JP3573179B2 - Waterproof floor with embedded heater unit and method of manufacturing the same - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a waterproof floor having a heating function in a space using water, such as an assembling bath unit and a toilet unit, and a method of manufacturing the waterproof floor.
[0002]
[Prior art]
An embedded heater unit disclosed in Japanese Patent Application Laid-Open No. 4-366324 will be described as a conventional technique according to the present invention.
FIG. 10 is a partial cross-sectional view of a state in which the embedded heater unit is used for a waterproof floor of an assembled bath unit.
FIG. 11 is a plan view of the heater unit.
The embedded heater unit 30 shown in FIG. 10 has the heater unit 32 embedded in the FRP 36 containing the reinforced filler.
The embedded heater unit 30 is adhered to the lower surface of the waterproof floor 31, and the lower surface is reinforced with a back plate 37 and covered with a heat insulating material 38.
The heater unit 32 is obtained by heat-welding a heating element 33 and a temperature detection line 34 shown in FIG. 11 integrally to a flexible mesh sheet 35.
However, this conventional technique has the following problems.
(A) When the embedded heater unit 30 is manufactured by a press molding method suitable for low-cost mass production, the heating element 33 or the temperature detection line 34 is torn by the flow of the molding material in the molding die during pressurization. Sometimes.
This often occurs particularly when a molding material flows into a concave portion of a molding die provided for forming a leg portion or the like of the main body.
In addition, if the device is manufactured by the hand lay-up method in order to prevent tearing, the number of manual steps increases, and the production cost increases.
(B) As shown in FIG. 11, the electric connection portion 39 of the heater unit 32 is provided so as to protrude from a side portion of the main body.
For this reason, there is a risk of electric leakage on the floor of the space using water. Also, it is necessary to devise a way to fit the unit wall.
(C) After the embedded heater unit 30 is manufactured as a single unit, it is bonded to the lower surface of the waterproof floor 31.
For this reason, the number of manufacturing steps increases and the cost increases. Also, the heating efficiency is reduced.
[0003]
[Problems to be solved by the invention]
Problems to be solved by the present invention are as follows.
(A) The floor unit and the heater unit can be integrally molded by a molding method such as a press molding method by preventing the heater unit from being broken by the flow of the molding material in the molding die under pressure.
(B) A means for attaching a lead wire to the electrode portion of the heater unit is integrally provided on the back surface of the main body so that the lead wire can be externally attached to the electrode portion of the heater unit from outside.
(C) At the time of molding, decoration such as a pattern can be applied to the surface of the flooring material.
[0004]
[Means for Solving the Problems]
The waterproof floor embedded with a heater unit according to claim 1 of the present application for solving the above-mentioned problem, comprises: a first resin layer forming a surface layer; a heater unit laminated on the first resin layer ; A second resin layer sandwiching the heater unit between the resin layer and a glass fiber nonwoven fabric laminated on the second resin layer so as to cover substantially the entire area of the heater unit; and covering the glass fiber nonwoven fabric the third consists of a resin layer, wherein the glass fiber first resin layer and the heater unit and the second resin layer sandwiched the glass fiber nonwoven fabric between the second resin layer so as The non-woven fabric and the third resin layer are integrally press-molded .
The waterproof floor with embedded heater units according to claim 2 is the waterproof floor with embedded heater units according to claim 1, wherein the heater units are at least one upper and lower glass cloth impregnated with a resin, and the heater wire is a heater wire. And molded integrally with each other.
A waterproof floor embedded with a heater unit according to a third aspect is characterized in that, in the waterproof floor embedded with a heater unit according to the first or second aspect , unevenness is formed on a surface of the heater unit.
A waterproof floor embedded with a heater unit according to claim 4 is the waterproof floor embedded with a heater unit according to any one of claims 1 to 3, wherein the electrode unit of the heater unit is made of heat-resistant rubber. It is characterized in that a cylinder is arranged and a lead wire mounting hole is formed.
The waterproof floor embedded with a heater unit according to claim 5 is the waterproof floor embedded with the heater unit according to any one of claims 1 to 4, wherein the surface layer is provided with a decorative layer on which a decoration such as a pattern is provided. It is characterized by having been provided.
A waterproof floor embedded with a heater unit according to claim 6 is the waterproof floor embedded with a heater unit according to claim 5, wherein the decorative layer is a prepreg sheet on which colors, patterns, and the like are printed.
Heater unit embedding method for manufacturing a waterproof floor according to claim 7, the heater unit is laminated on the first resin molding material for forming the surface layer, the second resin molding material was laminated so as to cover said heater unit A glass fiber non-woven fabric is laminated on the second resin molding material so as to cover substantially the entire area of the heater unit, and a third resin molding material is covered so as to cover the second resin molding material and the glass fiber non-woven fabric. The first resin molding material, the heater unit, the second resin molding material, the glass fiber nonwoven fabric, and the third resin molding material are laminated and press- molded integrally .
