JP2005278768A - Nonwoven fabric for electric heating carpet, and electric heating carpet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an electric heating carpet which is excellent stably with time in sound proofing and heat retaining property and which is flexible, or to provide a nonwoven fabric for the electric heating carpet where resin powder of an adhesive is not generated when cutting off the nonwoven fabric and which is simply adhered to an electric heating wire arrangement layer. <P>SOLUTION: The nonwoven fabric for the electric heating carpet is constituted so that a nonwoven fabric layer 2 of 300 to 700g/m<SP>2</SP>from a nonwoven fabric made of synthetic fibers of 40 to 90d thickness is integrally adhered to a rear surface coating layer 3 consisting of a nonwoven fabric made of synthetic fibers of 6 to 15d thickness. This is overlapped on the side of the rear surface of the electric heating wire arrangement layer 1, and a front surface coating layer 4 consisting of the nonwoven fabric made of the synthetic fibers of 6 to 15d thickness is overlapped on the side of the front surface to make an integrally laminated electric heating carpet. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a non-woven fabric used for an electric heating carpet of a heater and an electric heating carpet using the same.

  Heat retention and energy saving in electric heating carpets (also called electric carpets and hot carpets, which may be the main body excluding the top mat), which is a kind of heating equipment installed on the floor or tatami In order to enhance the effect of the above and to prevent electric heat from escaping from the back surface as much as possible, a material having a high heat retaining property is used on the back surface.

  The conventional electric carpet shown in FIG. 2 (only the main body excluding the covering mat) is provided with a surface nonwoven fabric layer 8 superimposed on the surface side of the heating wire arrangement layer 1 via an adhesive layer 7, and on the back side. A back nonwoven fabric layer 11 having a latex-impregnated hardened portion 10 is laminated through an adhesive layer 9 and these are laminated and integrated. When the latex impregnated with the nonwoven fabric is cured, the anti-slip effect and anti-pilling properties of the surface are improved.

  However, in order to sufficiently secure the heat retaining property of such an electric heating carpet, it is necessary to provide a fiber layer or a resin layer having a considerable thickness on the back surface of the heating wire arrangement layer 1. It is thought that there is a case where the thickness of the product becomes bulky and does not conform to consumer preference.

In addition, a non-woven fiber surface provided on the back side of the heating wire arrangement layer of the electric heating carpet is coated with a metal such as silver, nickel, aluminum, copper, etc. so as to efficiently reflect infrared rays. (See Patent Document 1).
JP 2000-328411 A (claims, paragraphs [0005] and [0006])

  However, the conventional electric carpet, which has a nonwoven fabric impregnated with latex resin on the back side of the heating wire arrangement layer, is hard to fold due to the impregnated latex resin, making it difficult to fold. Therefore, it is not easy to round.

  In addition, non-woven fabric impregnated with latex resin generates adhesive and latex powder when it is cut and crushed, which worsens the environment for reprocessing and recycles non-woven fabric that may be reused from electric carpets. And hinders ease of use.

  Further, since the conventional infrared reflective non-woven fabric uses, for example, a relatively thin fiber of about 1.5 d as a material, the thickness of the fiber layer is likely to decrease with time, and accordingly, between the fibers. A large amount of air cannot be retained, resulting in a decrease in heat retention or a sufficient soundproofing effect.

  Accordingly, an object of the present invention is to solve the above-mentioned problems, to make an electric heating carpet that is stable and excellent in soundproofing and heat retention over time and has good flexibility, or resin powder such as an adhesive is cut into a nonwoven fabric. It is a nonwoven fabric for electric heating carpet that does not sometimes occur and can easily bond the nonwoven fabric and the heating wire arrangement layer.

In order to solve the above-mentioned problem of the nonwoven fabric for electric carpets, in the nonwoven fabric for electric carpets provided integrally on the back surface side of the heating wire arrangement layer of the electric heating carpet, the nonwoven fabric is made from a synthetic fiber nonwoven fabric having a thickness of 40 to 90d. A nonwoven fabric laminate for electric carpets, which is a laminate in which a back coating layer made of a nonwoven fabric made of synthetic fibers having a thickness of 6 to 15 d is integrally provided on a nonwoven fabric layer of 300 to 700 g / m ² is formed.

  The electric heating carpet referred to in the present invention may be only the main body excluding the top mat, or may be one in which the electric heating main body and the tufted carpet are integrally formed.

  The fiber thickness of the nonwoven fabric is in the range of 40 to 90d. This is because a non-woven fabric layer capable of reliably insulating heat so as not to transmit the amount of heat generated by the heating wire cannot be formed with a fiber having a small diameter of less than 40d. In addition, fibers having a large diameter exceeding 90d are not preferable because the fiber gaps are not uniform and unevenness of the degree of heat insulation occurs in the plane direction of the nonwoven fabric layer.

Moreover, it is preferable that the thickness of a nonwoven fabric layer is 300-700 g / m < ² >, when the fiber of the said nonwoven fabric structure is made into predetermined thickness. This is because a thin nonwoven fabric layer having a thickness of less than 300 g / m ² cannot reliably insulate so as not to transmit the heat generated by the heating wire, and a nonwoven fabric layer having a thickness exceeding 700 g / m ² cannot There is a high possibility that the thickness becomes bulky and impairs consumer preference.

