diameter of the heating core 4 is reduced and the surface is also smoothed. In addition to the alignment or twisting, it is also conceivable to braid the conductor wire 5a on the core material 3.
  • the insulator layer 7 When forming the insulator layer 7, it may be performed by extrusion molding or the like, or may be covered with the insulator layer 7 previously formed into a tube shape, and the formation method is not particularly limited.
  • the material constituting the insulator layer 7 may be appropriately designed depending on the usage form or usage environment of the cord heater, for example, polyethylene resin, polyester resin, polyurethane resin, polyamide resin, vinyl chloride resin, Various materials such as fluororesin, synthetic rubber, fluororubber, ethylene-based thermoplastic elastomer, urethane-based thermoplastic elastomer can be used. Further, a protective coating may be further formed on the outer periphery of the insulator layer 7.
  • the cord-like heater of the present invention can be obtained.
  • the heat fusion part is formed in a dot pattern, for example, formed in a linear shape or a spiral line shape along the length direction of the cord-like heater, in addition to being formed on the entire outer periphery of the heating wire.
  • a form such as intermittent formation as in form 3 is conceivable.
  • the volume of the heat fusion part is sufficiently small, even if the heat fusion part is a combustible material, the burned material will disappear immediately and the fire will extinguish, and drip (combustion dripping) will also occur. Disappear. Therefore, it is preferable that the volume of the heat-sealed portion be the minimum that can maintain the adhesiveness with the base material. However, in the case of such an aspect, it is preferable that the insulator layer 7 or the insulating coating 5b is made of a flame retardant material.
  • a polymer composition having flame retardancy is preferably used as a material constituting the heat fusion part 9.
  • the polymer composition having flame retardancy is one having an oxygen index of 21 or more in a JIS-K7201 (1999) flammability test. Those having an oxygen index of 26 or more are particularly preferred.
  • Specific materials include, for example, olefin resin, polyester resin, polyamide resin, vinyl chloride resin, polyurethane resin, modified noryl resin (polyphenylene oxide resin), nylon resin, polystyrene resin, polyolefin thermoplastic elastomer, polyester.
  • Thermoplastic polymer materials such as thermoplastic thermoplastic elastomers and polyurethane thermoplastic elastomers, and those obtained by appropriately blending a flame retardant with these thermoplastic polymer materials.
  • thermoplastic polymer materials an olefin resin excellent in adhesiveness with a substrate is preferable.
  • the olefin resin include high density polyethylene, low density polyethylene, ultra low density polyethylene, linear low density polyethylene, polypropylene, polybutene, ethylene- ⁇ -olefin copolymer, ethylene-unsaturated ester copolymer, and the like. Is mentioned.
  • an ethylene-unsaturated ester copolymer is particularly preferable.
  • the combustion heat is smaller than that of a resin having a molecular structure of only carbon and hydrogen, such as polyethylene. This will lead to suppression of combustion.
  • the adhesiveness to the base material is also good, and since there is little decrease in the adhesiveness when an inorganic powder or the like is blended, it is suitable for blending various flame retardants.
  • Examples of the ethylene-unsaturated ester copolymer include an ethylene-vinyl acetate copolymer, an ethylene-methyl (meth) acrylate copolymer, an ethylene- (meth) ethyl acrylate copolymer, and an ethylene- (meth).
  • a butyl acrylate copolymer etc. are mentioned, These may be individual or the mixture of 2 or more types.
  • (meth) acrylic acid” represents both acrylic acid and methacrylic acid. Any of these materials may be selected, but a material that melts at a temperature lower than the decomposition start temperature or lower than the melting point of the material constituting the insulating coating 5b or the insulator coating 7 is better.
  • polyester-type thermoplastic elastomer is mentioned as a material excellent in adhesiveness with a base material.
  • Polyester-based thermoplastic elastomers include polyester-polyester type and polyester-polyether type, and polyester-polyether type is preferred because it has higher adhesiveness.
  • melt flow rate of the material constituting the heat-sealed portion 9 is 5.0 cm 3/10 minutes or more Preferably there is. This melt flow rate is measured at a temperature of 200 ° C. and a load of 2.16 kg according to the method A described in JIS-K7210 (1999).
  • the flame retardant examples include metal hydrates such as magnesium hydroxide and aluminum hydroxide, antimony oxide, melamine compound, phosphorus compound, chlorine flame retardant, bromine flame retardant and the like. These flame retardants may be appropriately subjected to surface treatment by a known method. In particular, a surface treatment that lowers the viscosity at the time of melting of the polymer composition constituting the heat fusion layer is preferable. Moreover, there is no limitation in particular in the method of forming the contact bonding layer 9, For example, you may form by well-known extrusion molding and may form by application
  • the base material and the cord-like heater will be peeled off during use, which will cause unexpected bending in the cord-like heater.
  • the possibility of disconnection is increased. If the conductor wire is disconnected, it not only serves as a heater but also may cause sparking due to chattering.
  • a good electric conductor such as a metal foil can be wound around the outer periphery of the conductor wire 5a in a part in the length direction.
  • a good electric conductor such as a metal foil can be wound around the outer periphery of the core material 3 (the inner surface of the conductor wire 5a) in a part of the length direction.
  • the base material 11 in addition to the nonwoven fabric shown in the above embodiment, for example, woven fabric, paper, aluminum foil, mica plate, resin sheet, foamed resin sheet, rubber sheet, foamed rubber sheet, stretched porous body, etc.
  • FMVSS No. Those having flame retardancy that pass the combustion test of 302 automotive inner layer material are preferred.
  • FMVSS means Federal Motor Vehicle Safety Standard, that is, the Federal Motor Vehicle Safety Standard.
  • a combustion test for automobile interior materials is defined.
  • non-woven fabrics are particularly preferable for use in car seat heaters because they have a good texture and are flexible.
  • the heat-fusible fiber constituting the non-woven fabric a fiber having a core-sheath structure having a low melting point polyester as a sheath component is used.
  • a fiber having a core-sheath structure having a low melting point polypropylene as a sheath component or a fiber having a core-sheath structure having polyethylene as a sheath component is conceivable.
  • the sheath portion of the heat-fusible fiber and the heat-fusible portion 9 are fused and integrated with each other while surrounding the core portion of the heat-fusible fiber.
  • the adhesion between the cord-like heater 1 and the nonwoven fabric becomes very strong.
  • flame retardant fiber use of various flame retardant fibers other than said flame retardant polyester is considered, for example.
  • the flame-retardant fiber refers to a fiber that passes JIS-L1091 (1999). By using such a flame retardant fiber, the base material is imparted with excellent flame retardancy.
  • the mixing ratio of the heat-fusible fiber is preferably 5% or more, and preferably 20% or less.
  • the mixing ratio of the heat-fusible fiber is less than 5%, sufficient adhesion cannot be obtained.
  • the mixing ratio of the heat-fusible fiber exceeds 20%, the nonwoven fabric becomes hard and not only the seated person may complain of an uncomfortable feeling, but also the adhesiveness with the cord-like heater decreases. .
  • the mixing ratio of the flame retardant fiber is 70% or more, preferably 70% or more and 95% or less. When the mixing ratio of the flame retardant fiber is less than 70%, sufficient flame retardancy cannot be obtained.
  • the mixing ratio of the flame-retardant fibers exceeds 95%, the mixing ratio of the heat-fusible fibers is relatively insufficient, and sufficient adhesiveness cannot be obtained.
  • the heat-fusible fiber is not mixed, for example, the above-mentioned material of the heat-sealing part and the material of the fiber constituting the base material are made of the same system, so that it is necessary and sufficient. Since adhesiveness may be obtained, it is fully possible that the heat-fusible fiber is not mixed.
  • the size and thickness of the nonwoven fabric are appropriately changed depending on the intended use, but the thickness (value measured during drying) is preferably about 0.6 mm to 1.4 mm, for example. . If a nonwoven fabric having such a thickness is used, when the cord heater and the nonwoven fabric are bonded and fixed by heating and pressing, the nonwoven fabric has a portion of 30% or more, preferably 50% or more of the outer circumference of the cord heater. It is because it will adhere
  • the surface on which the cord-like heater is disposed is the surface on which the cord-shaped heater is not disposed (hereinafter referred to as non-surface). It is preferable that the air gap is larger than the arrangement surface.
  • the state with many voids is, for example, a fabric such as a woven fabric or a non-woven fabric, a basis weight, that is, a state where the fiber weight per unit volume is small, and a porous body such as a foamed resin sheet or a foamed rubber sheet. Indicates a large state.
  • the base material according to the present invention include, for example, a woven fabric or a nonwoven fabric that is calendered with different strength on only one side or both sides by adjusting temperature and pressure, and a nonwoven fabric that is needle punched from only one side.
  • gap of a base material is especially continuous. This is because the anchor effect is increased and the adhesive strength is improved by the molten heat-sealing layer penetrating into the continuous voids.
  • a fabric body such as a woven fabric or a nonwoven fabric which is an aggregate of fibers, a foamed resin sheet or a foamed rubber sheet having continuous pores, and the like can be considered.
  • the non-arranged surface may have no gap.
  • the cord-like heater 10 when the cord-like heater 10 is disposed on the base material 11, the cord-like heater 10 may be fixed to the base material 11 in another manner instead of being bonded and fixed by fusion by heating and pressurization.
  • Various modes such as a mode in which the substrate 10 is sandwiched and fixed are considered.
  • the adhesive layer for fixing the planar heater 31 to the seat is composed only of an adhesive on the release sheet or the like from the viewpoint of the stretchability of the base material 11 and the maintenance of a good texture. It is preferable to form an adhesive layer by forming an adhesive layer and transferring the adhesive layer from the release sheet to the surface of the substrate 11.
  • this adhesive layer is preferably flame retardant, and FMVSS No. Those having flame retardancy that pass the combustion test of 302 automotive interior materials are preferred.
  • a polymeric acrylic pressure sensitive adhesive can be used.
  • the adhesive layer may be formed on the surface on which the substrate is disposed, or may be formed on the non-arranged surface.
  • Examples 1 to 5 Comparative Example 1
  • the materials of the heat-sealed portion of the cord heater were changed as shown in Tables 1 and 2 to obtain Examples 1 to 5 and Comparative Example 1 (blending amount) Is expressed in parts by weight).
  • Adhesiveness measured the force when fixing a base material and pulling up a cord-like heater upward and peeling.
  • the cord heater is energized and the power density of 6 w / m 2 is supplied, the adhesive property is fixed when the substrate is fixed and the cord heater is pulled up and peeled off in the same manner as the adhesive property. The force of was measured.
  • the flame retardancy was tested by the UL1581 horizontal combustion test (2008, 4th edition) for the cord-shaped heater before being placed on the base material, and FMVSS No.
  • the test was conducted by the combustion test of 302 automobile inner layer material.
  • spark resistance the operation of generating a spark by repeating contact / non-contact between the cut surfaces in a state where 13.5 V is applied and the cord heater disposed in the surface heater is cut is 2 times / second. After 500 cycles, the appearance of the planar heater was observed.
  • the test results are also shown in Table 1.
  • the planar heaters according to the examples of the present invention have sufficient values for adhesiveness and current-carrying adhesiveness.
  • the cord heater does not peel from the material.
  • the cord heaters in all the examples were not ignited even when in contact with flames, and were excellent in flame retardancy.
  • the cord-like heater of Comparative Example 1 burned at a burning rate of 25 mm / min or more and failed the horizontal combustion test.
  • FMVSS No. Although it was a level that passed the combustion test of 302, the flame continued through the cord heater for a while.
  • the planar heaters according to the examples of the present invention had no particular change in appearance even after 500 contact / non-contact operations, and were excellent in spark resistance.
  • the cut portion changed to black from about 200 times, the heat-sealed portion and the insulating coating melted around 400 times, and the conductor wire was completely exposed. It was way.
  • a tube is made of the material constituting the heat-sealed portion of Examples 1 to 5 and Comparative Example 1, and Ni—Cr wire is inserted from both ends of the tube, so that the current during conduction becomes 8A.
  • the operation of repeating contact and non-contact inside the tube was performed 500 times at a cycle of 1.5 times / second. According to this, the tubes made of the materials of Examples 1 to 5 were not abnormal in appearance, but the tube made of the material of Comparative Example 1 was changed to black and the occurrence of pinholes was confirmed.
  • the non-woven fabric as the base material was changed to the mixing ratio of the heat-fusible fiber and the flame-retardant fiber as shown in Table 3, and it was set as Examples 6 to 8 (the mixing ratio was (In parts by weight).
  • the test of the bending resistance of a base material, adhesiveness, and a flame retardance was done.
  • the bending resistance was measured by a cantilever method described in JIS-L1096 (1999).
  • Adhesiveness measured the force when fixing a base material and pulling up a cord-like heater upward and peeling.
  • the flame retardancy is FMVSS No. Tested by combustion test of 302 automotive inner layer material. The test results are also shown in Table 3.
  • Example 8 In terms of adhesiveness, Example 8 in which the amount of heat-fusible fiber mixed was 30% was slightly lower than Examples 6 and 7.
  • flame retardancy all of Examples 6 to 8 were self-extinguishing and showed excellent flame retardancy.
  • Example 9 The planar heater obtained by the third embodiment is referred to as Example 9.
  • the cord-like heater in the ninth embodiment is as shown in FIG.
  • the flame retardancy of Example 9 was measured.
  • the flame retardancy was tested by the UL1581 horizontal combustion test (2008, 4th edition) for the cord-shaped heater before being placed on the base material, and FMVSS No. Tested by combustion test of 302 automotive inner layer material.
  • combustion stopped at the part where the heat-sealing part 9 was interrupted, and no further combustion occurred, and no drip (combustion drop) was generated. Passed the exam.
  • FMVSS No. tested in the state of a planar heater The combustion test of 302 automotive inner layer material also passed because the combustion stopped and the fire was extinguished.
  • the cord-like heater is disposed in a predetermined shape such as a meandering shape on a base material such as an aluminum foil or a non-woven fabric to form a planar heater, such as an electric blanket, an electric carpet, a car seat heater, a steering heater, a heating toilet seat It can be suitably used for heaters for anti-fogging mirrors, cooking utensils and the like.
  • cord-shaped heater unit for example, a mode in which the cord-shaped heater is wound around and bonded to a pipe, a tank, or the like, or arranged in the pipe can be considered.
