JP5503571B2 - Manufacturing method of planar warmer and manufacturing apparatus of planar warmer - Google Patents

Description

  The present invention relates to a method for manufacturing a sheet heating device and an apparatus for manufacturing the sheet heating device using an electric heater as a heat source.

  Conventionally, this type of sheet heating device has a structure in which three layers of a backing material, a heater unit in which a heater wire is disposed on a base material, and a surface material are laminated. And between the heater unit and the surface material are attached by an adhesive. This type of surface heating device is manufactured by applying an adhesive to one main surface of the backing or the heater unit and applying an adhesive to the other main surface or the front material of the heater unit. A laminated body is formed by overlapping the material, the heater unit, and the surface material. Thereafter, the laminate is heated from the outside to melt the adhesive between the layers, and then press-molded using a mold.

  However, in this method, since heating is performed from the outside of the laminate, in order to sufficiently melt the adhesive between the layers, there is a problem that the outer surface material or backing material must be excessively heated. Excessive heating of the surface material or backing material may cause the quality of the surface material or backing material to deteriorate if the temperature exceeds the service temperature of the surface material or backing material in the usage condition of the surface heating device. . In particular, the surface material may be embossed for the design of the surface or the touch when touched, or it may use a material that is not very resistant to heat in order to make it soft. When heating is performed, the surface material may be deformed or deteriorated, and the design applied to the surface material may be damaged or the touch when touched may be adversely affected.

  On the other hand, as a method of manufacturing a planar warming device without using an adhesive, a heater unit in which a urethane foam material is applied on a backing and a heater wire is disposed on the substrate; There is also a method of laminating a surface material and press-molding them in a mold. At this time, the urethane foam material foams, and the urethane foam material oozes out from the base material side of the heater unit to the front material side due to the foaming pressure, and adheres to the front material, so that the backing material, the heater unit, and the front material are bonded together. It is also known (see, for example, Patent Document 1).

  17 (a) to 17 (c) show a conventional planar warmer described in Patent Document 1, and FIG. 17 (a) shows a perspective view showing the order of creating the planar warmer, 17 (b) shows a side view of the production order, and FIG. 17 (c) shows a cross-sectional view of the planar warming tool after molding. As shown in FIG. 17A, a front material 901, a heater unit 903 in which a heater wire 903b is arranged on a heater base material 903a, and a backing 905 in which a urethane foam material 904 is applied to the surface are prepared. As shown in FIG. 17 (b), they are stacked and placed in a mold (not shown), and are press-molded in the mold to form the planar warming tool shown in FIG. 17 (c).

JP 2001-041480 A

  However, the manufacturing method described in Patent Document 1 still has the following problems. That is, in the manufacturing method described in Patent Document 1, it is essential to prepare a mold in order to perform press molding, and it is necessary to prepare the mold for each shape and size of the planar warming tool. is there. In particular, the surface heating device that is installed and used on the floor surface is generally produced in many sizes, so the cost required to manufacture the mold increases, and a surface heating device of a different shape or size is used. It is difficult to improve production efficiency when it is necessary to exchange molds during production.

  The present invention solves the above-described conventional problems, and enables the production of a planar warming tool without using a mold while preventing adverse effects due to heating of the surface material, and the shape and size are different. It is an object of the present invention to provide a manufacturing method and a manufacturing apparatus that can easily cope with a surface warmer.

In order to solve the above-described problems, a method for manufacturing a planar warming device according to the present invention includes a planar heater unit in which a heater wire is disposed on a soaking sheet containing a metal component, and a laminate on the heater unit. A sheet heating device comprising a sheet-like member, wherein the sheet-like member and the heater unit are stacked with a hot-melt adhesive layer interposed therebetween. The electromagnetic induction heating coil is installed in the proximity of at least one of the front and back surfaces of the laminate and the laminate is moved in a predetermined moving direction, and magnetic lines of force are generated by the electromagnetic induction heating coil. It is not including a heating step to melt the adhesive by heating the soaking sheets of the heater unit, wherein the electromagnetic induction heating coil is a plurality arranged along the movement direction, These plurality of said electromagnetic induction heating coil is configured to independently power is controlled, and the interval between a plurality of said electromagnetic induction heating coil has become the adjustable, in said heating step, The plurality of electromagnetic induction heating coils repeatedly generate heat at the same portion of the laminate several times , and the adhesive layer is lower than the heat-resistant temperature of the adhesive and higher than the melting temperature of the adhesive In order to heat to temperature, it is the structure which controls the electric power supply to each said electromagnetic induction heating coil, and adjusts the space | interval of the said electromagnetic induction heating coils .

In addition, in order to solve the above-described problem, an apparatus for manufacturing a planar warmer according to the present invention includes a planar heater unit in which a heater wire is disposed on a soaking sheet containing a metal component, and the heater unit. An apparatus for manufacturing a planar warming device comprising a sheet-like member laminated on the laminate, wherein the sheet-like member and the heater unit are stacked with a hot-melt adhesive layer interposed therebetween A conveying means for conveying in a predetermined moving direction; and an electromagnetic induction heating means including a plurality of electromagnetic induction heating coils that are located downstream of the moving direction and arranged adjacent to each other in the moving direction; A heating unit moving mechanism for moving the distance between the electromagnetic induction heating coils in an adjustable manner, and a control unit, wherein the control unit supplies power independently to the plurality of electromagnetic induction heating coils. Is While being configured to be, by applying to at least one of the front and back surfaces of the laminate was conveyed, the magnetic field lines generated by a plurality of the heating coil of the electromagnetic induction heating means by said conveying means, The same location of the soaking sheet of the heater unit is repeatedly heated to melt the adhesive, and control of power supply to each electromagnetic induction heating coil by the control means And by adjusting the space | interval of the said electromagnetic induction heating coils by the said heating part moving mechanism, the layer of the said adhesive is lower than the heat-resistant temperature of the said adhesive, and higher than the melting temperature of the said adhesive Ru configuration der heating to a temperature.

  The above object, other objects, features, and advantages of the present invention will become apparent from the following detailed description of preferred embodiments with reference to the accompanying drawings.

  The method and apparatus for manufacturing a surface warmer of the present invention enables the production of a surface warmer without using a mold while preventing adverse effects due to heating of the surface material. It is possible to easily cope with different surface heating devices.

It is a perspective view which shows an example of the external shape of the planar warming tool manufactured in the manufacturing method of the planar warming tool which concerns on Embodiment 1 of this invention. It is a perspective view which shows an example of the state before assembling the main body of the planar warming tool shown in FIG. It is sectional drawing which shows an example of the completion state of the main body shown in FIG. It is sectional drawing which shows a specific example of the structural member of the main body shown in FIG. It is a perspective view which shows an example of the specific structure of the heater wire with which the main body shown in FIG. 4 is provided. It is a schematic diagram which shows an example of the preparatory process at the time of manufacturing the main body shown in FIG. (A) And (b) is a schematic diagram which shows an example of the heating process at the time of manufacturing the main body shown in FIG. 3, and a press process. (A) And (b) is a schematic diagram which shows an example of the hot press process at the time of manufacturing the main body shown in FIG. It is a schematic diagram which shows an example of the ultrasonic welding process at the time of manufacturing the main body shown in FIG. It is a schematic diagram which shows an example of the trimming process at the time of manufacturing the main body shown in FIG. (A) is a schematic diagram which shows a more preferable example of the heating process shown to Fig.7 (a), (b) is arrangement | positioning of two electromagnetic induction heating coils used by the heating process shown to (a). It is a schematic diagram shown. (A) is a graph which shows the temperature change of the aluminum sheet and surface material at the time of manufacturing the main body of a planar warming tool by the heating process shown to Fig.11 (a) and (b), (b), It is a graph which shows the induced electromotive force of the electromagnetic induction heating coil corresponding to the temperature change of a). (A) is a schematic diagram which shows an example of the heating process and press process at the time of manufacturing a main body in the manufacturing method of the planar warming tool which concerns on Embodiment 2 of this invention, (b) is (a) It is a schematic diagram which shows arrangement | positioning of the two electromagnetic induction heating coils used by the heating process shown to). (A) is a graph which shows the temperature change of the aluminum sheet in the heating process in the case of one electromagnetic induction heating coil shown to Fig.7 (a), and an adhesive sheet, (b) is shown to Fig.13 (a). It is a graph which shows the temperature change of the aluminum sheet in the heating process in the case of three electromagnetic induction heating coils, and an adhesive sheet. It is a schematic diagram which shows an example of arrangement | positioning of the several electromagnetic induction heating coil used at a heating process in the manufacturing method of the planar warming tool which concerns on Embodiment 3 of this invention. (A)-(c) is a schematic diagram which shows an example of the manufacturing apparatus of the planar warming tool which concerns on Embodiment 4 of this invention. (A) is a perspective view which shows an example of the manufacturing order of the conventional planar warming tool, (b) is sectional drawing which shows the other example of the manufacturing order of the conventional planar warming tool, (c ) Is a cross-sectional view showing a completed state of a conventional planar warming tool.

  The manufacturing method of the planar warming tool which concerns on this invention is a surface provided with the planar heater unit by which the heater wire was arrange | positioned by the soaking | uniform-heating sheet | seat containing a metal component, and the sheet-like member laminated | stacked on the said heater unit. A method of manufacturing a warming tool, comprising: a preparation step of forming a laminate in which the sheet-like member and the heater unit are stacked with a layer of a hot-melt adhesive interposed therebetween; An electromagnetic induction heating coil is installed in proximity to at least one of the front and back surfaces, and magnetic lines of force are generated by the electromagnetic induction heating coil while moving the laminated body in a preset movement direction, so that the soaking of the heater unit is performed. A heating step of melting the adhesive by causing the sheet to generate heat, and in the heating step, a plurality of the electromagnetic induction heating coils are arranged adjacent to each other at a position facing the laminate. It may be any configuration you are.

  According to the above configuration, the heat for melting the hot-melt type adhesive is obtained from the heat generation of the soaking sheet inside the planar warming tool, so that the adhesive can be efficiently melted in a short time. Can do. In particular, since the electromagnetic induction heating coil is arranged adjacently, a wide range can be heated at the same time, so that rapid heating of the soaking sheet can be avoided, and the temperature of the soaking sheet as a heat source can be reduced. It can be controlled within an appropriate range. Therefore, it is possible to carry out the bonding work of the sheet-like member in a short time, not only can suppress wasteful heat dissipation outside the planar warming tool, it is also possible to suppress the deterioration of the melting adhesive, The adhesion state of the sheet-like member can be made suitable.

  In addition, since the electromagnetic induction heating coils are arranged adjacent to each other, the heating capacity of each electromagnetic induction heating coil is set to be different, or the distance between the electromagnetic induction heating coils is changed, so that the surface heating is performed. Suitable heating according to the configuration of the tool can be realized.

  Furthermore, since it is not necessary to apply heat from the outside of the laminate using a mold for the bonding process of the sheet-like member in the manufacturing process of the sheet heating device, in addition to being able to save energy in the manufacturing process, The initial investment cost can be suppressed and the degree of freedom in design can be improved.

  In the manufacturing method of the said structure, the layer of the said adhesive agent contained in the said laminated body is comprised as an independent sheet-like member, or is laminated | stacked integrally previously on the said sheet-like member, or both It is a certain configuration. Thereby, according to various conditions such as the material, thickness, and properties of the sheet-like member to be bonded, an adhesive layer can be appropriately provided, so that the adhesive state of the sheet-like member is more suitable. can do.

