JP2014190603A - Planar heater - Google Patents

Abstract

PROBLEM TO BE SOLVED: To rationalize production and to improve appearance.SOLUTION: A planer heater includes: a rear surface material 150; a heat insulation sheet 140; a soaking sheet 120; a heater wire 132 disposed between the heat insulation sheet 140 and the soaking sheet 120; and a surface material 110. The soaking sheet 120 is disposed in which a plurality of sheets 120a and 120b are disposed by having a gap 123, the heater wire 132 is disposed in a meandering shape, and a straight line part 134 of the heater wire 132 is disposed so as to be substantially orthogonal to the gap 123 of the soaking sheet 120. As a small-sized sheet material is adopted for the soaking sheet 120, the planar heater can be manufactured at low cost. As the straight line part 134 of the heater wire 132 is disposed striding over the gap 123 of the soaking sheet 120, deterioration of intensity in the gap part is suppressed, and folding of the gap part and a fold trace being left in the gap part can also be suppressed. Thus, usability and appearance can be improved.

Description

  The present invention relates to a planar warming tool that uses an electric heater as a heat source.

  Conventionally, this type of sheet heating device has a heater wire on a soaking sheet in which an adhesive resin that melts at a predetermined temperature or more is coated on both surfaces of a metal sheet between a sheet-like surface material and a sheet-like heat insulating material. A main body having a laminated structure in which the heater unit is disposed, the soaking sheet is heated to melt the adhesive resin, and the surface material, the heater unit, and the heat insulating material are bonded to each other is formed. If the area of the main body is large, a plurality of soaking sheets are joined to form a large area soaking sheet, and the heater wire is placed on the entire surface of the main body so as to be substantially parallel to the joint of the soaking sheets. It arrange | positions in the meandering shape, and it has the structure arrange | positioned so that the location where the junction part of a soaking | uniform-heating sheet | seat and a heater wire cross | intersect may become the minimum (for example, refer patent document 1).

  FIG. 12 shows a conventional planar warming tool described in Patent Document 1. As shown in FIG. As shown in FIG. 12, the two soaking sheets 1 are joined in a state where they are overlapped at the center, and a joined portion 2 is formed. The heater wire 3 is arranged in a meandering manner so as to be parallel to the joint portion 2, and the intersection portion 4 between the joint portion 2 and the heater wire 3 is configured to have only two places.

JP 2012-138336 A

  However, in the conventional configuration, in the manufacturing process, when the heat equalizing sheet is heated using the induction heating device in the process of melting the adhesive resin, the joining portion where the heat equalizing sheets are overlapped generates more heat than the other parts. However, since the temperature is high, the control of the induction heating apparatus becomes complicated, and it has been desired to simplify the manufacturing process. As a solution to this problem, the heating of the joined portion was eliminated by heating the joined portion with a gap therebetween without overlapping the soaking sheets.

  However, since the surface material and the heat insulating material in the gap portion are not bonded by providing a gap in the joint portion, the bending strength of the gap portion is lower than that in other portions, and when storing a planar warming tool, etc. When the main body is lifted or rolled, the joint part may be bent, and the crease may remain and the appearance of the surface warmer may be deteriorated, and there is still room for improvement from the viewpoint of appearance quality and usability.

  The present invention solves the above-described conventional problems, and an object thereof is to provide a planar warming tool that can streamline the manufacturing process and is good in appearance quality and usability.

  In order to solve the above-described conventional problems, the sheet heating device of the present invention includes a sheet-like back surface material, a heat insulating sheet laminated on the back surface material, a soaking sheet laminated on the heat insulating sheet, and heat insulation. A heater wire disposed between the sheet and the soaking sheet, and a sheet-like surface material laminated on the soaking sheet, and the soaking sheet has a plurality of substantially rectangular sheets provided with a gap. The heater wire is arranged in a meandering shape so that straight portions and folded portions are alternately formed, and the straight portion of the heater wire is arranged so as to be substantially orthogonal to the gap of the soaking sheet. It is what has been.

  As a result, the soaking sheet employs a small-sized sheet material, so that material procurement is easy and can be produced at low cost.

