JP5828112B2 - Manufacturing method of surface heating device - Google Patents

Description

  The present invention relates to a method for manufacturing a planar warming tool using an electric heater as a heat source.

  Conventionally, this type of surface heating device is manufactured by applying a urethane foam material on a backing and laminating a heater unit having a heater wire on a base material and a surface material, and then depositing these on a gold plate. It is press-molded in the mold. At this time, the urethane foam material is foamed, and the foaming pressure causes the urethane foam material to ooze out from the base material side of the heater unit and adhere to the front material, thereby bonding the backing material, the heater unit and the front material together. (For example, refer to Patent Document 1).

  14A and 14B show a conventional planar warming tool described in Patent Document 1, wherein FIG. 14A is a perspective view showing a creation order of the planar warming tool, and FIG. 14B is a side view of the creation order. And (c) shows a cross-sectional view of a planar warming tool after molding. As shown in (a), a front material 1, a heater unit 3 in which a heater wire 3b is disposed on a heater base material 3a, and a backing material 5 having a urethane foam material 4 applied on the surface are prepared, and (b) As shown in the drawing, by laminating them and placing them in a mold and press molding them in the mold, the planar warming tool shown in (c) is molded.

JP 2001-041480 A

  However, in the conventional manufacturing method, it is indispensable to prepare a mold in order to perform the press molding process, and it is necessary to prepare the mold for each shape and size of the planar warming tool. It is common to produce a lot of sizes for the surface heating device that is installed on the floor surface, which increases the cost required to manufacture the mold, and also produces a surface heating device of a different shape and size. Since it is sometimes necessary to replace the mold, it is difficult to improve the production efficiency. From these viewpoints, there is still room for improvement.

  The present invention solves the above-described conventional problems, and provides a manufacturing method that enables the production of a planar warmer without using a mold and can easily cope with planar warmers of different shapes and sizes. The purpose is to do.

In order to solve the above-described conventional problems, the method for manufacturing a planar warming device according to the present invention includes a surface material and one surface of a soaking sheet in which an adhesive resin that melts at a predetermined temperature or more is coated on both surfaces of the metal sheet. A heater unit having a heater wire disposed thereon, and a method of manufacturing a planar warming tool including a heat insulating sheet, a surface material, a heater unit, a heat insulating sheet are laminated in this order, and a preparation step for obtaining these laminates, Heating that melts the adhesive resin by installing an electromagnetic induction heating device in the vicinity of either the surface material or the heat insulating sheet of the laminate, and heating the entire surface of the metal sheet sequentially by the electromagnetic induction heating device 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 metal sheet is a joined portion in which a plurality of sheets are joined A configuration having an electromagnetic induction heating device, an output for heating the end portion of the metal sheet is characterized in that heating in other low power than the output with respect to the plane portion of the metal sheet, producing a planar Todan tool Is the method.

  Thereby, it becomes possible to manufacture a large-sized planar warming tool in which a plurality of metal sheets are joined, and it is possible to easily manufacture planar warming instruments having different sizes with the same manufacturing equipment. In addition, since the heat generation on the entire surface of the metal sheet is uniform and the adhesive resin can be melted evenly, stable adhesion between the surface material, the heater unit, and the heat insulating sheet can be obtained, and the quality of the surface warmer is improved. Can do.

  The manufacturing method of the planar warming tool of this invention can manufacture easily the high quality planar warming tool from which size differs with the same manufacturing equipment.

The perspective view which shows the external shape of the planar warming tool in Embodiment 1 of this invention The perspective view which shows the state before the assembly of the main body in Embodiment 1 of this invention Sectional drawing which shows the completion state of the main body in Embodiment 1 of this invention Sectional drawing which shows the detail of the structural member of the main body in Embodiment 1 of this invention The perspective view which shows the detail of the heater wire in Embodiment 1 of this invention The schematic diagram which shows the preparation process of the main body in Embodiment 1 of this invention The schematic diagram which shows the heating process and press process of a main body in Embodiment 1 of this invention Schematic diagram showing the hot pressing process of the main body in Embodiment 1 of the present invention The schematic diagram which shows the ultrasonic welding process of the main body in Embodiment 1 of this invention Schematic diagram showing the trimming process of the main body in the first embodiment of the present invention Sectional drawing which shows the main body of another structure in Embodiment 1 of this invention The schematic diagram which shows the cross section of the main body after the ultrasonic welding process by the main body of another structure in Embodiment 1 of this invention. (A) is a schematic diagram which shows the cross section of the heating process and press process of a main body in Embodiment 2 of this invention, (b) is a schematic diagram which shows the plane of the heating coil used by a heating process. (A) is a graph showing the temperature change of the aluminum sheet and the adhesive sheet in the case of one heating coil, (b) is a graph showing the temperature change of the aluminum sheet and the adhesive sheet in the case of three heating coils. The schematic diagram which shows the cross section of the roller unit of another structure in Embodiment 2. FIG. The schematic diagram which shows the plane of the heating coil and aluminum sheet which are used at the heating process in Embodiment 3 of this invention The schematic diagram which shows the plane of the heating coil and aluminum sheet which are used at the heating process in Embodiment 4 of this invention The graph which shows the change of the output of the heating coil in each site | part of the aluminum sheet in Embodiment 4 of this invention (A) is a perspective view which shows the manufacturing order of the conventional planar warmer, (b) is sectional drawing which shows the manufacturing order of a planar warmer, (c) is sectional drawing which shows the completion state of a planar warmer

