JP3596419B2

JP3596419B2 - Floor heating panel using floor heating PTC heater with soaking sheet and floor heating PTC heater using floor heating with soaking sheet

Info

Publication number: JP3596419B2
Application number: JP2000110842A
Authority: JP
Inventors: 宗一郎川田; 雅司浦野; 太前田; 敏郎堀田
Original assignee: Matsushita Electric Works Ltd
Current assignee: Panasonic Electric Works Co Ltd
Priority date: 2000-04-12
Filing date: 2000-04-12
Publication date: 2004-12-02
Anticipated expiration: 2020-04-12
Also published as: JP2001296034A

Description

【０００１】
【発明の属する技術分野】
本発明は、均熱シート付き床暖房用面状ＰＴＣヒータ及び均熱シート付き床暖房用面状ＰＴＣヒータを用いた床暖房パネルに関するものである。
【０００２】
【従来の技術】
従来から電気抵抗の温度係数が正の特性をもつシート状抵抗体１の両端部に電極２を配設した面状ＰＴＣヒータ３を形成し、面状ＰＴＣヒータ３の上面にアルミニウム箔のような均熱シート４を積層すると共に面状ＰＴＣヒータの下面側に保護シートを積層し、面状ＰＴＣヒータの両端部で均熱シートと保護シートとをシールした図１０（ａ）に示すような均熱シート４付き面状ＰＴＣヒータ３が知られている。この端部におけるシール部２０の巾Ｍは略１０ｍｍ程度である。
【０００３】
そして、上記のような均熱シート４付き面状ＰＴＣヒータ３を、該均熱シート４付き面状ＰＴＣヒータ３よりも巾広の基板７の上に積層して図１０（ｂ）に示すような床暖房パネル６を構成している。このような構成の床暖房パネル６は図１１（ａ）のように並べて施工されるものであるが、床暖房パネルの側端部に均熱シート４付き面状ＰＴＣヒータ３が存在しない部分があるため、上記の床暖房パネルを敷設した床の温度分布は図１１（ｂ）のようになり、床暖房パネル６の側端部の均熱シート４付き面状ＰＴＣヒータ３が存在しない部分で温度が低下し、温度の不均一が生じてしまう。
【０００４】
ところで、基板７上に均熱シート４付き面状ＰＴＣヒータ３を積層した床暖房パネル６を床下地に載設して釘やビス等により固着する場合があるが、この場合には面状ＰＴＣヒータ３が存在しない部分で釘打ちやビス止めする必要があり、また、床暖房パネル６の上に床表面材を敷設して該床表面材を釘やビス等で固定する場合も、釘やビスを面状ＰＴＣヒータ３が存在しない部分で打ち込む必要があり、この点でも床暖房パネルに均熱シート４付き面状ＰＴＣヒータ３が存在しない部分を設けてこの部分で確実に釘打ちやビス止めができるようにすることも必要である。また、面状ＰＴＣヒータ３を基板７いっぱいまで拡げて積層することも考えられるが、隣接する床暖房パネル６同士で電極が接近しすぎて電気的に問題が生じる可能性があり、面状ＰＴＣヒータ３を基板７いっぱいまで拡げて積層するには問題がある。また、市販の面状ＰＴＣヒータ３は床暖房パネル６のモジュールと異なるが、市販の面状ＰＴＣヒータ３はコストが高いため、床暖房パネル６を市販の面状ＰＴＣヒータ３のサイズに合わせることも考えられるが、これだと建築モジュールが異なることになり、施工時の寸法合わせが困難となり、施工時の寸法合わせを容易にするためには建築モジュールに対応したモジュールの床暖房パネル６に市販の面状ＰＴＣヒータを用いる必要がある。この点でも床暖房パネル６よりも面状ＰＴＣヒータ３のサイズが小さくなる（なお、面状ＰＴＣヒータを拡げて発熱面積を増大させるとＰＴＣ部分が増加し、コストアップにつながる）。
【０００５】
上記のような理由により従来にあっては、図１０（ｂ）のように床暖房パネル６の両側端部上面に均熱シート４付き面状ＰＴＣヒータ３が存在しない部分を設ける必要があった。
【０００６】
また、従来にあっては、面状ＰＴＣヒータ３の両端部に電極２を設けたものにおいて、電極２が面状ＰＴＣヒータ３の上面に突出し、このため、図１２のようにシート状抵抗体１の上面と床表面材９との間に隙間Ｓが生じて床鳴りの原因となったり、あるいは床表面材９からの荷重が電極２部分に集中してこの部分が損傷しやすいという問題があった。
【０００７】
【発明が解決しようとする課題】
本発明は上記の点に鑑みてなされたものであり、複数並べて敷設した場合にコストを抑えつつ温度の不均一部分が生じないようにし、また、床鳴りが生じにくく、荷重がかかった場合に一箇所に集中してかかることがなくて損傷しにくい均熱シート付き床暖房用面状ＰＴＣヒータ及び均熱シート付き床暖房用面状ＰＴＣヒータを用いた床暖房パネルを提供することを課題とするものである。
【０００８】
【課題を解決するための手段】
上記課題を解決するために本発明に係る均熱シート付き床暖房用面状ＰＴＣヒータは、電気抵抗の温度係数が正の特性をもつシート状抵抗体１の両端部に電極２を配設した面状ＰＴＣヒータ３を形成し、面状ＰＴＣヒータ３の上面側に均熱シート４を積層すると共に面状ＰＴＣヒータ３の下面側に保護シート１２’を積層し、面状ＰＴＣヒータ３の両端部で均熱シート４と保護シート１２’とをシールし、該両端部のシール部２０から均熱シート４と保護シート１２’との重合部を外側方に連出してそれぞれ床暖房パネルの主体を構成するための基板７の両側端まで至る長さの連出部５をそれぞれ両端部に形成して成ることを特徴とするものである。このような構成とすることで、面状ＰＴＣヒータ３を複数枚並べた場合に、面状ＰＴＣヒータ３のシート状抵抗体１と隣接する面状ＰＴＣヒータ３のシート状抵抗体１とが離れていても、面状ＰＴＣヒータ３のシート状抵抗体１と隣接する面状ＰＴＣヒータ３のシート状抵抗体１との間の部分に位置する均熱シート４の面状ＰＴＣヒータ３の両端部よりも外側方に連出している両端部の連出部５の存在により温度の不均一が生じないようにできるものである。また、均熱シート４と保護シート１２’との重合部をそれぞれ両端部のシール部２０の両外側方に連出して連出部５を形成してあるので、両側にそれぞれ連出した連出部５の裏面側を保護シート１２’で保護できる。
