JP2015232419A - Planar heater and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a planar heater which suppresses occurrence of irregularity and wrinkles on a surface and which has high appearance performance.SOLUTION: A planar heater includes: a sheet-like rear surface material 250; a heat insulation sheet 230 laminated on the rear surface material 250; a heater unit 220 laminated on the heat insulation sheet 230; and a sheet-like surface material 210 laminated on the heater unit 220. The heat insulation sheet 230 is made of a nonwoven fabric in which a high melting point resin fiber and a low melting point resin fiber having a melting point lower than that of the high melting point resin fiber are mixed at a predetermined ratio. Thereby, it can be suppressed that a heater wire protrudes to the surface of the surface material by the heater wire being buried in the heat insulation sheet, and also, occurrence of wrinkles on the surface material is suppressed, and appearance of the planar heater can be improved.

Description

  The present invention relates to a planar warming tool using a surface material provided with water-imperviousness by a resin and a method for manufacturing the same.

  Conventionally, the structure of the body of a surface warming tool using a surface material provided with a resin water-impervious surface is composed of a surface material in which a laminate layer of an olefin resin is formed on an upper layer of a polyester resin nonwoven fabric, and a heater wire on an aluminum sheet. A heater unit having a laminated structure, a heat-insulating sheet composed of two layers of a polyester resin hollow cotton nonwoven fabric, a polyester resin and a polypropylene resin nonwoven fabric, and a back surface material of an olefin-based elastomer resin. An adhesive sheet that is melted by heat is interposed between the two and heated and pressed by a hot press to melt the adhesive sheet and bond the members together to manufacture a main body made of a laminate (see, for example, Patent Document 1). ).

JP 2012-117800 A

  However, since the surface material, the heater unit, the heat insulating sheet, and the back surface material are made of different materials in the structure and manufacturing method of the conventional surface heating device, each material is heated when heated at the same temperature by hot pressing. Because the thermal characteristics related to shrinkage and deformation of the laminate are different, the laminated body after hot pressing may have deformation such as wrinkles and irregularities on the surface, especially when a thin water shielding sheet is used. In view of the appearance performance, there is still room for improvement.

  The present invention has been made to solve such a problem, and provides a surface warmer that suppresses generation of wrinkles and irregularities on the surface of the main body and improves the appearance, and a method for manufacturing the same. It is an object.

  In order to solve the above-described conventional problems, the planar warming device of the present invention includes a sheet-like back surface material, a heat insulating sheet laminated on the back surface material, and a heat insulating sheet laminated on the heat insulating sheet. A heater unit in which a heater wire is disposed on a soaking sheet coated with a plastic adhesive resin, and a sheet-like surface material laminated on the heater unit, a back material, a heat insulating sheet, and a heater unit And the surface material are bonded to each other with an adhesive mainly composed of a thermoplastic resin, and the heat-insulating sheet includes a high melting point resin fiber and a low melting point resin fiber having a lower melting point than the high melting point resin fiber. It consists of the nonwoven fabric mixed by the ratio.

  As a result, the heater wire is buried in the heat insulating sheet, so that the heater wire can be prevented from projecting to the surface of the surface material, and the surface material can be prevented from being wrinkled. The appearance can be improved.

  The planar warming tool of the present invention can suppress the occurrence of irregularities and wrinkles on the surface, and can improve the appearance performance.

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 detail of 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 schematic diagram which shows the detail of the heater wire 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

  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 insulation sheet, and the thermoplastic adhesive resin was coated on both surfaces of the metal sheet A heater unit disposed on the heater unit, and a sheet-like surface material laminated on the heater unit, the back surface material, the heat insulating sheet, the heater unit, and the surface material, Is formed by bonding with an adhesive mainly composed of a thermoplastic resin, and in the heat insulating sheet, a high melting point resin fiber and a low melting point resin fiber having a lower melting point than the high melting point resin fiber are mixed at a predetermined ratio. A surface warming tool characterized by comprising a non-woven fabric.

  As a result, the heater wire is buried in the heat insulating sheet, so that the heater wire can be prevented from projecting to the surface of the surface material, and the surface material can be prevented from being wrinkled. The appearance can be improved.

