Surface heating appliances

Abstract

The present invention provides a surface-type heating device that can reduce the impact of heat emitted by the heater wire on the case. [Solution] The planar heating device 1 includes a main body 2 having a planar heater unit 24 having heater wires 242, with a plurality of planar members stacked above and below it, and a controller 3 having a case 30 installed on the main body 2, with a control board 31 for controlling the power supply to the heater unit 24 located inside the case 30. The case 30 has a heater wire inlet (inlet groove 521) for introducing the heater wires 242. A heat sink 7 that is thermally connected to the heater wires 242 is placed inside the case 30.

Description

Technical Field

[0001] The present disclosure relates to a planar heating device using an electric heater as a heat source.

Background Art

[0002] Patent Document 1 discloses a conventional planar heating device. This planar heating device includes a heating element, a main body incorporating the heating element, a controller for controlling the temperature of the heating element, a case forming the outer shell of the controller and attached to the main body, and a surface material covering a part of the upper surface of the case. Further, the planar heating device includes a power control element built in the case for supplying power to and controlling the heating element, a control board on which the power control element is mounted and controlled, a heat dissipation plate having a part connected to the power control element and another part attached between the case and the surface material outside the case through an opening of the case, and a temperature sensor for detecting the temperature of the heat dissipation plate.

[0003] In this planar heating device, a part of the heat dissipation plate connected to the power control element is attached between the case and the surface material through the opening of the case so that the heat generated from the power control element does not accumulate inside the case, and the heat is released to the outside of the case. However, simply providing the heat dissipation plate may cause the heat dissipation plate to become very hot depending on the energization time and heat generation amount conditions of the power control element, etc., and the surface temperature of the surface material on the case may rise above the appropriate temperature.

[0004] Therefore, by providing a temperature sensor for detecting the temperature of the heat dissipation plate, detecting the temperature of the heat dissipation plate, and stopping the energization of the power control element when the temperature reaches or exceeds a predetermined threshold temperature, it is possible to prevent the surface temperature of the surface material on the case from rising above a predetermined temperature.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

[0006] In the surface heating device disclosed in Patent Document 1, the heat generated by the power control element is dissipated to prevent the case from rising above a predetermined temperature, but no consideration is given to dissipating the heat generated by the heating element (specifically, the heater wire).

[0007] This disclosure aims to solve the above-mentioned conventional problems and to provide a surface-type heating device that can reduce the impact of heat generated by the heater wire on the case. [Means for solving the problem]

[0008] To solve the aforementioned conventional problems, the planar heating device of this disclosure includes a main body having a planar heater unit having heater wires, with a plurality of planar members stacked above and below it, and a controller having a case installed on the main body, the controller having a control board for controlling the energization of the heater unit disposed inside the case. The case has a heater wire inlet for introducing the heater wires. A heat sink is disposed inside the case that is thermally connected to the heater wires. [Effects of the Invention]

[0009] The planar heating device of this disclosure can reduce the impact of heat emitted by the heater wire on the case. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1 is a perspective view showing the appearance of a planar warming device in Embodiment 1 of this disclosure. [Figure 2] Figure 2 is a plan view of the controller for the same surface heating device. [Figure 3] Figure 3 is an exploded cross-sectional view of a part of the main body of the same surface-type warming device. [Figure 4] Figure 4 is a cross-sectional view of a part of the main body shown above. [Figure 5] Figure 5 is an exploded perspective view of the controller shown above. [Figure 6] Figure 6 is a plan view of the controller shown above with the upper case removed. [Figure 7] Figure 7 is a bottom view of the controller shown above. [Figure 8] Figure 8 is a bottom view of the controller with the lower case removed. [Figure 9] Figure 9 is a bottom view of the controller shown above with the lower case and heat sink removed. [Figure 10] Figure 10 is a cross-sectional view of the main part of the controller shown above. [Figure 11] Figure 11 is a plan view of the remote controller for the same surface heating device. [Modes for carrying out the invention]

[0011] (overview) The planar heating device 1 of this disclosure includes a main body 2 having a planar heater unit 24 having heater wires 242, with a plurality of planar members stacked above and below it, and a controller 3 having a case 30 installed on the main body 2, with a control board 31 for controlling the power supply to the heater unit 24 disposed inside the case 30. The case 30 has a heater wire inlet (inlet groove 521) for introducing the heater wires 242. A heat sink 7 that is thermally connected to the heater wires 242 is disposed inside the case 30.

[0012] The embodiments of this disclosure will be described below with reference to the drawings. However, this embodiment does not limit the disclosure.

