JP3861376B2 - Manufacturing method of surface heating device - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a surface heating device such as an electric carpet.
[0002]
[Prior art]
As a conventional method for manufacturing a sheet heating device such as an electric carpet, there has been a manufacturing method as disclosed in Japanese Patent Application Laid-Open No. 61-209147. As shown in FIG.
(1) Step of forming hot melt thin film 2 on the adhesive surface of soft synthetic resin foam 1 (2) Step of forming hot melt thin film 2 on the adhesive surface of surface material 3 (3) Soft synthetic resin foam 1 and surface material 3 (4) A step of heat-pressing the soft synthetic resin foam 1 and the surface material 3 with a heating element 4 and a superposed die 5 and a pressing die 6 It was. In addition, since the process of said (1) and (2) uses the same installation, process drawing is shared.
[0003]
In addition, as shown in FIG.
(1) The process of supplying the heat sealing sheet 8 on the back surface material 7 made of felt (2) The process of supplying the surface material 3 in which the heating element 4 is disposed on the heat sealing sheet 8 3) There was also a process comprising a step of hot pressing the surface material 3, the heat-sealing sheet 8, and the back surface material 7 with the lower heating plate 9 and the upper heating plate 10.
[0004]
Furthermore, as another conventional technique, as shown in FIG.
(1) Step of pulling out the long back material 7 made of felt (2) Step of supplying the base material 11 provided with the heating element 4 onto the back material 7 (3) The back material 7 and the above Step of applying hot melt adhesive 12 on top of base material 11 (4) Step of supplying long surface material 3 onto back surface material 7 and base material 11 (5) Surface material 3 and back surface The process which forms the laminated body 14 by crimping | compression-bonding the material 7 and the base material 11 with the hot roll 13 (6) There also existed the process of cut | disconnecting the said laminated body 14.
[0005]
Such a surface heating device is usually used on a floor of a tatami mat or a flooring of a floor, and is usually used while sitting on the floor. Therefore, the heat generated from the heating element 4 toward the floor of the tatami mat or the flooring is used. In order to increase the heat insulation efficiency so as not to escape and to obtain an appropriate cushioning property, the back surface material 7 such as a soft synthetic resin foam 1 and a felt that usually contains a large amount of air layer is used.
[0006]
[Problems to be solved by the invention]
However, since the conventional planar warming tool as described above is heat-pressed by a hot press or a hot roll, the air layer in the soft synthetic resin foam 1 or the back material 7 is crushed and the thickness is reduced. Therefore, there is a problem that the amount of heat generated from the heating element 4 escapes to the floor surface, that is, the heat insulation efficiency is deteriorated and the cushioning property is also impaired. Moreover, when changing the thickness of the planar warming tool, it is necessary to prepare a back material having a different thickness, and there is a problem that it takes a lot of time to switch the equipment in the process.
[0007]
[Means for Solving the Problems]
In order to solve the above problems, the present invention includes a step of placing a backing material on a lower mold, a step of applying a foamed resin material to the backing material, and a surface material unit in which a heating element is disposed. The upper mold is lowered from above the surface material unit, and the back material, the foamed resin material, and the surface material unit are sealed with the upper and lower molds. The process consists of foaming a foamed resin material in the foaming space formed between the upper and lower molds and molding it along the inner surface shape of the mold. A resin for preventing the foamed resin material from exuding is laminated in advance, and the upper mold is partitioned with the foaming space between the lower mold and the lower mold. A detachable convex part for pressing the peripheral part of the material and the surface material unit is arranged.
[0008]
According to the above invention, a cushioning property having a high heat insulation efficiency and a comfortable cushioning property can be obtained, and a cushioning material having a higher heat insulation efficiency and a comfortable cushion by changing the coating amount of the foamed resin material and the thickness of the removable mold part of the upper die A highly functional surface heating tool can be provided by simply changing the mold.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
The present invention includes a step of placing a backing material on a lower mold, a step of applying a foamed resin material to the backing material, and a surface material unit provided with a heating element on the backing material coated with the foamed resin material. The upper mold is lowered from above the surface material unit, the back material, the foamed resin material, and the surface material unit are sealed with the upper and lower molds, and between these upper and lower molds. The foaming resin material is foamed in the foaming space that can be formed and molded along the inner surface shape of the mold.
A resin for preventing the foamed resin material from exuding at the time of foaming is laminated in advance, and the upper mold is partitioned with the foaming space between the lower mold and the lower mold The detachable convex part which presses down the peripheral part of a backing material and a surface material unit is arranged.
[0010]
Therefore, between the surface material and the surface material unit, the surface material and the surface material unit are sealed with a lower mold and an upper mold having a detachable mold part without heat-pressing the surface material and the surface material unit. Since the foamed resin material is molded by foaming, the foamed resin material sufficiently includes a gas layer, and a planar warming tool having high heat insulation efficiency and comfortable cushioning properties can be obtained. Moreover, the surface warming tool of various thickness can be easily obtained by changing the convex part arrange | positioned at an upper metal mold | die, and changing the application quantity of a foamed resin material.
[0011]
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
[0012]
Example 1
As shown in FIG. 1, the manufacturing method of the planar warming tool of Example 1 of the present invention is as follows.
