JP2002267192A - Manufacturing method of waterproof heating mat for bathroom or the like - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a waterproof heating mat for a bathroom or the like that is safe in terms of electricity and structure. SOLUTION: In the manufacturing method, a heater unit 2 having a support 2c for fixing a heater wire 2a and a temperature detector 2b on a rear material 3, the surface of the heater unit 2 that is coated with an adhesive in advance and the rear material 3 affixed to the surface of a surface material 1 that is coated with an adhesive in advance, and the heater unit 2 is pinched between the rear and surface materials 3 and 1 and rear and surface materials 3 and 1 are integrated by an adhesive. By the manufacturing method, the entry of moisture into the heater unit 2 is prevented for improving electric waterproofness. Also, the amount of required adhesives is equally dispersed to each surface for uniform coating to each entire surface, and the entire surface of the rear and surface materials 3 and 1 can be bonded surely for also improving productivity.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a waterproof heating mat which is installed on a floor of a washing place such as a bathroom to heat the floor.

[0002]

2. Description of the Related Art Conventionally, there is no waterproof heating mat of this kind in a bathroom or the like, and as a method of heating a floor of a washing place such as a bathroom, as shown in FIG. Generally, a configuration in which the pipe 2a is buried, or a configuration in which a pipe 11 is provided under the floor surface as shown in FIG.

[0003]

However, the method of manufacturing a bathroom floor heating apparatus according to the above-mentioned conventional construction requires a corresponding arrangement in advance when a new bathroom is constructed, and is considerably expensive. There was a problem that. In addition, although the method of retrofitting an existing bathroom has an electric carpet and other electric rugs, it has been difficult to use it in a bathroom in terms of safety such as electric shock and waterproofness. On the other hand, in recent years, with the rise of comfortable spaces in the bathroom, there has been a tendency that only the lighting equipment section to which commercial power is supplied is partially modified and a step-down power supply is mounted in the bathroom.

The present invention solves the above-mentioned conventional problems, and provides a method for manufacturing a waterproof heating mat for use in a bathroom or the like which has good waterproofness, good productivity, is safe in terms of both electrical and structural aspects and is comfortable. The purpose is to provide.

[0005]

In order to solve the above-mentioned conventional problems, a method of manufacturing a waterproof heating mat according to the present invention comprises mounting a heater unit having a support for fixing a heater wire and a temperature detector on a backing material. Then, the surface of the heater unit and the backing material to which an adhesive has been applied in advance and the surface of the surface material to which the adhesive has been applied in advance are bonded to each other.

[0006] By interposing a heater unit between the backing material and the surface material and integrating the backing material and the surface material with an adhesive, the infiltration of moisture into the heater unit is eliminated and the electrical waterproofness is improved. be able to. Further, after applying an adhesive in advance to each of the surface of the heater unit, the surface of the backing material, and the surface of the surface material, the respective surfaces to which the adhesive is applied are bonded to each other to reduce the amount of the necessary adhesive. , And can be uniformly applied over the entire surface without any excess or shortage, and the entire surface of the backing material and the surface material can be securely adhered to each other, and the productivity is also improved.

[0007]

According to the first aspect of the present invention, a heater unit having a support for fixing a heater wire and a temperature detector is placed on a backing material, and the heater unit and an adhesive are applied in advance. The backing material and the surface of the surface material to which the adhesive has been applied are bonded together.The heater unit is sandwiched between the backing material and the surface material, and the backing material and the surface material are integrated with the adhesive. By doing so, it is possible to eliminate the intrusion of moisture into the heater unit and improve the electrical waterproofness. Further, after applying an adhesive in advance to each of the surface of the heater unit, the surface of the backing material, and the surface of the surface material, the respective surfaces to which the adhesive is applied are bonded to each other to reduce the amount of the necessary adhesive. , And can be uniformly applied over the entire surface without any excess or shortage, and the entire surface of the backing material and the surface material can be securely adhered to each other, and the productivity is also improved.

[0008] In the invention of claim 2, the solvent can be volatilized by applying the adhesive of claim 1 by spraying. Also, simultaneous application to both sides improves productivity.

[0009] The invention described in claim 3 is particularly advantageous in claims 1 and 2.
By using chloroprene rubber as the main component of the adhesive described in (1), a strong adhesive force can be obtained.