According to a first aspect of the present invention, there is provided a heater unit in which a heater wire is disposed on one surface of a surface material, a soaking sheet in which both surfaces of a metal sheet are coated with an adhesive resin that melts at a predetermined temperature or higher, and a heat insulating sheet. In the manufacturing method of the planar warming tool, including the surface material, the heater unit, the heat insulating sheet, a preparatory step of obtaining these laminates in order, the surface material of the laminate, and A heating step in which an electromagnetic induction heating device is installed in proximity to either side of the heat insulating sheet, and the adhesive resin is melted by sequentially generating heat over the entire surface of the metal sheet by the electromagnetic induction heating device; A pressing step of bonding the surface material, the heater unit, and the heat insulating sheet by pressing the laminate by means, and the metal sheet contacts a plurality of sheets. And the a configuration including a joint, the electromagnetic induction heating device was characterized by heating the output for heating the end portion of the metal sheet at low output than the output for another plan portions of the metal sheet This is a method for manufacturing a planar warming tool.

  This makes it possible to manufacture a large-sized surface warming tool in which multiple metal sheets are joined, making it possible to easily handle surface warming tools of different sizes in the same manufacturing facility, and evenly generating heat on the entire surface of the metal sheet. Thus, since the adhesive resin can be evenly melted, stable adhesion between the surface material, the heater unit, and the heat insulating sheet can be obtained, and the quality of the surface warmer can be improved.

In particular, according to a second aspect of the present invention, in the first aspect of the present invention, the control unit includes a control unit that controls an output of the electromagnetic induction heating device, and a position detection unit that detects a position of the joint. The output of the electromagnetic induction heating device is controlled based on the detection data of the detection means.

  As a result, the entire surface of the metal sheet can be uniformly heated only by the control operation of the electromagnetic induction heating device based on the position detection data. In addition, it is possible to deal with metal sheets having different sizes regardless of the presence or absence of the joining portion of the metal sheet, and it becomes possible to manufacture a wide range of planar heating devices with the same equipment.

  In a third aspect of the invention, in particular, in the first aspect of the invention, the electromagnetic induction heating device includes a plurality of heating coils having different outputs, and the joining portion, the vicinity of the joining portion, and another planar portion of the metal sheet. Is characterized in that it is heated by another heating coil.

  Thereby, it becomes possible to change an output for every heating coil, and since it can heat with the optimal output in the vicinity of a junction part and a junction part, uniform heat_generation | fever can be obtained by the metal sheet whole surface.

  In a fourth aspect of the invention, in particular, in any one of the first to third aspects of the invention, the electromagnetic induction heating device outputs an output for heating the vicinity of an end portion of the metal sheet to another plane portion of the metal sheet. It is characterized by heating at a higher output than.

  Thereby, it becomes possible to increase the heat generation near the end of the metal sheet, the heat generation on the entire surface of the metal sheet can be made more uniform, and more stable adhesion between the surface material, the heater unit and the heat insulating sheet can be obtained. Can do.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the present invention is not limited to the embodiments.

(Embodiment 1)
FIG. 1 is a perspective view showing a completed state of the planar warming device in Embodiment 1 of the present invention, FIG. 2 is a perspective view showing a state before the main body of the planar warming device is assembled, and FIG. It is sectional drawing which shows the completion state of the main body of a planar warming tool, and FIG. 4 is sectional drawing which shows the detailed structure of the member which comprises a main body.

<Structure of the surface heating device>
As shown in FIG. 1, the surface warmer is provided with a controller 101 at one end of a main body 100 composed of a plurality of sheet-like members, and power is supplied by a power cord 102 connected to the controller 101, thereby supplying the main body 100. It is a heating tool that is used by heating and installing on the floor of a house.

  As shown in FIG. 2, the main body 100 of the planar warming tool is a laminate including a surface material 200, an adhesive sheet 300, a heater unit 400, a heat insulating sheet 500, and a back material 600 as main components. As shown in the figure, they are sequentially laminated, the laminated body is bonded, and the periphery is compressed and sealed to form 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. A non-woven fabric 202 made of polyester is bonded to the back surface of the colored and patterned top sheet 201 with an adhesive 203 to form a sheet.

  The adhesive sheet 300 is formed by molding a polyethylene resin into a sheet shape, forms a flexible sheet shape 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 sheet heating device, and is formed by arranging the heater wire 420 in a meandering shape on one surface of a heat-uniforming sheet 410 mainly composed of aluminum.

  The soaking sheet 410 is a member for the purpose of uniformly diffusing the heat generated by the heater wire 420 over the entire surface of the main body 100, and has a thickness of about 0.01 mm whose main component is aluminum which is a metal sheet having high thermal conductivity. The aluminum sheet 411 is used as a base material, and both surfaces thereof are coated with an adhesive resin 412 made of polyethylene resin. The adhesive resin 412 made of polyethylene resin is melted and bonded by heating to about 97 ° C. or more. Demonstrate the function as an agent.

  As shown in FIG. 5, the heater wire 420 is formed by spirally winding a detection wire 422 for detecting temperature around a central glass fiber 421, forming an insulating layer 423 with nylon resin on the outer periphery, and forming the insulating layer 423. A heating wire 424 is spirally wound on the outer periphery, a PVC insulating layer 425 is formed on the outer periphery, and an adhesive layer 426 made of polyethylene resin is formed on the outer periphery of the insulating layer 425.

  As shown in FIG. 2, the heater unit 400 has the start end of the heater wire 420 arranged at one corner of the soaking sheet 410 and is arranged in a meandering shape so as to cover the entire area of the soaking sheet 410. Is arranged in the vicinity of the starting edge. 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 bonded and fixed to the soaking sheet 410.

