JP2005315483A - Mat for floor heating and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a mat for floor heating having excellent dimensional stability and construction efficiency. <P>SOLUTION: When a small joist 17 is fixed onto an elastic base material 13 at a position not overlapped with a heater wire 14, a heat distribution sheet 16 onto which a thermosetting adhesive agent is applied is stuck on the base material with its adhesive agent-coated surface facing to the base material side, and thermally pressed by pressing a heating plate 25 against the base material at the small joist fixed position. Since the thermosetting resin adhesive agent coated on the heat distribution sheet is penetrated into a substrate on the lower side of the heating plate and cured in a compressed state to a specified thickness, the adhesive agent maintains the specified thickness also after the pressing is removed. The small joist is fixedly disposed at the small joist fixing position to form the mat 11 for floor heating. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a floor heating mat used in an electric floor heating apparatus and a method for manufacturing the same.

  As a mat for a conventional electric floor heating device, as described in Patent Document 1 below, a heater sheet laminated on a flexible base material, and a small joists laminated on the heater sheet Are known.

In order to manufacture this floor heating mat, after applying an adhesive such as urethane resin to the surface of the flexible base material, the base material is placed on a press plate, and the applied adhesive is not dried and solidified. Then, the heater sheet is placed on the substrate with the heater wire facing downward. Furthermore, a small joist is placed on the wide interval portion of the heater sheet so as not to cover the heater wire through an aluminum sheet. Subsequently, the floor heating mat having the above-described configuration is manufactured by placing a thickness regulating jig having substantially the same thickness as the small joists and the heater wire around the periphery and performing pressing at a high temperature.
JP 2003-166720 A

  However, according to the structure of the floor heating mat of the above-mentioned prior art, a wooden small joist is arranged on an aluminum sheet laminated on a heater sheet. Therefore, heat is not easily transmitted to the back side of the small joists, and the temperature of the base material located on the back of the small joists does not rise to a temperature sufficient to cure the adhesive. For this reason, even if it is compressed to the specified thickness immediately after the pressing, a certain amount of return occurs when the pressing is released, and it is difficult to maintain the base material at the specified thickness.

  Further, since the small joists are pressed with the hot platen, the temperature is different between the front side that is in direct contact with the hot platen and the back side away from the hot platen. For this reason, the water content of the small joist varies between the front and back, causing warpage of the small joist. When warp occurs in the small joist, not only is it difficult to roll and handle the floor heating mat with the small joist, but also the workability when laying the floor heating mat is lowered.

  Furthermore, the operation of placing a plurality of small joists at specified positions on the base material and in parallel with each other is complicated and difficult.

  Therefore, the subject of this invention is providing the mat for floor heating which eliminates the disadvantage of the said prior art and has favorable dimensional stability and workability.

  In order to achieve the above object, the present invention according to claim 1 includes a base material formed of a material having elasticity, a heater wire provided on or inside the base material, and a thermosetting adhesive. A heat dispersion sheet that is attached on a substrate including a heater wire and promotes the dispersion of heat generated by the heater wire, and a small joist fixed on the heat dispersion sheet at a position that does not overlap the heater wire, The floor heating mat is characterized in that a thermosetting adhesive penetrates at least a base material located under a small joist and is cured by heat pressure.

  The present invention according to claim 2 is a thermosetting adhesive in which a heater wire is provided on the surface or inside of a base material formed of an elastic material, and then a heat dispersion sheet is formed on the base material including the heater wire. In addition, on the heat dispersion sheet, on the small joist fixed position that does not overlap with the heater wire, a hot plate having a surface substantially equal to the surface in contact with the substrate is pressed and hot pressed, Thus, after the base material portion under the small joist fixing position is formed to a specified thickness, the small joist is arranged and fixed at the small joist fixing position.

  The floor heating mat of the present invention heats a floor board using electric energy and thereby heats the upper space of the floor board.

  The base material in the floor heating mat of the present invention is preferably formed of an elastic material such as a non-woven fabric, a net-like sheet, paper, a perforated sheet, and the thickness thereof is generally about several mm, for example, about 3 mm. However, at the position where the small joists are fixed, it is cured in a compressed state to a specified thickness, for example, 0.5 mm.

