JP2014052150A - Electric carpet also acting as "kotatsu" - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electric carpet also acting as a "kotatsu" manufactured while a heating wire is being held and fixed between a heat insulation material and a surface material in which the electric carpet is to be used together with the "kotatsu" while the "kotatsu" is being held at a central part of the carpet, effectively taking heat without applying any electric energy to the electric carpet when no person utilizes it to get a power-saving effect and further it has an effect capable of reducing heat loss released to a floor surface.SOLUTION: There is provided an electric carpet also acting as a "kotatsu" comprising a surface material, heating wire, heat insulation material and adhesion layer in which the heating wire is held and fixed by the surface material and the heat insulation material, wiring of the heating wire is comprised of at least two or more systems.

Description

  The present invention relates to an electric carpet including a surface material, a heating wire, a heat insulating material, and an adhesive layer, and has an energy saving effect.

  A conventional method for manufacturing an electric carpet is, for example, in which a heating wire coated with a molten resin is wired on a heat insulating material made of, for example, needle punch felt, etc., hot-pressed and fixed once, and then an adhesive layer is formed thereon. The applied surface material is stacked, the heat insulating material and the surface material are bonded by heat press, the heating wire is fixed between the heat insulating material and the surface material, and then the outer edge is frayed with an overlock sewing machine to control heat generation. It is common to install a controller to perform.

  Due to the recent increase in power saving, more households use both electric carpets and kotatsu. When using kotatsu together, warm air gathers upward, so it is effective to take warmth from the electric carpet under your feet. On the other hand, if it is colder, you can warm your body from the buttocks of the seating surface. It is effective, and the rectangular kotatsu will use any or all of the four sides, and energizing parts of the electric carpet that are not used by humans is a problem as an energy loss from the viewpoint of energy saving and power saving. .

  Further, in recent houses, tatami floors have been reduced, and flooring of flooring has become a main component, so electric carpets are often used on flooring. On the flooring floor, the heat loss problem is aggravated because the heat of the electric carpet is more likely to escape to the floor than when used on a tatami mat.

  In Patent Document 1, the heating area of the heater of the square carpet is divided into two L-shaped blocks facing each other and a square block surrounded on all sides by these two L-shaped blocks, and the above-mentioned The heater wiring in the square block is arranged more densely than the other blocks, the heaters in the square block are always energized, and either or both of the heaters in the other two L-shaped blocks are energized. An electric carpet for use in combination with an electric kotatsu provided with a control device is described.

  Patent Document 2 describes an electric carpet having an energy saving effect in which a fiber material including a hollow fiber is included in a fiber of a heat insulating material and includes a large amount of an air layer.

  As another method, a heat insulating sheet (sold separately) is laid on the floor and an electric carpet is laid on the floor.

  However, the electric carpet as disclosed in Patent Document 1 is an electric carpet that can sufficiently warm the feet without energizing the kotatsu by setting the central part on which the electric kotatsu is placed at a higher temperature than the surrounding area. .

  Moreover, although the method of including a hollow fiber in the fiber of a heat insulating material like patent document 2 has recognized the effect, it has led to the significant increase in cost. Another method, in which a heat insulating sheet is laid on the floor, is inconvenient to handle, requires extra work twice during installation and storage, and is cumbersome.

JP-A-9-33058 JP-A-8-327078

  The present invention relates to an electric carpet manufactured by sandwiching a heating wire between a heat insulating material and a surface material, and when a kotatsu is installed at the center and used together, a portion of the electric carpet that is not used by a person is energized. An object of the present invention is to provide an electric carpet combined with a kotatsu that can effectively take warmth without saving, has a power saving effect, and has an effect of reducing heat loss escaping to the floor surface as much as possible.

  As a result of intensive studies to solve such problems, the present inventors include a surface material, a heating wire, a heat insulating material, and an adhesive layer, and the heat generation between the surface material and the heat insulating material. In an electric carpet in which wires are wired and the heat generating wires are sandwiched and fixed between the surface material and the heat insulating material, the heating air is at the top when the heating wires are used in combination with at least two systems. It is effective to take heat from the electric carpet under your feet, and if it is cold, it is effective to warm your body from the buttocks of the seating surface. It has been found that it is possible to prevent energization of parts of the electric carpet that are not used by humans, to effectively warm up, and to contribute to energy saving and power saving. Further, even in a portion where the heating wire is not energized, heat is transmitted by the heat diffusion soaking sheet laminated on the upper side of the heating wire, so that warmth can be felt. And about the spreading | diffusion of the heat | fever to the circumference | surroundings of an electric carpet, it discovered that the heat insulation performance could be improved by sewing the outer edge part of an electric carpet into a bag shape with an overlock sewing machine etc., and came to this invention.