  The heat insulating sheet 500 is provided for the purpose of suppressing the heat generated by the heater unit 400 from being transmitted to the floor surface unnecessarily, and the polyester resin nonwoven fabric 502 is provided on both surfaces of the sheet-like foamed urethane resin 501 having high heat insulating properties. Are bonded.

  The back material 600 is a member that comes into direct contact with the floor surface of the main body 100 of the planar warming device, and has mechanical properties as well as performances such as cushioning properties and resistance to slipping, and is an olefin elastomer having elasticity. The back surface sheet 601 is coated with a polyethylene resin adhesive layer 602.

  The planar warming device in the present embodiment is configured by installing the controller 101 at the corner of the main body 100 formed by assembling the above constituent members and connecting the start and end of the heating wire 424 of the heater unit 400 to the controller 101. The heating function of the surface warming tool can be exhibited.

<Manufacturing process of main body>
FIG. 6 is a schematic view showing a cross section of a preparation process in the manufacturing process of the main body, FIG. 7 is a schematic view showing a cross section of a heating process and a pressing process of the main body, and FIG. FIG. 9 is a schematic view showing a cross section of a hot press process for forming, FIG. 9 is a schematic view showing a cross section of an ultrasonic welding process for welding a peripheral part of the main body, and FIG. 10 is a cutting of an unnecessary part of the peripheral part of the main body. It is a schematic diagram which shows the cross section of the trimming process to perform.

  As shown in FIG. 6, in the preparation process, the adhesive layer 602 of the back material 600 is placed on a horizontal platform 710, the heat insulating sheet 500 is stacked thereon, and the heater wire of the heater unit 400 is placed thereon. The adhesive sheets 300 are stacked so that 420 is on the lower side, and the adhesive sheets 300 are stacked thereon, and the non-woven fabric 202 of the surface material 200 is stacked on the upper side, thereby forming a stack of the main body 100 in a ready state.

  In this step, as shown in FIG. 4, the heater unit 400 has an outer dimension smaller than that of other members. Therefore, it is important to arrange the heater unit 400 at the center of the heat insulating sheet 500. The laminated body of the main bodies 100 laminated in the preparation process is then sent to the heating process.

  As shown in FIG. 7, as processing equipment for the heating process, the main body 100 is placed and moved in the horizontal direction as indicated by an arrow A, and a substantially oval heating larger than the width of the main body 100. The electromagnetic induction heating apparatus 721 provided with the control part (not shown) which controls the output of the coil 722 and the heating coil 722 is essential.

  The transport unit 720 includes a position detection unit (not shown) that detects the movement position of the stacked body of the main body 100. In the present embodiment, as specific position detecting means, position detecting means for detecting the position of the main body 100 by detecting the number of rotations of the driving motor of the conveying means 720 and calculating the moving distance of the main body 100 is provided. Adopted.

  When the magnetic body lines are generated from the heating coil 722 of the electromagnetic induction heating device 721 arranged above while the laminated body of the main body 100 laminated in the preparation step is moved in the horizontal direction indicated by the arrow A by the conveying means 720, the heater unit 400 is generated. An eddy current is generated in the aluminum sheet 411, and 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 adhesive resin 412 made of polyethylene resin and the adhesive sheet 300 melt in a few seconds, the electromagnetic induction heating device 721 is operated while the main body 100 is moved at a predetermined speed by the conveying means 720, so that the entire surface of the main body 100 is continuously moved. Can be melted across.

  At this time, it is important to keep the distance between the heating coil 722 of the electromagnetic induction heating device 721 and the aluminum sheet 411 constant, and the laminated main body 100 is moved while being lightly pressed and maintained at a predetermined thickness.

  In the heating process, it is important to appropriately control the temperature rise due to heat generation, and the output of the heating coil 722 is controlled by the control unit of the electromagnetic induction heating device 721 in accordance with the transport speed of the transport unit 720. In particular, the lines of magnetic force tend to concentrate on the ends of the aluminum sheet 411, and the ends become high temperature. On the other hand, the lines of magnetic force are weak in the vicinity of the ends, so that a phenomenon in which heat generation of the aluminum sheet 411 is suppressed occurs. The adhesive resin 412 cannot be sufficiently melted.

  Therefore, when the heating coil 722 passes in the vicinity of the end portion, the output of the heating coil 722 is increased so as not to generate a low temperature region as compared with the case where the other flat portion of the aluminum sheet 411 is heated. The timing for controlling the output is performed based on the information of the position detecting means of the conveying means 720.

  Further, the heater unit 400 is arranged so that the heater wire 420 is on the lower side. By disposing the aluminum sheet 411 so as to oppose the heating coil 722 of the electromagnetic induction heating device 721, the distance between the heating coil 722 and the aluminum sheet 411 can be easily maintained, and the entire surface of the aluminum sheet 411 can be uniformly heated. it can.

  Further, by arranging the heating coil 722 and the heater wire 420 of the electromagnetic induction heating device 721 via the aluminum sheet 411, the heat generation of the heater wire 420 itself can be suppressed, and temperature spots can be suppressed. A uniform and stable heating action can be obtained.

  As shown in FIG. 7, the pressing step is a step that is performed continuously and integrally with the heating step, and the equipment necessary for this step is equipment that can press the main body 100 continuously. In this embodiment, as shown in FIG. 7, a pressing roller 730 is used in which both the upper and lower rollers are rotationally driven in the direction of arrow B and pressed from above as indicated by arrow C.

