JP2002357328A - Floor heating panel and production method for same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor heating panel having a rigidity and an impact resistance necessary therefor and capable of being easily formed, worked and recycled. SOLUTION: The floor heating panel 100 comprises a flat plate 101 made of a foaming synthetic resin and having pipe grooves 10 recessed for positioning heat source pipes and a synthetic resin sheet 102 laminated on the surface of the flat plate 101 on which the pipe grooves 10 are not formed by a thermal compression. The rigidity of the flat plate 101, particularly, the rigidity of the part whose thickness is reduced due to the formation of the pipe grooves 10 is reinforced by the rigidity of the synthetic resin sheet 102.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor heating panel, and more particularly to a composite panel of a foamed synthetic resin and a reinforcing member, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, in a floor heating system, foam synthetic resins such as polyethylene, polypropylene, and polystyrene have been used as a material of a floor heating panel for fitting and fixing a heat source pipe such as a hot water pipe. . As shown in FIG. 11, the floor heating panel 1 is formed by recessing a pipe groove 2 for fitting a heat source pipe such as a hot water pipe having an outer diameter of about 8 mm on one surface of a flat plate made of a synthetic resin foam. However, since the thickness of the floor heating panel 1 at the portion where the pipe groove 2 is recessed is reduced by the depth of the pipe groove 2, the rigidity, particularly the bending strength, is weak. I have. For this reason, in the case where the floor heating panel 1 made of a foamed synthetic resin is molded using a mold, the pipe groove portion is formed during a step of releasing the floor heating panel from the molding machine or during material handling in a subsequent processing step. In order to prevent cracks and cracks in the floor heating panel 1, the floor heating panel 1 made of foamed synthetic resin has a thickness sufficient to maintain rigidity. There is a case where a thickness as small as 9 mm, for example, which does not hinder opening and closing, is required.

[0003]

Accordingly, a thin floor heating panel is obtained by cutting a rectangular parallelepiped block of foamed synthetic resin into a flat plate shape using a nichrome wire or the like without using a molding process using a mold. It is formed by attaching a reinforcing member such as a wooden plate or a metal plate to the cut flat plate, and then recessing the pipe groove. According to this method, since the rigidity of the flat plate made of the foamed synthetic resin is reinforced by the reinforcing member and then the pipe groove is formed in a recess, it is possible to prevent the pipe groove portion from being cracked.

However, in general, when a block made of a foamed synthetic resin is cut using a nichrome wire or the like,
A thickness error of about 0.5 to 1.0 mm occurs in the cut flat plate, and the thickness error of the flat plate is preferably 0.5 mm or less in order to suppress occurrence of floor noise and the like in the floor heating system. Therefore, in order to further reduce the thickness error due to the cut, the surface of the cut foam synthetic resin plate is ground with sandpaper or the like so that the thickness error of the plate becomes 0.5 mm or less. I have. Therefore, the above-mentioned manufacturing method involves a lot of trouble for processing a block made of a foamed synthetic resin into a flat plate having a desired thickness error, which increases the manufacturing cost of the floor heating panel, and also causes a large amount of grinding. Disposal of foam synthetic resin waste also poses a problem.

When a reinforcing member such as a wooden board or a metal plate is attached to the surface of a flat plate made of a foamed synthetic resin, a step of bonding the reinforcing member and the flat plate made of a foamed synthetic resin using an adhesive is used. , And a step of drying the adhesive, so that the number of manufacturing steps is increased and materials such as an adhesive are also required. Therefore, there is a problem that the production cost is high, and there is a possibility that sick house syndrome may be caused to the occupants due to volatile substances contained in the adhesive.

Further, after the reinforcing member and the flat plate made of foamed synthetic resin are bonded with an adhesive, a cutting process is performed to recess a pipe groove for fitting a heat source pipe on the surface thereof.
Since the processing waste generated by the cutting is a mixture of a wood piece or a metal piece of a reinforcing member, an adhesive, and a foamed synthetic resin piece, it is extremely difficult to collect these for each material for recycling. . Also, when the used heating panel is discarded, similarly, since the metal or wooden reinforcing member and the flat plate made of foam synthetic resin are bonded,
It is also difficult to separate and recover them.

The present invention has been made in view of these problems, and has a rigidity and impact resistance required for a floor heating panel, and is easily formed and recycled, and a manufacturing method thereof. The aim is to provide a method.

[0008]

According to a first aspect of the present invention, there is provided a floor heating panel comprising: a foam synthetic resin flat plate in which a pipe groove for fixing a heat source pipe is formed; A floor heating panel including a synthetic resin reinforcing member, wherein the flat plate and the reinforcing member are thermocompression-bonded in a mold for molding the flat plate.

Further, according to the present invention (claim 2), in the floor heating panel according to claim 1, the flat plate and the reinforcing member are made of the same resin material. Here, the same resin material means that the synthetic resin as the main component is the same, and means that the presence or absence of various additives such as a foaming agent and the same up to the composition ratio are the same. is not.

