JP2005220570A - Heating floor structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a heating floor structure easy in site work, while reducing running cost, without causing a mesh opening and violent behavior. <P>SOLUTION: This heating floor is laminated so as to sandwich a pipe 24 by a base material 21 being a heat insulating material and a heating flooring 30. The heating flooring 30 is composed of a base board 33 being a hard fiber board provided by being adjusted to an average specific gravity of 1.2 to 1.7 by a thermocompression press, by impregnating a resin liquid of a diluted resin rate of 10 to 60% into a semicure mat of a specific gravity of 0.3 to 0.9 provided by applying the thermocompression press to a wet mat provided by combing slurry in a wet state with mineral fiber of 35 to 70 wt.%, an inorganic powdery body of 20 to 55 wt.% and a binder of 5 to 25 wt.% as an essential component. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a heat generating floor structure, and more particularly to a heat generating floor structure having a small thickness dimension when laminated.

  Conventionally, as the heat generating floor structure, there is a heat generating floor structure in which a heat generating member is sandwiched between a heat insulating material and a floor material. For example, there are a heat generation floor structure (FIG. 6A) in a wooden house and a heat generation floor structure (FIG. 6B) in a double floor of an apartment house.

  In the former, the joists 2 are juxtaposed at a predetermined pitch on the large pull 1, and the heat insulating material 3 is filled between the joists 2, and the plywood 4 (thickness 12 mm) is disposed on the joists 2 The floor heating panel 5 (thickness 12 mm) and the wood heating flooring 6 (thickness 6 to 12 mm) are sequentially laminated. A pipe 7 for circulating hot water is embedded in the floor heating panel 5.

On the other hand, in the latter, a joist 12 is juxtaposed on the floor base 10 via a floor bolt 11, a heat insulating material 13 is disposed between the floor bolt 11, and a floor panel 14 (thickness made of particle board) is formed on the joist 12. 12 to 20 mm), the plywood 15 (thickness 12 mm) is thrown away, then the floor heating panel 17 (thickness 12 mm) in which the pipe 16 is embedded and the wood heating flooring 18 (thickness 6). ˜12 mm). An example of the wood heating flooring 18 used in the heat generating floor structure is a soundproof floor material for floor heating (see Patent Document 1).
JP-A-8-165789

  However, since the soundproof flooring for floor heating uses plywood as a base material, there is a limit to the heat conductivity obtained, and there is a problem that the rise from the start of heating to a predetermined temperature is slow. In order to eliminate such problems, if hot water of high temperature (75 ° C. to 80 ° C.) is passed at the start of heating, the discarded plywood 4 and 15 and the wood heating flooring 6 and 18 contract by heat drying. However, there is a possibility that gaps may be generated at the joints between the heating floorings 6 and 18, or the entire floor may wave.

  Moreover, in the conventional exothermic floor structure, it is not only necessary to warm water from 75 ° C. to 80 ° C. at the start of heating, but also in normal heating, warm water cannot be used for floor heating unless it is heated from 55 ° C. to 60 ° C. So running costs are high.

  Furthermore, in order to achieve floor-free floor heating, it is necessary to set the floor base of the room where the floor heating panel is laid down one step lower, or to raise the floor base of the room where no floor heating panel is laid down, There is a problem that it takes time and effort to adjust the height of the floor base during construction on site.

  It is an object of the present invention to provide a heat generation floor structure that does not cause gaps or rampage, has low running cost, and is easy to construct on site.

Means for Solving the Problems and Effects of the Invention

  In order to achieve the above object, the heat generating floor structure according to the present invention is a heat generating floor structure in which a heat generating material is sandwiched between a heat insulating material and a floor material, and the floor material comprises 35 to 70% by weight of mineral fibers. The specific gravity obtained by subjecting a wet mat obtained by wet papermaking to a slurry containing 20 to 55% by weight of an inorganic powder and 5 to 25% by weight of a binder as an essential component is 0.3 to A hard fiberboard obtained by impregnating a 0.9 semi-cure mat with a diluted resin solution having a resin ratio of 10 to 60% and adjusting the average specific gravity to 1.2 to 1.7 by a hot press is used as a substrate. It is as a configuration. A decorative sheet may be attached and integrated on at least one side of the substrate.

  According to the exothermic floor structure according to the present invention, a flooring material having excellent thermal conductivity and excellent thermal dimensional stability, water resistance and scratch resistance, such as an inorganic board, can be used. For this reason, not only the start-up at the start of heating is quick, but also there is no gap or rampage, and the running cost is low. Further, since the flooring material has impact resistance, workability, and machinability that are similar to a wood material, it can be used in the form of a thin plate than the conventional example in combination with the thermal dimensional stability described above. . For this reason, even when it is made barrier-free, it is not necessary to adjust the height of the floor base as in the conventional example, and the construction at the site becomes easy. In particular, if a decorative sheet is attached and integrated on the substrate, the design is improved, and a heat generating floor according to the color tone of the room can be formed.

