JPH04209487A - woven heating element - Google Patents

Abstract

PURPOSE:To ensure the prevention of the meandering motion of an electrode wire by applying a three-layer structure to a flat yarn laid at both sides of the electrode wire. CONSTITUTION:A woven exothermic body A is constituted by weaving a yarn group 1 containing flat yarns 12 for exothermic wires 11 with a yarn group 2 containing flat yarns 22 for electrode wires 21 connected to the exothermic wires 11. Of the flat yarns 12 and 22, the flat yarns 22 are formed to have a three-layer structure comprising low density polyethylene layers 22b and 22c laminated on both sides of a substrate layer 22a. This substrate layer 22a ensures the ductility and strength of the flat yarns 22, while the layers 22b and 22c ensure quality for bonding the flat yarns 22 to a protection sheet. According to the aforesaid construction, the flat yarns 22 ensures the electrode wires 21 to be prevented from meandering.

Description

[Detailed Description of the Invention] <Industrial Application Field> The present invention relates to a fabric-like woven heating element that is used in electric blankets, electric carpets, etc., into which a fibrous heating element (heating wire) is woven. be.

<Prior Art> As shown in FIG. 4, the woven heating element 90 has heating wires 91
and a first polyethylene flat yarn 92.
A second yarn group 96 is electrically connected to the heating wire 91 and includes an electrode wire 94 for supplying power to the heating wire 91 and a polyethylene flat yarn 95. It consists of things.

In addition, the woven woven heating element 90 is heated and welded with protective sheets including an insulating layer, a protective electrode layer, etc. stacked on top and bottom of the woven heating element 90, and the protective sheets are laminated and integrated on both sides. After the woven flat yarns 92 and 95 are melted and integrated by the above heating, they are incorporated into an electric blanket or an electric carpet for use.

<Problems to be Solved by the Invention> However, in the conventional woven heating element 90, the adhesiveness of the flat yarns 92, 95 during thermal welding is not sufficient, so the metal electrode wire 94 tends to meander, and the If the electrode wires 94 meander, adjacent heating wires may overlap or
There is a risk that problems such as uneven heat generation and reduction in reliability such as bending resistance may occur. Further, the above-mentioned insight heating body 90 usually has a first yarn group 93 and a second yarn group 96.
The electrode wire 94 is manufactured by weaving it into a long belt shape and then cutting it into a predetermined length, but if the electrode wire 94 meanders during weaving, there is a problem that the cutting workability decreases. .

Therefore, in the above-mentioned heating element 90, spun rayon yarns (so-called staple yarns) 97 are arranged on both sides of the electrode wires 94, and the fluff on the surface of the spun rayon yarns 97 causes
Adhesion between the protective sheet and the spun rayon yarn 97, and between the spun rayon yarn 97 and the flat yarn 92 and the heating wire 91 is ensured to prevent the electrode wire 94 sandwiched between the spun rayon yarn 97 from meandering. ing.

However, the spun rayon yarn 97 has a smaller weaving pitch than the flat yarn 95, and the electrode wire 9
In order to ensure the adhesion necessary to prevent meandering of the electrode wires 4, it is necessary to arrange a plurality of electrode wires 94 on both sides of the electrode wire 94, as shown in the figure. For this reason, during the process of continuously weaving the shinken thermal body 90 using a loom, the loom must be taken up and stopped to weave in a plurality of spun rayon yarns 97, which reduces productivity. It was a problem.

In addition, both the spun rayon yarn 97 and the flat yarns 92 and 95 made of different materials can be welded to the protective sheet, and the temperature at which the spun rayon yarn 97 can be welded to the flat yarn 92 and the heating wire 91 is very low. There was also the problem that temperature control was difficult because it was limited to a narrow range. For example, if the surface of the protective sheet that comes into contact with the heating element 90 is made of polyethylene, as are the flat yarns 92 and 95, the temperature at which the above-mentioned members are welded is 135 to 14
It is limited to a narrow range of 0°C.