A floor heating panel according to a third aspect of the present invention includes a flat plate made of a synthetic resin foam having a recessed pipe groove for fixing a heat source pipe, and a reinforcing member provided on the flat plate. A floor heating panel provided, wherein the flat plate and the reinforcing member are fixed by fitting with at least a part of the reinforcing member when the flat plate is formed.

The present invention (claim 4) provides the floor heating panel according to claim 1 or 3, wherein the reinforcing member comprises:
A heat equalizing member for equalizing heat conduction from a heat source pipe is preliminarily laminated on a surface serving as a front side of the floor heating panel.

According to the present invention (claim 5), in the floor heating panel according to any one of claims 1 to 4, the foamed synthetic resin is made of a polystyrene resin.

According to a sixth aspect of the present invention, there is provided a floor heating panel manufacturing method, wherein a synthetic resin sheet for reinforcing the molded body is laminated on a molded body of a foamed synthetic resin for fixing a heat source pipe. A method for manufacturing a floor heating panel comprising: placing a synthetic resin sheet at a predetermined position of a mold for foaming a foamable synthetic resin into a predetermined shape; filling the mold space with the foamable synthetic resin. And by foam molding,
The molded article of the foamed synthetic resin and the synthetic resin sheet are thermocompression-bonded. Here, the expandable synthetic resin is a synthetic resin such as a styrene-based resin such as polystyrene and an olefin-based resin such as polyethylene and polypropylene, and is obtained by impregnating a foaming agent or the like to impart foamability.

According to a seventh aspect of the present invention, in the method for manufacturing a floor heating panel according to the sixth aspect, the molded article of the foamed synthetic resin and the synthetic resin sheet are made of the same resin material. is there.

[0015] A method of manufacturing a floor heating panel according to claim 8 of the present invention is a method of manufacturing a floor heating panel in which a reinforcing member is fitted to a molded article of foamed synthetic resin for fixing a heat source pipe. By arranging the reinforcing member at a predetermined position of a mold for foam-forming the foamable synthetic resin into a predetermined shape, filling the mold space with the foamable synthetic resin and foam-forming. A part of the molded article of the foamed synthetic resin is fitted to the fitting part of the reinforcing member.

According to a ninth aspect of the present invention, in the method for manufacturing a floor heating panel according to the sixth or eighth aspect, when the mold space is filled with a foamable synthetic resin and foamed,
After a predetermined gap is provided between the molds and the foamable synthetic resin is filled, the foamable synthetic resin is softened and the mold is completely closed.

The present invention (claim 10) provides claim 6
Or in the method for manufacturing a floor heating panel according to 8, before disposing the synthetic resin sheet or the reinforcing member at a predetermined position of the mold, heat conduction from a heat source pipe to one surface of the synthetic resin sheet or the reinforcing member. A heat equalizing member to be uniformed is stacked, and a synthetic resin sheet or a reinforcing member on which the heat equalizing member is stacked is arranged in a mold such that the heat equalizing member is on the surface side of the floor heating panel.

The present invention (claim 11) provides claim 6
11. The method for manufacturing a floor heating panel according to any one of items 1 to 10, wherein the foamed synthetic resin is made of a polystyrene resin.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A floor heating panel according to an embodiment of the present invention will be specifically described below with reference to the drawings. FIG. 1 shows a floor heating panel 1 according to a first embodiment of the present invention.
00 shows a cross-sectional structure. As shown in the figure, the floor heating panel 100 includes a flat plate (molded body) 101 made of a foamed synthetic resin in which a pipe groove 10 for fixing a heat source pipe is formed. It comprises a synthetic resin sheet (reinforcing member) 102 laminated on a flat plate 101.

As will be described in detail below, the flat plate 101 made of foamed synthetic resin is a rectangular plate having a size suitable for transportation and installation, and the thickness is not particularly limited. In the case of a floor heating panel or the like, the thickness is, for example, about 6 to 15 mm, and preferably about 8 to 12 mm, because it is necessary to have a thickness that does not hinder opening and closing of the door. On one side of the flat plate 101, a pipe groove 10 for placing a heat source pipe such as a hot water pipe having an outer diameter of, for example, about 5 to 11 mm is recessed at a predetermined position. The pipe groove 10 has substantially the same width and depth as the outer diameter of the heat source pipe (not shown). As shown in FIG. It is formed in a U-shape to match. The pipe groove 10 is formed so as to meander on one side of the flat plate 101 from a predetermined position on the side surface of the flat plate 101. Note that, as described above, a styrene-based resin, an olefin-based resin, or the like can be used as the foamed synthetic resin, but it is preferable to use foamed polystyrene in consideration of cost.

The synthetic resin sheet 102 is
And the same resin material, for example, polystyrene if the flat plate is expanded polystyrene.
It is a rectangle having substantially the same size as 01. The synthetic resin sheet 102 is laminated by thermocompression bonding on the other surface side of the flat plate 101, that is, the surface on which the pipe groove 10 is not formed.
The rigidity of the flat plate 101, particularly the rigidity of the portion where the pipe groove 10 is formed and the thickness is reduced, is reinforced.

