JP5208227B2 - Manufacturing method of planar warmer and manufacturing apparatus of planar warmer - Google Patents

Description

  The present invention relates to a method for manufacturing a sheet heating device and an apparatus for manufacturing the sheet heating device using an electric heater as a heat source.

  Conventionally, this type of sheet heating device has a structure in which three layers of a backing material, a heater unit in which a heater wire is disposed on a base material, and a surface material are laminated. And between the heater unit and the surface material are attached by an adhesive. This type of surface heating device is manufactured by applying an adhesive to one main surface of the backing or the heater unit and applying an adhesive to the other main surface or the front material of the heater unit. A laminated body is formed by overlapping the material, the heater unit, and the surface material. Thereafter, the laminate is heated from the outside to melt the adhesive between the layers, and then press-molded using a mold.

  However, in this method, since heating is performed from the outside of the laminate, in order to sufficiently melt the adhesive between the layers, there is a problem that the outer surface material or backing material must be excessively heated. Excessive heating of the surface material or backing material may cause the quality of the surface material or backing material to deteriorate if the temperature exceeds the service temperature of the surface material or backing material in the usage condition of the surface heating device. . In particular, the surface material may be embossed for the design of the surface or the touch when touched, or it may use a material that is not very resistant to heat in order to make it soft. When heating is performed, the surface material may be deformed or deteriorated, and the design applied to the surface material may be damaged or the touch when touched may be adversely affected.

  On the other hand, as a method of manufacturing a planar warming device without using an adhesive, a heater unit in which a urethane foam material is applied on a backing and a heater wire is disposed on the substrate; There is also a method of laminating a surface material and press-molding them in a mold. At this time, the urethane foam material foams, and the urethane foam material oozes out from the base material side of the heater unit to the front material side due to foaming pressure, and adheres to the front material, so that the backing material, the heater unit, and the front material are bonded together. It is also known (see, for example, Patent Document 1).

  13 (a) to 13 (c) show a conventional planar warmer described in Patent Document 1, and FIG. 13 (a) shows a perspective view showing the order of creating the planar warmer, FIG. 13 (b) shows a side view of the production sequence, and FIG. 13 (c) shows a cross-sectional view of the planar warming tool after molding. As shown in FIG. 13A, a front material 901, a heater unit 903 in which a heater wire 903b is disposed on a heater base material 903a, and a backing material 905 having a urethane foam material 904 applied on the surface are prepared. As shown in FIG. 13 (b), they are stacked and placed in a mold (not shown), and are press-molded in the mold to form a planar warming tool shown in FIG. 13 (c).

JP 2001-041480 A

  However, the manufacturing method described in Patent Document 1 still has the following problems. That is, in the manufacturing method described in Patent Document 1, it is essential to prepare a mold in order to perform press molding, and it is necessary to prepare the mold for each shape and size of the planar warming tool. is there. In particular, the surface heating device that is installed and used on the floor surface is generally produced in many sizes, so the cost required to manufacture the mold increases, and a surface heating device of a different shape or size is used. It is difficult to improve production efficiency when it is necessary to exchange molds during production.

  The present invention solves the above-described conventional problems, and enables the production of a planar warming tool without using a mold while preventing adverse effects due to heating of the surface material, and the shape and size are different. It is an object of the present invention to provide a manufacturing method and a manufacturing apparatus that can easily cope with a surface warmer.

In order to solve the above-described problems, a method for manufacturing a planar warming device according to the present invention includes a planar heater unit in which a heater wire is disposed on a soaking sheet containing a metal component, and a laminate on the heater unit. A sheet heating device comprising a sheet-like member, wherein the sheet-like member and the heater unit are stacked with a hot-melt adhesive layer interposed therebetween. The electromagnetic induction heating coil is installed in the proximity of at least one of the front and back surfaces of the laminate and the laminate is moved in a predetermined moving direction, and magnetic lines of force are generated by the electromagnetic induction heating coil. a heating step of melting the adhesive by causing exothermed said soaking sheets of the heater unit is carried out after the heating step, reduce its thickness by pressing the entire laminate Includes a pressing step that, the, in the pressing step, while moving the stack has passed the heating step, the pressing at a predetermined pressure interval both sides in a rectangular pressing surface, most in the pressing step On the upstream side, the laminate is introduced into the pressing surface at an introduction interval larger than the pressing interval .

Moreover, in order to solve the said subject, the manufacturing method of the planar warming tool which concerns on this invention has the planar heater unit by which the heater wire was arrange | positioned in the heat equalization sheet | seat containing a metal component, and the said heater unit An apparatus for manufacturing a planar warming device comprising a sheet-like member laminated on the laminate, wherein the sheet-like member and the heater unit are stacked with a hot-melt adhesive layer interposed therebetween A conveying means for conveying in a preset moving direction, an electromagnetic induction heating means located downstream of the moving direction and including a heating coil, and adjacent to the downstream side of the moving direction of the electromagnetic induction heating means. A pressing unit that presses both sides of the stacked body that is positioned and moves with a rectangular pressing surface to reduce the thickness of the stacked body, and a control unit, and the pressing unit has a predetermined pressing interval. As you press In the most upstream side of the pressing means being adapted to introduce the laminate into the pressing surface in the pressing gap greater than introducing interval, the control means, the front and back surfaces of the laminate is conveyed by said conveying means Applying a magnetic force line generated by the electromagnetic induction heating means to at least one of the heating unit so as to generate heat, melt the adhesive, and press the adhesive. The sheet-shaped member and the heater unit are bonded to each other by pressing the laminated body after melting.

  Furthermore, the present invention includes a planar heater unit manufactured by the above manufacturing method and provided with a heater wire on a soaking sheet containing a metal component, and a sheet-like member laminated on the heater unit. Also included is a planar warming tool in which the heater unit and the sheet-like member are bonded and fixed to each other by a hot-melt adhesive layer.

  The above object, other objects, features, and advantages of the present invention will become apparent from the following detailed description of preferred embodiments with reference to the accompanying drawings.

  The method and apparatus for manufacturing a surface warmer of the present invention enables the production of a surface warmer without using a mold while preventing adverse effects due to heating of the surface material. It is possible to easily cope with different surface heating devices.

It is a perspective view which shows an example of the external shape of the planar warming tool manufactured in the manufacturing method of the planar warming tool which concerns on Embodiment 1 of this invention. It is a perspective view which shows an example of the state before assembling the main body of the planar warming tool shown in FIG. It is sectional drawing which shows an example of the completion state of the main body shown in FIG. It is sectional drawing which shows a specific example of the structural member of the main body shown in FIG. It is a perspective view which shows an example of the specific structure of the heater wire with which the main body shown in FIG. 4 is provided. It is a schematic diagram which shows an example of the preparatory process at the time of manufacturing the main body shown in FIG. (A) And (b) is a schematic diagram which shows an example of the heating process at the time of manufacturing the main body shown in FIG. 3, and a press process. (A) And (b) is a schematic diagram which shows an example of the hot press process at the time of manufacturing the main body shown in FIG. It is a schematic diagram which shows an example of the ultrasonic welding process at the time of manufacturing the main body shown in FIG. It is a schematic diagram which shows an example of the trimming process at the time of manufacturing the main body shown in FIG. (A) is a schematic diagram which shows the case where the roller unit which is a more preferable example of the press process shown to Fig.7 (a) is used, (b) is the roller unit used at the press process shown to (a). It is a schematic diagram which shows the other example. (A) And (b) is a schematic diagram which shows an example of the manufacturing apparatus of the planar warming tool which concerns on Embodiment 2 of this invention. (A) is a perspective view which shows an example of the manufacturing order of the conventional planar warming tool, (b) is sectional drawing which shows the other example of the manufacturing order of the conventional planar warming tool, (c ) Is a cross-sectional view showing a completed state of a conventional planar warming tool.

  The manufacturing method of the planar warming tool which concerns on this invention is a surface provided with the planar heater unit by which the heater wire was arrange | positioned by the soaking | uniform-heating sheet | seat containing a metal component, and the sheet-like member laminated | stacked on the said heater unit. A method of manufacturing a warming tool, comprising: a preparation step of forming a laminate in which the sheet-like member and the heater unit are stacked with a layer of a hot-melt adhesive interposed therebetween; An electromagnetic induction heating coil is installed in proximity to at least one of the front and back surfaces, and magnetic lines of force are generated by the electromagnetic induction heating coil while moving the laminated body in a preset movement direction, so that the soaking of the heater unit is performed. A heating step in which the adhesive is melted by causing the sheet to generate heat, and a pressing step that is performed after the heating step and presses the entire laminated body. While step moving the stack through the, it is configured to press the both sides in the rectangular pressing surface.