  The heater wire is affixed to the surface of the substrate or embedded in the interior. The heater wire is preferably provided in a meandering manner, and this facilitates uniform heat transfer over the entire surface of the substrate.

  It is preferable to provide a heat sensitive wire in a meandering manner along the heater wire. By providing the heat sensitive wire, the controller can prevent the heater wire from being overheated. Heater wires and heat sensitive wires that are wired in a meandering manner in the floor heating mat enter and exit a wiring box provided in the floor heating mat.

  The heat dispersion sheet provided on the heater wire serves to disperse the heat generated by the heater wire, and is preferably provided on the entire surface of the substrate. As the heat dispersion sheet, a material having thermal conductivity and flexibility adhered to the surface of the nonwoven fabric, or a material having thermal conductivity and flexibility sandwiched between two nonwoven fabrics was integrated. Things. As a material having thermal conductivity and flexibility, a copper foil or an aluminum foil may be used.

  It is preferable to use a thermosetting adhesive that emits less formaldehyde, for example, a type arbitrarily selected from urea resins, phenol resins, melamine resins, urethane resins or their modified resins, isocyanate resins, synthetic rubbers, and the like. Or it is preferable to use multiple types. The thermosetting adhesive is used for adhering a heat dispersion sheet on a substrate including a heater wire (and a heat sensitive wire), and is applied to the front surface side of the substrate and / or the back surface side of the heat dispersion sheet. However, when applied to the substrate side composed of nonwoven fabric, mesh sheet, paper, perforated sheet, etc., there is a concern that it may penetrate into the inside of the substrate and reduce the adhesive force to the heat dispersion sheet. It is preferable to apply on the back side of the sheet, and laminate and attach the adhesive-coated surface toward the substrate.

  The floor heating mat is further provided with a small joist on the base material at a position that does not overlap the heater wire and heat sensitive wire, thereby preventing the load from above directly acting on the heater wire and heat sensitive wire. Protect the heater wire and heat sensitive wire. The small joists are temporarily fixed on the heat dispersion sheet at this position after the base material is compressed and cured to a prescribed thickness. The temporary fixing means may be adhesive bonding or mechanical fixing means such as double-sided tape. The shape of the small joist is not particularly limited, but generally, an elongated or strip-like thin plate or rod-like material is used. Small joists are made of wood such as plywood, wood board, wood fiber board (MDF, etc.), wood chipboard, and single board laminated board, as well as metal materials such as synthetic resin, iron, copper, and aluminum alloy. Alternatively, a shape member or the like can be used. When the small joist is provided on the base material or the heat dispersion sheet, the nail (screw) striking position when the floor heating mat is fixed to the floor base plate with a nail or a screw in the small joist is clarified, and It is also possible to prevent damage to the heater wires and heat sensitive wires with nails and screws. The small joists are provided in parallel to each other at a predetermined interval so that the floor heating mat can be rolled and stored.

  The hot pressing is performed by pressing a heating plate having a surface having a size substantially equal to the surface where the small joists are in contact with the substrate through the heat dispersion sheet. The heating plate is, for example, a steel plate, a copper plate, an aluminum plate, or the like. The heating temperature of the heating plate is set according to the type of thermosetting adhesive to be used, and the substrate is heated to a predetermined temperature. For example, when a urethane resin system is used as the thermosetting adhesive, the substrate is heated so that the temperature of the substrate is about 150 ° C.

  According to the floor heating mat of the present invention according to the first aspect, the thermosetting adhesive penetrates into the base material located under the small joists, and the base material portion is compressed and cured by hot pressure. For this reason, it is easy to make the base material of this part into the prescribed thickness, and the return after the decompression is prevented, so that the prescribed thickness can be maintained. As a result, the total thickness of the small joists, the heat dispersion sheet, and the cured base material portion located below these becomes constant, and the dimensional stability is improved.

  In addition, since the base material portion under the small joist is cured in a state compressed to a specified thickness, the small joist has a fixing means such as a nail or a screw through the base material portion in the compression hard state. Therefore, the fixing means has a large holding force and is firmly fixed. Furthermore, since the prescribed thickness is obtained, when the floor board is laid on the floor heating mat, the floor board is applied flat without being wavy.

