JP2012119167A - Planar heater - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a planar heater excellent in a cushioning property and durable strength capable, which can be produced without using a foam press-molding die.SOLUTION: The planar heater comprises: a surface material 200; and a rear surface material 600 provided on a lower side of a heat insulation sheet 500 provided on a lower side of a planar heater unit 400, in which a heater wire 420 is arranged on a lower surface of a uniform heat sheet 410 coated with an adhesive 412 containing resin on both of upper and lower surfaces of a metallic sheet 411. In the heat insulation sheet 500, nonwoven fabrics 502 and 503 are adhered on both of upper and lower surfaces of a foam sheet 501. Thereby, the planar heater excellent in a cushioning property and durable strength can be produced without using a foam press-molding die.

Description

  The present invention relates to a surface heating device using an electric heater as a heat source.

  Conventionally, this type of surface heating device is manufactured by applying a urethane foam material on a backing and laminating a heater unit having a heater wire on a base material and a surface material, and then depositing these on a gold plate. It is press-molded in the mold. At this time, the urethane foam material is foamed, and the foaming pressure causes the urethane foam material to ooze out from the base material side of the heater unit and adhere to the front material, thereby bonding the backing material, the heater unit and the front material together. (For example, refer to Patent Document 1).

  FIG. 11 shows a conventional planar warming tool described in Patent Document 1, in which (a) shows a perspective view showing the creation order of the planar warming tool, and (b) shows a side view of the creation order. And (c) shows a cross-sectional view of a planar warming tool after molding. As shown in (a), a front material 1, a heater unit 3 in which a heater wire 3b is disposed on a heater base material 3a, and a backing material 5 having a urethane foam material 4 applied on the surface are prepared, and (b) As shown in the drawing, by laminating them and placing them in a mold and press molding them in the mold, the planar warming tool shown in (c) is molded.

JP 2001-041480 A

  However, in the conventional planar warming tool, it is essential to prepare a mold in order to perform press molding processing at the time of manufacture, and it is necessary to prepare the mold for each shape and size of the planar warming tool In particular, it is common to produce many sizes of surface heating devices that are installed and used on the floor surface, which increases the cost required to manufacture the mold, and surface heating devices of different shapes and sizes. Since it is necessary to replace the mold when producing the tool, it is difficult to improve the production efficiency. From these viewpoints, there is still room for improvement.

  The present invention solves the above-described conventional problems, and enables the production of a planar warming tool without using a foam press molding die, and provides a planar warming tool excellent in cushioning and durability. Objective.

In order to solve the conventional problem, the surface warming tool of the present invention includes a surface material,
A soaking sheet in which an adhesive containing resin is coated on both upper and lower surfaces of the metal sheet;
A planar heater unit in which a heater wire is disposed on the lower surface of the soaking sheet;
A heat insulating sheet provided on the lower surface side of the heater unit;
A back surface material provided on the lower surface side of the heat insulating sheet;
With
The heat insulating sheet is characterized in that a nonwoven fabric is bonded to the upper and lower surfaces of a foam sheet.

Accordingly, a surface material, a heat-uniforming sheet coated with an adhesive containing resin on the upper and lower surfaces of the metal sheet, a planar heater unit in which a heater wire is disposed on the lower surface of the heat-heating sheet, and a foam sheet Heater sheet 3 can be manufactured by laminating and adhering a heat insulating sheet and a back material with nonwoven fabric bonded on both upper and lower surfaces, and a heater unit 3 in which heater wire 3b is arranged on surface material 1 and heater base material 3a at the time of manufacture as in the past. And a surface heating device without using a foam press molding die such as laminating a backing material 5 coated with a urethane foam material 4 on the surface and foaming urethane resin in the die to perform press molding. Can be produced.

  In this case, by laminating the surface material, the heater unit, and the heat insulating sheet in this order, and heating these laminates by electromagnetic induction heating, the heat for melting the adhesive resin is inside the planar warming tool. Since heat is generated from the metal sheet, the adhesive resin can be melted in a short time, so that the bonding work can be carried out in a short time, and wasteful heat radiation can be suppressed outside the surface heating device, so that the manufacturing process Energy saving. In addition, it does not use a foam press molding die that presses the surface warming tool by foaming urethane resin in the processing process, thus reducing mold investment costs and capital investment costs and improving design flexibility. be able to.

  In addition, since the non-woven fabric is bonded to the upper and lower surfaces of the foam sheet, the non-woven fabric of the upper and lower surfaces of the foam sheet and some of the fibers of the non-woven fabric bite into the foam sheet to obtain a strong adhesive force. Not only that, the tear strength is enhanced on both sides of the foam sheet, and even if the surface heating tool is folded, it can be prevented from partially peeling or tearing. In both cases, an excellent surface warmer can be obtained.

  The planar warming tool of the present invention enables production of a planar warming tool without using a foam press molding die, and can provide a planar warming tool excellent in cushioning properties and durability strength.

