JP3818079B2 - Manufacturing method of waterproof floor - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a waterproof floor with a heater unit inside.
[0002]
[Prior art]
Conventionally, a waterproof floor used in a bathroom or the like is provided with a heater unit.
[0003]
The waterproof floor provided with the conventional heater unit is formed by embedding a heater unit sandwiching an electric heater wire between synthetic resin sheets when forming the waterproof floor by the FRP hand lay-up method. In the method using the hand lay-up method, there is a problem that the number of production does not increase and the cost becomes high.
[0004]
Further, after forming the waterproof floor 8 ′ by pressing, there is a method in which a heater unit 4 ′ having an electric heater wire sandwiched between synthetic resin sheets is bonded to the back surface of the waterproof floor 8 ′ as shown in FIG. Then, after forming waterproofing floor 8 ', the process of bonding a heater unit is required. Further, the waterproof floor 8 ′ formed by pressing is almost always provided with ribs 13 in consideration of strength, and when the ribs 13 are present on the back surface as described above, when the heater unit 4 ′ is bonded, the heater unit It is necessary to divide 4 'into fine pieces and paste them together, or to provide notches in the ribs 13 to match the structure of the heater unit 4'. In the former case, there is no advantage in mass production by pressing, and manual work is not necessary. There is a problem that the production cost increases, and in the case of the latter, the workability is slightly improved, but the strength as the waterproof floor 8 'is reduced by cutting out the ribs 13. There is.
[0005]
In addition, when a waterproof floor is press-molded with a molding material such as sheet molding compound, it is conceivable to integrally form with a press with a heater unit sandwiching an electric heater wire between synthetic resin sheets. When molding material flows along the mold, the synthetic resin sheet of the heater unit softens and flows due to heating, and the electric heater wire cannot be held so that it does not move during molding, and the embedded position of the electric heater wire changes Therefore, there is a problem that the electric heater wires are too close to each other or too far apart, in particular, since there is a recess for the rib in the mold to form the rib, the molding material flows greatly in this part, Following this, the synthetic resin sheet of the heater unit flows, and the embedment position of the electric heater wire will shift further. There is a problem.
[0006]
[Problems to be solved by the invention]
The present invention has been made in view of the above points, and it is an object of the present invention to provide a method for manufacturing a waterproof floor that can embed an electric heater wire reliably at a predetermined position by press molding and has high strength. It is what.
[0007]
[Means for Solving the Problems]
In order to solve the above-mentioned problem, the waterproof floor manufacturing method according to the present invention includes an adhesive sheet 2 disposed between the upper and lower nonwoven fabric layers 1 and an electric heater wire 3 between the adhesive sheet 2 and one nonwoven fabric layer 1. In the state of being disposed, the adhesive sheet 2 is melted by hot pressing, and the upper and lower nonwoven fabric layers 1 are bonded by the adhesive sheet 2 via the electric heater wire 3 to form the heater unit 4, and the molding material 5 that forms the surface side; A method for producing a waterproof floor, in which a resin component of the molding material 5 is infiltrated and integrated into the nonwoven fabric layer 1 by heating and pressing with the upper and lower molds 6 and 7 through the heater unit 4 between the molding material 5 forming the back side. And both the nonwoven fabric layers 1 of the heater unit 4 consist of a polyester-type resin fiber and a glass cloth, It is characterized by the above-mentioned. By adopting such a method, the waterproof floor 8 in which the heater unit 4 exists can be formed by press molding, and the molding material 5 is formed when the molding material 5 is heat-press molded. Flows along the upper and lower molds 6, 7, the heater unit 4 previously arranges the adhesive sheet 2 between the upper and lower nonwoven fabric layers 1 and connects the electric heater wire 3 between the adhesive sheet 2 and one nonwoven fabric layer 1. The adhesive sheet 2 is melted by hot pressing in the arranged state, and the upper and lower nonwoven fabric layers 1 are bonded by the adhesive sheet 2 via the electric heater wire 3. It can be positioned so that it does not flow with the molding material 5, and the electric heater wire 3 can be embedded at a predetermined position in the waterproof floor 8 to be molded. In addition, the resin component of the molding material 5 is infiltrated and integrated into the nonwoven fabric layer 1 so that the heater wire 3 is firmly embedded in the waterproof floor 8. In addition, since the nonwoven fabric layer 1 of the heater unit 4 is made of polyester resin fibers and glass cloth, the glass cloth is strong against heat, and the nonwoven fabric layer 1 does not follow the flow of the molding material 5 by pressing, so that the electric heater is surely provided. The line 3 can be held at a predetermined position.
