JPH07142155A - Manufacture of electric heater using nonwoven fabric and relevant apparatus - Google Patents

Abstract

PURPOSE:To provide the nonwoven entangling method capable of forming the entangled region of ground fabrics into a continued pattern and capable of attaining the sufficient punching density in the entangled region. CONSTITUTION:Punching is applied to a plurality of ground fabrics 7, 8 with many barb needles 4, an entangled region entangled with these ground fabrics 7, 8 is formed into a predetermined pattern, and a heater wire is arranged in a non-entangled region. Many barb needles 4 protruded toward the ground fabrics 7, 8 are planted into the shrunk pattern of the entangled region on the throat plate 3 of a drive base 2 approaching to and separating from the ground fabrics 7, 8. Punching is applied to the fabric region to become the entangled region with the barb needles 4 while both the throat plate 3 of the drive base 2 and the ground fabrics 7, 8 are moved in sequence to many positions nearly uniformly dispersed in the prescribed face region perpendicular to the punching direction of the barb needles 4.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cloth-like electric heating device such as an electric blanket or an electric carpet, and in particular, a pair of base cloths sandwiching a heating element such as a heater wire are entangled with each other by needle punching. The present invention relates to a method of manufacturing an electric heating tool and related appliances.

[0002]

2. Description of the Related Art Conventionally, as an electric heater using a non-woven fabric, a pair of base fabrics made of non-woven fabrics are subjected to needle punching with a large number of needle needles, and a band-shaped entangled region in which both base fabrics are entangled, There has been proposed an electric blanket and a carpet in which non-entangled regions in which both base fabrics are not entangled are alternately formed, and heater wires meander along the non-entangled regions.
(JP-A-58-17794)

In the blanket and carpet, the length of each entangled region in the longitudinal direction is slightly shorter than the entire length of the blanket and carpet, and the heater wire is unentangled at both ends of the entangled region. It is folded back 180 ° in the region and extends to the next non-entangled region sandwiched between two entangled regions.

By the way, in the conventional needle punching process using a needle needle, a large number of needle needles (4) are planted in a needle plate (3) as shown in the figure, and the needle plate (3) is reciprocated up and down. The base fabrics (7) and (8) are driven to punch two base fabrics (7) and (8) by a large number of needles (4), and the base fabrics (7) and (8) are continuously moved in one direction. here,
To entangle two base cloths (7) and (8) with great strength,
Since it is necessary to sufficiently increase the punching density, conventionally, as shown in FIG. 5, the needle needles (4) are arranged obliquely with respect to the base cloth moving direction, and the needles are arranged in a direction orthogonal to the base cloth moving direction. The distance between the needles (4) is narrowed, and the number of punching strokes of the needle needles (4) per unit moving distance of the base fabric is increased as much as possible. According to this method, a sufficient punching density (area C) can be achieved after the base cloth has moved a certain distance (areas A and B).

[0005]

When the conventional electric blanket and carpet are manufactured by the conventional needle punching process, the needle plate (3) has a striped pattern corresponding to the pattern of the entangled region of the base cloth. A method is conceivable in which a needle needle is planted and the base cloth is continuously moved in the longitudinal direction of the entangled region while punching with the needle needle.

However, according to this method, since the entangled region of the base cloth is continuous in the longitudinal direction and a pattern interrupted in the longitudinal direction cannot be formed, the non-entanglement for folding back the heater wire as described above. In order to form the regions at both ends of the band-shaped entangled region, it is necessary to peel off the pair of base fabrics that have been entangled by the above method at both ends of the entangled region.
Therefore, conventional methods do not survive mass production. Furthermore, it is impossible to wire before entanglement as shown in FIG.

When the entangled region is interrupted in the longitudinal direction by the intermittent feeding of the base cloth, the punching density does not increase as in the area A or B of FIG. Sufficient entanglement strength is not obtained at the end of the entanglement area,
There is a problem that the entangled area is peeled off during long-term use or washing, and the heater wire is detached.

An object of the present invention is to provide a method of manufacturing an electric heating device, which can form an entangled region of a base cloth in a discontinuous pattern and can achieve a sufficient punching density in the entangled region. Is to provide.