  In this embodiment, a soaking plate may be laminated between the heating element and the flooring, or a plywood may be laminated on the lower surface of the heat insulating material. According to the former, heat diffusion becomes uniform and temperature unevenness is eliminated, so that more efficient heating is possible. Moreover, according to the latter, since the heat insulating material is supported by the plywood, the range of heat insulating materials that can be selected is widened, and the degree of freedom in design is widened.

  As another embodiment, the heating element may be one in which a pipe is filled with a warm liquid heat conduction medium for circulation, or may be an electric heating element. According to this embodiment, a heat generating body can be selected according to construction conditions, and the range of selection spreads.

In an embodiment according to the present invention, 0.5 to 15% by weight of heat-resistant organic fibers may be added as a partial substitute for mineral fibers.
According to this embodiment, since the heat-resistant organic fiber is added as a partial substitute for the mineral fiber, a floor material that is more excellent in impact resistance can be used in the heat generating floor structure.

As other embodiments, the slurry may be colored by adding a pigment, or may be colored by adding a pigment or a dye to a resin liquid diluted to a resin ratio of 10 to 60%. .
According to this embodiment, the color tone of the flooring can be selected and matched. For this reason, when the floor material is subjected to a cutting process such as a pseudo joint or chamfering, it is possible to make the background color a desired light color when it is desired to finish the surface light. As a result, the range in which materials can be procured becomes wider than when floor materials are produced from natural wood, and the stable supply of materials is facilitated, thereby improving the productivity.

Embodiments according to the present invention will be described with reference to the accompanying drawings of FIGS.
As shown in FIGS. 1 and 3, the basic structure of the first embodiment is substantially the same as that of the above-described conventional example. In addition, the plywood 4 (thickness 12 mm) is thrown over the joists 2 and the floor heating panel 20 (thickness 9 mm) and the wood heating flooring 30 (thickness 3 mm) are attached. It has a stacked structure.

  As shown in FIG. 3B, the floor heating panel 20 has a pipe 24 embedded in a groove 22 provided on the surface of a base material 21 that is a heat insulating material via a heat transfer material 23, and is covered with a soaking material 25. Is.

  Examples of the base material 21 include a plywood having a thickness of 7.0 mm to 8.5 mm, HDF, MDF, particle board, polystyrene foam, polyethylene foam, polyethylene terephthalate foam, polypropylene foam, urethane foam, and rock wool. A board etc. are mentioned.

  Examples of the heat transfer material 23 include thin plate materials and foil materials made of aluminum, copper, duralumin, iron, and the like having a thickness of 0.02 mm to 1.0 mm.

  Examples of the pipe 24 include those made of cross-linked polyethylene having an outer diameter of 7.2 mm to 8.2 mm, polybutene, copper, and the like.

  Examples of the soaking material 25 include thin plate materials such as aluminum, copper, duralumin, and iron, and foil materials having a thickness of 0.02 mm to 1.0 mm.

  As shown in FIG. 3A, the heating flooring 30 is a substrate 33 (made by Reinforced Dylite Daiken Co., Ltd.) having a thickness of 2.0 mm to 3.0 mm whose front and back surfaces are covered with a decorative material 31 and a back material 32. The substrate 33 is provided with a male part 34 and a female part 35 that can be fitted to each other on opposite side end surfaces.

  Examples of the decorative material 31 include a natural wooden decorative veneer having a thickness of 0.1 mm to 1.0 mm, a WPC processed decorative veneer, paper, or a decorative sheet made of olefin resin.

  Examples of the back material 32 include a thin plate material or a sheet material made of natural wood, paper, resin, and aluminum having a thickness of 0.1 mm to 1.0 mm. From the viewpoint of preventing the occurrence of warpage, it is preferable to combine materials having the same linear expansion coefficient between the decorative material 31 and the back surface material 32.

The reinforced die light serving as the substrate 33 is suitable for flooring, particularly floor heating, and is manufactured by the following procedure.
That is, mineral fiber, inorganic powder and binder are put into water, and additives such as water repellent, antifoaming agent and pigment are added and stirred, and then auxiliary additives such as flocculant are added. Thus, a slurry having a solid content rate of several percent is obtained. Next, a primary hot press (temperature 60 to 120 ° C., pressure 5 to 7 kg / cm ² , pressurization time) is applied to the wet mat obtained by paper making and dewatering from the slurry with a long-mesh type or round net type paper machine. 30 to 150 seconds) to obtain a pre-semi-cure mat, followed by drying with a hot air draft dryer to obtain a semi-cure mat. Then, the semi-cured mat is impregnated with the diluted resin solution and subjected to a second hot press to obtain a hard fiberboard having an average specific gravity of 1.2 to 1.7, and a makeup is applied to the front and back surfaces of the hard fiberboard. It consists of the process of sticking and integrating sheets.