  • Specific applications include, for example, antifreezing heaters such as pipes and freezer pipe drains, heat insulation heaters such as air conditioners and dehumidifiers, defrosting heaters such as refrigerators and freezers, drying heaters, and floor heating heaters. Can be suitably used.

Abstract

Provided are a cord-like heater which can be used for applications requiring fire-resistant properties, and a planar heater using the cord-like heater. A cord-like heater comprises a heat generating wire and a thermally bonded section which is formed on the outer periphery of the heat generating wire. The heat generating wire is formed by winding electrically conductive element wires on a core wire and applying insulation coating on the outer periphery of the wound electrically conductive element wires, or is formed by aligning parallel to each other or twisting together electrically conductive element wires coated with insulation coating. The thermally bonded section consists of a flame-resistant polymer composition, and the cord-like heater is configured to have flame-resistant properties satisfying a horizontal burning test in accordance with UL1581.

Description

コード状ヒータと面状ヒータCord heater and sheet heater
　本発明は、電気毛布、電気カーペット、カーシートヒータなどに好適に使用可能なコード状ヒータ及びそれを使用した面状ヒータに係り、特に、難燃性が必要な用途にも対応可能なものに関する。 The present invention relates to a cord-like heater that can be suitably used for an electric blanket, an electric carpet, a car seat heater, and the like, and a sheet-like heater using the cord-like heater, and more particularly, to a thing that can cope with an application that requires flame retardancy. .
　電気毛布、電気カーペット、カーシートヒータ等に使用されるコード状ヒータは、芯線にヒータ線を螺旋状に巻き、その上から絶縁体層による外被を被覆する構成のものが一般的に知られている。ここで、ヒータ線としては、銅線やニッケルクロム合金線などを引き揃え又は撚合せたものから構成されている。また、この発熱線の外周には熱融着部が形成され、この熱融着部により、例えば不織布やアルミ箔といった基材に接着されている（例えば、特許文献１、特許文献２、特許文献３など参照）。また、本発明に関連する技術として、当該出願人より特許文献４が出願されている。 Cord heaters used for electric blankets, electric carpets, car seat heaters, etc. are generally known to have a configuration in which a heater wire is spirally wound around a core wire and an outer cover is covered with an insulating layer from above. ing. Here, the heater wire is made of a copper wire, a nickel chrome alloy wire or the like that is aligned or twisted. Further, a heat-sealed portion is formed on the outer periphery of the heating wire, and the heat-bonded portion is adhered to a base material such as a nonwoven fabric or an aluminum foil (for example, Patent Document 1, Patent Document 2, Patent Document). 3 etc.). As a technique related to the present invention, Patent Document 4 has been filed by the applicant.
特開２００３－１７４９５２公報JP 2003-174952 A 特開２００５－３２２６０７公報JP 2005-322607 A 特開２００６－１１４４６３公報JP 2006-114463 A 特開２０１０－１５６９１号公報JP 2010-15691 A
　上記コード状ヒータの熱融着部としては、主としてポリエチレン樹脂が使用されている。しかし、このポリエチレン樹脂は燃えやすい材料であるため、万が一、発熱線の断線による異常加熱が起こったり、或いは、外部からの発火があったりした場合は、熱融着部が燃焼してしまう可能性がある。現状の対応では、基材の側に難燃材料を用いたり、発熱線の外周を難燃性の絶縁体層で被覆したりすることで燃焼を防止しているが、より確実を期すため、コード状ヒータの熱融着部の側でも難燃性を向上することも必要になっている。 ポ リ エ チ レ ン Polyethylene resin is mainly used as the heat fusion part of the cord heater. However, since this polyethylene resin is a flammable material, in the unlikely event that abnormal heating occurs due to disconnection of the heating wire, or there is ignition from the outside, the heat fusion part may burn There is. In the current response, combustion is prevented by using a flame retardant material on the side of the substrate or covering the outer periphery of the heating wire with a flame retardant insulator layer, but for more certainty, It is also necessary to improve flame retardancy on the side of the heat-sealed portion of the cord heater.
　特許文献２、３においては、ポリエチレン樹脂にハロゲンを発生しない難燃剤を配合して、コード状ヒータに使用することが記載されているが、この材料が使用されるのはあくまで絶縁被覆であり、熱融着部の難燃性については、何ら言及されていない。上記のように通常使用される熱融着性の樹脂材料は燃焼しやすいものであるため、このような特許文献２、３によるコード状ヒータでは、例え、絶縁被覆が難燃性であっても、その表面を火炎が伝播し、燃焼部位が拡大してしまう恐れがある。 In Patent Documents 2 and 3, it is described that a flame retardant that does not generate halogen is blended in a polyethylene resin and used for a cord-like heater, but this material is used only for insulation coating, No mention is made of the flame retardancy of the heat-sealed part. As described above, since the heat-fusible resin material that is normally used is easily combustible, even with such cord-like heaters according to Patent Documents 2 and 3, even if the insulation coating is flame-retardant, There is a risk that the flame propagates on the surface and the combustion part expands.
　本発明はこのような従来技術の問題点を解決するためになされたもので、その目的とするところは、難燃性が必要な用途にも対応可能なコード状ヒータ及びそれを使用した面状ヒータを提供することにある。 The present invention has been made in order to solve such problems of the prior art, and an object of the present invention is to provide a cord-shaped heater that can be used for applications that require flame retardancy, and a surface shape using the same. It is to provide a heater.
　上記目的を達成するべく、本発明の請求項１によるコード状ヒータは、発熱線と、該発熱線の外周に形成された熱融着部とを有するコード状ヒータであって、上記発熱線が、芯線上に導体素線を巻装し、その外周に絶縁被覆を施したものであるか、又は、絶縁被膜により被覆された導体素線を引き揃え又は撚り合わせたものであり、上記熱融着部が、難燃性高分子組成物からなるとともに、上記コード状ヒータは、ＵＬ１５８１水平燃焼試験に合格する難燃性を有することを特徴とするものである。
又、請求項２によるコード状ヒータは、請求項１記載のコード状ヒータにおいて、上記難燃性高分子組成物が、オレフィン系樹脂と、難燃剤とからなることを特徴とするものである。
又、請求項３によるコード状ヒータは、請求項２記載のコード状ヒータにおいて、ＪＩＳ－Ｋ７２１０のＡ法により温度２００℃、荷重２．１６ｋｇの条件で測定された、上記難燃性高分子組成物のメルトフローレートが、５．０ｃｍ３／１０分以上であることを特徴とするものである。
又、請求項４によるコード状ヒータは、請求項２又は請求項３記載のコード状ヒータにおいて、上記オレフィン系樹脂が、エチレン－不飽和エステル共重合体であることを特徴とするものである。
又、請求項５によるコード状ヒータは、請求項１～請求項４の何れかに記載のコード状ヒータにおいて、上記発熱線が、絶縁被膜により被覆された導体素線を引き揃え又は撚り合わせ、芯線上に巻装してなるものであることを特徴とするものである。
又、請求項６による面状ヒータは、請求項１～請求項５の何れかに記載のコード状ヒータを基材に配設したことを特徴とするものである。
又、請求項７による面状ヒータは、請求項６記載の面状ヒータにおいて、上記基材が、ＦＭＶＳＳ　Ｎｏ．３０２自動車内層材料の燃焼試験に合格する難燃性を有するものからなることを特徴とするものである。
又、請求項８による面状ヒータは、請求項７記載の面状ヒータにおいて、上記基材が、不織布からなることを特徴とするものである。
又、請求項９による面状ヒータは、請求項６記載の面状ヒータにおいて、上記不織布が、熱融着性繊維と、熱融着に寄与しない難燃性繊維とからなることを特徴とするものである。
又、請求項１０による面状ヒータは、請求項９記載の面状ヒータにおいて、上記不織布は、上記難燃性繊維が７０％以上混合されているとともに、上記熱融着性繊維が５％以上混合されていることを特徴とするものである。
又、請求項１１による面状ヒータは、請求項８～請求項１０の何れかに記載の面状ヒータにおいて、上記コード状ヒータの熱融着部が、上記不織布を構成する繊維を取り囲むことによって、上記コード状ヒータと上記基材とが接着していることを特徴とするものである。
又、請求項１２による面状ヒータは、請求項９又は請求項１０記載の面状ヒータにおいて、上記熱融着性繊維が、芯－鞘構造を有するとともに、該芯部分を取り囲んだ状態で、該鞘部分と上記コード状ヒータの熱融着部とが、互いに融着し一体化していることを特徴とするものである。
又、請求項１３によるコード状ヒータは、発熱線と、該発熱線の外周に形成された熱融着部とを有するコード状ヒータであって、上記発熱線が、芯線上に導体素線を巻装し、その外周に絶縁被覆を施したものであるか、又は、絶縁被膜により被覆された導体素線を引き揃え又は撚り合わせたものであり、上記コード状ヒータは、ＵＬ１５８１水平燃焼試験に合格する難燃性を有することを特徴とするものである。
又、請求項１４による面状ヒータは、請求項１３記載のコード状ヒータを基材に配設したことを特徴をとするものである。 In order to achieve the above object, a cord-like heater according to claim 1 of the present invention is a cord-like heater having a heating wire and a heat fusion part formed on the outer periphery of the heating wire, The conductor wire is wound around the core wire and the outer periphery thereof is covered with an insulating coating, or the conductor wire covered with the insulating coating is aligned or twisted. The landing portion is made of a flame retardant polymer composition, and the cord-like heater has flame retardant properties that pass the UL1581 horizontal combustion test.
A cord-like heater according to claim 2 is the cord-like heater according to claim 1, wherein the flame-retardant polymer composition comprises an olefin resin and a flame retardant.
Further, the cord-like heater according to claim 3 is the cord-like heater according to claim 2, wherein the flame-retardant polymer composition is measured according to JIS-K7210 method A at a temperature of 200 ° C. and a load of 2.16 kg. a melt flow rate of the object is characterized in that it is 5.0 cm 3/10 minutes or more.
A corded heater according to claim 4 is the corded heater according to claim 2 or 3, wherein the olefin resin is an ethylene-unsaturated ester copolymer.
A cord-like heater according to claim 5 is the cord-like heater according to any one of claims 1 to 4, wherein the heating wire is formed by aligning or twisting conductor wires covered with an insulating film, It is characterized by being wound on a core wire.
A sheet heater according to claim 6 is characterized in that the cord heater according to any one of claims 1 to 5 is disposed on a base material.
A sheet heater according to claim 7 is the sheet heater according to claim 6, wherein the base material is FMVSS No. It consists of what has the flame retardance which passes the combustion test of 302 automotive inner-layer material.
The sheet heater according to claim 8 is the sheet heater according to claim 7, characterized in that the substrate is made of a nonwoven fabric.
The sheet heater according to claim 9 is the sheet heater according to claim 6, wherein the non-woven fabric is composed of a heat-fusible fiber and a flame-retardant fiber that does not contribute to the heat-sealing. Is.
The sheet heater according to claim 10 is the sheet heater according to claim 9, wherein the non-woven fabric is mixed with 70% or more of the flame-retardant fiber and 5% or more of the heat-fusible fiber. It is characterized by being mixed.
The sheet heater according to claim 11 is the sheet heater according to any one of claims 8 to 10, wherein the heat fusion part of the cord heater surrounds the fibers constituting the nonwoven fabric. The cord heater and the base material are adhered to each other.
The sheet heater according to claim 12 is the sheet heater according to claim 9 or 10, wherein the heat-fusible fiber has a core-sheath structure and surrounds the core part. The sheath part and the heat fusion part of the cord heater are fused and integrated with each other.
According to a thirteenth aspect of the present invention, there is provided a cord-like heater having a heating wire and a heat fusion part formed on the outer periphery of the heating wire, wherein the heating wire has a conductor wire on the core wire. It is wound and the outer periphery is coated with an insulating coating, or a conductor wire coated with an insulating coating is aligned or twisted, and the cord heater is used in the UL 1581 horizontal combustion test. It has the flame retardance to pass.
A planar heater according to a fourteenth aspect is characterized in that the cord-shaped heater according to the thirteenth aspect is disposed on a base material.
　以上述べたように、本発明の請求項１によるコード状ヒータによると、上記熱融着部が、難燃性高分子組成物からなるとともに、上記コード状ヒータは、ＵＬ１５８１水平燃焼試験に合格する難燃性を有しているので、難燃性が必要な用途に使用することができる。
又、請求項２によるコード状ヒータによると、上記難燃性高分子組成物が、オレフィン系樹脂と、難燃剤とからなっているので、上記効果をより確実なものとすることができる。
又、請求項３によるコード状ヒータによると、ＪＩＳ－Ｋ７２１０のＡ法により温度２００℃、荷重２．１６ｋｇの条件で測定された、上記難燃性高分子組成物のメルトフローレートが、５．０ｃｍ３／１０分以上であるように構成されているので、上記効果をより確実なものとすることができる。
又、請求項４によるコード状ヒータによると、上記オレフィン系樹脂が、エチレン－不飽和エステル共重合体であるので、上記効果をより確実なものとすることができる。
又、請求項５によるコード状ヒータによると、上記発熱線が、絶縁被膜により被覆された導体素線を引き揃え又は撚り合わせ、芯線上に巻装してなっており、このような構成においても、上記したような効果を奏することができる。
又、請求項６による面状ヒータによると、請求項１～請求項５の何れかに記載のコード状ヒータを基材に配設しているので、難燃性が必要な用途に使用することができる。
又、請求項７による面状ヒータによると、上記基材が、ＦＭＶＳＳ　Ｎｏ．３０２自動車内層材料の燃焼試験に合格する難燃性を有するものからなっているので、上記効果をより確実なものとすることができる。
又、請求項８による面状ヒータによると、上記基材が、不織布からなっており、そのような構成においても、上記したような効果を奏することができる。
又、請求項９による面状ヒータによると、上記不織布が、熱融着性繊維と、熱融着に寄与しない難燃性繊維とからなっているので、上記効果をより高めることができる。
又、請求項１０による面状ヒータによると、上記不織布は、上記難燃性繊維が７０％以上混合されているとともに、上記熱融着性繊維が５％以上混合されているので、上記効果をより確実なものとすることができる。
又、請求項１１による面状ヒータによると、上記コード状ヒータの熱融着部が、上記不織布を構成する繊維を取り囲むことによって、上記コード状ヒータと上記基材とが接着しているように構成されているので、上記効果をより確実なものとすることができる。
又、請求項１２による面状ヒータによると、上記熱融着性繊維が、芯－鞘構造を有するとともに、該芯部分を取り囲んだ状態で、該鞘部分と上記コード状ヒータの熱融着部とが、互いに融着し一体化している構成になっており、そのような構成においても、上記したような効果を奏することができる。
又、請求項１３によるコード状ヒータによると、ＵＬ１５８１水平燃焼試験に合格する難燃性を有しているので、難燃性が必要な用途に使用することができる。
又、請求項１４による面状ヒータによると、請求項１３記載のコード状ヒータを基材に配設しているので、難燃性が必要な用途に使用することができる。 As described above, according to the cord-like heater according to claim 1 of the present invention, the heat fusion part is made of a flame retardant polymer composition, and the cord-like heater passes the UL1581 horizontal combustion test. Since it has flame retardancy, it can be used for applications that require flame retardancy.