  In addition, by arranging the linear portion of the heater wire across the gap of the soaking sheet, it is possible to suppress the strength of the gap portion from being lowered and to prevent the gap portion from being bent and leaving a crease. Therefore, it is possible to improve the usability and the appearance of the surface heating device.

  The planar warming tool of the present invention can achieve rationalization of production and improvement of appearance.

The perspective view which shows the external appearance of the planar warming tool 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 structural member of the main body in Embodiment 1 of this invention The top view which shows the heater unit 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 relationship of arrangement | positioning of the soaking | uniform-heating sheet | seat and heater unit in Embodiment 1 of this invention. Schematic diagram showing the hot press process in Embodiment 1 of the present invention Sectional drawing which shows the heater laminated body in Embodiment 1 of this invention (A) is a schematic diagram which shows the cross section of the heating process in the Embodiment 1 of this invention, and a press process, (b) is a schematic diagram which shows the plane of the heating coil used at a heating process. 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 Schematic diagram showing the state of arrangement of the soaking sheet and heater wire of a conventional sheet heating device

  1st invention is a sheet-like back surface material, the heat insulation sheet laminated | stacked on the said back surface material, the heat equalizing sheet laminated | stacked on the said heat insulating sheet, and between the said heat insulating sheet and the said heat equalizing sheet. A heater wire and a sheet-like surface material laminated on the soaking sheet, wherein the soaking sheet is provided with a plurality of substantially rectangular sheets provided with a gap, and the heater The wires are arranged in a meandering shape so that straight portions and folded portions are alternately formed, and the straight portions of the heater wires are arranged so as to be substantially orthogonal to the gaps of the soaking sheets. It is a surface heating device.

  As a result, the soaking sheet employs a small-sized sheet material, so that material procurement is easy and can be produced at low cost.

  In addition, by arranging the linear portion of the heater wire across the gap of the soaking sheet, it is possible to suppress the strength of the gap portion from being lowered and to prevent the gap portion from being bent and leaving a crease. Therefore, the appearance of the surface warmer can be maintained and improved.

  In particular, the second invention further includes a holding sheet laminated on the heat insulating sheet in the first invention, and between the heat insulating sheet and the metal sheet, between the holding sheet and the heat insulating sheet. Are provided with the heater wire.

  As a result, the heater sheet covers the heater wire so that the heater wire is prevented from projecting to the surface material side, and the occurrence of unevenness due to the heater wire on the upper surface of the surface material can be suppressed. The appearance can be improved.

  In particular, in the third invention, the back material, the heat insulating sheet, the holding sheet, the soaking sheet, and the surface material are bonded mainly with a thermoplastic resin in the second invention. They are bonded in order by the agent.

  As a result, the surface warming tool can be produced mainly by the bonding process as a production process, and a stable product can be produced at a low cost.

  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)
1 is a perspective view showing a completed state of a planar warming device in Embodiment 1 of the present invention, FIG. 2 is a cross-sectional view showing a completed state of the main body of the planar warming device, and FIG. FIG. 4 is a plan view showing the heater unit, FIG. 5 is a perspective view showing the detailed structure of the heater wire, and FIG. 6 is a soaking sheet and the heater unit. It is a schematic diagram which shows the relationship of arrangement | positioning.

<1> Configuration of planar warmer The planar warmer according to the present embodiment is a warmer that is installed and used on the floor of a house. As shown in FIG. 1, the planar warming tool is composed of a main body 100 composed of a plurality of sheet-like members and a controller 101 provided at one end of the main body 100. The controller 101 includes a controller (not shown) that controls the current supplied to the heater wire 132 built in the main body 100. Power is supplied through a power cord 102 connected to the controller 101. The controller 101 controls the temperature of the main body 100 to a set temperature by controlling the power supplied to the heater wire 132.

  As shown in FIG. 3, the main body 100 of the planar warming tool includes a surface material 110, a soaking sheet 120, a heater unit 130, a heat insulating sheet 140, and a back surface material 150 as main constituent members. The first adhesive sheet 160 is interposed between the heat insulating sheet 140 and the heat insulating sheet 140, and the second adhesive sheet 170 is interposed between the heat insulating sheet 140 and the back surface material.