  Examples of the mineral fiber include rock wool, slag wool, glass wool, and glass fiber, and these are used alone or in combination. The mineral fiber is added in an amount of 35 to 70% by weight, particularly 45 to 60% by weight. This is because if the mineral fiber is less than 35% by weight, the bending strength of the obtained semi-cured mat becomes weak and handling of the semi-cured mat becomes difficult. On the other hand, when the mineral fiber exceeds 70% by weight, the amount of inorganic powder added relatively decreases, and the obtained semi-cure mat is coated and impregnated with a resin solution diluted with water. This is because the density is hardly increased even by hot pressing.

  Heat resistant organic fibers may be used as a partial substitute for the mineral fibers. This is because the use of heat-resistant organic fibers dramatically improves the Charpy impact strength and is extremely effective in improving cracks, chipping and chipping during cutting of floor materials. Here, the heat-resistant organic fiber refers to a fiber that does not melt even when hot-pressed with heat of 150 to 200 ° C., for example, nylon, tetron, polyamide, polypropylene, polyethylene terephthalate, polyurethane, various rubber fibers, and These composites or wood fibers can be mentioned.

  The addition amount of the heat-resistant organic fiber is preferably 0.5 to 15% by weight of the total weight. This is because when the addition amount is less than 0.5% by weight, there is almost no effect of improving the Charpy impact strength. Further, if the addition amount exceeds 15% by weight, not only a cohesive failure occurs during papermaking, but a semi-cured mat having a non-uniform density is obtained, and even if the semi-cured mat is subjected to hot press again, the specific gravity is increased. This is because the Charpy impact strength is reduced.

  The length of the heat resistant organic fiber is preferably 1.0 to 15 mm. If the length is less than 1.0 mm, there is almost no effect of improving Charpy impact strength. If the length exceeds 15 mm, a cohesive failure occurs during papermaking, and a semi-cured mat with uniform density cannot be obtained. is there.

  The thinner the heat-resistant organic fiber is, the more uniformly it can be dispersed at the time of papermaking. Therefore, a thin one is preferable in order to exert an effect in a small amount, and generally has a diameter of 500 μm or less, more preferably 30. Those having a thickness of ˜100 μm are preferred.

  Examples of the inorganic powder include shirasu foam, silica flour, glass foam, calcium carbonate, aluminum oxide, vermiculite and the like, and these are used alone or in combination. Moreover, it is preferable to add the said inorganic powdery material in the ratio of 20 to 55 weight%. This is because when the inorganic powder is less than 20% by weight, the bending strength of the obtained semi-cured mat becomes weak and handling of the semi-cured mat becomes difficult. On the other hand, when the amount of the inorganic powder exceeds 55% by weight, the amount of the relatively added mineral fiber is reduced, and the obtained semi-cured mat is coated with a resin solution diluted with water, impregnated, This is because the density is hardly increased even by hot pressing.

  Examples of the binder include melamine resin, phenol resin, isocyanate resin, polyvinyl alcohol, acrylic emulsion or vinyl acetate emulsion and modified products thereof, starch, corn starch, soybean flour, wheat flour, etc. Or a mixture of two or more is used. The addition amount of the binder is preferably 5 to 25% by weight. This is because when the amount added is less than 5% by weight, the strength of the semi-cured mat is insufficient. Moreover, when the addition amount exceeds 25% by weight, the addition amount of the mineral fiber is relatively reduced, and in particular, the bending strength is weakened.

In particular, if the binder is an isocyanate resin, polyvinyl alcohol, acrylic emulsion or vinyl acetate emulsion and modified products thereof, starch, corn starch, soybean flour, wheat flour, 60 ° C. to 120 ° C. during semi-cure by the first hot press. Curing by heating at 0 ° C. and curing when drying to a moisture content of 10% or less can improve the bending performance of a semi-cured mat having a specific gravity of 0.3 to 0.9 and improve handling properties.
However, when the addition amount of polyvinyl alcohol, vinyl acetate emulsion and their modified products, starch, corn starch, soybean powder or wheat flour increases, the water resistance of the finally obtained flooring material deteriorates. For this reason, when using these as a binder, it is desirable to make the addition amount 5% by weight or less and use it together with other binders.

  On the other hand, for example, binders excellent in water resistance such as the melamine resin and the phenol resin are not completely cured by heat at 60 ° C. to 120 ° C. at the time of semi-curing by the first hot press, but are 150 to 250 ° C. By completely curing with a secondary hot press under high temperature and high pressure, the floor material finally obtained exhibits excellent water resistance. However, since the above-mentioned binder having excellent water resistance is expensive, it is not desirable that the amount added exceeds 20% by weight.

  Therefore, it is desirable to use at least two types of a binder for improving the handling property of the semi-cured mat and a binder for improving the water resistance of the finally obtained cosmetic material. However, from the viewpoint of cost and water resistance, it is not preferable that the added amount of the binder exceeds a maximum of 25% by weight.