Next, a method of manufacturing the floor heating panel 100 will be described. FIG. 2 is for explaining a part of the manufacturing process of the floor heating panel 100, and shows a cross-sectional configuration of a forming machine 900 for forming the floor heating panel 100. The molding machine 900 is divided into a fixed side 900a and a movable side 900b.
In the opening direction.

The fixed side 900a comprises a fixed side die plate 901a and a fixed side frame 903a having a fixed side mold 902a mounted thereon.
0b is provided on the moving side die plate 901b.
The moving side frame 903b to which the 02b is mounted is mounted.

As shown in the figure, a convex portion 20 having a U-shaped cross section for forming the pipe groove 10 is formed on the fixed mold 902a.
And a steam hole 21 for allowing steam to flow in. The pre-expanded particles of expandable synthetic resin are
2 is connected to a filling machine 904 for filling.

In the drawing, for convenience of explanation, one steam hole 21 is provided in the fixed mold 902a, but in practice, the inside of the mold space (cavity) of the mold 902 is provided. The steam holes 21 are also provided in the moving mold 902b and other places in order to allow the steam to flow uniformly into the mold.

The fixed side frame 903a and the movable side frame 903b have jacket chambers 30a and 30a inside.
b are formed respectively, and the jacket chambers 30a, 30
b, the fixed-side mold 902
a, the moving side mold 902b is heated respectively.

In the production of the floor heating panel 100, first, in a state where the molding machine 900 is opened as shown in the figure, the synthetic resin sheet 102 cut in advance to the same size as the plane shape of the floor heating panel 100 is removed. Moving side mold 902b
The mold 902 is then closed by moving the moving side 900b.

FIG. 3 shows a state in which the molding machine 900 is closed. After the synthetic resin sheet 102 is placed on the movable side mold 902b, the movable side 900b is moved to the fixed side mold 902a and the movable side mold 902a. It moves in the closing direction until a gap of about 20 mm or less, that is, cracking C is left between the mold 902b. In this state, pre-expanded particles of the expandable synthetic resin are filled into the mold space of the mold 902 from the filling machine 904.

In ordinary foam molding, the size of the cracking is about 1 to 2 mm and is mainly provided for venting air. In this case, the size of the cracking C is determined in consideration of the shape of the floor heating panel 100 and the like. Is set. As described in detail, the pre-expanded particles of the expandable synthetic resin sent into the mold space from the filling machine 904 need to spread over the entire mold space beyond the convex portion 20 of the fixed mold 902a. . However, the thinner the floor heating panel 100 is, the more the convex portion 20 and the mold 90 in the mold space are.
2b, the pre-expanded particles are difficult to pass through, so that the pre-expanded particles sent from the filling machine 904 into the mold space stay near the convex portion 20 and uniformly fill the entire mold space. It becomes difficult. Furthermore, each of the plurality of projections 2
When the interval between zeros is narrow, it is particularly difficult to uniformly fill the pre-expanded particles between the convex portions 20.
On the other hand, it is also difficult to mount the filling nozzle of the filling machine 904 at all places where the pre-expanded particles are difficult to fill, for example, between the convex portions 20 of the mold 902a because of an increase in equipment and labor. In order to solve this, a cracking C larger than a normal size is set in consideration of the shape of the floor heating panel 100 as described above and the like so that the pre-expanded particles of the expandable synthetic resin are distributed throughout the mold space. . As a result, the space between the convex portion 20 and the mold 902b is sufficiently ensured, and the pre-expanded particles sent from the filling machine 904 flow smoothly in the mold space, and many concave streaks such as the pipe groove 10 are formed. Even when manufacturing the provided thin floor heating panel 100,
The mold space can be uniformly filled with the pre-expanded particles.

After the pre-expanded particles of the expandable synthetic resin are filled in the mold space of the mold 902, the movable side 900b is moved again to bring the fixed mold 902a and the movable mold 902b into close contact. To close. At this time, the mold 902 is compressed while the pre-expanded particles filled in the mold space are compressed by an amount corresponding to the setting of the cracking C larger than usual as described above.
Since an extra force is required to completely close the molding machine 9,
00 requires a force to close the mold 902 more than before. In order to reduce this, when closing the mold 902, steam is caused to flow into the mold space via the jacket chambers 30 a and 30 b to preliminarily heat and soften the pre-expanded particles. Accordingly, the force required when closing the mold 902 is reduced, and the molding machine 900 can easily close the mold 902 with the same closing force as that of the related art.

After the mold 902 is completely closed,
Through the jacket chambers 30a and 30b, the vapor pressure of about 0.034 to 0.034 to the mold space of the mold 902 filled with the foamed synthetic resin pre-expanded particles from the steam hole 21 of the fixed mold 902a. .147 MPa (0.35 to 1.5 kg
/ Cm ² ) for about 3 to 30 seconds, preferably about 0.785 MPa (0.8 kg / cm ² ) for about 15
For a second, steam flows in.

The steam flowing into the jacket chambers 30a and 30b heats the fixed mold 902a and the movable mold 902b, respectively, and the steam flowing into the mold space of the mold 902 is
Pre-expanded particles of expandable synthetic resin and synthetic resin sheet 10
Heat 2 Thereby, while the pre-expanded particles of the expandable synthetic resin are expanded to form the flat plate 101,
It is thermocompression bonded to the synthetic resin sheet 102. In the foam molding of the expandable synthetic resin, pre-expanded particles that have been pre-expanded using steam or the like are often used, but the present invention is not limited to this, and is not pre-expanded. Of course, it can also be used.