[0013] (Embodiment 1) <1> Configuration of a surface-type warming device Figure 1 is a perspective view showing the external appearance of the surface-type warming device 1 in Embodiment 1 of this disclosure. Figure 2 is a plan view of the controller 3 of the same surface-type warming device 1.

[0014] As shown in Fig. 1, the planar heater 1 includes a substantially rectangular main body 2 composed of a plurality of sheet-like members, and a controller 3 integrally installed at a corner of the main body 2. Further, as an optional configuration, the planar heater 1 in Embodiment 1 has a remote controller 4 for wirelessly operating the controller 3.

[0015] As shown in Fig. 2, on the side surface of the controller 3, there is a power cord 32 for supplying power to the planar heater 1. On the front surface, there are a main power switch 33 for operating the power "on" and "off", and a temperature adjustment switch 34 for adjusting the temperature (adjusting the heat generation amount). On the upper surface of the controller 3, there are a receiving unit 35 for receiving the operation signal of the remote controller 4 and an indicator light 36 installed.

[0016] The planar heater 1 is installed on the floor surface of a house and heats the main body 2 by supplying power through a power cord 32 connected to the controller 3 by operating the main power switch 33 and the remote controller 4.

[0017] <2>Configuration of the main body Fig. 3 is an exploded cross-sectional view of a part of the main body of the planar heater 1 as described above. Fig. 4 is a cross-sectional view of a part of the main body as described above.

[0018] As shown in Fig. 3, the main body 2 of the planar heater is mainly composed of a surface material 21, a heater unit 24, a heat insulation sheet 26, and a back surface material 22. A first adhesive sheet 23 is interposed between the surface material 21 and the heater unit 24, a second adhesive sheet 25 is interposed between the heater unit 24 and the heat insulation sheet 26, and a third adhesive sheet 27 is interposed between the heat insulation sheet 26 and the back surface material 22, and it is composed of a laminate.

[0019] By adhesively processing the above laminate and compressing and welding the peripheral part, the main body 2 having a cross-sectional shape as shown in Fig. 4 is formed.

[0020] As shown in Figure 3, the surface material 21 is the uppermost component of the main body 2 of the surface-type heating device, and is the surface that the user directly contacts during use. The surface material 21 possesses not only mechanical strength but also necessary properties such as aesthetic appeal, stain resistance, and tactile feel. In this embodiment, the surface material 21 is a laminated sheet with a thickness of approximately 2 mm, in which a polyester nonwoven fabric 212 is bonded to the back surface of a colored and patterned surface sheet 211, mainly composed of polyvinyl chloride resin (hereinafter referred to as PVC), with adhesive 213.

[0021] The heater unit 24 is a heat source for the surface heating device, and consists of an aluminum sheet 241, which is mainly composed of aluminum, with a heater wire 242, which is a conductive wire, arranged in a meandering shape on one side.

[0022] The heater unit 24 has the starting end of the heater wire 242 positioned at one corner of the aluminum sheet 241, arranged in a meandering shape to cover the entire area of ​​the aluminum sheet 241, and the end of the heater wire 242 positioned near the starting end. By applying heat to the heater wire 242 while it is arranged in a meandering shape on the aluminum sheet 241, the adhesive layer of the heater wire 242 melts and adheres to the aluminum sheet 241.

[0023] The heat insulating sheet 26 is provided to suppress the unnecessary transfer of heat generated by the heater unit 24 to the floor surface and to provide cushioning for the surface heating device. In this embodiment, the heat insulating sheet 26 is made by mixing high-melting-point resin fibers, mainly composed of polyester resin, in a ratio of approximately 85% and low-melting-point resin fibers in a ratio of approximately 15%, and forming it into a felt-like material with a thickness of approximately 15 mm.

[0024] The heat insulating sheet 26 with the above configuration has high elasticity mainly due to high melting point resin fibers, and also possesses heat deformation properties that allow it to maintain its deformed state by being plastically deformed when heated near its melting temperature due to low melting point resin fibers.

[0025] By utilizing the above-mentioned characteristics of heat deformation, the heater wires 242 of the heater unit 24 can be embedded in the heat insulating sheet 26, and the aluminum sheet 241 of the heater unit 24 can be formed into a flat state.

[0026] The backing material 22 is the component of the main body 2 of the surface heating device that comes into direct contact with the floor surface, and possesses not only mechanical strength but also properties such as cushioning and slip resistance. In this embodiment, the backing material 22 is formed as a three-layer structure in which both sides of a polyethylene resin cross sheet are coated with polyethylene resin.

