JPH11154588A - Planar heating unit - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate workability without need to fix a heat radiation wire with an adhesive resin, and prevent breakage of a heat radiation wire by wiring the heat radiation wire at a link tissue part of a solid mesh knit cloth in which the mesh tissue is link with a link yarn, and is constructed in three dimension on a flat foundation tissue. SOLUTION: In a heating unit, a solid knit cloth in which a mesh tissue is linked and constructed in three dimension on planar tissues are used as a base cloth, and a heat radiation wire 4 is wired in a space in which a top foundation tissue 1 consisting of hexagonal mesh tissues and a back foundation tissue 2 consisting of planar tissues are formed by a link yarn 3. The heat radiation wire 4 is housed and wired in a solid space formed by the link yarn 3, and thus is free of protrusion to a surface and is free of different sense of surface. In addition, at the wired heat radiation wire 4, the link yarn 3 becomes a bulkhead, contact and close contact of the heat radiation wire never occur, and therefore, the wire can be used without being fixed by adhesive or the like to a base cloth, an occurrence of accidents or faults is lessened, and durability and safety is ensured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a planar heating element in which an electric heating wire is laid inside a three-dimensionally thick three-dimensional mesh structure excellent in shape retention and high in porosity. .

[0002]

2. Description of the Related Art Conventionally, as a sheet heating element, a nichrome heating wire alone, a heating wire in which a nichrome heating wire and a temperature sensing wire are integrated and wired on a nonwoven fabric or a woven or knitted fabric, carbon black or metal powder is used. Kneading with resin to adjust the electrical resistance and using the heating yarn imparted to the yarn as a part of the constituent yarns, kneading carbon black or metal powder with the resin in a woven or nonwoven fabric or woven knitted fabric Are widely used as heating elements such as electric carpets, electric blankets, electric cushions, and heating pads.

When a nichrome heating wire is used as a heating wire, it is advantageous to obtain a heating element having a large heating capacity. However, when the nichrome heating wire is wired on a fabric, it has an ability to absorb a protrusion caused by the thickness of the heating wire. Therefore, the projection of the heating wire remains on the surface of the obtained heating element as a tactile sensation. Such a protrusion of the heating wire has a problem that the protrusion becomes more prominent in proportion to the period of use of the heating element when the use period of the heat generator is prolonged. Products such as electric carpets, electric cushions, heating pads, etc., which are directly in contact with humans, particularly dislike the sense of discomfort of the projections due to the heating wires.

When the heating wires are wired on a relatively flat cloth, if the heating wires come into close contact with each other, there is a problem that the adhered portion generates high-temperature heat. To avoid this, it is necessary to fix the heating wires to the fabric surface. . As a method of fixing the heating wire, fixing with an adhesive resin is general. When fixed in this way, the movement of the heating wire is restricted, and the heating wire, whose free movement is obstructed, is repeatedly bent and has a problem that it is easy to break due to fatigue near the fixing portion.

[0005]

The conventional products as described above have a problem that the heating lines appear as a convex pattern on the surface of the heating element, a problem that the protrusions are uncomfortable, and a problem that the heating lines are easily broken. Was.

In the present invention, in view of the above situation, it is necessary to fix the heating wire with an adhesive resin without causing the heating wire to appear as a protruding pattern on the surface of the heating element, feeling the strangeness of the protruding portion. It is an object of the present invention to provide a sheet heating element which is easy to work without heat and is hard to break a heating wire.

[0007]

Means for Solving the Problems The inventors of the present invention have conducted intensive studies to solve such problems, and as a result, by connecting a heating wire to a connecting structure portion of a three-dimensional mesh knitted fabric,
The heating wire is protected by the connecting structure portion of the three-dimensional mesh knitted fabric,
The inventors have found that the wiring of the heating wire can be held by the connecting yarn of the three-dimensional mesh knitted fabric, and have reached the present invention.