  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. In the present embodiment, the heating process equipment and the pressing process equipment are integrally configured. By pressing in the pressing step, the surface material 200, the heater unit 400, and the heat insulating sheet 500 are bonded via the adhesive resin 412 made of polyethylene resin and the adhesive sheet 300.

  The next hot press process is a process in which two different operations are performed simultaneously. As shown in FIG. 8, the equipment necessary for this process is a hot press 740, and the lower die 741 of the hot press 740 has an entire surface of the main body 100. The upper die 745 is provided with a hot plate 746 for press-molding the periphery of the main body 100.

  In this process, the back surface material 600 is bonded and the peripheral portion of the main body 100 is stepped, and the back surface material 600 is heated by the hot plate 742 disposed on the lower die 741, so that the back surface sheet 601 of the back surface material 600 is formed. The back surface material 600 and the heat insulating sheet 500 are bonded together by melting the adhesive layer 602 coated on the upper surface and pressing it with a hot press. Further, by pressing the peripheral part of the main body 100 while heating it with the hot plate 746 provided in the upper mold 745, the peripheral mold is formed by pressing so as to reduce the peripheral thickness. The end portion of the hot plate 746 is formed on the phase 747 so that the phase is molded inward of the stepped portion.

  The next ultrasonic welding step is a step of welding the peripheral portion of the main body 100 that has been press-molded in the hot press step, and the equipment used in this step is along the peripheral portion of the main body 100 as shown in FIG. This is an ultrasonic welding machine 750 provided with a moving horn 751.

  Since the heater unit 400 has a smaller outer dimension than other members, the peripheral part of the main body 100 is composed of a surface material 200, an adhesive sheet 300, a heat insulating sheet 500, and a back material 600, all formed of a thermoplastic resin material. It consists of They are thinly formed by step press molding in the preceding heat press step, and by applying ultrasonic waves to the step press portion, the joint portion of each member can be heated and melted and reliably welded. The horn 751 to which ultrasonic waves are applied sequentially welds while moving the stepped portion.

  The final trimming process is a finishing process in which unnecessary portions around the periphery of the main body 100 are cut off and shaped, and the equipment used in this process simultaneously cuts the width direction on both sides of the main body 100 as shown in FIG. There are two disk-shaped cutters 760 and one cutter 760 that cuts while moving in the length direction.

  The unnecessary part of the stepped portion subjected to ultrasonic welding is cut off while moving the disk-shaped cutter 760 in the width direction and the length direction, and the main body 100 is finished to a predetermined dimension.

  As described above, in the manufacturing process of the main body according to the present embodiment, the heating process using the electromagnetic induction heating device 721 is a characteristic step, and the electromagnetic induction heating device 721 uses aluminum that is a member of the heater unit 400. By heating the sheet 411 itself, the resin is melted and bonded.

  As described above, the greatest feature of the heating process, which is a characteristic process in the manufacturing method of the present embodiment, is that the heat necessary for melting the resin is generated from the aluminum sheet 411 that is in direct contact with the resin. Since waste heat radiation to the outside can be suppressed by sandwiching the aluminum sheet 411 as a heat source between the front surface material 200, the heat insulating sheet 500, and the back surface material 600, heating to apply heat from the outside Compared to the method, the resin can be melted with a much smaller amount of heat, 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 having a low heat-resistant temperature can be used. It is.

  The aluminum sheet 411 is an essential component provided 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 sheet heating device is originally used. In addition to the original function, the aluminum sheet 411 is a manufacturing process. It can be used for the manufacturing process, and can be very effective 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, it can be heated in a short time in seconds, so there is no need to heat the entire surface of the main body 100 at the same time. It becomes possible to carry out the steps of heating, melting and bonding as a flow operation. In addition, since the heating is partially performed, the electromagnetic induction heating device 721 used for heating may be a small-capacity small-sized object, which can reduce equipment costs and reduce the maximum electric capacity during processing. it can.

  In addition, in the manufacturing method of the present invention using electromagnetic induction heating, a mold that is conventionally required for each size of the main body is unnecessary, and a heating coil 722 corresponding to the maximum size of the main body can be prepared. For example, since heat is generated only in the range of the aluminum sheet 411 which is a heat generation source, the main body 100 smaller than the heating coil 722 can be heated with the same equipment, and the equipment of the heating process is matched to the size of the main body 100. In this respect, the equipment cost can be reduced.

  In this embodiment, the surface material 200 and the heater unit 400 are bonded to each other through the adhesive sheet 300. However, the adhesive resin 412 made of polyethylene resin coated on both surfaces of the aluminum sheet 411 of the heater unit 400 is used. Therefore, when sufficient adhesive force with the surface material 200 is ensured, the adhesive sheet 300 can be omitted, and in this case, the material cost and the number of manufacturing steps can be rationalized.

  Further, in the present embodiment, as shown in FIG. 4, the members constituting the main body 100 are configured such that only the heater unit 400 has a smaller external dimension than the other members. As shown in FIG. 11, it is conceivable that the outer shape of the adhesive sheet 300 and the heat insulating sheet 500 is made small as in the heater unit 400. By adopting such a configuration, it is possible to omit the hot pressing step of thinly molding the peripheral portion of the main body 100.

  By omitting the hot press process and applying ultrasonic waves to the peripheral part of the main body 100 by the ultrasonic welding process, the surface material 200 and the back material 600 are heated and melted, and the peripheral part becomes thin as shown in FIG. Can be welded in a wet state.