  In the manufacturing method of the above configuration, the sheet-like member is a surface material that constitutes the surface of the planar warming tool, a back material that constitutes the back surface of the planar warming tool, and a heating material generated from the heater unit. What is necessary is just the structure which is at least any one of the heat insulation sheet which suppresses the heat transfer to the said back side. As a result, a laminated body is formed using at least one of the front surface material, the back surface material, and the heat insulating sheet, which are typical basic components of the surface warmer, and the heating process is performed. The preferred production of

  In the manufacturing method having the above-described configuration, the heater unit has a configuration in which the heater wire is disposed on one of the front and back surfaces of the soaking sheet, and in the heating step, the soaking in the laminate is performed. What is necessary is just the structure which installs the said laminated body so that the surface of the side which has not arrange | positioned the said heater wire of a sheet | seat may adjoin to the said electromagnetic induction heating coil. Thereby, since several electromagnetic induction heating coils can be arrange | positioned facing the soaking | uniform-heating sheet | seat which is a uniform plane, heat_generation | fever of a soaking | uniform-heating sheet | seat can be performed more uniformly and stably.

In the manufacturing method having the above configuration, the electromagnetic induction heating coil is a long plate-like coil that is longer than the width of the laminate, and the plurality of long plate-like coils are arranged in the longitudinal direction in the moving direction. Any configuration may be used as long as the configuration is adjacent to each other. As a result, the heating range is translated along the moving direction of the laminated body, and not only can the entire laminated body be efficiently and uniformly heated, but also a wide range by the adjacent long plate-like coils. Therefore, it is possible to effectively avoid rapid heating of the soaking sheet and to control the temperature of the soaking sheet in a more appropriate range.

In the manufacturing method having the above configuration, the electromagnetic induction heating coil is a short plate-like coil shorter than the width of the laminate, and the plurality of short plate-like coils intersect the moving direction of the laminate. What is necessary is just the structure arrange | positioned adjacently so that the whole width may be covered. Thereby, it becomes possible by changing the heating capacity of each short plate-shaped coil to change the degree of heating in the direction crossing the moving direction. Therefore, for example, when a plurality of soaking sheets are used in a partially overlapping manner in order to produce a planar warming tool having a larger size, even if the thickness of the soaking sheets in the laminate is partially different, It becomes possible to perform uniform heating throughout the body.

  In the manufacturing method of the said structure, what is necessary is just the structure which is further performed after the said heating process and further includes the press process which presses the said laminated body whole. Thereby, since a laminated body is pressed by a press process after melting the layer of an adhesive agent by a heating process, a sheet-like member can be pasted up favorably.

  Moreover, the manufacturing apparatus of the planar warming tool which concerns on this invention has the planar heater unit by which the heater wire was arrange | positioned by the soaking sheet containing a metal component, and the sheet-like member laminated | stacked on the said heater unit. A sheet heating device manufacturing apparatus comprising: a stacked body in which the sheet-like member and the heater unit are stacked in a state in which a layer of a hot-melt adhesive is interposed; A conveying means for conveying, an electromagnetic induction heating means including a plurality of heating coils located adjacent to each other on the downstream side in the moving direction, and a control means, the control means being conveyed by the conveying means. Further, by applying magnetic lines of force generated by the electromagnetic induction heating means to at least one of the front and back surfaces of the laminate, the soaking sheet of the heater unit is heated to melt the adhesive. It is configured to.

  According to the above configuration, since the conveyance unit and the electromagnetic induction heating unit are provided, the control unit heats the soaking sheet by the heating coil and melts the adhesive layer while moving the laminate. . Therefore, it is possible to carry out the bonding work of the sheet-like member in a short time, not only can suppress wasteful heat dissipation outside the planar warming tool, it is also possible to suppress the deterioration of the melting adhesive, The adhesion state of the sheet-like member can be made suitable.

  The manufacturing apparatus having the above-described configuration may further include a pressing unit that is positioned adjacent to the downstream side in the moving direction of the electromagnetic induction heating unit and presses both surfaces of the laminate. Thereby, since the laminated body is pressed by the pressing means after the adhesive layer is melted by the electromagnetic induction heating means, the sheet-like member can be bonded well.

Further, the planar Todan tool more obtained in the present invention, the produced by the method, a planar heater unit heater wire in the soaking sheets are provided containing a metal component, is laminated to the heater unit that a sheet-like member, the heater unit and the sheet-shaped member, a structure that is fixed by being bonded together by a layer of hot melt adhesive.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. In the following description, the same or corresponding elements are denoted by the same reference symbols throughout the drawings, and redundant description thereof is omitted.

(Embodiment 1)
[Configuration of surface heating device]
First, an example of the typical structure of the planar warming tool manufactured by this invention is demonstrated concretely with reference to FIG. 1 thru | or FIG. FIG. 1 is a perspective view showing an example of a completed state of a planar warming tool in Embodiment 1 of the present invention, and FIG. 2 is a perspective view showing an example of a state of the planar warming tool before assembly. 3 is a cross-sectional view showing a completed state of the main body shown in FIG. 2, FIG. 4 is a cross-sectional view showing a detailed structure of members constituting the main body shown in FIG. 3, and FIG. 5 is a main body shown in FIG. It is a perspective view which shows an example of the specific structure of a heater wire with which is provided.

  As shown in FIG. 1, the planar warming tool is provided with a control unit 101 at one end of a main body 100 composed of a plurality of sheet-like members, and is supplied with power from a power cord 102 connected to the control unit 101. It is comprised so that 100 may be heated and it functions as a heating tool which installs and uses on the floor surface of a house. The control unit 101 is a known control unit for controlling the heat generation operation of the main body 100 of the planar warming tool, and includes a display lamp (not shown) configured by a switch, a temperature adjustment knob, a light emitting diode, and the like.

  As shown in FIG. 2, the main body 100 of the surface warmer has a front material 200, an adhesive sheet 300, a heater unit 400, a heat insulating sheet 500, and a back material 600 as main components, and as shown in FIG. Are formed in order to have a cross-sectional shape as shown in FIG.

  As shown in FIG. 4, the surface material 200 is the outermost member of the main body 100 of the planar warming tool and has necessary performance such as design, contamination resistance, and tactile sense as well as mechanical strength. It is. The specific configuration is not particularly limited, but as a typical example, a main component is polyvinyl chloride resin (hereinafter referred to as PVC), and a polyester resin is applied to the back surface of the colored and patterned surface sheet 201. The thing of the structure which has adhere | attached the nonwoven fabric 202 which has a main component with the adhesive agent 203 and has comprised the sheet form can be mentioned. The nonwoven fabric 202 is provided to prevent the heater wire 420 from floating on the surface material 200 after the sheet-like member is bonded and integrated as a surface heating device.

  The adhesive sheet 300 functions as an adhesive member for attaching the surface material 200, and the configuration thereof is not specifically limited. As a typical example, a polyethylene (polyethylene) resin is formed into a sheet shape. It can be exemplified by a flexible sheet form at room temperature, and melts at about 97 ° C. or more to exhibit a function as an adhesive.

  The heater unit 400 is a heat source of the surface heating device, and its configuration is not specifically limited. As a typical example, a heater wire is provided on one side of a soaking sheet 410 mainly composed of aluminum. The thing which has arrange | positioned 420 to the serpentine shape can be mentioned. In addition, as the base material of the soaking sheet 410, the aluminum sheet 411 is used, but it is not limited to this, and as long as it is formed with the material which can be heated with an electromagnetic induction heating apparatus so that it may mention later. Since it is good, other metal materials, such as copper and stainless steel, may be sufficient.

  The soaking sheet 410 is a member used for uniformly diffusing the heat generated by the heater wire 420 over the entire surface of the main body 100, and its configuration is not specifically limited, but a representative example is thermal conductivity. An example is one in which an aluminum sheet 411 having a thickness of about 0.01 mm, which is mainly composed of aluminum, which is a high metal sheet, is used as a base material, and an adhesive resin 412 made of polyethylene resin is coated on both surfaces thereof. be able to. The adhesive resin 412 made of polyethylene resin is melted by being heated to about 97 ° C. or more and exhibits a function as an adhesive.

  Although the specific configuration of the heater wire 420 is not particularly limited, as a typical example, as shown in FIG. 5, a detection wire 422 for detecting the temperature around the center glass fiber 421 is spirally wound, An insulating layer 423 is formed on the outer periphery with nylon resin, a heating wire 424 is spirally wound on the outer periphery of the insulating layer 423, a PVC insulating layer 425 is formed on the outer periphery, and an outer periphery of the insulating layer 425 is formed on the outer periphery. An example in which an adhesive layer 426 made of polyethylene resin is formed can be given.

  As shown in FIG. 2, the heater unit 400 is arranged in a meandering shape so that the start end (one end) of the heater wire 420 is arranged at one corner of the soaking sheet 410 and covers the entire area of the soaking sheet 410. However, the terminal end (the other end) is arranged in the vicinity of the starting end. Further, as shown in FIG. 2, by applying heat with the heater wire 420 disposed, the adhesive layer 426 of the heater wire 420 is melted, and the heater wire 420 is bonded and fixed to the soaking sheet 410.

  The heat insulating sheet 500 is provided in order to suppress the heat generated by the heater unit 400 from being transmitted to the floor surface unnecessarily, and the specific configuration thereof is not particularly limited. A sheet-like foamed urethane resin 501 (foamed urethane sheet 501) having both sides bonded with a non-woven fabric 502 mainly composed of a polyester resin can be exemplified. Similar to the nonwoven fabric 202, this nonwoven fabric 502 is also configured to prevent the heater wire 420 from floating.

  The back material 600 is a member that directly contacts the floor surface of the main body 100 of the planar warming tool, and its specific configuration is not particularly limited, but as a typical example, an olefin elastomer is the main component. An example is one in which the upper surface of the back sheet 601 is coated with an adhesive layer 602 of polyethylene resin. A preferable example of the olefin-based elastomer is a thermoplastic olefin elastomer (hereinafter abbreviated as TPO). TPO has not only mechanical strength but also performance such as cushioning and resistance to slipping, and further has elasticity.

  In the surface warmer according to the present embodiment, the control unit 101 is installed at the corner of the main body 100 formed by assembling the above-described components, and the start and end of the heating wire 424 of the heater unit 400 are connected to the control unit 101. Configured to connect. As shown in FIG. 1, the planar warmer is supplied with power from a power cord 102 connected to the control unit 101, and the heating operation is controlled by the control unit 101, thereby generating a heating function as a planar warmer. Can be demonstrated.

  In addition, the planar warming tool manufactured by this invention may be provided with structures other than the main body 100, the control part 101, and the power cord 102, and is one of each sheet-like member which comprises the main body 100 mentioned above. The sheet-like member may be omitted. Moreover, the main body 100 may include other members having a non-sheet shape in addition to the sheet-like member described above.

