JPH0815111B2 - Manufacturing method of sheet heater - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing a planar heater molded body, and an object thereof is a planar heater molded body such as a heating toilet seat, a panel heater, a tower kotatsu heat source, and a kotatsu heat source. In particular, a surface on which a sheet-shaped heater molded body, in which a skin material is joined and integrated, and in which a heating wire is accurately arranged at a predetermined position, that is, near the surface without deviation, can be simply and efficiently manufactured. To provide a method for manufacturing a heater shaped body.

(Prior Art) Conventionally, a planar heater molded body in which a heating wire is embedded in a synthetic resin molded body is generally obtained by an injection molding method, but in this injection molding method, mesh engagement is fixed in advance. Molding is performed by arranging a heating wire in advance in the formed mold and then injecting (pressurizing) a synthetic resin molding material in a heat-melted state.

However, in this injection molding method, since it is necessary to fill a narrow mold with a synthetic resin molding material in a heat-melted state under pressure from the injection nozzle of the mold, it is difficult to fix the heating wire at the position where it is arranged in advance. The heating wire and the like are likely to be unevenly distributed in the molding material.

Therefore, as a post-treatment, it is necessary to stick the heating wire on the surface of the molded product by hand as a post-treatment, and the work is performed.

Since this work is complicated by hand, it is not preferable in terms of work accuracy.

On the other hand, as a method for obtaining a synthetic resin molded product in which a heating wire is provided on the back surface of a skin material, for example, in JP-A-49-128329, a heating plate having a planar heating element fixed to the back surface of a surface plate is formed. A method for producing a heat generating board, which is placed in a mold, filled with a mixed hard foam resin raw material liquid into a molding mold to form a hard foam resin layer, and integrating the heat generating plate and the hard foam resin layer. Is disclosed.

Further, in Japanese Patent Laid-Open No. 47-26729, the cord heater is arranged in a zigzag shape, an arbitrary position is positioned with an adhesive tape, and then the end of the adhesive tape is pulled out from the mold to prevent the slack of the cord heater. There is disclosed a method of manufacturing a heating element which is molded with an elastic material such as polyether.

Further, in JP-A-47-26729, after a planar heater is brought into contact with the inner peripheral surface of the toilet seat body curved in a convex curve, a back plate is closely attached to the opening surface of the toilet seat body, and then the back plate A method of manufacturing a heated toilet seat in which foamed resin is press-fitted into the inner space of the toilet seat body formed by fixing is disclosed.

On the other hand, the present inventors have already constructed a heating wire rod by filling a flexible synthetic resin tube with carbon fibers and / or carbon powder while maintaining a gap therebetween, and this heating wire rod is a plate-like synthetic resin. We have developed and clarified a planar heater that is embedded in a molded body. (Actual No. 1-75995) As a related surgical technique of this disclosed disclosure, the actual surgical technique is Sho 63-202095.
No. 1, "flat heater" and Japanese Patent Laid-Open No. 1-1249988 "flat heater molding method" have already been clarified.

As an example of this, for example, in Japanese Patent Laid-Open No. 1-1249988, carbon fibers and / or carbon powders (f) are contained in a flexible synthetic resin tube (t) as shown in FIG. 6 (A).
To form a heating wire (R) by holding a gap between them and forming the heating wire (R) with the upper mold (m-1) and the lower mold (m).
-2) is placed in a mold (m) consisting of 2) and then, while the thermoplastic synthetic resin molding material (k) is being injected into the mold (m) as shown in FIG. A plate-shaped synthetic resin molded body (H) as shown in FIG.
Disclosed is a method of manufacturing a planar heater (S) in which the heating wire (R) is integrally embedded.

(Problems to be Solved by the Invention) However, in the "method for producing a heat-generating board" disclosed in JP-A-49-128329, a foamed resin is left on one surface of a heat-generating plate or cured by heat treatment to form a laminate. Since it is a method only for obtaining, the bonding strength between the heat generating plate and the hard foamed resin layer is insufficient, and there is a problem that these cannot be bonded and integrated sufficiently without the interposition of an adhesive or the like.

Further, in the "method for producing a heating element" disclosed in Japanese Patent Laid-Open No. 47-26729, it is not possible to carry out effective heat conduction because the molding cannot be performed with the cord heater disposed near the surface. However, there was a problem that the skin material could not be strongly bonded and integrated on the surface.

Further, in the "heating toilet seat and its manufacturing method" disclosed in Japanese Patent Laid-Open No. 47-26729, a method in which a sheet heater is arranged inside a preformed synthetic resin toilet seat body and a foamed resin is filled Therefore, it is not possible to arrange the heater wire near the surface, and the toilet seat body is molded in advance with synthetic resin, then the planar heater is arranged, and then the foamed resin is filled and cured. Since it has to go through the step of covering the foamed resin injection port, the number of manufacturing steps is large, the manufacturing is lacking in simplicity, and it is not a method that can be used widely.