After the molding of the flat plate 101 and the thermocompression bonding with the synthetic resin sheet 102 are completed, the mold 902 is moved to the extent that the molded flat plate 101 and the synthetic resin sheet 102 have appropriate rigidity. The pressure of the foamed synthetic resin inside the mold 902 is reduced by cooling to such a degree that the foamed synthetic resin is not easily deformed even when taken out of the mold 902. The cooling method is water cooling,
It can be carried out by any method such as air cooling and vacuum cooling.

After cooling, the moving side 900b of the molding machine 900 is moved, the mold 902 is opened, and the floor heating panel 100 is released. Thus, the flat plate 1 made of the foamed synthetic resin
01 is formed, and the flat plate 10 is
1 and the synthetic resin sheet 102 are thermocompression bonded, and the floor heating panel 100 is integrally formed.

Thus, the synthetic resin sheet 102, which is a reinforcing member, can be laminated on the flat synthetic resin plate 101 without using an adhesive, which is required for the floor heating panel 100 in the manufacturing process or in use. Rigidity and impact resistance can be obtained. Therefore, it is possible to further reduce the thickness of the floor heating panel 100, and as shown in FIG. 4, the thickness of the floor heating panel is reduced to a thickness obtained by adding the depth of the pipe groove 10 and the thickness of the synthetic resin sheet 102. The thickness can be reduced.

The flat plate 101 and the synthetic resin sheet 102 made of the foamed synthetic resin are made of the same resin material, which has the advantage that the thermocompression bonding is strengthened and that the separation at the time of recycling is not required. This is preferable because recycling can be facilitated. As a preferred embodiment, the flat plate 101 made of a synthetic resin foam is
For example, in the case of expanded polystyrene, if the synthetic resin sheet 102 is made of a reinforced polystyrene resin such as high impact polystyrene, the flat synthetic resin sheet 101 and the synthetic resin sheet 102 are made of the same polystyrene material, and Since the sheet 102 has high elasticity, the floor heating panel has good performance.

In the present embodiment, in order to reduce the thickness error of the floor heating panel 100 formed by the molding machine 900 to 0.5 mm or less, the tightening pressure of the molding machine 900 is increased (normally). The mold support (not shown) is changed from a mold made of aluminum to a mold made of stainless steel, and the number of mold supports is increased (from about 1.1 to about 3 times). About three times).

Hereinafter, an example of use of the floor heating panel 100 will be described. FIG. 5 shows a cross-sectional structure in a state where a floor heating system is installed using the floor heating panel 100. As shown in the figure, the main floor heating panel 100 is placed on the floor base 3 of the floor on which the floor heating system is to be installed,
On the upper surface of the floor heating panel 100, a floor material 5 such as a flooring is laid with a heat equalizing member 4 interposed therebetween. A heat source pipe 6 serving as a heat source of a floor heating system is fitted in a pipe groove 10 of a flat plate 101 made of a foamed synthetic resin, and a paper sheet 7 is provided on a lower surface side of the flat plate 101 to prevent the heat source pipe 6 from coming off. Is affixed.

The heat equalizing member 4 is for uniformly transmitting the heat of the heat source pipe 6 to the floor material 5 and is a metal thin film such as an aluminum thin film. In addition, the material of the heat equalizing member 4 is not particularly limited as long as it can make the heat conduction uniform. For example, when a material made of aluminum is used as the heat equalizing member, the cost may be considered. Although a thin film is preferable, the thickness of the heat equalizing member in the present invention is not particularly limited.

Affixing the paper sheet 7 to the flat plate 101;
In addition, the fixing between the synthetic resin sheet 102 and the heat equalizing member 4 can be performed using an adhesive. However, considering the ease of separation at the time of recycling and the volatile substances contained in the adhesive, an adhesive tape or the like is used. Preferably,

Conventionally, as described above, since the block of the foamed synthetic resin is cut with a nichrome wire, a large number of fine irregularities are present on the cut surface, so that the adhesive tape is not easily adhered and the cut surface is formed by the cut. Since the foam synthetic resin powder is attached and even if an adhesive tape or the like is attached to the cut surface, the powder adheres to the adhesive surface such as the adhesive tape and easily peels off,
The adhesive was used to bond the foamed synthetic resin to other materials.

However, in the underfloor heating panel 100, a flat plate 101 made of a foamed synthetic resin is provided on the lower surface side of the mold 90.
2, the skin layer (coating layer) having a high resin density is formed on the surface of the flat plate 101 to have high smoothness, and the peel strength of an adhesive tape or the like is also high. It is high and can be easily joined by an adhesive tape or the like. On the other hand, since the synthetic resin sheet 102 is laminated on the upper surface side of the floor heating panel 100, joining with an adhesive tape or the like is easy. Note that this usage method is an example, and the application of the floor heating panel 100 is not limited to the floor heating system having the above-described configuration.

