JPH08243007A - Electric carpet - Google Patents

Abstract

PURPOSE: To provide an electric carpet which does not slide under a cover by the tramping pressure on the cover even if the cover is used over the carpet for a long time. CONSTITUTION: A heater unit 7 with cord-type heating element 6 is put between the surface material 1 and the rear surface material 2 made of fiber sheets. The surface material 1 is made of nonwoven felt 3 and many melted aggregates 4 made of melted fiber of the nonwoven felt are made on the surface. These melted aggregates 4, biting into the fiber of the rear surface of the cover, prevent the cover from sliding.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to electric carpets.

[0002]

2. Description of the Related Art The structure of a conventional electric carpet is shown in FIG. The electric carpet uses a nonwoven fabric 21 made into a felt by needle punching as the surface material 1 and the back surface material 2. Then, the heat-sealing film 8, the metal foil 9 such as aluminum, and the heat-sealing film 8 are laminated in this order,
Further, the electric carpet is constructed by sandwiching the heater unit 7, which has the heating wire 6 patterned and adhered to the lower surface thereof, between the front surface material 1 and the rear surface material 2.

When the electric carpet is used, since the heating wire 6 and the like are incorporated, it is difficult to care for washing and the like, and therefore a cover sheet is often laid and used. As the cover sheet 21, as shown in FIG. 4, a fiber sheet 23 having a pile 22 on its surface is generally used. However, the fiber sheet 23 having the pile 22 on the surface is
If it is used for a long period of time, a pedaling movement phenomenon occurs, and there is a problem that the cover sheet 21 and the electric carpet are displaced. The trampling movement phenomenon is because the pile 22 has hair lines that are inclined in a certain direction, so that the cover sheet 21 moves in the hair line direction when a load is applied, and even if the load is removed and the pile 22 is restored, the cover sheet 21 Is a phenomenon that does not return to the original position.

For this reason, it is disclosed in Japanese Utility Model Publication No. 60-24236 that the back surface of the cover sheet is subjected to slip prevention processing.

[0005]

However, when the back surface of the cover sheet is subjected to slip prevention processing, a direct flame treatment is performed after the resin is applied to the back surface in order to improve the entanglement of the pile and prevent the pile from coming off. However, the resin is hardened by this direct flame, and it becomes difficult to fold the cover sheet, so that it cannot be packaged and wrinkles easily occur, which makes the handling work difficult. Therefore, there is a demand for an electric carpet that can prevent the occurrence of a pedaling pressure movement phenomenon between the cover sheet and the electric carpet even if the cover sheet that is not particularly subjected to the slip prevention process is used.

The present invention has been made in view of the above facts, and an object of the present invention is to provide an electric carpet in which a treading movement phenomenon does not occur between the cover sheet and the cover sheet even when the cover sheet is used for a long period of time. To provide.

Another object of the present invention is to provide an electric carpet having an excellent anti-slip function with the floor.

[0008]

According to a first aspect of the present invention, there is provided an electric carpet in which a heater unit 7 having a cord-shaped heating wire 6 is provided between a surface material 1 and a back material 2 made of a fiber sheet. The electric carpet to be sandwiched is characterized in that a large number of molten lumps 4 of fibers constituting the non-woven felt are provided on the surface layer of the non-woven felt 3 as the surface material 1.

An electric carpet according to a second aspect of the present invention is the electric carpet according to the first aspect, in which the layer structure of the backing material 2 is a non-woven felt layer 11, and the non-woven felt layer 11 is integrated by needle punching. The spunbonded nonwoven fabric 12 and the foamed resin layer 13 that covers the outer surface of the spunbonded nonwoven fabric 12 are the outermost layers.

[0010]

The electric carpet according to claim 1 of the present invention has a structure in which the surface material 1 is the non-woven felt 3 on the surface layer, and the molten lumps 4 of the fibers forming the non-woven felt 4 are provided on the surface layer.
Since a large number of melted lumps 4 are provided,
Prevents the fibers from slipping into the back surface of No. 1.

In addition to the above functions, the electric carpet according to claim 2 of the present invention has the foamed resin layer 13 for covering the outer surface of the spunbonded nonwoven fabric 12 as the outermost layer because of its structure. It has a high coefficient of friction.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the drawings.

FIG. 1 is a fragmentary sectional view showing an electric carpet according to a first embodiment of the present invention disassembled for each constituent material.

As shown in FIG. 1, the electric carpet of the present invention has a heater unit 7 having a cord-shaped heating wire 6 sandwiched between a front surface material 1 and a rear surface material 2 which are made of a fiber sheet. The heater unit 7 is manufactured by laminating a heat-sealing film 8, a metal foil 9 made of aluminum or the like, and a heat-sealing film 8 in this order, and further bonding a cord-shaped heating wire 6 by pattern wiring on the lower surface thereof. It was done.

