JPH01134890A - Manufacture of thread-shaped exothermic lamination body - Google Patents

Abstract

PURPOSE:To prevent the occurrence of a folding wrinkle and bend in a lamination process by keeping a difference between the thickness of an electrode line portion in a lamination body and the thickness of the lamination body deducted by the portion within the predetermined range, arraying lamination films on a fabric and pressing the films with a roll while molten resin is being fed to a gap between the films and the fabric. CONSTITUTION:A difference between the thickness T1 of a portion 15 of a thread-shaped exothermic lamination body 15 and the thickness T2 of the lamination body 15 deducted by the portion is kept within a range given by the unequity of 0mm <T1-T2<=0.4mm. And a lamination film 12 is positioned on a fabric at the side of lamination and laminated under the pressure of a roll 11 while molten resin 13 is being fed to a gap between the film 12 and the fabric. As a lamination means, there is a method whereby molten resin is applied to a fabric comprising a thread-shaped exothermic body and a film is pressed thereto while a resin applied portion is being cooled, thereby forming a lamination body. Or a method whereby a lamination film and a fabric are pressed to each other via an intervening molten resin for bonding, is used.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method of laminating a covering layer such as an insulating layer on a cloth-like heater using a thread-like heating element.

[Prior Art] As a heating element, a filamentous heating element which is flexible like thread, has excellent mechanical strength such as abrasion resistance and bending resistance, and can be easily made into a woven or knitted fabric is disclosed in a patent application. 1986-
240351 (Japanese Unexamined Patent Publication No. 62-100970), Japanese Patent Application No. 60-240352 (Unexamined Japanese Patent Application No. 62-100971), Japanese Patent Application No. 60-240353 (Unexamined Japanese Patent Application No. 62-1<1)
Patent applications have been filed as Japanese Patent Application No. 0972) and Japanese Patent Application No. 60-240354 (Japanese Unexamined Patent Publication No. 62-100973). This filamentous heating element uses a filament as a core, and its periphery is coated with a conductive layer in which conductive particles of carbon, metal, etc. are dispersed in a synthetic resin binder to form a heat generating layer. The woven or knitted fabrics obtained from this filamentous heating element have excellent properties such as the flexibility characteristic of fabrics and the ability to efficiently produce planar heating elements that can be folded repeatedly, so they can be used in a variety of applications. Development is underway.

By the way, the filamentous heating element is characterized in that it has a higher resistance value than a metal resistance wire such as a dichrome wire because carbon particles are dispersed and contained in a resin to form a conductor. Therefore, it is possible to obtain a more uniform heating surface than a metal resistance wire heating element for the same power consumption, but on the other hand, in order to supply current to the filamentous heating element, a pair of electrodes, generally made of multiple metal wires such as copper, are arranged. It is necessary to provide the electrode line array to intersect with the filamentous heating element. In addition, the part other than the part where this electrode line array is arranged (hereinafter referred to as the base part) may simply be made of fabric by crossing the filamentous heating element, and it may be made of non-conductive general yarn (hereinafter referred to as other type).
It is made with fabric.

Furthermore, electric heaters using fabric as the filamentous heating element are usually made of a laminate with an electrically insulating layer provided on the surface because it is necessary to flow a current through the heating surface. To make a laminate that bends, generally a filamentous heating element is made of cloth, coated with molten resin at t<S-, pressed while cooling, bonded with a laminating film using molten resin, and then cooled. At the same time, it is crimped with a roll to form a laminate. In this case, since the electrode wires used in the part where the electrode line rows are arranged are generally metal wires,
Since it is thicker and more rigid than the ground yarn and the thread-like heating element, it has the characteristic that the fabric is thicker and harder than the ground part.

Therefore, when stacking layers as described above, when feeding is applied while crimping with rolls, the feeding speed of the electrode line row portion is much faster than the bottom portion, causing sag in the bottom portion, resulting in a stacked product of W1. There is a certain pressure that a laminate with folds and grain bends can be obtained.

That is, the fabric shown in FIG. 2 is changed to the fabric 11 as shown in FIG.
This causes bending and creases as shown in FIG.

In Fig. 2, the fabric has an electrode wire row 3 consisting of electrode wires 2 arranged near both ends, thread-like heating elements 4 arranged at regular intervals across it, and non-conductive It was woven using ground yarns 5 and 6 of different colors. If the roll (not shown) of the electrode line array 3 portion of the fabric 1 is fed at a higher speed than the base portion, slack will occur in the center of the fabric, which will not only deteriorate the appearance of the rll but also cause damage as shown by the dotted line in Fig. 3. When cut, the filamentous heating elements 4 are cut and the yield of the laminate original fabric is reduced.

