JP2007120132A - Outside flooring - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide outside flooring using an inexpensive and safe ceramic heating body not causing wire breakage, easily temperature-controlled, and having heat storage effect. <P>SOLUTION: This outside flooring is formed by integrally fixing a base part 2 with a built-in planar ceramic heating body 3 to the lower side of a planking 1 exposed to a road surface. In the ceramic heating body 3, a part of a carbonacious film 5 formed on the upper surface of an unglazed substrate 3a or a clay plate is peeled in a predetermined shape to form at least one or more independent carbonacious film segments 3b, current flow passages 3f are formed therein, and a current flows therein for heating. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an outer floor material incorporating a novel sheet-shaped ceramic heating element, in which a carbonaceous film is energized to generate heat.

  Traditionally, in cold areas and in winter, snow may have accumulated or frozen on the doorsteps and passages outside, so the passages are often unusable, and the snow is removed or thawed. The work to do was also very time consuming.

In order to solve such a situation, means for heating the outdoor ground from the inside has been devised. For example, the following patent document discloses an underground heat generation technique in which a cord-shaped heating wire is disposed on concrete and a heat conductive layer containing carbon-based ceramics is disposed thereon.
JP-A-7-106057

  However, in the above-mentioned literature technique, there is a risk of disconnection because the heating element is formed of a linear body, and since it is formed of a linear body, in order to sufficiently raise the temperature of the entire ground above it. It is necessary to run the heating wire vertically and horizontally, which is expensive. Moreover, once a heat conductive layer is laid on the heating wire, it is very difficult to replace the heating wire due to disconnection or to increase or decrease the heating wire for temperature control. There is also a risk of leakage due to disconnection.

  The present invention has been proposed on the basis of such circumstances. The purpose of the present invention is to provide a newly developed inexpensive and safe ceramic heating element that is free from disconnection, easy to control temperature, and has a heat storage effect. The purpose is to provide the used outer flooring.

  It is another object of the present invention to provide an outer floor material that can withstand the ingress of moisture such as rainwater and snow.

  In order to achieve the above object, an outer flooring material according to claim 1 is an outer flooring material in which a base part in which a planar ceramic heating element is built is formed integrally below a floor plate exposed from a road surface. In the ceramic heating element, a part of the carbonaceous film formed on the upper surface of the unglazed substrate or the ceramic plate is exfoliated into a predetermined shape to form at least one or more isolated carbonaceous film segments, and a conduction path is provided to them. To provide heat and generate heat.

  The outer flooring according to claim 2 is characterized in that the floorboard is made of a material having water permeability.

  According to a third aspect of the present invention, the ceramic heating element is covered with an insulating outer shell and is waterproofed and accommodated in an accommodation recess formed in the base portion, and the base portion is an accommodation recess of the ceramic heating element. A water-permeable part is formed around it to allow the water soaked in the floorboard to pass through the soil.

  According to a fourth aspect of the present invention, the ceramic heating element is provided with a current controller with a temperature sensor, and the energization is cut off when the temperature exceeds a predetermined temperature, and the energization is allowed within the predetermined temperature.

  In the outer floor material according to claim 5, an energization cord is led out to an energization path of each ceramic heating element, and the energization cords are connected to each other to energize and connect adjacent ceramic heating elements of the outer floor material. It has a structure to do.

  According to a sixth aspect of the present invention, a hole portion for accommodating the energization cord is formed on the side surface of the base portion.

  According to the outer floor material of claim 1, since the built-in ceramic heating element has at least one or more isolated carbonaceous film segments formed in a planar shape, the dimensions of the isolated carbonaceous film segments, By selecting the number, the electric resistance value can be adjusted, so that the temperature can be easily adjusted, and the surface temperature of the floorboard can be set to an appropriate temperature.

  This outer floor material can be applied to buildings, hotels, entrances of residential units, roads, and the like in cold regions, and can generate snow and dry rainwater by generating heat. Furthermore, if it is used in dirt, it can be used as an external floor type floor heating system.

  Further, since no electrical parts such as nichrome wires are required, there is no fear of disconnection, and manufacturing is easy and cost is low. Furthermore, since a carbonaceous film is not formed inside the unglazed substrate, it becomes a good heat storage body and also has a heat storage effect.

  According to the outer floor material according to claim 2, since the floorboard is made of a material having water permeability, moisture due to rain water, summer water spray, winter snow accumulation, etc. can be appropriately treated regardless of evaporation. The drainage is very good.