[0010] The invention described in claim 4 is particularly advantageous in claim 1,
After sandwiching the heater unit and bonding the backing material and the surface material with an adhesive by the manufacturing method described in 2, 3 and integrating them with an adhesive, the backing material and the surface material are rolled from the outside, so that the adhesive portion is removed. Bubbles are removed and air accumulation is eliminated.
In addition, since it is heated and pressed thereafter, a strong adhesive force can be obtained.

[0011] The invention according to claim 5 is particularly applicable to claim 1,
A concave portion is formed on the inner surface of the backing material described in 2, 3, and 4, the temperature detector is housed in the concave portion, and the heater unit is placed on the backing material. The heater unit functions as positioning when the heater unit is placed on the backing material, and the heater unit can always be placed at a fixed position without using a jig or the like on the backing material.

The invention according to claim 6 is particularly applicable to claim 1,
2, 3, 4 and 5, the surface of the heater unit and the backing material to which the adhesive has been applied in advance and the surface of the surface material to which the adhesive has been applied are bonded to each other, and then the outer peripheral side surface is die-cut. , It is possible to finish the outer peripheral side surface neatly.

According to a seventh aspect of the present invention, there is provided an opening provided in the backing material, and a cord case inserted into the opening. The cord case is inserted into the opening to connect a terminal of the heater wire to the power cord. After waterproofing the connecting portion with a heat-shrinkable tube, further waterproofing is performed using a coating agent in the cord case, so that the waterproofness is further improved.

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below in detail with reference to the drawings.

(Embodiment 1) FIG. 1 is an exploded perspective view showing a method of manufacturing a waterproof heating mat for a bathroom or the like in one embodiment of the present invention.

In FIG. 1, reference numeral 1 denotes a surface material, which is a thermoplastic resin called EVA, which is a copolymer of ethylene and vinyl acetate (hereinafter referred to as EVA), 2 denotes a heater unit,
A coated heater wire 2a and a waterproof thermostat 2b (temperature detector) for preventing overheating are fixed to a nonwoven fabric support 2c made of a polyester spunbond method, and the heater unit itself has a waterproof structure. In this case, there is no problem even if the adhesion described later is broken and water enters. Reference numeral 3 denotes a backing material of EVA, which is provided on its inner surface with a concave portion 3a for accommodating a thermostat, and has an opening 3b into which a cord case 4 is fitted.

The heater unit 2 is positioned and placed on the backing material 3 configured as described above such that the thermostat 2b is housed in the recess 3a.
The cord case 4 is then inserted and an adhesive containing chloroprene rubber as a main component is applied by a spray method. On the other hand, the same adhesive is applied to the inner surface of the surface material 1 by a spray method.
Simultaneous application to the backing material 3 and the surface material 1 leads to an increase in production speed.

As described above, the heater wire 2a and the temperature detector 2b
The heater unit 2 having a support 2c for fixing the heater unit 2 is placed on the backing material 3 and the surface of the heater unit 2 and the backing material 3 to which adhesive has been applied in advance, and the surface material 1 to which adhesive has been applied in advance.
Are bonded to each other, with the heater unit 2 interposed between the backing material 3 and the surface material 1 and the backing material 3 and the surface material 1
Is integrated with an adhesive, it is possible to prevent water from penetrating into the heater unit 2 and to improve electrical waterproofness. Also, after applying an adhesive in advance to each of the surface of the heater unit 2, the backing material 3, and the surface of the front material 1, the respective surfaces to which the adhesive is applied are bonded to each other, so that the necessary amount of the adhesive is obtained. Is dispersed on each of the surfaces, and can be uniformly applied over the entire surface without excess or shortage.
Can be securely bonded to each other, and productivity is also improved.

Further, by applying the adhesive by a spray method, the solvent contained therein easily evaporates when the adhesive flies in the air, so that gas does not accumulate on the adhesive surface and the surface of the front material 1 and the backing material 3 No partial swelling occurs, and the odor after bonding is greatly reduced. Furthermore, it can be applied evenly with the minimum necessary amount of adhesive, and more reliable adhesion can be achieved.

Then, by passing the laminated body between the rollers 5 and 6 as shown in FIG. 2, air bubbles inside the bonding surface can be more reliably removed, and the air pockets can be eliminated to make the surface uneven. The finish can be improved as follows.