The perspective view which shows the external shape of the planar warming tool in Embodiment 1 of this invention The perspective view which shows the state before the assembly of the main body in Embodiment 1 of this invention Sectional drawing which shows the completion state of the main body in Embodiment 1 of this invention Sectional drawing which shows the detail of the structural member of the main body in Embodiment 1 of this invention The perspective view which shows the detail of the heater wire in Embodiment 1 of this invention The schematic diagram which shows the preparation process of the main body in Embodiment 1 of this invention The schematic diagram which shows the heating process and press process of a main body in Embodiment 1 of this invention Schematic diagram showing the hot pressing process of the main body in Embodiment 1 of the present invention The schematic diagram which shows the ultrasonic welding process of the main body in Embodiment 1 of this invention Schematic diagram showing the trimming process of the main body in the first embodiment of the present invention (A) is a perspective view which shows the manufacturing order of the conventional planar warmer, (b) is sectional drawing which shows the manufacturing order of a planar warmer, (c) is sectional drawing which shows the completion state of a planar warmer

The first invention is a surface material;
A soaking sheet in which an adhesive containing resin is coated on both upper and lower surfaces of the metal sheet;
A planar heater unit in which a heater wire is disposed on the lower surface of the soaking sheet;
A heat insulating sheet provided on the lower surface side of the heater unit;
A back surface material provided on the lower surface side of the heat insulating sheet;
With
The heat insulating sheet is a planar warming tool in which a nonwoven fabric is bonded to both upper and lower surfaces of a foam sheet.

Thereby, a surface material, a soaking sheet coated with an adhesive containing resin on the upper and lower surfaces of the metal sheet, and a planar heater unit in which a heater wire is disposed on the lower surface of the soaking sheet,
It can be manufactured by laminating and bonding a heat insulating sheet having a nonwoven fabric bonded to both the upper and lower surfaces of the foamed sheet and a back material, and the heater wire 3b is disposed on the surface material 1 and the heater base material 3a at the time of manufacturing as in the past. Surface heating device without using a mold such as laminating a heater unit 3 and a backing 5 coated with urethane foam material 4 on the surface and foaming urethane resin in the mold and press molding. Can be produced.

  In this case, the heat for melting the adhesive resin by electromagnetically heating the laminate in which the surface material, the heater unit, the heat insulating sheet, and the back surface material are laminated is a metal sheet inside the planar warming tool. Since the adhesive resin can be melted in a short time, the bonding work can be carried out in a short time, and wasteful heat radiation to the outside of the planar warming tool can be suppressed. Energy saving can be achieved.

  Moreover, since a mold that foams urethane resin in the processing process and press-molds the surface heating device is not used, it is possible to reduce mold investment costs and capital investment costs, and improve design flexibility. .

  In addition, since the non-woven fabric is bonded to the upper and lower surfaces of the foam sheet, the non-woven fabric of the upper and lower surfaces of the foam sheet and some of the fibers of the non-woven fabric can only bite into the foam sheet to obtain a strong adhesive force. In addition, the tear strength is enhanced on both sides of the foam sheet, and even if the sheet heating tool is folded, it can prevent the problem of partial peeling or tearing. In both cases, an excellent surface heating tool can be obtained.

  In a second aspect of the invention, in particular, in the first aspect of the invention, the surface material has two fiber layers having different hardnesses between the surface sheet and the heater unit, and the surface sheet side is a hard layer. A soft layer may be provided on the heater unit side.

  Thereby, even if the planar heater unit in which the heater wire is disposed on the lower surface of the soaking sheet has irregularities, the hard fiber layer on the surface sheet side is soft and the irregularities of the heater unit on the surface sheet. It acts so as to prevent the transmission of a feeling, and when a person sits on a surface warming tool and uses it, there is no sense of incongruity and a smooth and comfortable feeling of use can be obtained.

  In a third aspect of the invention, in particular, in the first aspect of the invention, the surface material includes a non-woven fabric having a two-layer structure having an adhesive layer between the non-woven fabric and the non-woven fabric between the top sheet and the heater unit. Also good.

  Thereby, even if the planar heater unit in which the heater wire is arranged on the lower surface of the soaking sheet has irregularities, the nonwoven fabric having a two-layer structure having an adhesive layer between the nonwoven fabric and the nonwoven fabric is applied to the surface sheet. The heater unit acts so as to prevent the unevenness of the heater unit from being transmitted, and when a person sits on a surface heating device or the like, there is no sense of incongruity and a smooth and comfortable feeling of use can be obtained. That is, a slightly hard adhesive layer is formed between the nonwoven fabric and the soft nonwoven fabric is doubled on both sides of the adhesive layer, so that the transmission of the unevenness of the heater unit to the top sheet is prevented from mitigating. The In addition, the two-layered nonwoven fabric is familiar with the adhesive coated on the metal sheet of the heater unit, and strong adhesion between the top sheet and the heater unit can be obtained.