  In order to achieve the above object, the present invention provides the following means.

  [1] A surface material, a heat generating wire, a heat insulating material, and an adhesive layer are provided, the heat generating wire is wired between the surface material and the heat insulating material, and the heat generating wire is sandwiched between the surface material and the heat insulating material. An electric carpet bonded and fixed, wherein the heating wire has at least two lines.

  [2] The electric carpet combined with a kotatsu according to item 1 above, wherein a heat diffusion and soaking sheet is stacked on the upper side of the heating wire, and an outer edge portion of the electric carpet is sewn and integrated.

  [3] The electric carpet combined with a kotatsu according to the above item 1 or 2, wherein one system of the wiring of the heating wire is a central part of the electric carpet on which the combined use is placed, and the other system is other than the central part. .

  [4] The electric carpet combined with kotatsu according to any one of items 1 to 3, wherein the surface material is substantially rectangular and the heating wire is not wired at four corners of the surface material.

  In the invention of [1], a surface material, a heat generating wire, a heat insulating material, and an adhesive layer are provided, the heat generating wire is wired between the surface material and the heat insulating material, and the surface material and the heat insulating material In an electric carpet with a heating wire sandwiched and fixed, the wiring of the heating wire is composed of at least two systems. When a kotatsu is used together, a rectangular kotatsu is used by a person sitting on any or all of the four sides. However, by setting the wiring of the heating wire to 3 systems, 4 systems, 5 systems, etc., the portion of the electric carpet that is not used by a person can be prevented from energizing the corresponding system. Considering the use part, it can effectively warm up and contribute to energy saving and power saving.

  In the invention of [2], since the heat diffusion soaking sheet is laminated on the upper side of the heating wire, even in a portion where the heating wire is not energized, heat is transmitted so that warmth can be felt. . Moreover, the heat insulation performance can be improved by sewing the outer edge of the electric carpet into a bag shape with an overlock sewing machine or the like.

  In the invention of [3], one line of the heating wire wiring is in the central part of the electric carpet where the combined use is placed, and the other system is other than the central part. A heating wire system to be wired and a heating wire system to be wired other than the central portion, the heating wire system to be wired to the central portion is energized, and the heating wire system to be wired to other than the central portion is not energized Can be. Or it can also be set as the reverse pattern. That is, since warm air gathers in the upper part, it is effective to take heat from the electric carpet at the foot by energizing only the heating wire system wired in the central portion. When it is colder, it is effective to warm the body from the buttocks of the seating surface by energizing only the heating wire system that is wired outside the central part. Of course, both can be energized, and can effectively warm up, contributing to energy saving and power saving.

  In the invention of [4], since the surface material is substantially rectangular and the heating lines are not wired at the four corners of the surface material, only a relatively small number of people can use the electric carpet at the same time. It can contribute to energy saving and power saving.

It is explanatory drawing of the heating wire wiring diagram of the electric carpet concerning one Embodiment of this invention. It is explanatory drawing of the heating wire wiring diagram of the electric carpet concerning another one Embodiment of this invention.

  One embodiment of a kotatsu combined electric carpet according to the present invention will be described with reference to FIG. The electric carpet 1 combined with kotatsu includes a surface material 2, a heating wire 3, a heat insulating material 4, and an adhesive layer 5 (not shown), and the heating wire 3 is interposed between the surface material 2 and the heat insulating material 4. In the electric carpet in which the heating wire 3 is sandwiched and fixed between the surface material 2 and the heat insulating material 4, the heating wire 3 has at least two wirings.

  The surface material 2 and the heat insulating material 4 are not particularly limited as long as they can be bonded with an adhesive, but a polyester needle punch felt is preferable. Polyester needle punch felts are inexpensive and have excellent thermal insulation properties, and are used in many electric carpets.

Needle punched felt surface member 2 has a thickness of 2 to 3 mm, preferably polyester needle punched felt having a basis weight of 100 to 300 g / ^{m 2,} on the surface side of the surface material 2, SBR latex is applied in order to prevent fluffing Often. In addition, an adhesive layer 5 such as vinyl acetate is applied in advance to the overlapping surface side of the surface material 2, and the surface material 2 and the heat insulating material 4 are bonded to the heat generating wire 3 wired on the heat insulating material 4 side by hot pressing. The heating wire 3 is fixed by bonding.