In the surface material 1 of the electric carpet of the present invention, a large number of molten lumps 4 of fibers constituting the non-woven felt 3 are provided on the surface layer of the non-woven felt 3. Examples of the non-woven felt 3 include a non-woven fabric made of a web of fibers which is needle-punched into a felt. Examples of the above-mentioned fibers include synthetic fibers such as nylon, polyester, acrylic, rayon and vinylon, cotton and hemp. Etc. alone or mixed cotton. The molten lump 4 is formed by applying a direct flame of propane gas to the non-woven felt 3 to melt a part of the fibers. The electric carpet includes the cover sheet 21 because it includes the molten lump 4.
The fibers on the back side of the do not get stuck and do not cause the movement of treading pressure. Therefore, the number of the molten lumps 4 is not limited, but the larger the number, the greater the effect.

The surface material 1 has, for example, a fiber thickness of 3
Needle punching of polyester short fibers having a denier of about 20 to about 2 to 3 inches with a needle density of about 150 needles / cm ² to obtain a felt of 100 to 300 g / m ² , and then propane gas It is obtained by applying a direct flame and melting a part of the fibers. When the felt is prepared by fluffing fibers on the surface to be heated during the needle punching, the molten lump 4 can be easily formed. Further, when the needle punching is performed under the condition of a high needle density of about 150 needles / cm ² , a thin finish can be achieved, so that the foldability is not impaired.

As described above, according to the present invention, since the surface material 1 is composed of the non-woven felt 3, a large number of melted agglomerates 4 of the fibers constituting the non-woven felt are provided on the surface layer. In order to prevent the fibers on the back surface from slipping into the fiber, it is possible to prevent the trampling movement phenomenon that occurs between the electric carpet and the cover sheet when used for a long time.
Further, since the back surface of the cover sheet does not have to be subjected to the slip prevention process, the cover sheet can be easily folded and wrinkles do not occur.

Next, an electric carpet according to a second embodiment of the present invention will be described with reference to FIG. FIG. 1 is a cross-sectional view of a main part of an electric carpet according to a second embodiment of the present invention, disassembled and shown for each component.

In the electric carpet according to the second embodiment, the backing material 2 has a non-woven fabric felt layer 11, a spunbonded non-woven fabric 12 integrated with the non-woven felt layer 11 by needle punching, and an outermost layer. A foamed resin layer 13 covering the outer surface of the spunbonded nonwoven fabric 12 is formed. The surface material 1 and the heater unit 7 sandwiched between the surface material 1 and the back surface material 2 are the same as those in the first embodiment.

The non-woven felt layer 11 is formed of a fiber layer in which short fibers are deposited in the shape of a spider web. Examples of the short fibers include nylon, polyester,
Examples thereof include synthetic fibers such as acrylic, rayon and vinylon, and individual and mixed cotton such as cotton and hemp. The spunbond nonwoven fabric 1
In No. 2, long fibers that have been melt-spun by a melt extruder are deposited and heated and pressed at a temperature equal to or higher than the melting temperature of the long fibers by an embossing heat roll to produce a thin sheet. As the long fiber. For example, polyester and the like can be mentioned. The spunbonded nonwoven fabric 12 and the nonwoven fabric felt layer 11 are integrated by needle punching. Since the needle punching process is performed, a part of the felt forming the nonwoven fabric felt layer 11 is fluffed from the outer surface of the spunbonded nonwoven fabric 12. Furthermore, the above spunbonded nonwoven fabric 1
2 is made of fibers finer than the non-woven felt layer 11 and preferably has a high density. With the above configuration,
Since the foamed resin layer 13 described later is less likely to penetrate into the interior, a thick foamed resin layer 13 is formed even with a small amount of resin. As the thickness of the fiber at this time, specifically,
It is suitable that the spunbonded nonwoven fabric 12 has a long fiber of 1 to 3 denier and the nonwoven fabric felt layer 11 has a short fiber of about 5 to 20 denier.

The backing material 2 is the spunbonded nonwoven fabric 1 described above.
A foamed resin layer 13 is formed so as to cover the outer surface of No. 2. The foamed resin layer 13 is made of SBR (latex of styrene-butadiene copolymer), NBR (latex of acrylonitrile-butadiene copolymer), MBR (latex of methylmethacrylate-butadiene copolymer).
A resin composition containing a resin exhibiting viscoelasticity such as foams,
It is formed by solidification. The foamed resin layer 13 has a high friction coefficient with respect to the floor, deforms along a microscopic uneven shape and adheres to the floor, and absorbs this force against the force of lateral displacement, so that it has a function of preventing slipping on the electric carpet. Is given.

In the method of forming the foamed resin layer 13, the spunbonded nonwoven fabric 12 is laminated on the nonwoven fabric felt layer 11 and integrated by needle punching. Then, on the surface of the spunbonded nonwoven fabric 12, SBR, NBR, MB
A latex-like resin composition containing a resin exhibiting viscoelasticity such as R is applied by a floss coating method or the like. The resin composition contains a cross-linking agent and a foaming agent together with the resin, and optionally contains thermal expansion microcapsules, a foaming aid, a filler, a heat stabilizer, an anti-aging agent, and a thickener. The copolymerization ratio of the above resin and the above material may be appropriately selected. The above materials are mixed and stirred to apply the foamed latex-like resin composition. After applying the above resin composition, hot air drying at about 150 to 170 ° C. is performed to remove water and the crosslinking reaction of the resin composition is performed, whereby the foamed resin layer 13 is formed on the outer surface of the spunbonded nonwoven fabric 12. To be done. By the needle punching process, a part of the felt constituting the nonwoven fabric felt layer 11 is spunbonded nonwoven fabric 1
Since it is in a fluffy state from the outer surface of 2, the adhesion of the foamed resin layer 13 is strong. The resin composition is preferable not only for foaming by mechanical agitation but also for containing a thermally expanded microcapsule in the composition because the amount of resin can be further reduced and the thickness of the foamed resin layer 13 can be made uniform.

