WO2017026217A1 - ヒータユニット、ステアリングホイールおよびヒータユニットの製造方法 - Google Patents
ヒータユニット、ステアリングホイールおよびヒータユニットの製造方法 Download PDFInfo
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- WO2017026217A1 WO2017026217A1 PCT/JP2016/070383 JP2016070383W WO2017026217A1 WO 2017026217 A1 WO2017026217 A1 WO 2017026217A1 JP 2016070383 W JP2016070383 W JP 2016070383W WO 2017026217 A1 WO2017026217 A1 WO 2017026217A1
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- WIPO (PCT)
- Prior art keywords
- heater
- cord
- base material
- heater unit
- foam
- Prior art date
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Images
Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
- H05B3/34—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs
- H05B3/36—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs heating conductor embedded in insulating material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D1/00—Steering controls, i.e. means for initiating a change of direction of the vehicle
- B62D1/02—Steering controls, i.e. means for initiating a change of direction of the vehicle vehicle-mounted
- B62D1/04—Hand wheels
- B62D1/06—Rims, e.g. with heating means; Rim covers
- B62D1/065—Steering wheels with heating and ventilating means
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B1/00—Details of electric heating devices
- H05B1/02—Automatic switching arrangements specially adapted to apparatus ; Control of heating devices
- H05B1/0227—Applications
- H05B1/023—Industrial applications
- H05B1/0236—Industrial applications for vehicles
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/002—Heaters using a particular layout for the resistive material or resistive elements
- H05B2203/003—Heaters using a particular layout for the resistive material or resistive elements using serpentine layout
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/014—Heaters using resistive wires or cables not provided for in H05B3/54
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/017—Manufacturing methods or apparatus for heaters
Definitions
- the present invention relates to a steering wheel used in, for example, an automobile, a ship, and the like, and a heater unit used to warm the wheel portion, and in particular, the user does not feel uncomfortable during the steering operation. About.
- the steering wheel 71 includes a wheel portion 72, a spoke portion 73, and a boss portion 74, and the wheel portion 72 includes a wheel core material 77 and a covering material 78 made of synthetic resin, textiles, leather, or the like. It is formed.
- the heater unit 31 is installed between the wheel core member 77 and the covering member 78, and is connected to a lead wire (not shown) that is passed through the spoke portion 73 and the boss portion 74 to be supplied with power.
- a heater unit installed on a steering wheel for example, as shown in Patent Documents 1 and 2, a heater in which a cord-like heater is arranged in a predetermined pattern shape on a base material is known.
- the base material various foamed resin sheets, foamed rubber sheets, rubber sheets, nonwoven fabrics, woven fabrics, and the like are disclosed.
- JP 2003-317905 A Matsushita Electric Industrial Co., Ltd.
- JP 2011-121477 A Clave
- the cord heater 101 is simply disposed on the base materials 110 and 110 ′. Thickness has arisen in the place where is arranged. Therefore, when the user grips the steering wheel, the user feels unevenness and feels uncomfortable during the steering operation.
- the present invention has been made to solve the above-described drawbacks of the prior art, and an object of the present invention is to provide a steering wheel that does not give the user a sense of incongruity during steering operation, and to use the steering wheel. It is in providing the heater unit to be performed.
- a heater unit is a heater unit comprising a base material made of a polymer foam and a cord-like heater disposed on the base material,
- the thickness of the portion where the cord-like heater is disposed is thin so as to conform to the shape of the cord-like heater, and thereby has a generally flat shape.
- the cord-like heater has a heat fusion part formed in the outermost layer.
- the steering wheel according to the present invention comprises the above heater unit, a wheel core material, and a covering material, and the heater unit is installed between the wheel core material and the covering material.
- a heater unit manufacturing method is a heater unit manufacturing method comprising a base material made of a polymer foam and a cord-like heater, wherein the cord is formed in a predetermined pattern shape on the base material. And the base material is heated and pressurized with a flat plate, so that the thickness of the portion of the base material where the cord-like heater is disposed is reduced to conform to the shape of the cord-like heater. Thereby, a heater unit having a substantially flat shape is obtained.
- the user since the unevenness due to the cord-like heater does not appear and the shape is generally flat, the user does not feel uncomfortable when performing the steering operation.
- FIG. 3 is a perspective view showing a state in which a heater unit according to the present invention is embedded in a steering wheel, with a part cut away. It is a side view which cuts out the part and shows the structure of the cord-shaped heater used by this invention. It is a side view which cuts out the part and shows the structure of the cord-shaped heater used by this invention. It is a figure which shows the structure of the hot press type heater manufacturing apparatus used by this invention. In the heater unit of this invention, it is a partial perspective view which shows a mode that a cord-shaped heater is arrange
- the cord-like heater 1 in the present embodiment is configured as shown in FIG. First, on the outer periphery of the heater core 3 made of an aromatic polyamide fiber bundle having an outer diameter of about 0.2 mm, seven conductor wires 5a made of a tin-copper alloy wire having a wire diameter of 0.08 mm are aligned, and the pitch is 1.00 mm.
- the cord-shaped heater 1 is configured by being spirally wound.
- the conductor wire 5a is covered with an insulating film 5b made of polyurethane with a thickness of about 0.005 mm.
- a polyethylene resin blended with a flame retardant as the heat fusion part 9 is extruded and coated with a thickness of 0.25 mm.
- the cord-like heater 1 has such a configuration, and the finished outer diameter is 0.9 mm.