  As shown in FIG. 2, the main body 100 in which the laminated body is bonded and the peripheral portion is compression-welded is laminated with a surface material 110, a soaking sheet 120, a heater unit 130, a heat insulating sheet 140, and a back material 150. The first adhesive sheet 160 and the second adhesive sheet 170 are mostly laminated into the holding sheet 131 and the heat insulating sheet 140 of the heater unit 130 after the bonding process, so that the thickness hardly remains.

  The surface material 110 is a top surface member of the main body 100 of the planar warming tool, and is a surface that the user directly contacts at the time of use. The surface material 110 has not only mechanical strength but also necessary performance such as designability, stain resistance, and tactile sensation, and is mainly composed of a foam of a vinyl chloride resin (hereinafter referred to as PVC). A laminated sheet in which a polyester nonwoven fabric 112 is bonded to the back surface of the patterned top sheet 111 with an adhesive 113 and has a thickness of about 2 mm.

  The soaking sheet 120 is a member for the purpose of uniformly diffusing the heat generated by the heater unit 130 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 having high thermal conductivity. An aluminum sheet 121 is used as a base material, and an adhesive resin 122 made of polyethylene resin and EVA (ethylene-vinyl acetate copolymer resin) is coated on both sides thereof, and the adhesive resin 122 is heated to about 85 ° C. or more. By melting, it functions as an adhesive.

  The planar warming tool in the present embodiment is a large one having a long side of 2 m or more, and it is difficult to procure a large sheet that covers the entire surface with one soaking sheet 120. Therefore, two sheets 120a and 120b are used. Divided into sheets.

  As shown in FIG. 6, the soaking sheet 120 is configured such that a substantially rectangular sheet 120 a and a sheet 120 b are arranged in parallel with a gap 123 of about 5 mm, and the two sheets 120 a and 120 b and the gap 123 are arranged. The outer shape of the soaking sheet 120 is smaller than the surface material 110 and is formed to have the same size as the heater unit 130 or slightly smaller.

  The heater unit 130 is a heat source of the sheet heating device, and as shown in FIG. 4, the heater wire 132 is meandered on one side of a holding sheet 131 formed of polyester as a main component and a nonwoven fabric. .

  As shown in FIG. 5, the heater wire 132 is formed by spirally winding a detection wire 132b for detecting the temperature around the center glass fiber 132a, and forming an insulating layer 132c of nylon resin on the outer periphery thereof. A heating wire 132d is spirally wound on the outer periphery, a PVC insulating layer 132e is formed on the outer periphery, and an adhesive layer 132f made of polyethylene resin is formed on the outer periphery of the insulating layer 132e. 7 mm.

  In the heater unit 130, the start end 133 of the heater wire 132 is arranged at one corner of the holding sheet 131, and the straight portions 134 and the folded portions 135 are alternately formed to cover the entire area of the holding sheet 131 to form a meandering shape. The terminal end 136 is disposed in the vicinity of the starting end 133. Heat is applied in a state where the heater wires 132 are arranged in a meandering shape on the holding sheet 131, whereby the adhesive layer 132 f of the heater wires 132 is melted and fixedly adhered to the holding sheet 131.

  As shown in FIG. 6, the soaking sheet 120 and the heater unit 130 are disposed so that the straight portion 134 of the heater wire 132 is orthogonal to the gap 123 of the soaking sheet 120.

  The surface material 110, the soaking sheet 120, and the heater laminate 180 are bonded by the adhesive resin 122 coated on both surfaces of the soaking sheet 120, and the gap 123 of the soaking sheet 120 is not filled with the adhesive resin. Therefore, this part is not bonded, and becomes a part where the bending strength is weaker than the other bonded part, but the linear part 134 of the heater wire 132 is disposed across the gap 123, so that It is the structure which can suppress the difference in intensity | strength.

  The heat insulating sheet 140 is provided for the purpose of obtaining the function of suppressing the heat generated by the heater unit 130 from being unnecessarily transmitted to the floor and the cushioning property of the surface heating device. About 85% of the melting point resin fibers and about 15% of the low melting point resin fibers are mixed to form a felt shape having a thickness of about 15 mm.

