JP2009028136A - Heating element and heating element manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a heating element which starts up fast to the start of heating and causes no cost increases because the heating element can be manufactured by a simple structure by using inexpensive materials while restraining the heating material from being irregularly and locally arranged. <P>SOLUTION: The heating element has the heating material, a core material holding the heating material, and a packing material storing the core material. The core material has a heating material holder holding the heating material in the inside and/or on the surface and an overlying member provided, superposed on the heating material holder. The heating material holder is a nonwoven fabric containing polypropylene and the overlying member contains polyethylene. The heating material holder and the overlying member are ultrasonically fused together. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a heating element and a method for manufacturing the heating element.

  Conventionally, a heating element in which a heating material that generates heat due to a chemical reaction with oxygen is contained in a packaging material has been used for heating and other purposes. When such a heating element is used for the purpose of warming, the heating element that is exposed to oxygen in the atmosphere through the packaging material generates heat by placing the heating element around the heating target part, thereby heating the target part. Was. However, since the conventional heating element has a configuration in which a powdery heating material is accommodated in a bag-like packaging material, the heating material is in a state of being freely movable in the packaging material. . For this reason, it is easy for heat-generating material to gather downward, and although the temperature of the part where heat-generating material has gathered can be raised, other parts (the upper part of the packaging material) are in contact with the packaging material. However, it was difficult to exert a sufficient heating effect. Further, the uneven distribution of the heat generating material in the packaging material may increase the time (rise time) for generating heat up to a temperature suitable for heating.

  On the other hand, in order to prevent the heat generating material in the packaging material from being displaced or unevenly distributed, the packaging material is configured using a material such as a porous (air-permeable) film, and excessive air is required inside the packaging material. There has been proposed a heating element that maintains a negative pressure so as not to flow in and restricts the movement of the heating element inside the packaging material. Many of such heating elements are mainly used by providing an adhesive layer on one side of the packaging material and adhering to a predetermined part (for example, on the underwear) by the adhesive force. In addition, for example, a heating structure, a filling sheet, and a sheet-like heating element described in Patent Documents 1 to 3 have been proposed.

JP-A-53-84247 Japanese Patent Publication No.62-4220 Japanese Patent No. 2840609

However, in the conventional heating element described above, the arrangements described in Patent Documents 1 to 3 have the following problems, although the heat generating material can be prevented from being offset or unevenly distributed.
(1) The material cost increases by using an expensive material such as the porous (air-permeable) film or a new material.
(2) Since the structure is complicated, the manufacturing cost of the heating element increases.
(3) By adopting a new structure for holding the heat generating material, it becomes difficult for the heat generating material to come into contact with the outside air, and the rise time to a temperature suitable for warming becomes longer.

  Therefore, the present invention realizes a simple and easy-to-expose structure using an inexpensive material, so that the rise to the start of heat generation is quick without increasing the cost, and the heat generating material is offset and unevenly distributed. An object is to provide a heating element that can be suppressed.

  In order to solve the above problems, a heating element of the present invention is a heating element that includes a heating material, a core material that holds the heating material, and a packaging material that houses the core material. It is characterized by having a heat generating material holding body capable of holding the material inside and / or on the surface, and a stacking member provided to overlap the heat generating material holding body.

  In the heating element of the present invention, the core material is characterized in that it has at least a two-layer structure by the heating material holder and the overlapping member.

  In the heating element according to the present invention, the heating material holder is made of a material having a gap into which the heating material enters.

  In the heat generating body of the present invention, the heat generating material holding body is composed of a nonwoven fabric.

  In the heating element of the present invention, the heating material holder includes polypropylene, and the overlapping member includes polyethylene.

  In the heating element of the present invention, the heating material holder and the overlapping member are ultrasonically welded.

  In the heating element of the present invention, the heating material holder and / or the overlapping member has a hardness capable of maintaining the outer shape of the core material.

  In addition, the heating element manufacturing method of the present invention includes a heat generating material, a core material that holds the heat generating material, and a packaging material that houses the core material, and the core material includes the heat generating material inside and / or the surface. A heating material holder that is held on the heating material holder and a stacking member that is provided on the heating material holder, the step of forming the heating material holder, and the heating material holder On the other hand, it has the process of fixing a stacking member, and the process of supplying a heat generating material from the site | part in which the stacking member is not provided among heat generating material holding bodies.