  According to the above configuration, the heat for melting the hot-melt type adhesive is obtained from the heat generation of the soaking sheet inside the planar warming tool, so that the adhesive can be efficiently melted in a short time. Can do. Furthermore, since the laminated body in a state where the adhesive is melted is pressed with a rectangular pressing surface while being moved, at least a part of the laminated body can be held in a pressed state for a predetermined time. Therefore, it is possible to continue pressing the laminate for a period of time from the melting of the adhesive layer by the heat generation of the soaking sheet to solidification, and to make the adhesive state of the sheet-like member suitable. it can.

  In the manufacturing method of the said structure, what is necessary is just the structure pressed in the said press process, cooling the said laminated body. Thereby, since the fuse | melted adhesive agent can be rapidly solidified as needed, manufacturing efficiency can be improved.

  In the manufacturing method of the said structure, the layer of the said adhesive agent contained in the said laminated body is comprised as an independent sheet-like member, or is laminated | stacked integrally previously on the said sheet-like member, or both Any configuration may be used. Thereby, according to various conditions such as the material, thickness, and properties of the sheet-like member to be bonded, an adhesive layer can be appropriately provided, so that the adhesive state of the sheet-like member is more suitable. can do.

  In the manufacturing method of the above configuration, the sheet-like member is a surface material that constitutes the surface of the planar warming tool, a back material that constitutes the back surface of the planar warming tool, and a heating material generated from the heater unit. What is necessary is just the structure which is at least any one of the heat insulation sheet which suppresses the heat transfer to the said back side. As a result, a laminated body is formed using at least one of the front surface material, the back surface material, and the heat insulating sheet, which are typical basic components of the surface warmer, and the heating process is performed. The preferred production of

  An apparatus for manufacturing a planar warming device according to the present invention includes a planar heater unit in which a heater wire is disposed on a soaking sheet containing a metal component, and a sheet-like member stacked on the heater unit. An apparatus for manufacturing a warming device, in which the sheet-like member and the heater unit are stacked in a state in which a layer of a hot-melt adhesive is interposed and transported in a preset moving direction Conveying means, electromagnetic induction heating means located on the downstream side in the moving direction and including a heating coil, and both surfaces of the stacked body located adjacent to and downstream of the moving direction in the electromagnetic induction heating means A pressing means that presses a rectangular pressing surface, and a control means, wherein the control means applies the electromagnetic induction heating means to at least one of the front and back surfaces of the laminate conveyed by the conveying means. By Applying the generated magnetic lines of force causes the soaking sheet of the heater unit to generate heat, melt the adhesive, and press the laminated body after the adhesive is melted by the pressing means. Thus, the sheet-like member and the heater unit are bonded.

  According to the above configuration, since the conveying means, the electromagnetic induction heating means, and the pressing means are provided, the control means generates heat by the heating coil and melts the adhesive layer while moving the laminate. Thereafter, the laminate is pressed by the pressing means. In particular, since the pressing means presses with a rectangular pressing surface while moving the laminated body, at least a part of the laminated body can be held in a pressed state for a predetermined time. Therefore, it is possible to continue pressing the laminate for a period of time from the melting of the adhesive layer by the heat generation of the soaking sheet to solidification, and to make the adhesive state of the sheet-like member suitable. it can.

  In the manufacturing apparatus having the above-described configuration, the pressing unit is configured by arranging roller units each having a rotating belt wound around the outer periphery of a plurality of rotating rollers so as to face each other, and pressing the stacked body by the pressing unit. Any configuration may be used as long as the stacked body is moved between the roller units facing each other. Since the pressing means is constituted by a roller unit, it is possible to press the laminate well with a rectangular pressing surface.

  In the manufacturing apparatus having the above configuration, the roller unit may be configured to rotate the rotating belt by rotationally driving at least one of the rotating rollers. Thereby, it is possible to operate the roller unit satisfactorily with a simple configuration.

  The manufacturing apparatus having the above configuration may further include a cooling unit that cools the stacked body while the stacked body is pressed while being moved by the pressing unit. Thereby, since the fuse | melted adhesive agent can be rapidly solidified as needed, manufacturing efficiency can be improved.

  Further, the present invention includes a planar heater unit manufactured by the above manufacturing method and provided with a heater wire on a soaking sheet containing a metal component, and a sheet-like member laminated on the heater unit. Also, a planar warming tool having a configuration in which the heater unit and the sheet-like member are bonded and fixed to each other by a hot-melt adhesive layer is also included.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. In the following description, the same or corresponding elements are denoted by the same reference symbols throughout the drawings, and redundant description thereof is omitted.

(Embodiment 1)
[Configuration of surface heating device]
First, an example of the typical structure of the planar warming tool manufactured by this invention is demonstrated concretely with reference to FIG. 1 thru | or FIG. FIG. 1 is a perspective view showing an example of a completed state of a planar warming tool in Embodiment 1 of the present invention, and FIG. 2 is a perspective view showing an example of a state of the planar warming tool before assembly. 3 is a cross-sectional view showing a completed state of the main body shown in FIG. 2, FIG. 4 is a cross-sectional view showing a detailed structure of members constituting the main body shown in FIG. 3, and FIG. 5 is a main body shown in FIG. It is a perspective view which shows an example of the specific structure of a heater wire with which is provided.

  As shown in FIG. 1, the planar warming tool is provided with a control unit 101 at one end of a main body 100 composed of a plurality of sheet-like members, and is supplied with power from a power cord 102 connected to the control unit 101. It is comprised so that 100 may be heated and it functions as a heating tool which installs and uses on the floor surface of a house. The control unit 101 is a known control unit for controlling the heat generation operation of the main body 100 of the planar warming tool, and includes a display lamp (not shown) configured by a switch, a temperature adjustment knob, a light emitting diode, and the like.

  As shown in FIG. 2, the main body 100 of the surface warmer has a front material 200, an adhesive sheet 300, a heater unit 400, a heat insulating sheet 500, and a back material 600 as main components, and as shown in FIG. Are formed in order to have a cross-sectional shape as shown in FIG.

  As shown in FIG. 4, the surface material 200 is the outermost member of the main body 100 of the planar warming tool and has necessary performance such as design, contamination resistance, and tactile sense as well as mechanical strength. It is. The specific configuration is not particularly limited, but as a typical example, a main component is polyvinyl chloride resin (hereinafter referred to as PVC), and a polyester resin is applied to the back surface of the colored and patterned surface sheet 201. The thing of the structure which has adhere | attached the nonwoven fabric 202 which has a main component with the adhesive agent 203 and has comprised the sheet form can be mentioned. The nonwoven fabric 202 is provided to prevent the heater wire 420 from floating on the surface material 200 after the sheet-like member is bonded and integrated as a surface heating device.

  The adhesive sheet 300 functions as an adhesive member for attaching the surface material 200, and the configuration thereof is not specifically limited. As a typical example, a polyethylene (polyethylene) resin is formed into a sheet shape. It can be exemplified by a flexible sheet form at room temperature, and melts at about 97 ° C. or more to exhibit a function as an adhesive.

  The heater unit 400 is a heat source of the surface heating device, and its configuration is not specifically limited. As a typical example, a heater wire is provided on one side of a soaking sheet 410 mainly composed of aluminum. The thing which has arrange | positioned 420 to the serpentine shape can be mentioned. In addition, as the base material of the soaking sheet 410, the aluminum sheet 411 is used, but it is not limited to this, and as long as it is formed with the material which can be heated with an electromagnetic induction heating apparatus so that it may mention later. Since it is good, other metal materials, such as copper and stainless steel, may be sufficient.

  The soaking sheet 410 is a member used for uniformly diffusing the heat generated by the heater wire 420 over the entire surface of the main body 100, and its configuration is not specifically limited, but a representative example is thermal conductivity. An example is one in which an aluminum sheet 411 having a thickness of about 0.01 mm, which is mainly composed of aluminum, which is a high metal sheet, is used as a base material, and an adhesive resin 412 made of polyethylene resin is coated on both surfaces thereof. be able to. The adhesive resin 412 made of polyethylene resin is melted by being heated to about 97 ° C. or more and exhibits a function as an adhesive.