The method for manufacturing a waterproof floor with embedded heater units according to claim 8 is the method for manufacturing a waterproof floor with embedded heater units according to claim 7, wherein the heater unit is formed by impregnating a glass cloth with a resin. It is characterized by laminating at least one sheet each on the upper and lower sides and integrally molding.
A method for manufacturing a waterproof floor with embedded heater units according to claim 9 is the method for manufacturing a waterproof floor with embedded heater units according to claim 7 or 8 , wherein a nylon taffeta is laminated at the time of molding the heater unit and after molding. peel off the said nylon taffeta, and forming an uneven surface of the heater unit.
According to a tenth aspect of the present invention, in the method for manufacturing a waterproof floor with a heater unit embedded therein according to any one of the seventh to ninth aspects, the electrode unit of the heater unit is provided with a heat-resistant. A cylindrical member made of a rubber material is disposed to form a lead wire mounting hole.
A method of manufacturing a waterproof floor with a heater unit embedded therein according to claim 11 is the method of manufacturing a waterproof floor with a heater unit embedded therein according to any one of claims 7 to 10. The decorative layer is formed by disposing the printed prepreg sheet.
[0005]
BEST MODE FOR CARRYING OUT THE INVENTION
As an embodiment (part 1) of a waterproof floor embedded with a heater unit and a method of manufacturing the same according to the present invention, a waterproof floor of a bus unit and a method of manufacturing the same will be described.
FIG. 1 is a sectional view of a molding die and an exploded sectional view of a molding material of a waterproof floor in which a heater unit is embedded.
FIG. 2 is an exploded view of the molding material of the waterproof floor embedded with the heater unit.
FIG. 3 is a plan view when the heater unit is arranged.
FIG. 4 is a cross-sectional view illustrating a state in which the mold is closed after the supply of the molding material is completed.
FIG. 5 is a cross-sectional view of the formed waterproof floor embedded with the heater unit.
FIG. 6 is a perspective view of the lead wire mounting hole forming member.
FIG. 7 is a cross-sectional view near the lead wire mounting hole of the waterproof floor embedded with the heater unit. FIG. 8 is a sectional view of a mold and an exploded sectional view of a molding material when the heater unit is molded.
The mold 1 shown in FIG. 1 includes an upper mold 2 and a lower mold 3. As shown in FIG. 4, when the upper mold 2 and the lower mold 3 are closed, the upper mold 2 and the lower mold 3 have a gap that forms the outer shape of the heater unit embedded waterproof floor 21. The lower mold 3 forms the front surface of the waterproof floor 21, and the upper mold 2 forms the back surface of the waterproof floor 21. Therefore, the waterproof floor 21 is formed upside down.
The concave portion 14 of the upper mold 2 is for forming the leg portion 19 shown in FIG.
The molding die 1 is mounted on a slide surface of a press (not shown) as an upper die 2 as a movable die, and is mounted on a head surface of the press as a fixed die as a lower die 3. The upper mold 2 and the lower mold 3 are provided with a heating device.
In addition, since SMC (Sheet Molding Compound) and BMC (Bulk Molding Compound) are used as the molding material, the molding pressure is increased, so that the molding die 1 needs to have sufficient strength and rigidity.
[0006]
A method for manufacturing the waterproof floor 21 with the heater unit embedded therein will be described.
(1) A release agent is applied to the surfaces of the upper mold 2 and the lower mold 3.
(2) The upper mold 2 and the lower mold 3 are heated.
The heating temperature varies depending on the molding conditions. In this case, the upper mold 2 is heated to 135 ° C. and the lower mold 3 is heated to 145 ° C.
(3) The molding material 4 is arranged.
The molding material 4 uses SMC obtained by mixing a curing agent, a thickener, an internal release agent, a pigment, a filler, a glass fiber, and the like with an unsaturated polyester resin. As the thickener, use is made of alkaline earth metal oxides and hydroxides.
Since the molding material 4 is an SMC in a paste state previously formed into a sheet shape, the molding material 4 does not flow out of the lower mold 3 even when laminated.
At this time, the viscosity of the molding material 4 is reduced during the production of the material to improve the impregnation of the glass fiber or the like, and is increased during the molding. The same applies when BMC is used.
(4) The heater unit 5 is arranged on the molding material 4.
The heater unit 5 shown in FIG. 3 has a heater wire 20 including a plurality of heating elements 10, two electrodes 11 for supplying electricity to the heating elements 10, and a lead wire mounting portion 12 for supplying external power. It has. The heater wire 20 is sandwiched between glass cloths 22 impregnated with resin and integrally formed by press molding.
A method for manufacturing the heater unit 5 will be described.