[0027] The first adhesive sheet 23, the second adhesive sheet 25, and the third adhesive sheet 27 are all made by molding polyethylene resin into a sheet shape. At room temperature, they are flexible sheets, and at approximately 85°C they melt and exhibit their function as adhesives.

[0028] After bonding, the first adhesive sheet 23, the second adhesive sheet 25, and the third adhesive sheet 27 are almost completely absorbed into the nonwoven fabric 212 and the heat insulating sheet 26, so there is hardly any thickness left.

[0029] Each of the above-mentioned surface material 21, first adhesive sheet 23, second adhesive sheet 25, heat insulating sheet 26, third adhesive sheet 27, and back material 22 constitutes a planar member that is laminated above and below the planar heater unit 24.

[0030] <3> Controller configuration Figure 5 is an exploded perspective view of the controller 3 shown above. Figure 6 is a plan view of the controller 3 with the upper case 5 removed. Figure 7 is a bottom view of the controller 3 shown above. Figure 8 is a bottom view of the controller 3 with the lower case 6 removed. Figure 9 is a bottom view of the controller 3 with the lower case 6 and heat sink 7 removed. Figure 10 is a cross-sectional view of the main part of the controller 3 shown above.

[0031] As shown in Figure 2, the controller 3 has a roughly rectangular shape. A power cord 32, which is a conductive wire that supplies power to the surface heating device 1, is installed on the side of the controller 3. A main power switch 33 for turning the power on and off is installed on the front of the controller 3. A receiving unit 35 for receiving operation signals from the remote controller 4 and an indicator light 36 are installed on the top surface of the controller 3.

[0032] The indicator lights 36 consist of two lights: a main power indicator light 361 that displays the "on" or "off" status of the main power switch 33 installed on the controller 3, and an energy saving light 362 that displays the energy saving setting. Note that other indicator lights may also be installed as indicator lights 36.

[0033] As shown in Figure 5, the controller 3 comprises, as its main components, a case 30 consisting of an upper case 5 and a lower case 6 molded from a resin material, a control board 31 with the function of controlling the power supply to the surface heating device 1, and a heat sink 7. The upper case 5 is exposed on the upper side of the surface heating device 1. The lower case 6 is exposed on the lower side of the surface heating device 1.

[0034] The case 30 is made of resin and consists of a roughly box-shaped upper case 5 and a roughly flat lower case 6 joined together with screws, forming a hollow space inside.

[0035] The upper case 5 is box-shaped with an open bottom, and a nearly vertical outer wall 51 is integrally molded along its outer circumference. The outer wall 51 does not necessarily have to extend around the entire circumference of the upper case 5; it is sufficient if it extends around at least half of the circumference.

[0036] As shown in Figures 5 and 9, a portion of the outer peripheral wall 51 in the circumferential direction is formed by a double wall section consisting of an outer wall 52 and an inner wall 53. The portion where the outer wall 52 and inner wall 53 are provided is the portion where the heater wire 242 is introduced into the case 30 of the controller 3 from outside the case 30.

[0037] To further explain, in Embodiment 1, four heater wires 242 (more precisely, four parts that make up the ends of two heater wires 242) are introduced into the case 30 from outside the case 30 and connected to the control board 31. Four introduction grooves 521 are formed in the outer wall 52 through which the four heater wires 242 are inserted, and four introduction grooves 531 are formed in the inner wall 53 at positions corresponding to the introduction grooves 521 through which the four heater wires 242 are inserted. The introduction grooves 521 and 531 constitute the heater wire inlet for introducing the heater wires 242.

[0038] As shown in Figure 5, the upper case 5 has multiple screw receiving parts (screw holes) 54, and the lower case 6 has screw insertion holes 64. By inserting a screw into the screw insertion hole 64 and screwing it into the screw receiving part 54, the upper case 5 and the lower case 6 can be fixed together with screws.

[0039] The front of the upper case 5 has a power switch mounting section 55 for installing the main power switch 33 and the temperature control switch 34. Additionally, the side of the upper case 5 has a power cord mounting section 56 for connecting the power cord 32.

[0040] The main power switch 33 is a waterproof type switch, and when pressed into the power switch mounting section 55, the waterproof gasket (not shown) attached to the main power switch 33 adheres tightly to the power switch mounting section 55, ensuring a waterproof structure.

[0041] As shown in Figure 2, a light-receiving window 57 molded from a translucent resin material that transmits infrared rays, and two display windows 58 molded from a transparent resin material are tightly fixed to the top surface of the upper case 5.

[0042] The remote controller 4 transmits an infrared operation signal, which is received by a receiver 35 (see Figure 6) installed on the control board 31 after passing through the light-receiving window 57.

