KR20130022583A - Manufacturing method of planar heating element and thermal mat using planar heating element manufactured thereby - Google Patents

Abstract

The present invention relates to a method for manufacturing a planar heating element, and a thermal mat using the planar heating element manufactured by the method. More specifically, the thermosensitive line for sensing the heating temperature of the planar heating element is integrally integrated in the weaving process of the planar heating element. The present invention relates to a method for manufacturing a planar heating element that can improve productivity, reduce production costs, and improve durability, and a thermal mat using the planar heating element produced by the method.
The manufacturing method of the planar heating element of the present invention is arranged in a zigzag form so as to sense the heating temperature of the planar heating element, and the planar heating element formed of a linear member having a characteristic of changing a resistance value corresponding to the heating temperature. A method of manufacturing a heating element, comprising: a planar body forming yarn supplying step of supplying a heating yarn and a fiber yarn selected from a carbon yarn or a carbon-containing yarn containing carbon as a weft yarn and a warp yarn to a loom; A thermosensitive wire supplying step of supplying the thermosensitive wire to the loom as a weft and / or warp yarn; A weaving step of weaving the exothermic yarn, the fiber yarn, and the thermal radiation line supplied through the planar body forming yarn supplying step and the temperature sensitive wire supplying step into a planar body by the loom; Cutting step of cutting the planar body woven by the weaving step to the desired size; And a thermosensitive wire connecting step of electrically connecting and connecting the thermosensitive wires included in the planar body cut by the cutting step to form a closed circuit having a zigzag shape.
Accordingly, since the thermosensitive wire sensing the heating temperature of the planar heating element is integrally woven and installed in the weaving process of the planar heating element, it can be easily and quickly arranged and fixed without sewing with a separate fixing lower thread or using an adhesive. It works. As a result, productivity can be improved and production costs can be reduced, and since the thermal wire is fixed to the heating yarn and the fiber yarn without being exposed to the surface of the planar heating element, it can maintain a firm fixed state and be exposed to the surface of the planar body. Since it is also not possible to prevent damage due to the friction action has the effect of improving durability.

Description

FIELD OF THE INVENTION A method of manufacturing a planar heating element, and a thermal mat using a planar heating element manufactured by the method. TECHNICAL FIELD

The present invention relates to a method for manufacturing a planar heating element, and a thermal mat using the planar heating element manufactured by the method. More specifically, the thermosensitive line for sensing the heating temperature of the planar heating element is integrally integrated in the weaving process of the planar heating element. The present invention relates to a method for manufacturing a planar heating element that can improve productivity, reduce production costs, and improve durability, and a thermal mat using the planar heating element produced by the method.

In general, the heating wire used as a heat source of the heater is used as a metal wire such as copper wire that generates heat by itself due to its high resistance value, but when folded during use, it is easily damaged or broken, and the resistance value becomes unstable due to oxidation when used for a long time, and the size of the magnetic field is high. There was a problem that a large amount of electromagnetic waves are harmful to the human body is increased.

Accordingly, in recent years, carbon wires or planar heating elements in which carbon is coated on the surface of a fiber or a film by precipitation or printing, and heat-resistant fibers are woven by weft and warp are widely applied. Such a planar heating element is provided with copper wires, which are power lines, on both sides of the woven planar body, and when current is supplied through the power supply lines on both sides, heat generation is performed by resistance generated from carbon sand or carbon powder.

In the above-mentioned heating mat using the planar heating element, the planar heating element is laminated on the upper surface of the bottom pad, and the pad body is formed in the form of a cover pad on the upper surface of the planar heating element, and then the upper surface of the planar heating element is used to detect the heating temperature. It is manufactured in the form of installing a temperature sensing device manufactured by a bimetallic method. In addition, a thermal mat such as an electric blanket or an electric blanket is provided with a cushion pad between the bottom surface of the planar heating element or the planar heating element and the cover pad to provide a cushioning function.