  According to a second invention, in the first invention, the blending ratio of the low melting point resin fibers in the heat insulating sheet is 10% or less.

  Thereby, in particular, since it is possible to obtain the effect of reducing the dimensional change in the lateral direction after the press release in the hot press process, the deformation of the surface material and the heater unit bonded to the heat insulating sheet is reduced, Generation | occurrence | production of a wrinkle in a surface material is suppressed and the external appearance of a planar warming tool can be improved more.

  According to a third aspect of the present invention, a back material, an adhesive sheet mainly composed of a thermoplastic resin, a high melting point resin fiber, and a low melting point resin fiber having a lower melting point than the high melting point resin fiber are mixed in a predetermined ratio. A laminate in which a heat-insulating sheet composed of a nonwoven fabric, a heater unit in which heater wires are arranged on a soaking sheet in which a thermoplastic adhesive resin is coated on both surfaces of a metal sheet, and a sheet-like surface material are laminated in this order. The adhesive sheet, the adhesive resin, and the low melting point resin fiber are heated at a temperature lower than the melting point of the high melting point resin fiber and higher than the melting point of the low melting point resin fiber while pressing the laminate. Is a method for manufacturing a planar warming tool.

  Thus, the heater wire can be buried in the heat insulating sheet by melting the low melting point resin fiber in the hot pressing process, and the heater wire can be prevented from protruding to the surface of the surface material, and the surface material Thus, it is possible to easily produce a surface warmer having high appearance performance.

  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> Configuration of planar warmer FIG. 1 is a perspective view showing a completed state of the planar warmer in Embodiment 1 of the present invention, and FIG. 2 is a cross section showing a completed state of the main body of the planar warmer 3 is a cross-sectional view showing a detailed configuration of members constituting the main body, FIG. 4 is a plan view showing the heater unit, and FIG. 5 is a schematic diagram showing a detailed configuration of the heater wire.

  As shown in FIG. 1, the planar warming tool 100 according to the present embodiment has a controller 110 disposed at one end of a main body 200 composed of a plurality of sheet-like members, and power is supplied by a power cord 111 connected to the controller 110. The main body 200 is heated by being supplied, and the main body 200 is installed on the floor surface of a house, and is a planar warming tool that is used by hanging the carpet cover 120 thereon.

  The carpet cover 120 has a three-layer structure in which a polyester fiber pile fabric is attached to the surface of a foamed urethane sheet with a thickness of about 2 mm, and a polyester fiber nonwoven fabric is attached to the back surface. Is given.

  As shown in FIG. 2, the main body 200 of the surface warmer includes a sheet-like surface material 210, a sheet-like heater unit 220, a felt-like heat insulating sheet 230, a sheet-like adhesive sheet 240, and a sheet-like The back material 250 is a main constituent member, and these members are bonded by heating and pressing with a hot press apparatus, and the outer periphery is subjected to a welding process by ultrasonic welding. In the completed state, the adhesive sheet 240 interposed between the heat insulating sheet 230 and the back surface material 250 mainly penetrates into the heat insulating sheet 230, so that almost no thickness remains.

  As shown in FIG. 3, the surface material 210 is an uppermost member in the main body 200 of the planar warming tool, and is a surface that is highly likely to be directly contacted and visually observed by the user. The surface material 210 is provided with many performances necessary as a surface material such as design properties, stain resistance, and tactile sensation in addition to mechanical strength and water impermeability, and is mainly made of vinyl chloride resin (hereinafter referred to as PVC). The upper layer 211 is colored and patterned on the surface of the sheet as the component, and a two-layer laminated sheet in which the lower layer 212 of the polyester nonwoven fabric is bonded to the back surface of the upper layer 211, and the thickness is about 0.2 mm. Since the surface material is thin, it has the effect of efficiently transferring the heat of the heater unit 220 to the carpet cover 120. However, since the surface material 210 is thin, the unevenness inside the main body 200 is It is a material that is easily noticeable on the surface and easily generates wrinkles due to heat and pressure applied during processing.

  The heater unit 220 is a heat source of the sheet heating device, and as shown in FIG. 4, heater wires 224 are arranged in a meandering shape on one side of a heat equalizing sheet 221 mainly composed of aluminum.

