JP3921278B2

JP3921278B2 - Heated floor panel and manufacturing method thereof

Info

Publication number: JP3921278B2
Application number: JP21487297A
Authority: JP
Inventors: 和雅吉田; 慎一河野
Original assignee: Daikin Industries Ltd
Current assignee: Daikin Industries Ltd
Priority date: 1997-08-08
Filing date: 1997-08-08
Publication date: 2007-05-30
Anticipated expiration: 2017-08-08
Also published as: JPH1163533A

Description

【０００１】
【発明の属する技術分野】
本発明は、住宅などの電気式暖房床に使用される暖房床パネルおよびその製造方法に関し、特に、暖房床パネルの外殻部材内に組み込まれる埋設パネルの生産効率を高める対策に係る。
【０００２】
【従来の技術】
一般に、電気式暖房床パネルは、断熱材と、該断熱材の上面側に所定の配線形状に加工したヒータ線、たとえば１〜８ｃｍ程度の間隔をあけて蛇行する配線形状に加工したヒータ線とで埋設パネルを一体的に形成し、床面材の四辺に枠材を固着してなる外殻部材内に上記埋設パネルを組み込んで構成される。その場合、ヒータ線は、その上側つまり床面側から局所的或いは集中的に荷重が作用すると、断線などの不具合を生じることがあるため、断熱材の上層にヒータ線を埋設することで、床面側から作用する集中荷重などからヒータ線を保護し、かつ断熱材の断熱性により熱効率の向上を図るようにしている。
【０００３】
そして、従来、このような電気式暖房床パネルの製造方法としては、断熱材の上面に、ルーターによりヒータ線の配線形状（蛇行形状）に合わせた溝加工を施した後、この溝に沿ってヒータ線を埋め込むことで、ヒータ線を、その配線形状を維持した状態で断熱材に埋設し、断熱材とヒータ線とをパネル状に一体的にするようにしている。
【０００４】
また、その他の電気式暖房床パネルの製造方法としては、有底枠状に組んだ外殻の内側底面に、ヒータ線を蛇行形状に配線して設置した後、上記外殻の内側にヒータ線の上方から発泡性ウレタン樹脂液などの発泡性合成樹脂液を流し込み、その後、発泡性合成樹脂液を発泡硬化させることで、断熱材の上層に配線形状を維持した状態でヒータ線を埋設して、断熱材とヒータ線とを一体的に形成するようにしている。
【０００５】
【発明が解決しようとする課題】
ところが、上述した２通りの電気式暖房床パネルの製造方法では、それぞれ次のような欠点を保有している。
【０００６】
すなわち、上記前者の断熱材の上面にルーターによる溝加工を施すものでは、その溝加工が配線形状に則して行われるためにその加工作業が非常に手間と時間を要し、溝加工の生産性が低いものとなる。しかも、溝にヒータ線を埋め込む作業も多大な手間を要し、埋設パネルひいては電気式暖房床パネルの生産効率が極めて低いといった欠点がある。
【０００７】
一方、上記後者のヒータ線の上方から発泡性合成樹脂液を流し込むものでは、発泡性合成樹脂液の調合や注入に大掛かりな設備が必要となる。しかも、埋設パネルを均一厚さに形成する上で、発泡性合成樹脂液を安定して均一に充填することが非常に困難を極めるといった欠点もある。
【０００８】
本発明はかかる点に鑑みてなされたもので、その目的とするところは、スプリングバックの少ない断熱材に予めヒータ線収納溝を型押し成形により形成しておくとともに、ヒータ線を予めヒータ線収納溝と合致させた形状にしておくことで、断熱材に対するルーターによる溝加工や埋め込み作業を省くとともに、大掛かりな設備や発泡性合成樹脂液の注入作業を不要とし、埋設パネルを簡単にかつ極めて生産性良く形成して、電気式暖房床パネルの生産効率を向上せんとするものである。
【０００９】
【課題を解決するための手段】
上記目的を達成するため、請求項１記載の発明が講じた解決手段は、暖房床パネルとして、鉱物質繊維製板状体の表面に予め型押し成形により所定の配線形状にヒータ線収納溝が形成され、かつサーモスタット収納用孔部が打ち抜き加工された断熱材と、該断熱材のヒータ線収納溝に収納され、該ヒータ線収納溝の配線形状に合致する形状に予め形成されたヒータ線と、上記サーモスタット収納用孔部に収納され、上記ヒータ線と接続されたサーモスタットと、上記断熱材のヒータ線収納溝側に上記ヒータ線及び上記サーモスタットと接して設けられ、熱伝導性板材よりなる均熱板とで埋設パネルを構成する。そして、上記埋設パネルを、床面材の四辺に枠材を固着してなる外殻部材内に均熱板を床面材側に向けて組み込む構成としたものである。
【００１０】
これにより、請求項１記載の発明では、型押し成形性および型押し成形後の戻り（スプリングバック）の少なさに優れた鉱物質繊維製板状体により断熱材が構成され、この断熱材の表面に型押し成形によってヒータ線収納溝が所定の配線形状に確実かつ容易に形成されることになる。その場合、断熱材のヒータ線収納溝の配線形状と合致する形状に予め形成したヒータ線がヒータ線収納溝に容易に収納されるので、断熱材に複雑なルーターによる溝加工や埋め込み作業を行う必要がない上、発泡性合成樹脂液を発泡硬化させる場合における大掛かりな設備を不要にしつつ断熱材の発泡充填不均一による不具合が防止され、埋設パネルが極めて生産性良く形成される。
【００１１】
そして、このようにして得られた埋設パネル（断熱材、ヒータ線および均熱板）は、外殻部材内に組み込まれることによって、ヒータ線方式の電気式暖房床パネルが簡単に生産される。
【００１２】
請求項２記載の発明が講じた解決手段は、請求項１記載の発明の構成要件に加えて、均熱板に接して設けられるヒータ線を、均熱板に予め一体に固着せしめる構成としたものである。
【００１３】
これにより、請求項２記載の発明では、ヒータ線と均熱板とが予め一体に固着されているので、埋設パネルの生産性が一層高められる。しかも、ヒータ線の熱が確実かつ均一に均熱板に伝達される。
【００１４】
請求項３記載の発明が講じた解決手段は、請求項２記載の発明のヒータ線を特定したことを特徴とする。具体的には、導線と該導線を被覆する熱可塑性樹脂製の外被とでヒータ線を構成し、その外被の溶融により均熱板に固着する構成としたものである。
【００１５】
これにより、請求項３記載の発明では、ヒータ線は、例えば加熱した均熱板に外被を溶融させることで、配線形状を維持した状態に固着されるので、特別な接着剤等を用いなくともヒータ線が均熱板に簡単に固着され、埋設パネルの生産性がより一層高められる。しかも、均熱板に対するヒータ線の接触がより確実なものとなり、ヒータ線の熱が均熱板に対してより良好にかつ均一に伝達される。
【００１６】
請求項４記載の発明が講じた解決手段は、請求項１ないし請求項３のいずれか１つに記載の発明のヒータ線収納溝を特定したことを特徴とする。具体的には、ヒータ線収納溝を、ヒータ線の径よりも深く形成し、そのヒータ線の下部側とヒータ線収納溝の底部との間に隙間を設ける構成としたものである。