【０００９】
また、シート状抵抗体１の両端部に配設した電極２をシート状抵抗体１の上面側に突出させることなく下面側に突出させることが好ましい。このような構成とすることで、シート状抵抗体１の上面側に床表面材９を敷設した場合に、面状ＰＴＣヒータ３の上面に積層した均熱シート４との間に隙間が生じないようにできるものである。
【００１０】
また、本発明の均熱シート付き面状ＰＴＣヒータを用いた床暖房パネルは、基板７の上面に請求項１記載の均熱シート４付き面状ＰＴＣヒータ３を積層し、均熱シート４の両端部の連出部５を基板７の上面の両端部に積層して成ることを特徴とするものである。このように、床暖房パネル６の上面部の両端部に均熱シート４の両端部の連出部５があるため、床暖房パネル６の上面全体において温度の不均一が生じないようにでき、これにより、床暖房パネル６同士を隣接して施工しても、温度の不均一が生じないようにできるものである。また、床暖房パネル６を床下地材に載置して釘やビスで固着する場合や、床暖房パネル６の上に床表面材９を敷設する場合、面状ＰＴＣヒータ３の両端部よりも外側方に連出した連出部５部分で釘打ちやビス止め等により固着することで床暖房パネル６を床下地材に載設したり、あるいは床表面材９を床暖房パネル６部分に固着するという固着構成も可能となり、ＰＴＣヒータ３部分を損傷することがないものである。また、床暖房パネル６を並設しても隣接する床暖房パネル６同士で電極２が接近しすぎることがなく、電気的に問題が生じないようにできるものである。
【００１１】
また、均熱シート４の上面に電気絶縁シート２１を積層することが好ましい。図５に示すような床表面材９を追加施工するものにおいては、特に、露出する面状のＰＴＣヒータ３の電気絶縁がより保たれるものである。このように、均熱シート４の上面に電気絶縁シート２１を積層してあるので、均熱シート４の電気絶縁を行うことができるものである。
【００１２】
また、シート状抵抗体１の両端部に配設した電極２をシート状抵抗体１の上面側に突出させることなく下面側に突出させ、基板７の上面に凹部８を設け、基板７の凹部８に面状ＰＴＣヒータ３の電極２を嵌め込むことが好ましい。このような構成とすることで、基板７の上面にＰＴＣヒータ３を積層した場合、シート状抵抗体１の下面側に突出した電極２を基板７の上面の凹部８に嵌め込んで収めることができ、これにより床暖房パネル６の上面部を電極２が上面側に突出しない平坦面とすることができ、床暖房パネル６の上面部に床表面材９を敷設した場合に、隙間が生じないようにできるものである。
【００１３】
【発明の実施の形態】
以下、本発明を添付図面に示す実施形態に基づいて説明する。
【００１４】
電気抵抗の温度係数が正の特性をもつシート状抵抗体１の両端部に電極２を配設して面状ＰＴＣヒータ３を形成し、この面状ＰＴＣヒータ３の上面に均熱シート４を積層すると共に面状ＰＴＣヒータ３の下面に保護シート１２’を積層し、面状ＰＴＣヒータ３の両端部で均熱シート４と保護シート１２’とをシールし、更に該シール部２０から少なくとも均熱シート４を外側方に連出して巾広の連出部５を形成して均熱シート４付き面状ＰＴＣヒータ３を形成してある。本発明においては両端部のシール部２０から均熱シート４と保護シート１２’との重合部をそれぞれ外側方に連出して床暖房パネル６の両側端まで至る長さの連出部５を形成してある。このように両端部に巾広の連出部５を連出した均熱シート４付き面状ＰＴＣヒータ３は、後述の床暖房パネル６の主体を構成するための基板７の巾と等しくなっている。なお、実施形態においては例えば図１においてＭで示す示すシール部２０の巾は図８に示す従来例におけるシール部２０と同じ略１０ｍｍであり、シール部２０から外側方に連出する連出部５の長さＮは例えば略２３ｍｍであるが、連出部５の長さＮが上記寸法にのみに限定されないのはもちろんである。
【００１５】
面状ＰＴＣヒータ３に均熱シート４、保護シート１２’を積層するに当たっては、シート状抵抗体１の下面の両側部に電極２を配設して超音波融着により取着してシート状抵抗体１の下面の両側部に電極２を取着した面状ＰＴＣヒータ３を形成し、次に、この面状ＰＴＣヒータ３の上面にアルミ箔よりなる均熱シート４、絶縁用樹脂フィルム１０、融着用低融点樹脂層１１を積層したフィルム１２を配置するとともに、面状ＰＴＣヒータ３の下面にアルミ箔よりなる均熱シート４、絶縁用樹脂フィルム１０、融着用低融点樹脂層１１を積層した保護シート１２’を配置して超音波融着により固着するものであり、これにより、均熱シート４付きのフィルム１２が面状ＰＴＣヒータ３の上面に固着され、保護シート１２’が面状ＰＴＣヒータ３の下面に固着され、面状ＰＴＣヒータ３の両端部で均熱シート４付きのフィルム１２と保護シート１２’とを固着してシール部２０を形成し、更に、この面状ＰＴＣヒータ３の両端部のシール部２０から外方に向けて突出した均熱シート４付きのフィルム１２の端部と保護シート１２’の端部とを固着して、図１に示すような両端部に均熱シート４の両端部の巾広の連出部５が突出した均熱シート４付き面状ＰＴＣヒータ３を形成するものである。ここで、図７に示すように電極２の外周部の樹脂外皮部分２ａを外面に部分的に突起１５を突設しておくことで、超音波融着により融着する際に突起１５部分で確実に超音波融着ができるものである。