  The soaking sheet 221 is a member for the purpose of uniformly diffusing the heat generated by the heater wire 224 over the entire surface of the main body 200, and has a thickness of about 0.01 mm whose main component is aluminum which is a metal sheet having high thermal conductivity. Is formed by coating an adhesive resin 223 made of polyethylene resin on both sides thereof, and the adhesive resin 223 made of polyethylene resin is melted and bonded by heating to about 97 ° C. or higher. Demonstrate the function as an agent.

  As shown in FIG. 5, the heater wire 224 has a temperature detection wire 224b for detecting temperature around a central glass fiber 224a spirally wound, and an insulating layer 224c is formed of nylon resin on the outer periphery thereof. A heating wire 224d is spirally wound around the outer periphery of 224c, a PVC insulating layer 224e is formed on the outer periphery, and an adhesive layer 224f made of polyethylene resin is formed on the outer periphery of the insulating layer 224e. It is about 2.7 mm.

  As shown in FIG. 4, the heater unit 220 arranges the start end of the heater wire 224 at one corner of the soaking sheet 221, and alternately turns the straight portion and the folded portion so as to cover the entire area of the soaking sheet 221. It is formed and arranged in a meandering shape, and the terminal end is disposed in the vicinity of the starting end. Heat is applied in a state in which the heater wire 224 is arranged in a meandering shape on the soaking sheet 221, whereby the adhesive layer 224 f of the heater wire 224 is melted and bonded and fixed to the soaking sheet 221.

  The heat insulating sheet 230 is provided for the purpose of obtaining a cushioning property of the surface warming tool 100 due to the function of suppressing the heat generated by the heater unit 220 from being unnecessarily transmitted to the floor and the high elasticity mainly of the high melting point resin fiber. A high melting point resin fiber mainly composed of a polyester resin is mixed at a ratio of about 92% and a low melting point resin fiber at a ratio of about 8% to form a felt shape having a thickness of about 15 mm. The melting temperature of the high melting point resin fiber is about 250 ° C., and the melting temperature of the low melting point resin fiber is about 85 ° C.

  When the heat insulating sheet 230 having the above configuration is heated to a temperature lower than 250 ° C. which is the melting temperature of the high melting point resin fiber and higher than 85 ° C. which is the melting temperature of the low melting point resin fiber, for example, 100 ° C., the low melting point resin fiber is melted. By doing so, the high-melting fiber is easily deformed, and the melted low-melting fiber serves to bond the main points of the high-melting fiber, whereby the effect of maintaining the deformed state of the heat insulating sheet 230 can be obtained.

  In particular, when pressure is applied to the heat insulating sheet 230 in the vertical direction by hot pressing, the heat insulating sheet 230 expands in the horizontal direction, and when the pressure is released, it generally returns to the original dimensions. Since the deformed state can be maintained by the adhesive action of the fibers, it is possible to obtain an effect of suppressing the return to the original dimensions after releasing the press.

  The outer dimension of the heat insulating sheet 230 is the same as or slightly larger than the outer dimension of the soaking sheet 221 of the heater unit 220.

  By utilizing the heating characteristics of the heat insulating sheet 230 as described above, the heater wire 224 is heated while pressing the heater wire 224 of the heater unit 220 facing the heat insulating sheet 230 in a stacked state. The unevenness of the soaking sheet 221 of the heater unit 220 can be suppressed, and the elasticity of the heat insulating sheet 230 can be maintained.

  In order to embed the heater wire 224 in the heat insulating sheet 230 as described above, it is important that the heat insulating sheet 230 has a sufficient thickness, and the heat insulating sheet 230 is four times or more the diameter of the heater wire 224. In this embodiment, the thickness of the heat insulating sheet 230 is 5.6 times that of 15 mm with respect to the diameter of the heater wire 224 of 2.7 mm.

  The adhesive sheet 240 is a sheet-like hot-melt adhesive that bonds the heat insulating sheet 230 and the back surface material 250. The adhesive sheet 240 is formed by forming a polyethylene resin into a sheet shape having a thickness of about 60 μm, forms a flexible sheet shape at room temperature, and melts at about 97 ° C. or more to exhibit a function as an adhesive. . The outer shape of the adhesive sheet 240 is larger than that of the heat insulating sheet 230 and is formed to have substantially the same dimensions as the back surface material 250.