  The heating element manufacturing method of the present invention is characterized by including a step of guiding the heating material into the heating material holder by vibrating the core after the heating material is supplied.

  According to the present invention, the heat generating material, the core material that holds the heat generating material, and the packaging material that houses the core material, and the core material can hold the heat generating material inside and / or on the surface. By having the heat generating material holding body and the overlapping member provided to be overlapped with the heat generating material holding body, the rise to the start of heat generation is fast while suppressing the deviation and uneven distribution of the heat generating material. Since it can be manufactured with a simple configuration using an inexpensive material, a heating element that does not increase the cost can be provided.

  Hereinafter, a heating element and a method for manufacturing the heating element according to an embodiment of the present invention will be described in detail with reference to FIGS. FIG. 1 is a plan view showing a configuration of a heating element 10 according to the present embodiment. FIG. 2 is a cross-sectional view taken along the line II-II in FIG. 1, showing the manufacturing process of the heating element 10 according to the present embodiment. FIG. 3 is a partial enlarged cross-sectional view taken along line III in FIG. 2, showing the configuration of the heating element 10 according to the present embodiment.

  As shown in FIG. 1 or FIG. 2G, the heating element 10 according to this embodiment includes a heating material 40, a core material 20 that holds the heating material 40, and a packaging material 30 that houses the core material 20 therein. And having. Below, the detailed structure of each member is demonstrated along a manufacturing process.

  As shown in FIG. 2, the core member 20 has a two-layer structure including a sheet-like heat generating material holder 21 and a sheet-like overlapping member 22 provided to overlap the heat generating material holder 21.

(1) Formation process of exothermic material holder 21 Exothermic material holder 21 is formed as a nonwoven fabric constituted with a material containing resin (for example, polypropylene) (Drawing 2 (a)). Further, the heat generating material holding body 21 is formed so as to have a hardness capable of elastically maintaining the outer shape of the core member 20 even when the heat generating body 10 is used while maintaining the softness as the nonwoven fabric. . Since the formation of the heat generating material holder 21 can be performed by a known nonwoven fabric manufacturing method (for example, a spunbond method or an air-through method), detailed description thereof is omitted. By making the heat generating material holder 21 non-woven, a large number of voids into which the heat generating material 40 enters are formed, and the heat generating material 40 is held in the gap or on the surface of the heat generating material holder 21. In addition, since a large number of gaps are formed, the heat generating material 40 held in the heat generating material holder 21 can easily come into contact with the air, thereby shortening the rise time until the heat generation material 40 starts to generate heat.

  Here, the heat generating material 40 is a substance that generates heat by reacting with oxygen. For example, (1) iron, (2) sodium chloride, potassium chloride, magnesium chloride, calcium chloride, and other metal chlorides ( 3) There are potassium sulfate, sodium sulfate, magnesium sulfate and other metal sulfates.

(2) Laminating member fixing step The laminating member 22 is formed into a sheet shape by rolling, for example, with a material containing a resin (for example, polyethylene). Note that the overlapping member 22 may be formed so as to have a hardness capable of elastically maintaining the outer shape of the core member 20 when the heating element 10 is used, similarly to the heating material holder 21.

  The overlapping member 22 is overlapped with the heat generating material holder 21 and fixed by joining the surfaces in contact with each other by ultrasonic welding, thereby forming a sheet-like core material 20 (FIG. 2). (B)). It should be noted that the location where ultrasonic welding is performed can be arbitrarily determined, and in addition to the entire surface, only the peripheral edge can be formed in an X shape on four corners of a rectangular shape or two diagonal lines. The conditions for ultrasonic welding are set according to the material used for the heat generating material holder 21 and the overlapping member 22, the bonding strength between the heat generating material holder 21 and the overlapping member 22, and the hardness required for the core material 20. In ultrasonic welding, heating is not required, and ultrasonic waves can be applied only to the bonding surface. For this reason, it can join in the state which maintained the softness of the heat generating material holding body 21 comprised with the whole shape before joining of the heat generating material holding body 21 and the lamination | stacking member 22, and the nonwoven fabric.

