JPH0760733B2 - Woven heating element - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a woven heating element used as a heating element embedded in a carpet, a seat, or the like.

(Prior art) A woven heating element formed by weaving a heating wire, a heating tape, etc. in parallel with fibers is flexible and has the advantage that it does not feel uncomfortable when incorporated into a carpet. It is widely used and is known from, for example, Japanese Utility Model Publication No. 53-158516.

However, on the other hand, it has an advantage in use, but since it cannot be easily woven during the manufacturing process, it requires complicated means, and there is a problem that the cost becomes high. Is proposed.

By the way, the non-conductive fiber yarn, which is the sheet base material of the planar heating element, is replaced with an ultra-thin and narrow non-conductive tape because it has the advantages of low cost and being extremely thin. It has been commercialized recently.

(Problems to be Solved by the Invention) The non-conductive tape is mainly made of a synthetic resin, and for example, a tape made of polyethylene and having a width of 4 to 5 mm and a thickness of 20 μm is used. ,
Furthermore, it has the advantages of good adhesion to the insulating outer covering sheet that is adhered or welded, and low raw material cost, but on the other hand, the smooth surface makes it very slippery and stretchable. Since it is difficult to be stretched with a slight tension because it has, even if it is possible to maintain a normal weaving structure in the weaving process, in the subsequent post-treatment between the warp and weft rows Because the entanglement is weak, the tape movement is likely to occur and it may be unwound in extreme cases.Therefore, only densely woven structures that are closely arranged with each other can be formed. There is a problem in that the value is lost, and as a result, the processing speed of the loom is slow, productivity is impaired, and the cost is increased.

The present invention has been made in view of the fact that various problems are encountered in the process of weaving as described above, and a non-conductive tape having a three-layer structure in which the surface layer has a heat-welding property is provided. By adopting a special structure that is combined with the coated heating tape, the adhesiveness at the intersection between the warp row and the weft row is increased, thus preventing deformation and displacement of the weave design and forming a coarse weave structure. Therefore, the purpose is to achieve improvement in productivity and cost.

(Means for Solving the Problem) However, as is apparent from the accompanying drawings showing the embodiments of the present invention, in the invention of claim 1, the high melting point polymer tape (4) is used as a core and is placed on both sides thereof. The non-conductive tape (1) having a three-layer structure sandwiched between the low-melting polymer tapes (5) is used as warp or weft, and the conductive tape (6) is used as a core. The coated heating tape (2) having a three-layer structure sandwiched by the tapes (5) is woven as wefts or warps, and the cross-contact portion of the low melting point polymer tape (5) is subjected to a heat treatment performed after the weaving. It is characterized by the structure of a woven heating element that is welded and fixed.

The invention according to claim 2 has a configuration in which an electrode strip portion (3) for connecting a conductor and applying a power source is added to the woven heating element according to claim 1, and a plurality of copper foil yarns are provided. Electrode strips (3) consisting of parallel conductive yarn rows of (7) are provided at predetermined intervals in a warp row or weft row consisting of only the non-conductive tape (1), and a low heat treatment is performed after weaving. The copper foil thread (7) and the conductive tape (6) are brought into contact with each other by melting the melting point polymer tape (5).

(Operation) Low melting point polymer tape (5) which is the surface layer of the non-conductive tape (1) in one weaving yarn row and low melting point which is the surface layer of the coated heating tape (2) in the other weaving yarn row The polymer tape (5) and the polymer tape (5) are heat-treated immediately after the weaving process at a predetermined temperature necessary for melting, so that the fixing based on the welding at each cross contact portion is surely performed, and thus the texture is shifted. There is no phenomenon, and therefore a physically robust weaving heating element can be obtained even with a coarse weave having some voids between adjacent tapes.

(Example) Hereinafter, the Example of this invention is described based on drawing.

FIG. 2 shows a raw material of an endless continuous plain weaving material having a predetermined width and having an electrode strip portion (3) extending in the weft direction (left and right direction in the figure). And a pair of electrode strips (3) in parallel,
The sheet (3) is formed at regular intervals.

The above-mentioned fabric is to obtain a unit body of a woven heating element having a predetermined area by cutting in the width direction at the portion of the chain double-dashed line shown in FIG. Insulating sheets formed by attaching polyethylene films on both sides are adhered, welded, or the like to form a woven heating element whose surface is insulated and protected, and then attached to a carpet or the like.

The woven heating element has a warp structure in the warp direction (vertical direction in FIG. 2), and the coated heating tapes (2) are arranged on the other hand.
As a weft composition in the weft direction, a non-conductive tape (1) is arranged and has a woven structure which is woven into a plain weave as a whole and enlarged and shown in FIGS. 1 and 3.

The non-conductive tape (1) has a three-layer structure as shown in cross section in FIG. 4, and is a high melting point polymer tape (4), for example, a polyester resin having a thickness of 20 μ (melting point 120 to 1).
30 ° C) tape (4) as a core, and along both sides, tape with a low melting point polymer (5), for example, a 10 μ thick polyethylene resin tape (melting point about 80 ° C) (5) , Width 4.3mm, thickness 40μ tape.