A pre-semi-cure mat is obtained by subjecting a wet mat obtained by wet papermaking to a primary hot press. The semi-cure to improve the rigidity of the semi-cure mat, which will be described later, and improve the handling property is the first hot press with a pressure of 3-7 kg / cm ² , a temperature of 60-120 ° C., and a pressurization time of about 40 seconds to 5 minutes. Done in The press used for the primary hot press may be a single-stage or multi-stage batch press, or a continuous hot-press belt press.

  Then, the semi-cure mat having a specific gravity of 0.3 to 0.9 is obtained by drying the pre-semi-cure mat to a water content of 10% or less with a hot air dryer or the like preset at about 80 to 250 ° C.

  By applying a resin solution diluted with water to each of the front and back surfaces of the semi-cured mat and subjecting it to a second hot press under higher temperature and pressure conditions than the first hot press, the average specific gravity is 1.2 to 2. A hard fiberboard having a thickness of 1.7 and a thickness of 2 to 6 mm is obtained.

  For the resin liquid, vinyl urethane, acrylic emulsion, vinyl acetate emulsion, latex emulsion and modified products or mixtures thereof are used, and any water-soluble resin can be used. Among these, since the latex emulsion improves the bending strength of the hard fiberboard, it is preferably used by mixing with other resins in a small amount (5 to 25% by weight). However, if the addition amount increases, the suitability of the sander deteriorates, so an addition amount exceeding 25% by weight is not preferable. Moreover, in order to improve a sander suitability, you may add hard resins (5-25 weight%), such as a melamine resin, a phenol resin, and an epoxy resin. However, if the amount of these resins added is too large, the resin becomes hard and brittle, which is not preferable.

  The resin ratio of the resin liquid is preferably adjusted to 10 to 60% by weight, particularly 15 to 40% by weight. If the resin ratio is less than 10% by weight, the effect of improving the dimensional stability and scratch resistance due to the impregnated resin liquid cannot be expected. If the resin ratio exceeds 60% by weight, the permeability of the resin liquid decreases. It is.

Further, the resin solution diluted with water so as to have a resin ratio of 10 to 60% by weight is preferably impregnated by applying or dipping at least 300 g / m ² on the front and back surfaces of the semi-cured mat. For example, when the coating amount is 200 g / m ² , most of the layer impregnated with the resin is removed by grinding of about 0.2 mm, and desired scratch resistance cannot be obtained. In particular, when used as a flooring, it is generally sanded so that the surface is uniform before applying a decorative sheet or the like, and is ground by about 0.1 to 0.2 mm. For this reason, a coating amount of 300 g / m ² or more, preferably 400 g / m ² is required in order for the resin to remain sufficiently even after grinding of about 0.2 mm.

  The semi-cured mat exhibits a certain degree of water repellency due to the semi-curing of the adhesive, so that the surface tension of the resin diluted with water is a penetrant (a kind of surfactant, in order to increase the permeability of the resin liquid. Drugs that lower and increase permeability). Further, in addition to the penetrant, an antifoaming agent or a release agent may be optionally added.

In particular, when impregnating a resin solution diluted with water, at the time of the second hot press under high temperature and high pressure, burrs (water or resin solution containing excess resin impregnated in the semi-cured mat at the time of press Therefore, it is necessary to apply an amount corresponding to the thickness and specific gravity. For example, in the case of a semi-cured mat having a thickness of 6 mm and an average specific gravity of 0.4, when the total amount of the resin liquid impregnated from the front and back surfaces exceeds 800 g / m ² , burrs begin to occur and exceeds 1200 g / m ² . A lot of burrs are generated. Accordingly, in the case of a semi-cured mat having a thickness of 6 mm and an average specific gravity of 0.4, it is preferable to apply and impregnate a resin 400 to 500 g / m ² (total amount 800 to 1000 g / m ² ) on each of the front and back surfaces.

  Moreover, before applying and impregnating the resin liquid, the generation of burrs may be suppressed by providing a through hole that communicates the recess or the front and back surfaces on at least one surface. These recesses or through holes also have an effect of allowing the resin liquid diluted with water to penetrate inside.

  When the pitch between the recesses or the through-holes is larger than 2 cm, the effect of assisting infiltration is thin. Therefore, it is desirable to provide the recesses or through-holes with a pitch of 2 cm or less, preferably 1 cm or less. For example, when recesses or through holes are provided at a pitch of 2 cm, 25/10 cm square recesses or through holes are provided in each 10 cm. In addition, when the pitch is 1 cm, approximately 100/10 cm square recesses or through holes are formed.

  The concave portion or the through hole may be provided by a batch type press with a large number of needle-like protrusions protruding from a flat plate, and it is preferable that the recess or the through hole is continuously processed by a large number of needle-like protrusions provided on the surface of the rotating roll .