  In a fourth aspect of the invention, in particular, in the first aspect of the invention, the heat insulating sheet has a non-woven fabric bonded to both surfaces of the foam sheet, and the non-woven fabric on the heater unit side is thicker than the non-woven fabric on the back material side. Also good.

  Thus, even when a cord-like heater wire having a diameter of about 3 mm is used for the heater of the heater unit, the cord-like heater wire is formed on the non-woven fabric on the heater unit side that is thicker than the non-woven fabric on the back material side. Because it can be embedded, when a person sits on a surface heating device, etc., it can make it difficult for the person to feel unevenness due to the heater wire, and there is no sense of incongruity and a smooth and comfortable feeling of use is obtained. be able to.

According to a fifth aspect of the present invention, in particular, in the first aspect, the nonwoven fabric on the heater unit side is polyester resin 96% polypropylene resin 4% basis weight 180 g / m ² , and the back material side nonwoven fabric is polyester resin 95% polypropylene. By setting the resin weight per unit area to 100 g / m ² , the most favorable adhesion can be achieved in terms of cost effectiveness.

  In a sixth aspect of the invention, in particular, in any one of the first to fifth aspects of the invention, the laminate of the surface material, the heater unit, and the heat insulating sheet is heated by electromagnetic induction, thereby the metal of the heater unit. The surface material, the heater unit, and the heat insulating sheet are bonded to each other by heating the sheet to melt the adhesive and pressing the laminated body by a pressing unit.

  As a result, the electromagnetic induction heating device and the pressing means can be configured as separate facilities, facilitating the manufacture and maintenance of the facilities, and constructing the manufacturing process as a flow operation, thereby improving the production efficiency. Can be improved. In addition, unlike a surface heating device that is press-molded in a conventional mold, there is no need to cover the entire surface of the surface heating device with a mold, and the electromagnetic induction heating device and the pressing means start heating and pressing from a part. Since it can be performed sequentially to the entire area, the electromagnetic induction heating device and the pressing means can be handled with a small facility, so that the cost for the production facility can be reduced, and the surface heating tool of different shapes and sizes can be used. Manufacturing can be carried out with the same equipment.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the present invention is not limited to the embodiments.

(Embodiment 1)
FIG. 1 is a perspective view showing a completed state of the planar warming device in Embodiment 1 of the present invention, FIG. 2 is a perspective view showing a state before the main body of the planar warming device is assembled, and FIG. It is sectional drawing which shows the completion state of the main body of a planar warming tool, and FIG. 4 is sectional drawing which shows the detailed structure of the member which comprises a main body.

<Structure of the surface heating device>
As shown in FIG. 1, the surface warmer has a control unit 101 disposed at one end of a main body 100 composed of a plurality of sheet-like members, and power is supplied by a power cord 102 connected to the control unit. It is a warming tool used by heating 100 and installing it on the floor of a house.

  As shown in FIG. 2, the main body 100 of the surface warmer has a front material 200, an adhesive sheet 300, a heater unit 400, a heat insulating sheet 500, and a back material 600 as main constituent members, and as shown in FIG. 3 are formed in a cross-sectional shape as shown in FIG. 3 by sequentially laminating, bonding these members, and compressing and sealing the peripheral portion. The adhesive sheet 300 is not always necessary for the reason described later.

As shown in FIG. 4, the surface material 200 is the outermost member of the main body 100 of the planar warming tool and has necessary performance such as design, contamination resistance, and tactile sense as well as mechanical strength. And a two-layered nonwoven fabric having an adhesive layer 204 between a polyester nonwoven fabric 202 and a nonwoven fabric 203 on the back surface of a colored and patterned surface sheet 201, the main component of which is vinyl chloride resin (hereinafter referred to as PVC). Bonded to form a sheet.

  The adhesive sheet 300 is formed by molding a polyethylene resin into a sheet shape, forms a flexible sheet shape at room temperature, and melts at about 97 ° C. or more to exhibit a function as an adhesive.

  The heater unit 400 is a heat source for the surface heating device, and includes a heater wire 420 arranged in a meandering shape on one side of a soaking sheet 410 mainly composed of aluminum.

  The soaking sheet 410 is a member for the purpose of uniformly diffusing the heat generated by the heater wire 420 over the entire surface of the main body 100, and has a thickness of about 0.01 mm whose main component is aluminum, which is a metal sheet with high thermal conductivity. An aluminum sheet 411 is used as a base material, and both surfaces thereof are coated with an adhesive resin 412 made of polyethylene resin, and the adhesive resin 412 made of polyethylene resin is melted by being heated to about 97 ° C. or more to form an adhesive. As a function. As described above, the adhesive sheet 412 made of polyethylene resin is coated on the upper and lower surfaces of the aluminum sheet 411 which is a metal sheet, so that the adhesive sheet 300 is not necessarily required, and the surface can be obtained even if the adhesive sheet 300 is omitted. There is no particular problem in the adhesion between the material 200 and the heater unit 400.

