JPS5930407B2 - Electric carpet manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing an electric carpet used as a heating appliance.

Conventionally, an electric carpet used as a heating device has the structure shown in FIG. 1, and was manufactured as follows.

As the first step, grooves 2 of a predetermined pattern are formed on the mat fabric 1.
In the process of processing the cylinder 2 by hot pressing, the heating wire 3 and the temperature detection wire 4 are arranged and fixed in the groove 2 using adhesive tape 5.

Note that when the heating wire 3 is locally abnormally overheated, it melts due to the heat, and the heating resistance wire 6, for example, a thin copper wire, and the abnormal overheating detection wire 7, for example, copper foil are short-circuited.
The outer periphery of the heating resistance wire 6 is coated with a crystalline polymer layer 8, such as nylon, which plays the role of a temperature fuse in combination with a control circuit that interrupts the current flowing through the wire, and an insulating coating material 9, such as vinyl chloride, is coated. be.

In addition, in order to control the heat generated from the heating wire 3 to a set temperature, the temperature detection wire 4 is made of a heat sensitive layer 10 whose impedance changes depending on the temperature, such as nylon or vinyl chloride with a surfactant added thereto, and a core wire. 11 consists of a temperature sensing electrode 12 wound around, for example, Tetoron fiber, a temperature sensing electrode 13 around the outside of the heat sensitive layer 10, made of, for example, copper foil, and further coated with an insulating coating material 14, such as vinyl chloride.

In the third step, a heat-fusible film 15 is placed on the matte 1 on which the heating wires 3 and the temperature detection wires 4 are arranged and fixed, and then a carpet top layer 16 is placed on top.

In the fourth step, the heat-fusible film 15 is melted under pressure using a heat press or hot roll whose temperature is set to a temperature higher than the melting point of the heat-fusible film 15, and the mat fabric 1 and carpet top layer 16 are melted.
Electric carpets were manufactured by gluing.

A sectional view of the electric carpet shown in FIG. 1 is shown in FIG.

However, according to the above-mentioned manufacturing method, in the second step, the work of pasting the adhesive tape 5 in order to arrange and fix the heat generating wires 3 and the temperature detection wires 4 in the grooves 2 of the matte material 1 is over 100 places, which takes a huge amount of time. The disadvantage was that it was not suitable for mass production because it required manpower.

In addition, once the heat generating wires 3 and temperature detection wires 4 are arranged and fixed, they tend to stand out from the grooves 2 of the matte fabric 1, and if the fourth step of heat press processing is performed as is, the heat generation wires 3 or temperature detection wires 4 that have come out from the grooves 2 will There was a drawback that the heat-sensitive layer 10 of the temperature detection line 4 was deformed due to the pressure applied between the mat fabric 1 and the carpet top fabric 16, resulting in unfavorable characteristics.

Furthermore, since the outermost insulation coatings 9 and 14 of the heating wire 3 and the temperature detection wire 4 are made of vinyl chloride, etc.
Even when hot pressing is carried out in the process, it does not adhere to the heat-fusible film 15, leaving a gap, resulting in poor heat conduction to the carpet upholstery 16 side.

The present invention has been made in consideration of the above-mentioned drawbacks, and after arranging heating wires and temperature detection wires coated with a heat-fusible coating layer in a predetermined pattern, the heat-fusible film is heated. The tack-attached unit is then sandwiched between the matte base and the carpet top layer, and the heat-adhesive film is melted by applying heat and pressure using a heat press or hot roll, and the matte base and carpet are bonded together. By making it easier to adhere to the top surface of the carpet, work efficiency is significantly improved, and heat generation lines and temperature detection lines are prevented from protruding from the grooves of the mat surface.Furthermore, the adhesion to the top surface of the carpet is made sufficient to prevent heat generation. The aim is to provide an electric carpet with excellent mass productivity and quality by improving conduction.

DESCRIPTION OF THE PREFERRED EMBODIMENTS The method for manufacturing an electric carpet according to the present invention will be explained in detail below with reference to the drawings.

FIG. 3 shows the structure of the heating wire 3 used in the present invention, in which the outer periphery of the heating resistance wire 6 is coated with a crystalline polymer layer 8, and the crystalline polymer layer 8 is made of, for example, nylon 11.
Alternatively, the abnormal overheat detection wire 7 is wound around the outer circumference of the nylon 12, an insulating coating material 9 is coated thereon with, for example, vinyl chloride, and the outermost layer is coated with a heat-fusible coating layer 17, such as polyethylene or nylon.

FIG. 4 shows the structure of the temperature sensing wire 4 used in the present invention. Temperature sensing electrodes 12 and 13 are wound around the outer periphery of the core wire 11 via the heat sensitive layer 10, and an insulating coating is further wrapped around the outer periphery of the core wire 11. 14, and the outermost layer is a heat-fusible coating layer 1.
8 coated.