Next, the method of manufacturing the electric carpet according to the second embodiment will be concretely exemplified.

The surface material 1 can be manufactured as follows. For example, as the non-woven felt 3, 85% by weight of polyester short fibers (of which 4 to 40 denier fibers are dispersed)
A web of 200 g / m ² basis weight consisting of a blend of 0% by weight of dyed cotton) and 15% by weight of low melting point short fibers such as polypropylene is needle-punched into a felt, and then heat treated at 180 ° C. A low melting point fiber such as polypropylene is melted and reinforced by a binder effect. Further, the fluffed felt is heat-treated with a direct flame of propane gas to melt a part of the fibers to form a large number of molten lumps 4.

The back material 2 can be manufactured as follows. For example, as the non-woven felt layer 11, a synthetic fiber of 3 to 20 denier nylon, polyester, acrylic, rayon, or vinylon, and a 470 g / m ² basis weight formed of cotton and hemp mixed cotton fibers Using the web,
As the spunbonded nonwoven fabric 12, 30 g of 100 wt% polyester 3 denier filament dyed in black
/ M ² basis weight used as a thermal compression processed thickness 0.12mm at embossed heat roll, entangling the web and the spunbonded nonwoven fabric is subjected to needle punching, and integrated. As a resin composition, 100 parts by weight of an MBR resin having a copolymerization ratio of 4: 6 (hereinafter referred to as "part"), 2 parts of a cross-linking agent, 5 parts of a foaming agent, and 5 parts of thermal expansion microcapsules. A water-emulsion type latex having a solid content of 50% by weight is used, and this is agitated to obtain a foaming state of 3 times, and 200 g / m in wet from the 12 side of the spunbonded nonwoven fabric.
^{2 is} applied and dried with hot air at 170 ° C. to remove water and to crosslink the resin composition to form a foamed resin layer 13 on the outer surface of the spunbonded nonwoven fabric 12.

The heater unit 7 has, for example, a thickness of 100.
A metal foil 9 made of an aluminum foil having a thickness of 30 μm is superposed between two heat-sealing films 8 made of low-density polyethylene having a thickness of μm, and a heat-bonding layer is formed on the outer side of the metal foil 9 as a one-wire type. It can be manufactured by patterning the heat-sensitive heating wire 6.

The electric carpet has, for example, the above surface material 1.
It can be produced by sandwiching the heater unit 7 between the backing material 2 and the backing material 2 and adhering it by hot pressing.

[0028]

The electric carpet according to the first aspect of the present invention is not particularly subjected to the slip prevention processing because the molten lump 4 prevents the fibers from being trapped in the back surface of the cover sheet 21 due to its constitution. Even if the cover sheet is used for a long period of time, no pedaling movement phenomenon occurs between the electric carpet and the cover sheet. Further, since the back surface of the cover sheet does not have to be subjected to the slip prevention process, the cover sheet can be easily folded and wrinkles do not occur.

In addition to the above effects, the electric carpet according to the second aspect of the present invention has the foamed resin layer 13 because of its constitution.
Has a high coefficient of friction with respect to the floor, and therefore has a function of preventing slippage with the floor.

[Brief description of drawings]

FIG. 1 is a fragmentary sectional view showing an electric carpet according to a first embodiment of the present invention disassembled for each component.

FIG. 2 is a cross-sectional view of a main part of an electric carpet according to a second embodiment of the present invention disassembled and shown for each component.

FIG. 3 is a cross-sectional view of a main part of a conventional electric carpet disassembled for each constituent material.

FIG. 4 is a sectional view of a main part of a cover sheet.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Surface material 2 Back surface material 3 Non-woven felt 4 Molten agglomerate 6 Exothermic line 7 Heater unit 11 Non-woven felt layer 12 Spunbonded non-woven fabric 13 Foamed resin layer

Claims (2)

[Claims] 1. An electric carpet in which a heater unit (7) having a cord-shaped heating wire (6) is sandwiched between a surface material (1) and a back surface material (2) made of a fiber sheet, An electric carpet characterized in that a large number of molten lumps (4) of fibers constituting the non-woven felt are provided on the surface layer of the non-woven felt (3) as the surface material (1). 2. The backside material (2) has a layer structure of a nonwoven fabric felt layer (11) and a spunbonded nonwoven fabric (1) integrated with the nonwoven fabric felt layer (11) by needle punching.
2) and this spunbond nonwoven fabric as the outermost layer (12)
The electric carpet according to claim 1, comprising a foamed resin layer (13) covering the outer surface of the electric carpet.