JP2014235926A - Heater unit - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a heater unit that can be sufficiently used for a heating toilet seat, and that has improved workability when adhered.SOLUTION: A heater unit 1 comprises: a substrate 11 on which a base part 12, an adhesion layer 13 and an exfoliation sheet 14 are laminated and that is divided into plural parts; and a heating element 21 arranged on the substrate 11. A protrusion piece 15 projecting corresponding to shapes of the substrate 11 and the adhesion layer 13 is formed at an end of the exfoliation sheet 14. The protrusion pieces 15 of the respective plural divided substrates 11 are adjacent to each other. One part of the base part 12 and the adhesion layer 13 is folded onto a face side on which the adhesion layer 13 exists, so as to form the protrusion pieces 15. The heater unit 1 has a reinforcing material, and the heating element is held by the reinforcing material and the base part.

Description

  The present invention relates to a heater unit used for, for example, a heating toilet seat, and more particularly to an improved workability when attaching the heater unit.

  Conventionally, a so-called heating toilet seat having a heating function is known as a toilet seat of a Western-style toilet. As such a thing, there exists a thing which performs an electrical heating using the planar heater unit by which the cord-shaped heater was arrange | positioned on the aluminum foil base material, for example. This heater unit will be affixed to the upper part in a toilet seat by the contact bonding layer formed in the base material. Here, since the shape of the toilet seat is generally a horseshoe shape, if a base material having a shape suitable for the shape of the toilet seat is formed by punching as it is, a lossy portion is very large. Thus, for example, Patent Document 1 describes a heater unit in which a base material is punched into a shape obtained by dividing a horseshoe shape in order to reduce loss, and a cord-like heater is disposed so as to be continuous therewith.

  On the other hand, the manufacture of the heater unit and the assembly of the heating toilet seat are usually separate processes. Therefore, when transporting the heater unit between processes, keep one side of the adhesive layer covered with the release sheet, and when assembling to the toilet seat, peel off the release sheet and use the adhesive layer to place the heater unit in the toilet seat Will be fixed.

  As a technique related to the present invention, for example, Patent Documents 2 to 4 have been filed by the applicant.

Japanese Patent No. 2994733: Clave JP 2010-70682 A: Clave JP 2012-17396 A: CLAVE JP 2012-17397 A: Clave

  Here, in the case of the conventional heater unit described above, since the end of the adhesive layer and the end of the release sheet are evenly aligned at the end of the base material, only the release sheet can be gripped. It is difficult to peel only the release sheet. In actual work, in order to prevent the worker from being injured and protect the product, the worker carries out the work by wearing a protective gear such as a work gloves, so that it is more difficult to peel only the release sheet. Since this is a difficult operation, even the adhesive layer may be peeled off from the heater unit when only the release sheet is peeled off. If this happens, the base material may wrinkle as the adhesive layer is reapplied, and the base material may break as the adhesive layer is peeled off. .

  Since Patent Document 2 describes an adhesive tape in which a part of the release sheet is peeled from the adhesive layer, the above-described problem can be solved to some extent if the heater unit uses this adhesive tape. However, in the heating toilet seat, since the base material is divided as described above, the release sheet is also divided, and it takes time to separate each release sheet separately. Therefore, even with the invention of Patent Document 2, workability has not been sufficient.

  The present invention has been made in order to solve such problems of the prior art, and an object of the present invention is to provide a heater unit having improved workability particularly when sticking.

In order to achieve the above object, a heater unit according to the present invention is a heater comprising a base, an adhesive layer, and a release sheet, and a base material divided into a plurality of parts, and a heating element disposed on the base material. The unit is a unit, and at the end of the release sheet, a protruding piece protruding from the shape of the base material and the adhesive layer is formed, and the protruding pieces in each of the divided bases Are close to each other.
Further, it is conceivable that a part of the base and the adhesive layer are folded on the surface side where the adhesive layer exists, thereby forming the protruding piece.
Further, it is conceivable that the heating element is held between the reinforcing material and the base portion.
Note that “protrusion pieces are close to each other” means that the distance is such that a normal worker can hold the protruding pieces at the same time when holding the protruding sides.

  According to the present invention, since the plurality of projecting pieces are close to each other, the plurality of release sheets can be peeled by a single operation, and workability can be improved.