【００１７】
これにより、請求項４記載の発明では、暖房床パネルの上面側、つまり床面材側からヒータ線の上部側に歩行荷重などが作用して床面材が僅かに撓んでも、ヒータ線がヒータ線収納溝内で挟圧されずに底部側（隙間側）に逃げ、ヒータ線収納溝内での挟圧によるヒータ線の損傷が効果的に回避される。
【００１８】
請求項５記載の発明が講じた解決手段は、暖房床パネルの製造方法として、鉱物質繊維製板状体の表面に所定の配線形状となる凸部を備えた型板を当てて加熱加圧することによりヒータ線収納溝が刻設され、かつサーモスタット収納用孔部が打ち抜き加工された断熱材を用意しておく。そして、上記ヒータ線収納溝の配線形状に合致する形状に予め形成されたヒータ線を熱伝導性板材よりなる均熱板に固着する。次いで、上記ヒータ線が固着された均熱板を床面材の四辺に枠材を固着してなる外殻部材内に上記床面材に重ね合わせて組み込む。その後、上記断熱材を外殻部材に組み込んで上記ヒータ線が断熱材のヒータ線収納溝に収納され、かつサーモスタットが上記サーモスタット収納用孔部に収納された暖房床パネルを得るようにしている。
【００１９】
請求項６記載の発明が講じた解決手段は、暖房床パネルの製造方法として、鉱物質繊維製板状体の表面に所定の配線形状となる凸部を備えた型板を当てて加熱加圧することによりヒータ線収納溝がヒータ線の径よりも深く刻設され、かつサーモスタット収納用孔部が打ち抜き加工された断熱材を用意しておく。そして、導線と該導線を被覆する熱可塑性樹脂製の外被とからなり、上記ヒータ線収納溝の配線形状に合致する形状に予め形成されたヒータ線を熱伝導性板材よりなる均熱板に上記外被の溶融により固着する。次いで、上記ヒータ線が固着された均熱板を床面材の四辺に枠材を固着してなる外殻部材内に上記床面材に重ね合わせて組み込む。その後、上記断熱材を外殻部材に組み込んで上記ヒータ線が断熱材のヒータ線収納溝に収納され、かつサーモスタットが上記サーモスタット収納用孔部に収納された暖房床パネルを得るようにしている。
【００２０】
さらに、請求項７記載の発明が講じた解決手段は、請求項５または請求項６記載の発明の構成要件に加えて、断熱材、ヒータ線および均熱板により埋設パネルを構成する。そして、外殻部材の枠材にバッカー材を固着して該バッカー材と床面材とで上記埋設パネルを挟み込んで暖房床パネルを得るようにしている。
【００２１】
これにより、請求項５ないし請求項７記載の発明では、ヒータ線収納溝は、鉱物質繊維製板状体よりなる断熱材の表面に加熱加圧により形成されているので、形成後のスプリングバックがより少ないものとなり、良好なヒータ線収納溝が生産性良く形成される。特に、加熱加圧前に、鉱物質繊維性板状体（断熱材）の表面に水などで湿り気を与えておけば、鉱物質繊維性板状体の表面の軟化によりヒータ線収納溝が無理なく形成されるとともに、加熱加圧時の熱で水分を蒸発させてヒータ線収納溝のスプリングバックを抑えた鉱物質繊維性板状体の表面の固化が可能となり、より良好なヒータ線収納溝が形成される。
【００２２】
しかも、外殻部材の床面材を下向きにすれば上方に開口する外殻部材の開口部からヒータ線を固着した均熱板および断熱材が順次円滑に組み込まれ、外殻部材の枠材をバッカー材で固着して暖房床パネルが簡単に得られ、埋設パネルの生産性の著しい向上に加えて、ヒータ線方式の電気式暖房床パネルの生産性が著しく向上する。
【００２３】
【発明の実施の形態】
以下、本発明の第１の実施の形態を図面に基づいて説明する。
【００２４】
図４は、住宅などの電気式暖房床パネルに組み込んで使用される埋設パネルを示す。この埋設パネル１は、平面視で一辺側が長尺な矩形状を呈する断熱材２と、該断熱材２の上面側に配線形状に加工しておいたヒータ線３、サーモスタット１５より導出される導出線１６および送り線１７と、該各線３，１６，１７の上部側に設けられた均熱板２３とから構成されている。ここで、送り線１７は、隣り合う埋設パネル１間のヒータ線３同士を電気的に接続するのに用いられる。
【００２５】
そして、図５に示すように、上記埋設パネル１は、表面側となる床面材としての矩形状の上面材２２にその四辺を囲むよう枠材２１を固着してなる外殻部材４内に組み込まれ、この状態で、上記外殻部材４の開口部４ａをバッカー材としての下面材２４で蓋をして暖房床パネル５を形成し、この暖房床パネル５を、施工する部屋の敷設面積に応じて縦横に並べて組み合わせることで、暖房床Ａを構成するようにしている。上記上面材２２の上面には表面仕上げ材２５が貼着される。
【００２６】
ここで、上記暖房床パネル５の製造方法の一例を説明する。
【００２７】
先ず、断熱材２を得るまでの前半の工程を図１に基づいて説明する。
【００２８】
第１工程として、図１の（ａ）に示すように、断熱材２を用意する。この場合、断熱材２としては、ロックウール板などの鉱物質繊維製板状体を適用している。この実施形態では、澱粉など水溶性バインダを用いたロックウール板（厚さが約７mmで、比重０．３〜０．５程度）を断熱材２として用いるが、断熱材２はその芯層が表裏層よりも比重の高い材料からなる多層構成にすることもできる。具体的には、表裏層が鉱物質繊維と無機質粉体とを主原料とした高密度層にし、芯層がシラス発泡体のような軽量無機質発泡体が主原料の軽量層にするなどであり、この場合は、全体比重が０．５〜１．０程度であっても、芯層が座屈し易いので細かい溝を形成する場合にも適用できるのである。
【００２９】
次いで、第２工程として、断熱材２の上面（表面）に水を塗布し、断熱材２の表層を軟化させる。この水の塗布はスポンジロールで行われ、その塗布量は、過剰に塗布すると水分蒸発に時間がかかるため、断熱材２の上面全域では４〜８ｇ／尺^２に設定される。尚、水の塗布は、後述するヒータ線収納溝２ｂ、導出線収納溝２ｃおよび送り線収納溝２ｄにそれぞれ対応する部分のみ行われるようにしても良い。また、塗布する水の中に、撥水材やメラミンなどの熱硬化性樹脂を混入させても良く、この場合には、水分の蒸発に伴い断熱材２上面の耐水性が向上し、その後の寸法変化が防止できるとともに、上面の硬度が高くなって荷重に対する耐性が向上する。この第２工程は、良好なヒータ線収納溝２ｂ、導出線収納溝２ｃおよび送り線収納溝２ｄを形成する上で好適であるが、特に必要とするものではない。
【００３０】
その後、第３工程として、図１の（ｂ）に示すように、断熱材２を下面が下側となるようホットプレス１２の下板１２ａの下側金型１０ａ上面に載置する。
【００３１】
そして、第３工程として、図１の（ｃ）に示すように、下面にヒータ線３、導出線１６および送り線１７の配線形状（図４参照）に倣って突出するヒータ線用凸部９ａ、導出線用凸部９ｂおよび送り線用凸部９ｃ（図３参照）を備えたホットプレス１２の上板１２ｂの上側金型１０ｂ（型板）を、断熱材２の上面側から当てて加熱加圧し、図１の（ｄ）に示すように、ヒータ線収納溝２ｂ、導出線収納溝２ｃおよび送り線収納溝２ｄを上面側に刻設した断熱材２を得る。このとき、ホットプレス１２（下型１２ａ，上板１２ｂ）による上下両金型１０ｂ，１０ａ間での加熱加圧は、上側金型１０ｂを予め２００°Ｃ〜３００°Ｃに加熱しておき、２〜４kg／cm^２の圧力で行う。
【００３２】