FIG. 3 shows one method of final bonding, in which a hot platen 7 is heated and pressed to make the bonding strength uniform and strong. At this time, the temperature of the hot platen is set so as not to exceed the heat resistant temperature of EVA. In addition, the size of the heater unit 2 is the surface material 1, the backing material 3
Because it is smaller, the four sides of the main body are firmly fixed between the EVA.

FIG. 4 is a perspective view of the main body after the die is cut out. The surface of the heater unit 2 and the backing material 3 to which an adhesive has been applied in advance and the surface of the surface material 1 to which the adhesive has been applied in advance are adhered to each other. After the alignment, the outer peripheral side surface is die-cut, so that the outer peripheral side surface can be finely finished.

FIG. 5 is a connection diagram of a heater wire and a power supply cord. After the two parts are twisted and soldered, they are fixed by a heat-shrinkable tube 8 containing a hot melt, and a silicon-based coating agent 9 Seal with. As a result, the waterproofing is performed twice, and the waterproofness is further improved.

[0024]

As described above, according to the present invention, a heater unit having a support for fixing a heater wire and a temperature detector is placed on a backing material, and the heater unit is preliminarily coated with an adhesive. The surface of the backing material and the surface of the surface material to which an adhesive has been applied in advance are bonded to each other.The heater unit is sandwiched between the backing material and the surface material, and the backing material and the surface material are bonded with an adhesive. By the integration, it is possible to eliminate the intrusion of water into the heater unit and improve the electrical waterproofness. In addition, the required amount of adhesive can be dispersed on each surface and applied evenly over the entire surface without any excess or shortage, and the entire backing and surface material can be securely bonded, improving productivity. I do.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view of a method for manufacturing a waterproof heating mat according to one embodiment of the present invention.

FIG. 2 is a cross-sectional view showing one embodiment of a method for removing air bubbles from the adhesive surface of the waterproof heating mat.

FIG. 3 is a sectional view showing an embodiment of the method for bonding the waterproof heating mat.

FIG. 4 is a perspective view of the waterproof heating mat after die cutting.

FIG. 5 is a cross-sectional view of a connection portion between a heater wire and a power cord of the waterproof heating mat.

FIG. 6 is a cross-sectional view of a conventional washing floor.

FIG. 7 is a cross-sectional view of another conventional washing floor.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Front material 2 Heater unit 2a Heater wire 2b Thermostat (Temperature detector) 2c Support 3 Backing material 3a Depression 3b Opening 4 Code case 8 Heat shrink tube 9 Coating agent

Claims (7)

[Claims] 1. A heater unit having a support for fixing a heater wire and a temperature detector is placed on a backing material, and the surface of the heater unit and the backing material to which adhesive has been applied in advance, A method of manufacturing a waterproof heating mat in which the surfaces of the applied surface materials are bonded to each other. 2. The method for manufacturing a waterproof heating mat according to claim 1, wherein the adhesive is a spray coating method. 3. The method for producing a waterproof heating mat according to claim 1, wherein a main component of the adhesive is chloroprene rubber. 4. After bonding the surface of the heater unit and the backing material to which adhesive has been applied in advance, and the surface of the surface material to which adhesive has been applied in advance, applying a roll, and thereafter heating the entire surface. The method for manufacturing the waterproof heating mat according to claim 1, wherein the mat is pressed. 5. The waterproof heating system according to claim 1, wherein a concave portion is formed on an inner surface of the backing material, and the heater unit is mounted on the backing material while a temperature detector is housed in the concave portion. Mat production method. 6. The outer peripheral side surface is die-cut after bonding the surface of the heater unit and the backing material to which adhesive has been applied in advance and the surface of the surface material to which adhesive has been applied in advance. The method for producing a waterproof heating mat according to any one of claims 1 to 5. 7. An opening provided in a backing material, a cord case inserted into the opening, a cord case is inserted into the opening, and a terminal of the heater wire is connected to a power cord. The method for producing a waterproof heating mat according to any one of claims 1 to 6, wherein the waterproofing heating mat is subjected to a waterproofing treatment using a coating agent in the cord case after the waterproofing treatment with the heat shrinkable tube.