  The heat insulating sheet 140 having the above-described configuration is provided with high elasticity mainly by a high melting point resin fiber, and is heat-deformed capable of maintaining a deformed state by being plastically deformed by a low melting point resin fiber in a heating state near a melting temperature. It has the characteristics of.

  The outer dimensions of the heat insulating sheet 140 are the same as or slightly larger than the outer dimensions of the soaking sheet 120 constituted by the two sheets 120 a and 120 b and the holding sheet 131 of the heater unit 130.

  By utilizing the characteristics of the heat deformation, by heating while pressing in a state where the heater wire 132 of the heater unit 130 is opposed to the heat insulating sheet 140 and laminated on the heat insulating sheet 140 via the first adhesive sheet 160, The heater wire 132 can be embedded in the heat insulating sheet 140, the holding sheet 131 of the heater unit 130 can be formed in a flat state, and the elasticity of the heat insulating sheet 140 can be maintained.

  In order to embed the heater wire 132 in the heat insulating sheet 140 as described above, it is important that the heat insulating sheet 140 has a sufficient thickness, and the heat insulating sheet 140 is four times or more the diameter of the heater wire 132. In the present embodiment, the thickness of the heat insulating sheet 140 is 5.6 times that of 15 mm with respect to the diameter of the heater wire 132 of 2.7 mm.

  The back material 150 is a member that directly contacts the floor surface of the main body 100 of the planar warming tool, and has mechanical strength and performance such as cushioning and slippage. The back material 150 is formed in a three-layer structure in which both surfaces of a polyethylene resin cloth sheet are coated with a polyethylene resin. The outer surface of the back material 150 is formed to have substantially the same dimensions as the surface material 110.

  The first adhesive sheet 160 is a sheet-like hot melt adhesive that bonds the heater unit 130 and the heat insulating sheet 140 together. The first adhesive sheet 160 is formed by forming a polyethylene resin into a sheet shape having a thickness of about 30 μm. The first adhesive sheet 160 forms a flexible sheet shape at room temperature and melts at about 85 ° C. to function as an adhesive. To do. The outer shape of the first adhesive sheet 160 is smaller than the holding sheet 131 of the heater unit 130.

  The second adhesive sheet 170 is a sheet-like hot melt type adhesive that bonds the heat insulating sheet 140 and the back surface material 150. The second adhesive sheet 170 is formed by forming a polyethylene resin into a sheet shape having a thickness of about 60 μm. The second adhesive sheet 170 has a flexible sheet shape at room temperature and melts at about 85 ° C. to function as an adhesive. To do. The external shape of the second adhesive sheet 170 is larger than that of the heat insulating sheet 140 and smaller than the back surface material 150.

  Since most of the first adhesive sheet 160 and the second adhesive sheet 170 penetrate into the holding sheet 131 and the heat insulating sheet 140 after the bonding process, the thickness hardly remains as shown in FIG.

  By laminating the above-mentioned constituent members and heating and pressing in the manufacturing process described later, the main body 100 of the planar warming tool having a cross section shown in FIG. 2 is formed.

<2> Manufacturing Process of Main Body FIG. 7 is a schematic diagram showing a cross section of the hot press process in the first process, and FIG. 8 is a schematic diagram showing a cross section of the heater laminate processed in the first process. (A) It is a schematic diagram which shows the cross section of the electromagnetic induction heating process which is a 2nd process, and the press process which is the 3rd process, (b) is a schematic diagram which shows the plane of the heating coil in an electromagnetic induction heating process. FIG. 10 is a schematic view showing a cross section of an ultrasonic welding process for welding the peripheral part of the main body, which is the fourth process, and FIG. 11 is a cross section of a trimming process for cutting an unnecessary part of the peripheral part of the main body, which is the fifth process. It is a schematic diagram which shows.

  The first process is a hot pressing process in which the heater unit 130, the heat insulating sheet 140, and the back material 150 are bonded by hot pressing. This process is a process in which heating and pressing operations are performed simultaneously. As shown in FIG. 7, the equipment necessary for this process is a heat press 200, and the lower mold 210 and the upper mold 220 of the heat press 200 are formed on the entire surface of the main body 100. Plate-like hot plates 211 and 221 are provided.