The floor heating panel 1 according to the present embodiment
Alternatively, the heat equalizing member 4 can be manufactured by laminating the heat equalizing member 4 in advance. In detail, in the manufacturing of the floor heating panel 100 described above, before the synthetic resin sheet 102, for example, a polystyrene resin sheet is placed on the moving mold 902b of the molding machine 900, the synthetic resin sheet 102 is roughly placed on one surface side of the synthetic resin sheet 102. A heat equalizing member 4 cut into the same shape, for example, an aluminum sheet is laminated. The joining between the synthetic resin sheet 102 and the heat equalizing member 4 is performed by a known and arbitrary method. The synthetic resin sheet 102 on which the heat equalizing member 4 is laminated is placed on the moving mold 902b.
The heat equalizing member 4 is arranged so as to be in contact with the mold 902b, that is, the heat equalizing member 4 is arranged on the surface side of the floor heating panel 100, and the pre-expanded particles of the expandable polystyrene resin are formed in the same manner as described above. By filling and molding the mold space of the mold 902, the flat synthetic resin 101 and the synthetic resin sheet 102 are thermocompression bonded. In this way, the floor heating panel having the heat equalizing member 4 laminated on the surface can be integrally formed. Thereby, the step of laminating the heat equalizing members 4 at the time of constructing the floor heating system is omitted, and the construction of the floor heating system can be simplified.

Also in the present manufacturing method, the thickness of the heat equalizing member 4 is not particularly limited as described above.
Increasing the thickness of the heat equalizing member 4 can also provide a reinforcing effect to the heat equalizing member 4. Therefore, by laminating the heat equalizing member 4 on the synthetic resin sheet 102 in advance, the synthetic resin sheet 102 as a reinforcing member is given a function of equalizing the heat conduction of the heat source pipe, that is, a so-called heat equalizing function. The rigidity of the sheet 102 can be increased to enhance the reinforcing effect. Further, by setting the thickness ratio of the synthetic resin sheet 102 and the heat equalizing member 4 so that both effects are exhibited most efficiently, It is possible to obtain a thin and thin floor heating panel having a thermal effect and high rigidity by a simplified manufacturing method, that is, at low cost.

Hereinafter, a floor heating panel 200 according to a modification of the first embodiment will be described. FIG. 6 shows a cross-sectional structure of a floor heating panel 200 according to the present modification. As shown in the figure, the floor heating panel 200 is a flat plate (molded) made of a foamed synthetic resin in which the pipe groove 10 is recessed. Body) 2
And a synthetic resin sheet (reinforcing member) 202 laminated on the upper surface of the flat plate 201.

That is, the floor heating panel 200 according to this modification is
Is formed by laminating a synthetic resin sheet 202 having a concave surface along the shape of the pipe groove 10 on a surface of the flat plate 201 on which the pipe groove 10 is recessed. The size, shape, material, and the like of 202 are the same as those of the flat plate 101 and the synthetic resin sheet 102 shown in the first embodiment.

The method of manufacturing the floor heating panel 200 is the same as in the first embodiment, except that the flat plate 201 is formed in the mold 902 for forming the flat plate 201, and the flat plate 201 and the synthetic resin sheet 202 are formed. And thermocompression bonding. In detail, first, the floor heating panel 100
After the synthetic resin sheet 202 cut into a shape substantially the same as the plane shape of the above and formed into the pipe groove 10 to be recessed in the flat plate 201 and the approximate shape is placed at a predetermined position of the fixed mold 902a, the metal The mold 902 is closed. Next, pre-expanded particles of the expandable synthetic resin are filled into the mold space of the mold 902 from the filling machine 904. At this time, the method for filling the pre-expanded particles in the mold 902 with the cracking C remaining, and thereafter softening the pre-expanded particles with steam to completely seal the same is the same as described above. After the mold 902 is sealed, steam is further introduced to heat the pre-expanded particles of the expandable synthetic resin and the synthetic resin sheet 202, whereby the pre-expanded particles of the expandable synthetic resin are expanded to form the flat plate 201. At the same time, it is thermocompression bonded to the synthetic resin sheet 202. Flat plate 201
After completion of molding and thermocompression bonding with the synthetic resin sheet 202, the floor heating panel 200 is cooled and released.

In the molding machine 900 shown in FIG. 2, a mold 90 having a projection 20 for forming the pipe groove 10 is used.
2a is mounted on the fixed side frame 903a, but in this modified example, the synthetic resin sheet 20 is attached to the mold 902a.
In order to dispose 2, the mounting positions of the mold 902a and the mold 902b are preferably reversed so that the mold 902b and the filling machine 904 communicate with each other. Thereby, the pre-expanded particles can be smoothly and uniformly filled in the mold space without interference of the synthetic resin sheet 202.

Also, the mold 902 and the filling machine 904 can be mounted without reversing the mounting positions of the molds 902a and 902b.
The communication position with the synthetic resin sheet 202 is set so that the filling of the pre-expanded particles is not hindered by the synthetic resin sheet 202, or the position where the pre-expanded particles are filled in the mold space from the filling machine 904 is required for the synthetic resin sheet 202. May be provided.