  The concave portion needs to have a diameter of 3.0 mm or less, and preferably about 0.5 to 1.5 mm. When the diameter exceeds 3.0 mm, when the second hot press is performed under high temperature and high pressure conditions, uneven portions communicating with the front and back surfaces are generated and cannot be used as a flooring. However, when the concave portion has a diameter of 1.5 mm or more, the concave portion is hardly completely filled even when pressed under a high temperature and high pressure condition. For this reason, when providing the recessed part with a diameter of 1.5 mm or more, it is desirable to use only one side and to use the surface provided with the recessed part for the back surface of the flooring.

  The depth of the recess is preferably half or more of the entire thickness of the semi-cure mat. However, when the concave portion is a decorative surface, it is preferable that the diameter is 1.0 mm or less and the depth is not more than half of the entire thickness of the semi-cured mat. This is because by applying a high-temperature and high-pressure press in the second hot press, the recess itself is crushed by the hot press and is filled with resin, so that the recess can hardly be identified on the surface.

  On the other hand, in the case of a through hole, as described above, if the hole has a diameter of 1.5 mm or more, the hole is not completely filled even if pressed under high temperature and high pressure conditions. In the case of holes, a diameter of 1.0 mm or less is desirable.

The second hot press performed under high temperature and high pressure is performed under press conditions of a temperature of 150 to 250 ° C., a pressure of 10 to 30 kg / cm ² , and a pressing time of about 3 to 30 minutes. At this time, by performing temporary pressing for several tens of seconds to several minutes at a pressure of about 0 to 5 kg / cm ² before applying the high-temperature and high-pressure press, the main pressing is performed for 15 to 20 kg / cm ^2. , The generation of burrs can be suppressed. A distance bar may be arranged between the two press plates so that the thickness can be adjusted to a desired thickness. In this case, since a long press with a uniform surface is required, a batch-type single-stage or multi-stage hot-pressure press is suitable.

  A decorative sheet is attached and integrated on at least one side of the hard fiberboard obtained as described above to form a flooring. In addition, the decorative sheet may be coated, and examples of the coating include urethane coating and UV coating.

  When used as a general flooring, grooving or chamfering is performed on the decorative sheet. For example, after applying a veneer with a thickness of 0.25 mm, sanding the surface, coloring and UV coating, using a router to make a round chamfer with a width of 0.5 mm, from the chamfered part The hard fiberboard is visible. For this reason, if the pigment is added to the slurry in advance, or if the pigment or dye is added in advance to the resin liquid to be impregnated, the hard fiberboard is pre-colored in the same or similar color as the decorative sheet. A flooring with no finished finish can be obtained.

For example, when a pigment is added to the slurry, the amount of the pigment added is preferably 1 to 10% by weight. This is because if it is less than 1% by weight, the desired coloring cannot be obtained, and if it exceeds 10% by weight, the strength is adversely affected.
Moreover, when adding a pigment to a resin liquid, it is preferable that the addition amount of a pigment is 0.5 to 5 weight%. If the amount is less than 0.5% by weight, the desired coloration cannot be obtained, and if it exceeds 5% by weight, it is difficult to disperse in the resin liquid.
Furthermore, when adding a dye to a resin liquid, it is preferable that the addition amount of a dye is 0.1 to 2 weight%. This is because if it is less than 0.1% by weight, the desired coloring cannot be obtained, and if it exceeds 2% by weight, no further effect can be obtained.

  Basically, if the color is set to be lighter than the decorative sheet provided on the surface, the groove portion can be arbitrarily colored according to the color applied to the veneer. On the other hand, any color can be selected for coloring the groove portion. For this reason, for example, it is also possible to arrange the grooves in an accented manner by coloring them in completely different colors.

  Further, since the flooring material is thin, it cannot be said that the flooring material with the decorative sheet only on the front surface is not warped. Therefore, it is desirable to attach a backer material as the back surface material. As the backer material, in order to prevent the occurrence of warpage, it is desirable to apply a material having the same linear expansion coefficient as that of the decorative sheet attached to the surface of the flooring material. In addition, when using as a base material for floor coverings for floor heating, if a metal foil or a metal plate such as an aluminum sheet that can be expected to have a more uniform temperature effect is attached to the surface of the backer material, The soaking material of the heating panel may be omitted.

  Although the decorative material according to the above-described embodiment has been described as applied to a floor heating floor material, it may be applied not only to a normal floor material but also to an inner wall material, a ceiling material, and an outer wall material. is there.

In the second embodiment, as shown in FIG. 2, joists 12 are juxtaposed on the floor base 10 via floor bolts 11, and a heat insulating material 13 is disposed between the floor bolts 11. After laying the floor panel 14 made of a board, the plywood 15 is discarded and then the floor heating panel 20 and the wood heating flooring 30 are sequentially laminated.
Since the heating panel 20 and the wood heating flooring 30 used in the heat generating floor structure are the same as those in the first embodiment, the same parts are denoted by the same reference numerals and the description thereof is omitted.