  In addition, the adhesive used for the planar warming device according to the present embodiment is particularly a specific type as long as it is a heat-melt type (hot-melt) whose main component is a material to be melted by heat. It is not limited. In the configuration examples shown in FIG. 2 and FIG. 4, the adhesive 203 (surface material adhesive layer) integrally laminated on the surface material 200 is formed as an independent sheet-like member as a layer of the hot-melt adhesive. The adhesive sheet 300 and the heater sheet 400 have a soaking sheet 410 that includes an adhesive resin 412 (a soaking sheet adhesive layer) laminated on both surfaces of the aluminum sheet 411, both of which are polyethylene resins, Although it is a layer composed of at least an olefinic thermoplastic resin such as a polypropylene resin, other known thermoplastic resins may be used, or a thermoplastic material other than the resin may be used. In addition, when the hot-melt adhesive is mainly composed of a thermoplastic resin, it may be a polymer alloy in which a plurality of thermoplastic resins are mixed, or may include known additives other than the resin. It may be a thermoplastic resin composition.

[Method for manufacturing surface heating device]
Next, a typical example of a method for manufacturing a planar warming tool including the main body 100 described above will be specifically described with reference to FIGS. 6 is a schematic diagram showing an example of a preparation process in the manufacturing process of the main body 100 as a schematic cross-sectional view, and FIGS. 7A and 7B show an example of a heating process and a pressing process of the main body 100 as a schematic cross-sectional view. FIGS. 8A and 8B are schematic views showing, as a schematic cross-sectional view, an example of a hot press process for bonding the back material 600 and molding the peripheral part of the main body 100, and FIG. FIG. 10 is a schematic diagram showing an example of an ultrasonic welding process for welding the peripheral part of 100 as a schematic cross-sectional view, and FIG. 10 shows an example of a trimming process for cutting an unnecessary part of the peripheral part of the main body 100 as a schematic cross-sectional view. It is a schematic diagram.

  The manufacturing method of the planar warming tool described in the present embodiment is a manufacturing method including a preparation process, a heating process, a pressing process, a thermal pressing process, an ultrasonic welding process, and a trimming process. In accordance with a specific configuration (particularly a specific configuration of the main body 100), other steps may be included, or some of the steps may be omitted.

(1) Preparation process First, a preparation process is demonstrated. The preparation step is a step of forming a laminate by stacking materials such as sheet-like members constituting the main body 100. Specifically, as shown in FIG. 6, the adhesive layer 602 of the back material 600 is disposed on a horizontal platform 710, the heat insulating sheets 500 are stacked thereon, and the heater wire 420 is placed on the lower side. Then, the heater units 400 are stacked, the adhesive sheets 300 are stacked thereon, and the surface material 200 is stacked thereon so that the nonwoven fabric 202 is on the lower side.

  Therefore, in this preparatory step, the sheet-like members constituting the main body 100, that is, the surface material 200, the adhesive sheet 300, the heater unit 400, the heat insulating sheet 500, and the back surface material 600 are not bonded in this order. It will be stacked on the platform 710. In the state where these sheet-like members are stacked, a laminated body (or a stacked body) in which the sheet-like members are not bonded to each other is configured. This laminate is referred to as a work 110 for convenience of explanation. Moreover, although the workpiece | work 110 which passed through the press process mentioned later, a heat press process, etc. will be in the state by which the sheet-like member was bonded together, in the following description, if it is before completing as the main body 100, it will be called the workpiece | work 110. To do.

  In this preparation step, as shown in FIG. 4, the heater unit 400 has a smaller outer dimension than other sheet-like members. Therefore, in the work 110, it is important to arrange the heater unit 400 in the center of the heat insulating sheet 500. . The workpieces 110 stacked in the preparation process are then sent to the heating process.

  Depending on the configuration of the surface warmer, the workpiece 110 prepared in the preparation step is stacked with at least one sheet-like member and the heater unit 400 with a hot-melt adhesive layer interposed therebetween. Anything can be used. For example, the workpiece 110 (laminated body) may be configured by only the surface material 200, the adhesive sheet 300, and the heater unit 400, or the workpiece 110 may be configured by only the back surface material 600, the heat insulating sheet 500, and the heater unit 400. .

  At this time, the adhesive layer may be configured as an independent sheet-like member like the adhesive sheet 300, or laminated in advance on another sheet-like member like the adhesive layer 602 of the back material 600. Alternatively, as in the example shown in FIG. 6, an independent sheet-like member (adhesive sheet 300) and an adhesive layer (adhesive layer 602) previously laminated on another sheet-like member are used in combination. May be.

  In the preparation step, a sheet-like member positioning device that positions the sheet-like members may be used in order to stack the sheet-like members including the heater unit 400 more efficiently. The sheet-like member positioning device only needs to include a work table (corresponding to the platform 710) on which the sheet-like member can be placed, and a positioning reference portion provided integrally or detachably on the work table. Examples of the positioning reference portion include protrusions, steps, depressions, and the like provided at positions corresponding to the corner portions of the sheet-like member, and may further include a ruler with a scale for measuring the length. . In addition, a known stacking device or the like can be used for stacking the sheet-like members.

(2) Heating step Next, in the heating step, an electromagnetic induction heating coil is installed close to at least one of the front and rear surfaces of the laminate (work 110) prepared in the preparation step, and magnetic lines of force are generated by the electromagnetic induction heating coil. In this step, the heater unit 400 included in the workpiece 110 (more specifically, the aluminum sheet 411 constituting the soaking sheet 410) is heated to melt the adhesive layer. In the present embodiment, it is very preferable to use a plurality of electromagnetic induction heating coils. However, this point will be described later, and FIG. 7A illustrates the case where a single electromagnetic induction heating coil is used. A standard heating process will be described.

  As shown in FIG. 7 (a), as the equipment (heating device) used in the heating process, in this embodiment, the main body 100 is placed and transported in the horizontal direction as indicated by the block arrow A. An apparatus (conveying means) 720 and an electromagnetic induction heating apparatus 721 including an oval heating coil 722 larger than the width of the main body 100 are used. The electromagnetic induction heating device 721 is disposed in a part of a region where the aluminum sheet 411 to be heated is to generate heat. Specifically, in the electromagnetic induction heating device 721, the heating coil 722 is provided in the width direction in the vicinity of the rear end portion of the conveying device 720 (in the vicinity of a pressing roller 730 described later).

  The heating coil 722 is a long plate-like coil (or oval coil) longer than the width of the workpiece 110, and is installed at a position orthogonal to the moving direction (block arrow A direction) in the present embodiment. The spread of the heating coil 722 substantially becomes a heating surface of the workpiece 110 by the heating coil 722. In the present embodiment, the length in the longitudinal direction of the heating surface of the heating coil 722 is larger than the width of one side of the workpiece 110. Further, the heating surface of the heating coil 722 does not include the entire surface of the workpiece 110 but is set one-dimensionally so as to heat a part of the length of the workpiece 110.

  The workpieces 110 stacked in the preparation process are moved in the horizontal direction indicated by the block arrow A by the transfer device 720. When the magnetic field lines are generated from the heating coil 722 of the electromagnetic induction heating device 721 disposed above as the workpiece 110 moves, the magnetic field lines are applied to the workpiece 110, so that an eddy current is generated in the aluminum sheet 411 of the heater unit 400. The aluminum sheet 411 itself heats up due to the eddy current and the resistance of the aluminum sheet 411. The adhesive resin 412 made of polyethylene resin coated on both surfaces of the aluminum sheet 411 and the adhesive sheet 300 adhered and laminated on the heater unit 400 are melted by the heat generated from the aluminum sheet 411.

  Since the workpiece 110 receives the magnetic lines of force from the heating coil 722 while being conveyed by the conveying device 720 at a predetermined speed, the heat generation range of the aluminum sheet 411 constituting the workpiece 110 also moves sequentially at the predetermined speed. As a result, the entire area of the aluminum sheet 411 that should generate heat can be heated.

  Thus, the aluminum sheet 411 is heated to a temperature sufficient for the adhesive sheet 300 to melt by the magnetic lines of force generated from the heating coil 722 of the electromagnetic induction heating device 721. For this purpose, the heating temperature of the aluminum sheet 411 is about 130 ° C. to 175 ° C. At this time, since heat generated from the aluminum sheet 411 is transferred to the surface material 200 via the adhesive sheet 300, the outer surface of the surface material 200 is not directly exposed to heat although there is a certain temperature rise. Therefore, the temperature of the outer surface of the surface material 200 is a temperature at which the surface of the surface material 200 does not deteriorate or does not cause deformation that impairs the design property due to heat even if it does not deteriorate. It can be suppressed to 120 ° C. or lower. Therefore, by using such a method, it is possible to effectively prevent the surface material 200 from being adversely affected by heating (deformation, alteration, or the like that impairs designability).

  Further, since the adhesive resin 412 made of polyethylene resin and the adhesive sheet 300 are melted in a few seconds, if the electromagnetic induction heating device 721 is operated while moving the workpiece 110 at a predetermined speed by the conveying device 720, the adhesive resin 412 and As the workpiece 110 moves, the adhesive sheet 300 is continuously melted immediately below the electromagnetic induction heating device 721 (heating coil 722). As a result, the adhesive resin 412 and the adhesive sheet 300 can be melted over the entire surface.

  At this time, it is preferable to control so that the distance (interval) between the heating coil 722 of the electromagnetic induction heating device 721 and the aluminum sheet 411 is kept constant, and the workpiece 110 on which the sheet-like members are laminated is lightly pressed and maintained at a predetermined thickness. Move while.

  Moreover, it is preferable that the heater unit 400 is arrange | positioned so that the heater wire 420 may become a lower side in the workpiece | work 110 among sheet-like members. That is, it is preferable to install the work 110 so that the surface of the work 110 on the side where the heater wire 420 of the soaking sheet 410 is not disposed is close to the heating coil 722. When the workpiece 110 is installed in this way, the aluminum sheet 411 is disposed so as to face the heating coil 722 of the electromagnetic induction heating device 721. Therefore, the distance (interval) between the heating coil 722 and the aluminum sheet 411 is kept constant. Therefore, the entire surface of the aluminum sheet 411 can be heated uniformly.

  Further, when the heater unit 400 is arranged as described above, the aluminum sheet 411 is interposed between the heating coil 722 of the electromagnetic induction heating device 721 and the heater wire 420. Therefore, since heat generation of the heater wire 420 itself can be suppressed, temperature unevenness can be suppressed. As a result, the heating action by the aluminum sheet 411 can be realized more stably and uniformly.

  In the heating process, as shown in FIG. 7A, the heater unit 400 is arranged such that the arrangement direction of the heater wire 420 and the conveyance direction (block arrow A direction, movement direction) of the conveyance device 720 are orthogonal to each other. However, the present invention is not limited to this, and the work 110 may be arranged so that the arrangement direction of the heater wire 420 coincides with the block arrow A. .

  For example, when the heater wire 420 itself generates heat by the electromagnetic induction heating device 721 in a state where the conveying direction and the arrangement direction of the heater wire 420 are substantially orthogonal, large temperature unevenness occurs due to the heat generated by the heater wire 420. In this case, if the work 110 is arranged so that the arrangement direction of the heater wire 420 is substantially coincident with the conveying direction, currents in opposite directions to the heater wire 420 can be generated. Heat generation can be suppressed and occurrence of temperature unevenness can be suppressed in some cases.