  Although the specific configuration of the heater wire 420 is not particularly limited, as a typical example, as shown in FIG. 5, a detection wire 422 for detecting the temperature around the center glass fiber 421 is spirally wound, An insulating layer 423 is formed on the outer periphery with nylon resin, a heating wire 424 is spirally wound on the outer periphery of the insulating layer 423, a PVC insulating layer 425 is formed on the outer periphery, and an outer periphery of the insulating layer 425 is formed on the outer periphery. An example in which an adhesive layer 426 made of polyethylene resin is formed can be given.

  As shown in FIG. 2, the heater unit 400 is arranged in a meandering shape so that the start end (one end) of the heater wire 420 is arranged at one corner of the soaking sheet 410 and covers the entire area of the soaking sheet 410. However, the terminal end (the other end) is arranged in the vicinity of the starting end. Further, as shown in FIG. 2, by applying heat with the heater wire 420 disposed, the adhesive layer 426 of the heater wire 420 is melted, and the heater wire 420 is bonded and fixed to the soaking sheet 410.

  The heat insulating sheet 500 is provided in order to suppress the heat generated by the heater unit 400 from being transmitted to the floor surface unnecessarily, and the specific configuration thereof is not particularly limited. A sheet-like foamed urethane resin 501 (foamed urethane sheet 501) having both sides bonded with a non-woven fabric 502 mainly composed of a polyester resin can be exemplified. Similar to the nonwoven fabric 202, this nonwoven fabric 502 is also configured to prevent the heater wire 420 from floating.

  The back material 600 is a member that directly contacts the floor surface of the main body 100 of the planar warming tool, and its specific configuration is not particularly limited, but as a typical example, an olefin elastomer is the main component. An example is one in which the upper surface of the back sheet 601 is coated with an adhesive layer 602 of polyethylene resin. A preferable example of the olefin-based elastomer is a thermoplastic olefin elastomer (hereinafter abbreviated as TPO). TPO has not only mechanical strength but also performance such as cushioning and resistance to slipping, and further has elasticity.

  In the surface warmer according to the present embodiment, the control unit 101 is installed at the corner of the main body 100 formed by assembling the above-described components, and the start and end of the heating wire 424 of the heater unit 400 are connected to the control unit 101. Configured to connect. As shown in FIG. 1, the planar warmer is supplied with power from a power cord 102 connected to the control unit 101, and the heating operation is controlled by the control unit 101, thereby generating a heating function as a planar warmer. Can be demonstrated.

  In addition, the planar warming tool manufactured by this invention may be provided with structures other than the main body 100, the control part 101, and the power cord 102, and is one of each sheet-like member which comprises the main body 100 mentioned above. The sheet-like member may be omitted. Moreover, the main body 100 may include other members having a non-sheet shape in addition to the sheet-like member described above.

  In addition, the adhesive used for the planar warming device according to the present embodiment is particularly a specific type as long as it is a heat-melt type (hot-melt) whose main component is a material to be melted by heat. It is not limited. In the configuration examples shown in FIG. 2 and FIG. 4, the adhesive 203 (surface material adhesive layer) integrally laminated on the surface material 200 is formed as an independent sheet-like member as a layer of the hot-melt adhesive. The adhesive sheet 300 and the heater sheet 400 have a soaking sheet 410 that includes an adhesive resin 412 (a soaking sheet adhesive layer) laminated on both surfaces of the aluminum sheet 411, both of which are polyethylene resins, Although it is a layer composed of at least an olefinic thermoplastic resin such as a polypropylene resin, other known thermoplastic resins may be used, or a thermoplastic material other than the resin may be used. In addition, when the hot-melt adhesive is mainly composed of a thermoplastic resin, it may be a polymer alloy in which a plurality of thermoplastic resins are mixed, or may include known additives other than the resin. It may be a thermoplastic resin composition.

[Method for manufacturing surface heating device]
Next, a typical example of a method for manufacturing a planar warming tool including the main body 100 described above will be specifically described with reference to FIGS. 6 is a schematic diagram showing an example of a preparation process in the manufacturing process of the main body 100 as a schematic cross-sectional view, and FIGS. 7A and 7B show an example of a heating process and a pressing process of the main body 100 as a schematic cross-sectional view. FIGS. 8A and 8B are schematic views showing, as a schematic cross-sectional view, an example of a hot press process for bonding the back material 600 and molding the peripheral part of the main body 100, and FIG. FIG. 10 is a schematic diagram showing an example of an ultrasonic welding process for welding the peripheral part of 100 as a schematic cross-sectional view, and FIG. 10 shows an example of a trimming process for cutting an unnecessary part of the peripheral part of the main body 100 as a schematic cross-sectional view. It is a schematic diagram.

  The manufacturing method of the planar warming tool described in the present embodiment is a manufacturing method including a preparation process, a heating process, a pressing process, a thermal pressing process, an ultrasonic welding process, and a trimming process. In accordance with a specific configuration (particularly a specific configuration of the main body 100), other steps may be included, or some of the steps may be omitted.

(1) Preparation process First, a preparation process is demonstrated. The preparation step is a step of forming a laminate by stacking materials such as sheet-like members constituting the main body 100. Specifically, as shown in FIG. 6, the adhesive layer 602 of the back material 600 is disposed on a horizontal platform 710, the heat insulating sheets 500 are stacked thereon, and the heater wire 420 is placed on the lower side. Then, the heater units 400 are stacked, the adhesive sheets 300 are stacked thereon, and the surface material 200 is stacked thereon so that the nonwoven fabric 202 is on the lower side.

  Therefore, in this preparatory step, the sheet-like members constituting the main body 100, that is, the surface material 200, the adhesive sheet 300, the heater unit 400, the heat insulating sheet 500, and the back surface material 600 are not bonded in this order. It will be stacked on the platform 710. In the state where these sheet-like members are stacked, a laminated body (or a stacked body) in which the sheet-like members are not bonded to each other is configured. This laminate is referred to as a work 110 for convenience of explanation. Moreover, although the workpiece | work 110 which passed through the press process mentioned later, a heat press process, etc. will be in the state by which the sheet-like member was bonded together, in the following description, if it is before completing as the main body 100, it will be called the workpiece | work 110. To do.

  In this preparation step, as shown in FIG. 4, the heater unit 400 has a smaller outer dimension than other sheet-like members. Therefore, in the work 110, it is important to arrange the heater unit 400 in the center of the heat insulating sheet 500. . The workpieces 110 stacked in the preparation process are then sent to the heating process.

  Depending on the configuration of the surface warmer, the workpiece 110 prepared in the preparation step is stacked with at least one sheet-like member and the heater unit 400 with a hot-melt adhesive layer interposed therebetween. Anything can be used. For example, the workpiece 110 (laminated body) may be configured by only the surface material 200, the adhesive sheet 300, and the heater unit 400, or the workpiece 110 may be configured by only the back surface material 600, the heat insulating sheet 500, and the heater unit 400. .

  At this time, the adhesive layer may be configured as an independent sheet-like member like the adhesive sheet 300, or laminated in advance on another sheet-like member like the adhesive layer 602 of the back material 600. Alternatively, as in the example shown in FIG. 6, an independent sheet-like member (adhesive sheet 300) and an adhesive layer (adhesive layer 602) previously laminated on another sheet-like member are used in combination. May be.

  In the preparation step, a sheet-like member positioning device that positions the sheet-like members may be used in order to stack the sheet-like members including the heater unit 400 more efficiently. The sheet-like member positioning device only needs to include a work table (corresponding to the platform 710) on which the sheet-like member can be placed, and a positioning reference portion provided integrally or detachably on the work table. Examples of the positioning reference portion include protrusions, steps, depressions, and the like provided at positions corresponding to the corner portions of the sheet-like member, and may further include a ruler with a scale for measuring the length. . In addition, a known stacking device or the like can be used for stacking the sheet-like members.

(2) Heating step Next, in the heating step, an electromagnetic induction heating coil is installed close to at least one of the front and rear surfaces of the laminate (work 110) prepared in the preparation step, and magnetic lines of force are generated by the electromagnetic induction heating coil. In this step, the heater unit 400 included in the workpiece 110 (more specifically, the aluminum sheet 411 constituting the soaking sheet 410) is heated to melt the adhesive layer. In the present embodiment, it is very preferable to use a plurality of electromagnetic induction heating coils. However, this point will be described later, and FIG. 7A illustrates the case where a single electromagnetic induction heating coil is used. A standard heating process will be described.