In the third embodiment, the basic structure is substantially the same as that of the first and second embodiments described above. The difference is that the floor heating panel 40 incorporating the electric heating wire 44 is used as shown in FIG. It is.
The floor heating panel 40 has frame members 42 and 42 arranged on both side edges of the upper surface of a substrate 41 made of plywood, and a heat insulating material 43 is laminated therebetween. Then, the electric heating wire 44 is meandered on the upper surface of the heat insulating material 43 and a thermostat 45 is disposed. Further, the electric heating wire 44 is covered with a soaking plate 46 and then the heating flooring 30 is bridged over the frame members 42 and 42. As the electric heating element, a linear electric heating element or a planar electric heating element can be used.

  According to the present embodiment, since the floor heating panel 40 and the heating flooring 30 can be unitized in advance, there is an advantage that on-site construction becomes easy and workability is improved. Other configurations are substantially the same as those of the above-described embodiment, and thus description thereof is omitted.

(Example 1)
50% by weight of rock wool as mineral fiber, 40% by weight of calcium carbonate as inorganic powder, 3% by weight of starch and 7% by weight of powdered phenol resin as a binder are put into water to obtain a slurry of 5% solid component. A small amount of an antifoaming agent was added thereto and stirred. The slurry was made with a long net paper machine and then dehydrated with a suction pump to obtain a wet mat with a moisture content of 50%. The wet mat was subjected to a first hot press under the press conditions of a temperature of 90 ° C., a pressure of 7 kg / cm ² , and a pressurization time of 1 minute to obtain a pre-semi-cure mat. This pre-semi-cure mat is cut into a size of 30 cm × 90 cm with a water cutter and dried with a hot air dryer adjusted to 220 ° C. to obtain a semi-cure mat with a moisture content of 5%, a thickness of 7 mm and a specific gravity of 0.45. Obtained.

A resin solution was applied and impregnated at 400 g / m ^{2 on} each of the front and back surfaces of the semi-cured mat with a flow coater. The resin solution was prepared by adding 20 parts by weight of latex to 80 parts by weight of acrylic emulsion and diluting with water to adjust the resin ratio to 35%. And 0.05% by weight of a release agent. Then, a 3.0 mm distance bar is arranged on both sides of the semi-cured mat, and the second hot press is performed under the press conditions of a temperature of 190 ° C., a pressure of 15 kg / cm ² , and a pressurization time of 20 minutes to obtain a thickness of 3 A hard fiber board of .3 mm was obtained.

The front and back surfaces of the hard fiber board were sanded to obtain a 3.0 mm hard fiber board with uniform surface. As a result of visual observation of the appearance at this time, it was confirmed that the resin-reinforced surface was uniform. Furthermore, an adhesive (130 g / m ² ) mixed with vinyl acetate emulsion and isocyanate was applied to the front and back surfaces of the hard fiber board, and a 0.45 mm-thick hip dry veneer was attached thereto. And the surface of the said hips dry veneer was UV-coated to obtain a flooring, which was used as a sample.

  In order to verify the scratch resistance of the sample, a caster resistance test, a falling ball impact test, and a Charpy impact test were performed. The caster test is a test in which an iron single-wheel caster carrying a weight of 25 kg is reciprocated 500 times on the same portion of the sample, and the amount of depression at this time is measured. The falling ball impact test is a test in which an iron ball having a weight of 500 g is dropped from a height of 75 cm and the amount of dent generated at this time is measured. The Charpy impact test is a destructive test in which measurement is performed with a Charpy impact strength tester. However, in order to judge the suitability of the flooring as a base material, the hard fiber board alone having a thickness of 3.0 mm, which is not subjected to surface decoration such as a decorative sheet, was also tested in the Charpy impact test. In addition, in order to confirm the suitability as a base material, the length of the hard fiber board having a thickness of 3.0 mm was measured in a heat-resistant drying test (60 ° C., 96 hours) and a hot water resistance test (70 ° C., 4 hours). The dimensional change rate was measured. The measurement results are shown in FIG.

(Example 2)
45% by weight of rock wool as mineral fiber, 5% by weight of nylon fiber (length 5 mm, diameter 25 μm) as heat-resistant organic fiber, 40% by weight of calcium carbonate as inorganic powder, 3% by weight of starch as binder, and powder 7% by weight of phenol resin was put into water to obtain a slurry having a solid content of 5%, and a small amount of an antifoaming agent was added thereto and stirred. The slurry was made with a long net paper machine and then dehydrated with a suction pump to obtain a wet mat with a moisture content of 50%. The wet mat was subjected to a first hot press under the press conditions of a temperature of 90 ° C., a pressure of 7 kg / cm ² and a pressurization time of 1 minute to obtain a pre-semi-cure mat. This pre-semi-cure mat is cut into a size of 30cm x 90cm with a water cutter and further dried with a hot air dryer adjusted to 220 ° C, so that the semi-cure mat has a water content of 5%, a thickness of 7mm and a specific gravity of 0.45. Got.