  On the other hand, in places where small joists do not exist, a heater wire and a heat dispersion sheet are arranged on or inside the elastic base material, but the thermosetting adhesive does not easily penetrate into the base material portion. Therefore, elasticity is maintained without curing. Therefore, when the floor heating mat is placed on the floor base and the floor board is laid on the floor heating mat, the base material under the heater wire is compressed. As a result, the heater wire comes into close contact with the back surface of the floor board via the heat dispersion sheet, so that the heat generated by the heater wire is efficiently transferred to the floor board via the heat dispersion sheet, thereby improving the floor heating efficiency.

  According to the method for manufacturing a floor heating mat of the present invention according to claim 2, the heat dispersion sheet is stuck on the base material including the heater wire by the thermosetting adhesive, and the thermosetting adhesive. Penetrates into the substrate. And by pressing the heating plate against the fixed position of the small joists on the heat dispersion sheet affixed to the base material, this part of the base material is compressed and the thermosetting adhesive penetrated into the base material Since the agent is cured by heating, the base material at the small joist fixed position is formed to a specified thickness. In this case, since the base material at the small joist fixing position is directly heated, it is quickly heated to a temperature sufficient to cure the thermosetting adhesive.

  In addition, the base material at the position where the small joist is fixed is formed by curing to a specified thickness with a thermosetting adhesive, and therefore the base material including the heat dispersion sheet of this portion even after the heat pressure is released. The thickness remains unchanged from the specified thickness. Further, since the small joists are fixed on the base material including the heat dispersion sheet having a predetermined thickness, the plural small joists are fixed in parallel to each other at predetermined positions of the base material including the sheets. It becomes easy.

  Further, since the small joists themselves are not heated by hot pressure or the like as in the prior art, they hardly warp. For this reason, since the floor heating mat with small joists can be rolled, the handling becomes easy, and the workability when laying the floor heating mat is improved.

  Hereinafter, an embodiment of a floor heating mat according to the present invention will be described with reference to the accompanying drawings. The floor heating mat 11 of this embodiment heats the floor board 18 using electric energy and heats the upper space of the floor board, and is made of an elastic material (for example, a spunbond nonwoven fabric having a thickness of about 3 mm). The formed nonwoven fabric 13 and the electric heater wire 14 fixed to the nonwoven fabric 13 in a meandering manner are provided. Further, a heat dispersion sheet 16 that is adhered to the nonwoven fabric 13 including the heater wire 14 by a thermosetting adhesive applied to the back surface and promotes dispersion of heat generated in the heater wire 14, and the heat dispersion sheet 16 A small joist 17 attached to a position not overlapping with the heater wire 14 is provided. Further, in this embodiment, the heat sensitive wire 15 is fixed in a meandering manner on the nonwoven fabric 13 so as not to overlap with the heater wire 14, and the heating temperature by the heater wire 14 is controlled via the controller 20 described later and abnormal. It acts to detect and prevent overheating. The nonwoven fabric 13 located under the small joist has a prescribed thickness (0.5 mm in this embodiment).

  In the floor heating mat 11, there is a vertical distance D difference between the upper surface of the small joist 17 and the upper end of the heater wire 14 and / or the heat sensitive wire 15. By giving this vertical distance D, when the floor board 18 is laid, the heater wire 14 and the heat sensitive wire 15 sink into the nonwoven fabric 13, and the upper surface of the small joist 17 and the upper end of the heater wire 14 and the heat sensitive wire 15 coincide. That is, since the heater wire 14 is in close contact with the back surface of the floor plate 18 via the heat dispersion sheet 16, the heat generated by the heater wire 14 is easily transmitted uniformly over the entire surface of the floor plate 16.

  As shown in FIG. 6, an example of the heat dispersion sheet 16 is a thin plate (copper foil, aluminum, etc.) having heat conductivity and flexibility on the surface of a base sheet 16a such as a nonwoven fabric, a net having a certain degree of heat resistance, and paper. A foil or the like) having a two-layer structure in which 16b is laminated and adhered. As another example, it is possible to use a three-layer structure in which the base sheet is used on the front and back, and a thin plate having thermal conductivity and flexibility is sandwiched between them and laminated and adhered and integrated. The heat dispersion sheet 16 is provided on the entire surface of the nonwoven fabric 13 via the heater wire 14 and the heat sensitive wire 15, and dissipates the heat generated by the heater wire 14 in a plane and efficiently transmits it to the floor plate 18.