  As shown in FIG. 7 (a), as the equipment (heating device) used in the heating process, in this embodiment, the main body 100 is placed and transported in the horizontal direction as indicated by the block arrow A. An apparatus (conveying means) 720 and an electromagnetic induction heating apparatus 721 including an oval heating coil 722 larger than the width of the main body 100 are used. The electromagnetic induction heating device 721 is disposed in a part of a region where the aluminum sheet 411 to be heated is to generate heat. Specifically, in the electromagnetic induction heating device 721, the heating coil 722 is provided in the width direction in the vicinity of the rear end portion of the conveying device 720 (in the vicinity of a pressing roller 730 described later).

  The heating coil 722 is a long plate-like coil (or oval coil) longer than the width of the workpiece 110, and is installed at a position orthogonal to the moving direction (block arrow A direction) in the present embodiment. The spread of the heating coil 722 substantially becomes a heating surface of the workpiece 110 by the heating coil 722. In the present embodiment, the length in the longitudinal direction of the heating surface of the heating coil 722 is larger than the width of one side of the workpiece 110. Further, the heating surface of the heating coil 722 does not include the entire surface of the workpiece 110 but is set one-dimensionally so as to heat a part of the length of the workpiece 110.

  The workpieces 110 stacked in the preparation process are moved in the horizontal direction indicated by the block arrow A by the transfer device 720. When the magnetic field lines are generated from the heating coil 722 of the electromagnetic induction heating device 721 disposed above as the workpiece 110 moves, the magnetic field lines are applied to the workpiece 110, so that an eddy current is generated in the aluminum sheet 411 of the heater unit 400. The aluminum sheet 411 itself heats up due to the eddy current and the resistance of the aluminum sheet 411. The adhesive resin 412 made of polyethylene resin coated on both surfaces of the aluminum sheet 411 and the adhesive sheet 300 adhered and laminated on the heater unit 400 are melted by the heat generated from the aluminum sheet 411.

  Since the workpiece 110 receives the magnetic lines of force from the heating coil 722 while being conveyed by the conveying device 720 at a predetermined speed, the heat generation range of the aluminum sheet 411 constituting the workpiece 110 also moves sequentially at the predetermined speed. As a result, the entire area of the aluminum sheet 411 that should generate heat can be heated.

  Thus, the aluminum sheet 411 is heated to a temperature sufficient for the adhesive sheet 300 to melt by the magnetic lines of force generated from the heating coil 722 of the electromagnetic induction heating device 721. For this purpose, the heating temperature of the aluminum sheet 411 is about 130 ° C. to 175 ° C. At this time, since heat generated from the aluminum sheet 411 is transferred to the surface material 200 via the adhesive sheet 300, the outer surface of the surface material 200 is not directly exposed to heat although there is a certain temperature rise. Therefore, the temperature of the outer surface of the surface material 200 is a temperature at which the surface of the surface material 200 does not deteriorate or does not cause deformation that impairs the design property due to heat even if it does not deteriorate. It can be suppressed to 120 ° C. or lower. Therefore, by using such a method, it is possible to effectively prevent the surface material 200 from being adversely affected by heating (deformation, alteration, or the like that impairs designability).

  Further, since the adhesive resin 412 made of polyethylene resin and the adhesive sheet 300 are melted in a few seconds, if the electromagnetic induction heating device 721 is operated while moving the workpiece 110 at a predetermined speed by the conveying device 720, the adhesive resin 412 and As the workpiece 110 moves, the adhesive sheet 300 is continuously melted immediately below the electromagnetic induction heating device 721 (heating coil 722). As a result, the adhesive resin 412 and the adhesive sheet 300 can be melted over the entire surface.

  At this time, it is preferable to control so that the distance (interval) between the heating coil 722 of the electromagnetic induction heating device 721 and the aluminum sheet 411 is kept constant, and the workpiece 110 on which the sheet-like members are laminated is lightly pressed and maintained at a predetermined thickness. Move while.

  Moreover, it is preferable that the heater unit 400 is arrange | positioned so that the heater wire 420 may become a lower side in the workpiece | work 110 among sheet-like members. That is, it is preferable to install the work 110 so that the surface of the work 110 on the side where the heater wire 420 of the soaking sheet 410 is not disposed is close to the heating coil 722. When the workpiece 110 is installed in this way, the aluminum sheet 411 is disposed so as to face the heating coil 722 of the electromagnetic induction heating device 721. Therefore, the distance (interval) between the heating coil 722 and the aluminum sheet 411 is kept constant. Therefore, the entire surface of the aluminum sheet 411 can be heated uniformly.

  Further, when the heater unit 400 is arranged as described above, the aluminum sheet 411 is interposed between the heating coil 722 of the electromagnetic induction heating device 721 and the heater wire 420. Therefore, since heat generation of the heater wire 420 itself can be suppressed, temperature unevenness can be suppressed. As a result, the heating action by the aluminum sheet 411 can be realized more stably and uniformly.

  In the heating process, as shown in FIG. 7A, the heater unit 400 is arranged such that the arrangement direction of the heater wire 420 and the conveyance direction (block arrow A direction, movement direction) of the conveyance device 720 are orthogonal to each other. However, the present invention is not limited to this, and the work 110 may be arranged so that the arrangement direction of the heater wire 420 coincides with the block arrow A. .

  For example, when the heater wire 420 itself generates heat by the electromagnetic induction heating device 721 in a state where the conveying direction and the arrangement direction of the heater wire 420 are substantially orthogonal, large temperature unevenness occurs due to the heat generated by the heater wire 420. In this case, if the work 110 is arranged so that the arrangement direction of the heater wire 420 is substantially coincident with the conveying direction, currents in opposite directions to the heater wire 420 can be generated. Heat generation can be suppressed and occurrence of temperature unevenness can be suppressed in some cases.

  In addition, although the heating process shown to Fig.7 (a) is used for adhesion | attachment with the surface material 200, the heater unit 400, and the heat insulation sheet 500, the use of a heating process is not limited to this, The heat insulation sheet 500 and a back surface It can also be used for adhesion to the material 600. Specifically, in FIG. 7A, the front and back surfaces of the workpiece 110 may be replaced and installed in the transfer device 720. Furthermore, as shown in FIG. 7B, the upper side (surface material 200) In addition, a pair of heating coils 722 (and the electromagnetic induction heating device 721) are installed so as to face both the front and back surfaces of the workpiece 110 by separately providing an electromagnetic induction heating device 721 on the lower side (back surface material 600 side). May be.

  In this case, if a sheet-like member 430 having the same configuration as that of the soaking sheet 410 is sandwiched between the heat insulating sheet 500 and the back surface material 600, adhesion of the surface material 200, the heater unit 400, and the heat insulating sheet 500, and heat insulation Bonding of the sheet 500 and the back surface material 600 can be performed in a single heating step. Therefore, for example, by performing only the step pressing described later as a separate step, the heat pressing step described later can be substantially omitted.

(3) Pressing Step Next, in the present embodiment, the pressing step is a step that is integrally performed continuously with the heating step, as shown in FIG. In this pressing step, the entire workpiece 110 heated by the pressing device is pressed. The equipment used in the pressing process may be equipment (pressing device) capable of continuously pressing the workpiece 110. In the present embodiment, as shown in FIG. A pressing roller 730 including a roller 731 and a lower roller 732 is used. In addition, the structure of a press apparatus is not limited to the press roller 730, For example, other well-known structures, such as a press apparatus, may be sufficient.

  The upper roller 731 and the lower roller 732 constituting the pressing roller 730 can be rotationally driven in the direction of arrow B, respectively, and the workpiece 110 can be moved between them. Further, as indicated by the black block arrow C, the upper roller 731 can be pressed downward. As a result, the workpiece 110 can be continuously pressed.

  The pressing roller 730 is preferably arranged at a position overlapping or adjacent to a part of the area of the aluminum sheet 411 that should generate heat. Specifically, in the present embodiment, as shown in FIG. 7A, a pressing roller 730 is provided on the downstream side in the moving direction of the workpiece 110 (block arrow A) when viewed from the electromagnetic induction heating device 721. ing. At this position, the workpiece 110 can be pressed by the pressing roller 730 following the location where the aluminum sheet 411 generates heat in the heating process.