(3) Heating material supply step Subsequently, the heat generating material 40 is supplied from the upper surface 21a to which the overlapping member 22 is not joined to the heat generating material holder 21 of the core member 20 formed as described above (FIG. 2). (C)). At this time, the core member 20 is placed (and fixed) on the vibration table 50. The vibration table 50 can vibrate along a plane parallel to the upper surface 21a.

  In the present embodiment, after the heat generating material 40 is supplied to the core member 20 from the upper surface 21 a side, the core member 20 is vibrated by the vibration table 50. By vibrating the core member 20 in this way, the heat generating material 40 remaining on the upper surface 21a can be guided into the gap of the heat generating material holding body 21 (FIG. 2D). Here, the frequency and strength of the vibration of the core material 20 by the vibration table 50 are set according to the constituent material of the heat generating material holder 21, the size and number of the gaps, and the material and particle size used for the heat generating material 40. As an example, it is preferable to divide the amount of the heat generating material 40 to be enclosed in the packaging material 30 into 1 to 4 times, and in particular, more reliably by performing it in 3 to 4 times. This is preferable because a predetermined amount of the heat generating material 40 can be induced.

  In the core material 20 to which the heat generating material 40 is supplied, the heat generating material holding body 21 is made of a nonwoven fabric, so that the heat generating material 40 can be held in the internal space and the surface, and the overlapping member 22 contains a resin. Since it forms a sheet, the heat generating material 40 supplied into the heat generating material holder 21 can be received by the overlapping member 22 even if it is dropped from the lower part of the heat generating material holder 21. Thereby, an amount of the heat generating material 40 to be enclosed in the packaging material 30 can be reliably held by the core material 20.

  Note that the overlapping member 22 may have a shape other than the sheet shape as long as it can receive the heat generating material 40 that has fallen off from the heat generating material holder 21. For example, the heat generating material holder 21 can be formed in a tray shape that can be received in the recess, and the shape of the overlapping member 22 can be appropriately selected.

(4) The accommodation process in the packaging material 30 Next, the core material 20 is accommodated in the packaging material 30 (FIG.2 (e)-(g)). The packaging material 30 includes a first nonwoven fabric 31 and a first resin sheet 32 disposed outside the overlapping member 22, and a second resin sheet 33 and a second nonwoven fabric 34 disposed outside the heat generating material holder 21. Prepare.

  The first nonwoven fabric 31, the first resin sheet 32, the second resin sheet 33, and the second nonwoven fabric 34 are sheet-like members having substantially the same rectangular shape in plan view. The core material 20 is surrounded by the first resin sheet 32 and the second resin sheet 33, and the first resin sheet 32 and the second resin sheet 33 are covered with the first nonwoven fabric 31 and the second nonwoven fabric 34. The packaging material 30 is fixed by ultrasonic welding at a peripheral edge portion 30a corresponding to four sides of the rectangular shape.

  The first resin sheet 32 and the second resin sheet 33 are formed into a sheet shape by, for example, rolling molding using a material containing a resin (for example, polyethylene). The 1st nonwoven fabric 31 and the 2nd nonwoven fabric 34 are formed as a nonwoven fabric comprised with the material containing resin (for example, polypropylene). Immediately after the first resin sheet 32 or the second resin sheet 33 is formed by rolling, the first nonwoven fabric 31 and the second resin sheet 32, the second nonwoven fabric 34 and the second nonwoven fabric 34 are bonded by pressing the first nonwoven fabric 31 or the second nonwoven fabric 34. The resin sheets 33 are bonded to each other. A through hole 30 b is formed in the joined second nonwoven fabric 34 and second resin sheet 33. By forming the through hole 30b, air permeability is ensured with respect to the heat generating material holding body 21, and outside air is introduced into the heat generating material holding body 21 through the through hole 30b, so that the heat generating material 40 can generate heat.

  Next, a procedure for housing the core material 20 in the packaging material 30 will be described. First, the bonded first non-woven fabric 31 and the first resin sheet 32 are placed on the holding base 51 so that the first resin sheet 32 faces upward, and the core material 20 is overlapped by the overlapping member 22 of the first resin. The sheet 32 is placed in contact with the sheet 32 (FIG. 2E). The peripheral portions 31 a and 32 a of the first nonwoven fabric 31 and the first resin sheet 32 are placed on the end portion 51 a of the holding base 51.