In addition, Japanese Unexamined Patent Publication No. 1-12 shown in FIGS.
Also in the technique disclosed in Japanese Patent Publication No. 49988, since the heating wire (R) is embedded inside the heating element (H) made of a synthetic resin molded body, the heating wire (R) is defined within the heating element (H). In addition to the fact that the heating wire (R) cannot be surely embedded in the position, the heating wire (R) can be arranged near the surface inside the heating element (H) so that heat can be more effectively conducted to the user on the surface of the heating element (H). There was a problem that I could not.

In view of the above-mentioned conventional drawbacks, in the industry, the heat generating wire is arranged at a fixed position and the heat generating wire is arranged near the surface of the sheet-shaped heater molded body, so that the thermal efficiency is very good and the It has been desired to create a method for obtaining an excellent planar heater molded body that does not transmit heat to the user.

(Means for Solving the Problem) In the present invention, a flexible skin material in which a heat-generating member is held on at least one surface is arranged over the entire width of the gap between the upper and lower molds for the upper and lower separation molds, A thermoplastic synthetic resin molding material is supplied in a heat-melted state into a gap between the heating wire holding surface of the skin material and the upper mold or the lower mold, and the upper and lower molds are engaged with each other, and the synthetic resin molding in a fluid state by this pressure. The conventional problems are solved by providing a method for manufacturing a planar heater molded body, which is characterized in that a synthetic resin molded body and the skin material are integrally molded while spreading the material into the upper mold or the lower mold. Dissolve in a grudge.

(Example) Hereinafter, a method for manufacturing a planar heater molded body according to an example of the present invention will be described with reference to the drawings.

1 and 2 to 3 (A), (B), (C)
[Fig. 4] is a schematic view showing one embodiment of a method for manufacturing a planar heater according to the present invention, showing a method for forming a heated toilet seat in the order of steps.

In the drawing, (1) is a heating wire such as a nichrome wire,
(2) is a skin material, and (3) is a mold.

The mold (3) is composed of an upper mold (3A) and a lower mold (3B), which can be separately meshed vertically.

As shown in FIG. 1, the heating wire (1) is replaced with the skin material (2).
It is attached to the lower surface of and placed over the entire width between the upper mold (3A) and the lower mold (3B).

The arrangement of the skin material (2) and the heating wire (1) does not necessarily have to be on the lower mold (3B), but is temporarily fixed to the upper mold (3A) or the heating wire (1) is in the upper mold (3A) direction. The mold may be placed on the lower mold (3A) so as to face, or may be stretched between the upper mold (3A) and the lower mold (3).

The heating wire (1) is formed by filling a heating resistance wire such as a nichrome wire or a flexible thermoplastic synthetic resin tube developed by the present inventors with carbon fibers while holding a gap between them. But it's okay.

Here, a thermoplastic resin such as ABS resin (acrylonitoyl-butadiene-styrene copolymer resin), polystyrene resin, or polyester resin is preferably used for the synthetic resin tube.

The carbon fiber may have any of a long shape (5 to 20 mm) and a short shape (less than 5 mm), and both pitch type and polyacrylonitrile type are preferably used.

In the present invention, examples of the skin material (2) include woven cloth, non-woven cloth, metal, fiber, net of thermoplastic resin, paper, metal foil or thermoplastic resin, and sheet or film of thermoplastic elastomer. The uneven pattern, the one decorated with printing or dyeing, or the foam may be used.

Further, it is also possible to use these in the form of a laminated product in which these are used alone or two or more kinds of adhesives are laminated.

Next, as shown in FIG. 1, the molten synthetic resin (4) is supplied into the gap between the surface of the skin material (2) on which the heating wire (1) is arranged and the lower mold (3B).

 This supply may be performed by injection, injection or the like.

While supplying the molten synthetic resin (4), the upper mold (3A) and the lower mold (3B) are engaged with each other as shown in FIG. (3A) (3B)
Mold while pushing to every corner inside.

As the molten synthetic resin (4) used in the present invention, any of those usually used in compression molding, injection molding and extrusion molding can be used, and examples thereof include polypropylene, polyethylene, polystyrene, and arylonitrile-styrene-butane. A non-foaming or foaming resin such as a gen block copolymer and a thermoplastic elastomer such as nylon, and an additive such as an inorganic filler, a filler such as glass fiber, a pigment, a lubricant, an antistatic agent and the like are added thereto. It may be one.

In this way, an integrated preform (P ₁ ) of the planar heater molding (P) shown in FIGS. 3A and 3B is obtained.

From this preform (P ₁ ) to the unnecessary part (2) of the skin material (2)
The a) and the molding unnecessary part (5) are deleted by post-processing.