  As shown in FIG. 5, the heater wire 420 is formed by spirally winding a detection wire 422 for detecting temperature around a central glass fiber 421, forming an insulating layer 423 with nylon resin on the outer periphery, and forming the insulating layer 423. A heating wire 424 is spirally wound on the outer periphery, a PVC insulating layer 425 is formed on the outer periphery, and an adhesive layer 426 made of polyethylene resin is formed on the outer periphery of the insulating layer 425.

  As shown in FIG. 2, the heater unit 400 has the start end of the heater wire 420 arranged at one corner of the soaking sheet 410 and is arranged in a meandering shape so as to cover the entire area of the soaking sheet 410. Is arranged in the vicinity of the starting edge. As shown in FIG. 2, by applying heat with the heater wire 420 disposed, the adhesive layer 426 of the heater wire 420 is melted and bonded and fixed to the soaking sheet 410.

  The heat insulating sheet 500 is provided for the purpose of suppressing the heat generated by the heater unit 400 from being wastedly transmitted to the floor surface and dissipated, and is a foamed sheet 501 that is a sheet-like foamed urethane resin having high heat insulating properties. The polyester resin nonwoven fabrics 502 and 503 are bonded to both the upper and lower surfaces.

The upper surface of the foam sheet 501, that is, the nonwoven fabric 502 on the heater unit 400 side has a polyester resin 96% polypropylene resin 4% basis weight of 180 g / m ² , and the lower surface of the foam sheet 501, that is, the polyester resin 95% polypropylene of the nonwoven fabric 503 on the back material 600 side. The thickness is made thicker than the resin 5% basis weight of 100 g / m ² .

  The back material 600 is a member that comes into direct contact with the floor surface of the main body 100 of the planar warming tool, and has mechanical strength as well as performance such as cushioning properties and resistance to slipping, and is an olefin-based elastomer having elasticity. The back surface sheet 601 (hereinafter referred to as TPO) is coated with an adhesive layer 602 made of polyethylene resin. Note that an adhesive sheet 300 may be used instead of the coating of the polyethylene resin adhesive layer 602.

In the planar warmer in the present embodiment, the control unit 101 is installed at the corner of the main body 100 formed by assembling the above-described components, and the start and end of the heating wire 424 of the heater unit 400 are connected to the control unit 101. Thus, the heat generating function of the planar warming tool can be exhibited.

<Manufacturing process of main body>
FIG. 6 is a schematic view showing a cross section of a preparation process in the manufacturing process of the main body, FIG. 7 is a schematic view showing a cross section of a heating process and a pressing process of the main body, and FIG. FIG. 9 is a schematic view showing a cross section of a hot press process for forming, FIG. 9 is a schematic view showing a cross section of an ultrasonic welding process for welding a peripheral part of the main body, and FIG. 10 is a cutting of an unnecessary part of the peripheral part of the main body. It is a schematic diagram which shows the cross section of the trimming process to perform.

  As shown in FIG. 6, in the preparation process, the adhesive layer 602 of the back material 600 is placed on a horizontal platform 710, the heat insulating sheet 500 is stacked thereon, and the heater wire of the heater unit 400 is placed thereon. The adhesive sheets 300 are stacked so that 420 is on the lower side, and the non-woven fabric 202 of the surface material 200 is stacked on the adhesive sheet 300 thereon.

  In this step, as shown in FIG. 4, the heater unit 400 has an outer dimension smaller than that of other members. Therefore, it is important to arrange the heater unit 400 at the center of the heat insulating sheet 500. The members of the main body 100 laminated in the preparation process are then sent to the heating process.

  As shown in FIG. 7, the processing equipment for the heating process includes a conveying means 720 for placing the main body 100 and moving it horizontally as indicated by an arrow A, and a heating coil larger than the width of the main body 100. The electromagnetic induction heating device 721 plays a valuable role.

  When the main body 100 stacked in the preparation process is moved in the horizontal direction indicated by the arrow A by the conveying means 720 and magnetic lines of force are generated from the heating coil 722 of the electromagnetic induction heating device 721 disposed above, the aluminum sheet of the heater unit 400 is obtained. An eddy current is generated in 411, and the aluminum sheet 411 itself heats up due to the eddy current and the resistance of the aluminum sheet 411. The adhesive resin 412 made of polyethylene resin coated on both surfaces of the aluminum sheet 411 and the adhesive sheet 300 adhered and laminated on the heater unit 400 are melted by the heat generated from the aluminum sheet 411. Since the adhesive resin 412 made of polyethylene resin and the adhesive sheet 300 are melted in a few seconds, the electromagnetic induction heating device 721 is operated while the main body 100 is moved at a predetermined speed by the conveying means 720 to continuously cover the entire surface of the main body 100. Can be melted.