  According to the outer flooring according to claim 3, since the water permeable portion is provided in the base portion, it is possible to prevent rain from entering the housing recess by guiding rainwater or the like to the ground, and to incorporate the built-in ceramic heat generation. Since the body is waterproofed with an insulating outer skin, it is possible to prevent rusting of the internal electrodes, short-circuiting of the carbonaceous film, and electric leakage.

  According to the outer flooring of claim 4, a current controller with a temperature sensor is attached to the ceramic heating element, and the energization is cut off when a predetermined temperature is exceeded, and the energization is allowed within the predetermined temperature. Therefore, excessive heating and overcurrent can be prevented. Moreover, since the unglazed substrate has a heat storage action, the surface can be maintained at a sufficient temperature even after the current controller stops energization. Therefore, energization can be performed intermittently and the operating cost can be suppressed.

  According to the outer floor material according to claim 5, since the energization cord is led out to the energization path of the ceramic heating element, a plurality of outer floor materials can be connected by crossover wiring, and roads and entrances in cold regions can be connected. It can be used for a wide range of applications such as the tip.

  According to the outer floor material of the sixth aspect, since the encasing recess for the energizing cord is formed on the side surface of the base portion, the energizing cord that does not need to be connected can be accommodated so as not to be disturbed. .

  Embodiments of the present invention will be described below with reference to the accompanying drawings.

  FIG. 1 is an exploded perspective view seen from the front side showing an embodiment of the outer flooring material of the present invention.

  The outer floor material 10 has a floor plate 1 that is exposed from the road surface on the front side, and a base portion 2 in which a planar ceramic heating element 3 that generates heat when energized is embedded is fixed to the floor plate 1 integrally therewith. It is the structure formed as follows.

  The floor board 1 is preferably made of a water-permeable material such as shells, tiles, concrete, and tiles that are bonded and cured with a heat-resistant binder.

  The base part 2 is made of heat-resistant resin or the like, and passes through the housing recess 2a for housing the ceramic heating element 3 and the moisture soaked into the floor plate 1 provided in the periphery of the housing recess 2a. For this purpose, there are provided a water permeable portion 2b that penetrates to the back surface and a side recess 2c that accommodates the energizing cord 3c connected to the ceramic heating element 3.

  FIG. 2 is a perspective view of the outer floor material 10 of the present invention viewed from the back side, and FIG. 3 is an AA in a state where the floor plate 1 and the base portion 2 of the outer floor material 10 shown in FIG. It is a longitudinal section structure figure of a line. The structure of the housing recess 2a of the base portion 2 and the ceramic heating element 3 will be described with reference to these drawings.

  An accommodation recess 2a is formed on the back side of the base portion 2, and the ceramic heating element 3 is accommodated therein. A back cover 2d that can be opened and closed with a screw or the like is provided at the opening of the housing recess 2a.

  The ceramic heating element 3 is formed by forming a part of the carbonaceous film formed on the upper surface of the unglazed substrate 3a or the ceramic plate into a predetermined shape to form at least one or more isolated carbonaceous film segments 3b. The carbonaceous film segment 3b is energized by providing a current path so that the carbonaceous film segment 3b generates heat.

  2d shown in FIG. 2 is a current controller with a temperature sensor for interrupting energization when the heat generation temperature exceeds a predetermined temperature. Reference numeral 3g denotes a conductive plate for connecting the energization cord 3c. The detailed energization structure of the ceramic heating element 3 will be described later with reference to FIG.

  The ceramic heating element 3 is covered with an insulating outer skin (not shown) formed by applying a heat-resistant resin or paint. The insulating skin prevents moisture from entering the ceramic heating element 3.

  That is, the outer floor material 10 guides rainwater and the like to the ground by the water permeable portion 2 b provided in the base portion 2 to prevent water from entering the housing recess 2 a and covers the ceramic heating element 3. It has a structure that can be further waterproofed by an insulating skin. Such a waterproof structure can prevent internal electrode rust, carbonaceous film short circuit, and leakage.

  Next, the energization structure of the ceramic heating element 3 will be described.

  FIG. 4A is a view showing the arrangement of carbonaceous film segments and electrodes of the planar ceramic heating element, and FIG. 4B is an equivalent circuit diagram of the ceramic heating element shown in FIG.

  A plurality of carbonaceous film segments 3b are formed on the upper surface of the ceramic heating element 3, and each carbonaceous film segment 3b is surrounded or blocked by a non-carbonaceous band 3e not forming a carbonaceous film. And formed in an isolated state. These carbonaceous film segments 3b are connected by an energization path such as a copper thin plate 3f, and are energized from the outside through an electroconductive plate 3g and an energization cord 3c.