If the above-mentioned welding cannot be performed sufficiently, a gap will be created between the discerning heating element 90 and the protective sheet, and the detection reliability of the safety protection circuit for abnormal heating detection etc. provided on the outside of the protective sheet will be impaired. There was a risk that the heating element 90 and the like would be damaged during use.

The present invention was made in view of the above circumstances, and
The object of the present invention is to provide a thermal body that can reliably prevent meandering of electrode wires without using spun rayon yarns made of different materials and having different weaving pitches.

Means for Solving the Problems> In order to solve the above problems, the present inventors investigated the cause of the low adhesiveness during thermal welding of conventional flat yarns. As a result, conventional flat yarns consist of high-density polyethylene produced by low- or medium-pressure processes;
It has been found that because its surface is extremely dense and smooth, its adhesion to other members is low. Therefore, as a result of further investigation, the present invention was completed.

Therefore, the thermal body of the present invention is characterized in that at least the flat yarns arranged on both sides of the electrode wire have a three-layer structure in which low-density polyethylene layers are laminated on both sides of a polyethylene base layer. There is.

Effects> In the heating element of the present invention having the above structure, at least the surface of the low-density polyethylene layer formed on both sides of the flat yarn disposed on both sides of the electrode wire has a fluff similar to the fluff of the spun rayon yarn. It has a structure with a large number of side chains that act as

<Example> Below, the discerning heat body of the present invention will be described with reference to the drawings showing examples.

As shown in FIG. 3, the heating element A of this embodiment includes a first yarn group 1 including a heating wire 11 and a flat yarn 12 made of polyethylene, and an electrode wire electrically connected to the heating wire 11. 21 and polyethylene flat yarn 2
It is constructed by weaving a second yarn group 2 including 2.

The heating wire 11 may be a narrow, thin tape-shaped material made by dispersing conductive particles such as carbon particles in a flexible and heat-resistant binder resin such as polytetrafluoroethylene, for example, made by Daikin Industries, Ltd. The company's product name ``Florotron'') is used.

As the polyethylene flat yarns 12 and 22,
A narrow and thin tape-like material is used, and among both flat yarns 12 and 22, the flat yarn 2 of the second yarn group 2
2 is a base layer 2 made of polyethylene, as shown in FIG.
It has a three-layer structure in which low-density polyethylene layers 22b and 22c are laminated on both sides of 2a. The base layer 22a is for ensuring the stretchability and strength of the flat yarn 22, and is made of high-density (density about 0.93 to 0.94 g/aA) polyethylene manufactured by a low pressure method or a medium pressure method. . The low-density polyethylene layers 22b and 22c are for ensuring adhesion of the flat yarn 22 to the protective sheet, and are manufactured using a high-pressure method and have a density of 0.915.
It is made of low density polyethylene of about 0.925g/-.

The flat yarn 22 having the three-layer structure uses a piece of high-density polyethylene manufactured by a low-pressure method or a medium-pressure method as a raw material for the base layer 22a, and the low-density polyethylene layer 22a is
2b and 22c can be integrally manufactured using polyethylene pieces manufactured by a high-pressure method as the raw materials in the same manner as extrusion lamination of ordinary multilayered films.

As the electrode wire 21, a core wire made of spun rayon thread or the like with copper foil wound spirally is used.

The weaving heating element A of this embodiment has the first yarn group 1 as the warp and the second yarn group as the warp.
VA having the same structure as usual, with yarn group 2 as the weft
After weaving continuously as shown in Figure 2 using
An electrode band portion Al in which the electrode wires 21 are woven in the vicinity of two parallel sides, respectively.

It is manufactured by cutting at the position indicated by the two-dot chain line in the figure so that A1 is located.

In the textile heating element of this example, which has the above configuration,
Since the flat yarn 22 of the second yarn group 2 has low-density polyethylene layers 22b and 22c with excellent adhesive properties on both sides, the flat yarn 22 reliably prevents meandering of the electrode wire 21.