- the substrate 10 according to Embodiment 1 is made of a foamed polyurethane resin having an apparent density of 0.04 g / cm 3 (conforming to JIS K7222), a hardness of 220 N (conforming to JIS K6400-2), and a thickness of 8 mm.
- FIG. 6 is a diagram showing a configuration of a hot press type heater manufacturing apparatus 13 for heating and pressurizing the base material on which the cord-like heater 1 is disposed.
- a hot press jig 15 there is a hot press jig 15, and a plurality of locking mechanisms 17 are provided on the hot press jig 15.
- the locking mechanism 17 includes a pin 19, and the pin 19 is inserted into a hole 21 drilled in the hot press jig 15 from below.
- a retaining member 23 whose tip is a needle is attached to the upper portion of the pin 19 so as to be movable in the axial direction, and is always urged upward by a coil spring 25. Then, as indicated by phantom lines in FIG. 7, the cord-like heater 1 is placed on one of the base materials 10 while the cord-like heater 1 is hooked on the retaining members 23 of the plurality of the retaining mechanisms 17. It will be arranged in a shape.
- a press hot plate 27 is arranged above and below the plurality of locking mechanisms 17 so as to be able to move up and down. That is, the cord-like heater 1 is disposed in a predetermined pattern shape while being hooked on the retaining members 23 of the plurality of retaining mechanisms 17, and the substrate 10 is placed thereon. In this state, the press hot plate 27 is lowered to heat and press the cord-like heater 1 and the substrate 10. In order to achieve the effect of the press hot plate 27, it is necessary to design at least the amount of compression of the base material 10 to be larger than the outer diameter of the cord heater 1.
- the base material 10 is compressed, and the heat-sealing layer 9 of the cord-like heater 1 is fused, so that the cord-like heater 1 and the base material 10 are bonded and fixed.
- the retaining members 23 of the plurality of retaining mechanisms 17 move downward against the urging force of the coil spring 25 during heating and pressurization due to the lowering of the press hot plate 27.
- the base material 10 is turned upside down, and further heated and pressurized by a press hot plate from the surface on which the cord-like heater 1 is disposed.
- FIGS. 1 and 2 are enlarged cross-sectional views showing the main part of FIG. Since the base material 10 is compressed by the flat press hot plate 27, the portion where the cord-like heater 1 is disposed is more strongly pressurized. Thereby, the location in the base material 10 where the cord-like heater 1 is disposed is a shape that follows the shape of the cord-like heater 1 and is thinner than the other locations. Further, the heat fusion layer 9 of the cord-like heater 1 is also greatly deformed by heating and pressurizing, and the thickness of the portion not in contact with the base material 10 is reduced and becomes a substantially flat shape.
- the heater unit 31 has no unevenness even at the place where the cord-like heater 1 is disposed, and has a substantially flat shape, and the substantially flat shape is maintained by maintaining the shape of the heat sealing layer 9. Will be. Further, the heater unit 31 obtained in this way can improve the mechanical strength because the base material 10 is compressed and has a high density.
- the thickness of the heater unit obtained by this Embodiment is 1.00 mm
- the minimum thickness of the base material 10 in the location in which the cord-like heater 1 is disposed is 0.52 mm
- the cord-like heater The thickness of the base material 10 at a location where 1 was not disposed was 1.00 mm.
- FIG. 9 the SEM photograph of the principal part in the cross section of the heater unit 31 is shown.
- the heat fusion layer 9 of the cord heater 1 was impregnated from the surface of the base material 10 to a portion of about 0.5 mm.
- the change in thickness within a range of about ⁇ 10% is substantially flat and substantially constant.
- the change in thickness is generally flat if the user does not feel unevenness visually or feel.
- both ends of the cord-like heater 1 are pulled out and connected to the lead wire 35, and the cord-like heater 1 and the temperature control device 39 are connected to the lead wire 35. And a connector (not shown) are connected.
- the temperature control device is arranged on the cord heater 1 and controls the temperature of the heater unit by the heat generated by the cord heater 1.
- the protrusion 10 f may be formed on the base material 10.
- the connection part of the temperature control device 39 and the cord-like heater 1 and the lead wire 35 may be protected by being covered with the protruding part 10f of the base material in order to protect against impact and the like. From this point of view, it is conceivable that the protruding portion 10f is not heated and pressurized.
- the heater unit 31 having the above-described configuration is installed between the wheel core member 77 and the covering member 78 of the steering wheel 71 in the state shown in FIG.
- the base material 10 is provided with an adhesive layer (not shown) for adhering the heater unit 31 and the steering wheel covering material 78.
- an adhesive layer made of only an adhesive is previously formed on the release sheet, and the adhesive layer is transferred from the release sheet to the surface of the substrate 10. Thereby, the adhesive does not enter the inside of the base material 10, and an adhesive layer is formed only on the surface of the base material 10.
- the cover material 78 is bonded to the cover material 78. This is because unevenness due to the cord-like heater 1 hardly appears on the surface of the covering material 78.
- the heater unit 31 according to the embodiment obtained as described above was used for actual use while being incorporated in a steering wheel as shown in FIG.
- the number of users who answered that the embodiment was uncomfortable was zero.
- the substrate 10 As the substrate 10, a single foam made of a polyurethane foam resin having an apparent density of 0.04 g / cm 3 (conforming to JIS K7222), a hardness of 220 N (conforming to JIS K6400-2), and a thickness of 6 mm is used. A cord-like heater was disposed as in the first embodiment. In this way, a heater unit as shown in FIGS. 1 and 2 was obtained. At this time, the substrate 10 is compressed by heating and pressing until the thickness reaches 1 mm, and after the heating and pressing, the apparent density is 0.32 g / cm 3 (conforming to JIS K7222).