  2-5 is a figure explaining the manufacturing method of the floor heating mat 11 of FIG. 1 in order of a process, FIG. 2 is sectional drawing of the state which affixed the heater wire 14 and the heat sensitive wire 15 on the nonwoven fabric 13. FIG. 3 is a cross-sectional view of a state in which a heat dispersion sheet 16 is stuck on the nonwoven fabric 13, the heater wire 14 and the heat sensitive wire 15 in FIG. 2, and FIG. 4 shows a heating plate 25 on the heat dispersion sheet 16 in FIG. FIG. 5 is a cross-sectional view of a state in which it is placed, and FIG. 5 is a cross-sectional view of a state in which heat is pressed between the upper and lower hot platens of the hot-press press shown in FIG.

  More specifically, first, as shown in FIG. 2, the heater wire 14 and the heat sensitive wire 15 are attached to the nonwoven fabric 13 in a meandering manner. Further, as shown in FIG. 3, a urethane resin adhesive is applied to the back surface of the heat dispersion sheet 16, and this is applied onto the nonwoven fabric 13 (FIG. 2) in a state where the heater wires 14 and the heat sensitive wires 15 are attached. To wear. The urethane resin-based adhesive applied to the back surface of the heat dispersion sheet 16 is in direct contact with the surface (upper surface) of the nonwoven fabric 13 particularly at a location where the heater wire 13 and the heat sensitive wire 14 are not present, and enters the inside of the nonwoven fabric 13 from the surface side. To penetrate.

  Next, as shown in FIG. 4, the heater wire 14, the heat sensitive wire 15, and the heat dispersion sheet 16, which are superimposed on the nonwoven fabric 13 (FIG. 3), are placed on the lower hot platen 27 of the hot press. Then, the heating plate 25 is disposed on the heat dispersion sheet 16 between the heater wires 14 (where the heater wires 14 do not exist), and the upper hot platen 26 of the hot press is lowered and hot pressed. The position where the heating plate 25 is disposed is a position where the small joists 17 should be fixed.

  The heating plate 25 is made of a material having excellent thermal conductivity such as aluminum, and has a surface having a size approximately equal to the surface where the small joists 17 are in contact with the nonwoven fabric 13. The thickness is preferably 3 mm, for example, and is larger than the thickness of the small joists 2.5 mm so that the heat pressure can be reliably performed. The heating plate 25 is heated by contacting the upper hot platen 26 heated to a high temperature. Therefore, the hot pressure lowers the heated upper hot platen 26 and makes it contact with the heating plate 25 to raise the temperature of the heating plate 25 to a predetermined temperature. This is done by pressing against 13.

  In this case, the lower hot platen 27 should be heated to some extent. For example, the lower hot platen 27 is preferably heated to 70 to 80 ° C. By doing so, the dimensional stability of the nonwoven fabric 13 to be compression-hardened is increased. The hot press temperature is set according to the type of the thermosetting adhesive to be used, and the nonwoven fabric 13 is heated to reach a predetermined temperature. When a urethane resin system is used as the thermosetting adhesive, the substrate is heated so that the temperature of the substrate is about 150 to 160 ° C. The hot pressing time is appropriately selected between 1 and 10 minutes.

  As shown in FIG. 5, at the end of the hot pressing, the nonwoven fabric 13 positioned under the heating plate 25 is compressed and heated by the hot pressure and flattened by the curing of the thermosetting adhesive that has penetrated into the nonwoven fabric 13. And has a specified thickness, for example, 0.5 mm. On the other hand, since the thermosetting resin hardly permeates into the nonwoven fabric 13 where the heating plate 25 is not disposed and there is almost no thermosetting resin, the non-cured resin does not cure even after hot pressing. Yes. Due to this elasticity, the heater wire 14 and the heat sensitive wire 15 are pressed against the back surface of the floor board 18 through the heat dispersion sheet 16.

  A floor heating apparatus using the floor heating mat 11 manufactured as described above will be described with reference to FIGS.

