JP2009090020A - Heater unit for cushion, and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a heater unit for cushion which is improved in durable performance in a heat generation wire by preventing the deviation of the heat generation wire in the heater unit during usage and the addition of unreasonable force on the heat generation wire in a heat generating cushion with a structure where a cuhsion member and the heater unit are laminated and covered with a surface material, and to provide its manufacturing method. <P>SOLUTION: The cushion is composed of: the cushion member; the heater unit; and the surface material. In the heater unit, the heat generation wire is sewed onto a nonwoven fabric by fixed pitch, Then, another nonwoven fabric with an adhesive applied thereon is superimposed on the surface with the heat generation wire sewed thereon, and the heat generation wire is held by adhesion. Accordingly, the heat generation wire is firmly fixed to the nonwoven fabrics by the two methods of sewing and adhesion. Even when the heater unit is largely deformed, the heat generation wire keeps the held and fixed state between the nonwoven fabrics without deviating the fixed position. <P>COPYRIGHT: (C)2009,JPO&amp;INPIT

Description

  The present invention relates to a heater unit that can sufficiently withstand deformation of a cushion in a heat generating cushion having a structure in which a cushion member and a heater unit are laminated and covered with a surface material, and a manufacturing method thereof.

  The heater unit for electric carpets that has been widely used in the home for the past, for example, has a heating wire on a heat insulating material made of needle punch felt, etc. The heat insulating material and the surface material are bonded to each other by pressure bonding while melting the sheet, and the heating wire is fixed between the heat insulating material and the surface material. After that, the outer edge is frayed with an overlock sewing machine, and a controller is attached to produce an electric carpet. An electric carpet is originally used on a flat floor surface, and is not intended to be used by being greatly deformed by bending or rolling like a cushion. If an electric carpet heater unit is used for a specification that repeatedly undergoes a large deformation such as a cushion, the heating wire may be disconnected, or the wiring position of the heating wire may change, causing abnormal heat generation. (In the present invention, the heater unit refers to a heating wire and / or a member that holds the heating wire and generates heat when energized.)

  In patent document 1, the heating appliance used on a sofa is proposed, and a heater unit is fixed only at a peripheral part to protect the heater wire against load stress from the upper surface of the appliance main body or in the horizontal direction. Is described.

  Moreover, in patent document 2, in the foam molding cushion or sheet molding process, if the heating wire is interconnected and embedded with a plurality of loop shapes and a band connecting them, stress on the heating wire is not strongly applied. An electrical heater for cushions with improved durability is described.

  However, the method of fixing the heater unit only in the peripheral part as in Patent Document 1 is not suitable for cushioning because if the wire is bent or rounded and greatly deformed, the wiring position is displaced, leading to abnormal heat generation. Met. Moreover, in the method as disclosed in Patent Document 2, wiring is complicated and expensive.

JP 2001-353045 A JP 10-304949 A

  In the heat generation cushion having a structure in which a cushion member and a heater unit are laminated and covered with a surface material, the heat generation line of the heater unit is not displaced during use, and excessive stress is not applied to the heat generation line. An object of the present invention is to provide a heater unit for a cushion with improved durability performance of the heating wire and a method for manufacturing the same.

  As a result of intensive studies to solve such problems, the present inventors have first sewed a heating wire to the nonwoven fabric of the cushion heater unit with a sewing machine, and then bonded the other nonwoven fabric firmly with an adhesive to generate heat. As a result of finding out that disconnection of a wire can be prevented, the present invention provides the following means.

  [1] In a cushion composed of a cushion member, a heater unit, and a surface material, the heater unit sews heating lines to a nonwoven fabric at a constant pitch, and then applies an adhesive to the surface on which the heating lines are sewn. A method of manufacturing a heater unit for a cushion, characterized in that another non-woven fabric is laminated and the heating wire is sandwiched and adhered.

  [2] The method for manufacturing a cushion heater unit according to [1], wherein the cushion heater unit is sewn so that a sewing angle at which the heating wire is sewn to the nonwoven fabric is 40 to 50 degrees.