【００１６】
上記のように形成した均熱シート４付き面状ＰＴＣヒータ３は図７（ａ）のように、上面側には電極２が突出することなく、下面側にのみ電極２が突出した形状となっており、したがって均熱シート４付き面状ＰＴＣヒータ３の上面は連出部５を含めて平坦面となっている。
【００１７】
上記の均熱シート４付き面状ＰＴＣヒータ３には電極２の端部にリード線１３を接続具１４を介して接続するものであり、電極２の端部にリード線１３を接続具１４を介して接続するに当たってはかしめにより接続するものである。この接続具１４を介してかしめ固着した場合に図７（ｂ）のように、接続具１４部分が均熱シート４付き面状ＰＴＣヒータ３の上面側に突出することなく下面側にのみ突出するように構成するものである。
【００１８】
上記の均熱シート４付き面状ＰＴＣヒータ３を基板７の上面に積層接着することで図３に示すような床暖房パネル６を形成するものである。ここで、両側端部に巾広の連出部５を突出形成した均熱シート４と基板７の横巾とが同じになるように形成してあり、基板７の全上面に均熱シート４が配置されることになる。また、図５に示すように、均熱シート４付き面状ＰＴＣヒータ３は上面が平坦面で下面側に電極２部分とかしめによる接続部分（接続具１４部分）が突出しているので、基板７の上面に凹部８を形成して上記下面側に突出した電極２部分及びかしめによる接続部分を嵌め込むように構成してある。これにより、基板７の上面にＰＴＣヒータ３を積層した場合、床暖房パネル６の上面部の均熱シート４部分を全面にわたって電極２が上面側に突出しない平坦面とすることができる。
【００１９】
上記のような構成の床暖房パネル６は複数枚並べて施工されるものであり、複数枚並べた床暖房パネル６の上面に床表面材９を載設するものである。この場合、均熱シート４付き面状ＰＴＣヒータ３は上面が平坦面で下面側に電極２部分とかしめによる接続部分（接続具１４部分）が突出していて上面は平坦面となっているので、均熱シート４の上面に隙間無くぴったりと床表面材９の下面が密着するものであり、このため、隙間が生じることによる床鳴りの発生を防止し、また、床表面材９に荷重がかかった場合に一箇所に集中してかかることがなくて一箇所に集中してかかることによる損傷を防止できるものである。
【００２０】
ところで、上記のように複数の床暖房パネル９を敷設した場合、本発明の床暖房パネル９においては、温度分布が不均一とならないように電極２間寸法に制約のある面状ＰＴＣヒータ３であっても、均熱シート４の両端部を巾に制約のある面状ＰＴＣヒータ３の両端から巾広の連出部５を突出させてあるので、床暖房パネル６の上面全体において温度の不均一が生じないようにでき、これにより、床暖房パネル６同士を隣接して施工しても、図４（ｂ）に示すように温度の不均一が生じないようにできるものである。
【００２１】
また、床暖房パネル９を床下地材の上に載置して釘やビス等により固着する際に、面状ＰＴＣヒータ３の両端部よりも外側方に連出したの連出部５部分で床暖房パネル６に床表面材９を釘打ちやビス止め等により固着することで取付けることができ、また、床表面材９を敷設する場合も、面状ＰＴＣヒータ３の両端部よりも外側方に連出した連出部５部分で床暖房パネル６に床表面材９を釘打ちやビス止め等により固着することで取付けることを可能とし、これによりＰＴＣヒータ３部分を損傷することなく床暖房パネル９を施工したり、あるいは床暖房パネル９に床表面材９を固着したりできるものである。
【００２２】
なお、基板７の側端部の一端部に凹所を設けるとともに他端部に突所を設けて凹所と突所とを嵌合することで床暖房パネル９同士を接合するものの場合には、突所部分で釘打ちすることで床暖房パネル９を床下地材に固着することができるものである。この場合には連出部５から釘打ちやビス止め等をして床下地材に固着する必要がないものである。
【００２３】
なお、上記実施形態においては均熱シート４付き面状ＰＴＣヒータ３を基板７の上面に積層接着することで床暖房パネル６を形成した例を示したが、両側端部に外方向に向けて連出部５を連出した均熱シート４付き面状ＰＴＣヒータ３を現場で直接床下地材の上に敷設するようにしてもよいものである。この場合も、連出部５により巾広にできたにもかかわらず、連出部５を連出した均熱シート４付き面状ＰＴＣヒータ３の温度分布が不均一とならないようにきるものである。
【００２４】
なお、基板７は例えば、麻、綿、パーム、合成繊維、バインダーなどからなる繊維マットで形成してあり、この繊維マットで形成した基板７は上層７ａと下層７ｂとで構成されており、上層７ａが硬く、下層７ｂが上層７ａに対して柔らかくてクッション性を持たせてある。上層７ａを下層７ｂに対して硬くするには上記繊維ボードの場合、例えば、上層７ａのパーム量を多くし、下層７ｂのパーム量を少なくしてある。もちろん、基板７としては上記実施形態にのみ限定されないものである。
【００２５】
次に、図８、図９に本発明の他の実施形態を説明する。本実施形態においては、上面側に均熱シート４を積層すると共に面状ＰＴＣヒータ３の下面側に保護シート１２’を積層した前述の面状ＰＴＣヒータ３の上の均熱シート４の上面に更に電気絶縁シート２１を積層し、この電気絶縁シート２１により電気絶縁した均熱シート４付き床暖房用面状ＰＴＣヒータ３を基板７の上面に積層して床暖房パネル９を形成してある。このように均熱シート４の上面に電気絶縁シート２１を積層することで、均熱シート４の電気絶縁を図ることができるものである。ここで、電気絶縁シート２１の積層に当たっては、図９に示すように、面状ＰＴＣヒータ３の上面側に均熱シート４を積層すると共に面状ＰＴＣヒータ３の下面側に保護シート１２’を積層した後に図９のように、上の均熱シート４の上面に電気絶縁シート２１を積層して均熱シート４付き床暖房用面状ＰＴＣヒータ３を形成するものである。
【００２６】
