JPS63148033A - Manufacture of electric space heater - Google Patents

Abstract

PURPOSE:To simplify the manufacturing work of a device by a method wherein a thermally fused film layer which can be stuck to vinyl chloride is previously placed at its rear material and after the layer is formed into one body with a heating wire and a temp. detecting wire which are sheathed by vinyl chloride, this unit is heated and fused with an insulating material together. CONSTITUTION:On the periphery of an inner winding 15 wound spirally on a core yarn 16 an insulating layer 14 is formed and on the layer an outer winding 13 is wound spirally and then on the periphery of the outer winding a vinyl chloride-made sheath 12 is formed and thus, a heating element is constituted. At the one side of a surface cloth 41 a thermally fused film 42 is previously lamination-processed. After a heating wire 1 and a temp. detecting wire 2 are wired on a base plate 6, a surface material 4 having the film layer 42 below is put on the base plate and then the cloth is pressurized for a fixed time from its top by a hot plate to stick the sheath 12 and the film layer 42 together. When this integral article is removed from the plate 6, a unit indicated in Fig. No.1 is formed. Thereby, as the thermally fused film layer is not in contact with the hot plate, the film layer does not stick to the hot plate and sticking strength between the film layer and the cloth is improved.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application This invention relates to a method of manufacturing an electric heater such as an electric carpet.

Conventional technology A conventional example of a method for manufacturing an electric car vent is published in the Japanese Patent Publication Publication No. 5
As seen in Japanese Patent Application No. 9-30407, as shown in FIGS. 2 and 2, as shown in FIGS. 1 and the temperature detection wire 2 are wired on the substrate, and then the adhesive sheet 3 having the heat-fusible film layers 31 and 32 is heat-pressed and integrated into one unit. 4 and the heat insulating material 6, and heat and pressure bonded them to integrate them.

Problems to be Solved by the Invention However, in this manufacturing method, the heating platen and the heat-fusible film layer 32 come into contact with each other in the step of heat-fusing the heating wire 1 and the temperature sensor a2 to the adhesive sheet 3; At this time, there was a problem in that it adhered to the hot plate side. Of course, on the heating plate side,
Although it is treated with fluororesin, etc., which is difficult to adhere to, it also needs to be heated and fused in a short time, making it easier to adhere to the hot plate since it is pressed at a fairly high temperature. For this reason, the layer on the upper surface side 32 of the heat-fusible film layer of the adhesive sheet 3 is made of a material that is somewhat difficult to bond. Therefore, although it does not adhere to the hot plate, the adhesive force with the surface material 4 also becomes weak, which is a paradoxical problem.

In addition, due to the three-piece structure of the surface material 4, unit, and heat insulating material 5, the positioning work of the three members was complicated.

In view of the above problems, the present invention provides a method for manufacturing an electric heater that is easy to operate.

Means for Solving the Problems In order to solve the above-mentioned problems, the manufacturing method of the present invention includes the following steps:
A heat-fusible film layer that can be bonded to vinyl chloride is provided on the back side of the surface material in advance, and after this is integrated with the vinyl chloride heating wire and temperature detection wire, this unit is heat-fused to the heat insulating material. The method was to do so.

Function The surface material used in the present invention has a heat-fusible film layer adhered to the back side in advance, so that the adhesion at the outer fabric part of the surface material is perfect, and when pressed during heat-sealing, Since it is the outer fabric side that comes into contact with the disc, there is no worry that the aforementioned adhesive sheet will adhere to the hot disc.

Embodiment FIG. 2 shows the structure of the heating wire used in this embodiment, in which an insulating layer 14 is formed around the outer periphery of an inner winding 15 spirally wound around a core yarn 16, and an outer winding 13 is spirally wound, and an outer sheath 12 is formed around the outer periphery to constitute a heating element. The material of this jacket 12 is generally vinyl chloride. still,
The temperature detection wire has exactly the same structure as the heating wire, with the only difference being the materials of the inner and outer windings and the resin composition of the insulating layer.

On the other hand, the surface material, as shown in FIG. 3, has a structure in which a heat-fusible film 42 is laminated on one side of a surface cloth 410 in advance.

In FIG. 4, a heating wire 1 and a temperature sensing wire 2 are wired on a substrate 6. In FIG. Here, although the slide pin 7 is necessary to define the wiring position, it becomes an obstacle when heat-sealing the surface material 4, so it is designed so that it can be moved in the vertical direction via a spring material. ing. Further, the upper surface of the substrate 6 is treated with a fluororesin because the outer cover 12 and the 5 l-7' heat-fusible film layer 42 come into contact with the upper surface. After wiring in this way, the surface material 4 is placed with the heat-fusible film layer 42 side facing down,
When pressure is applied on top of it for a certain period of time using a hot platen, the above-mentioned outer covering 1
2 and the heat-fusible film layer 42 are fused and integrated. When this integrated structure is removed from the substrate 6, a unit as shown in FIG. 1 is formed.

As a second example, when the surface material has a three-layer structure of a surface cloth 41, a metal foil 43, and a heat-fusible film layer 42 as shown in FIG. 6, the same method as described above is applied. Then, the unit is manufactured.