Thus, similar to the first embodiment,
Laminating a synthetic resin sheet 202 as a reinforcing member on a foam synthetic resin flat plate 201 without using an adhesive to obtain rigidity and impact resistance required for the floor heating panel 200 in a manufacturing process or in use. Can be. Therefore, the first
The same effect as that of the embodiment can be obtained.

FIG. 7 shows the use state of the floor heating panel 200. As shown in FIG. 7, the main floor heating panel 20 is placed on the floor base 3 of the floor on which the floor heating system is to be installed.
No. 0 is placed so that the surface where the pipe groove 10 is recessed faces upward, and the heat source pipe 6 is fitted into the pipe groove 10. Further, a floor member 5 such as a flooring is laid on the upper surface of the floor heating panel 200 with a heat equalizing member 4 interposed therebetween for uniform heat conduction. Therefore, also in the floor heating panel 200 according to this modification, similarly to the first embodiment, the synthetic resin sheet 202 and the heat equalizing member 4 are joined using an adhesive tape or the like without using an adhesive. can do.

In this embodiment, the synthetic resin sheet 102 is provided only on one surface of the flat plate 101 made of foamed synthetic resin.
Alternatively, the synthetic resin sheet 202 is laminated, but it goes without saying that the synthetic resin sheet 102 and the synthetic resin sheet 202 may be laminated on both sides of the flat plate 101.

Hereinafter, a floor heating panel 300 according to a second embodiment of the present invention will be described. FIG. 8 shows a cross-sectional structure of a floor heating panel 300 according to the second embodiment of the present invention. As shown in FIG.
Numeral 0 includes a flat plate (molded body) 301 made of a foamed synthetic resin in which the pipe groove 10 for fixing the heat source pipe is recessed, and a metal plate (reinforcing member) 302 fitted to the flat plate 301. It becomes.

The size, shape, material, etc. of the flat plate 301 made of a foamed synthetic resin are the same as those of the flat plate 301 described in the first embodiment.
01, the detailed description is omitted.

The flat shape of the metal plate 302 is the same as that of the flat plate 30.
1 is provided with a fitting portion 22 that is bent in, for example, a U-shape at both ends thereof. When the fitting portion 22 is fitted to the flat plate 301, the metal plate 302 forms the other side of the flat plate 301, that is, the pipe groove 10.
Is fixed to the surface on which the metal plate 30 is not formed.
2, the rigidity of the flat plate 301, especially the pipe groove 1
The rigidity of the portion where the thickness is reduced by forming 0 is reinforced.

The fitting portion 22 does not need to be provided continuously over the entire side end of the metal plate 302.
The metal plate 30 is provided only near the four corners of the metal plate 302.
In consideration of the weight of 2 and the easiness of processing, the metal plate 302 may be provided on a part or the entire periphery of the metal plate 302,
2 at the desired position on the fixing surface.

Next, a method of manufacturing the floor heating panel 300 will be described. In the manufacture of the floor heating panel 300, first, the fitting portion 22 previously moves the metal plate 302 formed by, for example, bending or welding to the moving-side mold 902b.
And the mold 902 is closed, and the pre-expanded particles of the expandable synthetic resin are filled into the mold space of the mold 902 from the filling machine 904 in the same manner as in the first embodiment. At this time, the method for filling the pre-expanded particles in the mold 902 with the cracking C remaining, and thereafter softening the pre-expanded particles with steam to completely seal the same is the same as described above.

After filling the mold space of the mold 902 with the pre-expanded particles of the expandable synthetic resin, steam is further introduced into the mold 902 to heat the pre-expanded particles of the expandable synthetic resin. The pre-expanded particles are foamed to form the flat plate 301, and are also foam-formed so as to fit with the fitting portion 22 of the metal plate 302, so that the flat plate 301
2 is fixed. Thereafter, the mold 902 is cooled, and the floor heating panel 300 is released.

As a result, the metal plate 302 as a reinforcing member is attached to the flat plate 301 made of a foamed synthetic resin without using an adhesive.
Can be fixed, and rigidity and impact resistance required for the floor heating panel 100 can be obtained in a manufacturing process or in use. Therefore, the same effect as in the first embodiment can be obtained.

FIG. 9 shows a cross-sectional structure of a state in which a floor heating system is installed using the floor heating panel 300. As shown in FIG. The main floor heating panel 300 is placed on the top, and a floor material 5 such as a flooring is placed on the upper surface of the floor heating panel 300.
Is laid. A heat source pipe 6 serving as a heat source of the floor heating system is fitted into the pipe groove 10 of the flat plate 301 made of a foamed synthetic resin. In order to prevent the heat source pipe 6 from being detached, a paper sheet 7 is provided on the lower surface side of the flat plate 301. Is affixed.

As described above, according to the floor heating panel 300, when the floor heating system is installed, the metal plate 302 and the floor member 5 can be joined without using an adhesive. Further, in the main floor heating panel 300, the metal plate 302 as a reinforcing member can also serve as a heat equalizing member, so that the heat equalizing member does not have to be provided, and construction is easy.