上記実施形態においては、あらかじめ上面に電気絶縁シート２１を積層した均熱シート４付き床暖房用面状ＰＴＣヒータ３を基板７の上面に積層して床暖房パネル９を形成した例につき説明したが、均熱シート４付き床暖房用面状ＰＴＣヒータ３を基板７の上面に積層した後、均熱シートの上面に電気絶縁シート２１を積層してもよいものである。
【００２７】
【発明の効果】
上記のように本発明の請求項１記載の発明にあっては、電気抵抗の温度係数が正の特性をもつシート状抵抗体の両端部に電極を配設した面状ＰＴＣヒータを形成し、面状ＰＴＣヒータの上面側に均熱シートを積層すると共に面状ＰＴＣヒータの下面側に保護シートを積層し、面状ＰＴＣヒータの両端部で均熱シートと保護シートとをシールし、該両端部のシール部から均熱シートと保護シートとの重合部を外側方に連出してそれぞれ床暖房パネルの主体を構成するための基板の両側端まで至る長さの連出部をそれぞれ両端部に形成してあるので、電極間の巾に制約のある面状ＰＴＣヒータであっても両端部の連出部の存在により温度の不均一が生じない巾広の均熱シート付きＰＴＣヒータを提供できるものである。また、均熱シートと保護シートとの重合部をそれぞれ両端部のシール部の両外側方に連出して連出部を形成してあるので、両側にそれぞれ連出した連出部の裏面側を保護シートで保護できる。
【００２８】
また、請求項２記載の発明にあっては、上記請求項１記載の発明の効果に加えて、シート状抵抗体の両端部に配設した電極をシート状抵抗体の上面側に突出させることなく下面側に突出させてあるので、シート状抵抗体の上面側に床表面材を敷設した場合に、面状ＰＴＣヒータの上面に積層した均熱シートとの間に隙間が生じないようにできて、床鳴りが生じにくいと共に荷重がかかった場合に一箇所に集中して損傷するというようなことがないものである。
【００２９】
また、請求項３記載の発明にあっては、基板の上面に請求項１記載の均熱シート付き面状ＰＴＣヒータを積層し、均熱シートの両端部の連出部を基板の上面の両端部に積層してあるので、床暖房パネルの上面部の両端部に均熱シートの連出部があるため、床暖房パネルの上面全体において温度の不均一が生じないようにできるものであり、これにより、床暖房パネル同士を隣接して施工しても、温度の不均一が生じないものである。また、床暖房パネルを床下地材に載置して釘やビスで固着する場合や、床暖房パネルの上に床表面材を敷設する場合、面状ＰＴＣヒータの両端部よりも外側方に連出した連出部部分で釘打ちやビス止め等により固着することで床暖房パネルを床下地材に載設したり、あるいは床表面材を床暖房パネル部分に固着するという固着構成が可能となるものであり、ＰＴＣヒータ部分を損傷することなく施工できるものである。また、床暖房パネルを並設しても隣接する床暖房パネル同士で電極が接近しすぎることがなく、電気的に問題が生じないようにできるものである。また、市販の面状ＰＴＣヒータを建築モジュールに対応した床暖房パネルに使用できて、コストを低下し施工時の寸法合わせを容易にすることが可能である。
【００３０】
また、請求項４記載の発明にあっては、上記請求項３記載の発明の効果に加えて、均熱シートの上面に電気絶縁シートを積層してあるので、上の均熱シートの上面に電気絶縁シートを積層してあるので、均熱シートの電気絶縁を行うことができて安全である。
【００３１】
また、請求項５記載の発明にあっては、上記請求項３又は請求項４記載の発明の効果に加えて、シート状抵抗体の両端部に配設した電極をシート状抵抗体の上面側に突出させることなく下面側に突出させ、基板の上面に凹部を設け、基板の凹部に面状ＰＴＣヒータの電極を嵌め込んであるので、基板の上面にＰＴＣヒータを積層した場合、シート状抵抗体の下面側に突出した電極を基板の上面の凹部に嵌め込んで収めることができ、これにより床暖房パネルの上面部を電極が上面側に突出しない平坦面とすることができ、床暖房パネルの上面部に床表面材を敷設した場合に、隙間が生じないようにできて、床鳴りが生じにくいと共に荷重がかかった場合に一箇所に集中して損傷するというようなことがないものである。
【図面の簡単な説明】
【図１】本発明の斜視図である。
【図２】同上の分解断面図である。
【図３】同上の均熱シート付きＰＴＣヒータを基板に積層して形成した床暖房パネルの平面図である。
【図４】（ａ）は同上の床暖房パネルを複数並設した状態の平面図であり、（ｂ）は（ａ）の温度分布を示すグラフである。
【図５】（ａ）は同上の均熱シート付きＰＴＣヒータと基板と床表面材とを示す分解斜視図であり、（ｂ）は同上に用いる基板の斜視図である。
【図６】（ａ）は電極部分が下面側に突出している状態を示す説明図であり、（ｂ）はかしめにより固定した接続具部分が下方に突出している状態を示す斜視図である。
【図７】同上の電極の斜視図である。
【図８】本発明の他の実施形態の斜視図である。
【図９】同上の電気絶縁シートの積層工程の一例を示す説明図である。
【図１０】（ａ）は従来例を示すＰＴＣヒータの斜視図であり、（ｂ）は床暖房パネルの平面図である。
【図１１】（ａ）は従来例の床暖房パネルを複数並設した状態の平面図であり、（ｂ）は（ａ）の温度分布を示すグラフである。
【図１２】（ａ）は従来例の床暖房パネルの上面に床表面材を敷設した状態の分解斜視図であり、（ｂ）は断面図である。
【符号の説明】
１シート状抵抗体
２電極
３面状ＰＴＣヒータ
４均熱シート
５連出部
６床暖房パネル
７基板
８凹部[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a planar PTC heater for floor heating with a soaking sheet and a floor heating panel using the planar PTC heater for floor heating with a soaking sheet.