As the heat insulating material 4, a polyester needle punch felt having a thickness of 3 to 8 mm and a basis weight of 300 to 500 g / m ² is preferable, and an acrylic resin may be applied to the floor surface side of the heat insulating material 4 for the purpose of preventing slippage. Many.

  There are at least two systems of wiring patterns for the heating wires 3. As an example, a pattern in which the wiring of the heating wire 3 is made into two systems as shown in FIG. 1 is prepared, and a controller that can be set such that each system is energized independently or not energized is used. Further, as shown in FIG. 2, a pattern in which the heating wires 3 are not provided at the four corners of the rectangular electric carpet is preferable.

  As the heating wire 3, it is preferable to use a wire in which the heater wire is covered with a resin such as vinyl chloride and the surface thereof is further covered with a polyethylene resin having a melting point lower than that of vinyl chloride. For example, wiring is performed on a silicon plate in a wiring pattern as shown in FIG. 1, and a heat insulating material 4 is placed on the silicon plate. By performing hot pressing, the polyethylene resin covering the heater wire is melted and the heat insulating material 4 generates heat. Line 3 is glued. At this time, the heating wire 3 is melt bonded so as to be embedded in the heat insulating material 4.

  Next, if the heat generating wire 3 is bonded to the heat insulating material 4 and the surface material 2 is overlapped and hot pressed so as to sandwich the heat generating wire 3, the surface material 2 and the surface material 2 are bonded by the vinyl acetate adhesive layer provided on the surface material 2. The heat insulating material 4 is firmly bonded.

  The outer edge of the carpet thus prepared is frayed with an overlock sewing machine, etc., and a controller is attached to complete the electric carpet.

  Moreover, it is preferable to laminate a heat diffusion soaking sheet 6 on the heating wire 3. In addition, the thermal diffusion soaking sheet 6 may be laminated on the lower side of the heating wire 3, or the thermal diffusion soaking sheet 6 may be laminated on both the upper side and the lower side of the heating wire 3. Good.

  Since the thermal diffusion soaking sheet 6 has excellent thermal diffusibility, the heat generated by the heating wire 3 can be generated by laminating the heat diffusion soaking sheet 6 on the upper side of the heating wire 3. Since the heat is diffused over the entire heat diffusion soaking sheet 6, the effect of achieving soaking over time is exhibited. And since the surface material 2 laminated | stacked on the upper side of the heat | fever diffusion soaking sheet 6 is warmed, not only the part to which the said heat generating wire 3 was wired but the periphery of the said heat generating wire 3 as well as the part not wired Because heat is transmitted to the water, you can feel the warmth effectively.

  A heat diffusion soaking sheet 6 may be laminated below the heating wire 3. In this case, the heat diffusion soaking sheet 6 transfers the heat generated in the heating wire 3 to the heat diffusion soaking sheet 6, and the surface material 2 by the radiant heat of the heat diffused over the entire heat diffusion soaking sheet 6. You can feel the warmth effectively.

  Examples of the heat diffusion soaking sheet 6 include an aluminum sheet. Aluminum sheets are preferred because they are readily available and are flexible and relatively easy to handle.

  The thickness of the thermal diffusion soaking sheet 6 is preferably 5 to 100 μm. In this range, a sufficient heat diffusing effect is exhibited, and the heat diffusing and soaking sheet 6 exhibits a sufficient effect of heat soaking across the entire sheet. If it is less than 5 μm, the strength is weak and there is a possibility of tearing. If it exceeds 100 μm, it becomes heavy and handling of the electric carpet becomes difficult, which is not preferable.

  The method of laminating the thermal diffusion soaking sheet 6 on the heating wire 3 is not particularly limited, and examples thereof include a method using a known adhesive and a method using a needle punch. Among these, a needle punch method is preferable because needle punch felt can be simultaneously performed in the manufacturing process. In the process of manufacturing a needle punch felt suitable as the surface material 2, the needle punch felt and the heat diffusion soaking sheet 6 are overlapped in the process of giving a needle punch, and the needle punch felt is placed from the needle punch felt side. It is preferable to apply processing.