  In addition, although the heating process shown to Fig.7 (a) is used for adhesion | attachment with the surface material 200, the heater unit 400, and the heat insulation sheet 500, the use of a heating process is not limited to this, The heat insulation sheet 500 and a back surface It can also be used for adhesion to the material 600. Specifically, in FIG. 7A, the front and back surfaces of the workpiece 110 may be replaced and installed in the transfer device 720. Furthermore, as shown in FIG. 7B, the upper side (surface material 200) In addition, a pair of heating coils 722 (and the electromagnetic induction heating device 721) are installed so as to face both the front and back surfaces of the workpiece 110 by separately providing an electromagnetic induction heating device 721 on the lower side (back surface material 600 side). May be.

  In this case, if a sheet-like member 430 having the same configuration as that of the soaking sheet 410 is sandwiched between the heat insulating sheet 500 and the back surface material 600, adhesion of the surface material 200, the heater unit 400, and the heat insulating sheet 500, and heat insulation Bonding of the sheet 500 and the back surface material 600 can be performed in a single heating step. Therefore, for example, by performing only the step pressing described later as a separate step, the heat pressing step described later can be substantially omitted.

(3) Pressing Step Next, in the present embodiment, the pressing step is a step that is integrally performed continuously with the heating step, as shown in FIG. In this pressing step, the entire workpiece 110 heated by the pressing device is pressed. The equipment used in the pressing process may be equipment (pressing device) capable of continuously pressing the workpiece 110. In the present embodiment, as shown in FIG. A pressing roller 730 including a roller 731 and a lower roller 732 is used. In addition, the structure of a press apparatus is not limited to the press roller 730, For example, other well-known structures, such as a press apparatus, may be sufficient.

  The upper roller 731 and the lower roller 732 constituting the pressing roller 730 can be rotationally driven in the direction of arrow B, respectively, and the workpiece 110 can be moved between them. Further, as indicated by the black block arrow C, the upper roller 731 can be pressed downward. As a result, the workpiece 110 can be continuously pressed.

  The pressing roller 730 is preferably arranged at a position overlapping or adjacent to a part of the area of the aluminum sheet 411 that should generate heat. Specifically, in the present embodiment, as shown in FIG. 7A, a pressing roller 730 is provided on the downstream side in the moving direction of the workpiece 110 (block arrow A) when viewed from the electromagnetic induction heating device 721. ing. At this position, the workpiece 110 can be pressed by the pressing roller 730 following the location where the aluminum sheet 411 generates heat in the heating process.

  It is essential that the driving speed of the pressing roller 730 be linked to the heating time of the heating process, and it is important that the pressing roller 730 be arranged close to the heating coil 722 so that the resin melted by the heating process can be pressed in as short a time as possible. is there. In this embodiment, as schematically shown in FIG. 7A, the heating process equipment and the pressing process equipment are integrally configured. By pressing the workpiece 110 in the pressing step, the surface material 200, the heater unit 400, and the heat insulating sheet 500 are bonded together via the adhesive resin 412 and the adhesive sheet 300.

(4) Hot press process A hot press process is performed after a press process. The hot press process is a process in which two different operations are performed simultaneously, as will be described later. Specifically, as shown in FIG. 8A, the equipment used for the hot press process is a hot press device 740. A lower heat plate 742 that covers the entire surface of the workpiece 110 is disposed on the lower die 741 of the heat press apparatus 740, and an upper heat plate 746 that presses the peripheral portion of the workpiece 110 is provided on the upper die 745. 8A and 8B, the lower heating plate 742 and the upper heating plate 746 are hatched with cross lines for convenience of explanation.

  In the hot pressing process, the adhesion of the back surface material 600 and the step pressing molding of the peripheral part of the work 110 are performed simultaneously. Therefore, the back surface material 600 is heated by the lower heat plate 742 disposed on the lower mold 741, and the adhesive layer 602 (see FIG. 4) coated on the upper surface of the back surface sheet 601 of the back surface material 600 is melted. And the back material 600 and the heat insulation sheet 500 are adhere | attached by pressing the workpiece | work 110 whole by a hot press process. Further, by pressing the peripheral part of the work 110 while heating it with the upper heating plate 746 provided in the upper mold 745, the peripheral part of the work 110 is step-formed so as to be thinner than the central part. As shown in FIG. 8B, the thickness of the warming surface portion 111 that is the center portion is larger than the thickness of the stepped portion 112 that has been stepped by the step pressing.

  The upper heating plate 746 has a substantially rectangular frame shape having an opening on the inner side so as to correspond to the peripheral portion in order to press-mold the peripheral portion of the work 110. A concave curved surface 747 is formed at the inner end (periphery) of the upper heating plate 746 as shown in FIG. By providing the concave curved surface 747, as shown in FIG. 8 (b), the inner side of the stepped portion 112 generated by stepping molding (outward as viewed from the central heating surface portion 111) is not a stepped surface. The convex curved surface 113 can be molded.

(5) Ultrasonic welding process An ultrasonic welding process is performed after a hot press process. In the ultrasonic welding step, the peripheral portion of the workpiece 110 that has been step-formed by the hot press step, that is, the step-pressing portion 112 is welded. As shown in FIG. 9, the equipment used in this step is an ultrasonic welder 750 including a horn 751 that moves along the peripheral portion (step pressing portion 112) of the workpiece 110.

  As described above, the heater unit 400 is formed to have a smaller outer dimension than other sheet-like members. Therefore, the heater unit 400 is located on the warming surface portion 111 that is the central portion of the workpiece 110, but the heater unit 400 is hardly located on the stepped portion 112 that is the peripheral portion of the workpiece 110. Therefore, the stepped portion 112 is composed of the surface material 200, the adhesive sheet 300, the heat insulating sheet 500, and the back surface material 600, and as a result, is entirely formed of a thermoplastic resin material.

  That is, the stepped portion 112 is a portion formed by a thermoplastic material around the main body 100 in addition to being a portion molded thinner than the warming surface portion 111 in the central portion by step forming in the heat pressing step of the previous step. It is a small part of. Therefore, by applying an ultrasonic wave to the stepped portion 112 by the horn 751, the joint portion of each sheet-like member is heated and melted and welded, so that the periphery of the work 110 is sufficiently welded and fixed. Can do.

  It should be noted that the horn 751 to which the ultrasonic waves are applied may be configured so as to perform welding sequentially while moving on the peripheral portion (step pressing portion 112) of the workpiece 110. Further, in order to perform the ultrasonic welding process, the work 110 only needs to be placed on the work table 711, but the work table 711 is provided integrally with the ultrasonic welding machine 750. It may be a thing, may be prepared as an independent thing, platform 710 used in the preparation process, lower mold 741 used in the hot press process, etc. may be used. In addition, if the stepped portion 112 can be appropriately welded and fixed, a welding device other than the ultrasonic welder 750 can be used.

(6) Trimming process The trimming process is performed as the last process in the present embodiment and is a finishing process of the main body 100 performed after the ultrasonic welding process, and the equipment used is a trimming apparatus. Specifically, as shown in FIG. 10, in the trimming step, unnecessary portions of the peripheral portion (step pressing portion 112) of the work 110 placed on the work table 711 are cut off and shaped by the trimming device. . In the present embodiment, a cutter device 760 including a disk-shaped rotary cutter is used as the trimming device. Although the configuration of the cutter device 760 is not particularly limited, two rotary cutters that simultaneously cut while moving the stepped portions 112 on both sides in the width direction of the work 110, and the longitudinal direction of the work 110 A configuration including a single rotary cutter that cuts while moving the step pressing portion 112 on one side of the above can be mentioned.

  By cutting off unnecessary portions of the peripheral portion (step pressing portion 112) of the workpiece 110 welded and fixed by ultrasonic welding using the cutter device 760, the dimensions of the workpiece 110 are set in a predetermined range. Thereby, the main body 100 is completed. In order to perform the trimming step, the work 110 only needs to be placed on the work table 711. The work table 711 is provided integrally with the cutter device 760. Alternatively, it may be prepared as an independent one, the platform 710 used in the preparation process, the lower mold 741 used in the hot press process, or the like may be used, or used in the ultrasonic welding process. The same work table 711 may be used.

(7) Other steps, etc. After that, the control unit 101 and the power cord 102 are attached to the main body 100, and if necessary, the main body 100 is subjected to decoration processing, etc. By performing this process, a planar warming tool is completed.

  Note that details of the preparation process, the heating process, the pressing process, the hot pressing process, the ultrasonic welding process, and the trimming process are not limited to the above-described methods. For example, the heating process and the pressing process are performed while moving the main body 100 in the moving direction of the block arrow A, but the present invention is not limited to this, and the electromagnetic induction heating device 721 and the main body 100 are fixed in place. The pressing roller 730 may be moved.

  Moreover, you may make it implement a press process simultaneously with a heating process. In the case of this method, the pressing step is preferably pressed by a press. When this processing method is adopted, the capacity of the electromagnetic induction heating device can be further reduced, and capital investment can be suppressed.

  Here, in the manufacturing method of the planar warming tool mentioned above, the heating process using the electromagnetic induction heating device 721 is particularly important. As described above, the heating step is a step in which the resin is melted and bonded by causing the aluminum sheet 411 itself, which is one of the constituent members of the heater unit 400, to generate heat by the electromagnetic induction heating device 721.

  The greatest feature of the heating process is that heat necessary for melting the resin is generated from the aluminum sheet 411 that is in direct contact with the resin. By sandwiching between the sheet 500 and the back surface material 600, wasteful heat radiation to the outside can be suppressed. As a result, the resin can be melted with a much smaller amount of heat compared to a heating method in which heat is applied from the outside, less power is required for heating, and a high energy saving effect can be obtained.

  In addition, since the temperature of the surface portion of the main body 100 does not increase by generating heat from the inside of the main body 100, the material used for the surface portion, for example, the surface material 200 is heated even if a low heat-resistant temperature is used. It is possible to effectively prevent the adverse effects (deformation, alteration, etc.) caused by.

  In addition, the aluminum sheet 411 is originally provided in the main body 100 for the purpose of uniformly diffusing the heat generated by the heater wire 420 over the entire surface of the main body 100 when the planar warming tool is used. is there. Therefore, by using it in the manufacturing process in addition to the original function, a very large effect can be obtained in terms of manufacturing cost and man-hours.

  In addition, since the aluminum sheet 411 as a heat source is in direct contact with the resin to be melted, heating can be performed in a short time in units of seconds (about 10 seconds or less, preferably about 2 or 3 seconds). Therefore, it is not necessary to heat the entire surface of the main body 100 at the same time, and it is possible to partially perform the heating, melting, and bonding processes as a flow operation while moving the main body 100. In addition, since heating is partially performed, the electromagnetic induction heating device 721 used for heating can be reduced in size and size, can reduce equipment costs, and lower the maximum electric capacity during processing. be able to.

  Moreover, in the manufacturing method of the present invention using electromagnetic induction heating, a mold for a heating process prepared corresponding to the dimensions of the main body 100 which has been necessary in the past is unnecessary, and the main body as the electromagnetic induction heating device 721 is used. A heating coil 722 corresponding to the maximum dimension of 100 may be prepared. Accordingly, since the entire width direction of the aluminum sheet 411 which is a heat generation source under the heating coil 722 can be heated, the main body 100 having a width smaller than the heating coil 722 can be heated with the same equipment. is there. Therefore, it is not necessary to prepare a plurality of heating process facilities in accordance with the size of the main body 100, and the facility cost can be reduced in this respect as well.