However, since the thermal mat has a relatively large surface area, a large number of temperature sensing devices must be installed for even and accurate temperature control. As a result, the manufacturing labor of the thermal mat is increased and the manufacturing cost is increased, and since the temperature sensing device is relatively thick and made of metal, it causes pain in contact with the human body or deteriorates the merchandise due to poor contact feeling. There was a problem.

In addition, even if a plurality of temperature sensing devices are installed on the thermal mat, it is impossible to control the surface temperature evenly and thus cannot be densely installed over the entire area. For example, when the user's body or object is placed on a specific part where the temperature sensing device is not installed and receives a concentrated load, it cannot be detected even if the corresponding part is heated rapidly. In addition to being burned, there was a problem that a fire occurs in severe cases.

In order to solve the above problems, the present applicant has developed a thermal mat using a planar heating element as disclosed in Korean Patent Application No. 10-2009-0047545.

The thermal mat using the planar heating element is electrically connected to the surface heating element 110 that generates heat by the power source, the temperature sensing line 120, the power supply unit 130, and the thermal sensing line 120 that sense the heating temperature of the planar heating element 110. A control unit for controlling the driving of the power supply unit 130 by detecting the heating temperature of the planar heating element 110 based on the resistance measurement unit 140 connected to measure the resistance value and the resistance value applied from the resistance measurement unit 140. 150.

In addition, the temperature sensing line 120 is arranged to have a zigzag shape on one surface of the planar heating element 110, and has a characteristic that the resistance value changes in response to a heating temperature. In this case, since the temperature sensing function can be performed over the entire surface area of the planar heating element 110, the heating temperature can be detected more accurately and stably even without installing a plurality of expensive temperature sensing devices.

However, in order to install the above-described thermal wire 120 to the planar heating element, it can be fixed by attaching by using an adhesive harmful to the human body or by sewing by embroidery, but when attached with an adhesive, it will adversely affect the human body and heating the planar heating element Since it deteriorates at the time, there is a disadvantage in that sufficient durability cannot be secured.

In addition, when the embroidery method is applied, the thermal wire must be sewn with a bobbin thread while being arranged in a zigzag form on the surface heating element, so the installation work is very difficult, and the installation time takes a lot of work time, resulting in low productivity and high production cost. It has an upside disadvantage.

In addition, since the heating wire constituting the planar heating element is damaged by the needle in the process of sewing the thermal radiation line to the planar heating element, there is a disadvantage in that the heating effect is adversely affected and durability is lowered.

In addition, since the thermosensitive wire is installed in the form of being exposed to the surface of the surface heating element, if the lower thread is damaged by the friction action, it may not be able to maintain a firm fixing state, and the quality of the thermosensitive wire may be reduced.

The present invention has been proposed in view of the above, by constructing a thermosensitive wire for sensing the heating temperature of the planar heating element integrally in the weaving process of the planar heating element, the productivity is improved, the production cost is reduced as well as the durability is improved It is an object of the present invention to provide a method for producing a heating element, and a thermal mat using the planar heating element manufactured by the method.

In order to achieve the above object, the method for manufacturing a planar heating element according to the present invention is arranged to have a zigzag shape to detect the heating temperature of the planar heating element, the linear member having a characteristic that the resistance value changes in response to the heating temperature A method of manufacturing a planar heating element having a thermal radiation line, the method comprising: a planar body forming yarn supplying step of supplying a heating yarn and a fiber yarn selected from a carbon yarn or a carbon-containing yarn containing carbon as a weft yarn and a warp yarn to a loom; A thermosensitive wire supplying step of supplying the thermosensitive wire to the loom as a weft and / or warp yarn; A weaving step of weaving the exothermic yarn, the fiber yarn, and the thermal radiation line supplied through the planar body forming yarn supplying step and the temperature sensitive wire supplying step into a planar body by the loom; Cutting step of cutting the planar body woven by the weaving step to the desired size; And a thermosensitive wire connecting step of electrically connecting and connecting the thermosensitive wires included in the planar body cut by the cutting step to form a closed circuit having a zigzag shape.