According to the cord-like heater according to claim 2, since the flame retardant polymer composition is composed of an olefin resin and a flame retardant, the above effect can be further ensured.
Further, according to the cord-like heater according to claim 3, the flame flow rate of the flame retardant polymer composition measured by the method A of JIS-K7210 at a temperature of 200 ° C. and a load of 2.16 kg is 5. Since it is comprised so that it may be 0 cm < 3 > / 10 minutes or more, the said effect can be made more reliable.
According to the cord-like heater according to claim 4, since the olefin-based resin is an ethylene-unsaturated ester copolymer, the above effect can be further ensured.
Further, according to the cord-like heater according to claim 5, the heating wire is formed by arranging or twisting conductor wires covered with an insulating film and wound on the core wire. The effects as described above can be obtained.
Further, according to the planar heater according to claim 6, since the cord-like heater according to any one of claims 1 to 5 is disposed on the base material, it is used for an application that requires flame retardancy. Can do.
Moreover, according to the planar heater according to claim 7, the base material has FMVSS No. Since it consists of what has the flame retardance which passes the combustion test of 302 automotive inner-layer material, the said effect can be made more reliable.
According to the planar heater of the eighth aspect, the substrate is made of a nonwoven fabric, and the above-described effects can be achieved even in such a configuration.
Further, according to the planar heater according to the ninth aspect, since the nonwoven fabric is composed of the heat-fusible fiber and the flame-retardant fiber that does not contribute to the heat-sealing, the above effect can be further enhanced.
Further, according to the planar heater according to claim 10, the nonwoven fabric is mixed with 70% or more of the flame-retardant fiber and 5% or more of the heat-fusible fiber. It can be made more reliable.
Further, according to the planar heater according to claim 11, the cord-shaped heater and the base material are bonded together by the heat-sealed portion of the cord-shaped heater surrounding the fibers constituting the nonwoven fabric. Since it is comprised, the said effect can be made more reliable.
According to the planar heater according to claim 12, the heat-fusible fiber has a core-sheath structure and surrounds the core portion, and the heat-sealed portion of the cord-shaped heater and the sheath portion. However, the above-described effects can be obtained even in such a configuration.
Moreover, according to the cord-like heater according to claim 13, since it has flame retardancy that passes the UL1581 horizontal combustion test, it can be used for applications that require flame retardancy.
Further, according to the planar heater according to claim 14, since the cord-like heater according to claim 13 is disposed on the base material, it can be used for an application requiring flame retardancy.
本発明による実施の形態１－１を示す図で、コード状ヒータの構成を示す一部切り欠き側面図である。It is a figure which shows Embodiment 1-1 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater. 本発明による実施の形態１－１を示す図で、ホットプレス式ヒータ製造装置の構成を示す図である。FIG. 5 is a diagram illustrating the embodiment 1-1 according to the present invention and is a diagram illustrating a configuration of a hot press type heater manufacturing apparatus. 本発明による実施の形態１－１を示す図で、コード状ヒータを所定のパターン形状に配設する様子を示す一部斜視図である。FIG. 5 is a diagram showing the embodiment 1-1 according to the present invention, and is a partial perspective view showing a state in which cord-like heaters are arranged in a predetermined pattern shape. 本発明による実施の形態１－１を示す図で、面状ヒータの構成を示す平面図である。It is a figure which shows Embodiment 1-1 by this invention, and is a top view which shows the structure of a planar heater. 本発明による実施の形態１－１を示す図で、面状ヒータを車両用シート内に埋め込んだ様子を一部切り欠いて部示す斜視図である。FIG. 5 is a diagram showing the embodiment 1-1 according to the present invention, and is a perspective view showing a part of the state in which the planar heater is embedded in the vehicle seat. 本発明による実施の形態１－２を示す図で、コード状ヒータの構成を示す一部切り欠き側面図である。It is a figure which shows Embodiment 1-2 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater. 本発明による実施の形態１－３を示す図で、コード状ヒータの構成を示す一部切り欠き側面図である。It is a figure which shows Embodiment 1-3 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater. 本発明による実施の形態２を示す図で、コード状ヒータの構成を示す一部切り欠き側面図である。It is a figure which shows Embodiment 2 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater. 本発明による実施の形態３－１を示す図で、コード状ヒータの構成を示す一部切り欠き側面図である。It is a figure which shows Embodiment 3-1 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater. 本発明による実施の形態３－２を示す図で、コード状ヒータの構成を示す一部切り欠き側面図である。It is a figure which shows Embodiment 3-2 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater. 本発明による実施の形態４を示す図で、コード状ヒータの構成を示す一部切り欠き側面図である。It is a figure which shows Embodiment 4 by this invention, and is a partially notched side view which shows the structure of a cord-shaped heater. 本発明による実施の形態１－１を示す電子顕微鏡写真で、基材とコード状ヒータの接着状態を４５倍に拡大して示すものである。In the electron micrograph showing Embodiment 1-1 according to the present invention, the adhesion state of the base material and the cord-shaped heater is enlarged 45 times.
　以下、図１乃至図７を参照して本発明の実施の形態１（実施の形態１－１～実施の形態１－３を説明する。これらの実施の形態は、本発明を面状ヒータとし、車両用シートヒータに適用することを想定した例を示すものである。 Hereinafter, Embodiment 1 of the present invention (Embodiment 1-1 to Embodiment 1-3) will be described with reference to FIG. 1 to FIG. 7. These embodiments use the present invention as a planar heater. The example which assumes application to the seat heater for vehicles is shown.
（実施の形態１－１）
まず、図１乃至図５を参照して本実施の形態１－１を説明する。この実施の形態におけるコード状ヒータ１０の構成から説明する。本実施の形態におけるコード状ヒータ１０は図１に示すような構成になっている。まず、外径約０．２ｍｍの芳香族ポリアミド繊維束からなるヒータ芯３があり、該ヒータ芯３の外周には、素線径０．０８ｍｍの錫鍍金硬質錫入り銅合金線（ＴＨ－ＳＮＣＣ－３）からなる６本（図１ではその内の３本のみ示している。）の導体素線５ａを引き揃えて構成されたものがピッチ約０．７ｍｍで螺旋状に巻装されている。このヒータ芯３上に導体素線５ａを巻装したものの外周に、絶縁体層７としての四フッ化エチレン－六フッ化プロピレン共重合体（ＦＥＰ）が約０．１５ｍｍの肉厚で押出・被覆され、発熱線１が構成されている。又、この発熱線１の外周には、更に、熱融着部９としての難燃剤が配合されたポリエチレン樹脂が０．２ｍｍの厚さで押出・被覆されている。コード状ヒータ１０はこのような構成になっていて、その仕上外径は１．１ｍｍである。又、屈曲性や引張強度を考慮した場合には上記ヒータ芯３は有効であるが、ヒータ芯３の代わりに複数本の発熱体素線を引き揃えるか或いは撚り合わせたものを使用することも考えられる。また、このコード状ヒータ１は、それ単体でＵＬ１５８１水平燃焼試験（２００８年、第４版）に合格する難燃性を有するものである。
なお、「ＵＬ」とは、アメリカ保険業者安全試験所（Ｕｎｄｅｒｗｒｉｔｅｒｓ　Ｌａｂｏｒａｔｏｒｉｅｓ　Ｉｎｃ．，）により作成された安全規格である。 (Embodiment 1-1)
First, Embodiment 1-1 will be described with reference to FIGS. The configuration of the cord-like heater 10 in this embodiment will be described. The cord-like heater 10 in the present embodiment is configured as shown in FIG. First, there is a heater core 3 made of an aromatic polyamide fiber bundle having an outer diameter of about 0.2 mm, and a tin-plated hard tin-containing copper alloy wire (TH-SNCC) having an element wire diameter of 0.08 mm is provided on the outer periphery of the heater core 3. -3), which is formed by aligning six conductor wires 5a (only three of them are shown in FIG. 1) is wound spirally at a pitch of about 0.7 mm. . On the outer periphery of the conductor core 5a wound around the heater core 3, a tetrafluoroethylene-hexafluoropropylene copolymer (FEP) as an insulator layer 7 is extruded with a thickness of about 0.15 mm. The heating wire 1 is formed by covering. Further, the outer periphery of the heating wire 1 is further extruded and coated with a polyethylene resin containing a flame retardant as the heat-sealing portion 9 to a thickness of 0.2 mm. The cord-shaped heater 10 has such a configuration, and its finished outer diameter is 1.1 mm. In addition, the heater core 3 is effective when considering flexibility and tensile strength. However, instead of the heater core 3, a plurality of heating element strands may be aligned or twisted. Conceivable. Moreover, this cord-shaped heater 1 has a flame retardance which passes the UL1581 horizontal combustion test (2008, 4th edition) alone.
“UL” is a safety standard created by Underwriters Laboratories Inc., USA.
　次に、上記構成をなすコード状ヒータ１０を接着・固定する基材１１の構成について説明する。本実施例における基材１１は、低融点ポリエステルを鞘成分とする芯鞘構造を有する熱融着性繊維１０％と、難燃性ポリエステル繊維からなる難燃性繊維９０％とを混合させた不織布（目付１００ｇ／ｍ２、厚さ０．６ｍｍ）で構成されている。このような基材１１は、型抜き等の公知の手法により所望の形状とされる。 Next, the structure of the base material 11 for bonding and fixing the cord-like heater 10 having the above structure will be described. The base material 11 in this example is a non-woven fabric in which 10% heat-fusible fiber having a core-sheath structure having low melting point polyester as a sheath component and 90% flame-retardant fiber made of flame-retardant polyester fiber are mixed. (A basis weight is 100 g / m 2 and a thickness is 0.6 mm). Such a base material 11 is formed into a desired shape by a known method such as die cutting.
　次に、上記コード状ヒータ１０を基材１１上に所定のパターン形状で配設して接着・固定する構成について説明する。図２はコード状ヒータ１０を基材１１上に接着・固定させるためのホットプレス式ヒータ製造装置１３の構成を示す図である。まず、ホットプレス治具１５があり、このホットプレス治具１５上には複数個の係り止め機構１７が設けられている。上記係り止め機構１７は、図３に示すように、ピン１９を備えていて、このピン１９はホットプレス冶具１５に穿孔された孔２１内に下方より差し込まれている。このピン１９の上部には係り止め部材２３が軸方向に移動可能に取り付けられていて、コイルスプリング２５によって常時上方に付勢されている。そして、図３中仮想線で示すように、これら複数個の係り止め機構１７の係り止め部材２３にコード状ヒータ１０を引っ掛けながら所定のパターン形状にて配設することになる。 Next, a description will be given of a configuration in which the cord heater 10 is disposed on the base material 11 in a predetermined pattern shape and bonded and fixed. FIG. 2 is a diagram showing a configuration of a hot press type heater manufacturing apparatus 13 for bonding and fixing the cord-like heater 10 on the base material 11. First, there is a hot press jig 15, and a plurality of locking mechanisms 17 are provided on the hot press jig 15. As shown in FIG. 3, the anchoring mechanism 17 includes a pin 19, and the pin 19 is inserted into a hole 21 drilled in the hot press jig 15 from below. A retaining member 23 is attached to the upper portion of the pin 19 so as to be movable in the axial direction, and is always urged upward by a coil spring 25. Then, as indicated by phantom lines in FIG. 3, the cord-like heaters 10 are hooked on the locking members 23 of the plurality of locking mechanisms 17 and arranged in a predetermined pattern shape.
　図２に戻って、上記複数個の係り止め機構１７の上方にはプレス熱板２７が昇降可能に配置されている。すなわち、コード状ヒータ１０を複数個の係り止め機構１７の係り止め部材２３に引っ掛けながら所定のパターン形状にて配設し、その上に基材１１を置く。その状態で上記プレス熱板２７を降下させてコード状ヒータ１０と基材１１に、例えば、２３０℃／５秒間の加熱・加圧を施すものである。それによって、コード状ヒータ１０側の熱融着部９と基材１１側の熱融着性繊維が融着することになり、その結果、コード状ヒータ１０と基材１１が接着・固定されることになる。
尚、上記プレス熱板２７の降下による加熱・加圧時には複数個の係り止め機構１７の係り止め部材２３はコイルスプリング２５の付勢力に抗して下方に移動するものである。 Returning to FIG. 2, a press hot plate 27 is disposed above the plurality of locking mechanisms 17 so as to be movable up and down. That is, the cord-shaped heater 10 is arranged in a predetermined pattern shape while being hooked on the retaining members 23 of the plurality of retaining mechanisms 17, and the base material 11 is placed thereon. In this state, the press hot plate 27 is lowered to heat and press the cord-like heater 10 and the base material 11 at, for example, 230 ° C./5 seconds. As a result, the heat fusion part 9 on the cord-like heater 10 side and the heat-fusible fiber on the substrate 11 side are fused, and as a result, the cord-like heater 10 and the substrate 11 are bonded and fixed. It will be.
It should be noted that the retaining members 23 of the plurality of retaining mechanisms 17 move downward against the urging force of the coil spring 25 during heating and pressurization due to the lowering of the press hot plate 27.
　基材１１のコード状ヒータ１０を配設しない側の面には、接着層の形成、或いは、両面テープの貼り付けがなされても良い。これは、座席に取り付ける際、面状ヒータ３１を座席に固定するためのものである。 An adhesive layer may be formed or a double-sided tape may be attached to the surface of the substrate 11 where the cord heater 10 is not disposed. This is for fixing the planar heater 31 to the seat when it is attached to the seat.