  By omitting the hot pressing step, it is possible to reduce initial investment costs and manufacturing man-hours such as manufacturing equipment and molds.

  Further, in the present embodiment, the heating coil 722 of the electromagnetic induction heating device 721 employs a thing that is larger than the width of the main body 100 and covers a part in the length direction. The dimensions are not limited to this. For example, a product having dimensions smaller than the width and length of the main body 100 may be prepared, and the heating process and the pressing process may be sequentially performed from the corners of the main body 100. In the case of this method, the pressing step is preferably pressed by a press. When this processing method is adopted, the electromagnetic induction heating device can be handled with a small capacity, and the capital investment can be suppressed.

  In the present embodiment, in the heating step and the pressing step, the processing is performed while moving the main body 100. However, the present invention is not limited to this. The main body 100 is fixed at a fixed position, and an electromagnetic induction heating device is used. The pressing roller may be moved.

  In the present embodiment, as shown in FIG. 7, in the heating process, the heater unit 400 is arranged in a direction in which the arrangement direction of the heater wire 420 and the arrow A which is the conveyance direction of the conveyance means 720 are orthogonal to each other. However, when the temperature unevenness due to heat generation of the heater wire 420 itself is large, the heater wire 420 is arranged by arranging the heater wire 420 in the direction corresponding to the arrow A and performing the heating process. In this case, it is possible to suppress temperature unevenness that can suppress the heat generation of the heater wire 420 itself by generating currents in opposite directions.

  Moreover, in this Embodiment, although the aluminum sheet was used as a base material of the soaking | uniform-heating sheet | seat 410, it is not restricted to this, Other metals, such as copper and stainless steel, may be sufficient.

  Further, in the present embodiment, the adhesion by electromagnetic induction heating is adopted only for the adhesion of the surface material 200, the heater unit 400, and the heat insulating sheet 500, but is not limited to this, and the heat insulating sheet 500 and the back surface material 600 are bonded. It can also be used for bonding. In that case, it is necessary to sandwich a member having the same configuration as that of the soaking sheet 410 between the heat insulating sheet 500 and the back surface material 600, and if the electromagnetic induction heating device is separately prepared on the lower side as the heating equipment, the same process is performed. Can be implemented within.

(Embodiment 2)
FIG. 13A is a schematic diagram showing a cross section of the heating process and the pressing process in the second embodiment, and FIG. 13B is a schematic diagram showing a plane of the heating coil in the heating process. FIG. 14A is a graph showing the temperature change of the aluminum sheet and the adhesive sheet when heated by one heating coil in the heating process, and FIG. 14B shows the aluminum sheet when heated by three heating coils. It is a graph which shows the temperature change of an adhesive sheet.

  The structure of the planar warming tool in this Embodiment is the same as that of Embodiment 1, and a point different from Embodiment 1 is that a heating process and a press process are different among the manufacturing processes of a main body. In the heating process, heating is performed using three electromagnetic induction heating devices 721, and in the pressing process, a long pressing time can be secured by using a roller unit composed of a rotating roller and a belt as pressing means. It is that.

  As shown in FIG. 13A, three electromagnetic induction heating devices 721 a, 721 b, and 721 c are installed in a direction substantially perpendicular to the moving direction of the main body 100 and in close proximity to each other. The three electromagnetic induction heating devices 721a, 721b, and 721c are provided with substantially elliptical heating coils 722a, 722b, and 722c that are wider than the main body 100, and each heating coil can control power supply independently. Thus, an optimum heating state can be obtained by linking with the conveyance speed of the main body 100. The heating coils 722a, 722b, and 722c do not necessarily have the same shape and the same performance, and the three may have different specifications.

  As shown in the figure, the roller unit 735 which is a pressing means used in the pressing step is composed of a rotating roller 737 composed of three rollers 737a, 737b and 737c, and a belt 736 wound around the outer periphery of the rotating roller 737. The contact surface of the belt 736 that presses the main body 100 is configured to form a substantially rectangular plane. A cooling air passage 738 is provided in the center of each of the rollers 737a, 737b, and 737c. The cooling air passage 738 is connected to a blower (not shown) that blows the cooling air to constitute a cooling means.

  The roller units 735 are respectively provided above and below, the lower roller unit 735 is fixedly installed at a fixed position, and the upper roller unit 735 includes a pressure device (not shown) that moves up and down. The main body 100 can be pressed by moving it downward.

  Further, at least the lower roller unit 735 is provided with a drive device (not shown), and the belt 736 is driven by rotating the rotating roller 737 with the drive device, and the main body placed on the roller unit 735. 100 can be moved in the direction indicated by arrow A at a predetermined speed. The moving speed of the roller unit 735 is synchronized with the moving speed of the conveying means 720 in the heating process.

  The operation and action of the embodiment configured as described above will be described below.

  In the heating process in the present embodiment, as in the first embodiment, the main body 100 stacked in the preparation process is moved upward in the horizontal direction as indicated by the arrow A by the conveying means 720 and is disposed above the electromagnetic induction. By generating magnetic lines of force from the heating device 721, an eddy current is generated in the aluminum sheet 411 of the heater unit 400, and the aluminum sheet 411 itself heats up due to the eddy current and the resistance of the aluminum sheet 411.

  Then, 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.

  In the present embodiment, since the three heating coils 722a, 722b, and 722c are arranged in parallel substantially in the direction of movement, the three heating coils 722a and 722b are arranged at the same location on the aluminum sheet 411. Since the magnetic field lines are sequentially supplied from 722c, it is possible to ensure a long heating time, reduce the power supplied to each heating coil, and take time to pass through the three heating coils. 411 can be heated.