[0009]

In the method for manufacturing an electric heater according to the present invention, the needle plate (3) of the drive table (2) approaching and separating from the base cloths (7) and (8) has a base plate. Cloth (7) (8)
A large number of needle needles (4) projecting toward are erected in a pattern in which the entanglement region (10) is reduced. Then, both the needle plate (3) of the drive table (2) and the base cloth are sequentially moved to a large number of positions which are substantially uniformly dispersed in a predetermined plane area orthogonal to the punching direction of the needle needle (4). At the same time, punching is performed by the needle needle (4) on the base cloth region which is the entanglement region (10).

As will be described later in detail with reference to Examples, the driving table (2) or the needle plate (3) reciprocates in the Y direction momentarily, and punches with the needle needle (4). X together
The base cloths (7) and (8) are moved by a roller (13) or the like in the direction to perform punching.

[0011]

In the above manufacturing method, both the needle plate (3) and the base cloth of the drive table (2) are made substantially uniform within a predetermined surface area orthogonal to the punching direction of the needle needle (4). By sequentially moving to a large number of positions that vary, the punching position of the needle needle (4) varies at a fine interval within a predetermined range on the base cloth, and the punching density is increased.
According to this method, the entangled region (10) is formed in an enlarged pattern of the planting pattern of the needle needle (4).

As shown in FIG. 2, even with an intermittent pattern,
By increasing the number of punching strokes as much as possible, the punching density is increased only in the predetermined entangled region (10), and at the same time, the non-entangled region (11) for folding back the heater wire (12) is also formed. Will be.

[0013]

EFFECTS OF THE INVENTION According to the method for manufacturing an electric heater using the nonwoven fabric of the present invention, the entangled region of the base fabric can be formed in an intermittent pattern, and a sufficient punching density is achieved in the entangled region. It is possible to

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An example in which the present invention is applied to an electric blanket will be described below with reference to the drawings. A drive base 2 is connected to a lower portion of a drive unit 1 in FIGS. Two
Slide device 14 (generally XY
The so-called table device) is installed. A needle plate 3 is mounted on the slide device 14, and the needle plate 3
Needle needles 4 are planted in the.

The stripper plate 5 and the bed plate 6 are provided with substantially rectangular or substantially elliptical slot holes 9 arranged in a pattern so that the needle needles 4 do not hit even if they reciprocate in a predetermined Y direction. ing. The slot 9 has a size slightly larger than the width of the entangled region 10.
Further, the stripper plate 5 and the bed plate 6 are fixed by a connecting portion 15 for convenience of description later. The connecting portion 15 has a function of moving up and down.

The base fabrics (7, 8) are stripper plates 5
The roller 13 is used to stop or pass between the roller and the bed plate 6. A method for manufacturing an electric blanket of the present invention using a nonwoven fabric manufacturing machine having the above structure will be described.

The manufacturing method of FIGS. 2A and 2B will be described. (A) As a first step, the lower layer base fabric 8 is preliminarily formed in a predetermined wiring position in the non-entangled region 11 with a temporary adhesive or the like. Wire. (B) In the second step, the upper layer base cloth 7 is mounted on the lower layer base cloth 8 having the fixed-shape wiring of (a) so as to cover the heater wire and form a sandwich state. Further, in order to confirm the fixed wiring position, a detection hole 16 having a diameter of about 5 mm is formed in the end portions (generally referred to as ears) of the upper and lower base fabrics (7, 8). [Fig. 1
(B)] (c) In the third step, the base fabric (7, 8) is the roller 1
The sheet 3 is conveyed to a predetermined position between the stripper plate 5 and the bed plate 6. The detection hole 16 is detected by an optical sensor 17 or the like and stopped at a predetermined position. (D) In the fourth step, the connecting portion 15 between the stripper plate 5 and the bed plate 6 is moved up to a position where needle punching can be performed, and the needle needle 4 performs punching processing described later. (E) As a fifth step, when the predetermined entanglement region 10 is entangled by the punching process of (d) and completed, the upper and lower base fabrics (7, 8) and the needle needle 4 are connected to a predetermined position where they do not hit. The section 15 descends, [see FIG. 1 (a)], and then the upper and lower base fabrics (7, 8) are conveyed to the next step by the rollers 13. (F) As a sixth step, the detection hole 16 is cut as a target and the heater wire end is housed in the socket 18. Furthermore, the periphery of the blanket is machined to complete.