The method may include a terminal part forming step of supplying and weaving metal yarns having electrical conductivity to both sides of the planar heating element so as to be electrically connected to the heat generating yarn to form a strip-shaped terminal part.

The thermal radiation may be composed of a carbon yarn or a carbon-containing yarn containing a carbon component.

In order to achieve the above object, the thermal mat using the planar heating element according to the present invention is a planar heating element that generates heat by the power applied; A temperature sensing line disposed to have a zigzag shape so as to sense a heating temperature of the planar heating element and formed of a linear member having a characteristic of changing a resistance value corresponding to the heating temperature; A power supply unit supplying power to the planar heating element and the temperature sensitive wire; A resistance measuring unit electrically connected to the temperature sensing wire and measuring a resistance value; And a control unit for controlling the driving of the power supply unit by detecting a heating temperature of the planar heating element based on the resistance value applied from the resistance measuring unit, wherein the planar heating element contains carbon yarn or carbon component as weft and warp yarns. And a strip-shaped terminal woven and formed by a heat-generating yarn and a fiber yarn selected from carbon-containing yarns, and a strip-shaped terminal portion woven and formed by a metal yarn having electrical conductivity on both sides of the planar body. In the weaving process of the planar body is supplied with a weft or inclined, weaved so as to be intertwined with the heating yarn and the fiber yarn, characterized in that it is electrically connected and connected to form a closed circuit of the zigzag form.

A memory unit storing heating temperature data of the planar heating element corresponding to the resistance value detected by the resistance measuring unit; And an input unit for inputting an input signal such as heating temperature, heating time, power on / off, etc. of the planar heating element, wherein the controller is configured to generate a heating temperature corresponding to a resistance value applied from the resistance measuring unit. It may be configured to control the driving of the power supply unit by reading from the unit and comparing with the heating temperature of the planar heating element preset by the input unit.

The manufacturing method of the planar heating element of the present invention, and the thermal mat using the planar heating element manufactured by the method is fixed separately because we are integrally woven and installed in the weaving process of the planar heating element to detect the heating temperature of the planar heating element There is an effect that can be quickly and easily placed and fixed without sewing with a thread for the dragon or using an adhesive. As a result, productivity can be improved and production costs can be reduced, and since the thermal wire is fixed to the heating yarn and the fiber yarn without being exposed to the surface of the planar heating element, it can maintain a firm fixed state and be exposed to the surface of the planar body. Since it is also not possible to prevent damage due to the friction action has the effect of improving durability.

1 is a perspective view showing a method of manufacturing a planar heating element according to an embodiment of the present invention;
2A to 2E are views for explaining a method of manufacturing a planar heating element according to an embodiment of the present invention;
Figure 3 is a block diagram showing a thermal mat using a planar heating element according to an embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

1 is a perspective view showing a method of manufacturing a planar heating element according to an embodiment of the present invention, Figures 2a to 2e is a view for explaining a method of manufacturing a planar heating element according to an embodiment of the present invention, Figure 2a is a woven FIG. 2B is a schematic enlarged cross-sectional view of part A of FIG. 2A, FIG. 2C is a view showing a cutting step, and FIG. 2D is a state in which a thermosensitive wire connection step is performed. Figure 2e is a view showing a state in which the manufacturing process of the surface heating element is completed.

1 and 2e, the method of manufacturing a planar heating element according to an embodiment of the present invention is a planar body forming yarn supply step (S1), a temperature sensitive wire supply step (S2), weaving step (S3), cutting step (S4) And a thermostat connection step (S5), comprising a planar body that performs a heating operation upon application of power, and is arranged to have a zigzag shape on one side thereof so as to sense a heating temperature on the planar body and the heating temperature. Correspondingly, the thermosensitive wire 20 formed of a linear member having a characteristic of changing resistance value is integrally woven.

The planar body forming yarn supplying step (S1) is a step of supplying the heating yarn and the fiber yarn heated by the applied power to the weaving yarn 11 and the warp yarn 12 to the loom. The fiber yarn is selected and supplied, and the fiber yarn is selected from natural fiber yarn or synthetic fiber yarn, but the fiber yarn having heat resistance is applied.