First, the heater wire 20 shown in FIG. 8 is sandwiched between two upper and lower glass cloths 22 impregnated with a resin, and both sides thereof are covered with a nylon taffeta 23. Laminate in the formed mold. The nylon taffeta 23 is a cloth woven with nylon fibers.
Next, press molding is performed under certain conditions (for example, pressure: 40 kgf / cm ² , temperature: 160 ° C., pressure holding time: 90 minutes). By performing the press molding, the resin impregnated in the glass cloth 22 flows and enters the texture of the nylon taffeta 23 provided on both the front and back surfaces, whereby the heater wire 20, the glass cloth 22, and the nylon taffeta 23 are integrally formed. Heater unit 5 can be obtained.
Then, by removing the nylon taffeta 23 on both sides, it is possible to obtain unevenness on both sides of the heater unit 5 according to the weave of the nylon taffeta 23. The unevenness improves the adhesion to the resin material during the formation of the waterproof floor, and prevents the heater unit 5 from peeling off.
The heater unit 5 may be formed by bonding a heating element to a polyester non-woven fabric, or by weaving a bundle of carbon fibers into a woven cloth made of glass fiber, or by using a sheet-shaped substrate provided with heating wires. Good.
(5) The mounting hole forming member 9 is bonded to the lead wire mounting portion 12 with an adhesive.
The mounting hole forming member 9 shown in FIG. 6 forms a hole so that a lead wire can be retrofitted to the lead wire mounting portion 12 after molding, and has a cylindrical shape made of heat-resistant rubber. . The inside is filled with silicone rubber 18 in advance, so that the molding materials 6 and 8 to be laminated therefrom do not enter the inside of the mounting hole forming member 9 to cover and hide the lead wire mounting portion 12.
(6) The molding material 6 is laminated.
The molding material 6 is a material similar to the molding material 4. The molding material 6 is provided with a through hole 13 so that the mounting hole forming member 9 is not crushed by the molding material 6.
(7) The glass fiber nonwoven fabric 7 is arranged.
The glass fiber non-woven fabric 7 is a non-woven mat-shaped non-woven fabric obtained by fusing glass into fibers. As shown in FIG. 3, the glass fiber nonwoven fabric 7 is arranged to the lead connection portion 12 of the heater unit 5 covers the removal Kuhobo whole.
(8) The molding material 8 is laminated.
The molding material 8 is a material similar to the molding material 6. A through hole 13 is also provided in the molding material 8.
(9) By operating a controller (not shown) of the press machine, the upper mold 2 and the lower mold 3 are closed and pressurized as shown in FIG.
At this time, the heating unit 5 and the molding materials 6 and 8 in the vicinity thereof are prevented from being drawn into the concave portion 14 and the rib portion (not shown) of the upper mold 2 by the glass fiber nonwoven fabric 7, and the heating element of the heater unit 5 is formed. 10 and the electrode 11 can be prevented from being broken.
The molding materials 4, 6, and 8 are softened by setting the temperature of the molding die 1, and are cured after a predetermined time has elapsed.
(10) Open the upper mold 2 and the lower mold 3 and take out the waterproof floor 21 shown in FIG.
(11) A lead wire (not shown) is attached to the lead wire attaching portion 12 of the heater unit 5 shown in FIG.
The lead wire is for supplying electric power from the outside to the heater unit 5, and the silicon rubber 18 filled in the mounting hole forming member 9 shown in FIG. 6 is removed and connected to the lead wire mounting portion 12 by soldering. .
[0007]
As an embodiment (part 2) of a waterproof floor with embedded heater units and a method of manufacturing the same according to the present invention, a waterproof floor of a bus unit with a colored pattern on the surface and a method of manufacturing the same will be described.
FIG. 9 is a sectional view of a molding die and an exploded sectional view of a molding material of a waterproof floor in which a heater unit is embedded.
The convex portion 16 provided on the lower mold 3 is for preventing the molding material from flowing at the time of pressurization. The projections 17 are used to form joints on the floor.
[0008]
A method for manufacturing the waterproof floor 21 will be described.
(1a) A release agent is applied to the surfaces of the upper mold 2 and the lower mold 3.
(1b) The prepreg sheet 15 is arranged on the lower mold 3.
The prepreg sheet 15 is obtained by impregnating diallyl phthalate resin into titanium paper, and the titanium paper is colored.
(1c) The bubbles existing between the prepreg sheet 15 and the lower mold 3 are removed by a defoaming roller (not shown), and the adhesion is improved.
The subsequent molding method is the same as (2) to (11) of the first embodiment (part 1).
[0009]
【The invention's effect】
According to the present invention, the following effects can be obtained.
(A) The heater unit is prevented from being broken due to the flow of the molding material in the molding die during pressurization, and can be manufactured by a molding method such as a press molding method.
(B) Since the molded product is provided with the lead wire mounting hole for the electrode portion of the heater unit, the lead wire can be retrofitted after molding.