- FIG. 10 is an enlarged cross-sectional view showing the main part of FIG. At this time, the substrate 10 is compressed by heating and pressing until the thickness reaches 1 mm, and after the heating and pressing, the apparent density is 0.32 g / cm 3 (conforming to JIS K7222).
- the foam on the side where the cord-like heater 1 is disposed is the first foam 11 and the opposite foam is the second foam.
- the first foam 11 and the second foam 12 are firmly bonded. Therefore, it can prevent that the 1st foam 11 and the 2nd foam 12 isolate
- an adhesive layer may not be used. The first foam 11 and the second foam 12 can be fixed at locations where the cord-like heater 1 is not provided.
- peel strength was measured with respect to the base material 10 on which the two foams were laminated.
- the peel strength is measured by a push-pull gauge.
- the base material 10 is cut into 25 mm ⁇ 150 mm, a 50 mm portion from the end in the longitudinal direction is peeled in advance, the end of the first foam 11 is fixed to a push-pull gauge, and the end of the second foam 12
- the part was gripped and peeled in the direction opposite to the push-pull gauge at a speed of 10 mm / s (peeling angle 180 degrees), and the value at which the maximum load was obtained was defined as the peel strength.
- the peel strength between the first foam 11 and the second foam 12 in the heater unit 31 according to Embodiment 3 measured in this way was 6.2 N, which was a sufficient value for practical use. . Moreover, when the state after peeling was confirmed, it was confirmed that the peeling was not due to interface peeling but due to material destruction, and from this point it was confirmed that sufficient adhesion was obtained. For reference, when the peel strength was measured in the same manner using a sample in which the first foam 11 and the second foam 12 were bonded with a double-sided adhesive tape, the peel strength was 13.7 N. .
- the first foam 11 and the second foam 12 are simply heated and pressed in the same manner as in the third embodiment to obtain high compression, and the first foam 11
- the peel strength was measured in the same manner using a sample to which the second foam 12 was fixed, the peel strength was 5.0 N, and interface peeling was performed.
- the base material 10 made of only one ordinary foam if a crack or tear occurs in the foam, the crack or tear is enlarged and the base material 10 is torn.
- a base material is formed by laminating a plurality of foams, even if cracks or tears occur in one foam, the expansion of the cracks and tears can be accommodated only in the foams, and in other foams It does not affect.
- the base material 10 can be prevented from being torn. Moreover, if the base material 10 is formed by laminating the first foam body 11 and the second foam body 12, the composite characteristics can be obtained by making these two foam bodies have different characteristics. It can be set as the substrate which has. For example, the following can be considered. Regarding one foam, it is conceivable to select one having a high porosity. By setting the foam on the side where the cord-like heater 1 is disposed to have a high porosity, the cord-like heater 1 enters the foam more reliably, and a generally flat heater unit 31 can be obtained.
- the foam on the side where the cord-like heater 1 is not disposed has a high porosity, and other resin is melt-filled to form a composite material.
- a steering wheel having the heater unit 31 embedded therein can be obtained by bonding the heater unit 31 onto the wheel core 77 and injection molding urethane resin or the like thereon, but the cord-like heater 1 is not disposed. If a foam having a high porosity is used as the foam on the side, injection molded urethane resin or the like is filled in the pores of the foam, and the heater unit 31 is securely fixed.
- foams having different hardnesses it is possible to make it difficult to feel the presence of the cord-like heater 1 when the user touches the heater unit 31 or a product incorporating the same.
- foams with excellent flame retardancy foams with high tensile strength, foams with excellent chemical resistance, foams with excellent heat resistance, foams with excellent withstand voltage characteristics, foams with electromagnetic shielding properties, low resilience
- various foams such as a foam having heat resistance, a foam excellent in low-temperature brittleness, and a foam having high thermal conductivity, the heater unit 31 provided with an additional function can be obtained.
- the non-porous portion of the second foam 12 enters the pores of the first foam 11, and the non-porous portion of the first foam 11 enters the pores of the second foam 12, It is confirmed that the first foam 11 and the second foam 12 are fixed by the anchor effect. Further, the heat fusion layer 9 of the cord heater 1 was impregnated from the surface of the base material 10 to a portion of about 5 mm.
- FIGS. 12A to 14C are views showing the external appearance of the heater unit
- FIG. 12A shows the fourth embodiment
- FIG. 12B shows the fifth embodiment
- FIG. 12C shows the sixth embodiment
- . 13A to 13C are views showing the outer appearance of the back surface of the heater unit
- FIG. 13A shows the fourth embodiment
- FIG. 13B shows the fifth embodiment
- FIG. 13C shows the sixth embodiment
- . 14A to 14C are views showing SEM photographs of the cross section of the heater unit
- FIG. 14A shows the fourth embodiment
- FIG. 14B shows the fifth embodiment
- the heater units of the fourth to fifth embodiments include a base material made of a polymer foam and a cord-like heater.
- the cord-shaped heater has seven conductor strands made of a tin-copper alloy wire having a strand diameter of 0.08 mm on the outer periphery of a heater core made of an aromatic polyamide fiber bundle having an outer diameter of about 0.19 mm. Aligned and formed in a spiral with a pitch of 1.00 mm. The thickness of the insulating coating of the conductor wire is 0.005 mm. A state in which the conductor wire is spirally wound around the outer periphery of the heater core in this manner is called a core material.
