JP2605859B2 - Electric heater manufacturing method - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a main body configuration of an electric heater such as an electric carpet and a method of manufacturing the same.

2. Description of the Related Art Conventionally, as shown in FIG. , Thermal insulation 5
And was to be glued together. (For example,
59-30407) That is, the heater wire and the temperature detection wire
It was to be adhered to the back of the front cloth.

However, in the above-described method, a backing layer made of resin latex or the like is formed on the back surface of the outer cloth 3 to fix pile yarns. In order to adhere, the adhesive surface had to be flat, and the resin latex layer was considerably thick.
Therefore, the heat generated by the heater wire attached to the back of the top cloth has a large thermal resistance in the layer of resin latex, so there is little heat release to the front of the top cloth and insufficient heating or the backside temperature of the heater body is too high. There was a problem.

Furthermore, as a component of the heater body, a surface cloth,
When there are three parts, a heater unit and a heat insulating material, when they are integrated, the positioning of each part is complicated.

Therefore, a first object of the present invention is to obtain a main body of an electric heater that can efficiently release the heat of a heater wire to the surface of a surface cloth.

A second object is to simplify the integration process by forming a two-piece structure of a surface cloth and a heat insulating material when bonding the electric heater body.

Means for Solving the Problems In order to achieve the above object, the present invention provides a step of previously fixing a heater wire and a temperature detecting wire to a base cloth, and tufting a pile yarn directly on the base cloth to form a back surface (heater). And a step of backing on the surface on which the wire and the temperature detection wire are adhered).

Since the method of the present invention for producing a main body of an electric heater is obtained through the above-described steps, a backing layer of resin latex and a layer of a heat insulating material are formed in a downward direction (backward direction) of the heater wire, so that heat insulation is good. Therefore, the heat of the heater wire can be efficiently released to the surface, and the heating capacity is improved.

Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.

In FIGS. 1 and 2, reference numeral 1 denotes a heater wire (a temperature detection line is also a part of the present configuration, but is structurally exactly the same as the heater wire, and is omitted in the following description), and 2 is a base cloth. is there. The heater 1 has an inner winding 12 wound on a core yarn 11, a temperature-sensitive layer 13 is provided thereon, an outer winding 14 is wound thereon, and an outer insulating layer 15 and an outer adhesive layer 16 are sequentially formed. It is. In addition, the base cloth 2 and the heater wire 1 are integrated by placing the base cloth on a heater wire which has been previously wired at a predetermined position, and heating and compressing the base cloth to melt the jacket adhesive layer and melt the base cloth. It is done by bonding with.

Next, the pile yarn 31 is directly transferred to the base cloth already wired with the heater wire.
However, if the pile is protruded from the wiring side to the opposite side as in the configuration of FIG. 3, the heater wire will not be erroneously damaged.

A backing process is performed on the back surface of the surface cloth 3 thus obtained, which is formed by applying and drying a resin latex, and serves to stop pile yarn. Therefore, when the pile yarn is composed of a thick yarn, it is general to use a large amount of latex or foam to thicken the backing layer.

FIG. 4 shows a cross section in which the outer cloth 3 and the heat insulating material 5 are bonded. Here, the processing of the end face is such that the base cloth is folded and adhered to the back surface of the heat insulating material, and the processing of the overlock sewing machine or the like is unnecessary.

 Next, the operation of the configuration of the embodiment will be described.

The base fabric has a role as a base material for fixing the heater wires and the temperature detection wires in wiring and a role as a base material for tufting the pile yarn. And
When the heater wire is adhered to the base cloth of the outer cloth and is located above the backing layer, the backing layer is used as a heat insulating material, and when this layer is configured to be thick like a hand tuft carpet. Acts as a highly efficient thermal insulator.

When the base fabric is larger than the heat insulating material, the side surface can be covered by folding the end surface after bonding.
As shown in FIG. 5 as a second embodiment of the present invention,
After the heater wire 1 is fixed to the lower surface of the first base cloth 21 and then the second base cloth 22 is adhered so as to sandwich the heater wire 1, a heater unit is formed as in the above-described embodiment. In some cases, a pile yarn is tufted to form a top cloth.

In this case, there is an advantage that the fixing of the heater wire is strong. Other operations are exactly the same as in the first embodiment.

Effects of the Invention As described above, according to the manufacturing method of the present invention, the following effects can be obtained.

(1) Since the heat of the heater wire can be efficiently emitted to the upper surface, the heating efficiency is good and the back surface temperature of the main body can be lowered.

(2) Since it is the bonding of the two parts of the surface cloth and the heat insulating material,
Positioning is easy, and the manufacturing process can be simplified.

(3) The end face treatment of the electric heater main body can also be performed by the method of folding back the base cloth.

[Brief description of the drawings]

FIG. 1 is a configuration diagram of a heater wire used in one embodiment of the present invention, FIG. 2 is a cross-sectional view of a heater unit in which the heater wire is fixed to a base fabric, FIG. FIG. 5 is a sectional view of a heater main body, FIG. 5 is a sectional view of a heater unit in a second embodiment, and FIG. 6 is a sectional view of a conventional electric heater. 1 ... heater wire, 2 ... base cloth, 3 ... table cloth, 4 ... backing layer, 5 ... heat insulating material, 6 ... heater unit.

Claims (2)

(57) [Claims] A step of preliminarily wiring and fixing a heater wire and a temperature detection line to a base cloth; and a step of tufting a pile yarn on the base cloth to which the wiring is fixed and forming a backing layer on the back surface to form a front cloth. And a step of sequentially integrating the outer cloth with a heat insulating material. 2. The method according to claim 1, wherein the base cloth has a shape larger than the heat insulating material, and after the step of integrating the surface cloth and the heat insulating material, a step of folding the peripheral end of the surface cloth and bonding and fixing it to the back surface of the heat insulating material. The method for producing an electric heater according to claim 1.