  Thereafter, a flooring obtained by performing the same treatment as in Example 1 was used as a sample. The sample was subjected to a caster resistance test, a falling ball impact test, and a Charpy impact test. In addition, as tests for confirming suitability as a base material, a heat resistant drying test (60 ° C./96 hours), a hot water resistance test (70 ° C./four hours), and Charpy with respect to the 3.0 mm hard fiber board alone. An impact test was performed. The measurement results are shown in FIG.

(Comparative Example 1)
Sanding was performed on the front and back surfaces of a commercially available plywood (thickness: 3.3 mm) to obtain a plywood having a thickness of 3.0 mm. On the front and back surfaces of this plywood, an adhesive mixed with vinyl acetate emulsion and isocyanate was applied (130 g / m ² ), and a 0.45 mm. Furthermore, UV coating was applied to the surface of the cover dried veneer to obtain a flooring based on plywood, which was used as a sample.

  The sample was subjected to a caster resistance test, a falling ball impact test, and a Charpy impact test. Furthermore, as a test for confirming the suitability as a base material, a heat resistant drying test (60 ° C./96 hours), a warm water resistant test (70 ° C./four hours), and Charpy with respect to the 3.0 mm hard fiber board alone. An impact test was performed. The measurement results are shown in FIG.

(Comparative Example 2)
An aqueous solution containing 1% by weight of a penetrant was applied to the front and back surfaces of a semi-cure mat having a water content of 5%, a thickness of 7 mm, and a specific gravity of 0.45 used in Example 1, 400 g / m ² by impregnation with a flow coater. I let you. Then, a 3.0 mm distance bar is arranged on both sides of the semi-cured mat, and the second hot press is performed under the press conditions of a temperature of 190 ° C., a pressure of 15 kg / cm ² , and a pressurization time of 20 minutes to obtain a thickness of 3 A hard fiber board of .3 mm was obtained. Thereafter, the floor material obtained by the same treatment as in Example 1 was used as a sample. The sample was subjected to a caster resistance test, a falling ball impact test, and a Charpy impact test. Furthermore, as a test for confirming the suitability as a base material, a heat resistant drying test (60 ° C./96 hours), a warm water resistant test (70 ° C./four hours), and Charpy with respect to the 3.0 mm hard fiber board alone. An impact test was performed. The measurement results are shown in FIG.

(Comparative Example 3)
200 g / m ² of the resin solution was applied to the front and back surfaces of the semi-cure mat having a water content of 5%, a thickness of 7 mm, and a specific gravity of 0.45 used in Example 1. The resin solution was obtained by adding 1% by weight of a penetrant, 0.05% by weight of an antifoaming agent, and 0.05% of a release agent to an acrylic emulsion having a resin ratio of 35% diluted with water. Is.

Then, a 3.0 mm distance bar is arranged on both sides of the semi-cured mat, and the second hot press is performed under the press conditions of a temperature of 190 ° C., a pressure of 15 kg / cm ² , and a pressurization time of 20 minutes to obtain a thickness of 3 A hard fiber board of .3 mm was obtained. Next, both sides of the hard fiber board were sanded to obtain a 3.0 mm hard fiber board with a uniform surface. At this time, when the appearance was visually observed, it was confirmed that the resin was peeled off in most parts. Thereafter, the floor material obtained by the same treatment as in Example 1 was used as a sample.

  The sample was subjected to a caster resistance test, a falling ball impact test, and a Charpy impact test. In addition, as tests for confirming suitability as a base material, a heat resistant drying test (60 ° C./96 hours), a hot water resistance test (70 ° C./four hours), and Charpy with respect to the 3.0 mm hard fiber board alone. An impact test was performed. The measurement results are shown in FIG.

  As is clear from FIG. 5A, it was confirmed that Example 1 and Example 2 were clearly superior to Comparative Examples 1, 2 and 3 in the caster resistance test and the falling ball impact test. Further, in the Charpy impact test, it was found that Example 1 and Example 2 were superior to Comparative Examples 2 and 3 and slightly inferior to Comparative Example 1, but this is a practically no problem difference. .

  As is clear from FIG. 5B, it is clear that Example 1 and Example 2 are superior to Comparative Example 1 in terms of dimensional stability in the heat-resistant drying test, and are almost equivalent to Comparative Examples 2 and 3. became. Moreover, it became clear that Example 1 and Example 2 were superior to Comparative Examples 1, 2 and 3 in the dimensional stability in the hot water resistance test. Further, in the Charpy impact test, it was found that Example 1 and Example 2 were superior to Comparative Examples 2 and 3, but were inferior to Comparative Example 1.