  As shown in FIG. 7, the back material 150, the second adhesive sheet 170, the heat insulating sheet 140, the first adhesive sheet 160, and the heater wire 132 of the heater unit 130 are arranged in order on the heat plate 211 of the lower mold 210. Laminate. In this step, as shown in FIG. 7, the heater unit 130, the heat insulating sheet 140, the first adhesive sheet 160, and the second adhesive sheet 170 are smaller in outer dimensions than the back surface material 150, and therefore are arranged in the center of the back surface material 150. is important.

  Also, the first adhesive sheet 160 is formed to have an outer dimension smaller than the outer dimension of the heater unit 130, and the first adhesive sheet 160 is laminated so that the first adhesive sheet 160 does not protrude from the heater unit 130. It is possible to prevent 160 from adhering to the hot plate 221 of the upper mold 220.

  The hot plate 211 of the lower mold 210 and the hot plate 221 of the upper mold 220 are heated to a predetermined temperature, for example, about 100 ° C. This predetermined temperature is set to a temperature higher than the melting point of the low melting point resin fibers of the heat insulating sheet 140 and lower than the melting point of the high melting point resin fibers. In this heated state, the upper die 220 is lowered and the laminated member is heated and pressed and maintained for about 30 seconds, after which the upper die is opened.

  Thereby, a part or all of the low melting point resin fibers of the heat insulating sheet 140 are melted while the heater wire 132 is pressed against the heat insulating sheet 140. For this reason, the position where the heater wire 132 is provided in the heat insulating sheet 140 is recessed, and a recess in which a part or all of the heater wire 132 is accommodated is formed in the heat insulating sheet 140.

  Further, the first adhesive sheet 160 is melted, the heat insulating sheet 140 is bonded to the heater wire 132 and the holding sheet 131, and the second adhesive sheet 170 is melted to bond the heat insulating sheet 140 and the back surface material 150. .

  As shown in FIG. 8, the heater laminate 180 completed by the hot press process is in a state where the heater wire 132 of the heater unit 130 is embedded in the heat insulating sheet 140, and the holding sheet 131 that is the upper surface of the heater unit 130 is flat. It can be finished to the state.

  The second process is an electromagnetic induction heating process in which the surface material 110, the soaking sheet 120, and the heater laminate 180 are heated by the electromagnetic induction heating device 400.

  As the processing equipment used in the electromagnetic induction heating process, the surface material 110, the soaking sheet 120, and the heater laminate 180, which are all the members constituting the main body 100, are placed and moved in the horizontal direction as indicated by an arrow A. The electromagnetic induction heating apparatus 400 provided with the conveyance means 300 to be made, the substantially elliptical heating coil 410 larger than the width of the main body 100, and a control unit (not shown) for controlling the output of the heating coil 410 is essential.

  The conveyance means 300 includes position detection means (not shown) for detecting the movement position of the stacked body of the main body 100. In the present embodiment, as specific position detecting means, position detecting means for detecting the position of the main body 100 by detecting the number of rotations of the drive motor of the conveying means 300 and calculating the moving distance of the main body 100 is provided. Adopted.

  As shown in FIG. 9A, in the present embodiment, the electromagnetic induction heating device 400 includes three electromagnetic induction heating devices 400a, 400b, and 400c in a direction substantially perpendicular to the moving direction of the main body 100. In addition, they are installed close to each other in parallel. The three electromagnetic induction heating devices 400a, 400b, and 400c are provided with substantially elliptical heating coils 410a, 410b, and 410c that are wider than the main body 100, and each heating coil can control power supply independently. Thus, an optimum heating state can be obtained by linking with the conveyance speed of the main body 100. The heating coils 410a, 410b, and 410c do not necessarily have the same shape and the same performance, and the three may have different specifications.

  As shown in FIG. 9A, the heater laminate 180 formed in the first step, the soaking sheet 120, and the surface material 110 are laminated in this order on the transport unit 300. At this time, the heater laminated body 180 is arranged in a direction in which the linear portion 134 of the heater wire 132 is orthogonal to the conveyance direction indicated by the arrow A of the conveyance means 300, and the heat equalizing sheet 120 has an arrow A indicating that the gap 123 indicates the conveyance direction. So that it is parallel to By arranging in this way, the linear portion 134 of the heater wire 132 and the gap 123 of the heat equalizing sheet 120 are arranged orthogonally.