  FIG. 14 (a) shows the temperature rise of the aluminum sheet and the adhesive sheet when heated using one heating coil, and FIG. 14 (b) shows the case where heating is performed using three heating coils. The temperature rise is shown.

  When heating with a single heating coil as shown in FIG. 14 (a), since the time required for heating is short, it is necessary to supply high capacity power and raise the temperature in a short time. In 411, the temperature rapidly rises, and the temperature of the adhesive sheet 300 rises with a delay and reaches the melting temperature. When the adhesive sheet 300 reaches the melting temperature, the temperature of the aluminum sheet 411 rises above the heat resistance temperature of the adhesive resin 412 made of polyethylene resin coated on both surfaces of the aluminum sheet 411. When the adhesive resin 412 rises above the heat resistance temperature, the deterioration of the adhesive resin 412 is promoted.

  On the other hand, when heating with three heating coils as shown in FIG. 14 (b), the heating time can be secured long, so that the power capacity supplied to each heating coil can be lowered. The aluminum sheet 411 is sequentially supplied with the magnetic lines of force from the three heating coils 722a, 722b, and 722c, and continues to rise in temperature with a gentle curve as shown in the figure. The adhesive sheet 300 rises in temperature while delaying the temperature rise of the aluminum sheet 411. To reach the melting temperature. When the adhesive sheet 300 reaches the melting temperature, the temperature of the aluminum sheet 411 has not risen to the heat resistance temperature of the adhesive resin 412, and the performance of the adhesive resin 412 can be maintained.

  The main body 100 heated in the heating process is conveyed to the next pressing process. In the pressing step, while being held between the roller units 735 provided above and below, the drive device provided in the rotating roller 737 of the roller unit 735 continues to move in the conveying direction indicated by the arrow A.

  Meanwhile, the main body 100 is continuously pressed by the pressure device provided in the upper roller unit 735, and during that time, the cooling air is provided to the cooling air passages provided in the rollers 737a, 737b, 737c, and the adhesive sheet The surface material 200, the heater unit 400, and the heat insulating sheet 500 are securely bonded to each other through the adhesive sheet 300 by being cooled and solidified by being lowered from the melting temperature.

  Thus, in this embodiment, by providing three heating coils, it is possible to suppress the temperature rise of the aluminum sheet, it is possible to suppress deterioration of the adhesive resin, and high quality. It can be secured stably.

  Further, the roller unit makes it possible to ensure a long pressing time, and the pressing can be continued until the melted adhesive sheet is solidified reliably, so that the bonding performance and the dimensional accuracy can be ensured.

  In this embodiment, three electromagnetic induction heating devices are used. However, the present invention is not limited to this, and two or four or more devices may be used. Moreover, although it was set as the structure provided with one heating coil for every electromagnetic induction heating apparatus, the structure which equips one electromagnetic induction heating apparatus with several heating coils and can control each heating coil separately may be sufficient. .

  Further, the roller unit 735 serving as the pressing means is provided with the cooling air passage 738 as the cooling means, but the cooling means is not limited to this, and other types such as a water cooling type may be used. Further, the cooling means is not essential, and may be omitted when the adhesive sheet 300 falls below the melting temperature while passing through the roller unit 735 by slowing the conveyance speed. Further, as shown in FIG. 13A, the roller unit in the present embodiment has a configuration in which three rotating rollers 737 and a belt 736 are combined in the vertical direction, but the present invention is not limited to this. For example, FIG. Another configuration as shown in FIG.

  A roller unit 770 shown in FIG. 15 is wound around a rotating roller 737 composed of two rollers 737 a and 737 c, a pressing plate 739 installed between the two rollers 737 a and 737 c, and the outer periphery of the rotating roller 737. The main body 100 is configured to be pressed by two rollers 737 a and 737 c and a pressing plate 739 via the belt 736. By adopting such a configuration, it becomes possible to maintain the pressure stably over a long period of time with a flat surface, and a stable adhesion performance can be obtained.

(Embodiment 3)
FIG. 16 is a schematic diagram showing the plane of the heating coil of the electromagnetic induction heating device used in the heating process in the third embodiment.

  This embodiment differs from Embodiments 1 and 2 in that the configuration of the heating coil of the electromagnetic induction heating device used in the heating process is different, and in particular, a plurality of heating coils in the width direction of the main body. And an aluminum sheet is formed by joining two sheets. The main body having such a structure corresponds to the manufacture of a large surface heating device, and in particular, when the heater unit 400 becomes large, it is possible to procure a wide aluminum sheet 411 used for the soaking sheet 410. It is difficult to join and use two sheets, which is a manufacturing method corresponding to the manufacture of such a main body.

  The joining portion obtained by superposing the end portions of the two sheets has a structure in which the thickness of the aluminum sheet 411 is increased and the two end portions of the aluminum sheet 411 are included. Although the end tends to be concentrated and the end becomes high temperature, on the other hand, the magnetic field lines are weak in the vicinity of the end, so that the heat generation of the aluminum sheet 411 is suppressed. For this reason, when the bonding portion and other planar portions are heated under the same conditions, the temperature increase is suppressed at the bonding portion and its vicinity, and the adhesive resin 412 cannot be sufficiently melted. In the present embodiment, such inconvenience can be solved.