Further, in FIG. 4, when the slack increases, bending and creases 8 occur, which not only deteriorates the appearance but also poses a risk of causing problems such as the filamentous heating elements 4 coming into contact with each other and causing abnormal heat generation. be.

The present invention was made in order to solve the above-mentioned problem, and involves coating and pressing a molten resin onto a fabric on which an electrode line array for supplying current to a filamentous heating element is arranged. The aim is to provide a laminating means that does not cause folds, waves, or grain bends when laminating synthetic resin films or laminating synthetic resin films.

[Construction b1 of the invention] To achieve the above object, the method for producing a filamentous heat generating laminate of the present invention comprises a core yarn and a synthetic resin conductive layer formed around the core yarn containing conductive particles dispersed therein. A method for producing a filamentous heat generating laminate comprising a fabric having a filamentous heating element consisting of a filament and N number of electrode wires intersecting the filament, and a coating layer provided on at least one side of the fabric, in which the electrode line array portion of the laminate is The difference between the thickness (T1) and the thickness (T2) of the part of the laminated object excluding the part,
Supply molten resin to the fabric surface on the side to be laminated and press the coating layer with one call so that the range given by the following inequality, omm<'"1-'!" 2≦0.4mtll is satisfied. It is characterized by this.

Lamination means when applying the method of the present invention include a method in which a molten resin is applied to a fabric made of the filamentous heating element, and at least the coated side is pressed while cooling to form a laminate, and a lamination film and the fabric are This method involves interposing a molten resin for adhesion and pressing the two together while cooling.

The rolls used in the method of the present invention require functions such as crimping, cooling of the molten resin, and feeding of the laminate, so metal rolls are usually used as the cooling and feeding rolls (hereinafter referred to as cast drums). However, the other press roll is preferably a rubber roll made of silicone gono 1, S II IN, fluororesin, or the like. In addition,
The metal roll used is one coated with a suitable IM resin such as hard 17-mimetsu, fluororesin or silicone resin, and usually has a four-sided surface.

The difference in thickness between the electrode line array portion and the base portion of the method of the present invention,
("I"1-"I" 2) from omm to 0.4
The limitation to mm acts to prevent the occurrence of creases and grain bending in the resulting laminate. The preferred range is 0.005 mm to 0.3 mm, and the thicknesses 'f1 and 12 refer to substantial values that can be defined as the thickness of the laminate. A micrometer can be used.

That is, when the above-mentioned (1'l-'1'2) is 0mm or more, both the contact resistance and the measure of grain bending (arc shape, skewness) decrease rapidly, and gradually increase from about 0.005 mm.

On the other hand, the arc shape and obliqueness are approximately 0°3 mm from the above values.
It is almost zero value up to this value, and starts to rise from around this value, and reaches the limit value of the practical range of around 1% at about 0.4 mm.

The press pressure of the roll and the tension applied to the fabric when carrying out the present invention vary depending on the material of the roll, the fabric, and especially the specifications of the electrode wire, but generally the press pressure (linear pressure) is between 0 and 1.
~50 kg/cm, preferably 1-10 kg/cm
, the tension is 5-30 k(]/m, preferably 10
~20k (1/m).

The fabrics used in the present invention include woven fabrics, knitted fabrics, nets or mesh-like fabrics made of these fabrics, and scrims (rough fabrics).
, nonwoven fabrics, etc.

The ground yarn used in the fabric is not particularly limited as long as it is non-conductive and non-conductive fiber, and may be a yarn having strength as a fabric, such as a spun yarn, preferably a twisted yarn such as a double yarn or a triple twisted yarn. , multifilament, etc.

The lamination film is not particularly limited, but usually has a thickness of 60 to
Any resin may be used as long as it has heat resistance of about 120° C. and flexibility, and is usually a polyolefin such as polyester, polyethylene, polypropylene, or modified polyolefin.

As the electrode wire, a thin copper wire, preferably a stranded wire, which has been subjected to anti-rust treatment is used.

As the core yarn used in the filamentous heating element, either natural fiber or synthetic fiber can be used. Examples of commonly used fibers include polyamide fibers, polyester fibers, polyolefin fibers, and acrylic fibers.
If necessary, other desired fibers, such as aromatic polyamide fibers for the purpose of imparting heat resistance and high tensile strength, may be appropriately selected and used.