この場合、上側金型１０ｂの各凸部９ａ，９ｂ，９ｃがヒータ線３、導出線１６および送り線１７の径よりも過分に突出しており、ヒータ線収納溝２ｂ、導出線収納溝２ｃおよび送り線収納溝２ｄが各線３，１６，１７の径よりも深く形成されて、その各線３，１６，１７の下部側と各収納溝２ｂ，２ｃ，２ｄの底部との間に５mmを限度とする隙間２ｅが形成されるようになっている。このため、暖房床パネル５の上面側、つまり表面仕上げ材２５側から各線３，１６，１７の上部側に歩行荷重などが作用して表面仕上げ材２５および上面材２２が僅かに撓んでも、各線３，１６，１７が各収納溝２ｂ，２ｃ，２ｄ内で挟圧されずに底部側（隙間２ｅ側）に逃げ、各収納溝２ｂ，２ｃ，２ｄ内での挟圧による各線３，１６，１７の損傷を効果的に回避できる。
【００３３】
しかも、型押し成形性および型押し成形後の戻り（スプリングバック）の少なさに優れた鉱物質繊維製板状体により断熱材２が構成されているので、この断熱材２の上面側に型押し成形によってヒータ線収納溝２ｂ、導出線収納溝２ｃおよび送り線収納溝２ｄを所定の配線形状に確実かつ容易に形成することができる。
【００３４】
しかる後、上記第４工程として、ヒータ線３の蛇行区間に対応する断熱材２の所望位置に埋め込み用孔部２ａを打ち抜き加工する。この埋め込み用孔部２ａを打ち抜き加工するのは、温度ヒューズを備えたサーモスタット１５（図４に表れる）の高さが断熱材２の厚さと同じ寸法（７mm）に形成されているからである。
【００３５】
そして、次に、残る後半の工程を図２に基づいて説明する。
【００３６】
先ず、第５工程として、ヒータ線３を用意し、このヒータ線３を、上記第３工程で断熱材２の上面に加熱加圧により形成したヒータ線収納溝２ｂの形状に合致させた配線形状、つまり１〜８cm程度（最も多いのは３〜５cm程度）の間隔をあけて蛇行する配線形状（図４参照）に予め仮り加工しておく。このヒータ線３は、特に限定されるものではないが、ワイヤヒータをガラス繊維やケプラー繊維で補強した線径が０．２mm〜１．５mm程度の導線３ａを熱可塑性樹脂の外被３ｂで被覆して外径を２．０mm〜４．０mmにしたものが用いられる。また、導出線１６および送り線１７も、ヒータ線３と同様に導線１６ａ，１７ａを熱可塑性樹脂の外被１６ｂ，１７ｂで被覆してなるものが用いられる。
【００３７】
次いで、第６工程として、図２の（ａ）に示すように、加熱した均熱板２３を用意する。この場合、均熱板２３としては、厚さ０．３mm程度のアルミニウム板が適用されており、熱の上面材２２側への伝達を均一にするのに適している。
【００３８】
そして、上記加熱した均熱板２３に、上記第５工程で予め配線形状に仮り加工しておいたヒータ線３を載置し、外被３ｂの熱溶着により均熱板２３に固着して配線する。また、上記導線１６および送り線１７も同様に均熱板２３に所定の位置に固着して配線する。このように、ヒータ線３と均熱板２３とを予め一体に固着しておくことで、埋設パネル１の生産性が一層高められる上、ヒータ線３の熱が確実かつ均一に均熱板２３に伝達できる。しかも、各線３，１６，１７は、加熱した均熱板２３に外被３ｂ，１６ｂ，１７ｂを溶融させることで、配線形状を維持した状態に固着されるので、特別な接着剤等を用いなくとも各線３，１６，１７が均熱板２３に簡単に固着され、埋設パネル１の生産性を図る上で非常に有利なものとなる。
【００３９】
その後、第７工程として、図２の（ｃ）に示すように、上面材２２の裏面側にその四辺を囲むよう枠材２１を固着してなる外殻部材４を用意する。この上面材２２としては、剛性のある板状物を使用している。また、枠材２１としても、上面材２２と同様の材質の剛性材を使用しており、その両側端面（長尺辺側端面）に、暖房床パネル５同士を接合する雌雄実加工を両側端面で交互に施している。
【００４０】
そして、上面材２２が下向きとなるよう外殻部材４を反転させ、その枠材２１の内側に、上記第５工程でヒータ線３、導出線１６および送り線１７をそれぞれ溶融固着して配線した均熱板２３を外殻部材４の開口部４ａから各線３，１６，１７固着側が上向きとなるよう上記上面材２２の裏面側に載置して組み込む。
【００４１】
しかる後、第８工程として、図２の（ｄ）に示すように、上記外殻部材４の枠材２１の内側に開口部４ａから、上記第３工程で得た断熱材２をその各収納溝２ｂ，２ｃ，２ｄ側を下向けた状態で、上記第７工程で組み込んだ均熱板２３上の各線３，１６，１７が各収納溝２ｂ，２ｃ，２ｄに収納されるよう載置して組み込んでから、断熱材２の埋め込み用孔部２ａにサーモスタット１５を埋め込む。これにより、断熱材２の各収納溝２ｂ，２ｃ，２ｄの配線形状と合致する形状に予め形成した各線３，１６，１７が各収納溝２ｂ，２ｃ，２ｄに容易に収納されるので、断熱材２の上面側に複雑なルーターによる溝加工や埋め込み作業を行う必要がない上、発泡性合成樹脂液を発泡硬化させる場合における大掛かりな設備も不要となるため、埋設パネル１を極めて生産性良く形成できる。そして、このようにして得られた埋設パネル１（各線３，１６，１７を固着した均熱板２３および断熱材２）は、外殻部材４内に容易に組み込まれることによって、ヒータ線方式の電気式暖房床パネル５を簡単に生産することができる。
【００４２】
第９工程として、図２の（ｅ）に示すように、枠材２１（外殻部材４）の下側（図２のｅでは上側）に下面材２４を固着する。この下面材２４としては、合板、厚紙、クラフト紙、合成樹脂板、布、不織布、ガラスクロスシートなど、或いはそれらの２つ以上を組み合わせた複合板などを使用している。
【００４３】
そして、図２の（ｆ）に示すように、上面材２２が上側に位置するよう外殻部材４を上下反転させた後、上記上面材２２の外面（上面）に好みに応じた表面仕上げ材２５を張り付けることで、暖房床パネル５を得る。
【００４４】
これにより、暖房床パネル５は、埋設パネル１を一体化しておかなくとも、ヒータ線３、導出線１６および送り線１７を溶融固着した均熱板２３、並びに断熱材２を外殻部材４内へ順に挿入して重ね合わせて組付けることで簡単に製造され、暖房床パネル５の生産性の向上を図ることができる。しかも、断熱材２の材質および水を塗布した上面側でのホットプレス１２の金型１０ａ，１０ｂによる加熱加圧により、プレス解圧後に、断熱材２のヒータ線収納溝２ｂ、導出線収納溝２ｃおよび送り線収納溝２ｄの復元が効果的に抑制され、暖房床パネル５の生産性の向上を図る上で非常に有利なものとなる。
【００４５】
尚、本発明は上記実施形態に限定されるものではなく、その他種々の変形例を包含するものである。例えば、上記実施の形態では、ヒータ線３、導出線１６および送り線１７の外被３ｂ，１６ｂ，１７ｂを溶融により均熱板２３に固着したが、均熱板にヒータ線、導出線および送り線を粘着剤又は接着剤により固着されるようにしても良い。
【００４６】
また、ヒータ線収納溝２ｂ、導出線収納溝２ｂおよび送り線収納溝２ｄを各線３，１６，１７の径よりも深く形成したが、各線の径と同一の深さに各収納溝が形成されていても良い。
【００４７】
さらに、ヒータ線３を蛇行形状に配線したが、ジグザグ状など種々の熱効率の良い配線形状にしても良い。
【００４８】
しかも、上記実施の形態では、断熱材２の下面に下面材２４を固着したが、断熱材の下層が、剛性のある基材、たとえば合板・ＭＤＦ（中質繊維板）、金属板、合成樹脂板、無機質板等を複合した複合板により構成されるようにすることで、裏面材を不要にすることもできる。