  It is essential that the driving speed of the pressing roller 730 be linked to the heating time of the heating process, and it is important that the pressing roller 730 be arranged close to the heating coil 722 so that the resin melted by the heating process can be pressed in as short a time as possible. is there. In this embodiment, as schematically shown in FIG. 7A, the heating process equipment and the pressing process equipment are integrally configured. By pressing the workpiece 110 in the pressing step, the surface material 200, the heater unit 400, and the heat insulating sheet 500 are bonded together via the adhesive resin 412 and the adhesive sheet 300.

(4) Hot press process A hot press process is performed after a press process. The hot press process is a process in which two different operations are performed simultaneously, as will be described later. Specifically, as shown in FIG. 8A, the equipment used for the hot press process is a hot press device 740. A lower heat plate 742 that covers the entire surface of the workpiece 110 is disposed on the lower die 741 of the heat press apparatus 740, and an upper heat plate 746 that presses the peripheral portion of the workpiece 110 is provided on the upper die 745. 8A and 8B, the lower heating plate 742 and the upper heating plate 746 are hatched with cross lines for convenience of explanation.

  In the hot pressing process, the adhesion of the back surface material 600 and the step pressing molding of the peripheral part of the work 110 are performed simultaneously. Therefore, the back surface material 600 is heated by the lower heat plate 742 disposed on the lower mold 741, and the adhesive layer 602 (see FIG. 4) coated on the upper surface of the back surface sheet 601 of the back surface material 600 is melted. And the back material 600 and the heat insulation sheet 500 are adhere | attached by pressing the workpiece | work 110 whole by a hot press process. Further, by pressing the peripheral part of the work 110 while heating it with the upper heating plate 746 provided in the upper mold 745, the peripheral part of the work 110 is step-formed so as to be thinner than the central part. As shown in FIG. 8B, the thickness of the warming surface portion 111 that is the center portion is larger than the thickness of the stepped portion 112 that has been stepped by the step pressing.

  The upper heating plate 746 has a substantially rectangular frame shape having an opening on the inner side so as to correspond to the peripheral portion in order to press-mold the peripheral portion of the work 110. A concave curved surface 747 is formed at the inner end (periphery) of the upper heating plate 746 as shown in FIG. By providing the concave curved surface 747, as shown in FIG. 8 (b), the inner side of the stepped portion 112 generated by stepping molding (outward as viewed from the central heating surface portion 111) is not a stepped surface. The convex curved surface 113 can be molded.

(5) Ultrasonic welding process An ultrasonic welding process is performed after a hot press process. In the ultrasonic welding step, the peripheral portion of the workpiece 110 that has been step-formed by the hot press step, that is, the step-pressing portion 112 is welded. As shown in FIG. 9, the equipment used in this step is an ultrasonic welder 750 including a horn 751 that moves along the peripheral portion (step pressing portion 112) of the workpiece 110.

  As described above, the heater unit 400 is formed to have a smaller outer dimension than other sheet-like members. Therefore, the heater unit 400 is located on the warming surface portion 111 that is the central portion of the workpiece 110, but the heater unit 400 is hardly located on the stepped portion 112 that is the peripheral portion of the workpiece 110. Therefore, the stepped portion 112 is composed of the surface material 200, the adhesive sheet 300, the heat insulating sheet 500, and the back surface material 600, and as a result, is entirely formed of a thermoplastic resin material.

  That is, the stepped portion 112 is a portion formed by a thermoplastic material around the main body 100 in addition to being a portion molded thinner than the warming surface portion 111 in the central portion by step forming in the heat pressing step of the previous step. It is a small part of. Therefore, by applying an ultrasonic wave to the stepped portion 112 by the horn 751, the joint portion of each sheet-like member is heated and melted and welded, so that the periphery of the work 110 is sufficiently welded and fixed. Can do.

  It should be noted that the horn 751 to which the ultrasonic waves are applied may be configured so as to perform welding sequentially while moving on the peripheral portion (step pressing portion 112) of the workpiece 110. Further, in order to perform the ultrasonic welding process, the work 110 only needs to be placed on the work table 711, but the work table 711 is provided integrally with the ultrasonic welding machine 750. It may be a thing, may be prepared as an independent thing, platform 710 used in the preparation process, lower mold 741 used in the hot press process, etc. may be used. In addition, if the stepped portion 112 can be appropriately welded and fixed, a welding device other than the ultrasonic welder 750 can be used.

(6) Trimming process The trimming process is performed as the last process in the present embodiment and is a finishing process of the main body 100 performed after the ultrasonic welding process, and the equipment used is a trimming apparatus. Specifically, as shown in FIG. 10, in the trimming step, unnecessary portions of the peripheral portion (step pressing portion 112) of the work 110 placed on the work table 711 are cut off and shaped by the trimming device. . In the present embodiment, a cutter device 760 including a disk-shaped rotary cutter is used as the trimming device. Although the configuration of the cutter device 760 is not particularly limited, two rotary cutters that simultaneously cut while moving the stepped portions 112 on both sides in the width direction of the work 110, and the longitudinal direction of the work 110 A configuration including a single rotary cutter that cuts while moving the step pressing portion 112 on one side of the above can be mentioned.

  By cutting off unnecessary portions of the peripheral portion (step pressing portion 112) of the workpiece 110 welded and fixed by ultrasonic welding using the cutter device 760, the dimensions of the workpiece 110 are set in a predetermined range. Thereby, the main body 100 is completed. In order to perform the trimming step, the work 110 only needs to be placed on the work table 711. The work table 711 is provided integrally with the cutter device 760. Alternatively, it may be prepared as an independent one, the platform 710 used in the preparation process, the lower mold 741 used in the hot press process, or the like may be used, or used in the ultrasonic welding process. The same work table 711 may be used.

(7) Other steps, etc. After that, the control unit 101 and the power cord 102 are attached to the main body 100, and if necessary, the main body 100 is subjected to decoration processing, etc. By performing this process, a planar warming tool is completed.

  Note that details of the preparation process, the heating process, the pressing process, the hot pressing process, the ultrasonic welding process, and the trimming process are not limited to the above-described methods. For example, the heating process and the pressing process are performed while moving the main body 100 in the moving direction of the block arrow A, but the present invention is not limited to this, and the electromagnetic induction heating device 721 and the main body 100 are fixed in place. The pressing roller 730 may be moved.

  Moreover, you may make it implement a press process simultaneously with a heating process. In the case of this method, the pressing step is preferably pressed by a press. When this processing method is adopted, the capacity of the electromagnetic induction heating device can be further reduced, and capital investment can be suppressed.

  Here, in the manufacturing method of the planar warming tool mentioned above, the heating process using the electromagnetic induction heating device 721 is particularly important. As described above, the heating step is a step in which the resin is melted and bonded by causing the aluminum sheet 411 itself, which is one of the constituent members of the heater unit 400, to generate heat by the electromagnetic induction heating device 721.

  The greatest feature of the heating process is that heat necessary for melting the resin is generated from the aluminum sheet 411 that is in direct contact with the resin. By sandwiching between the sheet 500 and the back surface material 600, wasteful heat radiation to the outside can be suppressed. As a result, the resin can be melted with a much smaller amount of heat compared to a heating method in which heat is applied from the outside, less power is required for heating, and a high energy saving effect can be obtained.

  In addition, since the temperature of the surface portion of the main body 100 does not increase by generating heat from the inside of the main body 100, the material used for the surface portion, for example, the surface material 200 is heated even if a low heat-resistant temperature is used. It is possible to effectively prevent the adverse effects (deformation, alteration, etc.) caused by.

  In addition, the aluminum sheet 411 is originally provided in the main body 100 for the purpose of uniformly diffusing the heat generated by the heater wire 420 over the entire surface of the main body 100 when the planar warming tool is used. is there. Therefore, by using it in the manufacturing process in addition to the original function, a very large effect can be obtained in terms of manufacturing cost and man-hours.

  In addition, since the aluminum sheet 411 as a heat source is in direct contact with the resin to be melted, heating can be performed in a short time in units of seconds (about 10 seconds or less, preferably about 2 or 3 seconds). Therefore, it is not necessary to heat the entire surface of the main body 100 at the same time, and it is possible to partially perform the heating, melting, and bonding processes as a flow operation while moving the main body 100. In addition, since heating is partially performed, the electromagnetic induction heating device 721 used for heating can be reduced in size and size, can reduce equipment costs, and lower the maximum electric capacity during processing. be able to.