It is a top view which shows the heater unit by this Embodiment. It is a figure which shows the heater unit by this Embodiment, and is II-II 'sectional drawing in FIG. It is a figure which shows the heater unit by this Embodiment, and is a side view from the III direction in FIG. It is explanatory drawing which shows the manufacturing method of the heater unit by this Embodiment. It is a top view which shows the manufacturing method of the base material used by this Embodiment. It is a partially notched perspective view which shows the structure of the heat generating element used by this Embodiment. It is explanatory drawing which shows the method of forming the protrusion part part of the heater unit by this Embodiment. It is a top view which shows the heater unit by other embodiment. It is a figure which shows the heater unit by other embodiment, and is IX-IX 'sectional drawing in FIG. It is a figure which shows the heater unit by other embodiment, and is a side view from the X direction in FIG. It is a top view which shows the heater unit by other embodiment. It is a top view which shows the heater unit by other embodiment.

Hereinafter, the present invention will be described in more detail with reference to the drawings.
In the present embodiment, a substrate divided into two parts is used. One is a substrate 11a and the other is a substrate 11 '. As the base materials 11 and 11 ', those obtained by laminating base portions 12 and 12' made of aluminum foil, adhesive layers 13 and 13 'made of an adhesive, and release sheets 14 and 14' made of a polyester film were used. These base materials 11 and 11 'are punched into a shape obtained by dividing a horseshoe shape as shown by a solid line in FIG. In mass production, about 10 substrates are stacked and punched out by a press with a cutter. Further, as the heating element 21, as shown in FIG. 6, a cord in which a resistance wire 23 is spirally wound around a wire core 22 made of glass fiber, and an insulating coating 24 made of polyvinyl chloride resin is formed directly thereon. A shaped heater was used.

  A method for manufacturing the heater unit according to the present invention will be described below. First, as shown in FIG. 4, the heat generating element 21 is wired in a horseshoe shape on a molding table 31 having a retractable locking tool 32. Next, the base materials 11 and 11 ′ punched into a horseshoe shape are arranged on the wired heating element 21. At this time, the base portions 12 and 12 ′ are made to be in contact with the heating element 21. Next, a heating plate 34 heated to about 250 ° C. is applied thereon, and the heating element 21 and the base materials 11 and 11 ′ are heated under pressure. Here, when the heating element 21 is pressurized and heated by the hot plate 34, the locking tool 32 that holds the heating element 21 is immersed in the molding table 31. It does not hinder the fusion with the base material 11, 11 ′. As shown in FIG. 4, the molding table 31 is provided with a groove 33 so as to be located at the cutting boundary line of the base material 11, 11 ′ punched into a horseshoe shape. This is a place where the heat generating element 21 is released in order to prevent the heat plate 34 from directly touching the heat generating element 21 and excessively softening the insulating coating 24 when a gap occurs at the boundary.

  The heater unit 1 is obtained by such a manufacturing method as shown in FIG. In the heater unit 1, the insulating coating 24 positioned on the surface of the heat generating element 21 is softened and deformed by pressure heating, and is firmly bonded to the base portions 12 and 12 ′ of the base materials 11 and 11 ′. Moreover, the loss of the base materials 11 and 11 ′ according to the present embodiment was reduced to about 2/3 of the area that was effectively used. Furthermore, since the base materials 11 and 11 ′ are bonded together before the base 12 and the adhesive layer 13 are punched into a horseshoe shape, the bonding surfaces are shifted by the bonding operation of the base portions 12 and 12 ′ and the adhesive layers 13 and 13 ′. Or wrinkles on the bases 12 and 12 '. Therefore, work efficiency is high and productivity is high.

  At the ends of the base materials 11 and 11 ′, projecting pieces 15 and 15 ′ of the release sheets 14 and 14 ′ are formed. As a method for forming the protruding piece 15, for example, the one shown in FIG. 7 can be considered. First, at the end of the base material 11 configured as shown in FIG. 7A, a part of the release sheet 14 is peeled off from the adhesive layer 13 as shown in FIG. ), The base 12 and a part of the adhesive layer 13 are folded to the surface side where the adhesive layer 13 exists, and then the release sheet 14 is returned to the original position as shown in FIG. 7 (d). As a result, the release sheet 14 is formed with a protruding piece 15 where the adhesive layer 13 and the release sheet 14 are not in contact with each other. If the protruding piece 15 is gripped, the release sheet 14 is easily peeled off. It becomes possible. Further, as shown in FIGS. 1 and 3, the protruding piece 15 ′ of the release sheet 14 ′ is also formed on the base material 11 ′. Here, since the projecting pieces 15 and 15 'are formed at positions close to each other, when the operator peels off the release sheets 14 and 14', the projecting pieces 15 and 15 'are simultaneously held. can do. Therefore, a plurality of release sheets can be released by a single operation, and workability can be improved.