[0002]
[Prior art]
Conventionally, a planar PTC heater 3 in which electrodes 2 are arranged at both ends of a sheet-shaped resistor 1 having a positive temperature coefficient of electrical resistance is formed, and an upper surface of the planar PTC heater 3 is made of aluminum foil or the like. As shown in FIG. 10 (a), the heat equalizing sheet 4 was laminated, the protective sheet was laminated on the lower surface side of the planar PTC heater, and the heat uniformizing sheet and the protective sheet were sealed at both ends of the planar PTC heater. A planar PTC heater 3 with a heat sheet 4 is known. The width M of the seal portion 20 at this end is about 10 mm.
[0003]
Then, the planar PTC heater 3 with the soaking sheet 4 as described above is laminated on a substrate 7 wider than the planar PTC heater 3 with the soaking sheet 4, as shown in FIG. The floor heating panel 6 is constituted. The floor heating panels 6 having such a configuration are constructed side by side as shown in FIG. 11A, but there are portions where the planar PTC heater 3 with the soaking sheet 4 does not exist at the side end of the floor heating panel. Therefore, the temperature distribution of the floor on which the above-mentioned floor heating panel is laid is as shown in FIG. 11B, and the side end of the floor heating panel 6 is located at the portion where the planar PTC heater 3 with the soaking sheet 4 does not exist. The temperature drops, causing non-uniform temperature.
[0004]
By the way, there is a case where the floor heating panel 6 in which the planar PTC heater 3 with the heat equalizing sheet 4 is laminated on the substrate 7 is placed on the floor base and fixed with nails, screws or the like. It is necessary to nail or screw in a portion where the heater 3 does not exist. Also, when laying a floor surface material on the floor heating panel 6 and fixing the floor surface material with nails or screws, a nail or a screw may be used. It is necessary to drive a screw in a portion where the planar PTC heater 3 does not exist. In this respect, a portion where the planar PTC heater 3 with the soaking sheet 4 does not exist is provided on the floor heating panel, and nailing or screwing is surely performed in this portion. It is also necessary to be able to stop. It is also conceivable that the planar PTC heaters 3 are spread out and stacked to the full extent of the substrate 7. However, there is a possibility that the electrodes may be too close to each other between the adjacent floor heating panels 6, causing an electrical problem. There is a problem in laminating the heater 3 to the full extent of the substrate 7. In addition, although the commercially available planar PTC heater 3 is different from the module of the floor heating panel 6, the commercially available planar PTC heater 3 is expensive, so that the floor heating panel 6 is adjusted to the size of the commercially available planar PTC heater 3. However, in this case, the building modules are different, and it is difficult to adjust the dimensions at the time of construction. In order to facilitate the dimensioning at the time of construction, the floor heating panel 6 of the module corresponding to the building module is commercially available. It is necessary to use the planar PTC heater. Also in this regard, the size of the planar PTC heater 3 is smaller than that of the floor heating panel 6 (if the planar PTC heater is expanded to increase the heat generation area, the PTC portion increases, leading to an increase in cost).
[0005]
For the above-described reason, conventionally, it is necessary to provide a portion where the planar PTC heater 3 with the soaking sheet 4 does not exist on the upper surface of both end portions of the floor heating panel 6 as shown in FIG. .
[0006]
Conventionally, in the case where the electrodes 2 are provided at both ends of the planar PTC heater 3, the electrodes 2 protrude from the upper surface of the planar PTC heater 3, and therefore, as shown in FIG. There is a problem that a gap S is generated between the upper surface of the floor 1 and the floor surface material 9 to cause floor noise, or that the load from the floor surface material 9 is concentrated on the electrode 2 and the portion is easily damaged. there were.
[0007]
[Problems to be solved by the invention]
The present invention has been made in view of the above points, to prevent the occurrence of temperature non-uniformity portion while suppressing the cost when laying a plurality of side by side, and floor noise is less likely to occur, when a load is applied An object of the present invention is to provide a planar PTC heater for floor heating with a soaking sheet and a floor PTC heater using a planar PTC heater for floor heating with a soaking sheet, which is hardly damaged without being concentrated on one place. Is what you do.
[0008]
[Means for Solving the Problems]
In order to solve the above-mentioned problem, in a planar PTC heater for floor heating with a soaking sheet according to the present invention, electrodes 2 are arranged at both ends of a sheet-shaped resistor 1 having a positive temperature coefficient of electric resistance. A planar PTC heater 3 is formed, a heat equalizing sheet 4 is laminated on the upper surface side of the planar PTC heater 3, and a protective sheet 12 'is laminated on a lower surface side of the planar PTC heater 3, and both ends of the planar PTC heater 3 are formed. 'seals and, from the seal portion 20 of the end portions and the heat spreader sheet 4 the protective sheet 12' and the heat spreader sheet 4 the protective sheet 12 in parts subject of the respective floor heating panel bring out the overlapping portion of the outward it is characterized in that the communication output unit 5 the length of the lead up to both side ends of the substrate 7 for configuring comprising respectively formed at both ends of the. With such a configuration, when a plurality of planar PTC heaters 3 are arranged, the sheet-shaped resistor 1 of the planar PTC heater 3 is separated from the sheet-shaped resistor 1 of the adjacent planar PTC heater 3. , Both ends of the sheet PTC heater 3 of the heat equalizing sheet 4 located at a portion between the sheet resistor 1 of the sheet PTC heater 3 and the sheet resistor 1 of the adjacent sheet PTC heater 3 The non-uniformity of the temperature can be prevented by the presence of the extending portions 5 at both ends extending outward. In addition, since the overlapping portions of the heat equalizing sheet 4 and the protective sheet 12 'are respectively extended to both outer sides of the seal portions 20 at both end portions to form the extending portions 5, the extending portions 5 extended to both sides are respectively provided. The back surface of the portion 5 can be protected by the protective sheet 12 '.
[0009]
Further, it is preferable that the electrodes 2 disposed at both ends of the sheet-shaped resistor 1 are protruded to the lower surface side without being protruded to the upper surface side of the sheet-shaped resistor 1. With such a configuration, when the floor surface material 9 is laid on the upper surface side of the sheet-shaped resistor 1, no gap is generated between the heat equalizing sheet 4 stacked on the upper surface of the planar PTC heater 3. It is something that can be done.