  In particular, when comparing a sample in which a cover dry veneer is adhered and integrated on the front and back surfaces of a hard fiber board and a sample made of a hard fiber board alone, in the Charpy impact test, Comparative Example 1 and Examples 1 and 2 It was found that the difference was getting smaller. This is considered to be because the compatibility between the hard fiberboard and the dry cover single board is good, and the impact resistance is improved by the synergistic effect of the characteristics of the two by integrating them together.

(Example 3)
The thermal conductivity of a heating flooring using a reinforced die light having a thickness of 3 mm as a substrate was measured based on JIS A1412-2 using a thermal conductivity measuring device (manufactured by Eihiro Seiki Co., Ltd., model HC-071H). The measurement result was 0.14 Kcal / h · m · ° C.

(Comparative Example 4)
Except for the point that a 3 mm-thick plywood is used as a base material, the thermal conductivity of the heating flooring configured in the same manner as in the above-described third example was measured under the same conditions as in Example 3. The measurement result was 0.07 Kcal / h · m · ° C.

  From the above measurement results, it was found that even if the thickness was the same, Example 3 had a thermal conductivity approximately twice that of Comparative Example 4. For this reason, when the reinforced die light concerning Example 3 was used, it turned out that it can be remarkably thin rather than the normal flooring for heating combined with the measurement result regarding the above-mentioned impact resistance.

Example 4
About the heating floor structure using the flooring for heating which made the above-mentioned reinforced die light 3mm thick as a substrate, room temperature 20 ° C, hot water temperature 45 ° C, and the temperature rise of the floor after 30 minutes from the start of hot water was measured. . As a result, a temperature increase of 7 ° C. was confirmed.

(Comparative Example 5)
The temperature rise was measured under the same conditions as in Example 3 except that a 6 mm thick plywood was used as the substrate. As a result, a temperature increase of 4 ° C. was confirmed.

(Comparative Example 6)
The temperature rise was measured under the same conditions as in Example 3 except that a 12 mm thick plywood was used as the substrate. As a result, a temperature increase of 2 ° C. was confirmed.

  As is clear from Example 4 and Comparative Examples 5 and 6, it was confirmed that Example 4 was faster in temperature rise than Comparative Examples 5 and 6.

  Of course, the heat generating floor structure according to the present invention is not limited to the above-described embodiment, and may be applied to a heat generating floor structure incorporating another heat generating element.

It is sectional drawing which shows 1st Embodiment of the heat generation floor structure concerning this invention. It is sectional drawing which shows 2nd Embodiment of the heat generation floor structure concerning this invention. FIGS. A and B are cross-sectional views showing the wood heating flooring and floor heating panel used in the first and second embodiments. It is a fragmentary sectional perspective view which shows the floor heating panel and wood type heating flooring which are used for 3rd Embodiment of the heat generation floor structure concerning this invention. It is a graph which shows the test result of the Example concerning this invention, and a comparative example. FIGS. A and B are sectional views showing a heat generating floor structure according to a conventional example.

Explanation of symbols

20: Floor heating panel 21: Base material 22: Groove 23: Heat transfer material 24: Pipe 25: Heat equalizing material 30: Heating flooring 31: Cosmetic material 32: Back material 33: Substrate 40: Floor heating panel 41: Substrate 42 : Frame material 43: Heat insulating material 44: Heating wire 45: Thermostat 46: Heat equalizing plate

Claims (9)

In the heat generation floor structure laminated so as to hold the heating element with the heat insulating material and the floor material,
The floor material is heated to a wet mat obtained by wet-making a slurry containing 35 to 70% by weight of mineral fibers, 20 to 55% by weight of an inorganic powder, and 5 to 25% by weight of a binder. A semi-cured mat having a specific gravity of 0.3 to 0.9 obtained by pressure pressing is impregnated with a diluted resin solution having a resin ratio of 10 to 60%, and an average specific gravity of 1.2 to 1. A heating floor structure characterized in that a hard fiberboard obtained by adjusting to 7 is used as a substrate.   The heat generating floor structure according to claim 1, wherein a decorative sheet is bonded and integrated on at least one side of the substrate.   The heat generating floor structure according to claim 1 or 2, wherein a soaking plate is laminated between the heat generating element and the flooring.   The heat generating floor structure according to any one of claims 1 to 3, wherein a plywood is laminated on a lower surface of the heat insulating material.   The heating floor structure according to any one of claims 1 to 4, wherein the heating element is a pipe that is filled with a heated liquid heat transfer medium.   The heating floor structure according to any one of claims 1 to 4, wherein the heating element is an electric heating element. The heat generating floor structure according to any one of claims 1 to 6, wherein the flooring material is added with 0.5 to 15% by weight of heat-resistant organic fibers as a partial substitute for mineral fibers. The heating floor structure according to any one of claims 1 to 7, wherein the floor material is colored by adding a pigment to the slurry. The heat generating floor structure according to any one of claims 1 to 8, wherein the floor material is colored by adding a pigment or a dye to a resin liquid diluted to a resin ratio of 10 to 60%.

Images