  Thus, by needle punching, the needle pierces the needle punch felt and the heat diffusion soaking sheet 6 so that the fibers constituting the needle punch felt protrude on the surface of the heat diffusion soaking sheet 6. Laminated and held. More preferably, the method using an adhesive and the method using a needle punch are used in combination. The adhesive is preferably a hot melt resin and is suitable for bonding to the heating wire 3. In this case, it is preferable to perform needle punching using, for example, a heat diffusion soaking sheet in which a hot melt resin is applied on one side in advance or a heat diffusion soaking sheet in which a hot melt resin film is laminated.

  The method of laminating the heat diffusion soaking sheet 6 below the heating wire 3 may be performed in the same manner as the method of laminating the heat diffusion soaking sheet 6 above the heating wire 3. That is, in the process of manufacturing a needle punch felt suitable as the heat insulating material 4, the needle punch felt and the heat diffusion soaking sheet 6 are overlapped in the process of giving a needle punch from the side of the needle punch felt. It is preferable to perform needle punching.

  In order to laminate the heat diffusion soaking sheet 6 on both the upper side and the lower side of the heating wire 3, the heat diffusion soaking sheet 6 is laminated on the upper side of the heating wire 3, and the heat generation described above. What is necessary is just to combine the thermal diffusion soaking sheet 6 with the lamination on the lower side of the line 3.

  When using the surface material 2 or the heat insulating material 4 laminated with the heat diffusion soaking sheet 6, the adhesive layer 5 such as vinyl acetate is previously applied to the surface material 2 or the heat insulating material 4 not laminated with the heat diffusion soaking sheet 6. The surface material 2 and the heat insulating material 4 may be superposed and hot-pressed so that the surface of the heat diffusion soaking sheet 6 is sandwiched between the heating wires 3.

  Further, when the heat diffusion / heat equalizing sheet 6 is laminated on both the surface material 2 and the heat insulating material 4, for example, the heating wire 3 is formed so that the heat diffusion / heat equalizing sheet 6 previously coated with a hot melt resin faces each other. If the surface material 2 and the heat insulating material 4 are stacked and hot-pressed so as to be sandwiched, a polyethylene resin coated with a heater wire constituting the heating wire 3 by hot pressing, and a hot-melt resin applied to the heat diffusion soaking sheet 6 Melts and adheres firmly.

  An acrylic resin or the like may be applied to the floor surface side of the surface material 2 or the heat insulating material 4 for the purpose of preventing slipping. By doing in this way, it can prevent that the cover laid on the upper side of an electric carpet shifts | deviates, and that an electric carpet slips.

  The method of sewing the outer edge of the electric carpet is not particularly limited, and it is possible to sew by a known method called overlock or tape lock, to prevent fraying, and to integrate the surface material 2 or the heat insulating material 4 and the like. Good.

<Example 1>
A method for carrying out the present invention will be specifically described. In addition, the electric carpet of this invention and its manufacturing method are not limited to an Example. As the surface material 2 and the heat insulating material 4, needle punch felts made of polyester recycled cotton having a basis weight of ² mm and a basis weight of 300 g / m ² and a thickness of 4 mm and a basis weight of 500 g / m ² are prepared. Non-slip processing and fluff prevention on the upper side of the surface material 2 were performed in separate steps. Further, an adhesive layer of vinyl acetate was prepared on the upper side of the heat insulating material 4 in a separate process. As the heating wire 3, a wire material was prepared in which the heater wire was covered with a vinyl chloride resin and the surface thereof was covered with a polyethylene resin having a melting point lower than that of vinyl chloride. Next, the heating wire 3 was wired on the silicon plate according to the wiring pattern of FIG. The wiring pattern at the center of the electric carpet was the first system (rated power 260 W), and the wiring at the peripheral part was the second system (rated power 370 W). Next, the surface material 2 was overlaid on the silicon plate on which the heating wires were wired, and heat-pressed with a hot press. Next, the heat insulating material 4 and the surface material 2 were bonded to each other with a hot press machine by superposing the side of the heat insulating material 4 with the vinyl acetate adhesive layer on the lower side of the surface material 2 to which the heating wire was bonded. Next, a controller was joined to the corner portion, and the outer edge portion was frayed with an overlock sewing machine to form a kotatsu combined electric carpet. The electric carpet combined with the kotatsu thus obtained was laid on a Japanese-style tatami mat at a room temperature of 15 ° C., and a kotatsu (rated power 600 W) was placed on the center of the electric carpet, that is, the upper part of the first system of the heating wire 3. A kotatsu futon was put on and the power source of the kotatsu was turned on (power consumption 200W / hour). Subsequently, the kotatsu combined electric carpet was energized at 5 on the temperature adjustment scale from 1 to 5, and the power consumption after 6 hours was measured. As a result of energizing only the first system, it was warm from the feet, and compared with Comparative Example 1, the power consumption was reduced by 68%. As a result of energizing only the second system, it was warm from the buttocks, saving 37% of power consumption compared to Comparative Example 1. As a result of energizing the entire surface, it was warm from the feet and buttocks, and the power consumption was saved by 15% compared to Comparative Example 1. In this way, it is possible to switch and energize according to the necessary part, so that it was possible to effectively warm up and contribute to energy saving and power saving. Moreover, since the anti-slip process was given to the floor surface side of the surface material and the heat insulating material, there was no problem that the electric carpet slipped and slipped.