  The back material 250 is a member that comes into direct contact with the floor surface of the main body 200 of the planar warming tool 100, and has performance such as mechanical strength as well as cushioning properties and slip resistance. The back material 250 is obtained by coating a both sides of a low density polyethylene resin cloth sheet with a polyethylene resin. The outer shape of the back material 250 is formed to have substantially the same dimensions as the surface material 210.

<2> Manufacturing Process of Main Body FIG. 6 is a schematic diagram showing a cross section of the hot press process in the first process, and FIG. 7 is a schematic diagram showing a cross section of the ultrasonic welding process for welding the peripheral part of the main body as the second process. FIG. 8 is a schematic diagram showing a cross section of a trimming process for cutting unnecessary portions around the main body in the third process.

  The first step is a hot pressing step in which the surface material 210, the heater unit 220, the heat insulating sheet 230, the adhesive sheet 240, and the back surface material 250, which are all members constituting the main body 200, are bonded by hot pressing. This process is a process in which the heating and pressing operations are performed simultaneously. As shown in FIG. 6, the equipment necessary for this process is a heat press apparatus 300, and the lower mold 310 and the upper mold 320 of the heat press apparatus 300 are the main body. 200 includes flat plate-like hot plates 311 and 321 that cover the entire surface.

  As shown in FIG. 6, the heater unit 220 and the surface material 210 are laminated in this order on the heat plate 311 of the lower mold 310 so that the back material 250, the adhesive sheet 240, the heat insulating sheet 230, and the heater wire 224 are on the lower side. . In this step, as shown in FIG. 6, the heater unit 220 and the heat insulating sheet 230 are smaller in outer dimensions than the surface material 210, the adhesive sheet 240, and the back material 250, so that the surface material 210, the adhesive sheet 240, and the back material 250 It is important to place it in the center.

  The hot plate 311 of the lower mold 310 of the hot press apparatus 300 is heated to about 100 ° C., and the hot plate 321 of the upper mold 320 is heated to about 140 ° C. The temperature of the hot plate is such that the inside of the heat insulating sheet 230 is higher than the melting point 85 ° C. of the low-melting resin fiber and lower than the melting point 250 ° C. of the high-melting resin fiber during the hot press processing step. The adhesive resin 223 and the adhesive sheet 240 are set to have a temperature higher than the melting point of 97 ° C. In this heated state, the upper die 320 is lowered and the laminated member is heated and pressed and maintained for about 30 seconds, and then the upper die 320 is opened.

  Thereby, the adhesive resin 223 of the soaking sheet 221 is melted, the surface material 210 and the heater unit 220 are bonded, the heater unit 220 and the heat insulating sheet 230 are bonded, and the adhesive sheet 240 is melted, whereby the heat insulating sheet 230 and The back material 250 is bonded. In addition, when the heater wire 224 is pressed against the heat insulating sheet 230, a part or the whole of the low melting point resin fiber of the heat insulating sheet 230 is melted, so that a recess in which a part of the heater wire 224 is accommodated is formed in the heat insulating sheet 230. .

  By ending the hot pressing process, all the members constituting the main body 200 are bonded to form an integrated laminate.

  The second step is an ultrasonic welding step in which the surface material 210, the adhesive sheet 240, and the back surface material 250 at the periphery of the laminate of the main body 200 bonded in the first step are welded. The processing equipment used in the ultrasonic welding process is an ultrasonic welding machine 400 provided with a horn 410 capable of simultaneously ultrasonically welding two sides of the main body 200 as shown in FIG.

  Since the heater unit 220 and the heat insulating sheet 230 are formed to have smaller outer dimensions than the surface material 210, the adhesive sheet 240, and the back material 250, the periphery of the main body 200 is composed of the surface material 210, the adhesive sheet 240, and the back material 250. It is configured.