- a polyester resin in which a flame retardant as the heat fusion part 9 is blended is extruded and coated on the outer periphery of the core material.
- the diameter of the core material is 0.37 mm which is common in the fourth to sixth embodiments.
- the thickness (amount) of the heat fusion part 9 is the same as that of the fourth embodiment. It is 0.60 mm in the form, 0.77 mm in the fifth embodiment, and 0.97 mm in the sixth embodiment.
- the thickness of the heat-sealing part is 0.115 mm in the fourth embodiment, 0.20 mm in the fifth embodiment, and 0.30 mm in the sixth embodiment.
- a heat-sealing portion 9 is formed on the outermost layer that wraps the core material of the heater, and a cord-like heater is disposed on the substrate 10 and then heated and pressurized.
- the heat fusion part 9 of the cord heater is melted, so that it becomes liquid and penetrates into the polymer foam of the base material 10 to form a fixing part.
- the thickness (amount) of the heat-sealing part 9 is changed, a change occurs in a range in which the base material 10 which is a polymer foam is impregnated when melted.
- the fixing portion refers to a portion where the heat-sealed portion of the cord-shaped heater is melted and permeates and adheres to the polymer foam of the substrate 10 being pressed.
- the heat fusion part 9 is melted to form a fixed part, and it is not necessary to keep the original form of the heat fusion part 9. Rather, since the cord-like heater is pressed against the base material 10, it receives a repulsive force from the base material 10 before being heated and pressurized. By heating and pressurizing, a part or all of the heat welding part 9 is melted and becomes liquid, and it is considered that the heat welding part 9 enters the bubbles of the polymer foam from the part in contact with the base material 10.
- the shape penetrates in the width direction and the thickness direction with reference to the base material 10 in a cross-sectional view.
- the part united with the base material 10 which is a polymer foam is formed in the outermost layer part.
- the adhesive strength of a cord-shaped heater and the base material 10 is strengthened by forming the site
- the cord-like heater is inside the fixed portion, and the fixed portion enters the substrate 10. The thickness of the portion where the cord heater is disposed does not exceed the thickness of the portion of the base material 10 where the cord heater is not disposed.
- the thickness of the portion where the cord heater is disposed does not exceed the thickness of the portion of the base material 10 where the cord heater is not disposed, but the cord heater is disposed.
- the case where the thickness of the portion that has been slightly exceeded the thickness of the portion of the base material 10 on which the cord-like heater is not disposed is not completely excluded. Even if it is slightly exceeded, it can be said that it is within the scope of the present invention as long as it does not feel uncomfortable by operating the steering. From another viewpoint, depending on the rigidity of the fixing part containing the cord-like heater, it is assumed that even if it is thicker than the base material 10, it does not feel uncomfortable, and even if it is thinner than the base material 10, it does not feel uncomfortable. Is possible.
- the thickness (KA) of the base material 10 the diameter (KB) of the core material (core + element), the width (KC) of the heat-sealed part (fixed part) impregnated in the base material, and the thermal fusion impregnated in the base material
- KD depth of the base material of the landing portion
- the heater unit of the present embodiment includes a base material made of a polymer foam and a cord-like heater that is disposed on the base material with a heat-sealed portion formed on the outermost layer that wraps around the core material of the heater. The heat unit of the cord heater melts and the fixing unit penetrates into the polymer foam.
- the heater unit manufacturing method is characterized in that the heat-sealed portion of the cord heater is melted to form a fixing portion that has penetrated into the polymer foam.
- the thickness of the fixing portion exceeds 60% of the thickness of the base material.
- the thickness of the fixing portion is substantially the same as the entire thickness of the base material.
- the width of the fixed portion exceeds three times the width of the core material.
- the width of the fixing portion does not exceed five times the width of the core material.
- the thickness of the fixing portion exceeds 1.3 times the width of the core material.
- the thickness of the fixing portion does not exceed 2.5 times the width of the core material.
- numerical values are only specific examples of one embodiment. Therefore, even in consideration of a general sense of a person skilled in the art, a range from 50% of the lower limit to 200% of the upper limit, preferably 75 of the lower limit. The same effect can be expected in the range of% to 150% of the upper limit, and more preferably 90% of the lower limit to 110% of the upper limit. The inventor's consideration was as follows.
- the thickness of the heat-sealed part 0.115 mm can be said to be the thinnest practically feasible.
- the width and depth of the fixed part must be compared with the diameter of the core material (core + element wire) because the values necessary to securely fix the core material (core or element wire) to the base material are designed. I thought there was.
- our product has a configuration in which the strands are wound horizontally around the heater core, but it is also possible to realize it by simply twisting a plurality of strands without using the heater core.
- the wider the width of the fixed part the stronger the adhesive force. Too wide can cause discomfort.
- 300% ⁇ KC / KB ⁇ 500% is preferable.
- KD / KB> 100% so that it may not protrude from a base material. If it is too deep, it may cause a sense of incongruity, so it is considered preferable to set KD / KB ⁇ 250%.
- the present invention is not limited to the above embodiment.
- any conventionally known cord heater can be used.
- a heating element configured by aligning heating element strands is wound around the outer periphery of a heater core, and an insulating layer made of FEP is formed on the outer periphery.
- a cord-like heater having a heat-sealing layer made of polyethylene, a cord-like shape in which the heater core 3 has heat shrinkability and heat-meltability as disclosed in the specification of Japanese Patent Application No. 2007-158452.