  As described above, when the adhesive sheet 300 is not used, the adhesive resin 412 coated on the aluminum sheet 411, which is a metal sheet, performs the same adhesive action instead of the adhesive sheet 300, so the adhesive sheet 300 is omitted. There is no hindrance. By using this adhesive sheet 300, the amount of so-called adhesive (adhesive resin) can be increased more than in the case of coating. Therefore, depending on the type of nonwoven fabric 202 of the surface material 200, the adhesive strength required without increasing the adhesive It is effective when cannot be obtained.

  When the surface material 200, the heater unit 400, the heat insulating sheet 500, and the back surface material 600 are laminated and these laminates are heated by electromagnetic induction, the distance between the heating coil 722 of the electromagnetic induction heating device 721 and the aluminum sheet 411 is kept constant. It is important that the laminated main body 100 is lightly pressed and moved while maintaining a predetermined thickness.

  Further, the heater unit 400 is arranged so that the heater wire 420 is on the lower side. By arranging the aluminum sheet 411 so as to oppose the heating coil 722 of the electromagnetic induction heating device 721, the distance between the heating coil 722 and the aluminum sheet 411 can be easily maintained, and the entire surface of the aluminum sheet 411 can be uniformly heated. it can.

  In addition, by arranging the heating coil 722 and the heater wire 420 of the electromagnetic induction heating device 721 via the aluminum sheet 411, heat generation of the heater wire 420 itself can be suppressed, and temperature unevenness can be suppressed, so that it is stable. A heating effect can be obtained.

  As shown in FIG. 7, the pressing step is a step that is performed continuously and integrally with the heating step, and the equipment necessary for this step is equipment that can press the main body 100 continuously. In this embodiment, as shown in FIG. 7, a pressing roller 730 is used in which both the upper and lower rollers are rotationally driven in the direction of arrow B and pressed from above as indicated by arrow C.

  It is essential that the driving speed of the pressing roller 730 be linked to the heating time of the heating process, and it is important that the pressing roller 730 be arranged close to the heating coil 722 so that the resin melted by the heating process can be pressed in as short a time as possible. In the present embodiment, the heating process equipment and the pressing process equipment are integrally configured. By pressing in the pressing step, the surface material 200, the heater unit 400, and the heat insulating sheet 500 are bonded via the adhesive resin 412 made of polyethylene resin and the adhesive sheet 300.

  The next hot press process is a process in which two different operations are performed simultaneously. As shown in FIG. 8, the equipment necessary for this process is a hot press 740, and the lower die 741 of the hot press 740 has an entire surface of the main body 100. The upper die 745 is provided with a hot plate 746 for press-molding the periphery of the main body 100.

  In this process, the back surface material 600 is bonded and the peripheral portion of the main body 100 is stepped, and the back surface material 600 is heated by the hot plate 742 disposed on the lower die 741, so that the back surface sheet 601 of the back surface material 600 is formed. The back surface material 600 and the heat insulating sheet 500 are bonded together by melting the adhesive layer 602 coated on the upper surface and pressing it with a hot press. Further, by pressing the peripheral part of the main body 100 while heating it with the hot plate 746 provided in the upper mold 745, the peripheral mold is formed by pressing so as to reduce the peripheral thickness. The end portion of the hot plate 746 is formed on the phase 747 so that the phase is molded inward of the stepped portion.

  The next ultrasonic welding step is a step of welding the peripheral portion of the main body 100 that has been press-molded in the hot press step, and the equipment used in this step is along the peripheral portion of the main body 100 as shown in FIG. This is an ultrasonic welding machine 750 provided with a moving horn 751.

  Since the heater unit 400 has a smaller outer dimension than other members, the peripheral part of the main body 100 is composed of a surface material 200, an adhesive sheet 300, a heat insulating sheet 500, and a back material 600, all formed of a thermoplastic resin material. It consists of They are thinly formed by step press molding in the preceding heat press step, and by applying ultrasonic waves to the step press portion, the joint portion of each member can be heated and melted and reliably welded. The horn 751 to which ultrasonic waves are applied sequentially welds while moving the stepped portion.

  The final trimming process is a finishing process in which unnecessary portions around the periphery of the main body 100 are cut off and shaped, and the equipment used in this process simultaneously cuts the width direction on both sides of the main body 100 as shown in FIG. There are two disk-shaped cutters 760 and one cutter 760 that cuts while moving in the length direction.

  The unnecessary part of the stepped portion subjected to ultrasonic welding is cut off while moving the disk-shaped cutter 760 in the width direction and the length direction, and the main body 100 is finished to a predetermined dimension.

As described above, the planar warming device in the present embodiment is capable of melting the resin by causing the electromagnetic sheet heating device 721 to heat the aluminum sheet 411 itself, which is a member of the heater unit 400, in the manufacturing process of the main body. The necessary heat is generated from the aluminum sheet 411 that is in direct contact with the resin, and is sandwiched between the surface material 200, the heat insulating sheet 500, and the back surface material 600 with the aluminum sheet 411 that is a heat source as the center. Since it is possible to suppress wasteful heat dissipation to the resin, the resin can be melted with a much smaller amount of heat compared to a heating method in which heat is applied from the outside, and less power is required for heating, resulting in a high energy saving effect. be able to.