[0043] The control board 31 is equipped with an LED indicator light 36 (see Figure 6), which can be viewed from outside the controller 3 through a display window 58.

[0044] As shown in Figure 5, the lower case 6 is roughly rectangular and flat, and an outer peripheral wall 61 that connects to the upper case is integrally molded around the periphery of the lower case 6. The outer peripheral wall 61 is formed to be approximately the same shape as the outer peripheral wall 51 of the upper case 5.

[0045] As shown in Figure 6, a power switch mounting section 65 for installing the main power switch 33 and the temperature control switch 34 is formed on the front of the lower case 6. In addition, a power cord mounting section 66 for arranging the power cord 32 is formed on the side of the lower case 6. The power cord 32 is connected to the power cord mounting section 66 via a connector.

[0046] The control board 31 is composed of multiple components, including a microcomputer, and provides all control functions for the surface heating device 1, including power on / off, temperature detection and temperature control functions for the main unit 2, and communication functions with the remote controller 4.

[0047] <4> Remote controller configuration Figure 11 is a plan view of the remote controller 4 of the same planar heating device.

[0048] As shown in Figure 11, the remote controller 4 has an infrared transmitter 41 installed on the front of a roughly rectangular remote controller case 40 molded from resin material, and transmits operation signals from the infrared transmitter 41 to the controller 3 installed on the main unit 2.

[0049] Multiple operating switches 42 are installed on the top surface of the remote controller case 40. The operating switches 42 include a power switch 43 for turning the power of the surface heating device 1 on and off, a temperature control switch 44 for setting the temperature of the surface heating device 1, an area switching switch 45 for switching the heating range of the surface heating device 1, an energy saving switch 46 that automatically changes the set temperature according to changes in room temperature, and a power 1 / 2 switch 47 that alternately supplies power to 1 / 2 of the surface heating device's area to reduce the risk of circuit breaker trips when used simultaneously with other electrical appliances.

[0050] An LCD display unit 48 is located on the top surface of the remote controller case 40, and the status of operations performed by the operation switches 42 is displayed on the LCD screen of the display unit 48.

[0051] The remote controller 4 is powered by a built-in dry cell battery. Operation data from the operation switch 42 is transmitted as an infrared signal from the infrared transmitter 41, received by the receiver 35 of the controller 3, and the heater unit 24 of the main unit 2 is controlled.

[0052] <5> Operation and function of a surface-type warming device The basic method of using the surface heating device 1 is to connect the power cord 32 to an outlet and turn on the main power switch 33 of the controller 3, which will cause the main power indicator light 361 of the controller 3 to light up.

[0053] By turning the power switch 43 on the remote controller 4 to "on," power is supplied to the heater unit 24, and the heating of the main unit 2 begins.

[0054] The temperature of the main unit 2 is maintained at the temperature set by the remote controller 4. To change the temperature of the main unit 2, the set temperature can be changed by operating the temperature control switch 44 of the remote controller 4.

[0055] When discontinuing the use of the surface heating device 1, the power supply to the heater unit 24 is stopped by turning the main power switch 33 on the controller 3 of the main unit 2 to "off".

[0056] <6> heat sink As shown in Figures 5, 6, 8, and 10, a heat sink 7 is placed inside the case 30 and is thermally connected to the heater wire 242. When the heater wire 242 and the case 30 (upper case 5, lower case 6) come into contact and are thermally connected, the heat emitted by the heater wire 242 affects the resin case 30, accelerating deterioration such as discoloration and deformation of the case 30. Therefore, by placing the heat sink 7 inside the case 30, the heat emitted by the heater wire 242 is dissipated, and the impact on the case 30 is suppressed.

[0057] The heat sink 7 is rectangular in shape when viewed from above and is made of a metal such as copper or aluminum. As shown in Figures 5 and 8, the heat sink 7 has positioning holes 71 formed in it.

[0058] As shown in Figures 6, 8, and 9, in Embodiment 1, the heater wire 242 has a bent portion 243 located inside the case 30, and this bent portion 243 is thermally connected to the heat sink 7.

[0059] Furthermore, as shown in Figures 6 and 10, the heat sink 7 is thermally connected to the lower case 6. In Embodiment 1, a housing recess 62 for housing the heat sink 7 is formed on the inner surface (upper surface) of the lower case 6 facing the upper case 5. In a plan view, the housing recess 62 is formed in the region sandwiched between the outer wall 52 and the inner wall 53 of the upper case 5. As shown in Figure 6, a positioning projection 63 that protrudes upward is formed in the housing recess 62. The positioning projection 63 is inserted into the positioning hole 71 of the heat sink 7, positioning it and making it difficult for the heat sink 7 to come out of the housing recess 62.