<Comparative Example 1>
A conventional electric carpet having a rated power of 740 W and a wiring pattern on the entire surface was prepared. In the case of using kotatsu together, the kotatsu and electric carpet were turned on despite being used by one person.

<Example 2>
In Example 1, the wiring of the heating wire 3 was divided into two lines, and an electric carpet was obtained using a pattern in which the wiring of the heating wire 3 was not provided at the four corners of the rectangular electric carpet as shown in FIG. About the kotatsu combined electric carpet obtained in this way, the power consumption was measured in the same manner as in Example 1. As a result of energizing only the first system, it was warm from the ground up, saving 68% of power consumption compared to Comparative Example 1 of the conventional method. As a result of energizing only the second system, it was warm from the buttocks, saving 48% of power consumption compared to Comparative Example 1. In addition, since the wiring was not provided in the four corners of the electric carpet where a person does not sit, wasteful power consumption did not occur. As a result of energizing the entire surface, it was warm from the feet and buttocks, and 30% of power consumption was saved as compared with Comparative Example 1. In this way, it is possible to switch and energize according to the necessary part, so that it was possible to effectively warm up and contribute to energy saving and power saving.

<Example 3>
In Example 2, the same procedure as in Example 2 was used except that the surface material 2 obtained by laminating and integrating a 20 μm thick aluminum sheet coated with a hot-melt resin adhesive on one surface to the surface material 2 by needle punching was used. I got a kotatsu combined electric carpet. About the kotatsu combined electric carpet obtained in this way, the power consumption was measured in the same manner as in Example 1. As a result of energizing only the first system, it was warm from the ground up, saving 68% of power consumption compared to Comparative Example 1 of the conventional method. As a result of energizing only the second system, it was warm from the buttocks, saving 40% of power consumption compared to Comparative Example 1. Since the aluminum sheet having a thickness of 20 μm was laminated on the upper side of the heating wire, the heat from the second heating wire being energized was transmitted and the central part felt warm. As a result of energizing the entire surface, the entire surface was warm, and compared with Comparative Example 1, the power consumption was reduced by 22%. In this way, it was possible to effectively warm up using limited electricity, contributing to energy saving and power saving.

<Measurement method of power consumption>
Under a room temperature of 15 ° C., the surface temperature of the electric carpet was set to 45 ° C., the tatami mat was laid, and the power consumption was measured with a power consumption meter.

  In an electric carpet, it is suitably used as an electric carpet combined with kotatsu.

DESCRIPTION OF SYMBOLS 1 ... Kotatsu combined electric carpet 2 ... Surface material 3 ... Heat generating wire 4 ... Heat insulating material 5 ... Adhesive layer 6 ... Thermal diffusion soaking sheet 7 ... Controller 8 ... Outer edge (overlock)

Claims (4)

  A surface material, a heat generating wire, a heat insulating material, and an adhesive layer are provided, the heat generating wire is wired between the surface material and the heat insulating material, and the heat generating wire is sandwiched and fixed between the surface material and the heat insulating material. The electric carpet according to claim 2, wherein the heating wire is composed of at least two lines.   The electric carpet combined with a kotatsu according to claim 1, wherein a heat diffusion soaking sheet is overlapped on the upper side of the heating wire, and an outer edge portion of the electric carpet is sewn and integrated.   3. The electric carpet combined with kotatsu according to claim 1 or 2, wherein one system of wiring of the heating wire is a central part of the electric carpet on which the combined use is placed, and the other system is other than the central part.   The electric carpet according to any one of claims 1 to 3, wherein the surface material is substantially rectangular, and the heating wires are not wired at four corners of the surface material.