  In addition, since the temperature of the surface portion of the main body 100 does not increase by generating heat from the inside of the main body 100, the material used for the surface portion, for example, the surface material 200 having a low heat-resistant temperature can be used. It is.

  The aluminum sheet 411 is an essential component provided for the purpose of uniformly diffusing the heat generated by the heater wire 420 over the entire surface of the main body 100 when the sheet heating device is originally used. In addition to the original function, the aluminum sheet 411 is a manufacturing process. However, it is utilized, and a very large effect can be obtained in terms of manufacturing cost and man-hours.

  In addition, since the aluminum sheet 411 as a heat source is in direct contact with the resin to be melted, it can be heated in a short time in seconds, so there is no need to heat the entire surface of the main body 100 at the same time. It becomes possible to carry out the steps of heating, melting and bonding as a flow operation. In addition, since the heating is partially performed, the electromagnetic induction heating device 721 used for heating may be a small-capacity small-sized object, which can reduce equipment costs and reduce the maximum electric capacity during processing. it can.

  In addition, in the manufacturing method using electromagnetic induction heating, a mold that is conventionally required for each size of the main body is unnecessary, and a heating coil 722 corresponding to the maximum size of the main body of the electromagnetic induction heating device is prepared. Then, since heat is generated only in the range of the aluminum sheet 411 that is a heat source, the main body 100 that is smaller than the heating coil 722 can be heated with the same equipment, and the heating process according to the size of the main body 100 Therefore, it is possible to reduce the equipment cost.

  In the present embodiment, the length in the longitudinal direction of the heating surface of the heating coil 722 of the electromagnetic induction heating device 721 is larger than the width of one side of the main body 100. And it does not include the whole surface of the main body 100 but heats a part thereof. As described above, a configuration is adopted in which the heating surface is a part of the main body 100 such that the heating surface becomes a part thereof, and the whole is heated while being sequentially fed by a roller. However, the present invention is not limited to this. For example, an object having a size smaller than the width and length of the main body 100 may be prepared, and the entire surface may be swept while sequentially sweeping from any corner of the main body 100. Furthermore, you may make it implement a press process simultaneously with a heating process. In the case of this method, the pressing step is preferably pressed by a press. When this processing method is adopted, the electromagnetic induction heating device can be handled with a small capacity, and the capital investment can be suppressed.

  In the present embodiment, in the heating step and the pressing step, the processing is performed while moving the main body 100. However, the present invention is not limited to this. The main body 100 is fixed at a fixed position, and an electromagnetic induction heating device is used. The pressing roller may be moved.

In the present embodiment, as shown in FIG. 7, in the heating process, the heater unit 400 is arranged in a direction in which the arrangement direction of the heater wire 420 and the arrow A which is the conveyance direction of the conveyance means 720 are orthogonal to each other. However, when the temperature unevenness due to heat generation of the heater wire 420 itself is large, the heater wire 420 is arranged by arranging the heater wire 420 in the direction corresponding to the arrow A and performing the heating process. In the heater wire 4 by generating currents in opposite directions.
It is possible to suppress temperature unevenness that can suppress heat generation of 20 itself.

  Moreover, in this Embodiment, although the aluminum sheet was used as a base material of the soaking | uniform-heating sheet | seat 410, it is not restricted to this, Other metals, such as copper and stainless steel, may be sufficient.

  Further, in the present embodiment, the adhesion by electromagnetic induction heating is adopted only for the adhesion of the surface material 200, the heater unit 400, and the heat insulating sheet 500, but is not limited to this, and the heat insulating sheet 500 and the back surface material 600 are bonded. It can also be used for bonding. In that case, it is necessary to sandwich a member having the same configuration as that of the soaking sheet 410 between the heat insulating sheet 500 and the back surface material 600, and if the electromagnetic induction heating device is separately prepared on the lower side as the heating equipment, the same It can be carried out in the process.

  In the present embodiment, the heater wire 420 may be attached to the soaking sheet at the same time in the first step of obtaining the soaking sheet. Moreover, you may make it carry out simultaneously in the 3rd process which provides a laminated body. Thereby, it can be set as a more efficient manufacturing process.

  Further, the planar warming tool in the present embodiment includes a surface material 200, a soaking sheet 410 in which an adhesive 412 containing a resin is coated on both upper and lower surfaces of the metal sheet 411, and a heater wire 420 on the lower surface of the soaking sheet 410. Is provided, a heat-insulating sheet 500 provided on the lower surface side of the heater unit 400, and a back material 600 provided on the lower surface side of the heat-insulating sheet 500. Nonwoven fabrics 502 and 503 are bonded to the upper and lower surfaces of the foam sheet 501.