(C) Since the lead wire mounting hole is provided on the back surface of the molded product, there is no fear of leakage. Also, there is no need to consider the fit with a wall or the like.
(D) Since the floor material and the heater unit are integrally formed, the heating efficiency is good. (F) Since the floor material and the heater unit are integrally formed and the surface of the floor material can be decorated at the time of molding, the number of manufacturing steps can be reduced.
(G) By the above, a safe, richly decorative and highly efficient product can be mass-produced and provided at a low cost.
[Brief description of the drawings]
FIG. 1 is a sectional view of a molding die and an exploded sectional view of a molding material for a waterproof floor (part 1).
FIG. 2 is an exploded view of the molding material of the waterproof floor. FIG. 3 is a plan view when a heater unit is arranged. FIG. 4 is a cross-sectional view showing a state in which the molding die is closed after the supply of the molding material is completed. FIG. 6 is a cross-sectional view of the formed waterproof floor. FIG. 6 is a perspective view of a lead wire mounting hole forming member. FIG. 7 is a cross-sectional view of the vicinity of the lead wire mounting hole of the waterproof floor embedded with the heater unit. FIG. 9 is a sectional view of a molding die and an exploded sectional view of a molding material. FIG. 9 is a sectional view of a molding die and an exploded sectional view of a molding material of a waterproof floor (part 2).
FIG. 10 is an explanatory diagram of a conventional technology. FIG. 11 is an explanatory diagram of a conventional technology.
REFERENCE SIGNS LIST 1 Mold 2, 24 Upper mold 3, 25 Lower mold 4, 6, 8 Molding material 5 Heater unit 7 Glass fiber-containing nonwoven fabric 9 Mounting hole forming member 10 Heating element 11 Electrode 12 Lead wire mounting portion 13 Through hole 14 Concave 15 Prepreg Sheets 16 and 17 Convex portion 18 Silicon rubber 19 Leg 20 Heater wire 21 Heater unit embedded waterproof floor 22 Glass cloth 23 Nylon taffeta

Claims (11)

A first resin layer for forming the surface layer, and a heater unit which is stacked on the first resin layer, a second resin layer sandwiched the heater unit between the first resin layer, wherein the to sandwiched substantially the glass fiber nonwoven fabric laminated to the second resin layer so as to cover the entire area, the glass fiber nonwoven fabric between said to cover the glass fiber nonwoven second resin layer of the heater unit 3 , wherein the first resin layer, the heater unit, the second resin layer, the glass fiber nonwoven fabric, and the third resin layer are integrally press-molded. Waterproof floor with embedded heater unit. 2. The heater unit embedding according to claim 1 , wherein the heater unit is integrally formed by sandwiching a heater wire with at least one upper and lower glass cloth impregnated with a resin. Waterproof floor. The heater unit embedded waterproof floor according to claim 1 or 2, wherein irregularities are formed on a surface of the heater unit. The heater unit according to any one of claims 1 to 3, wherein a cylinder made of heat-resistant rubber is arranged at an electrode portion of the heater unit, and a lead wire mounting hole is formed. Embedded waterproof floor. The waterproof floor embedded with a heater unit according to any one of claims 1 to 4, wherein a decorative layer provided with a decoration such as a pattern is provided on the surface layer. The waterproof floor according to claim 5, wherein the decorative layer is a prepreg sheet on which colors, patterns, and the like are printed. A heater unit is laminated on a first resin molding material forming a surface layer, a second resin molding material is laminated so as to cover the heater unit , and the second resin is formed so as to cover substantially the entire area of the heater unit. A glass fiber nonwoven fabric is laminated on a molding material, a third resin molding material is laminated so as to cover the second resin molding material and the glass fiber nonwoven fabric, and the laminated first resin molding material and the heater unit are laminated. And a second resin molding material, a glass fiber nonwoven fabric, and a third resin molding material are integrally press- molded. The heater unit embedded waterproof floor according to claim 7, wherein the heater unit is formed by impregnating a glass cloth with a resin, laminating at least one sheet on each of upper and lower portions of the heater wire, and integrally molding the heater wires. Production method. Nylon taffeta laminated at the time of molding of the heater unit, by peeling the nylon taffeta after molding, embedding the heater unit according to claim 7 or claim 8, characterized in that for forming irregularities on the surface of the heater unit waterproof Floor manufacturing method. The heater unit embedded waterproofing according to any one of claims 7 to 9, wherein a cylinder made of heat-resistant rubber is arranged on an electrode portion of the heater unit to form a lead wire mounting hole. Floor manufacturing method. The prepreg sheet on which a color, a pattern, or the like is printed is disposed on the surface layer to form a decorative layer, and the heater unit embedded waterproof floor according to any one of claims 7 to 10 , wherein the decorative layer is formed. Method.

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