[Arrangement of electromagnetic induction heating coil]
Here, in the method for manufacturing a planar warming tool according to the present invention, it is particularly preferable that a plurality of heating coils 722 are arranged adjacent to each other at a position facing the workpiece 110 in the heating step. This point will be specifically described with reference to FIGS. 11A and 11B and FIGS. 12A and 12B.

  As shown in FIGS. 11A and 11B, in the present embodiment, the first electromagnetic induction heating device 721a and the first heating coil are disposed on the upstream side of the moving direction of the work 110 indicated by the block arrow A as a reference. 722a is provided, and a second electromagnetic induction heating device 721b and a second heating coil 722b are provided on the downstream side. The upstream first electromagnetic induction heating device 721a and the first heating coil 722a are used for preheating the workpiece 110, and the downstream second electromagnetic induction heating device 721b and the second heating coil 722b are used for preheating. It is used for the main heating of the workpiece 110. The first electromagnetic induction heating device 721a, the second electromagnetic induction heating device 721b, and the pressing roller 730 operate under the control of the manufacturing apparatus control unit (control unit) 712. In FIG. 11A, the manufacturing apparatus control unit 712 is simply described as “control unit”, but needless to say, it is different from the control unit 101 of the planar warming tool.

  As described above, each of the first heating coil 722a and the second heating coil 722b is a long plate-like coil (oval coil) longer than the width of the workpiece 110, and is substantially perpendicular to the moving direction (orthogonal). In place). Further, as shown in FIG. 11B, the first heating coil 722a and the second heating coil 722b are adjacently arranged in parallel in the longitudinal direction. In addition, although a parallel state is not specifically limited, In this Embodiment, if adjacent arrangement | positioning of the 1st heating coil 722a and the 2nd heating coil 722b is the state parallel in the longitudinal direction, it will not specifically limit, As needed , One may be inclined or both may be inclined. Further, the first heating coil 722a and the second heating coil 722b may have the same shape and the same performance, but may be used differently. Moreover, the 1st heating coil 722a and the 2nd heating coil 722b become a structure which can control electric power supply independently, respectively.

  In the heating step, as shown in FIG. 7A, if a single electromagnetic induction heating device 721 is provided, the soaking sheet 410 (aluminum sheet 411) can be sufficiently heated. Further, when the workpiece 110 is moved by the conveying device 720 below the single electromagnetic induction heating device 721, the heating coil 722 only heats the soaking sheet 410 in a one-dimensional manner, and consequently heats the whole. can do.

  Here, in recent years, surface heating devices having a larger area have been developed, and a simple method of using “floor heating” instead of “carpet” as a surface heating device has been proposed. Has been. According to the former (upsizing of the planar warming tool), the planar warming tool is provided with a soaking sheet 410 having a larger area. Further, according to the latter (use as simple floor heating), for example, the surface material 200 is required to have durability and water resistance that are closer to the floor surface, and the inner sheet-like member has a heater wire 420. There is a tendency for load resistance to protect the surface.

  In consideration of such a tendency, the present inventors examined, and in order to cope with an increase in the size of the soaking sheet 410 or an increase in the thickness of the main body 100, the output of the electromagnetic induction heating device 721 is increased. It became clear that the heating of the plurality of adhesive layers existing inside the workpiece 110 varied.

  That is, even if the soaking sheet 410 is heated as a whole, the heating by the heating coil 722 is one-dimensional, and the time required for heating is short. For this reason, when the output of the electromagnetic induction heating device 721 is increased, the soaking sheet 410 rapidly becomes high in temperature, so that a plurality of adhesive layers (adhesive sheet 300, adhesive 203, adhesive resin 412, adhesive layer 602, etc.) are formed. Among them, the layer close to the soaking sheet 410 is heated rapidly, but the separated layer is hardly heated. As a result, for example, even if the layer of the adhesive resin 412 formed integrally with the aluminum sheet 411 that is the main body of the soaking sheet 410 reaches the melting temperature, the adhesive sheet 300 separated from the soaking sheet 410 is melted. If the temperature does not reach the temperature and the adhesive sheet 300 reaches the melting temperature, the adhesive resin 412 is heated to a temperature equal to or higher than the heat-resistant temperature, so that the adhesive resin 412 is deteriorated.

  Therefore, in the present embodiment, for example, as shown in FIGS. 11A and 11B, two heating coils 722 are disposed adjacent to each other at a position facing the workpiece 110. Accordingly, the work 110 is preheated by the first electromagnetic induction heating device 721a and the first heating coil 722a, and then the work 110 is fully heated by the second electromagnetic induction heating device 721b and the second heating coil 722b. The variation in heating of the adhesive layer as described above is effectively suppressed, and each sheet-like member can be satisfactorily bonded. Therefore, the quality of the main body 100 can be further improved.

  This point will be described with reference to specific experimental results. First, in order to manufacture the main body 100 having an area of 1760 mm × 880 mm and a thickness of 11.5 mm, the surface material 200, the adhesive sheet 300, the heater unit 400, the heat insulating sheet 500, and the back surface material 600 were stacked (preparation step). ).

  The surface material 200 used at this time was a foam material sheet mainly composed of PVC having a thickness of 1.8 mm, and had a skin layer on the surface and generally used for a flooring sheet or the like. Note that a nonwoven fabric 202 having a thickness of about 2.5 mm mainly composed of a polyester resin was provided on the lower surface of the surface material 200 (the surface on the inner side of the workpiece 110). Further, an aluminum sheet 411 having a thickness of about 0.01 mm was used as the main body of the soaking sheet 410 included in the heater unit 400. Further, as the adhesive sheet 300 disposed between the surface material 200 and the aluminum sheet 411, a sheet having a thickness of 70 μm mainly composed of polyethylene resin was used.

  Furthermore, in order to perform temperature measurement in the heating process, as shown in FIG. 11B, a thermocouple is directly attached to the center portion P1 and the end portion P2 of the upper surface of the aluminum sheet 411, and a surface material is used. A workpiece 110 was manufactured after directly attaching a thermocouple to the central portion P1 of the outer surface 200. The workpiece 110 was moved by the transfer device 720 at a transfer speed of 60 mm / s, and the aluminum sheet 411 was heated using the first electromagnetic induction heating device 721a and the second electromagnetic induction heating device 721b (heating process). At this time, in order to raise the temperature of the adhesive sheet 300 to a temperature sufficient for melting, the first electromagnetic induction heating device 721a and the second electromagnetic induction heating device are set so that the temperature of the aluminum sheet 411 is 130 ° C. or higher and 175 ° C. or lower. 721b was controlled.

  In the heating step, temporal changes in the temperatures of the aluminum sheet 411 and the surface material 200 constituting the workpiece 110 were measured. The result is shown in the temperature change graph of FIG.

  As shown in FIG. 12A, the temperature of the aluminum sheet 411 is about 175 ° C. at the maximum at the central portion P1 and about 140 at the maximum at the end portion P2 in order to obtain a temperature sufficient to melt the adhesive sheet 300. Although it rose to ° C., the temperature of the surface material 200 was always lower than 120 ° C. Moreover, FIG.12 (b) is a graph which shows the induced electromotive force by the 1st electromagnetic induction heating apparatus 721a and the 2nd electromagnetic induction heating apparatus 721b, Comprising: M1 in the figure WHEREIN: The 1st electromagnetic induction heating apparatus 721a which performs preheating. In the figure, M2 indicates the induced electromotive force of the second electromagnetic induction heating device 721b that performs the main heating. In order to correspond to these induced electromotive forces M1 and M2, in FIG. 12A, the maximum value of the temperature rise occurs at about 15 seconds and about 32 seconds at least in the central portion P1 of the aluminum sheet 411. .

  The first maximum value (about 15 seconds) is generated corresponding to the preheating, and after the preheating is finished, the aluminum sheet 411 is slightly lowered from 100 ° C. in the central portion P1 of the aluminum sheet 411. It can be seen that almost no temperature drop occurs at the end P2 of the aluminum sheet, and the aluminum sheet 411 is preheated so as to be in the range of 80 to 100 ° C. When the main heating is performed, the temperature rapidly increases until the second maximum value (about 32 seconds) is generated, but the temperature does not increase until the temperature exceeds 175 ° C. Therefore, the plurality of adhesives The occurrence of heating variations in the layer is effectively suppressed.

  Thus, according to the present invention, the aluminum sheet 411 is preheated by the magnetic lines generated from the first heating coil 722a of the first electromagnetic induction heating device 721a, and then the second heating coil of the second electromagnetic induction heating device 721b. The surface of the surface material 200 is deformed by the heat of the surface material 200 while the temperature of the aluminum sheet 411 is raised to a temperature sufficient to melt the adhesive sheet 300 by performing main heating with the magnetic lines of force generated from 722b. The temperature can be suppressed to about 120 ° C. or less, which is a temperature at which no generation occurs.

  In addition, since the two-stage heating is performed, the temperature rise of the aluminum sheet 411 in the main heating is suppressed to 175 ° C. or lower. Therefore, for example, even when the adhesive sheet 300 reaches the melting temperature, the adhesive resin Since 412 is not heated above the heat-resistant temperature, the adhesive layer does not vary in heating, and deterioration of the adhesive layer is effectively suppressed. Moreover, since the aluminum sheet 411 rises only to a temperature sufficiently lower than the heat resistant temperature of the PVC used as the surface material 200 in the present embodiment, the surface material 200 is not thermally deteriorated. Further, since heat is not directly applied to the skin layer formed on the surface of the surface material 200, it is possible to avoid the phenomenon that has occurred in the conventional method, in particular, the mechanical embossing applied to the skin layer is removed by heat. be able to.

  In this way, in the method that enables the production of a planar warming tool without using a mold by using the method for manufacturing a planar warming tool according to the present invention, the surface material 200 is adversely affected by heating (design properties are reduced). It is possible to effectively prevent the occurrence of deformation, alteration, etc.

  In the present embodiment, the first electromagnetic induction heating device 721a includes the first heating coil 722a, and the second electromagnetic induction heating device 721b includes the second heating coil 722b. However, the configuration is not limited thereto, and the single electromagnetic induction heating device 721 may include the first heating coil 722a and the second heating coil 722b. In addition, if the electromagnetic induction heating means is preferably provided with a plurality of electromagnetic induction heating coils, the coil control unit that drives and controls the electromagnetic induction heating coil may be independently configured as another device.

  Further, for example, as the transport device 720 used in the present embodiment, a chucking transport device that fixes and transports the workpiece 110 by chucking is used, but a conveyor device, a transport device using a manipulator, or the like is used. Other configurations of the transfer device can be used. Furthermore, in this embodiment, since the heating step and the pressing step are continuously performed, the pressing roller 730 is provided downstream in the moving direction when viewed from the first heating coil 722a and the second heating coil 722b. As described above, as long as the equipment can press both surfaces of the workpiece 110, a pressing device having another configuration may be used.

  In other words, in the present invention, when manufacturing the planar warming tool, the stack (work 110) is transported in a preset moving direction (in the present embodiment, the transport device 720) and the downstream in the moving direction. A manufacturing apparatus having a configuration including a plurality of electromagnetic induction heating coils that are positioned and arranged adjacent to each other (in this embodiment, the first heating coil 722a and the second heating coil 722b) may be used. More preferably, the manufacturing apparatus further includes a pressing unit (in this embodiment, a pressing roller 730) that is positioned adjacent to the downstream side in the moving direction of the electromagnetic induction heating unit and presses both surfaces of the workpiece 110. Needless to say, other configurations are not specifically limited.