In this embodiment, the flat plate 301
The metal plate 302 is provided on the surface on the side where the pipe groove 10 is not recessed.
However, similar to the modification of the first embodiment, the pipe groove 10 of the flat plate 301 is formed by using a metal plate pressed in advance so as to match the shape of the pipe groove 10. A metal plate can also be fixed to the concave side.

Hereinafter, a floor heating panel 300a according to a modification of the second embodiment will be described. FIG.
It shows a cross-sectional structure of a floor heating panel 300a according to the present modification, and as shown in the figure, the floor heating panel 300a
Comprises a flat plate 301 made of a foamed synthetic resin having a recessed pipe groove 10 for fixing a heat source pipe, and a wooden board (reinforcing member) 303 fixed to the flat plate 301. The second embodiment is the same as the second embodiment except that the wooden board 303 is fixed as a member.

The wooden board 303 has a planar shape of the flat plate 30.
It is a rectangle slightly smaller than 1 and has a concave fitting portion 23 on the side surface. The wood plate 303 is fixed to the other surface of the flat plate 301, that is, the surface on which the pipe groove 10 is not formed, by fitting the fitting portion 23 to the flat plate 301.

The fitting portion 23 does not need to be provided continuously over the entire circumference of the side surface of the wooden board 303.
The wooden board 30 is provided only near the four corners of the wooden board 303.
In consideration of the weight of 3 and the easiness of processing, it can be provided on part or all of the side surface of the wooden board 303. Further, the shape of the fitting portion is not limited to the concave portion as described above, and may be, for example, a convex portion, an L-shaped projecting portion, or the like.

The method of manufacturing the floor heating panel 300a according to the modification is the same as that of the floor heating panel 300, except that the wooden board 303 on which the fitting portion 23 is formed is arranged at a predetermined position of the mold 902 in advance. The flat plate 30 is formed by foam molding.
1 is formed, and the wooden board 303 is fixed to the flat plate 301 by fitting with the fitting portion 23 of the wooden board 303.

Thus, the wood board 303 as a reinforcing member can be fixed to the flat plate 301 made of a foamed synthetic resin without using an adhesive, similarly to the second embodiment. The rigidity and impact resistance required for the floor heating panel 100 can be obtained. Therefore, the same effect as in the first embodiment can be obtained.

The main floor heating panel 300a can be used in the same manner as the floor heating panel 300. However, in order to make the heat conduction from the heat source pipe 6 to the floor material 5 uniform,
It is preferable to interpose the heat equalizing member 4 between the floor heating panel 300a and the floor material 5. In this case as well, as described in the first embodiment, the heat equalizing member 4 is previously laminated on one surface side of the wooden board 303, and the wooden board 303 is attached to the floor heating panel 300a. By arranging the floor heating panel 300a on which the heat equalizing member 4 is laminated so as to be disposed on the movable mold 902b so as to be on the front surface side, the construction of the floor heating system can be simplified. .

In the second embodiment and its modifications, a metal plate or a wooden plate is used as the reinforcing member. However, the reinforcing member is not limited to these, and may be, for example, reinforced plastic or other material. Can be used.

[0070]

As described above, according to the present invention,
The synthetic resin sheet, which is a reinforcing member, is placed in a mold for molding a foamable synthetic resin into a predetermined shape, and is thermocompression bonded by foam molding. The body and the synthetic resin sheet can be laminated, and a thin floor heating panel having rigidity and impact resistance can be obtained by a simple manufacturing process. As a result, the thickness of the floor heating panel can be further reduced, and the manufacturing cost can be reduced. Furthermore, the use of volatile substances that can cause so-called sick house syndrome can be reduced.

Further, according to the present invention, since the molded article of the foamed synthetic resin and the synthetic resin sheet are made of the same resin material, the thermocompression bonding between the molded article and the synthetic resin sheet can be strengthened. In addition, when the floor heating panel is discarded, it becomes easy to separate each material for recycling,
Recycling costs can be reduced and the recycling rate can be improved.

According to the present invention, a reinforcing member having a fitting portion of a predetermined shape is placed in a mold for molding a foamable synthetic resin into a fixed shape, and is fitted by foam molding. Therefore, the molded article of the foamed synthetic resin and the reinforcing member can be fixed without using an adhesive, and a thin floor heating panel having rigidity and impact resistance can be obtained by a simple manufacturing process. Thereby, the same effect as described above can be obtained.

According to the present invention, when foaming synthetic resin is filled in a mold space and foaming molding is performed, a predetermined gap is provided between the molds and the foaming synthetic resin is filled. Since the mold is completely closed by softening the foaming synthetic resin, sufficient mold space for filling the foaming synthetic resin is secured. Can be uniformly filled with foamable synthetic resin,
A thin floor heating panel having a concave groove such as a pipe groove can be reliably and easily manufactured.

Further, according to the present invention, since a heat equalizing member for equalizing heat conduction from the heat source pipe is previously laminated on one surface of the synthetic resin sheet or the reinforcing member, a floor heating panel having a heat equalizing action. Can be integrally formed. As a result, the cost of the floor heating panel can be reduced, and the step of laminating the heat equalizing members at the construction site is omitted, so that the construction of the floor heating system is simplified, and the cost of the entire floor heating system is reduced. Can also be achieved.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a cross-sectional structure of a floor heating panel 100 according to a first embodiment of the present invention.

