JP2002089865A - Electric heating surface heating unit and electric floor heating unit therewith - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a surface heating unit which can be reduced with the deviation of heat among adjacent panels and simplified with the assembling of flooring integral type electric heater panels. SOLUTION: An electric heater surface heating unit is formed with the lamination of electric heating surface heaters having a plurality of electric pole wires with insulation layers between them on a metal substrate, wherein the metal substrate, the insulation layers and the electric heating surface heaters of the electric heating surface heater unit are provided with cut offs at a same position in the direction of the lamination. The electric floor-heating panel is placed between a front surface floorboard and a back surface floorboard made of the plywood boards of such as similar or a size larger than the size of the unit, wherein the front floorboard and the back floorboard are directly fixed on the electric heating surface floor heating panel by adhesive applied to the cut off part and the peripheral part of the electric heating surface heating unit.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electric heating unit which is incorporated in a heating floor material, and more particularly to an electric heating unit having a structure capable of reducing heat unevenness by incorporating a flooring-integrated electric heating panel.

[0002]

2. Description of the Related Art Positive Temperature Coefficient
oefficient, hereinafter referred to as “PTC”. 2. Related Art A surface heating element using a composite material in which conductive particles having characteristics are dispersed in a resin is known. This surface heating element is made by attaching a metal foil or a metal plate as a heat equalizing plate, or forming a sheet laminated with metal foil into a tube shape in order to equalize the heat on the heat generating surface and transfer heat to the non-heat generating part. It was processed and a surface heating element was put inside.

On the other hand, the use of floor heating has rapidly progressed because houses have become highly airtight and highly heat-insulated, the heat source is not exposed, the room can be used effectively, and dust is not scattered.

[0004] Electric floor heating systems used for wooden floors include a joist method in which an electric heating panel is dropped between joists, a plywood integrated type method in which panels are installed on plywood steebari, and a surface floor material incorporated into a surface floor material. There is an integrated system, and a heating wire or a sheet-shaped composite heating element is mainly used as a heat source.

[0005]

In the case of the joist method and the integrated plywood method, the heat distribution on the surface is good because it is installed under the surface flooring material, but the time required for the floor surface to warm up after the power is turned on. As a result, a large amount of heat is lost to the lower surface, and a high-output electric heating element is required to sufficiently warm the surface.

In a flooring-integrated electric heating panel in which an electric heating element is incorporated in the surface flooring, the distance from the heat source to the surface flooring is short. There is an advantage that the time until the warming is short. However, when manufacturing the panel, after bonding the heating surface heating unit with plywood or similar material, in order to temporarily fix these components until the adhesive is completely solidified, a plastic tucker is driven in. When the tucker is driven into the heating element on which the current flows, there is a risk that the current is short-circuited between the heating element and the metal substrate. It is not possible to dispose the electric heating element at the peripheral portion, that is, at the connection portion with the adjacent panel, and as a result, it is difficult for the portion to warm up in this portion, causing heat unevenness.

SUMMARY OF THE INVENTION An object of the present invention is to provide a surface heating unit capable of reducing heat unevenness between adjacent panels and simplifying assembly of a flooring-integrated electric heating panel.

[0008]

In order to solve the above-mentioned problems, the present invention provides an electric heating unit comprising a metal substrate and an electric heating element having a plurality of electrode wires laminated via an insulating layer. Wherein the metal substrate, the insulating layer and the electric heating element have a defective portion at least at the same position in the stacking direction.

Further, in order to solve the above-mentioned problems, the present invention provides a method for manufacturing the above-mentioned electric heating unit, wherein the heating unit comprises a plywood having a size equal to or slightly larger than the unit, or a surface floor made of a material similar thereto. An electrically heated floor heating panel sandwiched between a floor material and a rear floor material, wherein the front floor material and the rear floor material are directly fixed by an adhesive applied to a defective portion and a peripheral portion of the planar heating unit. provide.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION An electric heating surface heating unit of the present invention has a wide effective heating surface with respect to the surface of a flooring floor material.
In addition, when assembling the flooring-integrated electric heating panel, in order to fix the front floor material and the rear floor material directly with an adhesive, the surface heating unit is provided with a cutout of a size that does not affect the uniformity. Have.

[0011] In order to manufacture an electric heating surface heating unit provided with the defective portion, an electric heating surface heating element in which an electric heating surface of a corresponding portion is cut in advance is used, and a metal substrate serving as a soaking plate is provided via an insulating layer. Alternatively, a method of laminating an electrically heated surface and an insulating layer, forming a hole in the insulating layer, performing an insulating treatment, and then laminating the metal substrate may be employed. . At this time, the insulating layer and the metal substrate also have equivalent or smaller defect portions at the same position. The size of the defective portion is set so as not to affect the soaking.