On the other hand, the coated heating tape (2) has a three-layer structure as shown in the cross section of FIG. 5, and the conductive tape (6) is, for example, a composite of tetrafluoroethylene resin (melting point 327 ° C.) and conductive carbon. Using a tape (6) made of a material and having a thickness of 110 μ as a core, along both sides thereof, a tape of a low melting point polymer (5), that is, a polyethylene resin tape (5) having a thickness of 10 μ, is used for sandwiching, It is formed into a tape with a width of 4.3 mm and a thickness of 130μ.

The high melting point polymer tape (4) and the low melting point polymer tape (5) are not limited to the above-mentioned examples, and resins having a large difference in melting point can be used in combination. Needless to say, various kinds of flexible electric resistors other than the above examples can be applied to the conductive tape (6).

Next, the electrode strip portion (3) is formed by arranging a plurality of copper foil threads (7) side by side and driving them between warp rows, as shown in an enlarged cross section in FIG. As 7), a double wound copper foil thread is used to drive 32 threads to form a 10 mm wide conductive thread row.

Immediately after plain weaving the raw fabric having the above-described weaving structure by a loom, it is passed through a nip roller (9) consisting of a pair of heating rollers (10) and (10) under heating as shown in FIG. To perform.

In this case, the surface heating temperature of the heating rollers (10) and (10) is the temperature at which the low melting point polymer tape (5) melts.
Set it to around 90 ° C.

However, the heating roller (10), (10) is the tape (5)
In order to prevent them from adhering due to melting, those subjected to surface treatment with good releasability are used.

By doing so, the low melting point polymer tape (5) of the coated heating tape (2) in the warp row and the same kind of tape (5) of the non-conductive tape (1) in the weft row are melted, and especially the orthogonal insertion is performed. The cross-contact portion is in an integrated state by melting, and when it solidifies due to cooling after passing through the nip roller (9), this cross-contact portion is welded and fixed.

Therefore, as a result of the warp yarns and the weft yarns being fixed by the tape (5) of the low melting point polymer of the surface layer at the eye portion of the cross contact portion, the occurrence of misalignment, unraveling, etc. is completely eliminated.
Even if a coarse weave is applied as shown in the figure, the tapes (1) and (2) are securely fixed in position.

With respect to the electrode strip portion (3), the tape (5) of the low melting point polymer, that is, the tape (5) of the coated heating tape (2) at the portion which cross-contacts the copper foil thread (7), is the nip roller ( 9) When passing, the copper foil yarn (7) enters into the molten layer of the low melting point polymer tape (5) and comes into contact with the conductive tape (6), as shown in FIG. Hold the state.

Therefore, the copper foil thread (7) and each conductive tape (6) are electrically conducted, and at the same time, the weaving texture is firmly fixed.

Unlike the example described above, only the non-conductive tape (1) may be arranged in the warp row and the coated heating tape (2) may be arranged in the weft row to have a warp-inverted structure.

(Effects of the Invention) As will be apparent from the above description, the present invention has a three-layer structure in which each tape (1), (2) has a low melting point polymer tape (5) as a surface layer. As a result of heat-melting 5) after weaving to weld the cross-contact portions, the weaving structure is securely fixed, and therefore the weaving heat generating element can have a coarse structure, so that the speed of the loom can be increased. In addition, the material cost is reduced by the minimum required tape material.

Furthermore, since the surface layer is the low melting point polymer tape (5), the adhesiveness to the insulating sheet is good and the folding endurance can be improved.

Further, in claim 2, by the heat treatment after weaving, electrical contact and fixing of the copper foil thread (7) and the conductive tape (6) are simultaneously and reliably performed, and the contact resistance can be kept to a minimum. There is.

[Brief description of drawings]

Each drawing shows an embodiment of the present invention. FIG. 1 is an enlarged weaving structure diagram, FIG. 2 is a plain plan view, FIG. 3 is a partially enlarged stereoscopic view, and FIGS. 4 and 5 are A cross-sectional view of the non-conductive tape and the coated heating tape, FIG. 6 is a cross-sectional view near the electrode strip,
The figure is a schematic manufacturing process diagram. (1) ... Non-conductive tape, (2) ... Coated heating tape,
(3) ... Electrode strip, (4) ... High melting point polymer tape,
(5) ... low melting point polymer tape, (6) ... conductive tape,
(7) ... Copper foil thread.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (56) References JP-A-60-37688 (JP, A) Actual development 62-99192 (JP, U) Actual public 37-5975 (JP, Y1)

Claims (2)

[Claims] 1. A non-conductive tape (1) having a three-layer structure in which a high melting point polymer tape (4) is used as a core, and a low melting point polymer tape (5) is sandwiched along both sides thereof to form a warp or weft. And weaving the coated heating tape (2) having a three-layer structure in which a conductive tape (6) is used as a core and is sandwiched by low melting point polymer tapes (5) along both sides thereof as a weft or a warp, A woven heating element, characterized in that the cross-contact portion of the low melting point polymer tape (5) is welded and fixed by a heat treatment performed after weaving. 2. A plurality of copper foil yarns (7) are arranged in parallel, and an electrode strip portion (3) consisting of a conductive yarn row is provided at a predetermined interval on a warp row or weft row consisting of only a non-conductive tape (1). , Low melting point polymer tapes based on heat treatment after weaving (5)
The woven heating element according to claim 1, wherein the copper foil thread (7) and the conductive tape (6) are brought into contact with each other by melting.