Next, the unit is placed in a predetermined position on a heat insulating material such as felt, and when pressure is applied again from above using a hot platen, the heat-fusible film layer 42 softens and the fibers of the heat insulating material 5 are impregnated and glued.

Considering productivity here, the lower the melting point of the heat-fusible film layer 42 is, the shorter the pressing time with the hot platen becomes, and the better the productivity. However, if the product is kept warm with a cushion, etc., the temperature of the product at the heated part of the cushion will be close to 100°C, so if a heat-fusible film layer 42 with a very low melting point is used, it will be difficult to bond the product. As the force decreases, the surface material 41, heating wire 1, etc., floats up. On the other hand, if a heat-sealing film layer 42 with a melting point of 130'C or more is used, the pressing time will be longer and the surface material 4. There is a problem if the heat insulating material 51, heat generating wire 1, etc. shrink due to heat and cause unevenness on the surface of the product. Therefore, the melting point is 1oo'C~
130°C can be said to be the optimum range for mass production.

In this embodiment, the case where the heat generating line 1 and the temperature detection line 2 are configured separately has been described, but the heat generating line 1 described above
In the case of the heating wire 1 made of a material whose electrical characteristics (resistance component and capacitor component) of the insulating layer 14 have a large temperature coefficient as shown in the structural diagram, the heating wire 1 also has a temperature detection function, and is a so-called temperature-sensitive heating wire. Since the temperature-sensitive heating wire is a wire, the above-described unit can be constructed simply by wiring the temperature-sensitive heating wire to a predetermined position. In this case, the steps from wiring to the substrate 6 to adhesion to the surface material 4 are completely the same.

Furthermore, the installation of the insulation material and the unit often includes a controller section in one corner of the cabinet.
There is a strong demand for dimensional accuracy in the end treatment of heating wires and temperature detection wires, and they must be installed with high precision.The main structure of the carpet main body is formed as described above, and the end treatment and controller After assembling the parts, the electric carpet is completed.

Effects of the invention As mentioned above, since the heat-adhesive film layer does not come into contact with the hot platen of the press, not only is there no problem in the process of adhering it to the hot platen, but the adhesive strength with the outer fabric material is also greatly improved. This makes it possible to provide highly reliable electric carpets.

Further, there is no need for a conventional adhesive sheet; for example, even if a film layer with a similar thickness is necessary for adhesive performance, it is much cheaper to directly bond it to the outer fabric material. Furthermore, the parts supply system for the process equipment is also simplified because the number of parts is small.

The work efficiency when installing the surface material and the heat insulating material can also be greatly improved, since the conventional complicated positioning of three parts can be replaced with the positioning of two parts.

In addition, since the unit has a surface material as a component, the base material is stronger and easier to handle than in the case of conventional adhesive sheets. More heating wires.

Since a heat-fusible coating layer for the temperature detection wire is not required, the productivity of the wire itself is improved and the cost is also reduced.

Furthermore, by reducing the wire diameter, the wire feels less strange after being incorporated into a product.

As described above, the manufacturing method of the present invention produces various great effects.

[Brief explanation of the drawing]

Fig. 1 is a structural diagram of the unit used in the first embodiment of the present invention, Fig. 2 is a structural diagram of the same heating wire, Fig. 3 is a structural diagram of the surface material used in the same embodiment, and Fig. 4 5 is a schematic diagram of the intermediate wiring process of the same embodiment, FIG. 5 is a structural diagram of a unit manufactured in the second embodiment of the present invention, and FIG. 6 is a structure of the electric carpet main body manufactured in the first embodiment. 7 is a structural diagram of the heat generating A-7 line used in the conventional example, FIG. 8 is a structural diagram of a unit manufactured in the conventional example, and FIG. 9 is a diagram showing the components of the conventional example. 1... Heat generation line, 2... Temperature detection line, 4
...Surface material, 5...Insulation material, 11.2
1... Heat-fusible coating layer, 12.22...
- Outer cover, 41...Outer fabric, 42...Thermoadhesive film layer. Name of agent: Patent attorney Toshio Nakao and one other person
4 Ripe garlic 2- Temperature detection line 111-1 front part η-thermal g-adhesive film layer 12-1 outer armpit 13 15-m-inner sidewall Fig. 4A Fig. 5 41 Fig. 6 1-1 exothermic line 2-Temperature Saikurachi line 6-Substrate 7-Slammed pin One surface material-A part-Heat-fusible film layer-Metal foil 5-1fr mature material Fig. 7 Fig. 8 Fig. 9- Exothermic line! 3~ Outer Port Line / 4-One Zetsu, #1 2- 逼X检查Il! 7 3 - Adhesive sheet 21 - Heat rv, spring release property coating layer film layer material 4 - & - Surface material 5 - Wr mature material

Claims (1)

[Claims] After wiring the heating wire and the temperature detection wire having the outermost vinyl chloride coating layer to predetermined positions on the substrate, a surface material having a heat-fusible film layer is placed on the back side, and the coating layer and the film are placed on the back side. The surface material, the heating wire, and the temperature detection wire are integrated into a unit by heat-bonding the layers, and the unit is placed so that the heat-fusible film layer is in contact with the heat insulating material,
A method of manufacturing an electric heater that integrates a surface material, a heat generating wire, a temperature detection wire, and a heat insulating material by heating and pressing.