  [3] A cushion heater unit manufactured by the method of 1 or 2 above.

  In the invention of [1], in the cushion composed of a cushion member, a heater unit, and a surface material, the heater unit sews heating lines to a nonwoven fabric at a constant pitch, and then, to the surface where the heating lines are sewed, Since another non-woven fabric coated with adhesive is stacked and the heating wire is pinched and bonded, the heating wire of the heater unit is firmly fixed to the non-woven fabric by two methods of sewing and bonding, and the surface material together with the cushion member Even if the heater unit is greatly deformed in accordance with the deformation of the cushion member and the surface material, the heating wire is firmly held between the nonwoven fabrics without shifting the fixed position. can do.

  In the invention of [2], in the heater unit, the heating wire is sewn to the nonwoven fabric so that the sewing angle is 40 to 50 degrees. Therefore, even if the heater unit is greatly deformed in accordance with the deformation of the cushion member and the surface material, the method of manufacturing the heater unit for the cushion firmly held between the nonwoven fabrics without shifting the position where the heating wire is fixed, and can do.

  In the invention of [3], since it is a heater unit manufactured by the method of the preceding item 1 or 2, it can be used as a heater unit for a cushion body having a large deformation, such as a cushion, a cushion, a bed, and a sofa. it can.

  The cushion heater unit 1 according to the present invention can be used, for example, as a heater unit sandwiched between cushion members of a circular electric cushion as shown in FIG. The heater unit 1 is sandwiched between the cushion members 2 and 3 made of a pair of upper and lower urethane foam resins of the electric cushion and placed in the surface material 5, and the periphery of the surface material is fastened with a fastener 6 to form a circular electric cushion. When a person is seated, the cushion members 2 and 3 are moderately elastically deformed to support the load. At this time, the heater unit 1 between the cushion members 2 and 3 is also deformed in the same manner as the cushion members 2 and 3, but the heating wire 4 is firmly fixed to the non-woven fabric by sewing and bonding. Since the load is supported by the strength of the two non-woven fabrics, the heating wire 4 is not stressed, the heating wire 4 is disconnected, or the wiring position of the heating wire 4 is not changed and the heater unit 1 does not generate abnormal heat. can do.

  As shown in FIG. 1 and FIG. 2, the heater unit 1 of the present invention includes, for example, a pair of upper and lower nonwoven fabrics 7, a heating wire 4, a sewing thread 8 for fixing them, and an adhesive layer 9. The pair of upper and lower nonwoven fabrics 7 is not particularly limited as long as it can be bonded with an adhesive, but a polyester needle punch felt is preferable. Polyester needle punch felts are inexpensive and have excellent heat insulation properties, and are used in many electric carpets and the like.

  As the heating wire 4, it is preferable to use a wire material in which the heater wire is covered with a resin such as vinyl chloride. In order to fix the heating wire 4 to the non-woven fabric, for example, a wiring pattern as shown in FIG. 2 is marked on the non-woven fabric, and the heating wire 4 is fed along the mark while sewing while moving the needle in a zigzag manner. The heating wire 4 is sewn on the nonwoven fabric. At this time, as shown in FIG. 3, it is preferable that the sewing angle 8 of the sewing thread 8 and the heating wire 4 for sewing the heating wire 4 in a zigzag manner is 40 to 50 degrees. At an acute angle of less than 40 degrees, the sewing pitch becomes long, the degree of freedom of the heating wire 4 increases, and wiring misalignment tends to occur. On the other hand, when the angle exceeds 50 degrees, the sewing pitch becomes too fine, and the production efficiency is deteriorated.

  The sewing machine is preferably a staggered sewing machine. The staggered sewing machine is a sewing machine that sews while swinging the needle from side to side. The heating wire 4 is supplied through the pipe according to the feed amount of the nonwoven fabric 7, and the needle of the staggered sewing machine is swung from side to side at the tip of the pipe. The sewing thread 8 at this time is not particularly limited, but a polyester thread is often used. The pitch of the staggered sewing machine and the tightening strength of the heating wire 4 are adjusted according to the thickness of the heating wire 4.