  An eddy current is generated in the aluminum sheet 121 of the soaking sheet 120 by generating magnetic lines of force from the electromagnetic induction heating device 400 disposed above while being moved in the horizontal direction as indicated by an arrow A by the conveying means 300. The aluminum sheet 121 itself heats up due to the eddy current and the resistance of the aluminum sheet 121. The adhesive resin 122 coated on both surfaces of the aluminum sheet 121 is melted by the heat generated from the aluminum sheet 121.

  At this time, it is important to keep the distance between the heating coil 410 of the electromagnetic induction heating device 400 and the aluminum sheet 121 constant, and the laminated main body 100 is moved while being lightly pressed and maintained at a predetermined thickness.

  In the heating process, it is important to appropriately control the temperature rise due to heat generation, and the output of the heating coil 410 is controlled by the control unit of the electromagnetic induction heating device 400 in accordance with the transport speed of the transport unit 300. In particular, the lines of magnetic force tend to concentrate at the ends of the aluminum sheet 121, and the ends become hot. On the other hand, the lines of magnetic force are weak in the vicinity of the ends, so that a phenomenon in which heat generation of the aluminum sheet 121 is suppressed occurs. The adhesive resin 122 cannot be sufficiently melted.

  Therefore, when the heating coil 410 passes in the vicinity of the end portion, the output of the heating coil 410 is increased so as not to generate a low temperature region as compared with the case where the other flat portion of the aluminum sheet 121 is heated. The timing for controlling the output is performed based on the information of the position detecting means of the conveying means 300.

  In the present embodiment, since the three heating coils 410a, 410b, and 410c are arranged in parallel substantially perpendicular to the moving direction, the three heating coils 410a and 410b are arranged at the same location on the aluminum sheet 121. Since the magnetic field lines are sequentially supplied from 410c, it becomes possible to secure a long heating time, reduce the power supplied to each heating coil, and take time to pass through the three heating coils. By raising the temperature of 121, it is possible to prevent the temperature of the adhesive resin 122 from overshooting above the heat resistance temperature, and to maintain the performance of the adhesive resin 122.

  The third step is a pressing step for pressing and bonding the main body 100 heated in the second step. As shown in FIG. 9A, the roller unit 500 that is a pressing means used in the pressing process is installed between a rotating roller 510 composed of two rollers 511 and 512 and two rollers 511 and 512. The pressing plate 520 and the belt 530 wound around the outer periphery of the rotating roller 510 are configured such that the main body 100 is pressed by the two rollers 511 and 512 and the pressing plate 520 via the belt 530. Yes. By adopting such a configuration, it becomes possible to maintain the pressure stably over a long period of time with a flat surface, and a stable adhesion performance can be obtained.

  The roller units 500 are respectively provided above and below, the lower roller unit 500 is fixedly installed at a fixed position, and the upper roller unit 500 includes a pressure device (not shown) that moves up and down. The main body 100 can be pressed by moving it downward.

  Further, at least the lower roller unit 500 is provided with a driving device (not shown), and the belt 530 is driven by rotating the rotating roller 510 with the driving device, and the main body placed on the roller unit 500. 100 can be moved in the direction indicated by arrow A at a predetermined speed. The moving speed of the roller unit 500 is synchronized with the moving speed of the conveying means 300 in the heating process.

  In the pressing step, while being held between the roller units 500 provided on the upper and lower sides, the drive device provided on the rotating roller 510 of the roller unit 500 continues to move in the transport direction indicated by the arrow A.

  In the meantime, the main body 100 is continuously pressed by the pressure device provided in the upper roller unit 500, and during that time, the adhesive resin 122 of the soaking sheet 120 is cooled and solidified at a temperature lower than the melting temperature, The surface material 110, the soaking sheet 120, and the heater laminate 180 are securely bonded.