【００４９】
さらにまた、上記実施の形態では、上面材２２の外面に表面仕上げ材２５を張り付けたが、上面材の外面（上面）に、木質化粧板やクッションフロア、カーペット等の化粧板が一体に接着されていても良い。
【００５０】
【発明の効果】
以上の如く、請求項１記載の発明における暖房床パネルによれば、鉱物質繊維製板状体よりなる断熱材の表面に確実かつ容易に型押し成形したヒータ線収納溝にヒータ線を容易に収納することで、埋設パネルを極めて生産性良く形成でき、この埋設パネルを外殻部材内に組み込んでヒータ方式の電気式暖房床パネルを簡単に生産することができる。
【００５１】
請求項２記載の発明における暖房床パネルによれば、ヒータ線と均熱板とを予め一体に固着して、埋設パネルの生産性を一層高めることができるとともに、ヒータ線の熱を確実かつ均一に均熱板に伝達することができる。
【００５２】
請求項３記載の発明における暖房床パネルによれば、ヒータ線をその外被の溶融により均熱板に配線形状に固着するので、特別な接着剤等を用いなくともヒータ線を簡単に固着でき、埋設パネルの生産性をより一層高めることができるとともに、均熱板に対するより確実なヒータ線の接触によりヒータ線の熱を均熱板に対してより良好にかつ均一に伝達することができる。
【００５３】
請求項４記載の発明における暖房床パネルによれば、ヒータ線収納溝内においてヒータ線の下部側とヒータ線収納溝の底部との間に隙間を設けたので、歩行荷重などにより床面材が僅かに撓んでもヒータ線収納溝内での挟圧によるヒータ線の損傷を効果的に回避することができる。
【００５４】
請求項５ないし請求項７記載の発明における暖房床パネルの製造方法によれば、ヒータ線収納溝を鉱物質繊維製板状体よりなる断熱材の表面に加熱加圧により形成したので、形成後のスプリングバックをより少なくして良好なヒータ線収納溝を生産性良く形成することができる。特に、鉱物質繊維性板状体の表面への湿り気付与により、ヒータ線収納溝を無理なく形成できるとともに、加熱加圧時の熱による鉱物質繊維性板状体の表面固化によってより良好なヒータ線収納溝を形成することができる。しかも、外殻部材の床面材を下向きにしてヒータ線を固着した均熱板および断熱材を外殻部材内に順次円滑に組み込んでバッカー材で固着すれば暖房床パネルを簡単に得ることができ、埋設パネルの生産性の著しい向上を図れるとともに、ヒータ方式の電気式暖房床パネルの生産性を著しく向上させることができる。
【図面の簡単な説明】
【図１】本発明の実施の形態に係る暖房床パネルを製造する場合の前半工程を示す説明図である。
【図２】暖房床パネルを製造する場合の後半工程を示す説明図である。
【図３】下面を上向きに逆転させた状態で視た上側金型の斜視図である。
【図４】埋設パネルの一部を切り欠いた状態を示す平面図である。
【図５】暖房床パネルの一部を切り欠いた状態を示す斜視図である。
【符号の説明】
１埋設パネル
２断熱材
２ｂヒータ線収納溝
２ｅ隙間
３ヒータ線
３ａ導線
３ｂ外被
４外殻部材
５暖房床パネル
９ａ，９ｂ，９ｃ凸部
１０ｂ上側金型（型板）
２１枠材
２２上面材（床面材）
２３均熱板
２４下面材（バッカー材）[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a heating floor panel used for an electric heating floor such as a house and a method for manufacturing the same, and particularly relates to a measure for increasing the production efficiency of an embedded panel incorporated in an outer shell member of the heating floor panel.
[0002]
[Prior art]
Generally, an electric heating floor panel includes a heat insulating material, a heater wire processed into a predetermined wiring shape on the upper surface side of the heat insulating material, for example, a heater wire processed into a wiring shape meandering with an interval of about 1 to 8 cm. The embedded panel is integrally formed, and the embedded panel is assembled in an outer shell member formed by fixing a frame material to four sides of the floor surface material. In that case, if a load acts locally or intensively from the upper side, that is, the floor surface side, the heater wire may cause problems such as disconnection. Therefore, by burying the heater wire in the upper layer of the heat insulating material, The heater wire is protected from concentrated loads acting from the surface side, and the heat efficiency is improved by the heat insulating property of the heat insulating material.
[0003]
And conventionally, as a manufacturing method of such an electric heating floor panel, after the groove processing according to the wiring shape (meandering shape) of the heater wire was performed on the upper surface of the heat insulating material by the router, along this groove By embedding the heater wire, the heater wire is embedded in the heat insulating material while maintaining its wiring shape, and the heat insulating material and the heater wire are integrated into a panel shape.