上記作業を行うことにより、図４に示すような車両用シートヒータの面状ヒータ３１を得ることができる。
尚、上記面状ヒータ３１におけるコード状ヒータ１０の両端、及び、温度制御装置３９にはコード４０が接続されており、このコード４０により、コード状ヒータ１０、温度制御装置３９、及び、コネクタ３５が接続されている。そして、このコネクタ３５を介して図示しない車両の電気系統に接続されることになる。 By performing the above operation, a sheet heater 31 of a vehicle seat heater as shown in FIG. 4 can be obtained.
A cord 40 is connected to both ends of the cord heater 10 in the planar heater 31 and to the temperature control device 39, and the cord 40 is connected to the cord heater 10, the temperature control device 39, and the connector 35. Is connected. And it connects to the electric system of the vehicle which is not illustrated via this connector 35.
　そして、上記構成をなす面状ヒータ３１は、図５に示すような状態で、車両用のシート４１内に埋め込まれて配置されることになる。すなわち、上記した通り、車両用シート４１の表皮カバー４３又は座席パット４５に、面状ヒータ３１が貼り付けられることとなるものである。 And the planar heater 31 which comprises the said structure is embedded and arrange | positioned in the vehicle seat 41 in the state as shown in FIG. That is, as described above, the planar heater 31 is attached to the skin cover 43 or the seat pad 45 of the vehicle seat 41.
（実施の形態１－２）
次に、図６を参照して実施の形態１－２について説明する。この実施の形態１－２の場合には、図６に示すように、絶縁被膜５ｂにより被覆された導体素線５ａを複数本撚り合わせたものを使用している。
なお、その他の構成は前記実施の形態１－１の場合と同様であり、同一部分には同一符号を付して示し、その説明は省略する。 (Embodiment 1-2)
Next, Embodiment 1-2 will be described with reference to FIG. In the case of the embodiment 1-2, as shown in FIG. 6, a plurality of conductor strands 5a covered with an insulating coating 5b are twisted.
Other configurations are the same as those of the embodiment 1-1, and the same parts are denoted by the same reference numerals and description thereof is omitted.
（実施の形態１－３）
　次に、図７を参照して実施の形態１－３について説明する。この実施の形態１－３の場合には、図７に示すように、絶縁被膜５ｂにより被覆された導体素線５ａを複数本引き揃えたものとなっている。
なお、その他の構成は前記実施の形態１－１の場合と同様であり、同一部分には同一符号を付して示し、その説明は省略する。 (Embodiment 1-3)
Next, Embodiment 1-3 will be described with reference to FIG. In the case of Embodiment 1-3, as shown in FIG. 7, a plurality of conductor strands 5a covered with an insulating coating 5b are aligned.
Other configurations are the same as those of the embodiment 1-1, and the same parts are denoted by the same reference numerals and description thereof is omitted.
（実施の形態２）
　次に、図８を参照して本発明の実施の形態２について説明する。本実施の形態２におけるコード状ヒータ１０の構成から説明する。本実施の形態におけるコード状ヒータ１０は図８に示すような構成になっている。
　なお、図８は概略図である。
まず、外径約０．２ｍｍの芳香族ポリアミド繊維束からなるヒータ芯３の外周に、素線径０．０８ｍｍの錫銅合金線からなる導体素線５ａを７本（図８ではその内の４本のみを示している。）引き揃え、ピッチ１ｍｍで螺旋状に巻装して発熱線１を構成する。
なお、導体素線５ａには、ポリウレタンからなる絶縁被膜５ｂが厚さ約０．００５ｍｍで被覆されている。この発熱線１の外周に、熱融着部９としての難燃剤が配合されたポリエチレン樹脂が０．２５ｍｍの厚さで押出・被覆されている。コード状ヒータ１０はこのような構成になっていて、その仕上外径は０．９ｍｍである。また、このコード状ヒータ１は、それ単体でＵＬ１５８１水平燃焼試験（２００８年、第４版）に合格する難燃性を有するものである。以下、基材１１等の構成や製造方法については、上記実施の形態１と同様である。 (Embodiment 2)
Next, a second embodiment of the present invention will be described with reference to FIG. The configuration of the cord-like heater 10 in the second embodiment will be described. The cord-like heater 10 in the present embodiment is configured as shown in FIG.
FIG. 8 is a schematic diagram.
First, on the outer periphery of the heater core 3 made of an aromatic polyamide fiber bundle having an outer diameter of about 0.2 mm, seven conductor wires 5a made of a tin-copper alloy wire having a wire diameter of 0.08 mm (in FIG. Only four wires are shown.) The heating wire 1 is formed by aligning and spirally winding at a pitch of 1 mm.
The conductor wire 5a is covered with an insulating film 5b made of polyurethane with a thickness of about 0.005 mm. On the outer periphery of the heating wire 1, a polyethylene resin containing a flame retardant as the heat fusion part 9 is extruded and coated with a thickness of 0.25 mm. The cord-like heater 10 has such a configuration, and its finished outer diameter is 0.9 mm. Moreover, this cord-shaped heater 1 has a flame retardance which passes the UL1581 horizontal combustion test (2008, 4th edition) alone. Hereinafter, the configuration and manufacturing method of the substrate 11 and the like are the same as those in the first embodiment.
　次に、図９及び図１０を参照して本発明の実施の形態３（実施の形態３－１、実施の形態３－２）を説明する。
（実施の形態３－１）
　まず、本実施の形態３－１におけるコード状ヒータ１０の構成から説明する。本実施の形態におけるコード状ヒータ１０は図９に示すような構成になっている。
なお、図９は概略図である。
まず、外径約０．２ｍｍの芳香族ポリアミド繊維束からなるヒータ芯３の外周に、素線径０．０８ｍｍの錫銅合金線からなる導体素線５ａを７本（図９ではその内の５本のみを示している。）引き揃え、ピッチ１ｍｍで螺旋状に巻装して発熱線１を構成する。
なお、７本の導体素線５ａの内、３本には、ポリウレタンからなる絶縁被膜５ｂが厚さ約０．００５ｍｍで被覆されている。残りの４本の導体素線５ａには絶縁被膜が被覆されていない。これら絶縁被膜５ｂが被覆されているものと被覆されていないものが交互に配置されるように、導体素線５ａは引き揃えられている。この発熱線１の外周に、熱融着部９としての難燃剤が配合されたポリエチレン樹脂が０．２５ｍｍの厚さで押出・被覆されている。コード状ヒータ１０はこのような構成になっていて、その仕上外径は０．９ｍｍである。また、このコード状ヒータ１は、それ単体でＵＬ１５８１水平燃焼試験（２００８年、第４版）に合格する難燃性を有するものである。以下、基材１１等の構成や製造方法については、上記実施の形態１と同様である。 Next, Embodiment 3 (Embodiment 3-1, Embodiment 3-2) of the present invention will be described with reference to FIG. 9 and FIG.
Embodiment 3-1
First, the configuration of the cord heater 10 in the present Embodiment 3-1 will be described. The cord-like heater 10 in the present embodiment is configured as shown in FIG.
FIG. 9 is a schematic diagram.
First, on the outer periphery of the heater core 3 made of an aromatic polyamide fiber bundle having an outer diameter of about 0.2 mm, seven conductor strands 5a made of a tin-copper alloy wire having a strand diameter of 0.08 mm (in FIG. Only five wires are shown.) The heating wire 1 is formed by aligning and spirally winding at a pitch of 1 mm.
Three of the seven conductor wires 5a are covered with an insulating film 5b made of polyurethane with a thickness of about 0.005 mm. The remaining four conductor wires 5a are not covered with an insulating film. The conductor strands 5a are aligned so that those covered with the insulating coating 5b and those not covered are alternately arranged. On the outer periphery of the heating wire 1, a polyethylene resin containing a flame retardant as the heat fusion part 9 is extruded and coated with a thickness of 0.25 mm. The cord-like heater 10 has such a configuration, and its finished outer diameter is 0.9 mm. Moreover, this cord-shaped heater 1 has a flame retardance which passes the UL1581 horizontal combustion test (2008, 4th edition) alone. Hereinafter, the configuration and manufacturing method of the substrate 11 and the like are the same as those in the first embodiment.
（実施の形態３－２）
次いで、本実施の形態３－２におけるコード状ヒータ１０の構成から説明する。本実施の形態におけるコード状ヒータ１０は図１０に示すような構成になっている。
なお、図１０は概略図である。
まず、外径約０．２ｍｍの芳香族ポリアミド繊維束からなるヒータ芯３の外周に、素線径０．０８ｍｍの錫銅合金線からなる導体素線５ａを７本（図１０ではその内の４本のみを示している。）引き揃え、ピッチ１ｍｍで螺旋状に巻装して発熱線１を構成する。
なお、７本の導体素線５ａの内、６本には、ポリウレタンからなる絶縁被膜５ｂが厚さ約０．００５ｍｍで被覆されている。残りの１本の導体素線５ａには絶縁被膜が被覆されていない。これら絶縁被膜５ｂが被覆されているものの中に被覆されていないものが配置されるように、導体素線５ａは引き揃えられている。この発熱線１の外周に、熱融着部９としての難燃剤が配合されたポリエチレン樹脂が０．２５ｍｍの厚さで押出・被覆されている。コード状ヒータ１０はこのような構成になっていて、その仕上外径は０．９ｍｍである。また、このコード状ヒータ１は、それ単体でＵＬ１５８１水平燃焼試験（２００８年、第４版）に合格する難燃性を有するものである。以下、基材１１等の構成や製造方法については、上記実施の形態１と同様である。 (Embodiment 3-2)
Next, the configuration of the cord heater 10 in the present Embodiment 3-2 will be described. The cord-like heater 10 in the present embodiment is configured as shown in FIG.
FIG. 10 is a schematic diagram.
First, on the outer periphery of the heater core 3 made of an aromatic polyamide fiber bundle having an outer diameter of about 0.2 mm, seven conductor strands 5a made of a tin-copper alloy wire having a strand diameter of 0.08 mm (in FIG. Only four wires are shown.) The heating wire 1 is formed by aligning and spirally winding at a pitch of 1 mm.
Of the seven conductor wires 5a, six are covered with an insulating coating 5b made of polyurethane with a thickness of about 0.005 mm. The remaining one conductor wire 5a is not covered with an insulating film. The conductor strands 5a are aligned so that the uncoated ones are disposed among those coated with the insulating coating 5b. On the outer periphery of the heating wire 1, a polyethylene resin containing a flame retardant as the heat fusion part 9 is extruded and coated with a thickness of 0.25 mm. The cord-like heater 10 has such a configuration, and its finished outer diameter is 0.9 mm. Moreover, this cord-shaped heater 1 has a flame retardance which passes the UL1581 horizontal combustion test (2008, 4th edition) alone. Hereinafter, the configuration and manufacturing method of the substrate 11 and the like are the same as those in the first embodiment.
（実施の形態４）
　次に、図１１を参照して本発明の実施の形態４について説明する。本実施の形態４におけるコード状ヒータ１０の構成から説明する。本実施の形態におけるコード状ヒータ１０は図１１に示すような構成になっている。まず、外径約０．２ｍｍの芳香族ポリアミド繊維束からなるヒータ芯３があり、該ヒータ芯３の外周には、素線径０．０８ｍｍの錫鍍金硬質錫入り銅合金線（ＴＨ－ＳＮＣＣ－３）からなる６本（図１１ではその内の３本のみを示している。）の導体素線５ａを引き揃えて構成されたものがピッチ約０．７ｍｍで螺旋状に巻装されている。このヒータ芯３上に導体素線５ａを巻装したものの外周に、絶縁体層７としての四フッ化エチレン－六フッ化プロピレン共重合体（ＦＥＰ）が約０．１５ｍｍの肉厚で押出・被覆され、発熱線１が構成されている。又、この発熱線１の外周には、更に、熱融着部９としての難燃剤を配合しないポリエチレン樹脂が、０．１ｍｍの厚さで、断続的に５ｍｍ間隔で被覆されている。コード状ヒータ１０はこのような構成になっていて、その仕上外径は０．９ｍｍである。このコード状ヒータ１は、それ単体でＵＬ１５８１水平燃焼試験（２００８年、第４版）に合格する難燃性を有するものである。以下、基材１１等の構成や製造方法については、上記実施の形態１と同様である。 (Embodiment 4)
Next, a fourth embodiment of the present invention will be described with reference to FIG. The configuration of the cord-like heater 10 according to the fourth embodiment will be described. The cord-like heater 10 in the present embodiment is configured as shown in FIG. First, there is a heater core 3 made of an aromatic polyamide fiber bundle having an outer diameter of about 0.2 mm, and a tin-plated hard tin-containing copper alloy wire (TH-SNCC) having an element wire diameter of 0.08 mm is provided on the outer periphery of the heater core 3. -3), which is composed of six conductor wires 5a (only three of them are shown in FIG. 11) arranged in a spiral at a pitch of about 0.7 mm. Yes. On the outer periphery of the conductor core 5a wound around the heater core 3, a tetrafluoroethylene-hexafluoropropylene copolymer (FEP) as an insulator layer 7 is extruded with a thickness of about 0.15 mm. The heating wire 1 is formed by covering. Further, the outer periphery of the heating wire 1 is further covered with a polyethylene resin not blended with a flame retardant as the heat fusion part 9 with a thickness of 0.1 mm and intermittently at intervals of 5 mm. The cord-like heater 10 has such a configuration, and its finished outer diameter is 0.9 mm. The cord-like heater 1 alone has flame retardancy that passes the UL1581 horizontal combustion test (2008, 4th edition). Hereinafter, the configuration and manufacturing method of the substrate 11 and the like are the same as those in the first embodiment.
　上記実施の形態のようにして得られた面状ヒータは、コード状ヒータの熱融着部９が、不織布（基材１１）を構成する繊維を取り囲むことによって、コード状ヒータ１０と基材１１とが強固に接着することになる。
図１２として、実施の形態１におけるコード状ヒータ１０の熱融着部９近傍の電子顕微鏡写真を示す。この写真からも、コード状ヒータの熱融着部９が、不織布（基材１１）を構成する繊維を取り囲んでいる状態を確認できる。特に、基材１１が不織布であって熱融着性繊維を含み、この熱融着性繊維が芯－鞘構造を有するとともに、鞘部分が低融点のものであれば、芯部分を取り囲んだ状態で、該鞘部分と上記コード状ヒータの熱融着部９とが、互いに融着し一体化することになる。これにより、コード状ヒータ１０と基材１１とが更に強固に接着することになる。 In the planar heater obtained as in the above embodiment, the cord-shaped heater 10 and the base material 11 are formed by the heat-sealed portion 9 of the cord-shaped heater surrounding the fibers constituting the nonwoven fabric (base material 11). And will adhere firmly.