  Moreover, in the manufacturing method of the present invention using electromagnetic induction heating, a mold for a heating process prepared corresponding to the dimensions of the main body 100 which has been necessary in the past is unnecessary, and the main body as the electromagnetic induction heating device 721 is used. A heating coil 722 corresponding to the maximum dimension of 100 may be prepared. Accordingly, since the entire width direction of the aluminum sheet 411 which is a heat generation source under the heating coil 722 can be heated, the main body 100 having a width smaller than the heating coil 722 can be heated with the same equipment. is there. Therefore, it is not necessary to prepare a plurality of heating process facilities in accordance with the size of the main body 100, and the facility cost can be reduced in this respect as well.

[Pressing method in pressing step]
Here, in the present embodiment, in the pressing step described above, a roller unit formed by winding a rotating belt around the outer periphery of a plurality of rotating rollers is used instead of the pressing roller 730 described in FIG. . An example of this roller unit will be specifically described with reference to FIGS. 11 (a) and 11 (b). FIG. 11A is a schematic view showing a particularly preferable example of the heating step and the pressing step in the present embodiment as a schematic cross-sectional view, and FIG. 11B shows a roller unit used in FIG. It is a schematic diagram of the other structural example.

  As shown in FIGS. 11A and 11B, in this embodiment, the roller unit 735 or 733 is used as the pressing means in the pressing step. Among these, as shown in FIG. 11A, the roller unit 735 includes a pair of an upper roller unit 735a and a lower roller unit 735b, all of which have three rotating rollers 737a, 737b and 737c and their outer periphery. The rotating belt 736 is wound around. An area of the rotating belt 736 facing the position where the upper roller unit 735a and the lower roller unit 735b face each other is an area for pressing the workpiece 110. Then, the rotation belt 736 is stretched by the rotation rollers 737a to 737c, whereby a rectangular (substantially rectangular or belt-like) pressing surface is formed in the region.

  The roller unit 735 is provided with a cooling means for cooling the workpiece 110. Specifically, a cooling air passage 738 is provided at the center of rotation of each of the rotation rollers 737a, 737b, and 737c, and a blower 760 that blows cool air is connected to the cooling air passage 738. Yes. Therefore, a cooling unit is configured by the blower 760 and the cooling air passage 738. Further, the electromagnetic induction heating device 721, the roller unit 735, and the blower 760 operate under the control of the manufacturing device control unit (control unit) 712. In FIG. 11A, the manufacturing apparatus control unit 712 is simply described as “control unit”, but needless to say, it is different from the control unit 101 of the planar warming tool.

  Of the upper roller unit 735a and the lower roller unit 735b constituting the roller unit 735, the lower roller unit 735b is fixedly installed at a fixed position. On the other hand, the upper roller unit 735a is provided with a pressure device (not shown) that can move the upper roller unit 735a in the vertical direction, and the work 110 transported and moved by the transport device 720 from the upper surface in the block arrow C direction. It is the structure which can be pressed to.

  The lower roller unit 735b is provided with a driving device (not shown) that rotationally drives at least one of the rotating rollers 737a to 737c. The rotating device 737a to 737c rotates by rotating the rotating rollers 737a to 737c. The moving belt 736 is rotated in the direction of arrow B, and the work 110 placed on the lower roller unit 735b can be conveyed and moved in the moving direction indicated by the block arrow A at a predetermined speed.

  When the upper roller unit 735a is moved downward toward the lower roller unit 735b by the pressure device, the work 110 placed on the lower roller unit 735b is sandwiched between the lower roller unit 735b and the lower roller unit 735b. When the work 110 is transported, the rotating belt 736 of the upper roller unit 735a also follows and rotates. Accordingly, the upper roller unit 735a does not require a driving device, but when it is desired to transport and move the workpiece 110 with a larger force, the upper roller unit 735a may be provided with a driving device.

  The conveyance speed of the workpiece 110 by the roller unit 735 may be set to a speed synchronized with the conveyance speed by the conveyance device 720 in the heating process, but may be set to a different speed as necessary. In the manufacturing process, when it is better to change the conveying speed of the conveying device 720 or the conveying speed by the roller unit 735, these conveying speeds may be changed under the control of the manufacturing apparatus control unit 712.

  In addition, as shown in FIG. 11B, in this embodiment, a rotating belt 736 is stretched by a pair of rotating rollers 737d and 737e, and the pressing surface support plate 739a, A roller unit 733 configured to install 739b can be used. The roller unit 733 includes a pair of opposed upper roller unit 733a and lower roller unit 733b, and the upper roller unit 733a is configured to be movable downward (in the direction of the block arrow C). 11 (a), but a pressing surface support plate 739a is installed on the back surface of the rotating belt 736 of the upper roller unit 733a, and on the back surface of the rotating belt 736 of the lower roller unit 733b. A pressing surface support plate 739b is provided.

  By providing the pressing surface support plates 739a and 739b, the back surface of the rectangular pressing surface of the rotating belt 736 can be supported. Therefore, when the workpiece 110 is pressed, the pressure on the pressing surface is made uniform as a whole. can do. The pressing surface support plates 739a and 739b not only make the pressing surface substantially flat, but also the distance between the pressing surface of the upper roller unit 733a and the pressing surface of the lower roller unit 733b (referred to as a pressing interval for convenience). It also has a function to keep it constant.

  Furthermore, if the pressing surface support plates 739a and 739b have a high thermal conductivity such as a stainless steel plate, the heat of the work 110 is transmitted to the pressing surface support plates 739a and 739b via the rotating belt 736, Since it is diffused, it can function as a cooling means. As long as this cooling can sufficiently solidify the adhesive, it is not necessary to provide a cooling means such as a blower type or a water cooling type.

  Further, as shown in FIG. 11B, the pressing interval G0 of the roller unit 733 may be constant from the upstream side to the downstream side in the moving direction, but the pressing step by the roller unit 733 is to reduce the thickness of the workpiece 110. Since it is also a process of reducing, it is preferable that the most upstream side of the roller unit 733 has an introduction interval G1 slightly larger than the pressing interval (G1> G0). As a result, the workpiece 110 having a thickness larger than the set pressing interval G0 can be smoothly introduced between the upper roller unit 733a and the lower roller unit 733b, and the continuity from the heating process to the pressing process is improved. Can be made.

  Here, the press interval G0 can be appropriately set according to various conditions. Since the upper roller unit 733a is configured to be movable downward, the upper roller unit 733a is moved up and down in accordance with conditions such as the type or number of sheet-like members constituting the workpiece 110 and the thickness of the workpiece 110 after pressing. By doing so, the pressing interval G0 can be set as appropriate.

  The introduction interval G1 may be realized by any method as long as it is set to be larger than the pressing interval G0. In the example shown in FIG. 11B, in the lower roller unit 733b, the upper surface of the upstream rotary roller 737d and the upper surface of the pressing surface support plate 739b are substantially the same surface, whereas the upper roller unit In 733a, the lower surface of the pressing surface support plate 739a is positioned below the lower surface of the rotating roller 737d by a distance H. As a result, the lower surface of the pressing surface support plate 739a positions the rotating belt 736 downward, and the rotating roller 737d of the upper roller unit 733a positions the rotating belt 736 on the upper side. An introduction interval G1 larger than the pressing interval G0 is secured.

  In the present embodiment, the cooling means is an air-cooled type constituted by the cooling air passage 738 and the blower 760, or a heat radiating plate like the pressing surface support plates 739a, 739b. It is not limited to this, A cooling device of other systems, such as a water cooling type, may be used. Further, the cooling means is not an essential component for the roller units 733 and 735. For example, if the workpiece 110 is slowed down so that the adhesive layer is solidified while passing through the roller units 733 and 735, the workpiece 110 may be omitted. Therefore, for example, it may be possible to omit the cooling means by using the rotating belt 736 and the rotating rollers 737a to 737e having high thermal conductivity.

  An example in which the pressing process is performed using the roller unit 735 (or roller unit 733) having the above-described configuration will be described. The workpiece 110 heated in the heating process is transported by the transport device 720 and moved to the roller unit 735. Then, in a state where the workpiece 110 is sandwiched between the upper roller unit 735a and the lower roller unit 735b, the rotating belt 736 is rotated via the rotating rollers 737a to 737c by the driving device provided in the lower roller unit 735b. As a result, the workpiece 110 continues to move between the upper roller unit 735a and the lower roller unit 735b in the moving method (the direction of the block arrow A).