The key point is the mechanical strength such as tensile strength required for the core yarn, and the heat resistance normally required is about 120°C at most. For example, spun yarn, preferably twisted yarn, double stranded yarn, textured yarn, multifilament, etc. are used as appropriate.

The thickness of the yarn used is usually 0.1 to 0.5 mmφ,
Preferably, the diameter may be 0.2 to 0.3 mφ.

The conductive particles used in the filamentous heating element are usually carbon particles, but are not particularly limited and may be metal particles, and it is usually preferable to use them as fine particles. In addition, as a flexible synthetic resin binder for dispersing conductive particles,
For example, polyurethane 1M resin, polyacrylic resin, butyral resin, etc. can be used as appropriate, but the material is not limited thereto.

To produce the filamentous heating element, the core yarn is passed through a suspension (usually a highly viscous liquid) in which conductive particles are dispersed in a synthetic resin binder solution, and the amount of adhesion is adjusted using a die. It is dried and solidified to produce a filamentous heating element. To stack the conductive layer, repeat the following process a predetermined number of times.
Usually 0.4-0.6 mmφ, preferably 0.5-0.
It is used as a thickness of 55mmφ. In general, filamentous heating elements using carphone particles as conductive particles have a diameter of 1 to 100.
, usually the electrical resistance can be adjusted to a range of 10 to 50.07 m.

Examples 1 to 3 and Comparative Examples 1 and 2] The method of the present invention will be specifically explained below with reference to Examples and Comparative Examples.

The filiform fibers used in each example and comparative example! The fabric consists of a thin copper wire with a diameter of 0.1.2 mm as warp threads,
An electrode wire made of three wooden strands, a thread-like heating element using No. 20 polyester spun yarn (50 threads/inch) as the ground thread, a diameter of 0.5 mm as the weft, and a batting interval of 5° 8 mm, and the ground. It was woven using No. 5 polyester spun yarn (25 threads/inch) as the thread. In addition, the thread-like heating element described in mf is made of polyester spinning type (20
The conductive layer was coated with a conductive layer in which fine carbon particles were dispersed in flexible polyester polyurethane, and the resistance value was approximately 14 Ω/mm.

The fabric is a plain weave fabric with a width of 950 mm,
The electrode line rows were arranged in two rows at 190 mm from the edge of the fabric, with an interval of 540 mm, and each electrode line row was
The 20 stranded copper wires are arranged in a width of 10 mm, and the thickness of that part is F. -1) was 0692 mm. The thickness of the base portion (Go o-2) was 0°45 mm.

The film used as the coating layer is a polyethylene film with a thickness of 40 μm, and low-density polyethylene (mel l~index 4°0g, /10 minutes,
A density of 0.925> was used.

For the laminates used in each example, an apparatus schematically shown in FIG. 1 was used. In the figure, a cast drum 10, which also serves as a cooling device for molten resin, is a hard chrome-plated metal roll maintained at 20°C, and a press roll 11 is a rubber roll. To this, the fabric 1 described above and the polyethylene film 12 are fed together to each roll as shown in the figure,
The low-density polyethylene 13 melted at 300° C. is supplied to an extruder with a diameter of 65 mm of a melt extrusion laminator (not shown), and is applied to the fabric immediately before the fabric 1 and the film 12 are pressed together from the 1-1 metal 14 having a width of 1100 mm. , thickness 80
A three-layer laminate 15 of polyethylene/fabric/polyethylene was obtained by discharging the product in the form of a μm film.

In each example and specific drawing example, the press pressure (linear pressure) is 0.
~40kg7cm, winding tension of laminate 2~30kg/
The lamination conditions and evaluation results are shown in Table 1. The evaluation will be based on creases, fabric bending, and contact resistance between the electrode wire and the filamentous heating element, and the evaluation of each result will be performed after listing the word list.

[Example 4] The same fabrics used in Examples 1 to 3 before being laminated were applied to a press roll device consisting of a pair of metal rolls, and a press pressure (linear pressure) of 7! Calendaring was performed with < g/cm, rolling cuff kg/m. The thickness of the electrode wire portion of the fabric after calendering (r'o-1> was 0.85 mm, and the thickness of the base portion (T o-2> was 0.41 mm. The fabric was laminated using a melt extrusion laminator on both sides of the fabric using the same coating material as in the previous example.The lamination conditions and evaluation results are listed in Table 1.

Notes: (1) Measurements for cloth purposes were based on the arcuateness and obliqueness defined in Monthly S L 109 (3). (2) Measurement of contact resistance value was based on the number of electrode wires used, The electrical resistance between the picture electrode wires was measured using a tester for a sample in which the electrode wire spacing and the number of filamentous heating elements were kept constant.