FIG. 12 shows an electron micrograph of the vicinity of the heat fusion part 9 of the cord-like heater 10 according to the first embodiment. Also from this photograph, it can be confirmed that the heat fusion part 9 of the cord heater surrounds the fibers constituting the nonwoven fabric (base material 11). In particular, if the base material 11 is a non-woven fabric and contains heat-fusible fibers, the heat-fusible fibers have a core-sheath structure and the sheath portion has a low melting point, the state surrounding the core portion Thus, the sheath part and the heat fusion part 9 of the cord heater are fused and integrated with each other. As a result, the cord-like heater 10 and the base material 11 are more firmly bonded.
　尚、本発明は、上記実施の形態１～実施の形態４に限定されるものではない。
　まず、コード状ヒータ１０は、発熱線１と熱融着部９とを有しているものであれば、従来公知の種々のコード状ヒータを使用することができる。
又、発熱線１の構成としては、例えば、上記実施の形態１－１のように、導体素線５ａを複数本撚り合わせ又は引き揃え、これを芯線３上に巻装し、その外周に絶縁被覆７を施したもの（図１参照）、上記実施の形態１－２のように、絶縁被膜５ｂにより被覆された導体素線５ａを複数本撚り合わせたもの（図６参照）、上記実施の形態１－３のように、絶縁被膜５ｂにより被覆された導体素線５ａを複数本引き揃えたもの（図７参照）、上記実施の形態２のように、絶縁被膜５ｂにより被覆された導体素線５ａを複数本撚り合わせ又は引き揃え、これを芯線３上に巻装したもの（図８参照）、などが挙げられるが、それら以外にも様々な構成のものが想定される。
また、上記実施の形態３－１のように、絶縁被膜５ｂにより被覆された導体素線５ａと絶縁被膜５ｂにより被覆されていない導体素線５ａが交互に配置された形態（図９）だけでなく、例えば、図１０に示すように、絶縁被膜５ｂにより被覆された導体素線５ａの本数を増やして、絶縁被膜５ｂにより被覆された導体素線５ａ同士を並べて配置するような形態も考えられ（実施の形態３－２）、それら以外にも様々な構成のものが想定される。
また、芯線３と導体素線５ａを撚り合せることも考えられる。 The present invention is not limited to Embodiments 1 to 4 described above.
First, as long as the cord-like heater 10 has the heating wire 1 and the heat fusion part 9, various conventionally known cord-like heaters can be used.
Further, as the configuration of the heating wire 1, for example, as in the above-described Embodiment 1-1, a plurality of conductor wires 5a are twisted or aligned, and these are wound on the core wire 3 and insulated on the outer periphery thereof. The one provided with the coating 7 (see FIG. 1), the one obtained by twisting a plurality of conductor wires 5a covered with the insulating coating 5b as in the above-described Embodiment 1-2 (see FIG. 6), As in Embodiment 1-3, a plurality of conductor wires 5a covered with the insulating coating 5b are aligned (see FIG. 7), and the conductor element covered with the insulating coating 5b as in Embodiment 2 above. A plurality of wires 5a are twisted or aligned, and the wires 5a are wound around the core wire 3 (see FIG. 8).
Further, as in the case of the above embodiment 3-1, only in the form (FIG. 9) where the conductor strands 5a covered with the insulating coating 5b and the conductor strands 5a not covered with the insulating coating 5b are alternately arranged. For example, as shown in FIG. 10, the number of the conductor strands 5a covered with the insulating coating 5b is increased and the conductor strands 5a covered with the insulating coating 5b are arranged side by side. (Embodiment 3-2) Various configurations other than these are envisaged.
It is also conceivable to twist the core wire 3 and the conductor wire 5a.
　芯線３としては、例えば、ガラス繊維等の無機繊維や、ポリエチレンテレフタレート等のポリエステル繊維、脂肪族ポリアミド繊維、芳香族ポリアミド繊維、全芳香族ポリエステル繊維等の有機繊維のモノフィラメント、マルチフィラメント、スパン、或いはそれらの繊維材料、若しくは、それらの繊維材料を構成する有機高分子材料を芯材とし、その周上に熱可塑性の有機高分子材料が被覆された構成を有する繊維などが挙げられる。また、芯線３を熱収縮性及び熱溶融性を有するものとすれば、導体素線５ａが断線してしまった際の異常加熱により芯線が溶融切断されるとともに収縮することで、巻装された導体素線５ａもこの芯線３の動作に追従し、断線した導体素線５ａの端部同士を分離することになる。そのため、断線した導体素線のそれぞれの端部が接したり離れたりすることや点接触のようなわずかな接触面積で接することがなくなり、異常発熱を防止することができる。また、導体素線５ａが絶縁被膜５ｂにより絶縁されている構成であれば、芯線３は絶縁材料にこだわる必要はない。例えば、ステンレス鋼線やチタン合金線等を使用することも可能である。しかし、導体素線５ａが断線したときのことを考慮すると、芯線３は絶縁材料であった方が良い。 As the core wire 3, for example, inorganic fibers such as glass fibers, polyester fibers such as polyethylene terephthalate, monofilaments of organic fibers such as aliphatic polyamide fibers, aromatic polyamide fibers, wholly aromatic polyester fibers, multifilaments, spans, or Examples thereof include fibers having a structure in which the fiber material or an organic polymer material constituting the fiber material is used as a core and a thermoplastic organic polymer material is coated on the periphery thereof. Further, if the core wire 3 has heat shrinkability and heat meltability, the core wire is melted and cut by contraction due to abnormal heating when the conductor wire 5a is disconnected, and the core wire 3 is wound. The conductor strand 5a follows the operation of the core wire 3 and separates the ends of the disconnected conductor strand 5a. For this reason, the ends of the disconnected conductor wires do not come into contact with or leave from each other, and contact with a slight contact area such as point contact can be prevented, and abnormal heat generation can be prevented. Moreover, if the conductor strand 5a is the structure insulated by the insulating film 5b, the core wire 3 does not need to stick to an insulating material. For example, a stainless steel wire or a titanium alloy wire can be used. However, considering that the conductor wire 5a is disconnected, the core wire 3 is preferably an insulating material.
　導体素線５ａとしては、従来公知のものを使用することができ、例えば、銅線、銅合金線、ニッケル線、鉄線、アルミニウム線、ニッケル－クロム合金線、銅－ニッケル合金、鉄－クロム合金、銅固溶体と銅銀共晶がファイバー状になった銀入り銅合金線などが使用できる。また、その断面形状についても種々のものが使用でき、通常使用される断面円形のものに限られず、いわゆる平角線と称されるものを使用しても良い。
但し、芯線３に導体素線５ａを巻装する場合は、これらの中でも、発熱線１を巻付けたときのスプリングバックする量が小さいものが良く、復元率が２００％以下となるものが好ましい。例えば、銅固溶体と銅銀共晶がファイバー状になった銀入り銅合金線などは、抗張力性に優れ引張強度や屈曲強度には優れるものの、発熱線を巻付けたときスプリングバックし易い。そのため、芯線３に巻装する際に、導体素線５ａの浮きや、過度の巻付けテンションによる導体素線５ａの破断が生じ易く、また加工後には撚り癖が生じ易いため好ましくない。特に、導体素線５ａに絶縁被膜５ｂが被覆される形態とした場合は、この絶縁被膜５ｂによる復元力も加わることになる。そのため、導体素線５ａの復元率が小さいものを選定し、絶縁被膜５ｂによる復元力をカバーすることが重要となる。 As the conductor wire 5a, a conventionally known wire can be used. For example, copper wire, copper alloy wire, nickel wire, iron wire, aluminum wire, nickel-chromium alloy wire, copper-nickel alloy, iron-chromium alloy A copper alloy wire containing silver in which a copper solid solution and a copper silver eutectic are formed into a fiber shape can be used. Various cross-sectional shapes can be used, and the cross-sectional shape is not limited to a generally used cross-sectional shape, and a so-called rectangular wire may be used.
However, when the conductor wire 5 a is wound around the core wire 3, among them, it is preferable that the amount of spring back when the heating wire 1 is wound is small, and the restoration rate is 200% or less. . For example, a silver alloy copper alloy wire in which a copper solid solution and a copper silver eutectic are formed into a fiber shape is excellent in tensile strength and bending strength, but easily springs back when a heating wire is wound. For this reason, when the wire is wound around the core wire 3, it is not preferable because the conductor wire 5 a is easily lifted or the conductor wire 5 a is easily broken due to excessive winding tension, and twists are likely to occur after processing. In particular, when the conductor wire 5a is covered with the insulating coating 5b, the restoring force by the insulating coating 5b is also applied. Therefore, it is important to select a conductor wire 5a with a low restoration rate and cover the restoring force of the insulating coating 5b.
　ここで、本発明で規定する復元率の測定について詳しく記述する。まず、導体素線に一定荷重を掛けながら、導体素線径の６０倍の径の円柱形マンドレルに対して、導体素線が重ならないように３回以上巻きつける。１０分後、荷重を取り去り導体素線をマンドレルから外し、弾性により復元した形状の内径を測定して、導体素線のスプリングバックする割合を次の式（Ｉ）により算出して、復元率として評価する。
Ｒ＝（ｄ２／ｄ１）×１００―――（Ｉ）
記号の説明：
Ｒ：復元率（％）
ｄ１：巻付試験に用いたマンドレル径（ｍｍ）
ｄ２：導体素線をマンドレルに巻きつけた後、荷重を開放して復元した形状の内径（ｍｍ） Here, the measurement of the restoration rate defined in the present invention will be described in detail. First, while applying a constant load to the conductor wire, it is wound three times or more around the cylindrical mandrel having a diameter 60 times the conductor wire diameter so that the conductor wires do not overlap. After 10 minutes, the load is removed, the conductor wire is removed from the mandrel, the inner diameter of the shape restored by elasticity is measured, and the springback ratio of the conductor wire is calculated by the following formula (I) as the restoration rate: evaluate.
R = (d 2 / d 1 ) × 100— (I)
Explanation of symbols:
R: Restoration rate (%)
d 1 : Mandrel diameter (mm) used in the winding test
d 2 : Inner diameter (mm) of the shape restored by releasing the load after winding the conductor wire around the mandrel
　導体素線５ａに被覆される絶縁被膜５ｂとしては、従来公知の樹脂材料等を使用することができ、例えば、ポリウレタン樹脂、ポリアミド樹脂、ポリイミド樹脂、ポリアミドイミド樹脂、ポリエステルイミド樹脂、ナイロン樹脂、ポリエステルナイロン樹脂、ポリエチレン樹脂、ポリエステル樹脂、塩化ビニル樹脂、フッ素樹脂、シリコーン樹脂などが挙げられる。これらの中でも、熱融着性を有する材料を使用すれば、導体素線５ａ同士を融着することができることから、接続端子との接続等の端末加工時に発熱線１がバラけることがないため、加工性を向上させることができ好ましい。また、端末加工としてハンダ付けする場合には、ハンダ付けの際の熱により絶縁被膜５ｂが除去されると非常に加工性が向上するため、絶縁被膜５ｂの材料としては、熱分解性が良いものであることが好ましい。また、ＦＥＰ、ＥＴＦＥ、ＰＦＡなどのフッ素樹脂は不燃性であり化学的に安定している材料であるため好ましい。特に、ＥＴＦＥは機械的強度及び耐スパーク性にも優れているため好ましい。 A conventionally known resin material or the like can be used as the insulating coating 5b covered with the conductor wire 5a. For example, polyurethane resin, polyamide resin, polyimide resin, polyamideimide resin, polyesterimide resin, nylon resin, polyester Nylon resin, polyethylene resin, polyester resin, vinyl chloride resin, fluororesin, silicone resin and the like can be mentioned. Among these, if a material having heat-fusibility is used, the conductor wires 5a can be fused together, so that the heating wire 1 does not vary during terminal processing such as connection with the connection terminal. It is preferable because it can improve the workability. Further, when soldering as terminal processing, since the workability is greatly improved when the insulating coating 5b is removed by the heat during soldering, the material of the insulating coating 5b has good thermal decomposability. It is preferable that Further, fluororesins such as FEP, ETFE, and PFA are preferable because they are nonflammable and chemically stable. In particular, ETFE is preferable because it is excellent in mechanical strength and spark resistance.
　上記導体素線５ａを引き揃え又は撚り合せて芯材３上に巻装する際には、撚り合せるよりも、引き揃えた方が好ましい。これは、発熱芯４の径が細くなるとともに、表面も平滑になるためである。また、引き揃え又は撚り合わせの他に、芯材３上に導体素線５ａを編組することも考えられる。 When the conductor strands 5a are aligned or twisted and wound on the core material 3, they are preferably aligned rather than twisted. This is because the diameter of the heating core 4 is reduced and the surface is also smoothed. In addition to the alignment or twisting, it is also conceivable to braid the conductor wire 5a on the core material 3.
　絶縁体層７を形成する場合は、押出成形等によって行っても良いし、予めチューブ状に成形した絶縁体層７を被せても良く、形成の方法には特に限定はない。絶縁体層７を構成する材料としても、コード状ヒータの使用形態や使用環境などによって適宜設計すれば良く、例えば、ポリエチレン系樹脂、ポリエステル系樹脂、ポリウレタン系樹脂、ポリアミド系樹脂、塩化ビニル樹脂、フッ素系樹脂、合成ゴム、フッ素ゴム、エチレン系熱可塑性エラストマー、ウレタン系熱可塑性エラストマー等、種々のものが挙げられる。また、この絶縁体層７の外周に、更に保護被覆を形成しても良い。 When forming the insulator layer 7, it may be performed by extrusion molding or the like, or may be covered with the insulator layer 7 previously formed into a tube shape, and the formation method is not particularly limited. The material constituting the insulator layer 7 may be appropriately designed depending on the usage form or usage environment of the cord heater, for example, polyethylene resin, polyester resin, polyurethane resin, polyamide resin, vinyl chloride resin, Various materials such as fluororesin, synthetic rubber, fluororubber, ethylene-based thermoplastic elastomer, urethane-based thermoplastic elastomer can be used. Further, a protective coating may be further formed on the outer periphery of the insulator layer 7.