(1) Step A for placing the backing material 15 on the lower mold 16 (2) Step B for applying the foamed resin material 17 to the backing material 15 (3) A surface material unit 18 in which the heating element 4 is disposed. Step C for placing on the backing material 15 to which the foamed resin material 17 is applied. (4) Further, the upper mold 19 is lowered from above the surface material unit 18, and the backing material 15, the foamed resin material 17, and the surface material. The unit 18 is sealed with the lower mold 16 and the upper mold 19, and the foamed resin material 17 is foamed in a space formed between the lower mold 16 and the upper mold 19 to follow the inner shape of the mold. And D step of molding.
[0013]
As the backing 15, a resin sheet or a nonwoven fabric or the like laminated with a resin on one side or both sides is used so that the foamed resin material 17 does not ooze out to the surface during foaming.
[0014]
As the front material 20, a needle punch felt or a non-woven fabric with a resin coating on the surface is used, and the foam resin material 17 oozes out to the surface during foaming on the surface in contact with the foam resin material 17 in the same manner as the back material 15. Laminate the resin so that it does not come.
[0015]
As shown in FIG. 2, the upper die 19 and the lower die 16 are shaped so that the lower die 16 is flat, and the upper die 19 is attached to and detached from the periphery having a height corresponding to the thickness of the surface heating tool. The possible convex part 21 is provided. The convex portion 21 serves as a thickness guide for making the thickness of the planar warming tool uniform after molding, and the backing material 15 and the surface material unit by the flow of the foamed resin material 17 when the foamed resin material 17 is foamed. When the lower mold 16 and the upper mold 19 are sealed so that the 18 does not move and cause wrinkles or misalignment on the surface, the peripheral portions of both the backing 15 and the front material unit 18 are removed. It also plays the role of holding down.
[0016]
Moreover, although the surface of the upper metal mold | die 19 and the lower metal mold | die 16 is made into the plane, you may provide uneven | corrugated shape. By providing the concavo-convex shape, the foam molded shape of the foamed resin material 17 is also concavo-convex, and an arbitrary pattern can be added to the surface warming tool surface. By forming the concavo-convex shape of the lower mold and the upper mold from the detachable mold part, an arbitrary pattern can be added to the surface warmer surface by exchanging a part of the mold.
[0017]
The foamed resin material 17 may be either a self-foaming material such as foamed polyurethane or a material that is foamed by injecting a foaming agent such as carbon dioxide gas such as foamed polyethylene or foamed polyvinyl chloride. However, in the case of a material to be foamed by injecting a foaming agent such as carbon dioxide gas, the pipe 22 is inserted and the foaming agent 25 is injected after sealing with the lower mold 16 and the upper mold 19 as shown in FIG. .
[0018]
Further, as a method of applying the foamed resin material 17, there are a one-point injection method, a substantially linear traverse injection method, a zigzag traverse injection method, or a spray spraying method to the center point of the backing material 15; It is preferable to apply by the zigzag traverse injection method.
[0019]
By making the manufacturing method in this way, the surface warming tool can be molded while foaming the foamed resin material 17 to sufficiently form the gas layer, so that the surface shape has a high heat insulation efficiency and a comfortable cushioning property. A warming tool can be obtained. In addition, by making a part of the lower mold and the upper mold detachable, it is possible to easily manufacture planar warming tools having various thicknesses and surface shapes.
[0020]
【The invention's effect】
As described above, according to the method for manufacturing a planar warming device of the present invention, the surface material and the surface material unit are sealed with the lower mold and the upper mold without being hot-pressed by a hot press or a hot roll. Since the foamed resin material is foamed between the surface material unit and the surface material unit and molded, the foamed resin material sufficiently contains a gas layer, and a surface warming tool having a high heat insulation efficiency and a comfortable cushioning property is obtained. Has the advantageous effect of being able to In addition, by making the convex part of the upper mold detachable, it is possible to easily manufacture a planar warming tool having various thicknesses and surface shapes.
[Brief description of the drawings]
FIG. 1 is a schematic process diagram of a method for manufacturing a planar warming device according to a first embodiment of the present invention. FIG. 2 is a fourth process diagram of the manufacturing method. FIG. 3 is a partial view of another fourth process of the manufacturing method. FIG. 4 is a schematic process diagram of a conventional method for manufacturing a planar warming tool. FIG. 5 is another schematic process diagram of the manufacturing method. FIG. 6 is another schematic process diagram of the manufacturing method.
4 Heating element 15 Backing material 16 Lower mold 17 Foamed resin material 18 Surface material unit 19 Upper mold 20 Surface material 21 Convex part 22 Pipe 23 Through-hole 24 Fixing jig

Claims (1)

The step of placing the backing material on the lower mold, the step of applying the foamed resin material to the backing material, and the surface material unit with the heating element placed on the backing material coated with the foamed resin material The upper mold is lowered from above the process and the surface material unit, the backing material, the foamed resin material, and the surface material unit are sealed with the upper and lower molds, and the foaming space created between these upper and lower molds The foamed resin material is foamed and molded along the inner surface shape of the mold, and the foamed resin material of the backing material and the front material unit prevents the foamed resin material from oozing out during foaming. The resin is laminated beforehand, and the foaming space is defined between the upper mold and the lower mold, and the periphery of the backing and the surface material unit is pressed with the lower mold. A method for manufacturing a planar warming device in which a detachable convex portion is arranged .

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