- Heater as disclosed in Japanese Patent Application No.
- a cord-like heater composed of a heating element in which conductor wires covered with an insulating film are aligned, disclosed in Japanese Patent Application Laid-Open No. 2007-134341
- a heating element such as a cord-like heater composed of a copper solid solution and a copper-silver eutectic silver-filled copper alloy wire made of fibers.
- FIG. 4 the thing of a structure as shown in FIG. 4 is also considered. Specifically, first, seven conductor strands 5a made of a tin copper alloy wire having a strand diameter of 0.08 mm are arranged on the outer periphery of a heater core 3 made of an aromatic polyamide fiber bundle having an outer diameter of about 0.2 mm.
- the cord-shaped heater 1 is configured by being spirally wound at a pitch of 1.00 mm.
- the conductor wire 5a is covered with an insulating film 5b made of polyurethane with a thickness of about 0.005 mm.
- the cord-like heater 1 has such a configuration, and its finished outer diameter is 0.38 mm.
- the base material 10 is not limited to the foamed polyurethane resin, and various polymer foams such as foamed resin sheets and foamed rubber sheets made of other materials are conceivable. In particular, those excellent in stretchability are preferable, and those whose hardness is adjusted so that the irregularities of the cord-like heater do not appear on the surface are preferable. Further, in order to adjust the hardness, there are methods such as adjusting the foaming rate, changing the state of bubbles to closed cells or open cells, and using a material having a hardness suitable for the purpose.
- a plurality of base materials 10 may be used.
- a plurality of base materials 10 may be laminated in layers. In this case, the plurality of base materials 10 may be made of different materials. Thereby, the unevenness
- the adhesive layer is formed so that the adhesive does not penetrate into the internal voids of the base material 10 such as in bubbles, the base material 10 is not cured and the stretchability is not impaired, and the texture is not deteriorated. preferable.
- the cord-like heater 1 when the cord-like heater 1 is disposed on the base material 10, the cord-like heater 1 may be fixed to the base material 10 according to other modes instead of being bonded and fixed by fusion by heating and pressing.
- the cord-like heater 1 may be fixed to the base material 10 by sewing, or another aspect may be used.
- the substrate 10 when the substrate 10 is heated and pressed, not only the press hot plate 27 but also the hot press jig 15 may be heated. At this time, it is also conceivable to change the compression rate of the base material 10, that is, change the porosity, by changing the temperature of the press hot plate 27 and the hot press jig 15.
- the adhesive layer for example, various types such as an adhesive layer made of a polymer acrylic pressure-sensitive adhesive and not using a tape base material, or an adhesive layer formed by forming an adhesive on both surfaces of a polypropylene film can be used. FMVSS No. If it has the flame retardance which passes the combustion test of 302 automotive interior materials, the flame retardance of a heater unit improves and is preferable. Moreover, in order not to impair the stretchability of the heater unit, an adhesive layer made of only an adhesive is preferable.
- Such a heater unit is used, for example, in a steering wheel used for automobiles, ships, various transportation vehicles, various agricultural vehicles, various civil engineering heavy machinery, etc., and is suitable as a heater unit for heating the wheel portion.
- the heater unit according to the present invention is not limited to the steering wheel, and is, for example, an electric blanket, an electric carpet, a car seat heater, a steering heater, and a heating toilet seat.
- Application to anti-fog mirror heaters, cooking utensils, floor heating heaters, clothes heaters, and the like is also conceivable.
- the present invention is not limited to the above embodiments. It goes without saying for those skilled in the art, ⁇ Applying mutually interchangeable members and configurations disclosed in the above embodiments by appropriately changing the combination thereof. ⁇ Although not disclosed in the above embodiments, it is a publicly known technique and the above embodiments. The members and configurations that can be mutually replaced with the members and configurations disclosed in the above are appropriately replaced, and the combination is changed and applied. It is an embodiment of the present invention that a person skilled in the art can appropriately replace the members and configurations that can be assumed as substitutes for the members and configurations disclosed in the above-described embodiments, and change the combinations and apply them. It is disclosed as.