　上記のような発熱線１の外周に、熱融着部９を形成することにより、本発明のコード状ヒータが得られる。熱融着部は、発熱線の外周の全周に形成する以外にも、例えば、コード状ヒータの長さ方向に沿って直線状やスパイラル線状に形成する、ドット模様に形成する、上記実施の形態３のように断続的に形成するなどの態様が考えられる。この際、熱融着部がコード状ヒータの長さ方向に連続していなければ、例え、熱融着部の一部に着火しても、燃焼部が広がらないため好ましい。また、熱融着部の体積が充分に小さければ、熱融着部が燃焼性の材料であっても、すぐに燃焼物がなくなり消火することになるし、ドリップ（燃焼滴下物）も発生しなくなる。従って、熱融着部の体積は、基材との接着性を保持できる最低限とすることが好ましい。
但し、これらのような態様の場合は、絶縁体層７或いは絶縁被膜５ｂが難燃性の材料から構成されていることが好ましい。 By forming the heat fusion part 9 on the outer periphery of the heating wire 1 as described above, the cord-like heater of the present invention can be obtained. The heat fusion part is formed in a dot pattern, for example, formed in a linear shape or a spiral line shape along the length direction of the cord-like heater, in addition to being formed on the entire outer periphery of the heating wire. A form such as intermittent formation as in form 3 is conceivable. At this time, if the heat fusion part is not continuous in the length direction of the cord-like heater, for example, even if a part of the heat fusion part is ignited, the combustion part does not spread, which is preferable. Also, if the volume of the heat fusion part is sufficiently small, even if the heat fusion part is a combustible material, the burned material will disappear immediately and the fire will extinguish, and drip (combustion dripping) will also occur. Disappear. Therefore, it is preferable that the volume of the heat-sealed portion be the minimum that can maintain the adhesiveness with the base material.
However, in the case of such an aspect, it is preferable that the insulator layer 7 or the insulating coating 5b is made of a flame retardant material.
　熱融着部９を構成する材料としては、難燃性を有する高分子組成物が好ましく使用される。ここでの難燃性を有する高分子組成物とは、ＪＩＳ－Ｋ７２０１（１９９９年）燃焼性試験における酸素指数が２１以上のものを示す。酸素指数が２６以上のものは特に好ましい。具体的な材料としては、例えば、オレフィン系樹脂、ポリエステル系樹脂、ポリアミド系樹脂、塩化ビニル樹脂、ポリウレタン樹脂、変性ノリル樹脂（ポリフェニレンオキサイド樹脂）、ナイロン樹脂、ポリスチレン樹脂、ポリオレフィン系熱可塑性エラストマー、ポリエステル系熱可塑性エラストマー、ポリウレタン系熱可塑性エラストマーなどの熱可塑性高分子材料や、これら熱可塑性高分子材料に、適宜難燃剤が配合されたものなどが挙げられる。これらの熱可塑性高分子材料の中でも、基材との接着性に優れるオレフィン系樹脂が好ましい。オレフィン系樹脂としては、例えば、高密度ポリエチレン、低密度ポリエチレン、超低密度ポリエチレン、直鎖状低密度ポリエチレン、ポリプロピレン、ポリブテン、エチレン－α－オレフィン共重合体、エチレン－不飽和エステル共重合体などが挙げられる。本発明においては、特に、エチレン－不飽和エステル共重合体が好ましい。エチレン－不飽和エステル共重合体は、分子内に酸素を有する分子構造であるため、ポリエチレンのような炭素と水素のみの分子構造をしている樹脂と比較して燃焼熱が小さくなり、その結果、燃焼の抑制につながることとなる。また、元々の接着性が高いため基材との接着性も良好である上、無機粉末等を配合した際の接着性の低下が少ないため、種々の難燃剤を配合するのに好適である。エチレン－不飽和エステル共重合体としては、例えば、エチレン－酢酸ビニル共重合体、エチレン－（メタ）アクリル酸メチル共重合体、エチレン－（メタ）アクリル酸エチル共重合体、エチレン－（メタ）アクリル酸ブチル共重合体などが挙げられ、これらの単独または２種以上の混合物であってもよい。ここで「（メタ）アクリル酸」とは、アクリル酸とメタクリル酸の両方を表すものである。これらの内から任意に選択すれば良いが、上記した絶縁被膜５ｂ或いは絶縁体被覆７を構成する材料の分解開始温度以下又は融点以下の温度で溶融する材料である方が良い。また、基材との接着性に優れる材料として、ポリエステル系熱可塑性エラストマーが挙げられる。ポリエステル系熱可塑性エラストマーとしては、ポリエステル－ポリエステル型、ポリエステル－ポリエーテル型のものがあるが、ポリエステル－ポリエーテル型の方が高い接着性を有するため好ましい。更には、基材との接着を容易なものとし、且つ、接着後の接着強度を確保するために、熱融着部９を構成する材料のメルトフローレートが５．０ｃｍ３／１０分以上であることが好ましい。このメルトフローレートは、ＪＩＳ－Ｋ７２１０（１９９９年）に記載されたＡ法により、温度２００℃、荷重２．１６ｋｇで測定される。難燃剤としては、例えば、水酸化マグネシウム、水酸化アルミニウム等の金属水和物、酸化アンチモン、メラミン化合物、リン系化合物、塩素系難燃剤、臭素系難燃剤などが挙げられる。これらの難燃剤には公知の方法で適宜表面処理を施しても良い。特に、熱融着層を構成する高分子組成物の溶融時粘度を下げるような表面処理であることが好ましい。また、接着層９を形成する方法には特に限定はなく、例えば公知の押出成形により形成しても良いし、塗布により形成しても良い。
尚、本発明において、コード状ヒータと基材との接着強度は非常に重要なものである。この接着強度が充分でないと、使用していくうちに基材とコード状ヒータとが剥離してしまい、それにより、コード状ヒータには予期せぬ屈曲が加わることになるため、導体素線が断線する可能性が高くなる。導体素線が断線すると、ヒータとしての役を果たさなくなるだけでなく、チャタリングによりスパークに至るおそれもある。 As a material constituting the heat fusion part 9, a polymer composition having flame retardancy is preferably used. Here, the polymer composition having flame retardancy is one having an oxygen index of 21 or more in a JIS-K7201 (1999) flammability test. Those having an oxygen index of 26 or more are particularly preferred. Specific materials include, for example, olefin resin, polyester resin, polyamide resin, vinyl chloride resin, polyurethane resin, modified noryl resin (polyphenylene oxide resin), nylon resin, polystyrene resin, polyolefin thermoplastic elastomer, polyester. Thermoplastic polymer materials such as thermoplastic thermoplastic elastomers and polyurethane thermoplastic elastomers, and those obtained by appropriately blending a flame retardant with these thermoplastic polymer materials. Among these thermoplastic polymer materials, an olefin resin excellent in adhesiveness with a substrate is preferable. Examples of the olefin resin include high density polyethylene, low density polyethylene, ultra low density polyethylene, linear low density polyethylene, polypropylene, polybutene, ethylene-α-olefin copolymer, ethylene-unsaturated ester copolymer, and the like. Is mentioned. In the present invention, an ethylene-unsaturated ester copolymer is particularly preferable. Since the ethylene-unsaturated ester copolymer has a molecular structure having oxygen in the molecule, the combustion heat is smaller than that of a resin having a molecular structure of only carbon and hydrogen, such as polyethylene. This will lead to suppression of combustion. Moreover, since the original adhesiveness is high, the adhesiveness to the base material is also good, and since there is little decrease in the adhesiveness when an inorganic powder or the like is blended, it is suitable for blending various flame retardants. Examples of the ethylene-unsaturated ester copolymer include an ethylene-vinyl acetate copolymer, an ethylene-methyl (meth) acrylate copolymer, an ethylene- (meth) ethyl acrylate copolymer, and an ethylene- (meth). A butyl acrylate copolymer etc. are mentioned, These may be individual or the mixture of 2 or more types. Here, “(meth) acrylic acid” represents both acrylic acid and methacrylic acid. Any of these materials may be selected, but a material that melts at a temperature lower than the decomposition start temperature or lower than the melting point of the material constituting the insulating coating 5b or the insulator coating 7 is better. Moreover, a polyester-type thermoplastic elastomer is mentioned as a material excellent in adhesiveness with a base material. Polyester-based thermoplastic elastomers include polyester-polyester type and polyester-polyether type, and polyester-polyether type is preferred because it has higher adhesiveness. In addition, the adhesion between the substrate and made easy, and, in order to secure the bonding strength after bonding, melt flow rate of the material constituting the heat-sealed portion 9 is 5.0 cm 3/10 minutes or more Preferably there is. This melt flow rate is measured at a temperature of 200 ° C. and a load of 2.16 kg according to the method A described in JIS-K7210 (1999). Examples of the flame retardant include metal hydrates such as magnesium hydroxide and aluminum hydroxide, antimony oxide, melamine compound, phosphorus compound, chlorine flame retardant, bromine flame retardant and the like. These flame retardants may be appropriately subjected to surface treatment by a known method. In particular, a surface treatment that lowers the viscosity at the time of melting of the polymer composition constituting the heat fusion layer is preferable. Moreover, there is no limitation in particular in the method of forming the contact bonding layer 9, For example, you may form by well-known extrusion molding and may form by application | coating.
In the present invention, the adhesive strength between the cord-like heater and the substrate is very important. If this adhesive strength is not sufficient, the base material and the cord-like heater will be peeled off during use, which will cause unexpected bending in the cord-like heater. The possibility of disconnection is increased. If the conductor wire is disconnected, it not only serves as a heater but also may cause sparking due to chattering.
　また、図１に示すようなコード状ヒータを使用する場合、長さ方向の一部分において、導体素線５ａの外周に金属箔などの電気良導体を巻き付けておくこともできる。また、図１に示すようなコード状ヒータを使用する場合、長さ方向の一部分において、芯材３の外周（導体素線５ａの内面）に金属箔などの電気良導体を巻き付けておくこともできる。これらのようにすることで、電気良導体が巻き付けられた部分において、電気は電気良導体に導通し、導体素線５ａにはほぼ導通しないため、この部分は発熱しなくなる。従って、発熱が不要な部分において、上記のように電気良導体を巻き付けることが考えられる。また、コード状ヒータの端部において、上記のように電気良導体が巻き付けられていれば、その部分はリード線部となる。従って、発熱部とリード線部が連続して形成されることになり、特別な接続加工、防水加工がなくても、防水がはかられることになる。そのため、このような構成は、多湿な環境、水がかかる環境、解氷を行う環境など、防水性が要求される用途に好適に使用される。 Further, when a cord-like heater as shown in FIG. 1 is used, a good electric conductor such as a metal foil can be wound around the outer periphery of the conductor wire 5a in a part in the length direction. Moreover, when using the cord-shaped heater as shown in FIG. 1, a good electric conductor such as a metal foil can be wound around the outer periphery of the core material 3 (the inner surface of the conductor wire 5a) in a part of the length direction. . By doing in this way, in the portion where the good electric conductor is wound, electricity is conducted to the good electric conductor and is not almost conducted to the conductor element wire 5a, so this portion does not generate heat. Therefore, it is conceivable to wind a good electrical conductor as described above in a portion where heat generation is unnecessary. Further, if the good electrical conductor is wound at the end of the cord-like heater as described above, that portion becomes a lead wire portion. Therefore, the heat generating portion and the lead wire portion are continuously formed, and waterproofing can be achieved without special connection processing and waterproof processing. Therefore, such a configuration is suitably used for applications that require waterproofing, such as a humid environment, an environment where water is applied, and an environment where ice removal is performed.
　基材１１としては、上記実施の形態で示した不織布の他に、例えば、織布、紙、アルミ箔、マイカ板、樹脂シート、発泡樹脂シート、ゴムシート、発泡ゴムシート、延伸多孔質体等、種々のものが使用できるが、ＦＭＶＳＳ　Ｎｏ．３０２自動車内層材料の燃焼試験に合格する難燃性を有するものが好ましい。ここで、ＦＭＶＳＳとは、Ｆｅｄｅｒａｌ
Ｍｏｔｏｒ Ｖｅｈｉｃｌｅ Ｓａｆｅｔｙ Ｓｔａｎｄａｒｄ、即ち、米国連邦自動車安全基準のことであり、そのＮｏ．３０２として、自動車内装材料の燃焼試験が規定されている。これらの中でも、不織布は、風合いが良く柔軟であるため、特にカーシートヒータの用途において好ましい。また、不織布を使用する場合も、上記実施の形態の場合には、不織布を構成する熱融着性繊維として、低融点ポリエステルを鞘成分とする芯鞘構造を有する繊維を使用しているが、それ以外にも、例えば、低融点ポリプロピレンを鞘成分とする芯鞘構造を有する繊維、又はポリエチレンを鞘成分とする芯鞘構造を有する繊維等の使用が考えられる。このような熱融着性繊維を使用することで、熱融着性繊維の芯部を取り囲んだ状態で、熱融着性繊維の鞘部と上記熱融着部９とが互いに融着し一体化することとなるため、コード状ヒータ１と不織布との接着は非常に強固なものとなる。又、難燃性繊維としては、例えば、上記の難燃性ポリエステルの他に、種々の難燃性繊維の使用が考えられる。ここで、難燃性繊維とは、ＪＩＳ－Ｌ１０９１（１９９９年）に合格する繊維のことを指す。このような難燃性繊維を使用することで、基材は優れた難燃性を付与されることとなる。 As the base material 11, in addition to the nonwoven fabric shown in the above embodiment, for example, woven fabric, paper, aluminum foil, mica plate, resin sheet, foamed resin sheet, rubber sheet, foamed rubber sheet, stretched porous body, etc. Although various types can be used, FMVSS No. Those having flame retardancy that pass the combustion test of 302 automotive inner layer material are preferred. Here, FMVSS means Federal
Motor Vehicle Safety Standard, that is, the Federal Motor Vehicle Safety Standard. As 302, a combustion test for automobile interior materials is defined. Among these, non-woven fabrics are particularly preferable for use in car seat heaters because they have a good texture and are flexible. Also, when using a non-woven fabric, in the case of the above embodiment, as the heat-fusible fiber constituting the non-woven fabric, a fiber having a core-sheath structure having a low melting point polyester as a sheath component is used. In addition, for example, use of a fiber having a core-sheath structure having a low melting point polypropylene as a sheath component or a fiber having a core-sheath structure having polyethylene as a sheath component is conceivable. By using such a heat-fusible fiber, the sheath portion of the heat-fusible fiber and the heat-fusible portion 9 are fused and integrated with each other while surrounding the core portion of the heat-fusible fiber. Therefore, the adhesion between the cord-like heater 1 and the nonwoven fabric becomes very strong. Moreover, as flame retardant fiber, use of various flame retardant fibers other than said flame retardant polyester is considered, for example. Here, the flame-retardant fiber refers to a fiber that passes JIS-L1091 (1999). By using such a flame retardant fiber, the base material is imparted with excellent flame retardancy.