Explaining punching, the driving unit 1
As a result, the drive base 2 and the needle plate 3 move up and down in the Z-axis direction. Further, as the needle plate 3 reciprocates in the Y direction by the slite device 14, the needle needle 4 reciprocates in the Y direction while vertically moving (punching).

Further, the base cloth (7, 8) is moved in the X direction by the roller 13. Therefore, the needle needle 4 is moved to the X. Punching while moving in the Y direction. That is, in the predetermined entangled surface area, the base cloth (7, 8) and the needle needle 4 are moved by both of them to sequentially move to a large number of positions which are substantially uniformly scattered, and punching is performed, resulting in an intermittent pattern. However, it is possible to increase the punch density.

The punching location and its orbit will be described with reference to the enlarged view of FIG. Needle needle 4 is 4-1
From 4-2 to 4-3 in turn in the Y direction at point 4
Punch to -a. At the end of punching at the turning point 4-a, the base cloth (7, 8) is moved by the roller 13 to the position in the X direction 4-b and stopped. Further, after the needle needle 4 punches the portion of 4-b, 4-4 to 4
Punch to -5. In this way, while reciprocating in the Y direction, the process advances in the X direction, and punching is completed to the end “point 4-c” before the point punched by the needles in the rear row.

Actually, the distances to the plurality of rear row needles are about 2 cm, respectively, so that the distance to be successively moved in the X direction is about 2 cm. Since the punching is 600 to 1,000 strokes per minute, the speed of the punching is fast until the end, and the punch density can be appropriately increased.

The movements in the X and Y directions are all intermittent feeds. Further, in order to punch the pattern of the entangled area 10, the arrangement of the needle needles, the reciprocating distance in the Y direction, the sizes of the slot holes of the stripper plate and the bed plate in accordance with them, and the like are calculated and moved. All the transportation and the like are performed by a control device (not shown).

Further, the slot holes 9 of the stripper plate 5 and the bed plate 6 are formed in a substantially rectangular shape or a substantially oblong shape so that when the needle needle 4 moves in the Y direction, the stripper plate 5 and the bed plate 6 are This is because the needle 4 is prevented from hitting. However, needle needle 4
When the stripper moves in the Y direction or the X direction, the stripper plate 5 and the bed plate 6 are simultaneously attached in the same direction and at the same distance, or the slide 2 device 1 is attached.
If it is linked so as to be synchronized with 4, the conventional circular slot does not have the above problem.

In the embodiment of FIGS. 3 (a) and 3 (b), the upper and lower base fabrics (7, 8) in which the upper base fabric 7 is mounted on the lower base fabric 8 are punched in the same manner as described above, and are subjected to a post-process. This is completed by cutting the detection hole 16 around the target, inserting the heater wire 12 therethrough, attaching the socket 18, and then sewing the periphery of the blanket. That is, it can be finished in the same manner as the finished product of FIG. Therefore, details are omitted.

According to the above-described method for manufacturing an electric blanket, the needle needle reciprocates in the Y direction with a substantially uniform width in every Y direction relative to the base fabric, punches while reciprocating, and further moves in the X direction by the roller. The punching density is increased only in a predetermined entangled region by increasing the number of punching trokes even in an intermittent pattern in order to continue punching. Therefore, it can be formed as shown in FIGS. 3 (a) and 3 (b), and when inserting in the next step, it is not necessary to remove the portion for folding back the heater wire.

Further, as shown in FIGS. 2 (a) and 2 (b), it is possible to perform fixed-shape wiring by an automatic machine in advance, which is very effective for mass production. Since the upper and lower base fabrics are not attached to each other with a strong adhesive unlike a conventional electric carpet, the product has a soft finish, is light in weight, easy to fold and store, and can be washed.