  As shown in FIG. 16, the aluminum sheet 411 is joined by polymerizing a part of two narrow aluminum sheets 411a and 411b by about 1 to 2 cm, and the joining part 411c is about twice as large as the other part. It is thick. The joining of the two aluminum sheets 411a and 411b is obtained by melting and bonding the adhesive resin 412 made of polyethylene resin coated on both surfaces of the aluminum sheet 411.

  Nine heating coils 722 are used. In the first row, long heating coils 722d and 722f are arranged on both sides, and a small heating coil 722e is arranged in the center. Similarly, in the second row, long heating coils 722g and 722i are arranged on both sides on both sides, and a small heating coil 722h is arranged on the center. Similarly, in the third row, long heating coils 722j and 722l are arranged on both sides, and a small heating coil 722k is arranged in the center.

  The small heating coils 722e, 722h, and 722k have dimensions larger than the width of the joint portion 411c, and the joint portion 411c and the vicinity of the joint portion can be individually heated. Further, the nine heating coils 722 are configured so that the power supply to each heating coil can be controlled independently, and an optimum heating state can be obtained by linking with the conveyance speed of the main body 100. it can.

  In the present embodiment configured as described above, electric power is supplied to the heating coil 722 and the aluminum sheet 411 is heated while the main body 100 is conveyed at a predetermined speed. In that case, the power supply to the small heating coils 722e, 722h, and 722k corresponding to the joining portion 411c where the aluminum sheet 411 is superimposed is relatively larger than the energization capacity to the other heating coils arranged on both sides. By increasing the temperature, the amount of heat generated in the vicinity of the joint portion 411c and the joint portion can be increased, and the entire aluminum sheet 411 can be heated to a temperature at which the adhesive resin 412 can be sufficiently melted.

(Embodiment 4)
FIG. 17 is a schematic diagram showing the relationship between the aluminum sheet and the heating coil in the fourth embodiment, and FIG. 18 is a graph showing the output of the heating coil changed for each part of the aluminum sheet.

  The heater unit in the present embodiment is formed by joining two sheets of soaking sheets as in the case of the third embodiment, but the difference from the third embodiment is the joining. This is that the portion is arranged in a direction substantially perpendicular to the conveying direction, that is, substantially parallel to the heating coil 722.

  As shown in FIG. 17, the aluminum sheet 411 is joined by a joining portion 411c in which the ends of the two aluminum sheets 411a and 411b are overlapped by about 1 to 2 cm. The joining of the two aluminum sheets 411a and 411b is obtained by melting and bonding the adhesive resin 412 made of polyethylene resin coated on both surfaces of the aluminum sheet 411.

  The heater wire 420 is disposed on the entire surface of the aluminum sheet 411 in a meandering manner so as to be substantially parallel to the joint portion 411c. In particular, the end portions of the aluminum sheets 411a and 411b forming the joining portion 411c and the heater wire 420 are arranged so as not to overlap. By arranging the heater wire 420 in this way, the insulating layer 425 of the heater wire 420 and the like are prevented from being damaged by heat even when the magnetic lines of force concentrate on the ends of the aluminum sheets 411a and 411b and the temperature rises. be able to.

  When the aluminum sheet 411 having such a configuration is used, as described in the third embodiment, the lines of magnetic force tend to concentrate on the end of the aluminum sheet 411 and the end becomes high temperature. Here, a crack may occur in the end portion of the aluminum sheet 411 when the end portion of the aluminum sheet 411 is processed, or when the laminated body after the heater wire 420 is disposed is moved.

  When such a crack occurs, the magnetic force concentrates on the tip portion of the crack by induction heating performed in the heating process. As a result, a portion (excessive high temperature portion) in which the temperature is excessively increased is generated so as to extend in a strip shape from the tip portion of the crack. This excessively high temperature part may reach the vicinity of the heater wire 420 or the place where it is disposed depending on the situation. In this case, the heater wire 420 may be excessively heated by the excessively high temperature portion and may be damaged.

  On the other hand, in the vicinity of the end portion of the aluminum sheet 411, as described in Embodiment 1, the lines of magnetic force are weakened in the heating process, so that a phenomenon in which heat generation of the aluminum sheet 411 is suppressed occurs. Specifically, since the magnetic field lines tend to concentrate on the start end portion 411d and the end end portion 411e, which are the end portions of the aluminum sheet 411, the end portions themselves become high temperature. On the other hand, since the lines of magnetic force are weak in the vicinity of the start end portion 411d and the end end portion 411e, heat generation of the aluminum sheet 411 is suppressed. Therefore, if not only the joining portion 411c but also the region near the end portion is heated under the same conditions as other flat portions, heat generation (temperature rise) of the aluminum sheet 411 is suppressed, and the adhesive resin 412 may not be sufficiently melted. .

  As described above, when induction heating the end portion of the laminate, in order to improve the adhesiveness, it is sufficient to heat at a high output similarly to the joint portion 411c, but the influence of the excessively high temperature portion accompanying the occurrence of cracks. If attention is paid to this, it is better to avoid high-power heating.

  Here, the entire circumference of the main body 100 can be sufficiently welded by applying ultrasonic waves to the peripheral portion of the laminate by the ultrasonic welding step described in the first embodiment. Therefore, even if the adhesive resin 412 in the vicinity of the end portion cannot be sufficiently melted in the heating process, the periphery of the planar warming tool can be sufficiently fixed by the ultrasonic welding process. That is, even when a relatively weakly bonded portion is generated in the vicinity of the end portion in the heating process, the portion can be supplemented by the ultrasonic welding process.