　熱融着性繊維の混合割合は、５％以上が好ましく、また、２０％以下が好ましい。熱融着性繊維の混合割合が５％未満だと、十分な接着性が得られない。又、熱融着性繊維の混合割合が２０％を超えると、不織布が固くなり、着座者が違和感を訴えることになり得るのみでなく、逆にコード状ヒータとの接着性が低下してしまう。更には、熱融着する際の熱によって基材が収縮し、設計で意図した寸法が得られなくなる可能性もある。難燃性繊維の混合割合は、７０％以上であり、好ましくは７０％以上９５％以下である。難燃性繊維の混合割合が７０％未満だと、十分な難燃性が得られない。又、難燃性繊維の混合割合が９５％を超えると、相対的に熱融着性繊維の混合割合が不足してしまい、十分な接着性が得られない。尚、熱融着性繊維の混合割合と難燃性繊維の混合割合を合算して１００％になる必要はなく、他の繊維を適宜混合させても良い。また、熱融着性繊維が混合されていない場合であっても、例えば、上記の熱融着部の材料と基材を構成する繊維の材料を同系統の材料とすることで、必要充分な接着性を得られることもあるので、熱融着性繊維が混合されていないことも充分に考えられる。 The mixing ratio of the heat-fusible fiber is preferably 5% or more, and preferably 20% or less. When the mixing ratio of the heat-fusible fiber is less than 5%, sufficient adhesion cannot be obtained. Moreover, when the mixing ratio of the heat-fusible fiber exceeds 20%, the nonwoven fabric becomes hard and not only the seated person may complain of an uncomfortable feeling, but also the adhesiveness with the cord-like heater decreases. . Furthermore, there is a possibility that the substrate shrinks due to heat at the time of heat-sealing, and the dimensions intended by the design cannot be obtained. The mixing ratio of the flame retardant fiber is 70% or more, preferably 70% or more and 95% or less. When the mixing ratio of the flame retardant fiber is less than 70%, sufficient flame retardancy cannot be obtained. On the other hand, if the mixing ratio of the flame-retardant fibers exceeds 95%, the mixing ratio of the heat-fusible fibers is relatively insufficient, and sufficient adhesiveness cannot be obtained. In addition, it is not necessary to add the mixing ratio of the heat-fusible fiber and the mixing ratio of the flame-retardant fiber to 100%, and other fibers may be appropriately mixed. Further, even when the heat-fusible fiber is not mixed, for example, the above-mentioned material of the heat-sealing part and the material of the fiber constituting the base material are made of the same system, so that it is necessary and sufficient. Since adhesiveness may be obtained, it is fully possible that the heat-fusible fiber is not mixed.
　又、不織布の大きさや厚さなどは、使用用途によって適宜に変更するものであるが、その厚さ（乾燥時に測定した値）は、例えば、０．６ｍｍ～１．４ｍｍ程度とすることが望ましい。このような厚さの不織布を使用すれば、加熱・加圧によりコード状ヒータと不織布とを接着・固定した際、不織布がコード状ヒータの外周の３０％以上、好ましくは５０％以上の部分と良好に接着することになるからであり、それによって、強固な接着状態を得ることができるからである。 In addition, the size and thickness of the nonwoven fabric are appropriately changed depending on the intended use, but the thickness (value measured during drying) is preferably about 0.6 mm to 1.4 mm, for example. . If a nonwoven fabric having such a thickness is used, when the cord heater and the nonwoven fabric are bonded and fixed by heating and pressing, the nonwoven fabric has a portion of 30% or more, preferably 50% or more of the outer circumference of the cord heater. It is because it will adhere | attach favorably and it can obtain a strong adhesion state by it.
　上記基材の中でも、空隙を有しているものが好ましく、特に、コード状ヒータが配設される面（以下、配設面と記す）が、コード状ヒータが配設されない面（以下、非配設面と記す）よりも空隙が多くなっているように構成されることが好ましい。空隙が多い状態とは、例えば、織布や不織布等の布体の場合、目付け、即ち単位体積当たりの繊維重量が小さい状態、発泡樹脂シートや発泡ゴムシートのような多孔体の場合、気孔率が大きい状態のことを示す。本発明による基材の具体的な態様としては、例えば、温度や圧力を調節するなどして片面のみ又は両面で強弱異なるカレンダー加工を行った織布又は不織布、片面のみからニードルパンチを行った不織布、片面にパイル形成や起毛をさせた布体、厚さ方向で気孔率が傾斜するように発泡制御した発泡樹脂シート又は発泡ゴムシート、空隙の多さが異なる材料を貼り合わせたもの、などが挙げられる。また、特に基材の空隙は連続していることが好ましい。これは、溶融した熱融着層が連続した空隙に浸透していくことで、アンカー効果が増して接着強度が向上するためである。このような空隙が連続している態様としては、繊維の集合体である織布や不織布等の布体、連続気孔を有する発泡樹脂シートや発泡ゴムシートなどが考えられる。尚、非配設面は空隙を有していないものも考えられる。 Among the above base materials, those having voids are preferable, and in particular, the surface on which the cord-like heater is disposed (hereinafter referred to as an arrangement surface) is the surface on which the cord-shaped heater is not disposed (hereinafter referred to as non-surface). It is preferable that the air gap is larger than the arrangement surface. The state with many voids is, for example, a fabric such as a woven fabric or a non-woven fabric, a basis weight, that is, a state where the fiber weight per unit volume is small, and a porous body such as a foamed resin sheet or a foamed rubber sheet. Indicates a large state. Specific examples of the base material according to the present invention include, for example, a woven fabric or a nonwoven fabric that is calendered with different strength on only one side or both sides by adjusting temperature and pressure, and a nonwoven fabric that is needle punched from only one side. , A cloth body with pile formation or raising on one side, a foamed resin sheet or foam rubber sheet that is foam-controlled so that the porosity is inclined in the thickness direction, and a laminate of materials with different numbers of voids, etc. Can be mentioned. Moreover, it is preferable that the space | gap of a base material is especially continuous. This is because the anchor effect is increased and the adhesive strength is improved by the molten heat-sealing layer penetrating into the continuous voids. As a mode in which such voids are continuous, a fabric body such as a woven fabric or a nonwoven fabric which is an aggregate of fibers, a foamed resin sheet or a foamed rubber sheet having continuous pores, and the like can be considered. In addition, the non-arranged surface may have no gap.
　また、コード状ヒータ１０を基材１１に配設する際、加熱加圧による融着によって接着・固定する態様でなく、他の態様によりコード状ヒータ１０を基材１１に固定しても良い。例えば、温風により熱融着層９を溶融させて接着・固定する態様、発熱線１に通電してその発熱により熱融着層９を溶融させて接着・固定する態様、加熱しながら一対の基材１０で挟持固定する態様など、種々の態様が考えられる。 In addition, when the cord-like heater 10 is disposed on the base material 11, the cord-like heater 10 may be fixed to the base material 11 in another manner instead of being bonded and fixed by fusion by heating and pressurization. For example, a mode in which the heat-fusible layer 9 is melted and bonded / fixed by hot air, a mode in which the heat-bonding wire 1 is energized and the heat-fused layer 9 is melted and bonded / fixed by the heat generation, Various modes such as a mode in which the substrate 10 is sandwiched and fixed are considered.
　また、面状ヒータ３１を座席に固定するための接着層については、基材１１の伸縮性の点や、良質な風合いの保持という点からすると、離型シート等の上に接着剤のみからなる接着層を形成し、該接着層を上記離型シートから上記基材１１表面に転写することによって接着層を形成することが好ましい。また、この接着層は、難燃性を有するものが好ましく、それ単独でＦＭＶＳＳ　Ｎｏ．３０２自動車内装材料の燃焼試験に合格するような難燃性を有するものが好ましい。例えば、高分子アクリル系粘着剤などが挙げられる。接着層は基材の配設面に形成しても良いし非配設面に形成しても良い。 In addition, the adhesive layer for fixing the planar heater 31 to the seat is composed only of an adhesive on the release sheet or the like from the viewpoint of the stretchability of the base material 11 and the maintenance of a good texture. It is preferable to form an adhesive layer by forming an adhesive layer and transferring the adhesive layer from the release sheet to the surface of the substrate 11. In addition, this adhesive layer is preferably flame retardant, and FMVSS No. Those having flame retardancy that pass the combustion test of 302 automotive interior materials are preferred. For example, a polymeric acrylic pressure sensitive adhesive can be used. The adhesive layer may be formed on the surface on which the substrate is disposed, or may be formed on the non-arranged surface.
（実施例１～５、比較例１）
　上記実施の形態２によって得られる面状ヒータについて、コード状ヒータの熱融着部について、表１、２に示すように材料を変更し、実施例１～５及び比較例１とした（配合量は重量部数で示す）。これらについて、接着性、通電接着性、難燃性、耐スパーク性の試験を行った。接着性は、基材を固定し、コード状ヒータを上方に引き上げて剥離したときの力を測定した。通電接着性は、コード状ヒータに通電をし、６ｗ／ｍ２の電力密度が供給された状態で、接着性と同様に、基材を固定し、コード状ヒータを上方に引き上げて剥離したときの力を測定した。難燃性は、基材に配設する前のコード状ヒータについてＵＬ１５８１水平燃焼試験（２００８年、第４版）により試験するとともに、面状ヒータの状態でＦＭＶＳＳ　Ｎｏ．３０２自動車内層材料の燃焼試験により試験し、両試験に合格したものを○、何れか一方でも不合格となったものを×とした。耐スパーク性は、面状ヒータに配設したコード状ヒータを切断し、１３．５Ｖを印加した状態で、切断面同士の接触・非接触を繰り返してスパークを発生させる動作を２回／秒の周期で５００回行った後、面状ヒータの外観を観察した。なお、試験結果は併せて表１に示す。 (Examples 1 to 5, Comparative Example 1)
Regarding the sheet heater obtained by the second embodiment, the materials of the heat-sealed portion of the cord heater were changed as shown in Tables 1 and 2 to obtain Examples 1 to 5 and Comparative Example 1 (blending amount) Is expressed in parts by weight). About these, the test of adhesiveness, electricity supply adhesiveness, a flame retardance, and spark resistance was done. Adhesiveness measured the force when fixing a base material and pulling up a cord-like heater upward and peeling. When the cord heater is energized and the power density of 6 w / m 2 is supplied, the adhesive property is fixed when the substrate is fixed and the cord heater is pulled up and peeled off in the same manner as the adhesive property. The force of was measured. The flame retardancy was tested by the UL1581 horizontal combustion test (2008, 4th edition) for the cord-shaped heater before being placed on the base material, and FMVSS No. The test was conducted by the combustion test of 302 automobile inner layer material. In the spark resistance, the operation of generating a spark by repeating contact / non-contact between the cut surfaces in a state where 13.5 V is applied and the cord heater disposed in the surface heater is cut is 2 times / second. After 500 cycles, the appearance of the planar heater was observed. The test results are also shown in Table 1.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000002
Figure JPOXMLDOC01-appb-T000002
　表１に示すように、本発明の実施例による面状ヒータは、接着性、通電接着性について、充分な値が得られているため、例えばカーシートヒータとして使用しても、使用中に基材からコード状ヒータが剥離するようなことはない。また、難燃性についても、すべての実施例におけるコード状ヒータについて、接炎しても着火せず、難燃性に優れるものであった。また、面状ヒータとしてみても、すぐに自己消火して燃焼が継続せず、難燃性に優れるものであった。これに対して比較例１のコード状ヒータは、２５ｍｍ／分以上の燃焼速度で燃焼し、水平燃焼試験に不合格となった。また、面状ヒータとしてみても、ＦＭＶＳＳ　Ｎｏ．３０２の燃焼試験には合格するレベルではあったものの、火炎がコード状ヒータを伝ってしばらく燃焼を継続していた。 As shown in Table 1, the planar heaters according to the examples of the present invention have sufficient values for adhesiveness and current-carrying adhesiveness. The cord heater does not peel from the material. In addition, regarding the flame retardancy, the cord heaters in all the examples were not ignited even when in contact with flames, and were excellent in flame retardancy. Further, even when viewed as a planar heater, it was self-extinguishing immediately and combustion did not continue, and it was excellent in flame retardancy. In contrast, the cord-like heater of Comparative Example 1 burned at a burning rate of 25 mm / min or more and failed the horizontal combustion test. Further, even when viewed as a planar heater, FMVSS No. Although it was a level that passed the combustion test of 302, the flame continued through the cord heater for a while.
　耐スパーク性について、本発明の実施例による面状ヒータは、５００回の接触・非接触動作の後も特段外観に変化はなく、耐スパーク性に優れていることが確認された。これに対して、比較例１の面状ヒータは、２００回頃から切断部が黒色に変色し、４００回を超える辺りで熱融着部及び絶縁被膜が溶融し、導体素線が完全に露出するようになった。また、参考として、実施例１～５及び比較例１の熱融着部を構成する材料によりチューブを作成し、このチューブの両端からＮｉ－Ｃｒ線を挿入して導電時の電流が８Ａとなるように印加し、チューブ内部で接触・非接触を繰り返す動作を１．５回／秒の周期で５００回行った。これによると、実施例１～５の材料によるチューブは、外観に異常は見られなかったが、比較例１の材料によるチューブは、黒色に変色するとともに、ピンホールの発生が確認された。 Regarding the spark resistance, it was confirmed that the planar heaters according to the examples of the present invention had no particular change in appearance even after 500 contact / non-contact operations, and were excellent in spark resistance. On the other hand, in the planar heater of Comparative Example 1, the cut portion changed to black from about 200 times, the heat-sealed portion and the insulating coating melted around 400 times, and the conductor wire was completely exposed. It was way. For reference, a tube is made of the material constituting the heat-sealed portion of Examples 1 to 5 and Comparative Example 1, and Ni—Cr wire is inserted from both ends of the tube, so that the current during conduction becomes 8A. The operation of repeating contact and non-contact inside the tube was performed 500 times at a cycle of 1.5 times / second. According to this, the tubes made of the materials of Examples 1 to 5 were not abnormal in appearance, but the tube made of the material of Comparative Example 1 was changed to black and the occurrence of pinholes was confirmed.