[0004]
As another method for manufacturing an electric heating floor panel, a heater wire is installed in a meandering shape on the inner bottom surface of an outer shell assembled in a bottomed frame shape, and then the heater wire is placed inside the outer shell. Pour a foamable synthetic resin liquid such as foamable urethane resin liquid from above, and then foam and cure the foamable synthetic resin liquid to embed the heater wire while maintaining the wiring shape in the upper layer of the heat insulating material The heat insulating material and the heater wire are integrally formed.
[0005]
[Problems to be solved by the invention]
However, the above-described two methods for manufacturing an electric heating floor panel each have the following drawbacks.
[0006]
In other words, in the former case where the upper surface of the heat insulating material is subjected to grooving by a router, since the grooving is performed according to the wiring shape, the processing work is very laborious and time-consuming, and the grooving is produced. The property is low. In addition, the operation of embedding the heater wires in the grooves also requires a great amount of labor, and there is a disadvantage that the production efficiency of the embedded panel and thus the electric heating floor panel is extremely low.
[0007]
On the other hand, in the case where the foamable synthetic resin liquid is poured from above the latter heater wire, a large facility is required for the preparation and injection of the foamable synthetic resin liquid. In addition, there is a drawback that it is extremely difficult to stably and uniformly fill the foamable synthetic resin liquid in forming the embedded panel with a uniform thickness.
[0008]
The present invention has been made in view of the above points. The object of the present invention is to preliminarily form a heater wire housing groove in a heat insulating material with less spring back by press molding and store the heater wire in advance. By keeping the shape matched with the groove, the groove processing and embedding work by the router on the heat insulating material can be omitted, and large-scale equipment and foaming synthetic resin liquid injection work are unnecessary, making the embedded panel easy and extremely produced. It is designed to improve the production efficiency of electric heating floor panels.
[0009]
[Means for Solving the Problems]
In order to achieve the above object, the solution provided by the invention according to claim 1 is that a heater wire storage groove is formed in a predetermined wiring shape by stamping in advance on the surface of a mineral fiber plate-like body as a heating floor panel. A heat insulating material that is formed and has a hole for thermostat storage punched therein, and a heater wire that is stored in the heater wire storage groove of the heat insulating material and is formed in advance in a shape that matches the wiring shape of the heater wire storage groove; A thermostat housed in the thermostat housing hole and connected to the heater wire, and a heater wire and a thermostat provided in contact with the heater wire and the thermostat on the heater wire housing groove side of the heat insulating material. A buried panel is composed of a hot plate. And the said embedding panel is set as the structure which incorporates a soaking | uniform-heating board toward the floor surface material side in the outer shell member formed by adhering a frame material to the four sides of the floor surface material.
[0010]
Thereby, in invention of Claim 1, a heat insulating material is comprised with the plate-shaped body made from the mineral fiber excellent in the moldability and the small return (spring back) after a mold-molding, The heater wire housing groove is surely and easily formed in a predetermined wiring shape by stamping on the surface. In that case, the heater wire pre-formed in a shape that matches the wiring shape of the heater wire storage groove of the heat insulating material is easily stored in the heater wire storage groove, so that the groove processing and embedding work by a complicated router is performed on the heat insulating material. This eliminates the need for a large amount of equipment for foaming and curing the foamable synthetic resin liquid, while preventing problems due to uneven foaming and filling of the heat insulating material, so that an embedded panel can be formed with extremely high productivity.
[0011]
And the embedded panel (heat insulating material, heater wire, and heat equalizing plate) obtained in this way is incorporated in the outer shell member, so that a heater wire type electric heating floor panel is easily produced.
[0012]
The solution provided by the invention according to claim 2 has a configuration in which, in addition to the constituent features of the invention according to claim 1, a heater wire provided in contact with the heat equalizing plate is integrally fixed to the heat equalizing plate in advance. Is.
[0013]
Thereby, in the invention of claim 2, since the heater wire and the heat equalizing plate are fixed together in advance, the productivity of the buried panel is further enhanced. In addition, the heat of the heater wire is reliably and uniformly transmitted to the soaking plate.
[0014]
The solution provided by the invention according to claim 3 is characterized in that the heater wire of the invention according to claim 2 is specified. Specifically, a heater wire is constituted by a conductive wire and a jacket made of a thermoplastic resin that covers the conductive wire, and is fixed to a heat equalizing plate by melting of the jacket.
[0015]
Thus, in the invention according to claim 3, the heater wire is fixed in a state in which the wiring shape is maintained by, for example, melting the outer cover on a heated soaking plate, so that no special adhesive or the like is used. In both cases, the heater wire is easily fixed to the soaking plate, and the productivity of the buried panel is further enhanced. In addition, the contact of the heater wire with the soaking plate becomes more reliable, and the heat of the heater wire is better and uniformly transmitted to the soaking plate.
[0016]
The solution provided by the invention according to claim 4 is characterized in that the heater wire storage groove of the invention according to any one of claims 1 to 3 is specified. Specifically, the heater wire housing groove is formed deeper than the diameter of the heater wire, and a gap is provided between the lower side of the heater wire and the bottom of the heater wire housing groove.
[0017]
Thereby, in invention of Claim 4, even if a walk load etc. act on the upper surface side of a heating floor panel, ie, the floor material side, from the floor material side and a floor material is bent slightly, a heater wire is not It escapes to the bottom side (gap side) without being pinched in the heater wire housing groove, and damage to the heater wire due to the pinching pressure in the heater wire housing groove is effectively avoided.
[0018]
The solution provided by the invention according to claim 5 is a heating floor panel manufacturing method in which a pressing plate is applied by applying a template having a convex portion having a predetermined wiring shape to the surface of a mineral fiber plate-like body. Thus, a heat insulating material in which the heater wire storage groove is engraved and the thermostat storage hole is punched is prepared. And the heater wire previously formed in the shape corresponding to the wiring shape of the said heater wire accommodation groove | channel is fixed to the soaking | uniform-heating board which consists of a heat conductive board material. Next, the heat equalizing plate to which the heater wire is fixed is incorporated into the outer shell member in which the frame material is fixed to the four sides of the floor surface material so as to overlap the floor surface material. Then, the said heat insulating material is integrated in an outer shell member, and the said heater wire is accommodated in the heater wire accommodation groove | channel of a heat insulating material , and the thermostat is obtained in the said thermostat accommodation hole .
[0019]
The solution provided by the invention according to claim 6 is a heating floor panel manufacturing method in which heating and pressurizing is performed by applying a template having a convex portion having a predetermined wiring shape to the surface of a mineral fiber plate-like body. Thus, a heat insulating material is prepared in which the heater wire housing groove is cut deeper than the diameter of the heater wire and the thermostat housing hole is punched out . Then, the heater wire, which is formed of a conductive wire and a jacket made of a thermoplastic resin that covers the conductive wire, is formed in advance in a shape that matches the wiring shape of the heater wire storage groove, and is formed into a soaking plate made of a heat conductive plate material. It adheres by melting of the jacket. Next, the heat equalizing plate to which the heater wire is fixed is incorporated into the outer shell member in which the frame material is fixed to the four sides of the floor surface material so as to overlap the floor surface material. Then, the said heat insulating material is integrated in an outer shell member, and the said heater wire is accommodated in the heater wire accommodation groove | channel of a heat insulating material , and the thermostat is obtained in the said thermostat accommodation hole .