  The floor heating apparatus 10 is provided around a floor heating mat 11 (a pair of floor heating mats 11 a and 11 b) disposed on the floor base plate 1 and the floor heating mat 11. A floor mat 18 disposed on the floor mat 18, the floor plate 18 laid on the floor mat 12, and a controller 20 that electrically controls the floor heating mat 11.

  The floor base plate 1 is laid on the joists 3, and between the joists 3 is filled with a heat insulating material 4 such as polystyrene foam. The floor base plate 1 supports a load applied to the floor plate 18 through floor heating mats 11a and 11b and a peripheral mat 12, and the material thereof is generally a wood type such as plywood, wood board, wood fiber board (MDF, etc.). used. The thickness of the floor base plate 1 is selected from a range of 12 to 30 mm, for example.

  Each of the floor heating mats 11a and 11b has the elastic nonwoven fabric 13 as a base material as described above, and heater wires 14 and heat sensitive wires 15 are provided in a meandering manner on the surface thereof. A small joist 17 (17a, 17b) that is covered and juxtaposed at a predetermined interval is formed (FIG. 1). The floor heating mats 11a and 11b have a common wiring box 23 in which terminals of the heater wire 14 and the heat sensitive wire 15 are gathered.

  The arrangement of the small joists 17 in the floor heating mats 11a and 11b has a substantially point-symmetrical positional relationship. The gaps are parallel to each other at an appropriate interval and alternately serve as a passage for the heater wire 14 at one end in the longitudinal direction. It is provided in a staggered pattern with a gap (Figs. 7 and 8). The small joist 17 is temporarily fixed to the nonwoven fabric 13 with a double-sided tape or the like (not shown). The small joists 17 are elongated or strip-shaped, and are disposed between the heat dispersion sheet 16 and the floor plate 18 provided on the surface of the floor heating mat 11. The small joists 17 are arranged so as not to overlap with the heater wires 14 and the heat sensitive wires 15, and are fixed to the floor base plate 1 with wood screws (screws) 19 through the heat dispersion sheet 16 and the nonwoven fabric 13 (FIG. 9). As described above, the non-woven fabric 13 located under the small joist 17 penetrates the thermosetting resin adhesive (urethane resin adhesive) applied to the back surface of the heat dispersion sheet 16 and is compressed by the hot press. It is hardened in a state of being formed, is formed to a prescribed thickness (0.5 mm), and maintains this prescribed thickness. Between the small joists 17 and 17, the nonwoven fabric 13 is substantially in surface contact with the floor plate 18 through the heat dispersion sheet 16.

  The peripheral mat 12 is provided on the floor base plate 1 between the four peripheral edges of the floor heating mats 11a and 11b and the walls 2 and 2 of the room, and the floor heating mat is laid on the floor plate 18 thereon. 11a, 11b and substantially the same thickness (3 mm in this embodiment). The peripheral mat 12 is formed of a flexible base material such as a nonwoven fabric.

  The floor board 18 is configured by attaching a decorative material to the surface of a base material. Plywood, wood board, wood fiber board (MDF, etc.), wood chipboard, single board laminated board, etc., wood, styrene resin board, vinyl chloride resin board, reinforced plastic board, polystyrene foam resin board, urethane foam resin It consists of a synthetic resin system such as a board, or a composite laminated board of a wood system and a synthetic resin system. As a decorative material to be stuck on such a substrate, a natural veneer obtained by cutting natural wood, an artificial veneer, a nonwoven fabric, paper, a synthetic resin sheet, or the like can be used, and a sheet of flexible material. You may use what printed various patterns on. As a synthetic resin sheet used as a decorative material, for example, an olefin resin, a vinyl chloride resin, a polyester resin, an acrylic resin, or the like can be used. The thickness of the decorative material is determined in the range of 0.05 to 1 mm, for example. Since the decorative material is extremely thin, the illustration is omitted and the thickness thereof is ignored, and the thickness of each floor board is assumed to be equal to the thickness of the plywood substrate. As an example, a decorative board obtained by sticking an optional decorative material as described above to the surface of a 9 mm thick plywood as a base material can be used as the floor board 18. The size of the floor board 18 is, for example, width 303 mm × length 1818 mm.