As shown in Table 1, the results of Examples 1 to 3 are omm<(
This laminate original fabric was within the range of T1-'T"2) 50.4mm, had a very good appearance with no creases, no fabric defects, and had a good contact resistance value of 42Ω. When it was cut to a width of 300 mm in the warp direction, it was possible to obtain a heater wattage of 65 W as designed without cutting the filamentous heating element.

On the other hand, in Comparative Example 1, both the unwinding force and the press roll linear pressure were lowered, so the value of (T1-1'2) was 0.
As large as 43 mm, creases occur at the edges of the fabric, making the fabric very rough.Furthermore, the flatness is poor, with many irregularities of several tens of meters in size occurring around the electrode line array, giving a poor appearance, and the resistance value is low. It showed a large value.

When this material was cut in the same manner as above, part of the filamentous heating element was cut off, and the heater wattage was 60W, which was the prescribed 65W.
W could not be obtained and the product was rejected, and it took time and effort to cut it to obtain a predetermined wattage, which resulted in a drawback that the yield of the laminate material was reduced.

In addition, in Comparative Example 2, both the unwinding boost force and the press roll linear pressure were increased, so T1-'r' 2 =olnm and there were no creases, but the fabric was warped and the appearance was poor. Moreover, the contact resistance value was large, and when it was cut in the same manner as described above, the number of heater straws was 61 W, which was the same as Comparative Example 1 because the desired value of 65 W could not be obtained. Note that the reason for the increase in the contact resistance value is that low density polyethylene entered between the electrode wire and the filamentous heating element due to high press pressure.

In Example 4, the electrode line array portion was pressed in advance [because this portion was made thinner, 'I''l-'''l'2=Q.

It shows a very small value of 0.05 mm, and wrinkles, cloth [1++
There was no occurrence of warping, the appearance was very good, the contact resistance was small, and a 35W laminate heater could be obtained by cutting to the predetermined dimensions.

In FIG. 1, by not using the laminating film 12 and using a press roll 11 through which cooling water is passed, and by supplying the fabric 1 instead of the laminating film 12, the fabric shown in the figure can be obtained. By omitting 1, even when laminated in the same manner as described above, it is possible to obtain a laminated body 15 that has no purpose as a cloth, as in the above embodiment.

[Effects of the Invention] As explained below, the method for laminating a filamentous heat generating laminate of the present invention comprises a core yarn and a synthetic resin conductive layer formed around the core yarn containing conductive particles dispersed therein. In a filamentous heat generating laminate formed by providing a coating layer on at least one side of a fabric having a filamentous heating element and a plurality of electrode wires intersecting with the filamentous heating element, the thickness (1'1) of the electrode line array portion of the laminate. The difference between the thickness of the laminated object part excluding the part ('T'2>) is kept within the range given by the following inequality, omm<'r1-T2≦o, 4 mm, and Since the lamination film is placed on the fabric surface and the molten resin is supplied between them, the film is laminated by pressure bonding with a roll.
The lamination process eliminates creases and fabric wrinkles, and the flatness around the boundary between the electrode part and base part of the laminate is good, creating a heater with a good appearance, low contact resistance, and high cutting yield. You can get the effect that you can.

[Brief explanation of the drawing]

Fig. 1 is a schematic explanatory diagram of the apparatus used to laminate the filamentous heat generating laminates of each example and comparative example, Fig. 2 is a partial plan view of a fabric made of filamentous heat generating elements, and Figs. The figure is an explanatory diagram for cloth purposes. 1... Fabric made of filamentous heating element, 10... Casl
~ drum, 11... press roll, 12... coating phase film, 13... molten resin, 14... "1 gold, 1
5... Filiform heat generating laminate.

Claims (1)

[Scope of Claims] At least one side of a fabric having a thread-like heating element made of a core yarn, a synthetic resin conductive layer formed around the core yarn and containing conductive particles dispersed therein, and a plurality of electrode wires intersecting the heating element. In the method for producing a filamentous heat generating laminate in which a coating layer is provided on the laminate, the difference between the thickness of the electrode line array portion (T_1) of the laminate and the thickness of the laminate body excluding this portion (T_2) is determined as follows: A filamentous heating element characterized in that the coating layer is crimped with a roll while supplying molten resin to the surface of the fabric on the side to be laminated so that the inequality 0mm<T_1-T_2≦0.4mm is satisfied. Method for manufacturing a laminate.