  Subsequently, the bonded second nonwoven fabric 34 and the second resin sheet 33 are stacked and placed so that the second resin sheet 33 is in contact with the heat generating material holder 21. At this time, the peripheral portions 33a and 34a of the second resin sheet 33 and the second non-woven fabric 34 are stacked on the peripheral portions 31a and 32a of the first resin sheet 31 and the first non-woven fabric 32 (that is, on the holding stand 51). The A holding table 52 having an ultrasonic horn is disposed at a position facing the holding table 51 (on the second non-woven fabric 34), and is laminated by an end 52a of the holding table 52 and an end 51a of the holding table 51. The peripheral edges 31a, 32a, 33a, and 34a in the state are sandwiched (FIG. 2 (f)). In this state, when an ultrasonic wave is applied to the peripheral portion 30a by the ultrasonic horn, the peripheral portion 32a of the first resin sheet 32 and the peripheral portion 33a of the second resin sheet 33 are ultrasonically welded to each other to form the packaging material 30. The core material 20 is enclosed inside (FIG. 2 (g), FIG. 3). Thereby, the heating element 10 as shown in FIG. 1 is completed.

  Below, a modification is demonstrated, referring FIG.4 and FIG.5. FIG. 4 is a cross-sectional view corresponding to FIG. 2G, showing the configuration of the heating element according to the modification. FIG. 5 is a partially enlarged cross-sectional view taken along line V in FIG. 4, showing the configuration of the heating element according to the modification.

  In the heating element 110 according to the modified example, an adhesive layer 135 and a release layer 136 are used instead of the first nonwoven fabric 31 of the above-described embodiment. In this heating element 110, the core material 20 is accommodated in the packaging material 130. It has become the composition.

  The packaging material 130 has the same configuration as the first resin sheet 32, the second resin sheet 33, and the second nonwoven fabric 34 of the packaging material 30 of the above-described embodiment, and the first resin sheet 132, the second resin sheet 133, and the nonwoven fabric. 134, and further includes an adhesive layer 135 and a release layer 136 on the first resin sheet 132 side. The second resin sheet 133 and the nonwoven fabric 134 are joined in advance similarly to the above-described embodiment, and further, a through hole 130b is formed. The adhesive layer 135 and the release layer 136 are formed in advance on the first resin sheet 132 using a known material, and the first resin sheet 132, the adhesive layer 135, and the release layer 136 have substantially the same planar shape. A sheet-like member is formed. Here, as the adhesive layer 135, for example, a solventless hot melt adhesive may be used, and a release layer 136 such as release paper is formed in order to ensure this adhesiveness until use.

  As with the packaging material 30 of the above-described embodiment, the packaging material 130 is bonded to the first resin sheet 132 and the second resin sheet 133 by ultrasonic welding of the peripheral edge portion 130a. The heating element 110 having such a configuration is used by peeling the release layer 136 from the adhesive layer 135 and adhering it to a predetermined part (for example, on the underwear) by the adhesive force of the adhesive layer 135.

By providing the above-described configuration and manufacturing through the above-described processes, the heating element according to the above-described embodiment and the modified example has the following effects.
(1) Since the heat generating material 40 can be uniformly disposed in the voids in the heat generating material holding body 21 or the surface of the heat generating material holding body 21, the deviation and uneven distribution of the heat generating material 40 can be suppressed. Therefore, it is possible to reliably and uniformly heat the entire desired range.

(2) Since the heat generating material holding body 21 and the overlapping member 22 are fixed by ultrasonic welding, for example, the overlapping member is in a state where the heat generating material holding body 21 which is a non-woven fabric does not melt as compared with the case where it is fixed by thermal welding. Adhesion with 22 can be realized. Therefore, the elastic softness of the nonwoven fabric can be left, and the heating element 10 (110) that is comfortable to the user can be provided even if the core material 20 is provided.