  The floor board 18 is laid in a direction orthogonal to the longitudinal direction of the small joists 17 so that the joint between the floor boards 18 is located on the small joists 17. Thereby, the deformation | transformation of the joint part of the floor board 18 not jumping up arises, and the floor surface without unevenness can be given. Further, the floor board 18 is formed with a male fruit 18a and a female fruit 18b along the longitudinal direction and the short side direction, and the nape 24 is driven into the base end portion of the male fruit 18a so as to be compressed under the small joist 17 and below. It is fixed to the floor base plate 1 through the nonwoven fabric 13.

  The controller 20 is connected to a wiring box 23 provided at one end of the joining edge of the floor heating mats 11 a and 11 b through a cable 21 and is supplied with power through a power cord 22. The power cord 22 may be used while being connected to the controller 20, but the power cord 22 is detachably connected to the controller 20 and a plug (not shown) is provided at the tip thereof. A plug is inserted into an outlet (not shown) and temporarily used for an energization test of the floor heating mats 11a and 11b. When the energization test is completed, the power cord 22 is removed, and the controller 20 and the distribution board are removed. (Not shown) may be connected to the power supply. The controller 20 controls on / off of the floor heating mats 11a and 11b, heating intensity, overheating prevention, electric leakage prevention, and the like, and performs other heating reservations as necessary.

  As described above, the thickness of the floor plate 18 is 9 mm, and the thickness of the floor heating mat 1 provided therebelow (that is, the nonwoven fabric 13 and the heat dispersion sheet 16 overlap below the small joists 17 so that the nonwoven fabric 13 overlaps. Is set so as to be 3 mm, the apparent thickness from the surface of the floor base plate 1 to the surface of the floor plate 18 is 12 mm. In this embodiment, the peripheral mat 12 is arranged around the floor heating mats 11a and 11b on the floor base plate 1, and the thickness of the peripheral mat 12 is laid on the peripheral mat 12. Since the thickness of the floor heating mats 11a and 11b is 3 mm, the total thickness of the peripheral mat 12 and the floor board 18 is also 12 mm, and the floor board 18 and the peripheral mat 12 constructed on the floor heating mats 11a and 12b. The surface of the floor board 18 to be constructed is flush.

1 is a cross-sectional view showing an embodiment of a floor heating mat according to the present invention. It is explanatory drawing which shows the 1st manufacturing process of this floor heating mat. It is explanatory drawing which shows the 2nd manufacturing process of this mat for floor heating. It is explanatory drawing which shows the 3rd manufacturing process of this mat for floor heating. It is explanatory drawing which shows the 4th manufacturing process of this floor heating mat. It is an expanded sectional view of an example of the heat dispersion sheet used for this floor heating mat. It is a perspective view which shows one Embodiment of the floor heating apparatus using the floor heating mat manufactured through the manufacturing process of FIGS. 2-5 in the state in the middle of construction of a floor board. It is a top view which omits a floor board and shows the construction state of this floor heating apparatus. It is BB expanded sectional drawing in FIG. It is an AA expanded sectional view in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Floor base plate 10 Floor heater 11 (11a, 11b) Floor heating mat 12 Perimeter mat 13 Unemployed cloth (base material)
14 Heater Wire 15 Heat Sensitive Wire 16 Heat Dispersion Sheet 17 (17a, 17b) Floor Heating Mat Small Radish 18 Floor Plate 25 Heating Plate

Claims (2)

Generated by the heater wire that is attached to the substrate including the heater wire with a base material made of elastic material, the heater wire provided on the surface or inside of the substrate, and the thermosetting adhesive A base plate on which the thermosetting adhesive is located at least under the small joists. A floor heating mat characterized by being infiltrated and cured by heat pressure. After providing a heater wire on the surface or inside of the base material made of a material having elasticity, a heat dispersion sheet is stuck on the base material including the heater wire with a thermosetting adhesive. On the dispersion sheet, a hot plate having a surface approximately the same size as the surface in contact with the base material is pressed on the small joisting fixed position that does not overlap with the heater wire, and is hot-pressed, and thus the base under the small joist fixing position. A method for manufacturing a floor heating mat, comprising: forming a material portion to a specified thickness, and arranging and fixing the small joist at the small joist fixing position.

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