JPH09234152A - Laminated sheet and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an eleccric carpet without any necessity of sewing and its manufacture method. SOLUTION: This unsewn electrical carpet is so constituted that a part of an assembled sheet part 4 composed of a right side sheet part 1, a rear sheet part 2, and a heating sheet part 3, which is provided with a heating element and inserted and stuck between the right side part L and the rear sheet part 2, is notched, a heating control means for controlling heating of the heating element is inserted in this notched part, and an end side joint part 11 which is formed by being heated and pressurized is formed on the right side sheet part 1 around the outer circumferential end part except the notched part of the assembled sheet part 4. The heating sheet part 3 is composed of a base cloth part 31 for the heating sheet and a heating wire 32 stuckly formed thereon. A recessed junction part 12 is also formed inside this end side joint part 11.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a non-sewn laminated sheet and a method for manufacturing the same. INDUSTRIAL APPLICABILITY The present invention is used for ordinary carpets (especially electric carpets), household rugs, cushions, footrest mats, automobile cushion covers and the like.

[0002]

2. Description of the Related Art Conventionally, as an electric carpet, for example, a front surface sheet, a rear surface sheet, and a heating element are provided, and the electric carpet is inserted and adhered between the front surface sheet and the rear surface sheet. One end of an assembling sheet including a heat generating sheet is cut out, and heat generating control means for controlling heat generation of the heating element is inserted in the notch, and the assembling sheet is formed. There is known an electric carpet in which the outer peripheral end portion of the gutter except the above-mentioned cutout portion is sewn by overlock.

The following methods are known as methods for manufacturing the above-mentioned conventional electric carpet. An adhesive is applied to one surface of each of the front surface sheet and the back surface sheet, and then the front surface sheet is set in a molding die, and a heat generating sheet having a heating element is set thereon. Then, a curing agent for an adhesive is applied to the back sheet, and the adhesive application side is set downward and set on the heat-generating sheet. After pressing the assembly sheet with a pressing machine, the bonded assembly sheet is released from the mold, and heat generation control means for controlling heat generation of the heating element is attached. The outer peripheral part is cut with scissors, and the outer peripheral end face is sewn overlock by a lock sewing machine.

[0004]

However, after cutting the outer peripheral portion of the assembly sheet in which the front surface sheet, the heat generating sheet, and the back surface sheet are attached, the outer peripheral end surface is overlaid with the lock thread. It took a lot of time to sew locks. Also,
When not sewing, there is a problem that the end surface of the product becomes unsightly due to fraying or the like.

SUMMARY OF THE INVENTION It is an object of the present invention to solve the above problems and provide a laminated sheet (especially electric carpet) which does not require sewing and a method for producing the same.

[0006]

In order to achieve the above-mentioned object, the inventors of the present invention have made earnest studies on a laminated sheet which does not require sewing, and as a result, the outer peripheral end of the assembly sheet is formed by a molding die. The present invention has been completed by finding that the need for sewing can be eliminated by heating and pressing.

The laminated sheet of the first invention comprises a front sheet portion 1, a back sheet portion 2, and a heating element, and is provided between the front sheet portion 1 and the back sheet portion 2. One end of an assembling sheet portion 4 including a heat generating sheet portion 3 that is inserted and adhered to is cut out, and the cutout portion 41 controls heat generation of the heating element. The means 5 is inserted and is an outer peripheral end portion of the assembly sheet portion 4 excluding the cutout portion 41 and an end portion formed by heating and pressing on the assembly sheet portion 4. The side joint portion 11 is formed.

The laminated sheet of the second aspect of the present invention is further heated and pressed inside the end side joint portion 11 shown in the carpet of the first aspect of the invention and on the assembly sheet portion 4. At least one concave joint 12 formed by the above is formed. Usually, the number of the recessed joint portions 12 is one, but the number is not limited to this, and it may be two or three. By providing the concave joint portion 12, even if the end portion side joint portion 11 is frayed or damaged due to some reason, the end portion side fray can be prevented from being transmitted to the inside. The front surface sheet portion 1, the back surface sheet portion 2 and the heat generating sheet portion 3 can all be made of non-woven fabric. As a result, the entire laminated body has elasticity, and the air permeability can be expressed as a whole. Further, the adhesive to be used can be introduced into the nonwoven fabric (or the surface layer of the nonwoven fabric), and the adhesive strength can be increased by the anchor effect.