[0020]
Furthermore, in addition to the constituent features of the invention described in claim 5 or claim 6, the solving means taken by the invention described in claim 7 constitutes an embedded panel with a heat insulating material, a heater wire and a soaking plate. Then, a backer material is fixed to the frame member of the outer shell member, and the embedded panel is sandwiched between the backer material and the floor surface material to obtain a heated floor panel.
[0021]
Thus, in the inventions according to claims 5 to 7, the heater wire housing groove is formed on the surface of the heat insulating material made of the mineral fiber plate-like body by heating and pressing, so that the spring back after the formation is formed. Therefore, a good heater wire housing groove is formed with high productivity. In particular, if the surface of the mineral fibrous plate (heat insulating material) is moistened with water or the like before heating and pressurizing, the heater wire storage groove is impossible due to the softening of the surface of the mineral fibrous plate. It is possible to solidify the surface of the mineral fiber plate that is formed with no heat and vaporized by heat during heating and pressurization to suppress the spring back of the heater wire storage groove, which makes the heater wire storage groove better Is formed.
[0022]
Moreover, if the floor material of the outer shell member is turned downward, the heat equalizing plate and the heat insulating material to which the heater wire is fixed are sequentially and smoothly incorporated from the opening of the outer shell member that opens upward, and the frame member of the outer shell member is A heated floor panel can be easily obtained by fixing with a backer material, and in addition to a significant improvement in the productivity of the buried panel, the productivity of the heater-wire-type electric heating floor panel is significantly improved.
[0023]
DETAILED DESCRIPTION OF THE INVENTION
DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, a first embodiment of the invention will be described with reference to the drawings.
[0024]
FIG. 4 shows a buried panel used by being incorporated in an electric heating floor panel such as a house. This embedded panel 1 is derived from a heat insulating material 2 having a long rectangular shape on one side in plan view, a heater wire 3 processed into a wiring shape on the upper surface side of the heat insulating material 2, and a thermostat 15. It comprises a line 16 and a feed line 17 and a soaking plate 23 provided on the upper side of each of the lines 3, 16, 17. Here, the feed line 17 is used to electrically connect the heater wires 3 between the adjacent buried panels 1.
[0025]
And as shown in FIG. 5, the said embedment panel 1 is in the outer shell member 4 formed by adhering the frame material 21 to the rectangular upper surface material 22 as the floor material on the surface side so as to surround the four sides. In this state, the opening 4a of the outer shell member 4 is covered with a lower surface material 24 as a backer material to form a heating floor panel 5, and the heating floor panel 5 is laid in a room for construction. The heating floor A is configured by combining them vertically and horizontally. A surface finishing material 25 is attached to the upper surface of the upper surface material 22.
[0026]
Here, an example of the manufacturing method of the said heating floor panel 5 is demonstrated.
[0027]
First, the process of the first half until obtaining the heat insulating material 2 is demonstrated based on FIG.
[0028]
As a 1st process, as shown to (a) of FIG. 1, the heat insulating material 2 is prepared. In this case, as the heat insulating material 2, a mineral fiber plate-like body such as a rock wool plate is applied. In this embodiment, a rock wool board using a water-soluble binder such as starch (thickness is about 7 mm and specific gravity is about 0.3 to 0.5) is used as the heat insulating material 2. A multilayer structure made of a material having a higher specific gravity than the front and back layers can also be used. Specifically, the front and back layers are high-density layers made mainly of mineral fibers and inorganic powders, and the core layer is a light-weight inorganic foam such as shirasu foam that is a light-weight layer of the main material. In this case, even if the total specific gravity is about 0.5 to 1.0, the core layer is likely to buckle, so that it can be applied to the case where fine grooves are formed.
[0029]
Next, as a second step, water is applied to the upper surface (surface) of the heat insulating material 2 to soften the surface layer of the heat insulating material 2. The application of water is performed with a sponge roll, and the application amount is set to ⁴ to 8 g / scale ² over the entire upper surface of the heat insulating material 2 because it takes time to evaporate the water when applied excessively. The application of water may be performed only on portions corresponding to heater wire storage grooves 2b, lead-out line storage grooves 2c, and feed line storage grooves 2d, which will be described later. In addition, a thermosetting resin such as a water repellent material or melamine may be mixed in the water to be applied. In this case, the water resistance of the upper surface of the heat insulating material 2 is improved as the moisture evaporates, and thereafter The dimensional change can be prevented, and the hardness of the upper surface is increased to improve the load resistance. This second step is suitable for forming a good heater wire housing groove 2b, lead-out wire housing groove 2c, and feed wire housing groove 2d, but is not particularly required.
[0030]
Then, as a 3rd process, as shown in FIG.1 (b), the heat insulating material 2 is mounted in the lower metal mold | die 10a upper surface of the lower board 12a of the hot press 12 so that a lower surface may become a lower side.
[0031]
Then, as a third step, as shown in FIG. 1C, the heater wire convex portion 9a that protrudes along the wiring shape (see FIG. 4) of the heater wire 3, the lead wire 16 and the feed wire 17 on the lower surface. The upper mold 10b (template) of the upper plate 12b of the hot press 12 having the lead wire convex portion 9b and the lead wire convex portion 9c (see FIG. 3) is applied from the upper surface side of the heat insulating material 2 and heated. As shown in FIG. 1D, the heat insulating material 2 in which the heater wire housing groove 2b, the lead wire housing groove 2c and the feed wire housing groove 2d are carved on the upper surface side is obtained. At this time, the heating and pressurization between the upper and lower molds 10b, 10a by the hot press 12 (lower mold 12a, upper plate 12b) is performed by heating the upper mold 10b to 200 ° C. to 300 ° C. in advance. The pressure is ^{2 to 4} kg / cm ² .
[0032]
In this case, the convex portions 9a, 9b, 9c of the upper mold 10b protrude excessively from the diameters of the heater wire 3, the lead wire 16 and the feed wire 17, and the heater wire storage groove 2b, the lead wire storage groove 2c, and The feed line storage groove 2d is formed deeper than the diameter of each of the lines 3, 16, and 17, and a limit of 5 mm is provided between the lower side of each of the lines 3, 16, and 17 and the bottom of each of the storage grooves 2b, 2c, and 2d. A gap 2e is formed. For this reason, even if a walking load or the like acts on the upper surface side of the heating floor panel 5, that is, the upper surface side of each line 3, 16, 17 from the surface finishing material 25 side, the surface finishing material 25 and the upper surface material 22 are slightly bent, Each line 3, 16, 17 escapes to the bottom side (gap 2e side) without being pinched in each storage groove 2b, 2c, 2d, and each line 3, 16 by the pinching pressure in each storage groove 2b, 2c, 2d , 17 can be effectively avoided.