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Abstract
Description
また、上記コード状ヒータが、最外層に熱融着部が形成されたものであることが考えられる。
本発明によるステアリングホイールは、上記のヒータユニットと、ホイール芯材と、被覆材とからなり、上記ホイール芯材と上記被覆材の間に上記ヒータユニットが設置されるものである。
また、本発明によるヒータユニットの製造方法は、高分子発泡体からなる基材と、コード状ヒータとからなるヒータユニットの製造方法であって、上記基材上に、所定のパターン形状で上記コード状ヒータを配設し、上記基材を平板によって加熱加圧することで、上記基材における上記コード状ヒータが配設される箇所の厚さを、該コード状ヒータの形状に沿うように薄くし、それによって概ね平坦な形状のヒータユニットとするものである。
まず、本実施の形態におけるコード状ヒータ1の構成から説明する。本実施の形態におけるコード状ヒータ1は図5に示すような構成になっている。まず、外径約0.2mmの芳香族ポリアミド繊維束からなるヒータ芯3の外周に、素線径0.08mmの錫銅合金線からなる導体素線5aを7本引き揃え、ピッチ1.00mmで螺旋状に巻装してコード状ヒータ1を構成する。なお、導体素線5aには、ポリウレタンからなる絶縁被膜5bが厚さ約0.005mmで被覆されている。この外周に、熱融着部9としての難燃剤が配合されたポリエチレン樹脂が0.25mmの厚さで押出・被覆されている。コード状ヒータ1はこのような構成になっていて、その仕上外径は0.9mmである。
基材10として、見かけ密度0.04g/cm3(JIS K7222準拠)、硬さ220N(JIS K6400-2準拠)、厚さ6mmの発泡ポリウレタン樹脂からなる1枚の発泡体を使用し、実施の形態1と同様にコード状ヒータを配設した。このようにして、図1及び図2に示すようなヒータユニットを得た。この際、厚さ1mmになるまで基材10を加熱加圧して圧縮しており、加熱加圧後は、見かけ密度0.32g/cm3(JIS K7222準拠)となっている。
基材10として、見かけ密度0.04g/cm3、(JIS K7222準拠)、硬さ220N(JIS K6400-2準拠)、厚さ4mmの発泡ポリウレタン樹脂からなる発泡体2枚を重ねて使用し、本実施の形態と同様にコード状ヒータを配設した。このようにして、図1及び図10に示すようなステアリングホイール用のヒータユニット31を得た。なお、図10は図1の要部を拡大して示す断面図である。この際、厚さ1mmになるまで基材10を加熱加圧して圧縮しており、加熱加圧後は、見かけ密度0.32g/cm3(JIS K7222準拠)となっている。実施の形態3では便宜的に、コード状ヒータ1が配設される側の発泡体を第1の発泡体11、反対側の発泡体を第2の発泡体とする。
この際、熱融着層9が、基材10を構成する第1の発泡体11及び第2の発泡体12の両方に含浸されるようにすれば、第1の発泡体11と第2の発泡体12が強固に接着される。そのため、第1の発泡体11と第2の発泡体12が分離してしまうことを防止できる。
なお、コード状ヒータ1を熱融着する際に、第1の発泡体11と第2の発泡体12に対して充分に加熱加圧して高圧縮とした場合、接着層を使用しなくても、コード状ヒータ1が配設されていない箇所について、第1の発泡体11と第2の発泡体12を固定させることができる。これは、一方の発泡体の気孔中にもう一方の発泡体の非気孔部が入り込み、アンカー効果によって2つの発泡体を固定させることによるものである。このようにして2枚の発泡体が積層された基材10に対し、剥離強度を測定した。剥離強度の測定は、剥離強度は、プッシュプルゲージによって測定される。基材10を25mm×150mmに切り出し、長手方向端部から50mmの部分を予め剥離しておき、第1の発泡体11の端部をプッシュプルゲージに固定し、第2の発泡体12の端部を掴持して、10mm/sの速度でプッシュプルゲージと反対の方向に引き剥がし(剥離角度180度)、最大荷重となった値を剥離強度とした。このようにして測定された実施の形態3によるヒータユニット31における第1の発泡体11と第2の発泡体12との剥離強度は、6.2Nであり、実使用上充分な値であった。また、剥離後の状態を確認したところ、界面剥離ではなく、材料破壊による剥離であることが確認でき、この点からも充分な接着が得られていることが確認された。参考までに、第1の発泡体11と第2の発泡体12とを両面粘着テープで接着したサンプルを使用して、同様に剥離強度を測定したところ、剥離強度は、13.7Nであった。また、コード状ヒータ1を使用せず、単に第1の発泡体11と第2の発泡体12とを上記実施の形態3と同様に加熱加圧して高圧縮とし、第1の発泡体11と第2の発泡体12とを固定したサンプルを使用して、同様に剥離強度を測定したところ、剥離強度は、5.0Nであり、界面剥離がされていた。
通常の発泡体1つのみからなる基材10の場合、万が一、発泡体に亀裂や裂けが生ずると、その亀裂や裂けが拡大していって、基材10として断裂してしまうことになる。ここで、複数の発泡体を積層した基材であれば、1つの発泡体に亀裂や裂けが生じても、その亀裂や裂けの拡大は、当該発泡体のみで収まり、他の発泡体には影響しない。そのため、基材10として断裂に至ることを防止できる。