In the method for manufacturing a laminated sheet according to the fourth aspect of the present invention, at least the mating surface of the surface sheet 1A and the heat generating sheet and the heat generating sheet 3A having a heat generating control means base for controlling heat generation of the heat generating element. An adhesive is applied to one side, an adhesive is applied to at least one of the mating surfaces of the back surface sheet 2A and the heat-generating sheet 3A, and then these sheets 1A, 3A and 2A are applied to each mating surface. Are sequentially arranged on the mold 6 so that the sheets 1A, 3A and 2A have corresponding one ends cut out, and then the push mold is closed to close the mold. The method is characterized by comprising a step of heating and pressing at a temperature of 50 to 150 ° C. to join the assembly sheet 4A. If the molding die temperature is lower than 50 ° C, the temperature is too low, and the molding and adhesion of the assembly sheet will be insufficient. Further, when the temperature exceeds 150 ° C, the sheets are bonded only by coming into contact with each other and the molding work becomes difficult (that is, the reaction becomes too fast, the initial tack becomes strong, and it becomes difficult to shift each member at the time of positioning). Is. In addition, in the case of a sheet-shaped thermoplastic adhesive, the above-mentioned "application of an adhesive" includes the meaning of disposing this sheet-shaped adhesive. By the manufacturing method of the present invention, the outer peripheral edge portion of the laminated body composed of three sheets (1A, 2A and 3A) is pressure-bonded,
A laminated sheet (for example, an electric carpet which is a final product) in which the end side joint portion 11 is formed in one step may be used,
Furthermore, it is also possible to use an intermediate stage laminated sheet (for example, an intermediate product for an electric carpet) in which a concave joint portion is formed at a position in consideration of the cutting margin.

Further, as shown in the fifth aspect of the invention, a concave joint portion is formed by the step of joining the assembling sheet 4A, and thereafter, the concave joint portion is cut, whereby an end portion is formed on the outer peripheral end side. The final shape can be formed by forming the part-side joint. In this case, the cut-and-removed portion becomes waste dust and the number of cutting steps is increased, but by providing a cutting allowance, a carpet having a desired shape can be manufactured safely and reliably. The cutting place (line) is the middle point (line) or the outermost peripheral edge point (line) of the concave joint, that is, the cutting line where the end-side joint remains on the outer edge after cutting. .

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described more specifically with reference to examples. (1) Structure of Laminated Sheet (Non-Sewn Electric Carpet) As shown in FIGS. 1 and 2, the non-sewn electric carpet of this embodiment has a front surface sheet portion 1, a heat-generating sheet portion 3 and a back surface. See
The assembly sheet section 4 is composed of the sheet section 2 and the heat generation control means 5.

The surface sheet portion 1 is made of felt (trade name;
"Nipan Bren", manufactured by Nishikawa Rose Co., Ltd.). This felt is made of polyester and has a basis weight of 350 g / m ² , a thickness of 3.2 ± 0.2 mm, a size of 1,800 mm in length, and 1,800 mm in width. still,
The weight of felt is 200-700g, depending on the application.
It can be an appropriate one of / m ² . If the basis weight is less than 200 g / m ² , the density is too small and the strength is insufficient as a carpet, and if it exceeds 700 g / m ² , the density is too large and the flexibility is insufficient as a carpet.

The heat generating sheet portion 3 is a base sheet portion 3 for heat generating sheet.
1 and a heating wire 32. Heating sheet (thickness: about 3.
5 mm) 3 is adhesively formed between the front surface sheet portion 1 and the back surface sheet portion 2. The base cloth portion 31 for this heat-generating sheet
Is a non-woven fabric made of polyester (with a basis weight of 50
g / m ² ). The exothermic line 32 is inserted between the exothermic sheet portion 31 and the back sheet portion 2, and is adhesively fixed to the surface of the exothermic sheet portion 31 (may be temporary adhering). This exothermic wire (outer diameter; about 1m
m, resin coating thickness: about 0.2 to 0.3 mm) 32
Is placed and attached so that the entire surface of the carpet can be heated evenly. The outer circumference of the heating wire is covered with polyvinyl chloride as an insulating material to a thickness of 1 mm.