[0033]
In addition, since the heat insulating material 2 is composed of the mineral fiber plate-like body excellent in the moldability and the small amount of return (springback) after the mold forming, the mold is formed on the upper surface side of the heat insulating material 2. The heater wire housing groove 2b, the lead-out wire housing groove 2c, and the feed wire housing groove 2d can be reliably and easily formed into a predetermined wiring shape by pressing.
[0034]
Thereafter, as the fourth step, the embedding hole 2a is punched into a desired position of the heat insulating material 2 corresponding to the meandering section of the heater wire 3. The reason why the hole 2a for embedding is punched is that the thermostat 15 (shown in FIG. 4) having a thermal fuse is formed to have the same dimension (7 mm) as the thickness of the heat insulating material 2.
[0035]
Then, the remaining second half process will be described with reference to FIG.
[0036]
First, as a fifth step, a heater wire 3 is prepared, and this heater wire 3 is matched to the shape of the heater wire housing groove 2b formed on the upper surface of the heat insulating material 2 by heating and pressing in the third step. In other words, it is preliminarily processed into a wiring shape (see FIG. 4) meandering with an interval of about 1 to 8 cm (most often about 3 to 5 cm). The heater wire 3 is not particularly limited, but a wire 3a having a wire diameter reinforced by glass fiber or Kepler fiber and having a wire diameter of about 0.2 mm to 1.5 mm is covered with a jacket 3b of a thermoplastic resin. The outer diameter is 2.0 mm to 4.0 mm. The lead wire 16 and the feed wire 17 are also formed by covering the conductive wires 16a and 17a with the outer sheaths 16b and 17b of the thermoplastic resin as in the heater wire 3.
[0037]
Next, as a sixth step, a heated soaking plate 23 is prepared as shown in FIG. In this case, an aluminum plate having a thickness of about 0.3 mm is applied as the soaking plate 23, which is suitable for uniform transmission of heat to the upper surface material 22 side.
[0038]
Then, the heater wire 3 that has been preliminarily processed into the wiring shape in the fifth step is placed on the heated soaking plate 23, and is fixed to the soaking plate 23 by thermal welding of the jacket 3b. To do. Similarly, the conductive wire 16 and the feed wire 17 are fixedly attached to the heat equalizing plate 23 at predetermined positions. Thus, by fixing the heater wire 3 and the heat equalizing plate 23 integrally in advance, the productivity of the embedded panel 1 can be further improved, and the heat of the heater wire 3 can be surely and uniformly heated. Can communicate to. Moreover, the wires 3, 16 and 17 are fixed in a state in which the wiring shape is maintained by melting the jackets 3b, 16b and 17b on the heated soaking plate 23, so that no special adhesive or the like is used. Both the wires 3, 16, and 17 are simply fixed to the soaking plate 23, which is very advantageous for improving the productivity of the embedded panel 1.
[0039]
Thereafter, as a seventh step, as shown in FIG. 2C, an outer shell member 4 is prepared in which a frame member 21 is fixed to the back side of the upper surface member 22 so as to surround the four sides. As the upper surface member 22, a rigid plate-like material is used. Moreover, the rigid material of the material similar to the upper surface material 22 is used also as the frame material 21, and the both male and female processing which joins the heating floor panels 5 to each other side end surface (long side side end surface) is performed on both side end surfaces. It is given alternately.
[0040]
Then, the outer shell member 4 is inverted so that the upper surface member 22 faces downward, and the heater wire 3, the lead-out wire 16 and the feed wire 17 are respectively melted and fixed inside the frame member 21 in the fifth step. The soaking plate 23 is mounted on the back surface side of the upper surface material 22 so that the wires 3, 16, and 17 are fixed upward from the opening 4a of the outer shell member 4.
[0041]
Thereafter, as the eighth step, as shown in FIG. 2 (d), the heat insulating material 2 obtained in the third step is stored in the inside of the frame member 21 of the outer shell member 4 from the opening 4a. With the grooves 2b, 2c, 2d facing down, the wires 3, 16, 17 on the heat equalizing plate 23 incorporated in the seventh step are placed so that they are housed in the housing grooves 2b, 2c, 2d. Then, the thermostat 15 is embedded in the embedding hole 2a of the heat insulating material 2. Accordingly, the wires 3, 16, and 17 formed in advance in a shape that matches the wiring shape of the storage grooves 2b, 2c, and 2d of the heat insulating material 2 are easily stored in the storage grooves 2b, 2c, and 2d. It is not necessary to perform groove processing and embedding work with a complicated router on the upper surface side of the material 2, and it is not necessary to use large-scale equipment for foaming and curing foaming synthetic resin liquid, so the embedded panel 1 is extremely productive. Can be formed. The buried panel 1 obtained in this way (the heat equalizing plate 23 and the heat insulating material 2 to which the wires 3, 16, and 17 are fixed) is easily incorporated into the outer shell member 4, thereby providing a heater wire system. The electric heating floor panel 5 can be easily produced.
[0042]
As the ninth step, as shown in FIG. 2E, the lower surface member 24 is fixed to the lower side (upper side in FIG. 2E) of the frame member 21 (outer shell member 4). As the lower surface material 24, plywood, cardboard, kraft paper, synthetic resin plate, cloth, non-woven fabric, glass cloth sheet, or a composite plate combining two or more thereof is used.
[0043]
Then, as shown in FIG. 2 (f), after the outer shell member 4 is turned upside down so that the upper surface material 22 is positioned on the upper side, the outer surface (upper surface) of the upper surface material 22 is surface-finished according to preference. By sticking 25, the heated floor panel 5 is obtained.
[0044]
As a result, the heating floor panel 5 does not integrate the buried panel 1, and the heat equalizing plate 23 in which the heater wire 3, the lead-out wire 16 and the feed wire 17 are melted and fixed, and the heat insulating material 2 are placed in the outer shell member 4. It is easily manufactured by inserting and stacking in order, and the productivity of the heated floor panel 5 can be improved. In addition, the heater wire storage groove 2b and the lead wire storage groove of the heat insulating material 2 after the pressure is released by heat and pressure by the molds 10a and 10b of the hot press 12 on the upper surface side coated with water and the material of the heat insulating material 2. The restoration of the 2c and the feed line storage groove 2d is effectively suppressed, which is very advantageous in improving the productivity of the heated floor panel 5.
[0045]
In addition, this invention is not limited to the said embodiment, Other various modifications are included. For example, in the above embodiment, the jackets 3b, 16b, and 17b of the heater wire 3, the lead wire 16 and the feed wire 17 are fixed to the heat equalizing plate 23 by melting, but the heater wire, the lead wire and the feed wire are attached to the heat equalizing plate. The wire may be fixed with an adhesive or an adhesive.
[0046]
Further, the heater wire storage groove 2b, the lead wire storage groove 2b, and the feed line storage groove 2d are formed deeper than the diameters of the lines 3, 16, and 17, but each storage groove is formed at the same depth as the diameter of each wire. May be.