Thus, the sheet-shaped heater molding (P) according to the present invention is obtained as shown in FIG. 3 (C).

The planar heater molding (P) shown in FIG. 3 (C) is a heated toilet seat.

FIGS. 4 (A) and 4 (B) show a heat source for the tower kotatsu (6) in the planar heater (P) of another embodiment.

5 (A) and 5 (B) are sectional views taken along line VV of FIG. 3 (C).

The planar heater molding (P) (heating toilet seat) is as shown in FIG. 3 (C) when seen in a plan view, and as shown in FIG. 5, a heating wire is provided in the vicinity of the surface of the synthetic resin molding (4). (1) is embedded integrally.

Further, according to the case of the present invention, FIG.
As shown, make a hole (2b) in the skin material, and use this skin material (2)
May be located in the planar heater molding (P).

The heating wire (1) is embedded near the surface of the plate-shaped synthetic resin molded body (4) via the skin material (2).

(Effects of the Invention) As described in detail above, according to the present invention, a flexible skin material having a heating wire on at least one surface is arranged over the entire width of the gap between the upper and lower molds for the upper and lower separation molds. The thermoplastic synthetic resin molding material is supplied in a heat-melted state into the gap between the heating wire holding surface of the skin material and the upper mold or the lower mold, and the upper and lower molds are meshed with each other. Since the method for manufacturing a planar heater molded body is characterized in that the synthetic resin molded body and the skin material are integrally molded while spreading the synthetic resin molding material into the upper mold or the lower mold, the heating wire is It is a sheet-shaped heater molded body with excellent thermal efficiency that is arranged near the surface of the sheet-shaped heater molded body, and the skin material is firmly joined and integrated so that heat is not directly transmitted to the user. An excellent sheet-shaped heater molding can be obtained with a single die engagement. Therefore, an excellent effect that an excellent planar heater molded product can be manufactured easily and efficiently is exerted.

Further, according to the present invention, a flexible skin material having a hole portion and holding a heating wire on at least one surface is disposed over the entire width of the gap between the upper and lower molds of the upper and lower separation molds. The thermoplastic synthetic resin molding material is supplied in a heat-melted state into the gap between the skin material and the upper mold or the lower mold, and the upper and lower molds are engaged with each other, and the synthetic resin molding material in a fluid state is caused to flow in the hole portion by this pressure. Since it is a method for producing a sheet-shaped heater molded article, which is characterized in that it is integrally formed with the skin material of the synthetic resin molded body while being expanded into the upper die and the lower die via This has an excellent effect that the heating wire can be accurately arranged without using one piece, and moreover, the planar heater molded body in which the heating wire is arranged near the surface via the skin material can be easily and efficiently manufactured.

[Brief description of drawings]

1 and 2 are manufacturing explanatory views of a sheet-shaped heater molded body according to an embodiment of the present invention, and FIGS. 3 (A) and 3 (B) are sheets of a sheet-shaped heater molded body according to an embodiment of the present invention. FIG. 3 (C) is an external view of a sheet-shaped heater molded body (heating toilet seat) according to an embodiment of the present invention, and FIGS. 4 (A) and (B) are other embodiments of the present invention. Explanatory drawing of the planar heater molded body which concerns on an example, 5th
FIG. 5A is a sectional view taken along the line VV of FIG. 3C, FIG. 5B is a sectional view taken along the line VV of FIG. 3 of another modification, and FIG. 6A and FIG. (B) and (C) are explanatory views of a conventional example. (1) …… Exothermic wire, (2) …… Surface material, (2b) …… Hole (3A) …… Upper mold, (3B) …… Lower mold (4) …… Molding resin (P) …… Surface Shaped heater molding

Claims (2)

[Claims] 1. A heating wire material for a skin material, wherein a flexible skin material having a heating wire material held on at least one surface is provided over the entire width of a gap between an upper mold and a lower mold of an upper and lower separation mold. The thermoplastic synthetic resin molding material is supplied in the molten state in the gap between the holding surface and the upper mold or the lower mold, and the upper and lower molds are engaged with each other, and the synthetic resin molding material in the fluid state is pressed by this pressure. A method for manufacturing a planar heater molded body, characterized in that the synthetic resin molded body and the skin material are integrally molded while being pushed into a mold. 2. A flexible skin material having a hole portion and holding a heating wire on at least one surface thereof is disposed over the entire width of the gap between the upper and lower molds for the upper and lower separation molds. The thermoplastic synthetic resin molding material is supplied in a heat-melted state into the gap between the skin material and the upper mold or the lower mold, and the upper and lower molds are engaged with each other, and the synthetic resin molding material in a fluid state is pressured by the pressure. A method for producing a sheet-shaped molded body, wherein the synthetic resin molded body and the skin material are integrally molded while being spread into the upper mold and the lower mold via the.