[0008]
The adhesive sheet 2 of the heater unit 4 is preferably a hot melt resin sheet. By adopting such a method, the heater unit 4 can be easily integrally formed by the heating press 4.
[0009]
Moreover, it is preferable that the electric heater wire 3 of the heater unit 4 has a meandering portion 3a. By adopting such a method, the electric heater wire 3 meanders when the molding material 5 flows during press molding, so that the tensile force applied to the electric heater wire 3 is absorbed while the play of the meandering portion expands and contracts. Thus, disconnection can be prevented.
[0010]
Moreover, it is preferable that the electric heater wire 3 is configured by winding the nichrome wire 16 around the core wire 15.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described based on embodiments shown in the accompanying drawings.
[0012]
In the present invention, a heater unit 4 having a layer structure as shown in FIG. 2 is first manufactured. The heater unit 4 is hot-pressed with the adhesive sheet 2 disposed between the upper and lower nonwoven fabric layers 1 and the electric heater wire 3 disposed between the adhesive sheet 2 and one nonwoven fabric layer 1 to melt the adhesive sheet 2. Then, the upper and lower nonwoven fabric layers 1 are bonded by the adhesive sheet 2 via the electric heater wire 3 to form the heater unit 4. Here, the nonwoven fabric layer 1 is made of polyester resin fibers and glass cloth. For example, there are cases where both nonwoven fabric layers 1 are nonwoven fabric layers formed by mixing polyester resin fibers and glass cloth. Here, of the nonwoven fabric layers 1 on both sides of the heater unit 4, one nonwoven fabric layer 1 is made of a glass cloth layer 1a made of glass cloth, and a fiber layer 1b made of fibers other than glass cloth arranged on at least one surface of the glass cloth layer 1a. You may comprise. In FIG. 4, one of the nonwoven fabric layers 1 on both sides of the heater unit 4 is bonded to a glass cloth layer 1a made of glass cloth, and a fiber layer 1b made of fibers other than glass cloth is bonded to the upper and lower surfaces of the glass cloth layer 1a. The sheet 2a is laminated and configured. Since the glass cloth layer 1a has a high strength and can reduce the basis weight, it can be satisfactorily impregnated with the molding material 5 such as SMC (sheet molding compound) and BMC (bulk molding compound), which will be described later. It is difficult to maintain the shape, or the handling performance is poor. By forming the nonwoven fabric layer 1 by laminating the fiber layer 1b made of fibers other than the glass cloth, the shape is maintained while preventing the fluffing and the handling property. Can be improved. Therefore, here, the glass cloth layer 1a uses a four-axis assemblage with a basis weight of 190 g / m 2, and the fiber layer 1b made of fibers other than the glass cloth is 119 g / m 2 and is a polyester long fiber nonwoven fabric by a spunbond method. . The glass cloth layer 1a has a large weight per unit area of 190 g / m @ 2 but has a large specific gravity compared to polyester and the like, so that the porosity of the glass cloth layer 1a is large and can be satisfactorily impregnated with the molding material 5 described later. is there. Here, when only the glass cloth layer 1a is used, the strength of shearing when the molding material 5 flows is insufficient, but the fiber layer 1b made of fibers other than the glass cloth is formed of a polyester long-fiber nonwoven fabric so that the molding material 5 flows. The strength against shearing can be secured.
[0013]
Further, as the adhesive sheet 2, either a thermosetting adhesive sheet or a thermoplastic adhesive sheet may be used, and the bonding conditions for bonding by hot pressing differ depending on the material of the adhesive sheet used. . Here, if the adhesive sheet 2 is a hot melt resin sheet, the heater unit 4 can be easily integrally formed by the heating press 4.