The temperature-sensing wire supplying step (S2) is a step of supplying the heat-sensitive wire 20 to the loom as weft and / or warp yarns, which will be described later by being supplied simultaneously with the heating and fiber yarns supplied by the planar forming yarn supplying step (S1). In the weaving step, it can be woven together with pyrogenic yarn and fiber yarn.

In addition, the thermal wire 20 may be selected and applied as long as the wire member 20 has flexibility, which is a characteristic of bending as a linear member, and has a characteristic of changing a resistance value according to the heating temperature of the planar heating element 1. Examples include carbon yarns or carbon-containing yarns containing carbon components in fiber yarns.

Weaving step (S3) is performed by a weaving machine, such as a weaving machine, as shown in Figures 2a and 2b heat generating yarn supplied through the planar body forming yarn supply step (S1) and the temperature sensitive wire supply step (S2), Weaving the fiber yarns and the thermal radiation line 20 to the planar body (10). For example, while weaving the heating yarn and the fiber yarn into a weft yarn and a warp yarn to form a planar body, when supplying the thermal radiation line 20 so as to be spaced apart at a predetermined interval as a weft yarn (weft weft arrangement direction), the warp yarn is woven in a warp 12 Temperature-sensitive wires are arranged at regular intervals along the longitudinal direction. At this time, the width of the planar body 10 is woven so as to have a width determined according to the number of people, such as one person, two people use, or the use of the bed, floor pad.

Cutting step (S4) is a step of cutting the planar body 10 is woven and discharged by the weaving step (S3) to a desired size, using a cutting cutter or scissors to cut according to the purpose or use. For example, when the planar heating element according to the present embodiment is applied to a bed heating mat, the planar heating element is cut to have a length corresponding to a normal bed length.

The thermocouple connection step (S5) is a step of electrically connecting the ends 21 of the thermosensitive wires 20 arranged adjacent to each other at equal intervals as shown in FIGS. 2C and 2D, and electrically connecting them. Afterwards, the thermosensitive wires 20 located at both edges of the planar body 10 are exposed to the outside and are electrically connected to each other so as to form a closed circuit having a zigzag shape. That is, as shown in FIG. 2C, two strands of temperature-sensitive wires (temperature lines 1 and 2) exposed adjacent to one end of the planar body are connected to each other, and are exposed adjacent to the other end of the second temperature-sensitive wire. Connect the three thermal lines to each other, and again by connecting the three and four thermal lines at one end.

On the other hand, the method of manufacturing a planar heating element according to the present embodiment has a terminal portion forming step (S6) to supply power to the heat generating yarn. The terminal part forming step (S6) is a weaving method to supply and weave metal yarns having electrical conductivity, such as copper wire, stainless steel wires, on both sides of the planar heating element to form the terminal part 30, but using a plurality of strands of metal yarns Weaving in form

And, the terminal portion forming step (S6) may be carried out in such a way that weaving together by supplying the weft or inclined metal yarn in the weaving step (S3), or may be carried out after the implementation of the thermocouple connection step (S5), this embodiment After the cutting step (S4) is carried out before the implementation of the thermocouple connection step (S5).

As described above, in the method of manufacturing the planar heating element according to the exemplary embodiment of the present invention, since the thermosensitive wires are arranged and woven together in the process of weaving the planar body, they can be easily arranged and fixed without sewing or using an adhesive for a separate fixing lower thread. Can be. Accordingly, since the arrangement and fixing work of the temperature sensing line 20 can be performed quickly, it is possible to expect an improvement in productivity and a reduction in production cost according to a reduction in working time.

In addition, since the problem of damaging the heat generating yarn by the needle in the process of sewing the thermal radiation wire to the planar heating element as in the related art is solved, durability can be improved without causing adverse effects on the heating action.

