JPS6259875B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing an electric carpet using a surface heating element.

Conventional electric carpets of this kind have been constructed by sandwiching a surface heating element with heating wires wired between a front surface material and a back surface material. The facing and backing materials used for such electric carpets include nylon,
Needle punched felt is made by twisting fiber materials such as polyester, acrylic, or wool into a thin base fabric (jute hessian cloth or non-woven fabric) to create a thick cloth-like shape, or by entwining only the fibers without using a base fabric. Nonwoven fabrics finished to approximately the same thickness are generally used, but in order to improve tensile strength and abrasion resistance (protection of heating wires), the entire back surface (the mating surface of the surface material and back material) is It is usually used by coating it with resin. This resin is generally SBR (styrene butadiene rubber) or NBR (nitrile butadiene rubber).
etc. are used to improve tensile strength and abrasion resistance because they have the effect of keeping the fibers intertwined, but they penetrate to about half the thickness of the felt and form a hard resin layer in the felt at room temperature. was. For this reason, conventional electric carpets have been impossible to fold. Also, resin must be applied to the back side of this backing material in advance.
There was a problem of high manufacturing costs.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a method for manufacturing an electric carpet that can protect heating wires and can be folded for easy storage, reducing the manufacturing cost.

An embodiment of the present invention will be described based on FIGS. 1 to 3. As shown in FIGS. 1 and 2, this method of manufacturing an electric carpet involves connecting a heating wire 1a, which is wired so that the number of points intersecting the planned bending line A to be as few as possible, from both sides with a comparative material such as polyester or polyethylene. A planar heating element 1 having a structure sandwiched between insulating layers 1b and 1c made of a highly heat-resistant material and further sandwiched between thermal adhesive layers 1d and 1e made of a low-melting point thermoplastic resin such as low-density polyethylene is scheduled to be bent. After punching a plurality of holes 1f in a certain width near the line A and in an area where the heating wire 1a does not exist (an area that does not damage the heating wire 1a), a fibrous material such as felt is punched as shown in FIG. Thermal adhesive layer 1 is sandwiched between a surface material 2 and a back material 3 (the back surface is untreated), and these are heat-pressed and bonded to the surface material 2 and back material 3.
d and 1e are infiltrated. Note that 4 and 5 are terminal connection portions, respectively.

As described above, the method for manufacturing the electric carpet of this embodiment is as follows:
When bonding the surface material 2 and the back material 3 to both surfaces of the surface heating element 1 using 1e, the resin of the thermal adhesive layers 1d and 1e simultaneously penetrates into the surface material 2 and the back material 3, and the surface material The heating wire 1a of the surface heating element 1 can be protected by improving the tensile strength and abrasion resistance of the heating element 2 and the backing material 3. In this case, the degree of bucking effect (abrasion resistance, tensile strength) can be selected by arbitrarily selecting the thickness of the thermal adhesive layers 1d and 1e. In addition, thermal adhesive layer 1
Since highly heat-resistant insulating layers 1b and 1c are arranged on the inner surfaces of d and 1e, surface material 2 is placed on the thermal adhesive layers 1d and 1e.
And no matter how much the back material 3 is inserted (the surface material 2
Even if the thermal adhesive resins 1d and 1e penetrate into the backing material 3), they do not reach the heating wire 1a, and the thermal adhesive layers 1d,
There is no need to make 1e excessively thick.

In addition, since a plurality of punched holes 1f were provided in an area with a constant width near the planned bending line A and where no heating wire 1a exists, the thermal adhesive layers 1d and 1e in this area were removed, and the fibers in that area were removed. The force that holds the two together (buckling effect) becomes weaker than other parts, so the bending rigidity of that part becomes smaller, and only that part can be bent. Looking only at the surface heating element 1, the bending rigidity is low in the vicinity of the punched hole 1f, so it is natural that bending becomes easier. Moreover, since the planned bending line A is determined by processing (drilling) the surface heating element 1, alignment with the front surface material 2 and the back surface material 3 is not necessary.

In addition, since the thermal adhesive layers 1d and 1e also produce a backing effect on the fibers, it is possible to omit the backing resin, and even if the strength is insufficient and elongation is a problem when handling the felt, the backing resin can be kept to the minimum necessary. The manufacturing cost can be reduced. Note that omitting the backing resin is sufficiently effective even when only one of the front material 2 and the back material 3 is used, and it is also effective when the backing resin layer is formed thinly.

In addition, it can be finished thinner by omitting the backing resin.

In addition, the buckling effect is approximately 400% when a 450g/ ^m2 felt made of nylon fibers with a thickness of 15 denier is buckled with SBR in advance.
g/m ² of resin was required, but according to this invention, the thickness of the low-density polyethylene layer, which is a thermal adhesive layer, is approximately 250 microns (approximately 250 g/m ² ). The same tensile strength and abrasion resistance were obtained. In addition, 80
When the invention was applied to both types of materials subjected to backing of approximately g/m ² , the effects were not significantly different between the two types.

As described above, in the method of manufacturing an electric carpet of the present invention, a thermal adhesive layer is applied to the main surface of a surface heating element on which heating wires are wired so that the number of intersections with planned bending lines is reduced, and the heating A punching hole is provided in an area where the heating wire does not exist in the vicinity of the planned bending line of the surface heating element to which the adhesive layer is attached, and the main surface of the surface heating element provided with the punching hole is made of a fibrous material. Since the covering material is heat-pressed and the thermal adhesive layer is infiltrated into the covering material, it is possible to protect the heating wires and reduce the manufacturing cost of an electric carpet that can be folded and easily stored.

[Brief explanation of the drawing]

1 to 3 are a perspective view, a sectional view, and a sectional view for explaining a method of manufacturing an electric carpet according to an embodiment of the present invention. DESCRIPTION OF SYMBOLS 1... Surface heating element, 1a... Heating wire, 1d, 1e... Heat adhesive layer, 1f... Punching hole, 2... Surface material, 3... Back material.

Claims (1)

[Claims] 1 A thermal adhesive layer is applied to the main surface of a surface heating element on which heating wires are wired so that the number of points that intersect with the planned bending line is reduced, and the above-mentioned bending plan of the surface heating element covered with this thermal adhesive layer is applied. A punching hole is provided in an area where the heating wire does not exist near the wire, and a covering material made of a fibrous material is thermally bonded to the main surface of the surface heating element in which the punching hole is provided, and the heating bonding material is bonded to the covering material. Method of manufacturing electric carpets by impregnating layers.