  Moreover, the thickness of the fiber which forms a back surface coating layer is 6-15d. Forming with a fiber having a small diameter of less than 6d is not preferable because the distance between the fibers is very close and the air flowability is almost lost, and a thick fiber exceeding 15d is not preferable because heat easily escapes.

  In the nonwoven fabric laminate of the present invention, since each layer formed of the nonwoven fabric is formed of fibers having a predetermined thickness as described above, there are sufficient gaps between the fibers. Further, by providing the back surface coating layer with a nonwoven fabric made of fibers having a predetermined denier that is considerably thinner than the fibers, it is difficult for air and sound to leak from the main nonwoven fabric layer, and heat and sound insulation that acts extremely efficiently A space is formed. Therefore, it becomes the nonwoven fabric laminated body for electric carpets with good sound insulation and heat retention.

  It is preferable that low-melting-point fibers are mixed in the nonwoven fabric layer or the surface coating layer or the nonwoven fabric forming both layers so that the nonwoven fabric layer can be easily heat-press bonded.

  When heat bonding is applied to the heating wire arrangement layer, there is no need to impregnate or apply an adhesive or latex, and the resin powder due to the adhesive does not occur when the nonwoven fabric is cut and used. It becomes a non-woven laminate for electric heating carpets that can be easily adhered to.

Next, in the present invention, in order to solve the above-described problems, a non-woven fabric layer of 300 to 700 g / m ² made of a non-woven fabric made of synthetic fiber having a thickness of 40 to 90 d is provided on the back side of the heating wire arrangement layer of the heating carpet. Thus, an electric carpet in which a back surface coating layer made of a synthetic fiber nonwoven fabric having a thickness of 6 to 15 d is integrally provided.

  In the electric carpet of the present invention configured as described above, the nonwoven fabric layer provided directly on the back surface side of the heating wire arrangement layer is formed of fibers of a predetermined thickness. Have a sufficient space between the fibers.

  Further, by providing the back surface coating layer with a nonwoven fabric made of fibers of a predetermined denier considerably thinner than the fibers of the nonwoven fabric layer, a denser fiber gap different from the sparse fiber gap formed in the nonwoven fabric layer described above. The surface covering layer is formed as the outermost layer, so that the air trapped in the nonwoven fabric layer is difficult to leak out, so that the heat retaining effect is enhanced and the sound wave passing therethrough is attenuated to enhance the soundproofing effect. In other words, the electric carpet is very good in soundproofing and heat insulation.

  Further, in order to make an electric carpet that exhibits such an action more reliably, a surface coating layer made of a nonwoven fabric made of synthetic fibers having a thickness of 6 to 15 d is integrally provided on the surface side of the heating wire arrangement layer of the electric heating carpet. An electric carpet is preferred.

  In the present invention, the nonwoven fabric for electric heating carpet is a laminate in which a non-woven fabric layer of a predetermined thickness is integrally provided with a back surface coating layer made of a non-woven fabric of a predetermined thickness, and preferably low melting point fibers are mixed in the non-woven fabric. Non-woven fabrics for electric carpets that do not generate resin powder such as latex or adhesive during processing such as cutting the reuse of non-woven fabric, and can be easily bonded to the heating wire arrangement layer by hot-pressure bonding There is an advantage to become.

  Further, in the invention relating to the electric heating carpet, a surface coating layer made of a predetermined nonwoven fabric is integrally provided on the back surface side of the heating wire arrangement layer via a nonwoven fabric layer made of a fiber having a predetermined thickness, and more preferably the heating wire arrangement layer Since the electric carpet is integrally provided with a surface covering layer having a predetermined thickness on the surface side, there is an advantage that the electric carpet is good in soundproofing, heat retention and flexibility.

Embodiments of the present invention will be described below with reference to the accompanying drawings.
As shown in FIG. 1, in the embodiment, a nonwoven fabric layer 2 having a thickness of 300 to 700 g / m ² made of a synthetic fiber nonwoven fabric having a thickness of 40 to 90 d is bonded and integrated on the back side of the heating wire arrangement layer 1 of the electric heating carpet. Through this, a back surface coating layer 3 made of a synthetic fiber nonwoven fabric having a thickness of 6 to 15d is integrally provided, and a surface coating made of a synthetic fiber nonwoven fabric having a thickness of 6 to 15d is provided on the surface side of the heating wire arrangement layer 1. It is an electric heating carpet in which the layer 4 is provided integrally.

  The heating wire arrangement layer 1 is a heating wire 5 that is a heating element connected to an automatic temperature controller such as a bimetal, and an insulating rubber or synthetic resin that wraps the heating wire 5 as used in known heating carpets. What is necessary is just to form with the insulating sheet 6 consisting of (it may be a textile product).