The above description of the embodiments is for explaining the present invention, and should not be construed as limiting the invention described in the claims or reducing the scope. or,
The configuration of each part of the present invention is not limited to the above embodiment, and it is needless to say that various modifications can be made within the technical scope described in the claims. For example, as shown in FIG.
Not only the punching trajectories of a and 4-b but also various changed punching trajectories are possible. Further, it is also possible to move the drive table main body directly connected to the needle plate in the Y direction without moving the needle plate in the Y direction with a slide device or the like. The needle needle is Y
It is possible not only to move both the direction and the base cloth in the X direction, but also to move both the needle needle and the base cloth to random points respectively for punching. Needless to say, the present invention can be applied not only to electric blankets but also to electric carpets.

[Brief description of drawings]

FIG. 1 (a) is a cutaway sectional view showing an example of a non-woven entanglement device. (B) It is a fracture | rupture top view of this apparatus and a roller.

FIG. 2 (a) is a partially cutaway plan view of the finished product showing the entanglement region and the heater wire. (B) It is a partially broken sectional view of the finished product.

FIG. 3A is a partially cutaway plan view of the semi-finished product before the heater wire is arranged, showing the entangled region. (B) It is a cross-sectional view of the semi-finished product cut away from the negative part.

FIG. 4 is a partial plan view showing a punching trajectory by moving the needle needle in both the Y direction and the base cloth in the X direction.

FIG. 5 is a partial plan view showing a punching track in a conventional technique.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Drive part 10 Entanglement area 2 Drive stand 11 Non-entanglement area 3 Needle plate 12 Heater wire 4 Needle needle 13 Roller 5 Stripper plate 14 Slight instrument 6 Bed plate 15 Connecting part 7 Upper layer base cloth 16 Detection hole 8 Lower layer base cloth 17 Optical sensor 9 Slot 18 Socket

Claims (7)

[Claims] 1. A entanglement in which a plurality of base fabrics (7) (8), at least one of which is a non-woven fabric, is punched using a large number of needle needles (4), and these base fabrics are entangled with each other. In the method for manufacturing an electric heating tool, in which the mating area (10) is formed in a predetermined pattern, and the non-entangled area (11) is provided with a heating element, the base cloths (7) and (8) are approached and separated from each other. The base plate (7) (8) is attached to the needle plate (3) of the drive base (2)
A large number of needle needles (4) projecting toward are erected in a pattern in which the pattern of the entanglement region (10) is reduced, and the needle plate (3) of the drive base (2) and the base fabrics (7) (8). ) Both
The needle needle (4) is moved sequentially to a large number of positions that are substantially uniformly scattered within a predetermined surface area orthogonal to the punching direction of the needle needle (4), and the needle needle (4 ) Is used to increase the punch density, and a method for manufacturing an electric heater using a non-woven fabric. 2. A heater wire (12), which is a heating element, is fixedly wired on a lower layer base cloth (8) at a predetermined position which is an unentangled region (11), and the heater wire (12) is covered to cover the upper layer substrate. The method for manufacturing an electric heater using a non-woven fabric according to claim 1, wherein after the cloth (7) is mounted, the needle needle (4) punches only a predetermined entangled region (10). 3. The non-entangled region (1) after punching a plurality of base fabrics (7) (8) with a needle needle (4).
The method for manufacturing an electric heating tool using a nonwoven fabric according to claim 1, wherein a heater wire (12) serving as a heating element is inserted into 1). 4. The reciprocating drive of the drive table (2) in the Z-axis direction approaching and separating from the base cloth (7) (8), and the Y-axis orthogonal to the Z-axis in synchronization with the reciprocating drive. By moving the drive base (2) or the needle plate (3) in a width that changes in each direction,
The method for manufacturing an electric heater using a non-woven fabric according to claim 1, wherein the base fabrics (7) and (8) are also punched while being moved in the X-axis direction by rollers (13) or the like. 5. A drive table (2), characterized in that a slide device (14) is attached in order to make the needle plate (3) movable in the X direction or the Y direction. 6. A stripper plate (1) having a plurality of substantially rectangular or substantially elliptical slot holes (9) when punching while the needle needle (4) moves in the X direction or the Y direction. 5) and bed plate (6). 7. A needle needle (4) set in a needle plate (3).
A stripper plate or bed plate having a device capable of moving in the X direction or the Y direction and simultaneously moving in the same direction and the same distance.