また、基材10が、第1の発泡体11及び第2の発泡体12を積層してなるものであれば、これら2つの発泡体を異なる特性のものとすることで、複合的な特性を有する基材とすることができる。例えば、以下のようなものが考えられる。一方の発泡体について、気孔率の高いものを選択することが考えられる。コード状ヒータ1を配設する側の発泡体を気孔率の高いものとすることで、コード状ヒータ1がより確実に発泡体中に入り込み、概ね平坦なヒータユニット31を得ることができる。また、コード状ヒータ1を配設しない側の発泡体を気孔率の高いものとし、その他の樹脂を溶融充填して複合材料とすることも考えられる。ヒータユニット31をホイール芯材77上に接着し、その上にウレタン樹脂等を射出成型することで、ヒータユニット31が埋設されたステアリングホイールを得ることができるが、コード状ヒータ1を配設しない側の発泡体を気孔率の高いものとした発泡体を使用すれば、射出成型したウレタン樹脂等が発泡体の気孔中に充填され、確実にヒータユニット31が固定されることになる。また、硬度が異なる発泡体を積層することで、ヒータユニット31やそれを組み込んだ製品に使用者が触れた際に、コード状ヒータ1が存在することを感じにくくさせることができる。また、難燃性に優れる発泡体、引張強度の高い発泡体、耐薬品性に優れる発泡体、耐熱性に優れる発泡体、耐電圧特性に優れる発泡体、電磁波遮蔽特性を備える発泡体、低反発性を有する発泡体、低温脆性に優れる発泡体、熱伝導率が高い発泡体等、種々の発泡体を組合せることによって、付加的な機能が付与されたヒータユニット31にすることができる。また、薄い発泡体を積層したものであれば、コード状ヒータを熱融着により配設する際にも、薄い発泡体に配設した後に、他の発泡体を貼付するような工程を取ることができ、発泡体による断熱の影響による融着不良を防ぐことができる。また、更に第3の発泡体等、他の発泡体を積層させた多層構造としても良い。この場合、全ての発泡体の気孔に熱融着層9が含浸されていることが好ましい。
図11に、実施の形態3によるヒータユニット31の断面における要部のSEM写真を示す。熱融着層9が第1の発泡体11及び第2の発泡体12の気孔中に含浸されていることが確認される。また、第1の発泡体11の気孔中に第2の発泡体12の非気孔部が入り込み、且つ、第2の発泡体12の気孔中に第1の発泡体11の非気孔部が入り込み、アンカー効果によって第1の発泡体11と第2の発泡体12が固定されていることが確認される。また、コード状ヒータ1の熱融着層9は、基材10の表面から約5mmの部分まで含浸されていた。
次に、図12A~図14Cを参照して、第4の実施形態、第5の実施形態、第6の実施形態を説明する。
図12A~12Cはヒータユニットの表面外観を示す図であり、図12Aは第4の実施形態を示し、図12Bは第5の実施形態を示し、図12Cは第6の実施形態を示している。
図13A~13Cはヒータユニットの裏面外観を示す図であり、図13Aは第4の実施形態を示し、図13Bは第5の実施形態を示し、図13Cは第6の実施形態を示している。
図14A~14Cはヒータユニットの断面のSEM写真を示す図であり、図14Aは第4の実施形態を示し、図14Bは第5の実施形態を示し、図14Cは第6の実施形態を示している。
第4~第5の実施形態のヒータユニットは、高分子発泡体からなる基材と、コード状ヒータとからなる。コード状ヒータは、上述したように、外径約0.19mmの芳香族ポリアミド繊維束からなるヒータ芯の外周に、素線径0.08mmの錫銅合金線からなる導体素線を7本引き揃え、ピッチ1.00mmで螺旋状に巻装して形成されている。導体素線の絶縁被膜の厚みは、0.005mmである。このようにしてヒータ芯の外周に導体素線を螺旋状に巻装した状態のことを芯材と呼ぶ。芯材の外周に、熱融着部9としての難燃剤が配合されたポリエステル系樹脂が押出・被覆されている。
芯材の径は、第4~第6の実施形態において共通の0.37mmであり、熱融着部9の厚み(量)を変えることで、コード状ヒータの外径は、第4の実施形態において0.60mm、第5の実施形態において0.77mm、第6の実施形態において0.97mmとなっている。また、それぞれにおいて、熱融着部の厚さは、第4の実施形態において0.115mm、第5の実施形態において0.20mm、第6の実施形態において0.30mmとなっている。
このヒータユニットでは、ヒータの芯材を包み込む最外層には熱融着部9が形成され、コード状ヒータを基材10上に配設させた上で加熱加圧する。この過程でコード状ヒータの熱融着部9が溶融するため、液状となって基材10の高分子発泡体に浸透し、固定部を形成する。熱融着部9の厚み(量)が変わることで、溶融したときに高分子発泡体である基材10に含浸される範囲に変化が生じる。固定部は、コード状ヒータの熱融着部が溶融し、押圧されている基材10の高分子発泡体に浸透して固着している部位を指している。
熱融着部9が溶融して固定部を形成しており、熱融着部9の原形をとどめている必要はない。むしろ、コード状ヒータは基材10に対して押圧されているので、加熱加圧される前は基材10から反発力を受けている。加熱加圧されることで、熱溶着部9は一部または全部が溶融して液状となり、基材10と接していた部分から高分子発泡体の気泡内に入り込むと考えられる。加熱加圧を終了して冷却した状態では、断面視で基材10を基準とした幅方向および厚み方向に浸透した形状となっていることが分かる。その最外層部分で高分子発泡体である基材10と合体した部位を形成することになる。このように両者が合体した部位を形成することにより、コード状ヒータと基材10との接着強度が強固になっていると推察される。
また、コード状ヒータは固定部の内部にあり、さらに固定部は基材10に入り込んでいる。コード状ヒータを配設した部位の厚さは、コード状ヒータを配設していない基材10だけの部位の厚さを超えていない。ただし、本実施例では、コード状ヒータを配設した部位の厚さは、コード状ヒータを配設していない基材10だけの部位の厚さを超えていないが、コード状ヒータを配設した部位の厚さがわずかにコード状ヒータを配設していない基材10の部位の厚さを超えている場合を完全に排除するものではない。わずかに超えているとしても、ステアリングを操作して違和感を感じない範囲であれば、本発明の範囲といえる。別の観点で、コード状ヒータを内蔵する固定部の堅さによっては、基材10よりも厚くても違和感を感じなかったり、基材10よりも薄くても違和感を感じなかったりすることは想定可能である。