  The surface material 110, the soaking sheet 120, and the heater laminate 180 bonded in the second and third steps are bonded by the adhesive resin 122 coated on both surfaces of the soaking sheet 120. Since the gap 123 of 120 is not filled with the adhesive resin, this portion is not bonded, and the bending strength is weaker than the other bonded portions.

  The fourth process is an ultrasonic welding process in which the surface material 110 and the back material 150 at the periphery of the main body bonded in the third process are welded. The processing equipment used in the ultrasonic welding process is an ultrasonic welding machine 600 including a horn 610 that moves along the periphery of the main body 100 as shown in FIG.

  Since the soaking sheet 120, the heater unit 130, and the heat insulating sheet 140 are formed to have smaller outer dimensions than the surface material 110 and the back surface material 150, the peripheral portion of the main body 100 is composed of the surface material 110 and the back surface material 150. Yes.

  By applying ultrasonic waves while moving the horn 610 of the ultrasonic welder 600 along the peripheral portion of the main body 100, the surface material 110 and the back surface material 150 are sequentially heated and melted to perform welding over the entire circumference.

  The trimming process of the fifth process is a finishing process in which unnecessary portions of the peripheral part of the main body 100 are cut off and shaped, and as shown in FIG. 11, the equipment used in this process has the width direction on both sides of the main body 100 simultaneously. Two disk-shaped cutters 700 to be cut and one cutter 700 to be cut while moving in the length direction.

  The unnecessary portion of the stepped portion subjected to ultrasonic welding is cut off while moving the disk-shaped cutter 700 in the width direction and the length direction, and the main body 100 is finished to a predetermined size, whereby the main body 100 is completed.

<3> Action, Effect As described above, the main body of the planar warming tool in the present embodiment is a configuration and manufacturing method that employs a small-sized sheet material that is easy to procure as the soaking sheet 120. It is easy to procure materials and can be produced at low cost.

  In addition, since the gap 123 generated by dividing the soaking sheet 120 is not filled with adhesive resin, this portion is not bonded and becomes a portion whose bending strength is weaker than other bonded portions, but the heater wire 132 By arranging the straight part 134 across the gap 123, the ratio of the intensity difference from the other parts can be suppressed. Thereby, even when the main body 100 is lifted or rolled, it is possible to prevent the portion of the gap 123 from being bent and leaving a crease, so that the appearance of the planar warming tool does not deteriorate.

  Further, the sheet heating device in the present embodiment employs a felt-like sheet obtained by mixing the high melting point resin fiber and the low melting point resin fiber as the heat insulating sheet 140, and melts the low melting point resin fiber by hot pressing. Since the heater wire 132 of the heater unit 130 can be embedded in the heat insulation sheet 140, the upper surface of the surface material 110 is not partially projected by the heater wire 132, and the upper surface of the surface material can be finished in a flat state. In addition, since the elasticity of the heat insulating sheet 140 can be maintained by the high melting point resin fiber, the feel and appearance at the time of use can be improved.

  In addition, since the holding sheet 131 serving as the upper surface of the heater unit 130 can be formed flat, generation of wrinkles, cracks, and the like due to unnecessary deformation applied to the soaking sheet 120 laminated on the upper surface of the heater unit 130. Damage can be suppressed, and stable performance and shape can be maintained.

  Moreover, since the hot plates 211 and 221 of the hot press 200 used in the hot press process are flat, if the hot plate having the maximum size of the main body 100 is used, it is possible to cope with the processing of the main body 100 having different dimensions. Therefore, the equipment cost can be reduced.

  Further, in the electromagnetic induction heating process, heat necessary for melting the adhesive resin 122 is generated from the aluminum sheet 121 that is in direct contact with the adhesive resin 122, and the aluminum sheet 121 that is a heat source is centered. By sandwiching between the surface material 110 and the heater laminate 180, wasteful heat radiation to the outside can be suppressed, so that the adhesive resin 122 is melted with a much smaller amount of heat than a heating method in which heat is applied from the outside. The power required for heating is small, and a high energy saving effect can be obtained.

  Moreover, 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 as the surface material 110 is, for example, a material having an excellent appearance design and a low heat resistance temperature. It is possible.