In addition, since the thermal radiation line 20 is not exposed to the surface of the planar heating element but is integrally fixed to the heating yarn and the fiber yarn, it is possible to maintain a firm fixed state and is not exposed to the surface of the planar body, and thus, due to frictional action. Damage can be prevented.

Figure 3 is a block diagram showing a thermal mat using a planar heating element according to an embodiment of the present invention.

2E and 3, the thermal mat 100 using the planar heating element according to an embodiment of the present invention has a planar shape in which the thermal radiation line 20 is integrally woven to the heating yarn and the fiber yarn through the above-described manufacturing method. The planar heating element (10) is electrically connected to the heating element (1), the power supply unit (110), the temperature sensing line (20), and the resistance value is applied from the resistance measuring unit (120). The control unit 130 for controlling the driving of the power supply unit 110 by detecting the heating temperature of 1) is characterized in that the thermosensitive wire 20 is integrally arranged and fixed during the weaving process of the planar heating element.

The planar heating element 1 includes a planar body 10 which is woven and formed by a heat generating yarn and a fiber yarn selected from a carbon yarn or a carbon-containing yarn containing a carbon component as the weft yarn 11 and the warp yarn 12. It consists of the strip | belt-shaped terminal part 30 which is woven and formed by the metal yarn which has electroconductivity on both sides of the upper body 10. As shown in FIG.

The thermal wire 20 is arranged in a weaving manner so as to be intertwined with the heating yarn and the fibrous yarn supplied in the weft or warp yarn during the weaving of the planar body 10, and the one end and the other end are electrically connected to each other to form a closed circuit in a zigzag form. Configure by connecting.

In addition, the thermal wire 20 is a linear member having a characteristic of changing a resistance value in response to a heating temperature, and various wires may be selected and applied as long as the resistance value is changed. Or carbon-containing yarns containing carbon components in the fiber yarns.

Thus, when the temperature sensing line 20 is composed of a linear member, it is possible to perform the temperature sensing function by evenly distributed over the entire surface area of the planar heating element 1, more accurate even if a lot of expensive temperature sensing device is not installed It can sense heating temperature stably.

On the other hand, the thermal mat 100 using the planar heating element according to the present invention is a memory unit 140, the planar shape that stores the heating temperature data of the planar heating element 1 corresponding to the resistance value detected by the resistance measuring unit 120 An input unit 150 for inputting input signals such as heating temperature, heating time, power on / off of the heating element 1, and a display unit for displaying heating temperature, operating state, heating time, etc. of the planar heating element 1 ( 160 is further provided.

The controller 130 is configured as a microcomputer having a program for controlling the driving of the power supply unit 110 by detecting the heating temperature of the planar heating element 1 based on the resistance value applied from the resistance measuring unit 140. For example, the controller 130 reads the heating temperature corresponding to the resistance value applied from the resistance measuring unit 120 from the memory unit 140 and compares the heating temperature of the planar heating element 1 preset by the input unit 150. By controlling the driving of the power supply unit 110. That is, when the heating temperature corresponding to the resistance value measured by the resistance measuring unit 120 is lower than the preset heating temperature, the power supply 110 is controlled to continuously supply power to the surface heating element 1, the resistance measuring unit When the heating temperature corresponding to the resistance value measured by the 120 is higher than the preset heating temperature, the power supply to the planar heating element 1 is cut off or the voltage of the supplied power is lowered to maintain the set heating temperature constant.

Hereinafter, the operation of the thermal mat using the planar heating element according to an embodiment of the present invention will be described briefly.

When the input unit 150 of the thermal mat 100 configured as described above is operated to supply power to the planar heating element 1 via the terminal unit 30 and set the heating temperature, the planar heating element 1 is The constituent carbon yarns perform the heating action while performing the exothermic action by the resistance value.

Then, when the planar heating element 1 is heated, heat is transmitted to the temperature sensing line 20 so that the resistance value changes in response to the heating temperature. The change in the resistance value is represented by a change in the current value in the resistance measurement unit 120 electrically connected to the temperature sensing line 20, and the resistance measurement unit 120 detects the resistance value based on the change and applies it to the controller 130. Done.