A non-woven fabric (non-woven felt made by Nishikawa Rose Co., Ltd.) is used for the back sheet portion 2. This non-woven fabric is made of polyester and has a thickness of 5 ± 0.5 mm and a size of 1,800 mm in length and 1,800 mm in width. A two-component urethane adhesive (trade name; “PUK prepolymer”, manufactured by Polyurethane Kasei Co., Ltd.) was used as an adhesive used for adhering each sheet portion. The heat generation control means 5 is for controlling heat generation of the heating element, and is composed of a control circuit device, a box for housing the same, and the like, and is connected to the tip of the heating wire. One end of an assembling sheet portion 4 composed of the front surface sheet portion 1, the heat generation sheet portion 3 and the back surface sheet portion 2 is cut out, and the heat generation control means 5 is provided with the cutout portion 41 ( The size is 100 mm in length and 200 mm in width). The heat generation control means 5 may be a final shape body to which a controller cover or the like is attached, or an intermediate body not attached thereto.

A linear end-side joint portion (thickness) formed by heating and pressing on the outer peripheral edge portion of the assembly sheet portion 4 excluding the notch portion 41 and on the surface sheet portion 1. About 1 mm, width; about 2 mm) 11 is formed. Further, a linear concave joint portion (thickness: about 1 m) formed by being heated and pressed inside the end portion side joint portion 11 and on the surface sheet portion 1.
m, width; about 3 mm) 12 is formed. The distance between the end side joint portion 11 and the concave joint portion 12 is about 10 to 20 mm.
(For example, 15 mm).

(2) Manufacture of a seamless electric carpet As shown in FIG. 3, a front sheet 1A, a back sheet 2A and a heat generating sheet 3A (1,850 × 1,850 respectively).
mm, thickness; about 3.2 to 5 mm). Notches (13A and 21A, 100, etc.) as attachment sites for the heat generation control means 5 are provided at the corresponding corners of the front surface sheet 1A, the back surface sheet 2A, and the heat generation sheet 3A.
mm × 200 mm) is formed by cutting. And
To the heat generating sheet 3A, the heat generating wires arranged in a meandering manner as shown in FIG. 3 are adhesively fixed so as not to come off during the working process. The adhesive used was the same as above. A heat generation control means base is provided at these cutout positions.

For the molding, a pair of upper and lower pressing dies (not shown) and a molding die 6 shown in FIG. 3 are used. This mold 6
Is made of aluminum and has a first linear convex portion (width: 3 m
m) 61 and a second linear convex portion (width: 3 mm) 62, each of which has two concave joint portions (12, 12) on the surface sheet 1A.
And two that will be 11 after cutting. ) Can be formed. The distance between the both convex portions is 15 mm. And, the three corners are 50 mmR. The assembly sheet 4A has a thickness of about 10 mm, and a spacer (not shown) having a thickness of about 0.5 mm is provided on the assembly sheet so that the heating wire 32A is not crushed during pressing. Is located on the outer periphery of The spacer may have any shape and height so as not to compress the heating wire during pressurization, and the location of installation may be variously selected. Further, although the spacer may be a separate body from the pressing die as described above, it is not limited to this and may be formed in the pressing die. For the press, a pressure type press machine using a hot plate (molding press device for veneer plate, manufactured by Yamamoto Industry Co., Ltd.) is used.

A roll coat of 40 to 60 g / m ² of the main agent of the adhesive is applied to one surface of the cut front sheet 1A and the back sheet 2A (the surface on the side where the heat-generating sheet 3A is adhered).
Application. This surface sheet 1A is set in a molding die 6, and ²⁰ to 50 g / m ² of a curing agent for this adhesive is spray-applied (total of main agent and curing agent; 60 to 110 g / m 2).
² ) and set the exothermic sheet 3A on it. After that, the same curing agent for the adhesive as described above was applied to the back sheet 2A in the same manner (total of main agent and curing agent; 60 to 110 g / m2).
² ) Then, apply heat to the backside sheet 2A on the adhesive coated side.
Set it on the heat-generating sheet 3A so as to come into contact with the sheet 3A. The adhesive may be applied by a method other than a roll coater and a spray. It is also possible to mix the base material of the adhesive and the curing agent for the adhesive, and then quickly apply the mixture to one surface of the front sheet 1A, the back sheet 2A, or the exothermic sheet 3A. It is also possible to apply using an adhesive containing a curing agent.