[0014]
As described above, one or two adhesive sheets 2 are arranged in advance between the upper and lower nonwoven fabric layers 1 (FIG. 2 shows an example in which one adhesive sheet 2 is arranged between the upper and lower nonwoven fabric layers 1. FIG. 3 shows an example in which two adhesive sheets 2 are disposed between the upper and lower nonwoven fabrics 1), with the electric heater wire 3 disposed between the adhesive sheet 2 and one nonwoven fabric layer 1 ( When two adhesive sheets 2 are disposed, an electric heater wire 3 is disposed between one adhesive sheet 2 and one nonwoven fabric layer 1, and the other adhesive sheet is further disposed between the one nonwoven fabric layer 1. 2), the adhesive sheet 2 is melted by hot pressing, and the upper and lower nonwoven fabric layers 1 are bonded by the adhesive sheet 2 via the electric heater wire 3 to form the heater unit 4, and the heater unit 4 is formed. Press molding material 5 with upper and lower molds 6 and 7 In which it embedded in the molding material 5 during that. Examples of the adhesive sheet 2 include a hot-melt polyamide adhesive sheet having a basis weight of 15 to 60 g / m <2> and a melting point of 120 [deg.] C. using a spunbond method.
[0015]
Then, as shown in FIG. 1, a molding material 5 such as SMC (sheet molding compound) or BMC (bulk molding compound) that forms the surface side is placed on the lower mold 7, and as described above, The heater unit 4 formed in advance is placed, and a molding material 5 such as SMC (Sheet Molding Compound) or BMC (Bulk Molding Compound) that forms the back side is placed on the heater unit 4. The waterproof floor 8 is integrally formed by clamping and pressurizing and heating.
[0016]
Moreover, although the example which has arrange | positioned the adhesive sheet 2 between the upper and lower nonwoven fabric layers 1 was shown in the said embodiment, it replaced with the said adhesive sheet 2, and the adhesive material which fuses by heating to at least one of the upper and lower nonwoven fabric layers 1 was shown. It may be provided in advance. For example, fibers that can be bonded by heat (that is, fibers that become an adhesive material) are woven into the fibers of glass cloth, or a nonwoven fabric is impregnated with a resin that becomes an adhesive material that melts by heating, such as a hot melt adhesive. (For example, a polyester nonwoven fabric is impregnated with a hot melt polyamide adhesive having a basis weight of 15 to 60 g / m 2 and a melting point of 120 ° C. in advance). FIG. 5 is an exploded view for explaining the layer structure of the heater unit in the present embodiment.
[0017]
Here, joint projections 10 are formed on the lower mold 7, and recesses 11 for rib formation are formed on the upper mold 6, and the upper and lower molds 6, 7 are clamped and molded. As shown in FIG. 8, joints 12 are formed on the surface of the waterproof floor 8 to be molded, and ribs 13 are formed on the back surface.
[0018]
In addition, when forming a decoration on the surface of the waterproof floor 8 to be molded, an SMC (Sheet Molding Compound) that forms a surface side on the pattern sheet 15 is placed on the lower mold 7 as shown in FIG. And a molding material 5 such as BMC (bulk molding compound) is placed and thereafter molded in the same manner as described above.
[0019]
Thus, when the upper and lower molds 6 and 7 are clamped and pressurized, heated and press-molded, the molding material 5 flows along the upper and lower molds 6 and 7, but the heater unit 4 is While the adhesive sheet 2 is disposed between the nonwoven fabric layers 1 and the electric heater wire 3 is disposed between the adhesive sheet 2 and one of the nonwoven fabric layers 1, the adhesive sheet 2 is melted by hot pressing and the electric heater wires 3 are interposed. The upper and lower nonwoven fabric layers 1 are bonded to each other by the adhesive sheet 2, and even when the molding material 5 flows, the electric heater wire 3 is held by the upper and lower nonwoven fabric layers 1 and does not flow with the molding material 5. (For this reason, the nonwoven fabric layer 1 is strong enough to resist the flow of the molding material 5). In particular, by providing the upper mold 6 with the concave portion 11 for rib formation, the molding material 5 is formed on the concave portion 11 side during press molding. Flowing into Therefore, the electric heater wire 3 can be kept in a predetermined position during molding, and the electric heater wire 3 is embedded at a predetermined position in the waterproof floor 8 to be molded. Is something that can be done. In addition, the resin component of the molding material 5 is infiltrated and integrated into the nonwoven fabric layer 1 so that the heater wire 3 is firmly embedded in the waterproof floor 8.
[0020]
In addition, when using a glass cloth to improve the strength of the nonwoven fabric layer, a resin-treated one may be used in order to improve the adhesion to the molding material 5 such as a sheet molding compound or a bulk molding compound. It is.