  In addition, when the magnetic field lines are generated by the electromagnetic induction heating coil to heat the soaking sheet 410, the electromagnetic induction heating coil can be moved without conveying the workpiece 110 by the conveying means. However, in consideration of the manufacturing efficiency of the sheet heating device, as described in the present embodiment, by applying the magnetic lines generated by the electromagnetic induction heating coil while moving the workpiece 110, the soaking sheet 410 is It is preferable to generate heat. That is, in the present embodiment, the soaking sheet 410 can be heated using the process of conveying the workpiece 110 from the heating process to the pressing process, so that the heating process and the pressing process can be performed continuously, Therefore, manufacturing efficiency can be improved.

  Here, the present invention includes a planar warming tool manufactured by the manufacturing method described above. Specifically, the surface warmer according to the present invention is manufactured by the manufacturing method or the manufacturing apparatus, and the above-described heater unit 400, a sheet-like member stacked on the heater unit 400, specifically, a surface material. 200, a heat insulating sheet 500, and a back material 600, and the heater unit 400 and the sheet-like member are bonded and fixed to each other by a layer of a hot-melt adhesive. The sheet heating device according to the present invention has such a configuration, so that each sheet-like member including the heater unit 400 is well bonded and fixed, and heat is applied from the outside during the manufacturing process. Since it does not substantially exist, the quality of the front and back surfaces can be improved.

(Embodiment 2)
In the embodiment, at least one electromagnetic induction heating coil may be used in the heating step, preferably a plurality of electromagnetic induction heating coils are used, and more preferably, a plurality of electromagnetic induction heating is provided at a position facing the laminate. Although it is the structure which arrange | positions a coil adjacently, the structure which arrange | positions several electromagnetic induction heating coils adjacent is not specifically limited, Various arrangement | positioning is employable. Further, a configuration different from that of the pressing roller 730 can be adopted as the pressing means. In the second embodiment, an example of another arrangement configuration of the electromagnetic induction heating coil and another configuration of the pressing unit will be specifically described with reference to the drawings.

[Configuration of electromagnetic induction heating coil and roller unit]
In the present embodiment, three electromagnetic induction heating coils are installed in the heating step, and a roller unit capable of securing a longer pressing time is used as the pressing means. Therefore, the electromagnetic induction heating coil and the roller unit will be described with reference to FIGS. 13 (a) and 13 (b). Fig.13 (a) is a schematic diagram which shows an example of the heating process in this Embodiment, and a press process as a schematic sectional drawing, FIG.13 (b) is a schematic top view of the parallel arrangement | positioning of the electromagnetic induction heating coil in a heating process. It is a schematic diagram shown as.

  The configuration of the planar warming tool according to the present embodiment is the same as that of the first embodiment. Further, the method of manufacturing the planar warming tool and the configuration of the manufacturing apparatus according to the present embodiment are basically the same as those of the first embodiment, but the heating process and the pressing process are one of the manufacturing processes of the main body 100. The department is different. Specifically, in the heating process, heating is performed using three electromagnetic induction heating devices 721, and in the pressing process, the roller unit 735 is used instead of the pressing roller 730 as the pressing means.

  The three electromagnetic induction heating devices 721 are a first electromagnetic induction heating device 721a, a second electromagnetic induction heating device 721b, and a third electromagnetic induction heating device 721c, respectively, from the upstream side in the moving direction of the workpiece 110. These include a first heating coil 722a, a second heating coil 722b, and a third heating coil 722c, respectively. The first to third electromagnetic induction heating devices 721a to 721c are the same as those described in the first embodiment, and the specific configurations of the first to third heating coils 722a to 722c included in the first to third electromagnetic induction heating devices 721a to 721c are also the same as those described above. This is the same as that described in the first embodiment.

  Moreover, the 1st-3rd heating coils 722a-722c are adjacently arranged so that it may become substantially parallel in the longitudinal direction. The first to third heating coils 722a to 722c may have the same shape and the same performance as in the first embodiment, or the three may have different specifications. Furthermore, each of the first to third heating coils 722a to 722c has a configuration in which the power supply can be controlled independently, and an optimum heating state can be obtained in conjunction with the conveyance speed of the workpiece 110.

  As shown in FIG. 13A, the roller unit 735 includes a pair of an upper roller unit 735a and a lower roller unit 735b, all of which are wound around three rotating rollers 737a, 737b, and 737c and the outer periphery thereof. The rotating belt 736 is formed. An area of the rotating belt 736 facing the position where the upper roller unit 735a and the lower roller unit 735b face each other is an area for pressing the workpiece 110. The rotation belt 736 is stretched by the rotation rollers 737a to 737c, so that a substantially rectangular pressing surface is formed in the region.

  The roller unit 735 is provided with a cooling means for cooling the workpiece 110. Specifically, a cooling air passage 738 is provided at the center of rotation of each of the rotation rollers 737a, 737b, and 737c, and an air blower (not shown) that blows cool air through the cooling air passage 738. Is connected. Therefore, a cooling means is comprised by the air blower which is not shown in figure and the cooling air path 738.

  Here, the cooling means used in the present embodiment is an air-cooled type constituted by the cooling air passage 738 and the air blower, but the cooling means is not limited to this, and other types of cooling such as a water-cooled type. It may be a device. Further, the cooling means is not an essential component for the roller unit 735. For example, it may be omitted if the workpiece 110 is cooled to such an extent that the adhesive layer is solidified while passing through the roller unit 735 by slowing the conveying speed of the workpiece 110.

  Of the upper roller unit 735a and the lower roller unit 735b constituting the roller unit 735, the lower roller unit 735b is fixedly installed at a fixed position. On the other hand, the upper roller unit 735a is provided with a pressure device (not shown) that can move the upper roller unit 735a in the vertical direction, and the work 110 transported and moved by the transport device 720 from the upper surface in the block arrow C direction. It is the structure which can be pressed to.

  The lower roller unit 735b is provided with a driving device (not shown) that rotationally drives at least one of the rotating rollers 737a to 737c. The rotating device 737a to 737c rotates by rotating the rotating rollers 737a to 737c. The moving belt 736 is rotated in the direction of arrow B, and the work 110 placed on the lower roller unit 735b can be conveyed and moved in the moving direction indicated by the block arrow A at a predetermined speed.

  When the upper roller unit 735a is moved downward toward the lower roller unit 735b by the pressure device, the work 110 placed on the lower roller unit 735b is sandwiched between the lower roller unit 735b and the lower roller unit 735b. When the work 110 is transported, the rotating belt 736 of the upper roller unit 735a also follows and rotates. Accordingly, the upper roller unit 735a does not require a driving device, but when it is desired to transport and move the workpiece 110 with a larger force, the upper roller unit 735a may be provided with a driving device.

  The conveyance speed of the workpiece 110 by the roller unit 735 may be set to a speed synchronized with the conveyance speed by the conveyance device 720 in the heating process, but may be set to a different speed as necessary.

  Here, in the present embodiment, the roller unit 735 includes the rotating belt 736 and the rotating rollers 737a to 737c. However, the three rotating rollers 737a to 737c can press the work 110. If the rotating belt 736 cannot be stretched, a flat pressing plate may be installed on the back surface of the rotating belt 736 so that the pressing surface of the rotating belt 736 is made substantially flat. Thereby, when pressing the workpiece | work 110, the pressure of a press surface can be made uniform as a whole.

  The pressing plate not only makes the pressing surface substantially flat, but also keeps the distance between the pressing surface of the upper roller unit 735a and the pressing surface of the lower roller unit 735b (referred to as a pressing interval for convenience) constant. It also has a function. Furthermore, if a high thermal conductivity material such as a stainless steel plate is used as the pressing plate, the heat of the work 110 is transmitted to the pressing plate via the rotating belt 736 and dissipated to the surroundings, so that it functions as a cooling means. Can be made. As long as this cooling can sufficiently solidify the adhesive, it is not necessary to provide a cooling means such as a blower type or a water cooling type.

  Further, the pressing interval of the roller unit 735 may be constant from the upstream side to the downstream side in the moving direction, but the pressing step by the roller unit 735 is also a step of reducing the thickness of the workpiece 110. On the most upstream side, it is preferable to slightly increase the pressing interval. Thereby, the workpiece 110 having a thickness larger than the set pressing interval can be smoothly introduced between the upper roller unit 735a and the lower roller unit 735b, and the continuity from the heating process to the pressing process is improved. be able to.

  Further, the first to third electromagnetic induction heating devices 721 a to 721 c, the roller unit 735, and the air blower provided in the roller unit 735 operate under the control of the manufacturing device control unit 712. In FIG. 13 (a), as in FIG. 11 (a), the manufacturing apparatus control unit 712 is simply described as “control unit”, but is different from the control unit 101 of the planar warming tool. Needless to say, there are.

[Heating step and pressing step]
Next, an example of a manufacturing method using the manufacturing apparatus for the planar warming device having the above-described configuration will be described with reference to FIGS. 14 (a) and 14 (b) in addition to FIGS. 13 (a) and 13 (b). Explained. FIG. 14A is a graph showing the temperature change of the soaking sheet 410 and the adhesive layer when heated by one electromagnetic induction heating coil in the heating process, and FIG. 14B is a graph showing three electromagnetic inductions. It is a graph which shows the temperature change of the soaking | uniform-heating sheet | seat 410 at the time of heating with a heating coil and the layer of an adhesive agent.

  In the present embodiment, the preparation process is the same as that in the first embodiment, and thus the description thereof is omitted. Next, in the heating process, the work 110 stacked in the preparation process is moved from the first to third electromagnetic induction heating devices 721a to 721c arranged above while being moved in the moving direction (the direction of the block arrow A) by the transport device 720. By generating magnetic lines of force and applying them to the workpiece 110, an eddy current is generated in the soaking sheet 410 (aluminum sheet 411) of the heater unit 400, and the aluminum sheet 411 itself is caused by the eddy current and the resistance of the aluminum sheet 411. Increase temperature by exotherm. Then, the heat generated from the aluminum sheet 411 melts the adhesive resin 412 coated on both surfaces of the aluminum sheet 411 and the adhesive sheet 300 stacked in close contact with the heater unit 400.

  Here, in the present embodiment, three electromagnetic induction heating coils, ie, a first heating coil 722a, a second heating coil 722b, and a third heating coil 722c, are arranged in parallel substantially in the direction of movement. Therefore, since the magnetic lines of force are sequentially supplied to the same portion of the aluminum sheet 411 by the first to third heating coils 722a to 722c, it is possible to ensure a long heating time. Therefore, the power supplied to each of the first to third heating coils 722a to 722c can be reduced, and the temperature of the aluminum sheet 411 is not increased rapidly, so that the aluminum sheet 411 is gently taken over time. Can generate heat.

  For example, the example shown in FIG. 12A is an example of a temperature change when only one electromagnetic induction heating device 721 is provided in the first embodiment, the broken line indicates the temperature of the aluminum sheet 411, and the solid line indicates adhesion. The temperature of the sheet 300 is shown. In the figure, “heat-resistant temperature” and “melting temperature” refer to the temperature of the adhesive (polyethylene resin). In the case where the workpiece 110 is heated by one heating coil 722, the aluminum sheet 411 rapidly rises to the melting temperature from the start of heating and further reaches the temperature exceeding the heat resistance temperature. On the other hand, the adhesive sheet 300 rises relatively slowly after the temperature rise of the aluminum sheet 411 and reaches the melting temperature.