That is, the present invention is characterized in that a heating wire is wired to a connecting structure portion of a three-dimensional mesh knitted fabric constructed three-dimensionally by connecting a mesh structure with a connecting yarn on a flat ground structure. The gist of the present invention is a planar heating element.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail.
The three-dimensional mesh knitted fabric according to the present invention is a three-dimensional mesh having a high porosity, a high porosity, and excellent three-dimensional thickness, which is formed three-dimensionally by connecting a mesh structure on a flat ground structure with a connecting yarn. It is a structure. Such a three-dimensional mesh knitted fabric is disclosed in, for example, Jpn.
As disclosed in Japanese Unexamined Patent Publication, using a knitting machine having a double-row needle bed such as a double Russell knitting machine, as a flat ground structure, a structure obtained by combining chain knitting and an inlay is used, and as a mesh structure, Is square or hexagonal with two sides
This is a three-dimensionally constructed knitted fabric using a structure composed of up to 60 courses and connecting these structures with connecting yarns.
FIG. 2 is an example of a knitting structure diagram of a three-dimensional mesh knitted fabric that can be used in the present invention, and is knitted with reeds L ₁ and L ₂ on a flat ground structure knitted with reeds L ₅ and L _6. The square mesh structure is connected by connecting yarns by reeds L ₃ and L ₄ to form a three-dimensional mesh knitted fabric.

The fibers used for the flat ground structure and the mesh structure may be ordinary textile fibers, and may be selected according to the intended use. Soft fibers made of synthetic fibers or natural fibers are preferred. Although there is no particular limitation on the connecting yarn, it is preferable to use a fiber having an appropriate rigidity such as a monofilament of synthetic fiber from the viewpoint of maintaining a three-dimensional shape, imparting cushioning properties to the product, and the like.

FIG. 1 is a schematic perspective view of a heating element showing an example of the present invention. The outer fabric 1 made of a hexagonal mesh structure and the lining 2 made of a planar texture are connected by connecting yarns 3 to form a three-dimensional structure. At this time, it is convenient to wire the heating wire 4 in a triangular space formed by the connecting yarn 3 that connects the mesh structure and the planar structure three-dimensionally. The wiring uses a pattern suitable for the intended heating element.

The heating wire may be a metal wire having a relatively high electric resistance such as a nichrome wire coated with a resin having a high electrical insulation such as a vinyl chloride resin or a silicon resin, or a carbon black wire may be formed on the surface of the fiber yarn. A heat-generating yarn obtained by applying a resin whose electric resistance is adjusted by kneading a metal or a metal and applying the resin by coating or the like can be used. A heating wire having a heat-sensitive function is used as a heating wire of a heating element having a relatively large heating area. A heating wire provided with a heat-sensitive function is widely used for an electric blanket, an electric carpet, etc. because of its excellent temperature management function.

These heating wires have a diameter of 1.5 to 1.5 mm.
Although a linear material having a circular cross section of 2.5 mmφ is often used, a three-dimensional mesh knitted fabric has a thickness by adjusting a distance between needle beds in a knitting machine having a double-row needle bed such as a double Russell knitting machine. Can be about 20 mm,
Even when the diameter of the heating wire is large, it is possible to prevent the projection of the heating wire from appearing on the surface of the heating element by appropriately setting the thickness of the three-dimensional mesh knitted fabric.

In the above-mentioned three-dimensional mesh knitted fabric, the upper structure is a mesh structure, and the connecting yarns for connecting the structures are arranged according to the structure, so that the heating wire can be inserted and wired in the connecting structure portion. Since such a space is formed, the heating element of the present invention can be obtained by inserting and wiring a heating wire into this connecting tissue portion. In the present invention, since the heating wires are wired in a relatively narrow gap, free movement is restricted, and furthermore, since the connecting yarn serves as a partition wall and can prevent the heating wires from sticking to each other, the heating wire is applied to the base cloth with an adhesive resin or the like. Can be used without fixing. The cause of the problem with the heating wire is the breakage of the heating wire and the destruction of the electrically insulating resin layer of the heating wire.These problems are caused by fixing the heating wire to the base cloth with adhesive resin or the like. Many applications, such as a medical heating pad, in which a heating element is deformed into a free shape and used, tend to cause a problem that a heating wire is disconnected. The heating element of the present invention can be used without fixing the heating wire to the base cloth in particular, so that these problems are less likely to occur and wiring of the heating element is easy.