  The carbon heating element 3 in FIG. 4A has four carbonaceous film segments 3b formed on the surface, and a conductive plate 3g to which a current-carrying cord 3c is attached is affixed to the non-carbonaceous band 3e at both ends. . As shown in the figure, the conductive plate 3g, the segment 3b, and the adjacent segments 3b are connected to each other by five copper thin plates 3f, and when this energization circuit is energized, each carbonaceous film segment 3b becomes as shown in FIG. It acts as a series electric resistance as shown in (b).

  The carbon film segment 3b can be adjusted in electric resistance value by adjusting the size and thickness thereof. In particular, by providing a plurality of segments 3b as shown in the drawing, the electric resistance value can also be determined by the connection method. Can be adjusted.

  FIG. 5 is a diagram showing an example of use of the outer flooring of the present invention.

  As shown in FIG. 5, the outer flooring 10 of the present invention is arranged in a plurality to connect the energization cords 3 c to each other, and heats the built-in ceramic heating element 3 (see FIGS. 2 and 3) by energizing from the outside. Thereby, the temperature above the floor plate 1 is raised.

  For example, the outer flooring 10 can be applied to buildings, hotels, entrances of residential units, roads, and the like in cold regions, and can be used for melting snow or drying rainwater by energizing the ceramic heating element 3 to generate heat. Furthermore, if it is used in dirt, it can be used as an external floor type floor heating system.

  In addition, when the outer floor material 10 is spread and used in this way, there may be a case where a part that does not require heat generation must be provided partially or temporarily. It can be accommodated in the recess 2c for the energizing cord so as not to get in the way.

  The external power is supplied from a normal power supply outlet, a generator, a solar cell, and the like.

  Further, the inside of the unglazed substrate 3a of the ceramic heating element 3 has a high electrical resistance and insulation because no carbonaceous film is formed. The surface of 1 can be kept at an appropriate temperature, so that power consumption can be suppressed. In the present embodiment, by providing a current controller 3d with a temperature sensor in the energization path 3f, the energization is interrupted when a predetermined temperature is exceeded, so that the carbonaceous film segment 3b is energized intermittently. For this reason, the heat generating portion composed of the carbonaceous film segment 3b repeats heat generation intermittently.

  FIG. 6 is a graph showing the temperature change of each part of the sidewalk floor board to which the present invention is applied. In the graph, the y-axis is temperature (° C.) and the x-axis is time.

  In the figure, a is the temperature of the carbonaceous film segment 3b, b is the temperature of the surface of the base plate 1, and c is the temperature of the outside air. Although the temperature change of the carbonaceous film segment 3b itself is violently repeated by the current controller 3d with the temperature sensor, the carbonaceous film segment 3b gradually changes regardless of the rapid temperature change of the carbonaceous film segment 3b due to the heat storage effect inside the unglazed substrate 3a and the floor plate 1. It remains almost constant just by changing the temperature.

  Next, the manufacturing method of the ceramic heat generating body 3 used for the outer floor material 10 of this invention is demonstrated.

  FIG. 7 is a flowchart showing an example of the manufacturing process of the ceramic heating element 3. In the figure, the flow indicated by the broken-line arrows indicates a general manufacturing process of the smoldering tile, and the manufacturing process of the ceramic heating element will be described below in comparison with the manufacturing process of the general smoldering tile.

  First, the clay clay (not shown) that is the raw material is crushed, and this is used as a base. After the soil is made uniform in size, it is hydrated and kneaded and laid for uniform moisture, and then the soil is left in a vacuum state. Kneading with a kneader (not shown) and pushing out the air in the clay (step S1). Next, it is molded into a roof tile or substrate 3a with a constant pressure (S2) and dried (S3). Thereafter, it is baked in an earth kiln while adjusting the temperature to about 1200 to 1300 ° C., and baked uniformly (S4). Up to this point, the same process is carried out for both the general siding tile and the ceramic heating element 3.

  In the case of general smoldering tiles (not shown), a hatching process using a gas containing hydrocarbon is then performed (S7), and after cooling, the shape, color gloss, etc. are examined ( S13), completed as a product.

  However, in the case of the ceramic heating element 3 used in the outer floor material of the present invention, it is molded into a substrate 3a having a predetermined shape, fired (S4), and then cooled (S5) to form the carbonaceous film segment 3b. A predetermined masking is performed so as to draw a peripheral circuit on the surface to be performed (see the non-carbonaceous zone 3e in FIG. 5A), and after drying (S6), the same hatching process as that of general smoldering tiles is performed. (S7). After that, the masking portion formed on the surface is removed (S8). In this way, a carbonaceous film segment 3b, which is an isolated thin uniform carbonaceous region, is obtained at a location surrounded by the non-carbonaceous zone 3e formed by masking removal. The steps of the masking process (S6), the hatching process (S7), and the masking removal process (S8) for forming the carbonaceous film segment 3b will be described in detail with reference to FIG.