[0060] The heat sink 7 is in contact with the case 30 and is thermally connected to it. However, when the case 30 is in contact with the heater wire 242, it does not receive heat from the narrow area in contact with the heater wire 242, but rather receives a small amount of heat per unit area from the entire heat sink 7. Therefore, deterioration such as discoloration and deformation of the case 30 can be suppressed.

[0061] In particular, since the heat sink 7 is in contact with the bent portion 243 of the case 30, direct contact between the bent portion 243, which has a large contact area with the case 30, and the case 30 can be avoided, making it easier to suppress deterioration such as discoloration and deformation of the case 30.

[0062] Furthermore, since the heat sink 7 is thermally connected to the lower case 6, heat transfer to the upper case 5, which is easily accessible to the user, is suppressed.

[0063] (summary) Based on the embodiments described above, the following aspects are disclosed.

[0064] The first embodiment of the planar heating device (1) includes a main body (2) having a planar heater unit (24) having heater wires (242) with a plurality of planar members (surface material 21, first adhesive sheet 23, second adhesive sheet 25, heat insulating sheet 26, third adhesive sheet 27 and back material 22) laminated above and below it, and a controller (3) having a case (30) installed on the main body (2), with a control board (31) for controlling the power supply to the heater unit (24) located inside the case (30). The case (30) has heater wire inlet openings (inlet grooves 521 and 531) for introducing the heater wires (242). A heat sink (7) that is thermally connected to the heater wires (242) is placed inside the case (30).

[0065] According to this embodiment, deterioration of the case (30) can be suppressed.

[0066] In the second embodiment of the planar heating device (1), in the first embodiment, the heater wire (242) has a bent portion (243) located inside the case (30). The bent portion (243) is thermally connected to the heat sink (7).

[0067] According to this embodiment, direct contact between the bent portion (243), which has a large contact area with the case (30), and the case (30) can be avoided, making it easier to suppress deterioration such as discoloration and deformation of the case (30).

[0068] In the third embodiment of the planar heating device (1), in the first or second embodiment, the case (30) has an upper case (5) exposed on the upper side of the planar heating device (1) and a lower case (6) exposed on the lower side. The heat sink (7) is thermally connected to the lower case (6).

[0069] According to this embodiment, heat transfer to the upper case (5), which is easily accessible to the user, is suppressed. [Industrial applicability]

[0070] As described above, the surface-type heating device 1 according to this disclosure can ensure high heat dissipation, and therefore can be applied to electrical equipment other than the surface-type heating device 1 that requires heat dissipation. [Explanation of Symbols]

[0071] 1 Planar heating device 2 Main unit 21 Surface material 211 Surface sheet 212 Nonwoven fabric 213 Adhesive 22 Backing material 23 First Adhesive Sheet 24 Heater Unit 241 Aluminum Sheet 242 Heater wire 243 Bending section 25 Second adhesive sheet 26 Insulation Sheet 27 Third adhesive sheet 3 Controllers 30 cases 31 Control board 32 Power cord 33 Main power switch 34 Temperature control switch 35 Receiving section 36 Indicator light 361 Main power indicator light 362 Energy-saving lamps 4 Remote controller 40 Remote Controller Case 41 Infrared Transmitter 42 Operating switches 43 Power switch 44 Temperature control switch 45 Area selector switch 46 Energy-saving switch 47 switches 48 Display section 5 Upper case 51 Outer wall 52 Exterior Wall 521 Inlet groove 53 Inner wall 531 Inlet groove 54 Screw receiving part 55 Power switch mounting section 56 Power cord mounting section 57 Light-receiving window 58 Display window 6. Lower case 61 Peripheral wall 62 Receiving recess 63 Positioning projection 64 Screw insertion holes 65 Power switch mounting section 66 Power cord mounting section 7 Heat sink 71 Positioning holes

Claims

1. The main body has a configuration in which multiple planar members are stacked above and below a planar heater unit having a heater wire, The controller includes a case installed on the main body, and a control board for controlling the power supply to the heater unit is located inside the case. The case has a heater wire inlet formed therein, A heat sink that is thermally connected to the heater wire is placed inside the case. Planar heating device.

2. The heater wire has a bent portion that is placed inside the case, The bent portion is thermally connected to the heat sink. The surface-type warming device according to claim 1.

3. The case has an upper case exposed on the upper side of the surface-shaped warming device and a lower case exposed on the lower side. The heat sink is thermally connected to the lower case. The planar warming device according to claim 1 or 2.

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