  As a result, the surface material 200, the soaking sheet 410 in which the adhesive 412 containing resin is coated on both the upper and lower surfaces of the metal sheet 411, and the planar heater unit in which the heater wire 420 is disposed on the lower surface of the soaking sheet 410. 400, a heat insulating sheet 500 in which non-woven fabrics 502 and 503 are bonded to both upper and lower surfaces of the foam sheet 501, and a back material 600 are laminated and bonded together. A heater unit 3 having a heater wire 3b disposed on 3a and a backing material 5 coated with a urethane foam material 4 on the surface thereof are laminated in a mold, and a urethane resin is foamed in the mold and press-molded. A surface heating device can be produced without using a mold.

  In this case, the heat for melting the adhesive resin 412 is generated from the metal sheet 411 inside the planar warming tool by electromagnetic induction heating of the laminate in which the surface material 200, the heater unit 400, and the heat insulating sheet 500 are laminated. Since it generates heat, the adhesive resin 412 can be melted in a short time, so that the bonding operation can be performed in a short time, and wasteful heat radiation to the outside of the planar warming tool can be suppressed. Energy saving can be achieved.

  Moreover, since a mold that foams urethane resin in the processing process and press-molds the surface heating device is not used, it is possible to reduce mold investment costs and capital investment costs, and improve design flexibility. .

  In addition, since the non-woven fabric is bonded to the upper and lower surfaces of the foam sheet 501 in the heat insulating sheet 500, the foam sheet 501 has the upper and lower non-woven fabrics 502 and 503 and some of the fibers of the non-woven fabric 502 and 503. In addition to obtaining strong adhesive strength, the tear strength is enhanced on both sides of the foam sheet 501, and even when the sheet heating tool is folded, it is possible to prevent problems such as partial peeling or tearing, A planar warming tool excellent in both cushioning properties and durability strength by the foamed sheet 501 can be obtained.

The foam sheet 501 of the heat insulating sheet 500 is not limited to a polyurethane foam foam sheet as long as it is suitable for heat resistance, cushioning properties, strength, adhesiveness, and the like. For example, a crosslinked foamed polyethylene sheet may be used. Further, the nonwoven fabrics 502 and 503 are not limited to the fibers of the polyester resin. For example, nylon fiber or polypropylene fiber may be used.

  In the present embodiment, the surface material 200 has a two-layered nonwoven fabric having an adhesive layer 204 between the nonwoven fabric 202 and the nonwoven fabric 203 between the topsheet 201 and the heater unit 400. Even if the planar heater unit 400 in which the heater wire 420 is disposed on the lower surface of the heat equalizing sheet 410 is uneven, the nonwoven fabric 202, 203 has a two-layer structure having an adhesive layer 204 between the nonwoven fabric 202 and the nonwoven fabric 203. Acts to block the transmission of the unevenness of the heater unit 400 to the top sheet 201, and when a person sits on the main body 100 of the surface heating device, etc., there is no sense of incongruity and a smooth and comfortable feeling of use is obtained. be able to.

  That is, a slightly hard adhesive layer 204 is formed between the nonwoven fabric 202 and the nonwoven fabric 203, and the soft nonwoven fabrics 202 and 203 are doubled on both sides of the adhesive layer 204. Transmission of unevenness is prevented from mitigating. Moreover, the two-layered nonwoven fabric 202 is adapted to the adhesive 412 coated on the aluminum sheet 411 of the heater unit 400, and strong adhesion between the surface material 200 and the heater unit 400 can be obtained.

  Further, in the nonwoven fabrics 202 and 203 of the present embodiment, the nonwoven fabric 203 on the surface sheet 201 side is formed in a hard layer laminated with TPO resin, and the nonwoven fabric 202 on the heater unit 400 side is a soft layer that is not laminated with resin. Thus, even if the planar heater unit 400 in which the heater wire 420 is disposed on the lower surface of the soaking sheet 410 is uneven, the nonwoven fabric has a two-layer structure having the adhesive layer 204 between the nonwoven fabric 202 and the nonwoven fabric 203. 202 and 203 can further prevent the unevenness of the heater unit 400 from being transmitted to the top sheet 201.

  That is, the surface material 200 has two fiber layers having different hardness between the surface sheet 201 and the heater unit 400, the surface sheet 201 side is a hard layer, and the heater unit 400 side is a soft layer, Even if the planar heater unit 400 in which the heater wire 420 is disposed on the lower surface of the heat equalizing sheet 410 is uneven, the nonwoven fabric 202, 203 has a two-layer structure having an adhesive layer 204 between the nonwoven fabric 202 and the nonwoven fabric 203. Acts to prevent transmission of the unevenness of the heater unit 400 to the top sheet 201, and when a person sits on the main body 100 of the surface heating device, the feeling of use is smoother and more comfortable. Can be obtained.