The metal substrate to be laminated on the electric heating element is used as a heat equalizing plate, and one continuous metal sheet for each electric heating element is used.

As the material of the metal substrate used in the electric heating unit of the present invention, for example, aluminum, copper,
Examples of the metal substrate used in the electric heating unit according to the present invention include an aluminum film or sheet having excellent thermal conductivity and having been subjected to surface oxidation processing.

The electric heating element used in the electric heating element of the present invention is obtained by covering and insulating a conductive sheet provided with electrodes with a cover material. And a sheet obtained by dispersing a conductive powder or the like into a sheet.

Examples of the thermoplastic resin used here include polyolefin resins, polystyrene resins, polyamide resins, polyester resins, and ionomer resins. Among these, acid-modified resins and ionomer resins are preferable in that they have adhesiveness to electrodes made of metal or the like, such as acid-modified polyethylene, acid-modified polypropylene, and acid-modified ethylene ethyl acrylate copolymer. Acid-modified polyolefin resins and ionomer resins are particularly preferred.

As the conductive powder, carbon black,
Graphite; metal powders such as copper powder and stainless steel powder; conductive fibers such as carbon short fiber, stainless steel short fiber and brass short fiber; metal oxides such as tin oxide and zinc oxide; and conductive whiskers. Among them, carbon black is preferred.

For example, when carbon black is used as the conductive powder, the mixing ratio of the thermoplastic resin and the conductive powder is preferably in the range of 10 to 45 parts by weight of carbon black per 100 parts by weight of the thermoplastic resin.

As a method for producing the conductive sheet, for example, a kneading machine such as a Henschel mixer, a Banbury mixer, a kneader, an extruder or the like is used to knead the thermoplastic resin and the conductive powder to form the conductive powder in the thermoplastic resin. Is prepared by dispersing a compound, forming the compound into a film or sheet by calendering or melt extrusion, and cutting the compound. The thickness of the film or sheet thus obtained is preferably in the range of 50 to 500 μm.

The insulating layer used for the electric heating unit is not particularly limited as long as it can electrically insulate between the metal base and the electric heating unit. For example, a resin sheet having a void is preferable.

The electrically heated floor heating panel of the present invention is, for example, an electrically heated surface heating unit of the present invention, wherein the surface floor is made of a plywood or a material similar in size to the unit or slightly larger than the unit. After sandwiching the material and the back floor material with an adhesive, insert a resin tucker into the defective part of the heating element, and temporarily fix the adhesive between the electric heating surface heating unit and the plywood or similar material until the adhesive solidifies. It can be manufactured by a fixing method. By manufacturing in this way, the front floor material and the back floor material,
It can be directly fixed by the adhesive applied to the defective part and the peripheral part of the electric heating unit.

The surface floor material constituting the electric heating floor heating panel is as follows:
MDF as a plywood material or a material similar to the plywood material with a decorative board attached to the surface of plywood
(Medium specific gravity fiberboard), HDF (high specific gravity fiberboard),
Polystyrene, polypropylene, polyethylene, polyurethane foam and the like are used.

As the adhesive used for attaching the flooring material and the heating element, there are a vinyl acetate emulsion type, an epoxy resin type, a rubber type and a polyurethane type adhesive, which can adhere more firmly and almost no organic solvent. An adhesive that does not contain is used.

Next, various embodiments of the electric heating unit according to the present invention will be described with reference to the drawings.

FIG. 1 is a conceptual view of the surface heating unit as viewed in plan. The lead wires 3 to 6 are taken out from the electric heating element 1 and the electric heating element 2, respectively, and connected to the power lines 7 and 8, respectively. The earth lead wire 9 is taken out from the soaking plate and connected to the connection cable 10. As the electric heating surface heating element, a part lacking a conductive sheet in advance is laminated with an exterior sheet, and a conductive defect part 11 is provided. The defective portion 11 of the conductive sheet is insulated by the outer sheet so that the conductive portion does not directly contact the outside. A metal base and an insulating layer are laminated on this, and a through hole 12 is provided in a range not covering the conductive sheet.