Therefore, there is no need to weave spun yarns of short fibers with different weaving pitches, such as spun rayon yarns, and productivity is improved accordingly.

In addition, since spun rayon yarn made of a different material is no longer necessary, - the temperature range in which thermal welding can be performed becomes wider, and temperature control becomes easier. For example, if the surface of the protective sheet that comes into contact with the fabric heating element A is made of polyethylene, the temperature at which welding can be performed is 130 to 140°C, which is double the range of the conventional one.

Therefore, there is no gap between the weaving heating element A and the protective sheet, and the detection reliability of the safety protection circuit for detecting abnormal heating, etc. provided outside the protective sheet is improved, and the weaving heating element There is no risk of it being damaged.

In the illustrated example, all the flat yarns 22 of the second yarn group 2 were formed into a three-layer structure in which low-density polyethylene layers 22b and 22c were laminated on both sides of a polyethylene base layer 22a. In the present invention, as long as at least the flat yarns 22° 22 arranged on both sides of the electrode wire 21 have the above three-layer structure, the other flat yarns do not need to have the three-layer structure. . However, if all the flat yarns 22 of the second yarn group 2 have a three-layer structure as in the above embodiment, there is an advantage that the adhesion of the textile heating element A to the protective sheet etc. can be further improved. be. Further, in the present invention, only the flat yarn 22 of the second yarn group 2 is smoothed,
The flat yarns 12 of the first yarn group 1 may also have a three-layer structure to further enhance the adhesion.

Heat generating wire 11, flat yarn 12 in yarn groups 1 and 2.
22, the arrangement of the electrode wires 21, etc. is not limited to the embodiment shown in the figure, and the above-mentioned wires can be arranged as appropriate in accordance with the heat generation pattern required of the textile heating element A. Further, the yarn group 1.2 may include a temperature detection line for detecting the temperature of the weaving source heating element.

The weaving of the weaving element A is not limited to the plain weave of the illustrated embodiment, and other weaving methods such as twill weave or satin weave may be adopted.

In addition, various design changes can be made without changing the gist of the present invention.

<Effects of the Invention> The textile heating element of the present invention is constructed as described above, and at least the flat yarns arranged on both sides of the electrode wires have low-density polyethylene layers laminated on both sides of the polyethylene base layer. Since the low-density polyethylene layer has excellent adhesion to other members, the flat yarn can reliably prevent meandering of the electrode wire.

Therefore, the textile heating element of the present invention does not use spun rayon yarn and can reliably prevent meandering of the electrode wire.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view showing the layer structure of a three-layered flat yarn used in the textile heating element of the present invention, FIG. 2 is a plan view showing the continuous production of the textile heating element of the invention, and FIG. The figure is a plan view showing one embodiment of the textile heating element of the present invention, and FIG. 4 is a plan view of a conventional textile heating element. A... Weaver heating element, 1... First thread group, 2...
...Second thread group, 11...Heating wire, 12...Flat yarn, 21...Electrode wire, 22...Flat yarn, 22a...Base layer, 22b, 22c...
Low density polyethylene layer. Patent applicant Daikin Industries, Ltd. Agent Patent attorney Takafumi Watanabe (and 2 others) A...Original heating element 22--Flat yarn 220--Base layer 22b, 22c...Low-density polyethylene layer Fig. 1 Fig. 2 A..., insight heating body 1... - first thread group 2 - thread group 11 of Atsushi 2... heating wire 12 - flat yarn 21 - - electrode wire 22 - ” ) 5-/ h“-′
1. . Go to 8 Figure 3

Claims (1)

[Claims] 1. A first yarn group (1) including a heating wire (11) and a polyethylene flat yarn (12);
11) and a second yarn group (2) containing a polyethylene flat yarn (22), at least the electrode wire Flat yarns (22) arranged on both sides of the polyethylene base layer (22a
) Low density polyethylene layers (22b) (22c) on both sides
A woven heating element (A) characterized by having a three-layer structure in which the following layers are laminated.