The trimming process of the fifth process is a finishing process in which unnecessary portions of the peripheral part of the main body are cut off and shaped. In the trimming process, a trimming apparatus 500 shown in FIG. 8 is used. The trimming apparatus 500 includes two disk-shaped rotary cutters 510. The two rotary cutters 510 arranged corresponding to the width direction end portions of the main body 200 cut the width direction end portions while moving in the length direction of the main body 200. Thereby, both sides in the width direction of the main body 200 are simultaneously cut. Next, the two rotary cutters 510 arranged corresponding to the lengthwise end portions of the main body 200 cut the lengthwise end portions while moving in the width direction of the main body 200. Thereby, the both sides of the length direction in a main body are cut | disconnected simultaneously.

  With such a trimming device, unnecessary portions in the peripheral portion of the main body are cut off, and the dimensions of the main body fall within a predetermined range. Thereby, the main body is completed.

<3> Action and Effect According to the above-described configuration and manufacturing method, a felt-like sheet in which high melting point resin fibers and low melting point resin fibers are mixed is employed as a heat insulating sheet. In the range where the low melting point resin fiber is melted by the hot pressing process and the heater wire is arranged, the heat insulating sheet is recessed along the heater wire, and the heater wire is embedded in the heat insulating sheet. Moreover, in the whole heat insulation sheet, the high melting point resin fiber compressed with the molten low melting point resin fiber is hardened, and the hollow shape formed by the heater wire is maintained. Thereby, it can suppress that a heater wire protrudes on the surface of a surface material, and it becomes difficult to give a user the discomfort which a heater wire hits, and the external appearance of a planar warming tool can be improved.

  In addition, by blending the high melting point resin fiber and the low melting point resin fiber in the above ratio, the melted low melting point fiber serves to adhere the key points of the high melting point fiber, thereby maintaining the deformation state. Since it can be obtained, it is possible to obtain the effect of reducing the lateral dimensional change after the release of pressure in the hot press process, and therefore the deformation of the surface material and the heater unit bonded to the heat insulating sheet is reduced. The occurrence of wrinkles on the surface material is suppressed, and the appearance of the surface warming tool can be improved.

  In the present embodiment, the high-melting point resin fiber of the heat insulating sheet 230 is blended at a ratio of about 92% and the low-melting point resin fiber at a ratio of about 8%. However, the present invention is not limited to this blending ratio. An approximate effect can be obtained by setting the blending ratio of the resin fibers to 10% or less, and a high effect can be obtained particularly in the range of 5% to 10%.

  The planar warming tool and the manufacturing method thereof according to the present invention are useful as a planar warming tool and a manufacturing method thereof for improving the feel on the surface and the appearance of the surface.

DESCRIPTION OF SYMBOLS 100 Surface heating device 200 Main body 210 Surface material 220 Heater unit 221 Heat equalizing sheet 222 Aluminum sheet (metal sheet)
223 Adhesive resin 224 Heater wire 230 Heat insulation sheet 250 Back material

Claims (3)

A sheet-like back material;
A heat insulating sheet laminated on the back material;
A heater unit in which a heater wire is disposed on a soaking sheet laminated on the heat insulating sheet and coated with a thermoplastic adhesive resin on both sides of the metal sheet;
A sheet-like surface material laminated on the heater unit,
The back material, the heat insulating sheet, the heater unit, and the surface material are bonded with an adhesive mainly composed of a thermoplastic resin,
The heat insulating sheet is composed of a nonwoven fabric in which a high melting point resin fiber and a low melting point resin fiber having a lower melting point than the high melting point resin fiber are mixed at a predetermined ratio.
Planar warmer. The blending ratio of the low melting point resin fiber in the heat insulating sheet is 10% or less.
The planar warming tool according to claim 1. Heat insulation composed of a nonwoven fabric in which a backing material, an adhesive sheet mainly composed of a thermoplastic resin, a high melting point resin fiber and a low melting point resin fiber having a melting point lower than that of the high melting point resin fiber are mixed at a predetermined ratio. A sheet and a heater unit in which heater wires are arranged on a soaking sheet in which a thermoplastic adhesive resin is coated on both surfaces of a metal sheet and a sheet-like surface material are laminated in order,
While pressing the laminate, by heating at a temperature lower than the melting point of the high melting point resin fiber and higher than the melting point of the low melting point resin fiber, the adhesive sheet and the adhesive resin are melted.
A method for manufacturing a surface heating device.

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