Heat-adhesive coating layer 17.18 shown in FIGS. 3 and 4
is a copolymer of polyethylene, polyethylene vinyl acetate, and a low melting point coated with a thickness of 0.1 to 0.5 mm and has the property of melting when heated above the melting point of the heat-fusible resin and solidifying when cooled. Nylon is suitable.

FIG. 5 shows a method for arranging heat generation lines and temperature detection lines in a fixed pattern. Pins 20 are arranged on a board 19, and heat generation lines 3 and temperature detection lines 4 are arranged along the pins 20. Coordinated.

Next, the heat-fusible film is heated from the heat-fusible film side onto a substrate 19 on which the heating wires 3 and temperature detection lines 4 shown in FIG. 5 are arranged, to form the unit shown in FIG. 6.

That is, the heat-fusible film and the heat-fusible coating layer 17,1
8 melts when heated and pressurized, and adheres when cooled.

When applying heat and pressure, inserting a release paper between the heat source and the heat-fusible film allows the bonding work to be carried out with good workability.

The heat-fusible film may be a single material having a thickness of 0.1 to 0.5 mvt, but as shown in FIG. 15 may be laminated.

If a unit with a heat generating wire and a temperature detection wire fixed to a heat-adhesive film as shown in Fig. 6 or Fig. 7 is inserted between the mat material and the carpet top material, and a heat press or heat roller is applied, A carpet having the structure shown in FIG. 8 is obtained.

That is, the heat-fusible film 15 is partially melted into the mat 1 and the carpet top 16 by heating and pressurizing, and when cooled, the adhesion is completed.

At that time, the heat-fusible coating layer 17.18 coated on the outermost part of the heating wire 3 and the temperature detection wire 4 also melts when heated and pressurized, and the melted heating wire 3 and the temperature detection wire The heat-fusible coating layers 17 and 18 coated on the matte fabric 1 are fused with the matte fabric 1, and the heat-generating wire 3 and temperature detection line 4 are completely adhered to the matte fabric 1 and the heat-fusible film 15. As can be seen from the sectional view of FIG. 9, there is no gap between the heating wire 3 and the temperature sensing wire 4 and the carpet top layer 16, resulting in good heat conduction.

Also, it is not necessary to groove groove 2 of mat fabric 1 in Figure 8 in advance using a heat press.If a soft mat fabric is used, the groove 2 of mat fabric 1 is not necessarily grooved in advance. Grooves can be formed in accordance with the arrangement pattern of the heating wires 3 and temperature sensing wires 4.

As described above, according to the electric carpet manufacturing method of the present invention, there is no need to tape the heating wires and temperature detection wires to place them in the grooves of the mat and arrange and fix them, so the working time is reduced to 4 times compared to the conventional method. In addition to this, the heating wires and temperature sensing wires that make up the unit are matted due to the action of the outermost heat-adhesive coating layer and heat-adhesive film of the heating wires and temperature sensing wires that make up the unit. The heat press process for adding grooves improves the adhesion between the mat and the carpet top layer without sticking out from the grooves, improving heat conduction to the carpet side. This makes it possible to manufacture electric carpets with excellent mass productivity, reliability, and characteristics.

[Brief explanation of the drawing]

Fig. 1 is a partially cutaway perspective view showing the structure of a conventional electric carpet, Fig. 2 is a sectional view of Fig. 1, and Figs. 3 to 9 show embodiments of the present invention. Figure 3 is a configuration diagram of the heat generating line, Figure 4 is a configuration diagram of the temperature detection line, Figure 5 is a diagram showing the arrangement of the heat generation line and temperature detection line. FIG. 8 is a partially cutaway perspective view showing the structure of an electric carpet, and FIG. 9 is a sectional view of FIG. 8. 1...Matte fabric, 3...Heating wire, 4.
... Temperature detection line, 15 ... Heat-adhesive film, 16 ... Carpet top layer, 17, 18.
...Heat-adhesive coating layer.

Claims (1)

[Claims] 1 Heat-generating wires and temperature detection wires coated in advance with a heat-adhesive coating layer that integrates the outermost carpet surface and mat surface are arranged in a predetermined pattern on the substrate, and the heat-generating wires and temperature detection wires are arranged in a predetermined pattern on the substrate. A heat-fusible film is placed on the substrate on which the wires are arranged, and the heat-fusible film and the heating wire and temperature detection wire are bonded together to form a unit, and then the unit is placed on a carpet. The carpet top layer and the mat layer are bonded together by sandwiching the heat-fusible film and the heat-fusible coating layer coated on the heat-generating wire and the temperature detection wire using a heat-pressing method. A method for producing an electric carpet characterized by adhesive bonding.