FIG. 2 is a molding machine 9 for molding a floor heating panel.
It is sectional drawing which shows the schematic structure of 00.

FIG. 3 is a sectional view showing the molding machine 900 in a closed state.

FIG. 4 is a cross-sectional view showing a cross-sectional structure of the floor heating panel 100 having the smallest thickness.

FIG. 5 is a sectional view showing an installation state of the floor heating panel 100.

FIG. 6 is a cross-sectional view showing a cross-sectional structure of a floor heating panel 200 according to a modified example of the first embodiment.

FIG. 7 is a sectional view showing an installation state of the floor heating panel 200.

FIG. 8 is a cross-sectional view showing a cross-sectional structure of a floor heating panel 300 according to a second embodiment of the present invention.

FIG. 9 is a cross-sectional view showing an installation state of the floor heating panel 300.

FIG. 10 is a sectional view showing a sectional structure of a floor heating panel 300a according to a modification of the second embodiment.

FIG. 11 is a schematic perspective view showing a configuration of a conventional floor heating panel 1.

[Explanation of symbols]

100, 200, 300, 300a Floor heating panel 101, 201, 301 Flat plate (molded body) made of foamed synthetic resin 102, 202 Synthetic resin sheet (reinforcing member) 10 Pipe groove 22, 23 Fitting portion 302 Metal plate (reinforcing member) ) 303 Wood board (reinforcing member) 4 Heat equalizing member 6 Heat source pipe 902 Mold

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme court ゛ (Reference) // B29K 25:00 B29K 25:00 105: 04 105: 04 B29L 9:00 B29L 9:00 31:10 31:10 F term (reference) 3L070 BD07 4F202 AA13 AB02 AD05 AD08 AD20 AG03 AG20 AH42 AH48 CA01 CA11 CA23 CB01 CB13 CK11 CQ01 4F204 AA13 AB02 AD05 AD08 AD20 AG03 AG20 AH42 AH48 EA01 EB01 EB13 EF02 EF05 EF05 EF05 EF05 EL

Claims (11)

[Claims] 1. A floor heating panel comprising: a foam synthetic resin flat plate having a recessed pipe groove for fixing a heat source pipe; and a synthetic resin reinforcing member laminated on the flat plate. The floor heating panel, wherein the flat plate and the reinforcing member are thermocompression-bonded in a mold for molding the flat plate. 2. The floor heating panel according to claim 1, wherein the flat plate and the reinforcing member are made of the same resin material. 3. A floor heating panel comprising: a flat plate made of a foamed synthetic resin having a recessed pipe groove for fixing a heat source pipe; and a reinforcing member provided on the flat plate. And the reinforcing member is fixed by fitting at least a part of the reinforcing member when the flat plate is formed. 4. The reinforcing member according to claim 1, wherein a heat equalizing member for equalizing heat conduction from a heat source pipe is previously laminated on a surface on the front side of the floor heating panel. Or the floor heating panel according to 3. 5. The foamed synthetic resin is made of a polystyrene resin.
The floor heating panel according to any one of the above. 6. A method for manufacturing a floor heating panel comprising a foamed synthetic resin molded body for fixing a heat source pipe and a synthetic resin sheet for reinforcing the molded body, comprising: A synthetic resin sheet is placed at a predetermined position of a mold for foaming and molding into a predetermined shape, and the mold space is filled with a foamable synthetic resin and subjected to foam molding. A method for manufacturing a floor heating panel, comprising thermocompression bonding with a resin sheet. 7. The method of manufacturing a floor heating panel according to claim 6, wherein the molded article of the foamed synthetic resin and the synthetic resin sheet are made of the same resin material. 8. A method of manufacturing a floor heating panel comprising a reinforcing member fitted to a molded body of a foamed synthetic resin for fixing a heat source pipe, the foamed synthetic resin being foamed into a fixed shape. The reinforcing member is disposed at a predetermined position of the mold, and the mold space is filled with an expandable synthetic resin and foamed, thereby forming a fitting portion between a part of the molded article of the foamed synthetic resin and the reinforcing member. And a method of manufacturing a floor heating panel. 9. When foaming synthetic resin is filled in the mold space and foam molding is performed, a predetermined gap is provided between the molds, the foaming synthetic resin is filled, and the foamable synthetic resin is softened. 9. The method of manufacturing a floor heating panel according to claim 6, wherein the mold is completely closed after the heating. 10. A heat equalizing member for equalizing heat conduction from a heat source pipe is laminated on one surface of the synthetic resin sheet or the reinforcing member before disposing the synthetic resin sheet or the reinforcing member at a predetermined position of a mold. The synthetic resin sheet or the reinforcing member on which the heat equalizing member is laminated is arranged in a mold such that the heat equalizing member is on the surface side of the floor heating panel.
Or the manufacturing method of the floor heating panel of 8. 11. The method for manufacturing a floor heating panel according to claim 6, wherein the foamed synthetic resin is made of a polystyrene resin.