  Therefore, in the present embodiment, in the control of the heating coil 722 by the control unit of the electromagnetic induction heating device 721, the possibility that the heater wire 420 is damaged due to the occurrence of cracks is improved rather than the improvement in the adhesiveness of the end. The emphasis is on elimination. That is, the control unit increases the output of the heating coil 722 so that the bonding portion 411c is higher than the temperature of the other flat portion, while the start end portion 411d and the end portion 411e are lower than the temperature of the other flat portion. Thus, control is performed to reduce the output of the heating coil 722.

  This control will be specifically described with reference to FIG. FIG. 18 is a graph showing changes in the output of the heating coil 722 at each part of the aluminum sheet 411.

  Heating of the aluminum sheet 411 is sequentially performed in the direction indicated by the arrow D. The control unit first starts driving the heating coil 722 at an output lower than the standard output from the vicinity of the start end 411d. Here, the degree (degree) of lowering the output may be determined according to the situation of the aluminum sheet 411. However, if the output is lowered beyond 10%, there is a possibility that the adhesive force is greatly lowered and a problem occurs. Therefore, the output may be set to be as low as possible within a range of 0 to 10%, depending on the state of occurrence of cracks at the ends caused by the manufacturing process.

  Next, after passing the vicinity of the start end part 411d, it changes to a standard output, and it changes to the high output 1-5% high until it passes the junction part 411c from the vicinity of the junction part 411c. Here, since the output is increased only to replenish the weak magnetic part in the vicinity of the end where the magnetic force is concentrated, if the output is higher than 10%, the end of the joint 411c (the aluminum sheet 411a). And the end of the aluminum sheet 411b) become high temperatures. In this case, the temperature of the aluminum sheet 411 excessively rises with the heater wire 420 being affixed, and an excessive temperature rise state that impairs the performance of the heater wire 420 may occur, causing a problem. obtain. After passing through the joint portion 411c, the output is changed to the standard output again, changed from the vicinity of the end portion 411e to a low output, and control is performed to stop driving the heating coil 722 after passing the end portion 411e.

  The change in the output of the heating coil 722 is performed at a timing in accordance with the positions of the start end 411d, the joining portion 411c, and the end end 411e with reference to the front edge of the heating coil 722 based on the information of the position detection unit of the transport unit 720. Is called. The output graph shown in FIG. 18 shows the output of one heating coil (for example, the heating coil 722a), and the other heating coils 722b and 722c also perform approximate control.

  By adopting the manufacturing method of this embodiment, the large-sized main body 100 using the aluminum sheet 411 having the joint 411c can be manufactured by the electromagnetic induction heating device 721 including the heating coil 722 having a simple configuration. The manufacturing of the small-sized main body 100 using the aluminum sheet 411 that does not have the joint portion 411c can be handled by changing the control method of the electromagnetic induction heating device 721 using the same manufacturing equipment. It is possible to expand the range of support and reduce equipment costs.

  In this embodiment, the aluminum sheet has only one joint, but the number of joints is not limited to one, and may be two or more, particularly the present invention. When the manufacturing method of the embodiment is adopted, even if the number of joints increases, it is possible to manufacture with the same manufacturing equipment, and from the small surface heating tool to the large surface heating equipment with the same manufacturing equipment. Can be manufactured.

  Moreover, in this Embodiment, although the three heating coils arrange | positioned in parallel were used, the number of heating coils is not restricted to this, What is necessary is just to change as needed.

  As described above, the method for manufacturing a planar warming device according to the present invention can heat a built-in metal soaking sheet to melt and bond the resin, so that the soaking sheet made of metal can be used. The present invention can also be applied to other uses such as manufacturing for other heating appliances.

100 body (laminate)
200 Surface material 300 Adhesive sheet 400 Heater unit 410 Heat equalizing sheet 420 Heater wire 411 Aluminum sheet (metal sheet)
411c Joint 411d Start end (end)
411e Termination part (end part)
412 Adhesive resin 500 Heat insulating sheet 721 Electromagnetic induction heating device 722 Heating coil 730 Pressing roller (pressing means)
735, 770 Roller unit (pressing means)

Claims (3)

Surface material,
A heater unit in which a heater wire is disposed on one surface of a soaking sheet coated on both surfaces of a metal sheet with an adhesive resin that melts at a predetermined temperature or higher;
In a method for manufacturing a sheet heating device including a heat insulating sheet,
A preparatory step of obtaining these laminates by laminating the surface material, the heater unit, and the heat insulating sheet in this order;
An electromagnetic induction heating device is installed in proximity to either one of the surface material and the heat insulating sheet of the laminate, and the electromagnetic induction heating device sequentially generates heat over the entire surface of the metal sheet. A heating step for melting the adhesive resin;
A pressing step of bonding the surface material, the heater unit, and the heat insulating sheet by pressing the laminate by pressing means,
The metal sheet is configured to have a joint portion obtained by joining a plurality of sheets,
The electromagnetic induction heating device is characterized in that the output for heating the vicinity of the end of the metal sheet is heated at a lower output than the output for the other flat portion of the metal sheet .
A method for manufacturing a surface heating device. A control unit for controlling the output of the electromagnetic induction heating device;
A position detection means for detecting the position of the joint,
The control unit controls the output of the electromagnetic induction heating device based on the detection data of the position detection unit,
The manufacturing method of the planar warming tool of Claim 1. The electromagnetic induction heating device includes a plurality of heating coils having different outputs,
The junction and the vicinity of the junction and the other flat portion of the metal sheet are heated by another heating coil.
The manufacturing method of the planar warming tool of Claim 1.

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