Next, a non-woven fabric of the same size as the non-woven fabric sewn with the heating wire 4 is pre-coated with vinyl acetate resin in a separate process. Thus, the heater unit 1 can be obtained.

<Example 1>
A method for carrying out the present invention will be specifically described. In addition, the heater unit of this invention and its manufacturing method are not limited to an Example.
As shown in FIG. 1, for example, the heater unit is sandwiched between cushion members of a circular electric cushion. As the surface material, the entire surface of the laminate in which the heater unit was sandwiched between two circular cushion members was covered, and the peripheral portion was wrapped with a fastener. As the cushion member, circular cushion members having different thicknesses of urethane foam were prepared. (Upper cushion member thickness 30 mm, lower cushion member thickness 50 mm) As the nonwoven fabric of the heater unit, ^two needle punch felts made of polyester recycled cotton with a basis weight of 2 mm and a basis weight of 300 g / m ² were prepared. What applied the adhesive layer of vinyl acetate 20g / m < ² > was prepared. On another sheet of nonwoven fabric, a line was drawn on the wiring pattern as shown in FIG. 2, and the heating wire 4 was sewn with a staggered sewing machine (SZ-21-5N manufactured by STAGER) according to the line. As the heating wire 4, a wire material having a diameter of 4 mm and a heater wire covered with a vinyl chloride resin was prepared, and the pitch of the staggered sewing machine was 4 mm. Next, the non-woven fabric coated with a vinyl acetate adhesive layer was laminated on the non-woven fabric sewn with the heating wire, and the non-woven fabric was bonded to each other with a heat press. Next, the ends of the two heating wires 4 were connected to a controller to form a heater unit for an electric cushion. Next, the heater unit was sandwiched between the two cushion members described above, housed in the surface material 5 as shown in FIG. 1, and the periphery was fastened with fasteners 6 to form an electric cushion. A bending endurance test of the electric cushion obtained in this way was conducted, but there was no deformation of the heater unit and no breakage of the heating wire was observed.

<Comparative Example 1>
In Example 1, an electric cushion was prepared in the same manner as in Example 1 except that the exothermic wires 4 were not sewn by the staggered sewing machine, and the non-woven fabrics were bonded together to sandwich the exothermic wires 4. In the durability test, there was partial peeling on the bonding surfaces of the nonwoven fabrics, and the heating lines were deformed, resulting in positional deviation.

<Durability test>
The work of bending the electric cushion to 4 times at random and returning it to its original state is one cycle. After repeating this work 5000 times, observe the appearance of the heater unit, check for the presence of disconnection and check the temperature. Judged.

It is the schematic of the electric cushion concerning one Embodiment of this invention. It is the schematic which shows the wiring condition of the heater unit concerning one Embodiment of this invention. It is the schematic which shows the relationship between the heating wire 4 and the sewing angle 10 of the heater unit concerning one Embodiment of this invention.

Explanation of symbols

1. Heater unit for cushion 2. Cushion member 3. Cushion member 4. Heating wire 5. Surface material 6. Fastener 7. Nonwoven fabric 8. Sewing thread 9. Adhesive layer 10. Sewing angle

Claims (3)

  In the cushion composed of a cushion member, a heater unit, and a surface material, the heater unit sews heating lines to a non-woven fabric at a constant pitch, and then another surface in which an adhesive is applied to the surface on which the heating lines are sewed. A method for manufacturing a heater unit for a cushion, characterized in that non-woven fabrics are stacked and heating wires are sandwiched and bonded.   The method for manufacturing a cushion heater unit according to claim 1, wherein the cushion heater unit is sewn so that a sewing angle at which the heating wire is sewn to the nonwoven fabric is 40 to 50 degrees.   The heater unit for cushions manufactured by the method of Claim 1 or 2.

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