  As described above, when one heating coil 722 is used, rapid heating is possible in a short time, but the electromagnetic induction heating device 721 supplies a high capacity power to the heating coil 722 in a short time. The temperature will rise. Therefore, while the heating time can be shortened, the temperature of the aluminum sheet 411 rises to a temperature higher than the heat resistance temperature, which causes deterioration of the adhesive resin 412 laminated on both surfaces of the aluminum sheet 411.

  On the other hand, the example shown in FIG. 12B is an example of a temperature change in the configuration including the present embodiment, that is, the first to third electromagnetic induction heating devices 721a to 721c. When three electromagnetic induction heating coils (first to third heating coils 722a to 722c) are used, the heating time can be lengthened. Therefore, the first to third electromagnetic induction heating devices 721a to 721c are respectively The power capacity supplied to the first to third heating coils 722a to 722c can be lowered, and the temperature rise of the aluminum sheet 411 can be made gentle.

  Therefore, after reaching the melting temperature, the aluminum sheet 411 stops increasing in temperature to some extent and does not generate heat until it exceeds the heat resistance temperature. Further, the adhesive sheet 300 gradually rises in temperature after the temperature rise of the aluminum sheet 411 and reaches the melting temperature. At the time when the adhesive sheet 300 reaches the melting temperature, the temperature of the aluminum sheet 411 has not risen to the heat resistance temperature, so that deterioration of the adhesive resin 412 that is the soaking sheet adhesive layer can be effectively suppressed. Adhesive performance of the resin 412 can be sufficiently maintained.

  The workpiece 110 heated in the heating process is transferred by the transfer device 720 and moves to the roller unit 735. The roller unit 735 is a pressing device that performs a pressing process, and in a state where the workpiece 110 is held between the upper roller unit 735a and the lower roller unit 735b, the rotation rollers 737a to 737c are driven by a driving device provided in the lower roller unit 735b. The rotating belt 736 rotates through the. As a result, the workpiece 110 continues to move between the upper roller unit 735a and the lower roller unit 735b in the moving method (the direction of the block arrow A).

  During this movement, the upper roller unit 735a continuously presses the upper surface of the workpiece 110 by a pressure device provided in the upper roller unit 735a. During this pressing and movement, the cooling rollers 737a to 737c are provided. Since cold air is blown into the air passage 738, the adhesive layer such as the adhesive sheet 300 is cooled. As a result, since the adhesive melted in the heating step is solidified, the sheet-like members (surface material 200, heater unit 400, and heat insulating sheet 500) are appropriately bonded through the adhesive layer.

  Thus, in this Embodiment, since the three electromagnetic induction heating coils are provided, the temperature rise of the aluminum sheet 411 can fully be suppressed. Therefore, deterioration of the adhesive can be effectively suppressed, and the quality of the obtained surface warming tool can be stably secured. Further, the roller unit 735 makes it possible to ensure a longer pressing time of the workpiece 110, and the pressure can be maintained until the molten adhesive layer is sufficiently solidified. As a result, the adhesion performance of the sheet-like member can be improved, and the dimensional accuracy of the lamination of the sheet-like member can be ensured.

  In this embodiment, since the first to third electromagnetic induction heating devices 721a to 721c are used in the heating step, three electromagnetic induction heating coils are also used, but the present invention is not limited to this, As in the preferred example of the first embodiment, two electromagnetic induction heating coils may be used, or four or more electromagnetic induction heating coils may be used. Further, as described above, since one electromagnetic induction heating device may include a single electromagnetic induction heating coil or a plurality of electromagnetic induction heating coils, the electromagnetic induction heating device used in the heating process may be provided. The number of does not match the number of electromagnetic induction heating coils. In addition, when one electromagnetic induction heating apparatus is provided with the several electromagnetic induction heating coil, it is preferable that it is the structure which can control each electromagnetic induction heating coil separately.

(Embodiment 3)
In the first and second embodiments, as the electromagnetic induction heating coil, a long plate-like coil having a heating surface with a size that exceeds the width of the workpiece 110 is used. However, the present invention is not limited to this, and preferably If a plurality of electromagnetic induction heating coils are arranged adjacent to each other, a shorter-shaped electromagnetic induction heating coil can be used. In the third embodiment, an example of a configuration using a shorter electromagnetic induction heating coil will be specifically described with reference to FIG. FIG. 15 is a schematic diagram showing, as a schematic plan view, an example of the arrangement of the electromagnetic induction heating coils of the electromagnetic induction heating device 721 used in the heating process in the third embodiment.

  In the present embodiment, as shown in FIG. 15, a plurality of electromagnetic induction heating coils shorter than the width direction of the workpiece 110 are used, and these electromagnetic induction heating coils are adjacent in a direction substantially perpendicular to the moving direction. Has been placed. Specifically, nine electromagnetic induction heating coils are used in total, and are arranged in three rows in order from the upstream side in the movement direction (block arrow A). In the first row as viewed from the upstream, long heating coils 722d and 722f having a large length are arranged on both sides, and a small circular heating coil 722e is arranged in the center. Similarly, in the second row, the long heating coils 722g and 722i are arranged on both sides, and the circular heating coil 722h is arranged in the center. Similarly, in the third row, the long heating coils 722j and 722l are arranged on both sides, and the circular heating coil 722k is arranged in the center.

  The long heating coils 722d, 722g, and 722j are arranged in this order along the moving direction, and are arranged in parallel so that their longitudinal directions are aligned with each other. These three electromagnetic induction heating coils constitute one heating region. Similarly, the long heating coils 722f, 722i, and 722l are also arranged in this order along the moving direction, and are arranged in parallel so that their longitudinal directions are aligned with each other. These three electromagnetic induction heating coils constitute one heating region. The circular heating coils 722e, 722h, and 722k are also arranged in this order along the moving direction, and a heating region constituted by the long heating coils 722d, 722g, and 722j, and the long heating coils 722f, 722i, and 722l. The heating area is formed so as to fill a space between the heating area and the heating area.

  These nine electromagnetic induction heating coils can independently control power supply to each of them, and are configured to realize suitable heating in conjunction with the moving speed of the work 110 by the transfer device 720. ing.

  Each of these electromagnetic induction heating coils may be provided in one electromagnetic induction heating device 721, and nine electromagnetic induction heating devices 721 may be used as a whole, or a plurality of electromagnetic induction heating devices may be used. The induction heating device 721 may be provided and a plurality of electromagnetic induction heating devices 721 may be used. Therefore, the number of electromagnetic induction heating coils included in one electromagnetic induction heating device 721 may be the same (for example, three in one unit) or may be different (for example, one is five and the other is four). Etc.) Moreover, the structure with which all nine pieces are equipped with one electromagnetic induction heating apparatus 721 may be sufficient.

  The configuration of the workpiece 110 used in the present embodiment is basically the same as that of the first or second embodiment, but the aluminum sheet 411 is not a single large area but a smaller area. Aluminum sheets 411a and 411b are used. These aluminum sheets 411a and 411b have an area slightly larger than half of the area of the workpiece 110, and as shown in FIG. They are integrated so as to have a size corresponding to the workpiece 110. Therefore, the overlapping portion 411c shaded in the figure has a thickness twice that of the other portions of the aluminum sheets 411a and 411b.

  The heating region configured by the long heating coils 722d, 722g, and 722j is a heating region configured by the long heating coils 722f, 722i, and 722l with the aluminum sheet 411a (upper side in FIG. 15 in FIG. 15) as a heating target. Uses an aluminum sheet 411b (lower side in FIG. 15) as a heating target. The circular heating coils 722e, 722h, and 722k have substantially the same dimensions as the width of the overlapping portion 411c (in other words, the overlapping portion 411c is formed in accordance with the width of the circular heating coil 722e). The parts 411c are individually heated.

  This embodiment is suitable for manufacturing a large planar warming tool. In particular, when the heater unit 400 is increased in size, it tends to be difficult to procure a wide aluminum sheet 411 to be used for the soaking sheet 410, so that two aluminum sheets 411a and 411b may be joined and used. . At this time, the thickness of the aluminum sheet 411 is increased at the joined portion (overlapping portion 411c), and current easily flows. As a result, the amount of heat generated by the overlapping portion 411c increases, and the temperature of the portion corresponding to the overlapping portion 411c becomes higher than the other portions, so that inconveniences such as partial deterioration of the adhesive easily occur. There is a fear.

  This embodiment can cope with the above-mentioned inconvenience, and supplies large power to nine electromagnetic induction heating coils while conveying the workpiece 110 at a predetermined speed, and joins aluminum sheets 411a and 411b. The sheet 413 is heated. At this time, the power supply to the small circular heating coils 722e, 722h and 722k corresponding to the central overlapping portion 411c of the large aluminum sheet 413, the long heating coils 722d, 722g and 722j arranged on both sides, or By making it relatively lower than the energization capacity to the long heating coils 722f, 722i and 722l, the entire large aluminum sheet 413 can be uniformly heated.

(Embodiment 4)
In each of the first to third embodiments, the description has been made centering on the manufacturing method of the planar warming tool. However, the present invention is not limited to the manufacturing method, and includes a manufacturing apparatus of the planar warming tool. . Therefore, an example of a manufacturing apparatus for a planar warming tool will be specifically described with reference to FIGS. 16 (a) to 16 (c) are schematic diagrams showing an example of a manufacturing apparatus for a planar warming tool according to Embodiment 4 of the present invention.

  For example, a planar warming tool manufacturing apparatus 700A (hereinafter, simply referred to as a manufacturing apparatus) shown in FIG. 16A is configured by only a workpiece heating apparatus 701 for performing a heating process. The workpiece heating device 701 includes electromagnetic induction heating units 723a and 723b, a heating unit moving mechanism 724, a workpiece chuck conveyance unit 725, and a conveyance support base 726. Since the electromagnetic induction heating units 723a and 723b are substantially the same as the electromagnetic induction heating device 721 described in the first to third embodiments, the description thereof is omitted. These electromagnetic induction heating units 723a and 723b include one heating coil 722a and 722b, respectively. Therefore, the workpiece heating device 701 shown in FIG. 16A corresponds to a configuration example (see FIGS. 11A and 11B) including the two electromagnetic induction heating coils in the first embodiment.

  The heating unit moving mechanism 724 moves the interval between the electromagnetic induction heating units 723a and 723b, that is, the interval between the heating coils 722a and 722b (referred to as a heating interval D) in an adjustable manner, both in FIG. As indicated by the direction block arrow E, the electromagnetic induction heating units 723a and 723b can be moved back and forth along the movement direction (block arrow A). The specific configuration is not particularly limited, and a known mechanical movement mechanism can be suitably used.

  As described in the first embodiment, the upstream electromagnetic induction heating unit 723a performs preliminary heating, and the downstream electromagnetic induction heating unit 723b performs main heating. However, the electromagnetic induction heating unit 723a, If the interval 723b is too large, the temperature of the soaking sheet 410 (aluminum sheet 411) generated by the preheating may be lower than the preferred temperature range. On the other hand, if the interval is too small, the heating regions of the electromagnetic induction heating units 723a and 723b overlap, and the temperature of a part of the soaking sheet 410 may become excessively high. Therefore, by making it possible to adjust the heating interval D between the electromagnetic induction heating units 723a and 723b, the heating process can be performed more appropriately.