The assembling sheet 4A set in the molding die 6 is sent to a press machine, and the pressing die is closed and pressed. The heating temperature at this time is 130 ° C. for the hot plate (not shown) in the upper stage of the press.
℃, the lower hot plate (not shown) 110 ℃, mold 6 is 6
The press pressure is about 50 kg / cm ² , and the pressing time is about 1 minute. After that, the bonded assembly sheet 4A is taken out of the press and released from the mold. Next, along the outer peripheral line of the embossing line of the molding die of the assembly sheet 4A (cutting margin; about 5 to 50 mm), the end side joint portion 11 is about 2 mm.
Cut with scissors so that it remains wide. As a result, an electric carpet was manufactured in which the end side joint portion 11 was formed on the outer peripheral end side and the concave joint portion 12 was formed inside thereof.

(3) Effect of the embodiment In the present electric carpet, since the end portion side joint portion 11 which is sufficiently integrally bonded is provided on the end portion side, the end portion will not be frayed without sewing. . Further, since the concave joint portion 12 is formed inside the end portion side joint portion 11,
Even if the end side joint portion 11 is frayed, the inner laminated body portion is not frayed. Furthermore, in this electric carpet, since a non-woven fabric is used for all the laminated sheets, the applied adhesive penetrates into the non-woven fabric surface layer,
This becomes an adhesive layer by heating and pressurization, so that the three layers can be easily adhered and the adhesive effect is also excellent due to the anchor effect. In addition, the carpet produced from this nonwoven fabric is elastic, comfortable to sit on, has a high-class feel, and is excellent in breathability. Further, since the adhesive used in this example is a urethane type reaction-curing type, excellent adhesive strength and elasticity are obtained, and workability is easy.

The present invention is not limited to the specific examples described above, and various modifications may be made within the scope of the present invention depending on the purpose and application. That is,
The constituent materials, sizes, shapes, and thicknesses of the front surface sheet, the heat generation sheet, and the back surface sheet can be variously changed.
As the adhesive, a reaction-curable adhesive other than the urethane-based adhesive used in the above-mentioned examples (epoxy adhesive, etc.) can be used, and other known emulsion-type or solvent-type adhesives can be used. Various adhesives can also be used. Instead of the liquid adhesive, a thermoplastic sheet adhesive can be used. In this case, it is arranged in the middle of each of the front surface sheet, the back surface sheet and the heat generating sheet, and is heated. In this case, it is also possible to use an adherable composite sheet in which the sheet-like adhesive is previously adhered and formed on the surface of another sheet.

The number (2, 3, etc.) of the recessed joints, the shape, size, depth, width, etc. of the recesses can be variously changed. The overall shape of this concave joint is usually
Although it is a single linear shape as shown in the above embodiment, it is not limited to this, for example, dotted line shape (broken line shape, one-dot chain line shape, two-dot chain line shape, etc.), or dot (round dot, square dot, etc.) The shape may be a linear shape as a whole, or may be a wave shape (including a square wave shape, a triangular wave shape, etc.), a zigzag shape, a coil shape, or the like. Moreover, the location of the concave joint, that is, the distance from the end-side joint can be selected in various ways. Further, if various patterns are formed on the surface of the molding die, various patterns can be formed on the surface of the electric carpet to be manufactured. This pattern may be, for example, a product name, a company name, a logo mark, or a pattern of flowers, animals, or the like.

The above-mentioned heating type laminated sheet may be a non-heating type laminated sheet which does not include the heat generating sheet portion 3, the notch portion 41 and the heat generation controlling means 5. That is, it is composed of an assembly sheet portion in which a front surface sheet portion and a back surface sheet portion are adhered to each other, and is an outer peripheral end portion of the assembly sheet portion and the assembly sheet. The laminated sheet may be characterized in that an end-side joint formed by being heated and pressed is formed on the part. However, a sheet (a nonwoven fabric coated and impregnated with an adhesive, a hot-melt adhesive type adhesive sheet, or the like) for adhering the two is provided between the front surface sheet portion and the back surface sheet portion. It may be arranged and formed. Further, notches, various patterns as described above, etc. may be provided at appropriate positions of the assembly sheet portion. Both the front surface sheet portion and the back surface sheet portion may be made of a non-woven fabric. In this case as well, in the same manner as described above, it can be manufactured by closing the pressing die and heating and pressing with the temperature of the forming die kept at 50 to 150 ° C. to join the assembly sheet 4A. . Further, similarly, it is also possible to form the concave joint portion by the step of joining the assembling sheets and then cut the concave joint portion to form the end side joint portion. Even in these cases, the same effects as those shown in the following "Effects of the Invention" section are provided.