[0021]
By the way, if the electric heater wire 3 of the heater unit 4 is a meandering portion 3a in which a straight line portion of a wiring pattern like a one-stroke drawing meanders continuously in a wavy shape as shown in FIG. 6, the play of the meandering portion expands and contracts. However, it is possible to absorb the tensile force applied to the electric heater wire 3 and prevent disconnection.
[0022]
Here, the electric heater wire 3 is formed by winding a nichrome wire 16 around a core wire 15 having a large elongation as shown in FIG. For example, the heater wire 3 may be one in which an aramid fiber is a core wire 16 and three nichrome wires 16 are spirally wound around the aramid fiber to form one heating wire with a Teflon tube.
[0023]
【The invention's effect】
As described above, in the present invention, the adhesive sheet is disposed between the upper and lower nonwoven fabric layers, and the adhesive sheet is melted by hot pressing in a state where the electric heater wire is disposed between the adhesive sheet and one nonwoven fabric layer. The upper and lower nonwoven fabric layers are bonded by an adhesive sheet via an electric heater wire to form a heater unit, and the upper and lower molds are formed via a heater unit between the molding material forming the front side and the molding material forming the back side. Since it is heated and pressed, a waterproof floor in which the heater unit is present can be formed by press molding to improve productivity, and the molding material can be formed regardless of being formed by press molding. Even when the molding material flows along the upper and lower molds during heat and pressure molding, the heater unit is formed with an adhesive sheet sandwiched between the upper and lower nonwoven fabric layers in advance. Therefore, the electric heater wire can be positioned and held by the upper and lower nonwoven fabric layers so that the electric heater wire does not flow together with the molding material, and the electric heater wire is placed at a predetermined position in the waterproof floor to be molded. Furthermore, since the upper and lower sides of the heater unit are non-woven fabric layers, the resin component of the molding material is infiltrated and integrated, and the heater wire is firmly embedded in the waterproof floor. In addition, since the nonwoven fabric layer of the heater unit is made of polyester resin fibers and glass cloth, the glass cloth is resistant to heat, and the nonwoven fabric layer is less likely to follow the flow of the molding material during pressing, ensuring reliable electrical heating. The heater wire can be held at a predetermined position, and a waterproof floor in which the electric heater wire is embedded at a more accurate position can be formed.
[0024]
Further, since the electric heater wire of the heater unit has a meandering portion, the play of the meandering portion can be expanded and contracted to absorb the pulling force applied to the electric heater wire and prevent disconnection.
[Brief description of the drawings]
FIG. 1 is an exploded view when a waterproof floor of the present invention is press-formed.
FIG. 2 is an exploded view for explaining a layer structure of a heater unit used in the above.
FIG. 3 is an exploded view for explaining another embodiment of the layer configuration of the heater unit used in the above.
FIG. 4 is an exploded view for explaining an embodiment of the nonwoven fabric layer used in the above.
FIG. 5 is an exploded view for explaining still another embodiment of the layer configuration of the heater unit used in the above.
FIG. 6 is an explanatory diagram showing a wiring pattern of an electric heater used in the above.
FIG. 7 is a perspective view of an electric heater used for the above.
FIG. 8 is a cross-sectional view of a waterproof floor manufactured according to the present invention.
FIG. 9 is a cross-sectional view of an example of a conventional waterproof floor.
[Explanation of symbols]
1 Nonwoven fabric layer 2 Adhesive sheet 3 Electric heater wire 4 Heater unit 5 Molding material 6 Upper mold 7 Lower mold 8 Waterproof floor

Claims (4)

An adhesive sheet is disposed between the upper and lower nonwoven fabric layers, and an electric heater wire is disposed between the adhesive sheet and one nonwoven fabric layer. A non-woven fabric layer is bonded to form a heater unit, and heat and pressure molding is performed between the molding material for forming the front side and the molding material for forming the back side by means of the upper and lower molds via the heater unit, and the molding material is formed on the non-woven fabric layer. A method for producing a waterproof floor in which the resin component is infiltrated and integrated, wherein both nonwoven fabric layers of the heater unit are made of polyester resin fibers and glass cloth. 2. The method for producing a waterproof floor according to claim 1, wherein the adhesive sheet of the heater unit is a hot melt resin sheet. The method for manufacturing a waterproof floor according to claim 1, wherein the electric heater wire of the heater unit has a meandering portion. The method for manufacturing a waterproof floor according to claim 3, wherein the electric heater wire is formed by winding a nichrome wire around a core wire.

Images