[0010]
In the floor heating panel using the planar PTC heater with a soaking sheet of the present invention, the planar PTC heater 3 with the soaking sheet 4 according to claim 1 is laminated on the upper surface of the substrate 7. It is characterized in that the extending portions 5 at both ends are laminated on both ends of the upper surface of the substrate 7. As described above, since the extending portions 5 at both ends of the heat equalizing sheet 4 are provided at both ends of the upper surface of the floor heating panel 6, it is possible to prevent the temperature from being uneven over the entire upper surface of the floor heating panel 6. Thereby, even if the floor heating panels 6 are installed adjacent to each other, it is possible to prevent the temperature from becoming uneven. Further, when the floor heating panel 6 is placed on the floor base material and fixed with nails or screws, or when the floor surface material 9 is laid on the floor heating panel 6, it is higher than both ends of the planar PTC heater 3. The floor heating panel 6 is mounted on the floor base material by fixing with the nailing or screwing, etc. at the portion 5 of the projecting portion that extends outward, or the floor surface material 9 is fixed to the floor heating panel 6 portion. Thus, the PTC heater 3 is not damaged. Further, even if the floor heating panels 6 are arranged side by side, the electrodes 2 do not come too close to each other between the adjacent floor heating panels 6, so that no electrical problem occurs.
[0011]
Further, it is preferable to laminate the electric insulating sheet 21 on the upper surface of the heat equalizing sheet 4. In the case of additionally constructing the floor surface material 9 as shown in FIG. 5, the electric insulation of the exposed planar PTC heater 3 is more particularly maintained. As described above, since the electric insulating sheet 21 is laminated on the upper surface of the heat equalizing sheet 4, electric insulation of the heat equalizing sheet 4 can be performed.
[0012]
Further, the electrodes 2 provided at both ends of the sheet-shaped resistor 1 are made to protrude from the lower surface side without projecting to the upper surface side of the sheet-shaped resistor 1, and a concave portion 8 is provided on the upper surface of the substrate 7. It is preferable that the electrode 2 of the planar PTC heater 3 is fitted into 8. With such a configuration, when the PTC heater 3 is stacked on the upper surface of the substrate 7, the electrode 2 protruding on the lower surface side of the sheet-shaped resistor 1 can be fitted into the recess 8 on the upper surface of the substrate 7. This allows the upper surface of the floor heating panel 6 to be a flat surface on which the electrodes 2 do not protrude toward the upper surface, and no gap is generated when the floor surface material 9 is laid on the upper surface of the floor heating panel 6. It is something that can be done.
[0013]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described based on embodiments shown in the accompanying drawings.
[0014]
Electrodes 2 are arranged at both ends of a sheet-shaped resistor 1 having a positive temperature coefficient of electric resistance to form a sheet-like PTC heater 3, and a heat equalizing sheet 4 is provided on the upper surface of the sheet-like PTC heater 3. At the same time, the protective sheet 12 ′ is laminated on the lower surface of the planar PTC heater 3, and the heat equalizing sheet 4 and the protective sheet 12 ′ are sealed at both ends of the planar PTC heater 3. The thermal sheet 4 is extended outward to form a wide extended portion 5 to form the planar PTC heater 3 with the thermal equalizing sheet 4. The communication output unit 5 the length of the lead up to both side edges of the overlapping portion of the soaking sheet 4 and the protective sheet 12 'respectively bring out outward the floor heating panel 6 from the sealing portion 20 of the both end portions in the present invention It is formed . As described above, the planar PTC heater 3 with the soaking sheet 4 having the wide extending portions 5 extended at both ends becomes equal in width to a substrate 7 constituting a main body of a floor heating panel 6 described later. I have. In the embodiment, for example, the width of the seal portion 20 indicated by M in FIG. 1 is approximately 10 mm, which is the same as the seal portion 20 in the conventional example shown in FIG. The length N of 5 is, for example, approximately 23 mm, but it goes without saying that the length N of the extended portion 5 is not limited to the above dimensions.
[0015]
In stacking the heat equalizing sheet 4 and the protective sheet 12 ′ on the planar PTC heater 3, the electrodes 2 are arranged on both sides of the lower surface of the sheet-shaped resistor 1 and attached by ultrasonic fusion to form a sheet. A planar PTC heater 3 having electrodes 2 attached to both sides of the lower surface of the resistor 1 is formed. Then, a heat equalizing sheet 4 made of aluminum foil and an insulating resin film 10 are formed on the upper surface of the planar PTC heater 3. And a film 12 on which a low-melting resin layer 11 for lamination is laminated, and a heat equalizing sheet 4 made of aluminum foil, a resin film 10 for insulation, and a low-melting resin layer 11 for lamination are laminated on the lower surface of the planar PTC heater 3. The protective sheet 12 ′ is arranged and fixed by ultrasonic fusion, whereby the film 12 with the heat equalizing sheet 4 is fixed to the upper surface of the planar PTC heater 3, and the protective sheet 12 ′ is planarized. Under PTC heater 3 The film 12 with the heat equalizing sheet 4 and the protective sheet 12 ′ are fixed at both ends of the planar PTC heater 3 to form a seal portion 20. The end of the film 12 with the heat equalizing sheet 4 protruding outward from the seal portion 20 and the end of the protective sheet 12 'are fixed to each other, and the heat equalizing sheet 4 is attached to both ends as shown in FIG. The planar PTC heater 3 with the heat-equalizing sheet 4 from which the wide extending portions 5 at both ends protrude is formed. Here, as shown in FIG. 7, the resin outer skin portion 2a of the outer peripheral portion of the electrode 2 is partially provided with the protrusion 15 on the outer surface thereof, so that when the ultrasonic fusion is performed, the protrusion 15 is formed. Ultrasonic fusion can be performed reliably.
[0016]
As shown in FIG. 7A, the planar PTC heater 3 with the heat equalizing sheet 4 formed as described above has a shape in which the electrodes 2 protrude only on the lower surface side without protruding on the upper surface side. Therefore, the upper surface of the planar PTC heater 3 with the soaking sheet 4 is a flat surface including the continuous portion 5.