[0024]

EFFECTS OF THE INVENTION Since the present laminated sheet has the end-side joints that are sufficiently integrally bonded to the end portions, sewing is not necessary, and the ends can be loosened without this sewing. Absent. In addition, the concave joint portion 1 is provided inside the end portion side joint portion.
In the carpet in which No. 2 is formed, even if the end side joint portion is frayed, the inner laminated body portion will not be frayed. In addition, in an electric carpet made of a non-woven fabric as a laminated sheet, it has elasticity, excellent sitting comfort, and excellent breathability. Furthermore, since the adhesive penetrates into the non-woven fabric surface layer, the adhesive strength is improved. Is also excellent. Further, according to the production method of the present invention, the useful laminated sheet shown above can be produced easily and reliably.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional view showing a sewing-free electric carpet according to an embodiment.

FIG. 2 is a plan view showing a sewing-free electric carpet according to an embodiment.

FIG. 3 is an explanatory view showing a laminated state of each sheet for manufacturing a seamless electric carpet in an example.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1; Surface sheet part, 1A; Surface sheet, 11; End side joining part, 12; Recessed joining part, 13A; Notch part, 2; Back face sheet part, 2A; Back face sheet, 21A Cutout portions, 3; heat generating sheet portion, 31; heat generating sheet base cloth portion, 32; heat generating wire,
3A; exothermic sheet, 31A; base sheet for exothermic sheet, 32
A: Heat generating wire, 4: Assembly sheet portion, 41: Notch portion, 5: Heat generation control means, 6; Mold, 61; First linear convex portion, 6
2; Second linear convex portion.

Claims (5)

[Claims] 1. A front surface sheet portion 1, a back surface sheet portion 2,
One end of an assembly sheet portion 4 including a heat generating sheet portion 3 which is provided with a heating element and is inserted and adhered between the front surface sheet portion 1 and the back surface sheet portion 2 is provided. The cutout portion 41 is cut out, and the cutout portion 41 has a heat generation control means 5 for controlling heat generation of the heating element.
Is attached and is an outer peripheral end portion of the assembly sheet portion 4 excluding the cutout portion 41 and is joined to the assembly sheet portion 4 by heating and pressing to form an end portion side joint. A laminated sheet having a portion 11 formed therein. 2. A front surface sheet portion 1, a back surface sheet portion 2,
One end of an assembly sheet portion 4 including a heat generating sheet portion 3 which is provided with a heating element and is inserted and adhered between the front surface sheet portion 1 and the back surface sheet portion 2 is provided. The cutout portion 41 is cut out, and the cutout portion 41 has a heat generation control means 5 for controlling heat generation of the heating element.
Is attached and is an outer peripheral end portion of the assembly sheet portion 4 excluding the cutout portion 41 and is joined to the assembly sheet portion 4 by heating and pressing to form an end portion side joint. A portion 11 is formed, and further, at least one concave joint portion 12 formed by being heated and pressed is formed inside the end portion side joint portion 11 and on the assembly sheet portion 4. A laminated sheet characterized by being formed. 3. The laminated sheet according to claim 1, wherein the front surface sheet portion 1, the back surface sheet portion 2 and the heat generating sheet portion 3 are all made of non-woven fabric. 4. An adhesive is applied to at least one of the mating surfaces of the surface sheet 1A and a heat generating sheet and a heat generating sheet 3A having a heat generating control means base for controlling heat generation of the heat generating element,
An adhesive is applied to at least one of the mating surfaces of the back sheet 2A and the heat-generating sheet 3A, and then these sheets are joined together.
To match the mating surfaces of 1A, 3A and 2A,
The sheets are sequentially arranged on the molding die 6, and at this time, these sheets 1
The corresponding ends of A, 3A and 2A are notched, and then the pressing die is closed to bring the temperature of the forming die to 50 to 50 ° C.
The assembly sheet 4 is heated and pressed at 150 ° C.
A method of manufacturing a laminated sheet, comprising the step of joining A. 5. The method according to claim 4, further comprising the step of forming a concave joint portion by the step of joining the assembling sheet 4A, and then cutting the concave joint portion to form an end side joint portion. Laminated sheet manufacturing method.