  The aluminum sheet 121 is an indispensable constituent member of the soaking sheet 120 provided for the purpose of uniformly diffusing the heat generated by the heater unit 130 over the entire surface of the main body 100 when the sheet heating device is originally used. In addition to this, it is utilized in the manufacturing process, and a very large effect can be obtained in terms of manufacturing cost and man-hours.

  Further, since the aluminum sheet 121 as a heat source is in direct contact with the adhesive resin 122 to be melted, heating can be performed in a short time in seconds, so that it is not necessary to heat the entire surface of the main body 100 at the same time. In addition, the heating, melting, and bonding steps can be performed as a flow operation. Moreover, since the heating is partially performed, the electromagnetic induction heating device 400 used for heating may be a small-capacity small-sized object, which can reduce equipment costs and lower the maximum electric capacity during processing. it can.

  In addition, in the manufacturing method of the present invention using electromagnetic induction heating, a mold that is conventionally required for each size of the main body is unnecessary, and a heating coil 410 corresponding to the maximum size of the main body is prepared. For example, since heat is generated only in the range of the aluminum sheet 121 that is a heat generation source, the main body 100 smaller than the heating coil 410 can be heated with the same equipment, and the heating process equipment according to the size of the main body 100. In this respect, the equipment cost can be reduced.

  In the present embodiment, the soaking sheet 120 and the heater unit 130 are configured as separate members. However, the present invention is not limited to this, and the heater wire 132 may be directly disposed on the soaking sheet 120. . In this case, the first step can be carried out by coating the adhesive resin 122 of the soaking sheet 120 only on the side where the heater wire 132 is disposed, and an adhesive sheet as a separate member is provided on the surface facing the surface material 110. By interposing, it becomes possible to implement the manufacturing process after the 2nd process.

  In the present embodiment, an aluminum sheet is used as the base material of the soaking sheet 120. However, the present invention is not limited to this, and other metals such as copper and stainless steel may be used.

  In the present embodiment, the soaking sheet 120 is composed of two sheets. However, the present invention is not limited to this. In the case of a larger surface heating device, three or more sheets may be used. Good.

  Further, the gap 123 of the soaking sheet 120 is 5 mm. However, the present invention is not limited to this, and the gap 123 may be formed in the range of 5 to 10 mm.

  In this embodiment, three electromagnetic induction heating devices are used. However, the present invention is not limited to this, and two or four or more devices may be used. Moreover, although it was set as the structure provided with one heating coil for every electromagnetic induction heating apparatus, the structure which equips one electromagnetic induction heating apparatus with several heating coils and can control each heating coil separately may be sufficient. .

  Moreover, in this Embodiment, although the electromagnetic induction heating apparatus has been arrange | positioned at the surface material side of a main body, you may arrange | position not only to this but to a back surface side.

  As described above, the planar warming device according to the present invention can streamline the manufacturing process and improve the appearance quality, and thus can be applied to the use of a laminated member formed by joining a plurality of members. .

110 Surface material 120 Soaking sheet 120a Sheet 120b Sheet 122 Adhesive resin (adhesive)
123 Gap 131 Holding sheet 132 Heater wire 134 Linear part 135 Folded part 140 Thermal insulation sheet 150 Back material 160 First adhesive sheet (adhesive)
170 Second adhesive sheet (adhesive)

Claims (3)

A sheet-like back material;
A heat insulating sheet laminated on the back material;
A soaking sheet laminated on the heat insulating sheet;
A heater wire disposed between the heat insulating sheet and the soaking sheet;
And a sheet-like surface material laminated on the soaking sheet,
The soaking sheet is provided with a plurality of substantially rectangular sheets with gaps therebetween.
The heater wire is arranged in a meandering shape so that straight portions and folded portions are alternately formed,
The linear portion of the heater wire is disposed so as to be substantially orthogonal to the gap of the soaking sheet.
Planar warmer. A holding sheet laminated on the heat insulating sheet;
Between the heat insulating sheet and the metal sheet, the heater wire is disposed between the holding sheet and the heat insulating sheet,
The planar warming tool according to claim 1. The back material, the heat insulating sheet, the holding sheet, the soaking sheet, and the surface material are sequentially bonded by an adhesive mainly composed of a thermoplastic resin.
The planar warming tool according to claim 2.

Images