  Next, the electrical resistance value, the insulation degree, etc. are inspected (S9), and an electric circuit is formed by attaching and processing the energization cord 3c, the copper thin plate 3f, etc. (S10), and the insulation treatment is performed with an insulation skin such as resin or paint. In step S11, final energization, power consumption, and heat generation are inspected (S12).

  FIG. 8 is a diagram showing the steps of the masking process, the hatching process, and the masking removal process in the manufacturing method of the present invention shown in FIG. 7, and each figure of (a) to (c) is a masking process. It is the figure which showed the partial cross section of each state after a process, a hatching process, and a masking removal.

(A) Masking treatment The masking agent 4 is applied to the portion where the non-carbonaceous band 3e on the unbaked substrate 3a is to be formed, dried and fixed. The masking agent 4 is preferably a silane-based or alumina-based brick adhesive, but is not limited thereto.

(B) Hatching treatment With the masking agent 4 applied, the masking agent 4 applied surface of the unglazed substrate 3a is brought into contact with the gas containing hydrocarbon without burning, and the gas component is impregnated into the unglazed substrate 3a. Let One side of the unglazed substrate 3a including the applied masking agent 4 is covered with a carbonaceous film 5 formed by tanning. At this time, the carbonaceous film 5 is formed as a uniform thin film only on the surface, and only the carbonaceous film 5 exhibits conductivity, and electricity does not flow inside the unglazed substrate 3a. In addition, you may make it hatch with respect to the unglazed board | substrate 3a with respect to the whole surface including a back surface and a side surface like a general smoldering tile.

(C) Masking removal process After the hatching process, after cooling, the masked part is etched and peeled together with the carbonaceous film 5 covered with the masking agent 4 to form a non-carbonaceous band 3e. Then, the portion surrounded by the non-carbonaceous zone 3e is formed as a carbonaceous film segment 3b isolated from the surroundings. When this carbonaceous film segment 3b is connected to an electrode and energized, the carbonaceous segment 3b generates heat. Each of the isolated segments 3b becomes an electric resistance, and the entire resistance value can be adjusted by connecting them in series or in parallel.

  The present embodiment shows an example of another manufacturing method of the ceramic heating element 3.

FIG. 9 is a flowchart showing main steps of the manufacturing method of the present embodiment. FIG. 10 is a perspective view of the ceramic heating element 3 as seen from the back side. In this example, three isolated carbonaceous film segments 3b are formed on the back surface of the roof tile.
Steps S21 to S25 shown in FIG. 9 are the same as S1 to S5 in FIG.

  After firing and cooling, masking tape 6 having no water absorption is applied to a plurality of locations on the back side of the unglazed substrate 3a (S26 and FIG. 10 (a)). As the masking tape 6, one that does not absorb water and does not wear out in response to glaze is desired. As an example, a curing tape used at a construction site or moving can be used.

  With the masking tape 6 applied, glaze is applied to the entire back surface and cured to form the glaze film 7 (S27 and FIG. 10 (b)), and then the masking tape 6 is removed ( S28 and FIG. 10 (c)), the hatching process is performed on the entire front and back surfaces of the unglazed substrate 3a (S29 and FIG. 10 (d)).

  Then, since the glaze film 7 is not formed at the location where the masking tape 6 is removed, gas is impregnated by the hatching process at that location, and a carbonaceous film is formed. The gas is not impregnated in the closed portion, and as a result, each of the plurality of carbonaceous film segments 3b is formed in an isolated state only at the location where the masking tape 6 is peeled off.

  Glaze is well-known as a glaze applied to the surface of baked goods to improve durability, but it is generally heat resistant and can be applied at room temperature and cured at room temperature. It is extremely easy to handle. Moreover, since the hardened film has the property of suppressing the impregnation of carbon particles, it functions as a mask during the sputtering of the carbonaceous film.

  Such glazes are made by combining alumina (neutral component), silica (acidic component), and alkali (base component). Transparent glaze, glossy white glaze, milky wrinkle, devitrification glaze, etc. are known. However, the type is not limited as long as the carbonaceous film is not impregnated during the formation of the carbonaceous film and can withstand the temperature rise.

  The process steps after the hatching process (S29) are the same as those in FIG.

  The present embodiment shows an example of still another method for manufacturing the ceramic heating element 3.