  Further, as shown in FIGS. 8, 9, and 10, a reinforcing member 41 made of aluminum foil or the like may be used, and the heating element 21 may be sandwiched between the reinforcing member 41 and the base portion 12. In particular, since a large external force may be applied to the heat generating element 21 at the boundary portion between the base material 11 and the base material 11 ′, the reinforcing material 41 is provided so as to cover the boundary portion between the base material 11 and the base material 11 ′. It is preferable to arrange them. Of course, the heating element 21 may be sandwiched between the reinforcing material 41 and the base portions 12 and 12 ′ on the entire surface of the base material 11 and the base material 11 ′.

  In addition, this invention is not limited to said embodiment. For example, for the base portion 12 of the substrate 11, in addition to aluminum foil, metal foil such as copper foil and stainless steel foil, PET, PPS, fluororesin, polypropylene resin, polyamide resin, polyimide resin, polyethylene resin, polyvinyl chloride resin, etc. Resin films consisting of isoprene rubber, styrene butadiene rubber, nitrile rubber, chloroprene rubber, ethylene propylene rubber, acrylic rubber, fluoro rubber, urethane rubber, silicone rubber and other rubber sheets (including foam rubber), non-woven fabric, woven fabric, knitted fabric Fabrics such as cloth and various paper materials are also conceivable. The adhesive layer 13 of the substrate 11 may be appropriately formed by a known method such as attaching a sheet-like adhesive or applying an adhesive. As the sheet-like adhesive, one obtained by applying an adhesive on both surfaces of the base material layer or one composed only of the adhesive can be appropriately selected. Since various adhesive components are commercially available, the adhesive may be appropriately selected according to the material of the base 12 and the material to which the heater unit 1 is attached. Also, what is called a pressure-sensitive adhesive is preferable because of its high workability. As for the release sheet 14 of the substrate 11, various resin sheets, release papers, and the like can be used as appropriate. In particular, those subjected to a release treatment such as a silicone coat are preferred. Moreover, about the contact bonding layer 13 and the peeling sheet 14, since it is united and marketed as a double-sided adhesive sheet with a peeling sheet, you may use this.

  Moreover, in the said embodiment, although the base material 11 which laminated | stacked the base 12, the adhesive layer 13, and the peeling sheet 14 previously was used, after arrange | positioning the heat generating element 21 in the base 12, the adhesive layer 13 and the peeling sheet 14 are used. May be attached.

  In addition to the cord heater, various heaters such as an etching heater, a carbon heater, and a foil heater can be used as the heating element 21.

  In the present embodiment, a base material obtained by dividing a horseshoe shape into two parts is used, but it may be divided into three parts or more. In this case, the projecting piece portion is formed on each base material, and the position of the projecting piece portion is designed so that the release sheet of the adjacent base material can be peeled off simultaneously. For example, when the base material is divided into 11, 11 ′ and 11 ″, the projecting piece portions 15a, 15b and 15c are formed as shown in FIG. 11, or the projecting piece portions 15a and 15c as shown in FIG. It is conceivable to form 15b, 15c, 15d.

  As described above, the heater unit according to the present invention has improved workability when attaching. In addition to the above-described heating toilet seat, this heater unit can be suitably used for, for example, an electric blanket, an electric carpet, a car seat heater, a steering heater, a defogging mirror heater, a heating cooker, a floor heating heater, and the like.

DESCRIPTION OF SYMBOLS 1 Heater unit 11, 11 'Base material 12, 12' Base part 13, 13 'Adhesive layer 14, 14' Release sheet 15, 15 'Protrusion piece part 21 Heating element 41 Reinforcement material

Claims (3)

A base unit, an adhesive layer, and a release sheet are laminated, a heater unit comprising a base material divided into a plurality of parts, and a heating element disposed on the base material,
At the end portion of the release sheet, a protruding piece portion protruding with respect to the shape of the base material and the adhesive layer is formed, and the protruding piece portions in each of the divided base materials are close to each other. A heater unit characterized by that. 2. The heater unit according to claim 1, wherein a part of the base and the adhesive layer is folded to a surface side where the adhesive layer exists, thereby forming the protruding piece. The heater unit according to claim 1, further comprising a reinforcing member, wherein the heating element is sandwiched between the reinforcing member and the base portion.

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