[0017]
The planar PTC heater 3 with the heat equalizing sheet 4 is connected to a lead wire 13 at an end of the electrode 2 via a connector 14. The lead 13 is connected to an end of the electrode 2 with a connector 14. When connecting via a cable, they are connected by caulking. 7 (b), the connector 14 protrudes only to the lower surface side without protruding to the upper surface side of the planar PTC heater 3 with the heat equalizing sheet 4, as shown in FIG. 7B. It is configured as follows.
[0018]
The floor heating panel 6 as shown in FIG. 3 is formed by laminating and bonding the planar PTC heater 3 with the heat equalizing sheet 4 on the upper surface of the substrate 7. Here, the heat equalizing sheet 4 formed with the projecting portions 5 having a wide width at both end portions and the horizontal width of the substrate 7 are formed so as to be equal to each other. Will be arranged. Also, as shown in FIG. 5, the planar PTC heater 3 with the heat equalizing sheet 4 has a flat upper surface and a connection portion (connector 14 portion) formed by caulking on the lower surface side of the electrode 2 portion. A concave portion 8 is formed on the upper surface of the electrode 2 so that the portion of the electrode 2 protruding toward the lower surface and the connection portion by caulking are fitted. Accordingly, when the PTC heaters 3 are stacked on the upper surface of the substrate 7, the heat equalizing sheet 4 on the upper surface of the floor heating panel 6 can be made a flat surface over which the electrodes 2 do not protrude toward the upper surface.
[0019]
A plurality of floor heating panels 6 having the above-described configuration are arranged side by side, and a floor surface material 9 is placed on the upper surface of the plurality of floor heating panels 6 arranged. In this case, the planar PTC heater 3 with the heat equalizing sheet 4 has a flat upper surface, and a connection portion (connector 14) formed by caulking protrudes from the lower surface side, and the upper surface is a flat surface. The lower surface of the floor surface material 9 is closely adhered to the upper surface of the heat equalizing sheet 4 without any gap, so that floor noise caused by the gap is prevented, and a load is applied to the floor surface material 9. In such a case, it is possible to prevent damage caused by concentration on one place without being concentrated on one place.
[0020]
By the way, when a plurality of floor heating panels 9 are laid as described above, in the floor heating panel 9 of the present invention, the planar PTC heater 3 having a limited dimension between the electrodes 2 so that the temperature distribution is not uneven. Even so, since the wide extending portions 5 protrude from both ends of the planar PTC heater 3 having both widths at both ends of the heat equalizing sheet 4, the temperature of the entire upper surface of the floor heating panel 6 does not vary. Even when the floor heating panels 6 are installed adjacent to each other, it is possible to prevent the temperature from becoming uneven as shown in FIG. 4B.
[0021]
In addition, when the floor heating panel 9 is placed on the floor base material and fixed with nails or screws, it is extended from the both end portions of the planar PTC heater 3 to the outside at the portion of the extension portion 5. The floor surface material 9 can be attached to the floor heating panel 6 by nailing, screwing, or the like. When the floor surface material 9 is laid, the floor surface material 9 is located outside the both ends of the planar PTC heater 3. The floor surface material 9 can be fixed to the floor heating panel 6 by nailing or screwing at the portion of the portion 5 that has been extended to the floor, thereby allowing the floor heating without damaging the PTC heater 3 portion. The panel 9 can be installed or the floor surface material 9 can be fixed to the floor heating panel 9.
[0022]
In the case where the floor heating panels 9 are joined to each other by providing a recess at one end of the side end of the substrate 7 and providing a protrusion at the other end and fitting the recess and the protrusion. The floor heating panel 9 can be fixed to the floor base material by nailing at the protruding portion. In this case, there is no need to fix the nail to the floor base material by nailing, screwing, or the like from the continuous portion 5.
[0023]
In the above embodiment, the floor heating panel 6 is formed by laminating and bonding the planar PTC heater 3 with the heat equalizing sheet 4 to the upper surface of the substrate 7. The planar PTC heater 3 with the soaking sheet 4 from which the extending portion 5 is extended may be directly laid on the floor base material at the site. Even in this case, the temperature distribution of the planar PTC heater 3 with the heat equalizing sheet 4 that has been extended from the extending portion 5 can be prevented from being non-uniform even though the width can be increased by the extending portion 5. is there.
[0024]
The substrate 7 is formed of, for example, a fiber mat made of hemp, cotton, palm, synthetic fiber, a binder, and the like. The substrate 7 formed of the fiber mat is composed of an upper layer 7a and a lower layer 7b. 7a is hard, and the lower layer 7b is softer than the upper layer 7a and has cushioning properties. To make the upper layer 7a harder than the lower layer 7b, in the case of the fiber board, for example, the palm amount of the upper layer 7a is increased and the palm amount of the lower layer 7b is decreased. Of course, the substrate 7 is not limited only to the above embodiment.
[0025]
Next, another embodiment of the present invention will be described with reference to FIGS. In the present embodiment, the heat equalizing sheet 4 is laminated on the upper surface side, and the protective sheet 12 ′ is laminated on the lower surface side of the planar PTC heater 3. Further, the floor heating panel 9 is formed by laminating an electric insulating sheet 21 and laminating the floor heating planar PTC heater 3 with the heat equalizing sheet 4 electrically insulated by the electric insulating sheet 21 on the upper surface of the substrate 7. By laminating the electric insulating sheet 21 on the upper surface of the heat equalizing sheet 4 in this manner, the electric insulation of the heat equalizing sheet 4 can be achieved. Here, when laminating the electric insulating sheet 21, as shown in FIG. 9, the heat equalizing sheet 4 is laminated on the upper surface side of the planar PTC heater 3 and the protective sheet 12 ′ is laminated on the lower surface side of the planar PTC heater 3. After lamination, as shown in FIG. 9, an electric insulating sheet 21 is laminated on the upper surface of the upper heat equalizing sheet 4 to form the planar heating PTC heater 3 with the heat equalizing sheet 4.