基材10の厚さ(KA)、芯材(芯+素線)の径(KB)、基材に含浸した熱融着部(固定部)の幅(KC)、基材に含浸した熱融着部(固定部)の基材の深さ(KD)とすると、以下の結果であった。
ここで、熱融着部の基材への含浸の状況を表すため、本実施形態においては、固定部の厚さと基材の厚みの比(KD/KA)、固定部の幅と芯材の幅の比(KC/KB)、固定部の厚さと芯材の幅の比(D/B)を計測したところ、以下の結果であった。
まず、本実施形態のヒータユニットは、高分子発泡体からなる基材と、ヒータの芯材を包み込む最外層には熱融着部が形成されて前記基材上に配設されるコード状ヒータとからなるヒータユニットであって、上記コード状ヒータの熱融着部が溶融して上記高分子発泡体に浸透した固定部を有している。
また、このヒータユニットの製造方法は、上記コード状ヒータの熱融着部を溶融せしめて上記高分子発泡体に浸透した固定部を形成させることを特徴としている。
さらに、これらに共通して、以下の特徴がある。
第4の実施形態より、上記固定部の厚さが、上記基材の厚みの60%を超えているといえる。
第5および第6の実施形態より、上記固定部の厚さが、上記基材の全体の厚みと略同一といえる。
第4の実施形態より、上記固定部の幅が、上記芯材の幅の3倍を超えるといえる。
第5および第6の実施形態より、上記固定部の幅が、上記芯材の幅の5倍を超えない
といえる。
第4の実施形態より、上記固定部の厚さが、上記芯材の幅の1.3倍を超えるといえる。
第5の実施形態より、上記固定部の厚さが、上記芯材の幅の2.5倍を超えないといえる。
むろん、少なくとも上記数値は一実施形態の具体例に過ぎないから、当業者の一般的な感覚を考慮しても、下限値の50%~上限値の200%の範囲、好ましくは下限値の75%~上限値の150%の範囲、さらに好ましくは下限値の90%~上限値の110%の範囲では、同様の効果を発することは期待できる。
発明者の考察は、以下のようであった。
現時点では、熱融着部厚さ=0.115mmのものが、現実的には実施可能な最も薄いものといえる。
熱融着部の含浸深さは、深いほど接着力は強くなる。基材裏側まで達するようなもの(KD/KA=100%)の場合、その部分が異物になってステアリング表面に浮き出て違和感となってしまう可能性はある。
固定部の幅や深さは、芯材(芯や素線)を基材に確実に固定するために必要な値が設計されるため、芯材(芯+素線)の径と対比する必要があると考えた。本実施形態では、当社品はヒータ芯に素線を横巻する構成としたが、ヒータ芯を使用せず複数の素線を撚り合わせるだけのものとして実現することも可能である。
固定部の幅も、広いほど接着力は強くなる。広すぎても違和感の原因となる。この点に関しては、300%≦KC/KB≦500%程度が好適であると考える。
芯材(芯+素線)に対する固定部の深さについて、基材からはみ出ないようにするためKD/KB>100%とする必要がある。深すぎても違和感の原因となるため、KD/KB≦250%程度にすることが好適であると考える。
製造方法に関して(見かけ密度0.04g/cm3のポリウレタンを0.8mmに圧縮する)
第4の実施形態~第5の実施形態の製造条件は以下のとおりであった。
熱圧縮条件
プレス熱板27 215℃±10℃
ホットプレス冶具15 15230℃±10℃
下降圧力 1回目0.3MPa 2回目0.5~1.0MPa
圧縮時間 25±2秒(s)
成果物の形態が異なる場合、例えば、基材や熱融着部に他種類の材料を使用する、基材の見かけ密度・気孔率が異なるものを使用する、圧縮後の厚さを変更する、等といった場合、この条件とは異なる条件にて加熱加圧することになる。また、もっと低い温度にして圧縮時間を長くする等、この条件に当てはまらない製法でも得られるものが同じになる可能性もある。
・上記実施例の中で開示した相互に置換可能な部材および構成等を適宜その組み合わせを変更して適用すること
・上記実施例の中で開示されていないが、公知技術であって上記実施例の中で開示した部材および構成等と相互に置換可能な部材および構成等を適宜置換し、またその組み合わせを変更して適用すること
・上記実施例の中で開示されていないが、公知技術等に基づいて当業者が上記実施例の中で開示した部材および構成等の代用として想定し得る部材および構成等と適宜置換し、またその組み合わせを変更して適用すること
は本発明の一実施例として開示されるものである。
Claims (6)
- 高分子発泡体からなる基材と、該基材上に配設されるコード状ヒータとからなるヒータユニットであって、
上記基材における上記コード状ヒータが配設される箇所の厚さが、該コード状ヒータの形状に沿うように薄くなっており、それによって概ね平坦な形状となっていることを特徴とするヒータユニット。 - 上記コード状ヒータが配設される箇所の厚さが、概略一定の厚みとなっていることを特徴とする請求項1記載のヒータユニット。
- 上記コード状ヒータが、最外層に熱融着部が形成されたものであることを特徴とする請求項1または請求項2に記載のヒータユニット。
- 請求項1に記載のヒータユニットと、ホイール芯材と、被覆材とからなり、上記ホイール芯材と上記被覆材の間に上記ヒータユニットが設置されるステアリングホイール。
- 高分子発泡体からなる基材と、コード状ヒータとからなるヒータユニットの製造方法であって、上記基材上に、所定のパターン形状で上記コード状ヒータを配設し、上記基材を平板によって加熱加圧することで、上記基材における上記コード状ヒータが配設される箇所の厚さを、該コード状ヒータの形状に沿うように薄くし、それによって概ね平坦な形状のヒータユニットとするヒータユニットの製造方法。
- 上記コード状ヒータが配設される箇所の厚さが、概略一定の厚みとなっていることを特徴とする請求項5記載のヒータユニットの製造方法。
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