  During this movement, the upper roller unit 735a continuously presses the upper surface of the workpiece 110 by the pressure device provided in the upper roller unit 735a. Furthermore, since the pressing surface of the upper roller unit 735a and the pressing surface of the lower roller unit 735b both have a rectangular shape, a wide range can be pressed simultaneously with a constant pressure. Therefore, in the pressing step, it is possible to continue pressing for a predetermined time until the melted adhesive in the work 110 is solidified. Therefore, the sheet-like member (surface material 200, heater unit) constituting the work 110 is used. 400 and the heat insulating sheet 500) can be adhered well. Further, during this pressing and movement, since the cold air is blown to the cooling air passage 738 provided in the rotating rollers 737a to 737c, the melted adhesive layer is cooled. As a result, solidification of the adhesive melted in the heating process is promoted, so that the sheet-like member is appropriately bonded via the adhesive layer.

  As described above, in the present embodiment, the roller unit 735 (or the roller unit 733) makes it possible to ensure a longer pressing time of the workpiece 110, and presses until the molten adhesive layer is sufficiently solidified. Can be maintained. As a result, the adhesion performance of the sheet-like member can be improved, and the dimensional accuracy of the lamination of the sheet-like member can be ensured.

  Here, in the present embodiment, a pressing device (pressing means) other than the roller unit 735 or 733 may be used. In other words, in the present invention, the workpiece 110 after the heating step is pressed with a rectangular pressing surface while being moved, so that the workpiece 110 is held in a pressed state for a predetermined time, and the sheet-like member and the heater unit 400 are held. Any pressing device other than the roller unit 735 or 733 can be used as long as it can be bonded.

  Specifically, for example, a structure in which a plurality of rotating rollers are arranged in a line along the moving direction and the work 110 is sandwiched and moved between a pair of upper and lower roller arrays, and three or more roller units are provided. A configuration in which the workpiece 110 is pressed using, a configuration in which a plate-like member that can move in the moving direction while pressing at least one of the front and back surfaces of the workpiece 110 is included, and the like is not particularly limited.

  Furthermore, in this embodiment, the roller unit 735 or 733 has a function of pressing and transporting the workpiece 110, but an independent moving unit or transport unit may be provided in addition to the roller unit 735 or 733. . For example, an independent moving means or conveying means for moving the workpiece 110 in the moving direction can be provided on the downstream side of the roller unit 735 or 733.

  In the present embodiment, a single electromagnetic induction heating device 721 is used in the heating step, but a plurality of electromagnetic induction heating devices 721 may be used. Also, a plurality of electromagnetic induction heating coils may be used instead of one. Therefore, a single electromagnetic induction heating device 721 may be configured to include a single heating coil 722, or a single electromagnetic induction heating device 721 may be configured to include a plurality of heating coils 722. Good. In addition, if the electromagnetic induction heating means is preferably provided with a plurality of electromagnetic induction heating coils, the coil control unit that drives and controls the electromagnetic induction heating coil may be independently configured as another device.

  Further, for example, as the transport device 720 used in the present embodiment, a chucking transport device that fixes and transports the workpiece 110 by chucking is used, but a conveyor device, a transport device using a manipulator, or the like is used. Other configurations of the transfer device can be used.

  In other words, in the present invention, when manufacturing the planar warming tool, the stack (work 110) is transported in a preset moving direction (in the present embodiment, the transport device 720) and the downstream in the moving direction. An electromagnetic induction heating means including a plurality of electromagnetic induction heating coils that are positioned adjacent to each other, and a press that presses both surfaces with a rectangular pressing surface while moving the laminate, such as roller units 733 and 735 It goes without saying that a manufacturing apparatus having a configuration including means may be used, and other configurations are not specifically limited.

  Here, the present invention includes a planar warming tool manufactured by the manufacturing method described above. Specifically, the surface warmer according to the present invention is manufactured by the manufacturing method or the manufacturing apparatus, and the above-described heater unit 400, a sheet-like member stacked on the heater unit 400, specifically, a surface material. 200, a heat insulating sheet 500, and a back material 600, and the heater unit 400 and the sheet-like member are bonded and fixed to each other by a layer of a hot-melt adhesive. The sheet heating device according to the present invention has such a configuration, so that each sheet-like member including the heater unit 400 is well bonded and fixed, and heat is applied from the outside during the manufacturing process. Since it does not substantially exist, the quality of the front and back surfaces can be improved.

(Embodiment 2)
In the first embodiment, the method for manufacturing the planar warming tool has been mainly described. However, the present invention is not limited to the manufacturing method, and includes a manufacturing apparatus for the planar warming tool. Therefore, an example of a manufacturing apparatus for a planar warming tool will be specifically described with reference to FIGS. 12 (a) and 12 (b). 12 (a) and 12 (b) are schematic diagrams showing an example of a manufacturing apparatus for a planar warming tool according to Embodiment 2 of the present invention.

  For example, a surface heating device manufacturing apparatus 700A (hereinafter simply referred to as a manufacturing apparatus) shown in FIG. 12A includes a work heating apparatus 701 for performing a heating process and a pressure application for performing a pressing process. An aligning device 702 is provided.

  The workpiece heating device 701 includes electromagnetic induction heating units 723a and 723b, a heating unit moving mechanism 724, a workpiece chuck conveyance unit 725, and a conveyance support base 726. Since the electromagnetic induction heating units 723a and 723b are substantially the same as the electromagnetic induction heating device 721 described in the first to third embodiments, the description thereof is omitted. These electromagnetic induction heating units 723a and 723b include one heating coil 722a and 722b, respectively. Therefore, the workpiece heating apparatus 701 shown in FIG. 12A is configured to include two electromagnetic induction heating coils, unlike the configuration example including one electromagnetic induction heating coil in the first embodiment. .

  The heating unit moving mechanism 724 moves the interval between the electromagnetic induction heating units 723a and 723b, that is, the interval between the heating coils 722a and 722b (referred to as a heating interval D) in an adjustable manner, both in FIG. As indicated by the direction block arrow E, the electromagnetic induction heating units 723a and 723b can be moved back and forth along the movement direction (block arrow A). The specific configuration is not particularly limited, and a known mechanical movement mechanism can be suitably used.

  The upstream electromagnetic induction heating unit 723a performs preliminary heating, and the downstream electromagnetic induction heating unit 723b is provided to perform main heating. Here, if the interval between the electromagnetic induction heating units 723a and 723b is too large, the temperature of the soaking sheet 410 (aluminum sheet 411) that generates heat by the preheating may be lower than the preferable temperature range. On the other hand, if the interval is too small, the heating regions of the electromagnetic induction heating units 723a and 723b overlap, and the temperature of a part of the soaking sheet 410 may become excessively high. Therefore, by making it possible to adjust the heating interval D between the electromagnetic induction heating units 723a and 723b, the heating process can be performed more appropriately.

  Here, the heating unit moving mechanism 724 may operate before the manufacture of the main body 100 to adjust the heating interval D, or the heating interval D may be set in consideration of manufacturing conditions and the like during the manufacture of the main body 100. You may adjust. The heating unit moving mechanism 724 may be manually operated by an operator of the workpiece heating apparatus 701 or may be configured to be automatically operated by a control unit (not shown). The heating unit moving mechanism 724 is configured to be able to move the electromagnetic induction heating units 723a and 723b in the vertical direction so that not only the heating interval D but also the interval between the surface of the workpiece 110 and the heating coils 722a and 722b can be adjusted. May be.

  The work chuck conveyance unit 725 is substantially the same as the conveyance device 720, and conveys the workpiece 110 in the conveyance direction (block arrow F in the figure, the same direction as the movement direction) by chucking. The conveyance support base 726 supports the heating unit moving mechanism 724, the work chuck conveyance unit 725, and the like. The workpiece heating device 701 may include a configuration other than the electromagnetic induction heating units 723a and 723b, the heating unit moving mechanism 724, the workpiece chuck conveyance unit 725, and the conveyance support base 726.

  The pressure laminating apparatus 702 includes the roller unit 735 described in the first embodiment and a roller support base 734 for supporting the roller unit 735. Note that the pressure laminating apparatus 702 may have other configurations.

  In the manufacturing apparatus 700A, since it is preferable to link the moving speed of the workpiece 110, the workpiece heating device 701 and the pressure laminating device 702 may be controlled by the same control device, or each has a separate control device. However, each control may be coordinated by using a known communication device or the like so that bidirectional communication is possible.