  The synthetic fiber non-woven fabric having a thickness of 40 to 90d is not particularly limited as the material of the fiber. For example, a synthetic fiber non-woven fabric is made of polyester fiber. Further, a nonwoven fabric in which an appropriate amount of acrylic fiber, polypropylene fiber, or the like is mixed with polyester fiber is also preferable.

  The nonwoven fabric fibers forming the back surface coating layer 3 laminated on the lower surface of the nonwoven fabric layer 2 have a thickness of 6 to 15d.

  The back surface coating layer 3 and the nonwoven fabric layer 2 can be integrated by overlapping needle punching, and can also be laminated and integrated by hot-pressure bonding as described below.

  That is, in the embodiment, low melting point fibers are mixed and used in both the back surface coating layer 3 and the nonwoven fabric layer 2. The low melting point fiber referred to in the present invention refers to a fiber having a melting point lower by about 5 ° C. than the melting point of the fibers constituting the nonwoven fabric layer 2 described above. For example, the low melting point fiber having a melting point of 110 to 160 ° C. % Is preferable.

  And the back surface coating layer 3 and the nonwoven fabric layer 2 are piled up and heat-pressure bonded, and these can be heat-pressure bonded simultaneously or separately. Moreover, you may provide the surface coating layer 4 which consists of a synthetic fiber nonwoven fabric of thickness 6-15d integrally by the heat bonding at the surface side of the heating wire arrangement | positioning layer 1. FIG. In this way, the surface of the surface coating layer 4 is thin and melted hot, so that a pilling (pilling) prevention property is high, and a surface state capable of preventing the top carpet from slipping can be obtained.

[Example 1]
A non-woven fabric made of polyester fiber having a thickness of 40d on the back side of the heating wire arrangement layer 1 (a heating element using a 100 W carbon heater) of the electric heating carpet (rectangular area 1.5 m ² ) having the cross-sectional structure shown in FIG. A non-woven fabric layer 2 having a thickness of 500 g / m ² is integrated by hot-pressure bonding, and a back surface coating layer 3 made of a non-woven fabric made of polyester fiber having a thickness of 10 d is provided integrally therewith, and the surface of the heating wire arrangement layer 1 is further provided. On the side, an electric heating carpet in which a surface coating layer 4 made of a nonwoven fabric made of polyester fiber having a thickness of 10 d was integrally provided.

  The obtained electric heating carpet was placed on a tatami indoors, and the temperature of the lower surface of the electric heating carpet in contact with the tatami was measured after 10 minutes of heating.

[Comparative Example 1]
An electrothermal carpet having a cross-sectional structure shown in FIG. 1 was obtained in the same manner as in Example 1 except that a 500 g / m ² nonwoven fabric layer 2 made of a polyester fiber nonwoven fabric having a thickness of 36 d was used. The temperature of the lower surface of the electric heating carpet in contact with the tatami mat was measured after 10 minutes of heating when the electric heating carpet was placed on the tatami indoors, and it was 43 ° C.

As is clear from the test results for Example 1 and Comparative Example 1, the nonwoven fabric layer made of a polyester fiber nonwoven fabric having a thickness of 40 d or more is extremely effective as compared with the case where a nonwoven fabric layer having a smaller diameter is adopted. It can be seen that the heat retention is increased.
Moreover, when the electric heating carpets of Example 1 and Comparative Example 1 were laid on a flooring (wood floor finish) reinforced concrete apartment floor (directly stretched) and impact sounds in the 125 Hz band to the 2000 Hz band were measured downstairs, Example 1 Compared with Comparative Example 1, an improvement tendency of about 5 to 10 dB was recognized.

The principal part expanded sectional view of the electric heating carpet of an embodiment An enlarged cross-sectional view of the main part of a conventional electric heating carpet

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Heating wire arrangement | positioning layer 2 Nonwoven fabric layer 3 Back surface coating layer 4 Surface coating layer 5 Heating wire 6 Insulation sheet 7, 9 Adhesive layer 8 Surface nonwoven fabric layer 10 Latex impregnation hardening part 11 Back surface nonwoven fabric layer

Claims (4)

In the nonwoven fabric for electric carpets provided on the back side of the heating wire arrangement layer of the electric heating carpet,
The nonwoven fabric, the nonwoven layer of 300 to 700 g / m ² composed of a synthetic fiber nonwoven fabric of thickness 40～90D, the back surface coating layer made of a synthetic fiber nonwoven fabric of thickness 6~15d a laminated body provided integrally A non-woven fabric for electric carpets, characterized in that:   The nonwoven fabric for electrothermal carpets according to claim 1, wherein low melting point fibers are mixed in the nonwoven fabric. Through the non-woven layer of 300 to 700 g / m ² composed of a synthetic fiber nonwoven fabric of thickness 40~90d on the back side of the heating wire arrangement layer of electric carpets, backside coating of synthetic fiber non-woven fabric thickness 6~15d An electric carpet made up of layers.   The electric carpet which integrally provided the surface coating layer which consists of a synthetic fiber nonwoven fabric of thickness 6-15d in the surface side of the heating wire arrangement | positioning layer in the electric heating carpet of Claim 3.

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