FIG. 11 is a flowchart of the main steps of the manufacturing method of this embodiment. FIG. 12 is a perspective view of the ceramic heating element 3 as seen from the back side of the roof tile.
Since steps S31 to S35 shown in FIG. 11 are the same as S1 to S5 of the first embodiment, the description thereof is omitted.

  This method is a method of applying oil-based ink instead of the masking tape used in Example 2.

That is, after firing and cooling, the oil-based ink P is applied to a plurality of locations on the back side of the unglazed substrate 1 (S36 and FIG. 12A). If glaze is applied to the entire back surface with oil-based ink P applied, the area where oil-based ink P is applied repels the glaze. The glaze film 7 is formed on the entire surface (S37 and FIG. 12B). After that, when the hatching process is performed without removing the oil-based ink P (S38 and FIG. 12C), the oil-based ink P evaporates and disappears due to the heat of hatching, so that the unglazed substrate 3a is exposed. For this reason, the gas is impregnated at that location, and a plurality of isolated carbonaceous film segments 3b are formed.
In addition, since the process step after a hatching process (S38) is the same as that of Example 1, illustration and description are abbreviate | omitted.

  That is, in this method, the cutting process and the tape removing process can be omitted as compared with a method using a masking agent and a masking tape. Further, the application of the oil-based ink P can further improve productivity by using offset printing, silk printing technology, or the like.

It is the disassembled perspective view seen from the front side which shows one Example of the outer flooring material of this invention. It is the perspective view which looked at the outer flooring of the present invention from the back side. FIG. 2 is a longitudinal sectional structural view taken along line AA in a state in which a floor plate and a base portion of the outer floor material shown in FIG. 1 are fixed. (A) is a figure which shows a planar ceramic heating element (figure which shows arrangement | positioning of a carbonaceous segment and an electrode), (b) is an equivalent circuit schematic of the ceramic heating element shown to (a). It is a figure which shows the usage example of the outer flooring of this invention. It is a graph which shows the temperature change of each part of the sidewalk floor board to which this invention is applied. It is a flowchart which shows an example of the manufacturing method of a ceramic heat generating body. (A)-(c) is a figure which shows the process of manufacturing a ceramic heat generating body, and is the figure which showed each process of a masking process, a hatching process, and a masking removal process. It is a flowchart which shows the principal part process of the other example of the manufacturing method of a ceramic heat generating body. (A)-(d) is a figure which shows the manufacturing process of the ceramic heating element shown in FIG. 9, and shows the state of the tile back surface after a masking tape sticking, a glaze application | coating, a masking tape removal, and a hatching process. FIG. It is a flowchart which shows the principal part process of the further another example of the manufacturing process of a ceramic heat generating body. (A)-(c) is a figure which shows the manufacturing process of the ceramic heating element shown in FIG. 11, and is the perspective view which showed the state of the tile back surface after an oil-based ink application | coating, glaze application | coating, and a hatching process. .

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Outer floor material 1 Base plate 2 Base part 2a Housing recess 2b Water-permeable part 2c Conduction cord accommodation recess 3 Ceramic heating element 3a Unglazed substrate 3b Carbonaceous film segment 3c Conduction cord 3d Current controller 3e Non-carbonaceous belt 3f Copper sheet (Electrical path)
5 Carbonaceous film 6 Masking tape 7 Glaze film P Oil-based ink

Claims (6)

Under the floor plate exposed from the road surface is an outer flooring material integrally formed with a base part incorporating a planar ceramic heating element,
The ceramic heating element is formed by exfoliating a part of a carbonaceous film formed on the upper surface of an unglazed substrate or a ceramic plate into a predetermined shape to form at least one or more isolated carbonaceous film segments, and providing a current path for them. An outer floor material that is energized to generate heat. In claim 1,
The outer floor material is an outer floor material made of a water-permeable material for the floorboard. In claim 2,
The ceramic heating element is covered with an insulating skin and is waterproofed and accommodated in an accommodation recess formed in the base part,
The said base part is an outer floor material which forms the permeation | transmission part which allows the water soaked in the said baseplate to pass in the earth around the accommodation recess of a ceramic heating element. In any one of Claims 1-3,
The ceramic heating element is provided with a current controller with a temperature sensor, and is cut off when a predetermined temperature is exceeded, and the outer floor material has a structure allowing energization within a predetermined temperature. In any one of Claims 1-4,
An outer floor material in which an energization cord is led out to the energization path of each of the ceramic heating elements, and the energization cords are connected to each other to energize and connect adjacent ceramic heating elements of the outer floor material. In claim 5,
The outer floor material which forms the recess which accommodates the said electricity supply cord in the side surface of the said base part.

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