The control unit 130 reads the heating temperature corresponding to the resistance value applied from the resistance measuring unit 120 from the memory unit 140 and compares the heating temperature of the planar heating element 1 preset by the input unit 150 to the power supply unit. The heating operation is performed while controlling the driving of the 110.

What has been described above is just one embodiment for carrying out the method of manufacturing a planar heating element according to the present invention, and a thermal mat using the planar heating element manufactured by the method, and the present invention is not limited to the above-described embodiment. As claimed in the following claims, any person having ordinary knowledge in the field of the present invention without departing from the gist of the present invention has the technical idea of the present invention to the extent that various changes can be made. something to do.

S1: Plane forming yarn supplying step S2: Thermostat supplying step
S3: weaving step S4: cutting step
S5: Connecting the temperature wire S6: Forming terminal
1: Planar heating element 10: Planar body
11: Weft 12: Slope
20: Temperature line 30: Terminal part
100: thermal mat 110: power supply
120: constant measurement unit 130: control unit
140: memory unit 150: input unit
160: display unit

Claims (5)

In the method of manufacturing a planar heating element having a temperature sensing line formed of a linear member having a characteristic of changing the resistance value corresponding to the heating temperature, arranged in a zigzag form so as to sense the heating temperature of the planar heating element,
A planar body forming yarn supplying step of supplying a heating yarn and a fiber yarn selected from carbon yarns or carbon-containing yarns containing carbon components as weft yarns and warp yarns to the loom;
A thermosensitive wire supplying step of supplying the thermosensitive wire to the loom as a weft and / or warp yarn;
A weaving step of weaving the exothermic yarn, the fiber yarn, and the thermal radiation line supplied through the planar body forming yarn supplying step and the temperature sensitive wire supplying step into a planar body by the loom; And
Cutting step of cutting the planar body woven by the weaving step to the desired size;
And a thermosensitive wire connecting step of electrically connecting and connecting the thermosensitive wires included in the planar body cut by the cutting step to form a closed circuit in a zigzag form.
The method of claim 1,
And a terminal portion forming step of supplying and weaving metal yarns having electrical conductivity to both sides of the planar heating element so as to be electrically connected to the heat generating yarns to form a strip-shaped terminal portion.
The method of claim 2,
The temperature sensitive line is a method for producing a planar heating element, characterized in that the carbon yarn or a carbon-containing yarn containing a carbon component.
A planar heating element that generates heat by an applied power source;
A temperature sensing line disposed to have a zigzag shape so as to sense a heating temperature of the planar heating element and formed of a linear member having a characteristic of changing a resistance value corresponding to the heating temperature;
A power supply unit supplying power to the planar heating element and the temperature sensitive wire;
A resistance measuring unit electrically connected to the temperature sensing wire and measuring a resistance value; And
A control unit for controlling the driving of the power supply unit by detecting the heating temperature of the planar heating element based on the resistance value applied from the resistance measurement unit,
The planar heating element is formed by weaving yarns and fiber yarns selected from carbon yarns or carbon-containing yarns containing carbon components as weft yarns and warp yarns, and metal yarns having electrical conductivity on both sides of the planar yarns. Weaving and strip-shaped terminal portion formed,
The thermosensitive wire is supplied to the weft or inclined in the weaving process of the planar body is woven to be intertwined with the heat generating yarn and fiber yarn, and then electrically connected and connected to form a closed circuit of zigzag form. Warm mat.
5. The method of claim 4,
A memory unit for storing heating temperature data of the planar heating element corresponding to the resistance value detected by the resistance measuring unit; And
And an input unit for inputting an input signal such as heating temperature, heating time, power on / off of the planar heating element,
The control unit is configured to control the driving of the power supply unit by reading a heating temperature corresponding to the resistance value applied from the resistance measuring unit from the memory unit and comparing the heating temperature of the planar heating element set by the input unit. Thermal mat using surface heating element.

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