  Here, the heating unit moving mechanism 724 may operate before the manufacture of the main body 100 to adjust the heating interval D, or the heating interval D is set in consideration of manufacturing conditions and the like during the manufacturing of the main body 100. You may adjust. The heating unit moving mechanism 724 may be manually operated by an operator of the workpiece heating apparatus 701 or may be configured to be automatically operated by a control unit (not shown). The heating unit moving mechanism 724 is configured to be able to move the electromagnetic induction heating units 723a and 723b in the vertical direction so that not only the heating interval D but also the interval between the surface of the workpiece 110 and the heating coils 722a and 722b can be adjusted. May be.

  The work chuck conveyance unit 725 is substantially the same as the conveyance device 720, and conveys the workpiece 110 in the conveyance direction (block arrow F in the figure, the same direction as the movement direction) by chucking. The conveyance support base 726 supports the heating unit moving mechanism 724, the work chuck conveyance unit 725, and the like. The workpiece heating device 701 may include a configuration other than the electromagnetic induction heating units 723a and 723b, the heating unit moving mechanism 724, the workpiece chuck conveyance unit 725, and the conveyance support base 726.

  A manufacturing apparatus 700 </ b> B illustrated in FIG. 16B includes a pressure bonding apparatus 702 in addition to the work heating apparatus 701. That is, the manufacturing apparatus 700 </ b> B is configured by integrally combining the workpiece heating apparatus 701 and the pressure laminating apparatus 702. The pressure laminating apparatus 702 includes the roller unit 735 described in the second embodiment and a roller support base 734 for supporting the roller unit 735. Note that the pressure laminating apparatus 702 may have other configurations.

  In manufacturing apparatus 700B, since it is preferable to link the movement speed of work 110, work heating apparatus 701 and pressure laminating apparatus 702 may be controlled by the same control apparatus, or provided with independent control apparatuses. However, each control may be coordinated by using a known communication device or the like so that bidirectional communication is possible.

  A manufacturing apparatus 700 </ b> C illustrated in FIG. 16C includes a workpiece preparation device 703 in addition to the workpiece heating device 701 and the pressure laminating device 702. The workpiece preparation device 703 is a facility for performing the preparation process described in the first embodiment, and various mechanisms for stacking and aligning the sheet-like members, or the workpiece 110 to be obtained, the workpiece heating device 701. What is necessary is just to provide the conveyance mechanism etc. for conveying to. Also in the manufacturing apparatus 700C, it is preferable that the control of the workpiece heating device 701, the pressure laminating device 702, and the workpiece preparation device 703 are linked.

  As described above, the method for manufacturing a planar warming device according to the present invention includes a heater on one surface of a soaking sheet in which a surface material and a metal sheet are coated with an adhesive resin that melts at a predetermined temperature or higher. A method for manufacturing a planar warming tool including a heater unit provided with a wire and a heat insulating sheet, wherein the surface material, the heater unit, and the heat insulating sheet are stacked in this order to obtain a laminate. A step of installing an electromagnetic induction heating device in proximity to one of the surface material and the heat insulating sheet of the laminate, and heating the metal sheet by the electromagnetic induction heating device A heating step of melting the resin, and a pressing step of bonding the surface material, the heater unit, and the heat insulating sheet by pressing the laminate by pressing means, and the electromagnetic Electrically heating device may have a configuration provided with a plurality of heating coils.

  As a result, the heat for melting the adhesive resin is generated from the metal sheet inside the planar warming tool, so that the adhesive resin can be melted in a short time, so that the bonding work can be carried out in a short time. In addition, it is possible to suppress wasteful heat radiation outside the surface heating device. Therefore, energy saving in the manufacturing process can be achieved.

  In addition, by providing a plurality of heating coils of the induction heating device, it is possible to heat a wide range at the same time, so it is possible to heat for a long time with a low heating capacity, and to increase the temperature of the metal sheet as a heat source. Can be suppressed. For this reason, it is possible to suppress deterioration of the molten resin and obtain stable adhesion performance. In addition, since a mold is not used in the machining process, initial investment costs can be suppressed and the degree of freedom in design can be improved.

  In the manufacturing method, the heating coil of the electromagnetic induction heating device may have a configuration in which a plurality of the heating coils are arranged in parallel. Thereby, while heating a wide range uniformly simultaneously, it becomes possible to heat the whole laminated body uniformly by moving a heating range in parallel.

  In the manufacturing method, the heating coil of the electromagnetic induction heating device may have a configuration in which a plurality of heating coils shorter than the width of the multilayer body are connected to cover the entire width of the multilayer body. As a result, the heating capacity can be changed for each heating coil, and uniform heat generation can be obtained even in metal sheets having different heat generation conditions, such as when the thickness of the metal sheet is partially different.

  Moreover, in order to implement | achieve the said manufacturing method, the manufacturing apparatus of the planar warming tool which concerns on this invention is a structure provided with at least some heating coil and the conveyance means which conveys a laminated body. As a result, it is possible to manufacture the surface heating device with low initial investment cost, energy saving and high efficiency.

  It should be noted that the present invention is not limited to the description of the above-described embodiment, and various modifications are possible within the scope shown in the scope of the claims, and are disclosed in different embodiments and a plurality of modifications. Embodiments obtained by appropriately combining the technical means are also included in the technical scope of the present invention.

  As described above, in the present invention, by heating the soaking sheet containing a metal material among the sheet-like members constituting the main body of the planar warming tool, the hot-melt adhesive is melted to each sheet-like member. Can be widely used in the field of manufacturing a surface warming device, and can also be applied to other uses such as the manufacture of other heating appliances equipped with a similar heat equalizing sheet.

100 body (body of the surface heating device)
110 Workpiece (laminated body, stacked body)
200 Surface material (sheet-like member)
203 Adhesive (adhesive layer, surface material adhesive layer)
300 Adhesive sheet (sheet-like member, adhesive layer)
400 Heater unit (sheet-like member)
410 Soaking sheet (sheet-like member)
411 Aluminum sheet (main body of soaking sheet)
412 Adhesive resin (adhesive layer, soaking sheet adhesive layer)
420 Heater wire 500 Thermal insulation sheet (sheet-like member)
600 Back material (sheet-like member)
712 Manufacturing device control unit (control means)
720 Conveying device (conveying means)
721 Electromagnetic induction heating device (electromagnetic induction heating means)
721a to 721c Electromagnetic induction heating device (electromagnetic induction heating means)
722 Heating coil (electromagnetic induction heating coil, long plate coil)
722a to 722c First to third heating coils (electromagnetic induction heating coil, long plate coil)
722d, 722f, 722g, 722i, 722j, 722l Long heating coil (electromagnetic induction heating coil, short plate coil)
722e, 722h, 722k Circular heating coil (electromagnetic induction heating coil, short plate coil)
730 Pressing roller (pressing means, pressing device)
735 roller unit (pressing means, pressing device)

Claims (9)

A method of manufacturing a planar warming tool comprising a planar heater unit in which a heater wire is disposed on a soaking sheet containing a metal component, and a sheet-like member laminated on the heater unit,
A preparation step of forming a laminate in which the sheet-like member and the heater unit are stacked in a state in which a layer of a hot-melt adhesive is interposed;
An electromagnetic induction heating coil is installed close to at least one of the front and back surfaces of the laminate, and the heater unit is configured to generate lines of magnetic force by the electromagnetic induction heating coil while moving the laminate in a preset moving direction. A heating step of melting the adhesive by heating the soaking sheet of
A plurality of the electromagnetic induction heating coils are arranged along the moving direction, and the plurality of electromagnetic induction heating coils are configured such that power supply is independently controlled, and the plurality of electromagnetic induction heating coils are configured. The spacing between the coils can be adjusted,
In the heating step, the plurality of electromagnetic induction heating coils repeatedly generate heat by repeating the same portion of the laminate several times,
Control of power supply to each of the electromagnetic induction heating coils to heat the adhesive layer to a temperature below the heat resistant temperature of the adhesive and above the melting temperature of the adhesive; and It is characterized by adjusting the interval between the electromagnetic induction heating coils,
A method for manufacturing a surface heating device. The adhesive layer included in the laminate is configured as an independent sheet-like member, or laminated in advance on the sheet-like member, or both.
The manufacturing method of the planar warming tool of Claim 1. The sheet-like member is
A surface material constituting the surface of the surface heating device,
A back material constituting the back surface of the planar warming tool, and
It is at least one of a heat insulating sheet that suppresses heat transfer to the back side of the heating heat generated from the heater unit,
The manufacturing method of the planar warming tool of Claim 2. The heater unit has a configuration in which the heater wire is disposed on either the front or back surface of the soaking sheet,
In the heating step, the laminated body is installed such that a surface of the laminated body on which the heater wire of the soaking sheet is not disposed is close to the electromagnetic induction heating coil. ,
The manufacturing method of the planar warming tool of Claim 1. The electromagnetic induction heating coil is a long plate coil longer than the width of the laminate,
A plurality of the long plate-like coils are arranged adjacent to each other along the moving direction in a state of being parallel in the longitudinal direction.
The manufacturing method of the planar warming tool of Claim 1. The electromagnetic induction heating coil is a short plate coil shorter than the width of the laminate,
The plurality of short plate coils are arranged adjacent to each other so as to cover the entire width of the laminated body, intersecting the moving direction,
The manufacturing method of the planar warming tool of Claim 1. It is performed after the heating step, and further includes a pressing step of pressing the entire laminate,
The manufacturing method of the planar warming tool of Claim 1. An apparatus for manufacturing a planar warmer comprising a planar heater unit in which a heater wire is disposed on a soaking sheet containing a metal component, and a sheet-like member laminated on the heater unit,
A conveying means for conveying the laminated body in which the sheet-like member and the heater unit are stacked in a state where a layer of a hot-melt adhesive is interposed, in a preset moving direction;
Electromagnetic induction heating means including a plurality of electromagnetic induction heating coils located downstream of the moving direction and arranged adjacent to each other in the moving direction;
A heating unit moving mechanism that adjustably moves an interval between the electromagnetic induction heating coils;
Control means,
The control means is configured such that power supply is controlled independently for each of the plurality of electromagnetic induction heating coils, and for at least one of the front and back surfaces of the laminate transported by the transport means Then, by applying magnetic lines of force generated by the plurality of heating coils of the electromagnetic induction heating means, the same portion of the soaking sheet of the heater unit is repeatedly heated multiple times to melt the adhesive. Is configured as
By controlling the power supply to the individual electromagnetic induction heating coils by the control means and adjusting the interval between the electromagnetic induction heating coils by the heating unit moving mechanism, the adhesive layer is bonded to the adhesive layer. Heating to a temperature lower than the heat-resistant temperature of the agent and higher than the melting temperature of the adhesive,
Manufacturing equipment for surface heating equipment. Further, the electromagnetic induction heating means is provided adjacent to the downstream side in the moving direction, and has a pressing means for pressing both surfaces of the laminate,
The manufacturing apparatus of the planar warming tool of Claim 8.

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