（実施例６～８）
　また、上記実施の形態１において、基材としての不織布につき、表３に示すように熱融着性繊維と難燃性繊維の混合割合を変化し、実施例６～８とした（混合割合は重量部数で示す）。これらについて、基材の剛軟性、接着性、難燃性の試験を行った。剛軟性は、ＪＩＳ－Ｌ１０９６（１９９９年）に記載されるカンチレバー法により測定した。接着性は、基材を固定し、コード状ヒータを上方に引き上げて剥離したときの力を測定した。難燃性は、ＦＭＶＳＳ　Ｎｏ．３０２自動車内層材料の燃焼試験により試験した。なお、試験結果は併せて表３に示す。 (Examples 6 to 8)
Further, in the first embodiment, the non-woven fabric as the base material was changed to the mixing ratio of the heat-fusible fiber and the flame-retardant fiber as shown in Table 3, and it was set as Examples 6 to 8 (the mixing ratio was (In parts by weight). About these, the test of the bending resistance of a base material, adhesiveness, and a flame retardance was done. The bending resistance was measured by a cantilever method described in JIS-L1096 (1999). Adhesiveness measured the force when fixing a base material and pulling up a cord-like heater upward and peeling. The flame retardancy is FMVSS No. Tested by combustion test of 302 automotive inner layer material. The test results are also shown in Table 3.
Figure JPOXMLDOC01-appb-T000003
Figure JPOXMLDOC01-appb-T000003
　剛軟性について、実施例６～８の何れについても、充分実使用可能な範囲の値ではあったが、熱融着性繊維の混合量が３０％の実施例８は、かなり固い感触となっていたことは否めず、風合いが重視されるカーシートヒータへの適用はやや難しいものとなった。また、接着性の面でも、熱融着性繊維の混合量が３０％の実施例８は、実施例６，７と比べてやや落ちる値となった。難燃性に関しては、実施例６～８の何れも自己消火しており、優れた難燃性を示していた。 Regarding the softness and softness, all of Examples 6 to 8 were values within the range where practical use was possible, but Example 8 in which the amount of heat-fusible fiber mixed was 30% had a fairly hard feel. It cannot be denied, and the application to the car seat heater where the texture is important is somewhat difficult. In terms of adhesiveness, Example 8 in which the amount of heat-fusible fiber mixed was 30% was slightly lower than Examples 6 and 7. Regarding flame retardancy, all of Examples 6 to 8 were self-extinguishing and showed excellent flame retardancy.
（実施例９）
　上記実施の形態３によって得られた面状ヒータについて、実施例９とした。この実施例９におけるコード状ヒータは、上記の通り、図１１に示すようなものである。この実施例９について難燃性を測定した。難燃性は、基材に配設する前のコード状ヒータについてＵＬ１５８１水平燃焼試験（２００８年、第４版）により試験するとともに、面状ヒータの状態でＦＭＶＳＳ　Ｎｏ．３０２自動車内層材料の燃焼試験により試験した。この試験によると、本願発明の実施例９は、熱融着部９が断続した部分で燃焼が止まってそれ以上燃焼することはなく、ドリップ（燃焼滴下物）の発生もなかったため、ＵＬ１５８１水平燃焼試験に合格となった。また、面状ヒータの状態で試験したＦＭＶＳＳ　Ｎｏ．３０２自動車内層材料の燃焼試験についても、燃焼が途中で止まって消火したことから合格となった。 Example 9
The planar heater obtained by the third embodiment is referred to as Example 9. As described above, the cord-like heater in the ninth embodiment is as shown in FIG. The flame retardancy of Example 9 was measured. The flame retardancy was tested by the UL1581 horizontal combustion test (2008, 4th edition) for the cord-shaped heater before being placed on the base material, and FMVSS No. Tested by combustion test of 302 automotive inner layer material. According to this test, in Example 9 of the present invention, combustion stopped at the part where the heat-sealing part 9 was interrupted, and no further combustion occurred, and no drip (combustion drop) was generated. Passed the exam. Moreover, FMVSS No. tested in the state of a planar heater. The combustion test of 302 automotive inner layer material also passed because the combustion stopped and the fire was extinguished.
　以上詳述したように本発明によれば、難燃性が必要な用途にも対応可能なコード状ヒータを得ることができる。このコード状ヒータは、例えば、アルミ箔や不織布等の基材上に蛇行形状等の所定の形状に配設されて面状ヒータとし、電気毛布、電気カーペット、カーシートヒータ、ステアリングヒータ、暖房便座、防曇鏡用ヒータ、加熱調理器具等に好適に使用可能である。また、コード状ヒータ単体としても、例えば、パイプや槽等に巻き付けて接着したり、パイプ内に配置したりするような態様が考えられる。具体的な用途としては、例えば、配管や冷凍庫のパイプドレーンなどの凍結防止用ヒータ、エアコンや除湿機などの保温用ヒータ、冷蔵庫や冷凍庫などの除霜用ヒータ、乾燥用ヒータ、床暖房用ヒータとして好適に使用することができる。また、上記面状ヒータの用途として例示した電気毛布、電気カーペット、カーシートヒータ、ステアリングヒータ、暖房便座、防曇鏡用ヒータ、加熱調理器具、床暖房等について、加熱対象物に本発明のコード状ヒータを直接貼り付けたり、巻き付けたりすることもできる。 As described in detail above, according to the present invention, it is possible to obtain a cord-like heater that can be used for applications that require flame retardancy. For example, the cord-like heater is disposed in a predetermined shape such as a meandering shape on a base material such as an aluminum foil or a non-woven fabric to form a planar heater, such as an electric blanket, an electric carpet, a car seat heater, a steering heater, a heating toilet seat It can be suitably used for heaters for anti-fogging mirrors, cooking utensils and the like. Moreover, as a cord-shaped heater unit, for example, a mode in which the cord-shaped heater is wound around and bonded to a pipe, a tank, or the like, or arranged in the pipe can be considered. Specific applications include, for example, antifreezing heaters such as pipes and freezer pipe drains, heat insulation heaters such as air conditioners and dehumidifiers, defrosting heaters such as refrigerators and freezers, drying heaters, and floor heating heaters. Can be suitably used. In addition, for the electric blanket, electric carpet, car seat heater, steering heater, heating toilet seat, anti-fog mirror heater, heating utensil, floor heating, etc., exemplified as the use of the above-described planar heater, It is also possible to directly attach or wrap the heater.
１　発熱線
３　芯材
５ａ　導体素線
５ｂ　絶縁被膜
７　絶縁体層
９　熱融着部
１０　コード状ヒータ
１１　基材
３１　面状ヒータ
４１　車両用シート
  DESCRIPTION OF SYMBOLS 1 Heating wire 3 Core material 5a Conductor strand 5b Insulating film 7 Insulator layer 9 Heat-sealing part 10 Corded heater 11 Base material 31 Planar heater 41 Vehicle seat

Claims (14)

  1. 発熱線と、該発熱線の外周に形成された熱融着部とを有するコード状ヒータであって、上記発熱線が、芯線上に導体素線を巻装し、その外周に絶縁被覆を施したものであるか、又は、絶縁被膜により被覆された導体素線を引き揃え又は撚り合わせたものであり、上記熱融着部が、難燃性高分子組成物からなるとともに、上記コード状ヒータは、ＵＬ１５８１水平燃焼試験に合格する難燃性を有することを特徴とするコード状ヒータ。 A cord-like heater having a heating wire and a heat-sealed part formed on the outer periphery of the heating wire, wherein the heating wire has a conductor wire wound around a core wire and an insulating coating is provided on the outer periphery thereof. Or a conductor wire covered with an insulating film is aligned or twisted, and the heat fusion part is made of a flame retardant polymer composition, and the cord heater Is a cord-like heater characterized by having flame retardancy that passes the UL1581 horizontal combustion test.
  2. 請求項１記載のコード状ヒータにおいて、
    上記難燃性高分子組成物が、オレフィン系樹脂と、難燃剤とからなることを特徴とするコード状ヒータ。     The cord-like heater according to claim 1,
    A cord-like heater, wherein the flame retardant polymer composition comprises an olefin resin and a flame retardant.
  3. 請求２記載のコード状ヒータにおいて、
    ＪＩＳ－Ｋ７２１０のＡ法により温度２００℃、荷重２．１６ｋｇの条件で測定された、上記難燃性高分子組成物のメルトフローレートが、５．０ｃｍ３／１０分以上であることを特徴とするコード状ヒータ。     The cord heater according to claim 2,
    Temperature 200 ° C. by method A JIS-K7210, was measured under a load of 2.16 kg, melt flow rate of the flame-retardant polymer composition, and characterized in that 5.0 cm 3/10 minutes or more Cord heater to be used.
  4. 請求項２又は請求項３記載のコード状ヒータにおいて、
    上記オレフィン系樹脂が、エチレン－不飽和エステル共重合体であることを特徴とするコード状ヒータ。     In the cord-like heater according to claim 2 or claim 3,
    A cord-like heater, wherein the olefin resin is an ethylene-unsaturated ester copolymer.
  5. 請求項１～請求項４の何れかに記載のコード状ヒータにおいて、
    上記発熱線が、絶縁被膜により被覆された導体素線を引き揃え又は撚り合わせ、芯線上に巻装してなるものであることを特徴とするコード状ヒータ。     The cord heater according to any one of claims 1 to 4,
    A cord-like heater, wherein the heating wire is formed by aligning or twisting conductor wires covered with an insulating film and winding them on a core wire.
  6. 請求項１～請求項５の何れかに記載のコード状ヒータを基材に配設したことを特徴とする面状ヒータ。 A planar heater comprising the cord heater according to any one of claims 1 to 5 disposed on a base material.
  7. 請求項６記載の面状ヒータにおいて、
    上記基材が、ＦＭＶＳＳ　Ｎｏ．３０２自動車内層材料の燃焼試験に合格する難燃性を有するものからなることを特徴とする面状ヒータ。     The planar heater according to claim 6, wherein
    The substrate is FMVSS No. 302. A planar heater comprising a flame retardant material that passes a combustion test of an automobile inner layer material.
  8. 請求項７記載の面状ヒータにおいて、
    上記基材が、不織布からなることを特徴とする面状ヒータ。     The planar heater according to claim 7,
    A planar heater, wherein the substrate is made of a nonwoven fabric.
  9. 請求項６記載の面状ヒータにおいて、
    上記不織布が、熱融着性繊維と、熱融着に寄与しない難燃性繊維とからなることを特徴とする面状ヒータ。     The planar heater according to claim 6, wherein
    A planar heater, wherein the nonwoven fabric is composed of heat-fusible fibers and flame-retardant fibers that do not contribute to heat fusion.
  10. 請求項９記載の面状ヒータにおいて、
    上記不織布は、上記難燃性繊維が７０％以上混合されているとともに、上記熱融着性繊維が５％以上混合されていることを特徴とするものである。     The planar heater according to claim 9, wherein
    The non-woven fabric is characterized in that 70% or more of the flame-retardant fiber is mixed and 5% or more of the heat-fusible fiber is mixed.
  11. 請求項８～請求項１０の何れかに記載の面状ヒータにおいて、
    上記コード状ヒータの熱融着部が、上記不織布を構成する繊維を取り囲むことによって、上記コード状ヒータと上記基材とが接着していることを特徴とする面状ヒータ。     The planar heater according to any one of claims 8 to 10,
    The sheet heater is characterized in that the cord-shaped heater and the base material are bonded together by the heat-sealed portion of the cord-shaped heater surrounding the fibers constituting the nonwoven fabric.
  12. 請求項９又は請求項１０記載の面状ヒータにおいて、
    上記熱融着性繊維が、芯－鞘構造を有するとともに、該芯部分を取り囲んだ状態で、該鞘部分と上記コード状ヒータの熱融着部とが、互いに融着し一体化していることを特徴とする面状ヒータ。     In the planar heater according to claim 9 or 10,
    The heat-fusible fiber has a core-sheath structure, and in a state of surrounding the core portion, the sheath portion and the heat-sealed portion of the cord heater are fused and integrated with each other. A planar heater characterized by
  13. 発熱線と、該発熱線の外周に形成された熱融着部とを有するコード状ヒータであって、上記発熱線が、芯線上に導体素線を巻装し、その外周に絶縁被覆を施したものであるか、又は、絶縁被膜により被覆された導体素線を引き揃え又は撚り合わせたものであり、上記コード状ヒータは、ＵＬ１５８１水平燃焼試験に合格する難燃性を有することを特徴とするコード状ヒータ。 A cord-like heater having a heating wire and a heat-sealed part formed on the outer periphery of the heating wire, wherein the heating wire has a conductor wire wound around a core wire and an insulating coating is provided on the outer periphery thereof. Or a conductor wire covered with an insulating film is aligned or twisted, and the cord heater has a flame retardancy that passes the UL1581 horizontal combustion test. Cord heater to be used.
  14. 請求項１３記載のコード状ヒータを基材に配設したことを特徴をとする面状ヒータ。
     
          A sheet heater comprising the cord heater according to claim 13 disposed on a substrate.

PCT/JP2010/061007 2009-07-03 2010-06-29 Cord-like heater and planar heater WO2011001953A1 (en)

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CN106196244A (en) * 2016-07-01 2016-12-07 宁波先锋电器制造有限公司 A kind of high acting electric heating device
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WO2021186972A1 (en) 2020-03-19 2021-09-23 株式会社クラベ Cord-shaped heater and planar heater
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WO2014103981A1 (en) 2012-12-25 2014-07-03 株式会社クラベ Cord-shaped heater and sheet-shaped heater
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WO2022054701A1 (en) 2020-09-10 2022-03-17 株式会社クラベ Cord-shaped heater and planar heater

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