[0047]
Further, although the heater wire 3 is wired in a meandering shape, it may be formed in various heat efficient wiring shapes such as a zigzag shape.
[0048]
Moreover, in the above embodiment, the lower surface material 24 is fixed to the lower surface of the heat insulating material 2, but the lower layer of the heat insulating material is a rigid base material such as plywood / MDF (medium fiber board), metal plate, synthetic resin. By using a composite plate in which a plate, an inorganic plate or the like is combined, the back material can be eliminated.
[0049]
Furthermore, in the above embodiment, the surface finishing material 25 is attached to the outer surface of the upper surface material 22, but a decorative plate such as a wooden decorative board, a cushion floor, or a carpet is integrally bonded to the outer surface (upper surface) of the upper surface material. May be.
[0050]
【The invention's effect】
As described above, according to the heating floor panel of the first aspect of the present invention, the heater wire can be easily placed in the heater wire housing groove that is surely and easily embossed on the surface of the heat insulating material made of the mineral fiber plate. By storing, the buried panel can be formed with extremely high productivity, and the heater panel type electric heating floor panel can be easily produced by incorporating the buried panel in the outer shell member.
[0051]
According to the heating floor panel of the invention described in claim 2, the heater wire and the heat equalizing plate are fixed together in advance, so that the productivity of the buried panel can be further enhanced, and the heat of the heater wire is surely and uniformly obtained. Can be transmitted to the soaking plate.
[0052]
According to the heating floor panel of the invention described in claim 3, since the heater wire is fixed in the wiring shape to the heat equalizing plate by melting the jacket, the heater wire can be easily fixed without using a special adhesive or the like. Further, the productivity of the buried panel can be further increased, and the heat of the heater wire can be more favorably and uniformly transmitted to the soaking plate by more reliable contact of the heater wire with the soaking plate.
[0053]
According to the heating floor panel of the invention of claim 4, since the gap is provided between the lower side of the heater wire and the bottom of the heater wire housing groove in the heater wire housing groove, the floor material is caused by walking load or the like. Even if it bends slightly, damage to the heater wire due to clamping pressure in the heater wire housing groove can be effectively avoided.
[0054]
According to the method for manufacturing a heated floor panel in the inventions according to claims 5 to 7, since the heater wire storage groove is formed on the surface of the heat insulating material made of a mineral fiber plate by heating and pressing, Therefore, a favorable heater wire housing groove can be formed with high productivity. In particular, the heater wire storage groove can be formed without difficulty by applying moisture to the surface of the mineral fiber plate, and a better heater can be obtained by solidifying the surface of the mineral fiber plate by heat during heating and pressurization. A line storage groove can be formed. Moreover, if the floor plate of the outer shell member is faced down and the heat equalizing plate and the heat insulating material, to which the heater wires are fixed, are smoothly and sequentially incorporated into the outer shell member and fixed with the backer material, a heated floor panel can be easily obtained. Thus, the productivity of the buried panel can be significantly improved, and the productivity of the heater type electric heating floor panel can be significantly improved.
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is an explanatory diagram showing a first half process when manufacturing a heated floor panel according to an embodiment of the present invention.
FIG. 2 is an explanatory view showing a latter half process in the case of manufacturing a heated floor panel.
FIG. 3 is a perspective view of the upper mold viewed with the lower surface turned upside down.
FIG. 4 is a plan view showing a state in which a part of the embedded panel is cut away.
FIG. 5 is a perspective view showing a state in which a part of the heating floor panel is cut away.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Embedded panel 2 Heat insulating material 2b Heater wire accommodation groove | channel 2e Crevice 3 Heater wire 3a Conductor 3b Outer jacket 4 Outer shell member 5 Heating floor panel 9a, 9b, 9c Convex part 10b Upper mold (template)
21 Frame material 22 Top surface material (floor surface material)
23 Heat equalizing plate 24 Bottom material (backer material)

Claims

A heat insulating material in which a heater wire storage groove is formed in a predetermined wiring shape by stamping in advance on the surface of the mineral fiber plate-like body , and the thermostat storage hole is punched ;
A heater wire that is housed in the heater wire housing groove of the heat insulating material and formed in advance in a shape that matches the wiring shape of the heater wire housing groove;
A thermostat housed in the thermostat housing hole and connected to the heater wire;
Provided on the heater wire storage groove side of the heat insulating material in contact with the heater wire and the thermostat , a buried panel is constituted by a heat equalizing plate made of a heat conductive plate material,
The embedded floor panel is a heating floor panel characterized in that a heat equalizing plate is incorporated toward the floor surface material side in an outer shell member formed by fixing a frame material to four sides of the floor surface material.

The heating floor panel according to claim 1, wherein the heater wire provided in contact with the soaking plate is fixed integrally with the soaking plate in advance.

The heating floor panel according to claim 2, wherein the heater wire includes a conductive wire and a jacket made of a thermoplastic resin that covers the conductive wire, and is fixed to the heat equalizing plate by melting of the jacket.

4. The heater wire storage groove according to claim 1, wherein the heater wire storage groove is formed deeper than a diameter of the heater wire and has a gap between a lower side of the heater wire and a bottom portion of the heater wire storage groove. The heating floor panel according to one.

A heater wire storage groove is engraved by punching a thermostat storage hole by applying a heat-pressed mold plate with a convex portion having a predetermined wiring shape on the surface of a mineral fiber plate. Prepare the insulation,
A heater wire previously formed in a shape that matches the wiring shape of the heater wire storage groove is fixed to a soaking plate made of a heat conductive plate material,
Next, the heat equalizing plate to which the heater wire is fixed is incorporated into the outer shell member in which the frame material is fixed to the four sides of the floor surface material so as to overlap the floor surface material,
Thereafter, the heat insulating material is incorporated into an outer shell member to obtain a heating floor panel in which the heater wire is accommodated in the heater wire accommodating groove of the heat insulating material , and the thermostat is accommodated in the thermostat accommodating hole. Manufacturing method of heating floor panel.

The heater wire storage groove is engraved deeper than the diameter of the heater wire by applying a heat-pressed mold plate with a convex portion having a predetermined wiring shape on the surface of the mineral fiber plate , and the thermostat storage Prepare a heat-insulating material with punched holes ,
A heater wire, which is formed of a conductive wire and a jacket made of a thermoplastic resin that covers the conductive wire, and is formed in advance in a shape that matches the wiring shape of the heater wire storage groove, is attached to the heat equalizing plate made of a heat conductive plate. Fixed by melting the coating,
Next, the heat equalizing plate to which the heater wire is fixed is incorporated into the outer shell member in which the frame material is fixed to the four sides of the floor surface material so as to overlap the floor surface material,
Thereafter, the heat insulating material is incorporated into an outer shell member to obtain a heating floor panel in which the heater wire is accommodated in the heater wire accommodating groove of the heat insulating material , and the thermostat is accommodated in the thermostat accommodating hole. Manufacturing method of heating floor panel.

A buried panel is constituted by the heat insulating material, the heater wire and the heat equalizing plate. The manufacturing method of the heating floor panel of Claim 5 or Claim 6 obtained.