  In the present embodiment, the non-woven fabric 502, 503 is bonded to both surfaces of the foam sheet 501, and the non-woven fabric 502 on the heater unit 400 side is thicker than the non-woven fabric 503 on the back material 600 side. Even when a cord-like heater wire 420 having a diameter of about 3 mm is used as the heater of the heater unit 400, the cord-like nonwoven fabric 502 on the heater unit 400 side, which is thicker than the nonwoven fabric 503 on the back material 600 side, is corded. Since the heater wire 420 can be embedded, when a person sits on the main body 100 of the planar warming tool, the person can make it difficult for the person to feel the unevenness due to the heater wire 420, making the person more uncomfortable. Smooth and comfortable use feeling can be obtained.

In addition, the non-woven fabric 502, 503 is bonded to both surfaces of the foam sheet 501, and the foam sheet 501 is foamed with a part of the non-woven fabric 502, 503 on both the upper and lower surfaces and a part of the fibers of the non-woven fabric 502, 503. Not only can the sheet 501 bite into the sheet, but strong adhesive strength can be obtained, and both sides of the foamed sheet 501 have improved tearing strength to prevent problems such as partial peeling or tearing even when the sheet heating tool is folded. Yes, foam sheet 50
The surface warming tool which was excellent in both the cushioning property by 1 and durable strength can be obtained.

The nonwoven fabric 502 on the heater unit 400 side has a polyester resin 96% polypropylene resin 4% basis weight of 180 g / m ² , and the back material 600 side of the nonwoven fabric 503 has a polyester resin 95% polypropylene resin 5% basis weight 100 g / m ² . As a result, the best bonding can be achieved in terms of cost effectiveness.

  Further, in the present embodiment, the surface material 200, the heater unit 400, and the heat insulating sheet 500 are sequentially laminated, and the laminated body is heated by electromagnetic induction, so that the aluminum sheet 411 of the heater unit 400 is heated and the adhesive 412 is applied. By melting and pressing the laminate with the pressing means 730, the surface material 200, the heater unit 400, and the heat insulating sheet 500 are bonded to each other, so that the electromagnetic induction heating device 721 and the pressing means 730 are separated from each other. Since it can be configured as equipment, it is easy to manufacture and maintain the equipment, and it is possible to construct the manufacturing process as a flow work, thereby improving the production efficiency. Further, unlike the surface warming tool that is press-molded in the conventional mold, it is not necessary to cover the entire surface warming tool with the mold, and the electromagnetic induction heating device 721 and the pressing means 730 are heated and pressed from a part. Since the electromagnetic induction heating device 721 and the pressing means 730 can be handled with small equipment since the entire process can be performed sequentially, the cost for the production equipment can be reduced, and different shapes and sizes can be used. It is possible to manufacture the warming tool in the same facility.

  As described above, the surface warming device according to the present invention can heat the built-in metal soaking sheet without using the foaming press die, melt the thermal resin, and bond the cushion. Since it has excellent properties and durability, it can be applied to floor heating devices used on floors such as kitchens and living rooms, and so-called electric carpets.

200 surface material 201 surface sheet 202 non-woven fabric 203 non-woven fabric 204 adhesive layer 400 heater unit 410 soaking sheet 411 metal sheet (aluminum sheet)
412 Adhesive resin (adhesive)
420 Heater wire 500 Thermal insulation sheet 501 Foam sheet (foamed urethane resin)
502 Nonwoven fabric 503 Nonwoven fabric 721 Electromagnetic induction heating device 730 Press roller (pressing means)

Claims (6)

Surface material,
A soaking sheet in which an adhesive containing resin is coated on both upper and lower surfaces of the metal sheet;
A planar heater unit in which a heater wire is disposed on the lower surface of the soaking sheet;
A heat insulating sheet provided on the lower surface side of the heater unit;
A back surface material provided on the lower surface side of the heat insulating sheet;
With
The heat insulating sheet is a sheet heating tool characterized in that a nonwoven fabric is bonded to the upper and lower surfaces of a foam sheet. The surface material has two fiber layers having different hardness between a surface sheet and the heater unit, and the surface sheet side is a hard layer and the heater unit side is a soft layer,
The planar warming tool according to claim 1. The surface material is formed by arranging a non-woven fabric having a two-layer structure having an adhesive layer between the non-woven fabric and the non-woven fabric between the top sheet and the heater unit.
The planar warming tool according to claim 1. The non-woven fabric is bonded to both surfaces of the foam sheet, and the non-woven fabric on the heater unit side is thicker than the non-woven fabric on the back material side.
The planar warming tool according to claim 1. The nonwoven fabric on the heater unit side is polyester resin 96% polypropylene resin 4% basis weight 180 g / m ² , and the back material side nonwoven fabric is polyester resin 95% polypropylene resin 5% basis weight 100 g / m ² .
The planar warming tool according to claim 4. The laminated body in which the surface material, the heater unit, and the heat insulating sheet are laminated in order is heated by electromagnetic induction to heat the metal sheet of the heater unit to melt the adhesive, and the pressing body is used to melt the laminated body. By pressing, the surface material, the heater unit and the heat insulating sheet are bonded,
The planar warming tool of any one of Claims 1-5.

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