[0015]

The heating element of the present invention is based on a three-dimensional knitted fabric in which a mesh structure is three-dimensionally connected and constructed on a plane structure, and a space formed by connecting yarns that three-dimensionally connect the mesh structure and the plane structure. The heating element is characterized by wiring a heating wire to the heating element. Since the heating wire is housed and wired in the three-dimensional space formed by the connecting yarn, there is no protrusion to the surface, and there is no unnatural feeling on the surface. In addition, the wiring of the heating wires can be used without fixing with adhesives to the base cloth, which has been generally used, since the connecting yarns serve as partition walls and the heating wires do not contact or adhere to each other. Then, accidents and breakdowns are less likely to occur, durability and safety are ensured, and wiring of the heating wires can be easily and freely performed. Furthermore, if a fiber having moderate rigidity is used as the connecting yarn, a product having excellent pressure resistance and cushioning properties can be obtained. Even if pressure is applied as a heating pad, etc., there is no protrusion of the heating wire and comfort is obtained, and since the heating wire is not fixed to the base fabric with an adhesive or the like, the above-mentioned human action or folding In addition, it is possible to solve the problems of durability and safety with less damage to the heating wire.

[0016]

Next, the present invention will be described specifically with reference to examples. Using an 18 gauge Karl Meier double Russell knitting machine, type RD6PLM-6, in the organization chart of FIG.
The reed L _5, L ₆ as a flat ground structure, polyester filament 2 to the reed L _1, L ₂ for the hexagonal mesh structure
50d / 48f and the yarn supplying the reed L _3, L ₄ hexagonal obtained by knitting with yarn supplying nylon monofilament 220d to mesh tissue warp direction diagonal length 11 for the connecting thread.
2mm, weft diagonal length 7.5mm, cloth thickness 5m
m, a Nichrome wire PVC-coated heating wire having a wire diameter of 2.1 mmφ, a length of 13 m and an electrical resistance of 80Ω manufactured by Tokyo Special Electric Cable Co., Ltd.
Wiring was performed at 5 mm to obtain a planar heating element of the present invention having a size of 600 mm x 850 mm. The weight of the obtained planar heating element was 300 g, which was flexible and highly elastic, and the surface of the heating element did not give a feeling of protrusion of the heating wire.

[0017]

According to the present invention, the planar heating element in which the heating wire is wired in the three-dimensional space of the three-dimensional mesh knitted fabric does not give a protruding feel due to the heating wire, and is not a method of fixing the heating wire with an adhesive or the like. Since the heating wires can be wired in the three-dimensional space, the wiring work is easy, and the occurrence of troubles due to the disconnection of the heating wires and the destruction of the electrically insulating resin layer of the heating wires can be reduced, and the durability can be reduced.
Superior effects in workability, comfort, safety, durability, etc., such as improved safety and improved comfort during use, because the three-dimensional knitted fabric has pressure resistance and cushioning properties Demonstrate.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view of a heating element showing an example of the present invention.

FIG. 2 is a knitting structure diagram of a three-dimensional mesh knitted fabric according to an example of the present invention.

[Explanation of symbols]

1 Outer tissue 2 lining tissue 3 connecting thread 4 heating line L ₁ ~L ₆ reed

Claims (1)

[Claims] 1. A planar shape characterized in that a heating wire is wired to a connection structure portion of a three-dimensional mesh knitted fabric constructed by connecting a mesh structure with a connection yarn on a flat ground structure. Heating element.