FIG. 2 is an assembly drawing of the electrically heated floor heating panel. The electric heating unit 13 is attached to the front floor member 14 and the rear floor members 15, 16 with an adhesive. Back floor material 15, 16
Are separated as spaces for accommodating the lead wires 3 to 6 of the surface heating element, the power wires 7 and 8, and the ground wires 9 and 10.
After assembling the electric floor heating panel and attaching it with an adhesive, the through hole 12 is formed in the electric heating surface heating unit so that the front floor material 13 and the rear floor materials 14 and 15 can be directly attached with the adhesive via the surface heating unit 13. Is provided. Since the electric heating unit of the present invention has PTC characteristics, it does not require a thermostat or a thermal fuse, and does not need to perform engraving on the floor materials 13 to 15.

[0026]

The present invention will be described in more detail with reference to the following examples.

<Example 1> On an olefin-based adhesive resin side of an electrically insulating film composed of a polyethylene terephthalate film having a total thickness of 0.1 mm and an olefin-based adhesive resin film, 270 mm between electrodes and a length of 1800 mm were used.
1 is a sheet heating element (conductive sheet) formed so as to have a resistance value of 90Ω in an atmosphere of ° C., as shown in FIG. A semi-circular heating element having a semi-circular shape having a diameter of 10 mm and having a defective portion of the conductive sheet to the end is disposed thereon, and a twisted wire electrode is disposed thereon at a position 11 mm from the longitudinal edge in parallel with the edge. In addition, an electrical insulating film is aligned and thermocompression-bonded, so that the inner layer made of an olefin-based adhesive resin film is on the bottom, and an aluminum soaking plate and an insulating layer are further laminated. The sheet thus formed was attached, and a hole was formed in an area not covered by the conductive sheet at the portion where the conductive sheet was missing to obtain an electroheating surface heating unit. This was sandwiched between floor materials with a urethane-based adhesive interposed therebetween to obtain an electric heating panel.

<Evaluation> The temperature distribution on the floor surface where a plurality of the electric heating panels obtained in Example 1 were arranged was measured using a thermography JTG-3210 manufactured by Nippon Kogaku.
It was within ° C.

[0029]

According to the electric heating unit of the present invention, the upper and lower floor members can be directly fixed with an adhesive when fixing the electric heating floor heating panel by providing the defective portion of the electric heating unit. The area of the heating element on the inside can be extended to the periphery of the panel. As a result, the effective heat generation area of the surface heat generation unit with respect to the flooring material surface can be increased, so that a product with improved heat unevenness can be provided in the flooring-integrated electrothermal floor heating panel.

The electric floor heating panel of the present invention can directly fix the upper and lower flooring materials with an adhesive by using the electric heating unit of the present invention, so that temporary fixing is not required and the production thereof can be mechanized. easy. In addition, since the electrically heated floor heating panel of the present invention uses an electrically heated surface heating unit having PTC characteristics, an overheating prevention device such as a thermostat or a temperature fuse is unnecessary, and these members are engraved on the panel flooring. Is also unnecessary.

[Brief description of the drawings]

FIG. 1 is a plan view of a surface heating unit of the present invention.

FIG. 2 is an assembly view of an example of an electrically heated floor heating panel of the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 heating surface heating unit 2 heating surface heating unit 3 heating surface heating element lead 4 heating surface heating element lead wire 5 heating surface heating element lead wire 6 heating surface heating element lead wire 7 power supply line 8 power supply line 9 earth lead wire 10 ground Wire 11 Conductive layer missing portion 12 Heating surface heating unit through hole 13 Heating surface heating unit 14 Front flooring 15 Back flooring 16 Back flooring

Continued on the front page F term (reference) 3K034 AA02 AA05 AA06 AA07 AA08 AA10 AA15 AA16 AA28 AA32 BA08 BA13 BA18 BB02 BB14 BC03 BC16 CA02 CA15 GA04 HA08 JA01 JA10 3L072 AA01 AB04 AC02 AD01 AD03 AD04 AD13

Claims (3)

[Claims] 1. An electric heating surface heating unit in which an electric heating surface heating element having a plurality of electrode wires is laminated on a metal substrate via an insulating layer, wherein at least the metal substrate, the insulating layer and the heating element are electrically connected. An electric heating surface heating unit having a defective portion at the same position in the stacking direction. 2. An electric heating surface heating unit according to claim 1, wherein a defective portion of the electric heating surface heating element is insulated. 3. A front floor material and a back floor made of a plywood or a material similar thereto having a size equal to or one size larger than the unit. An electrically heated floor heating panel sandwiched between materials, wherein the front surface floor material and the back surface floor material are directly fixed by an adhesive applied to a defective portion and a peripheral portion of the electrically heated surface heating unit. .