  A manufacturing apparatus 700 </ b> B illustrated in FIG. 11B includes a work preparation apparatus 703 in addition to the work heating apparatus 701 and the pressure laminating apparatus 702. The workpiece preparation device 703 is a facility for performing the preparation process described in the first embodiment, and various mechanisms for stacking and aligning the sheet-like members, or the workpiece 110 to be obtained, the workpiece heating device 701. What is necessary is just to provide the conveyance mechanism etc. for conveying to. In addition, also in the manufacturing apparatus 700B, it is preferable that control of the workpiece | work heating apparatus 701, the pressure bonding apparatus 702, and the workpiece | work preparation apparatus 703 is linked.

  As described above, the method for manufacturing a planar warming device according to the present invention includes a heater on one surface of a soaking sheet in which a surface material and a metal sheet are coated with an adhesive resin that melts at a predetermined temperature or higher. In a method for manufacturing a planar warming tool including a heater unit provided with a wire and a heat insulating sheet, a preparatory step of laminating the surface material, the heater unit, and the heat insulating sheet in this order to obtain these laminates; The electromagnetic induction heating device is installed close to one of the surface material and the heat insulating sheet in the laminate, and the metal sheet is heated by the electromagnetic induction heating device, whereby the adhesive resin is A heating step for melting, and a pressing step for bonding the surface material, the heater unit, and the heat insulating sheet by pressing the laminate by pressing means, and the pressing means , Comprising a roller unit which is belt wound around the outer circumference of the plurality of rotating rollers, the laminate just after the heating step, as long predetermined time is pressed to configure in the roller unit.

  As a result, the heat for melting the adhesive resin is generated from the metal sheet inside the planar warming tool, so that the adhesive resin can be melted in a short time, so that the bonding work can be carried out in a short time. Since wasteful heat dissipation can be suppressed outside the planar warming tool, energy saving in the manufacturing process can be achieved. Moreover, since the roller unit of the pressing means can simultaneously press a wide range with a constant pressure by winding a belt around the outer periphery of a plurality of rotating rollers, the pressing process is carried out while moving the laminate. In this case, the pressing is continued for a predetermined time until the melted adhesive resin is cured, and stable adhesive performance can be obtained. In addition, since a mold is not used in the machining process, initial investment costs can be suppressed and the degree of freedom in design can be improved.

  Moreover, in the said manufacturing method, the said roller unit should just be a structure provided with a drive device and pressing while conveying the said laminated body with the said drive device. Thereby, it becomes possible to press while moving a laminated body stably, and adhesion spots, a deformation | transformation, etc. in a press process can be reduced.

  Moreover, in the said manufacturing method, the said roller unit should just be a structure provided with a cooling means, and pressing while cooling the said laminated body with the said cooling means. As a result, it is possible to reduce the time of the pressing process and to reduce the size of the roller unit, thereby making it possible to improve the manufacturing efficiency and the equipment.

  In addition, in order to realize the above manufacturing method, the manufacturing apparatus for a planar warming tool according to the present invention is configured to move the stacked body, electromagnetic induction heating means including a heating coil, transport means for transporting the stacked body, Pressing means for pressing both surfaces with a rectangular pressing surface. As a result, it is possible to manufacture the surface heating device with low initial investment cost, energy saving and high efficiency.

  It should be noted that the present invention is not limited to the description of the above-described embodiment, and various modifications are possible within the scope shown in the scope of the claims, and are disclosed in different embodiments and a plurality of modifications. Embodiments obtained by appropriately combining the technical means are also included in the technical scope of the present invention.

  As described above, in the present invention, by heating the soaking sheet containing a metal material among the sheet-like members constituting the main body of the planar warming tool, the hot-melt adhesive is melted to each sheet-like member. Can be widely used in the field of manufacturing a surface warming device, and can also be applied to other uses such as the manufacture of other heating appliances equipped with a similar heat equalizing sheet.

100 body (body of the surface heating device)
110 Workpiece (laminated body, stacked body)
200 Surface material (sheet-like member)
203 Adhesive (adhesive layer, surface material adhesive layer)
300 Adhesive sheet (sheet-like member, adhesive layer)
400 Heater unit (sheet-like member)
410 Soaking sheet (sheet-like member)
411 Aluminum sheet (main body of soaking sheet)
412 Adhesive resin (adhesive layer, soaking sheet adhesive layer)
420 Heater wire 500 Thermal insulation sheet (sheet-like member)
600 Back material (sheet-like member)
712 Manufacturing device control unit (control means)
720 Conveying device (conveying means)
721 Electromagnetic induction heating device (electromagnetic induction heating means)
721a to 721c Electromagnetic induction heating device (electromagnetic induction heating means)
722 Heating coil (electromagnetic induction heating coil, long plate coil)
733 Roller unit (pressing means)
735 Roller unit (pressing means)
738 Cooling air passage (cooling means)
739 Pressing surface support plate (cooling means)
760 Blower (cooling means)

Claims (9)

A method of manufacturing a planar warming tool comprising a planar heater unit in which a heater wire is disposed on a soaking sheet containing a metal component, and a sheet-like member laminated on the heater unit,
A preparation step of forming a laminate in which the sheet-like member and the heater unit are stacked in a state in which a layer of a hot-melt adhesive is interposed;
An electromagnetic induction heating coil is installed close to at least one of the front and back surfaces of the laminate, and the heater unit is configured to generate lines of magnetic force by the electromagnetic induction heating coil while moving the laminate in a preset moving direction. Heating step of melting the adhesive by heating the soaking sheet of
A pressing step that is performed after the heating step and presses the entire laminate to reduce its thickness , and
In the pressing step, while moving the laminate through the heating step, both sides thereof are pressed with a rectangular pressing surface at a predetermined pressing interval , and more upstream than the pressing interval in the pressing step. The laminate is introduced into the pressing surface at a large introduction interval ,
A method for manufacturing a surface heating device. In the pressing step, the laminate is pressed while cooling,
The manufacturing method of the planar warming tool of Claim 1. The adhesive layer included in the laminate is configured as an independent sheet-like member, or laminated in advance on the sheet-like member, or both.
The manufacturing method of the planar warming tool of Claim 1. The sheet-like member is
A surface material constituting the surface of the surface heating device,
A back material constituting the back surface of the planar warming tool, and
It is at least one of a heat insulating sheet that suppresses heat transfer to the back side of the heating heat generated from the heater unit,
The manufacturing method of the planar warming tool of Claim 3. An apparatus for manufacturing a planar warmer comprising a planar heater unit in which a heater wire is disposed on a soaking sheet containing a metal component, and a sheet-like member laminated on the heater unit,
A conveying means for conveying the laminated body in which the sheet-like member and the heater unit are stacked in a state where a layer of a hot-melt adhesive is interposed, in a preset moving direction;
Electromagnetic induction heating means that is located downstream of the moving direction and includes a heating coil;
A pressing unit that is located adjacent to the downstream side in the moving direction of the electromagnetic induction heating unit and presses both sides of the moving laminate with a rectangular pressing surface to reduce its thickness ;
Control means,
The pressing means is configured to press both surfaces of the laminated body at a predetermined pressing interval and to introduce the laminated body to the pressing surface at an introduction interval larger than the pressing interval on the most upstream side of the pressing means. ,
The control means applies the magnetic force lines generated by the electromagnetic induction heating means to at least one of the front and back surfaces of the laminate transported by the transport means, so that the heat equalizing sheet of the heater unit is applied. The sheet-like member and the heater unit are bonded together by causing the heat generation to melt the adhesive and pressing the laminated body after the adhesive is melted by the pressing means. It is characterized by
Manufacturing equipment for surface heating equipment. The pressing means is constituted by arranging a roller unit formed by winding a rotating belt around the outer periphery of a plurality of rotating rollers so as to face each other.
The manufacturing of the planar warming tool according to claim 5, wherein the pressing of the stacked body by the pressing means is performed by moving the stacked body between the roller units facing each other. apparatus.   The said roller unit is comprised so that the said rotation belt may be rotated by rotationally driving at least 1 of the said rotation roller, The manufacture of the planar warming tool of Claim 6 characterized by the above-mentioned. apparatus. Furthermore, it is further provided with a cooling means for cooling the laminated body while pressing while moving the laminated body by the pressing means,
The manufacturing apparatus of the planar warming tool of Claim 5. Manufactured by the manufacturing method according to claim 1,
A sheet-like heater unit in which a heater wire is disposed on a soaking sheet containing a metal component, and a sheet-like member laminated on the heater unit,
The heater unit and the sheet-like member are bonded and fixed to each other by a layer of a hot-melt adhesive,
Planar warmer.

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