(3) Since the overlapping member 22 is provided for the heat generating material holding body 21 that holds the heat generating material 40, the core material is held in the heat generating material holding body 21 inside or on the surface. Even when 20 is vibrated or moved, the heat generating material 40 that falls off the heat generating material holder 21 during the vibration or movement can be received by the overlapping member 22. That is, even if the core member 20 is vibrated by the vibrating table 50 in the heat generating material supply step, the core member 20 can include a predetermined amount of the heat generating material 40 to be enclosed in the packaging material 30. Also, when the core material 20 holding the heat generating material 40 of the predetermined material is moved to be placed so that the overlapping member 22 is in contact with the first resin sheet 32 in the housing step in the packaging material 30. The overlapping member 22 receives the heat generating material 40 that falls off the heat generating material holder 21 by the moving operation, so that the first resin sheet 32 can be prevented from falling onto the peripheral portion 32a, and the ultrasonic waves at the peripheral portion 30a of the packaging material 30 can be prevented. Assured welding can prevent leakage of the heat generating material 40 from the packaging material 30.

(4) The first nonwoven fabric 31, the first resin sheet 32, the second resin sheet 33, and the second nonwoven fabric 34 that constitute the packaging material 30, and the heating material holder 21 and the heating material holder that constitute the core material 20. Any of 21 may be made of a material containing a resin such as polypropylene or polyethylene, and an existing inexpensive material may be used, so that an increase in material cost can be prevented.

(5) Since the structure is simple, the manufacturing cost of the heating element 10 (heating element 110) can be reduced.

It is a top view which shows the structure of the heat generating body which concerns on embodiment of this invention. It is sectional drawing in the II-II line | wire of FIG. 1 which shows the manufacturing process of the heat generating body which concerns on embodiment of this invention. It is the elements on larger scale in III of FIG. 2 which shows the structure of the heat generating body which concerns on embodiment of this invention. It is sectional drawing corresponding to FIG.2 (g) which shows the structure of the heat generating body which concerns on a modification. It is the elements on larger scale in V of Drawing 4 showing the composition of the heating element concerning a modification.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Heat generating body 20 Core material 21 Heat generating material holding body 22 Overlay member 30 Packaging material 30a Peripheral part 30b Through-hole 31 1st nonwoven fabric 31a Peripheral part 32 1st resin sheet 32a Peripheral part 33 2nd resin sheet 33a Peripheral part 34 2nd nonwoven fabric 34a peripheral edge 40 heating material 110 heating element 130 packaging material 130a peripheral edge 130b through hole 132 first resin sheet 132a peripheral edge 133 second resin sheet 133a peripheral edge 134 non-woven fabric 134a peripheral edge 135 adhesive layer 135a peripheral edge 136 peeling layer 136a peripheral edge Part

Claims (9)

A heating element comprising: a heat generating material; a core material that holds the heat generating material; and a packaging material that houses the core material,
The core material is
A heat-generating material holder capable of holding the heat-generating material inside and / or on the surface;
And a stacking member provided so as to overlap the heat generating material holding body.   The heating element according to claim 1, wherein the core material has at least a two-layer structure including the heating material holder and the overlapping member.   The heating element according to claim 1 or 2, wherein the heating material holder is made of a material having a gap into which the heating material enters.   The heating element according to any one of claims 1 to 3, wherein the heating material holder is made of a nonwoven fabric.   The heating element according to any one of claims 1 to 4, wherein the heating material holder includes polypropylene, and the overlapping member includes polyethylene.   The heating element according to any one of claims 1 to 5, wherein the heating material holder and the overlapping member are ultrasonically welded.   The heating element according to any one of claims 1 to 6, wherein the heating material holder and / or the overlapping member have a hardness capable of maintaining an outer shape of the core material. . A heat generating material, a core material that holds the heat generating material, and a packaging material that houses the core material,
The core material is a method for producing a heating element, comprising: a heating material holder that holds the heating material inside and / or on the surface; and a stacking member that is provided to overlap the heating material holder,
Forming the heat generating material holder;
Fixing the overlapping member to the heat generating material holder;
A step of supplying the heat-generating material from a portion of the heat-generating material holder that is not provided with the overlapping member.   9. The method of manufacturing a heating element according to claim 8, further comprising a step of guiding the heating material into the heating material holder by vibrating the core material after the heating material is supplied.

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