[0026]
In the above-described embodiment, an example is described in which the floor heating panel 9 is formed by stacking the planar heating PTC heater 3 with the heat equalizing sheet 4 on which the electric insulating sheet 21 is previously laminated on the upper surface on the upper surface of the substrate 7. After laminating the planar PTC heater 3 for floor heating with the heat equalizing sheet 4 on the upper surface of the substrate 7, an electric insulating sheet 21 may be laminated on the upper surface of the heat equalizing sheet.
[0027]
【The invention's effect】
As described above, in the invention according to claim 1 of the present invention, a planar PTC heater in which electrodes are arranged at both ends of a sheet-shaped resistor having a positive temperature coefficient of electrical resistance is formed, a protective sheet on the lower surface side of the planar PTC heater with laminating a soaking sheets on the upper surface of the planar PTC heaters are stacked, seal the the soaking sheet and the protective sheet at both ends of the planar PTC heater, the ends each opposite ends communicating out of a length ranging up to both side ends of the substrate for constituting a main body of each floor heating panel overlapping portion between the soaking sheets and protective sheet from the sealing portion of the parts to bring out outward since it is formed to provide a temperature PTC heater with soaking sheets of wide width nonuniformity does not occur in the presence of a continuous output of the two end portions be planar PTC heater with limited width between the electrodes You can do it. In addition, since the overlapping portion of the heat equalizing sheet and the protective sheet is extended to both outer sides of the seal portion at both ends to form an extended portion, the back side of the extended portion extended to both sides is formed. Can be protected with a protective sheet.
[0028]
According to the second aspect of the present invention, in addition to the effects of the first aspect, the electrodes disposed at both ends of the sheet-shaped resistor are projected to the upper surface side of the sheet-shaped resistor. And projecting to the lower surface side, so that when a floor surface material is laid on the upper surface side of the sheet-shaped resistor, there is no gap between it and the heat equalizing sheet laminated on the upper surface of the planar PTC heater. Thus, floor noise is unlikely to occur, and when a load is applied, there is no possibility of damage at one location.
[0029]
According to the third aspect of the present invention, the planar PTC heater with the heat equalizing sheet according to the first aspect is laminated on the upper surface of the substrate. Since it is laminated on the part, since there is a continuous portion of the heat equalizing sheet at both ends of the upper surface of the floor heating panel, it is possible to prevent the temperature unevenness from occurring over the entire upper surface of the floor heating panel, Thereby, even if floor heating panels are installed adjacent to each other, the temperature does not become uneven. Also, when the floor heating panel is placed on the floor base material and fixed with nails or screws, or when the floor surface material is laid on the floor heating panel, the floor heating panel is connected outside the both ends of the planar PTC heater. It is possible to fix the floor heating panel to the floor base material or fix the floor surface material to the floor heating panel part by fixing it with nailing or screwing at the extended portion that has been extended. It can be constructed without damaging the PTC heater portion. Further, even if the floor heating panels are juxtaposed, the electrodes are not too close to each other between the adjacent floor heating panels, so that no electrical problem occurs. Further, a commercially available planar PTC heater can be used for a floor heating panel corresponding to a building module, so that costs can be reduced and dimensional adjustment at the time of construction can be facilitated.
[0030]
Further, in the invention according to claim 4, in addition to the effect of the invention according to claim 3, since the electric insulating sheet is laminated on the upper surface of the heat equalizing sheet, Since the electric insulating sheet is laminated, the heat equalizing sheet can be electrically insulated, which is safe.
[0031]
According to a fifth aspect of the present invention, in addition to the effects of the third or fourth aspect of the present invention, electrodes provided at both ends of the sheet-shaped resistor are provided on the upper surface side of the sheet-shaped resistor. When the PTC heater is laminated on the upper surface of the substrate, the sheet-like resistor is not provided. The electrode protruding on the lower surface side of the body can be fitted into the concave portion on the upper surface of the substrate, and the upper surface of the floor heating panel can be a flat surface on which the electrode does not protrude on the upper surface side. When a floor surface material is laid on the upper surface of the floor, no gaps are created, floor noise is less likely to occur, and if a load is applied, it will not be damaged in one place is there.
[Brief description of the drawings]
FIG. 1 is a perspective view of the present invention.
FIG. 2 is an exploded sectional view of the same.
FIG. 3 is a plan view of a floor heating panel formed by laminating a PTC heater with a soaking sheet on the substrate.
FIG. 4A is a plan view showing a state in which a plurality of floor heating panels are arranged side by side, and FIG. 4B is a graph showing the temperature distribution of FIG.
FIG. 5A is an exploded perspective view showing a PTC heater with a heat equalizing sheet, a substrate, and a floor surface material, and FIG. 5B is a perspective view of the substrate used in the same.
FIG. 6 (a) is an explanatory view showing a state in which an electrode portion protrudes to the lower surface side, and FIG. 6 (b) is a perspective view showing a state in which a connecting portion fixed by caulking protrudes downward.
FIG. 7 is a perspective view of the electrode of the above.
FIG. 8 is a perspective view of another embodiment of the present invention.
FIG. 9 is an explanatory view showing an example of a step of laminating an electric insulating sheet according to the embodiment.
10A is a perspective view of a PTC heater showing a conventional example, and FIG. 10B is a plan view of a floor heating panel.
11A is a plan view showing a state in which a plurality of floor heating panels of a conventional example are arranged side by side, and FIG. 11B is a graph showing the temperature distribution of FIG.
12A is an exploded perspective view showing a state in which a floor surface material is laid on the upper surface of a conventional floor heating panel, and FIG. 12B is a cross-sectional view.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Sheet-shaped resistor 2 Electrode 3 Planar PTC heater 4 Heat equalizing sheet 5 Consecutive part 6 Floor heating panel 7 Substrate 8 Depression

Claims

A sheet-shaped PTC heater having electrodes disposed at both ends of a sheet-shaped resistor having a positive temperature coefficient of electric resistance is formed, and a heat equalizing sheet is laminated on the upper surface side of the sheet-shaped PTC heater and the sheet-shaped PTC is stacked. laminating a protective on the lower surface side sheet of the heater, and sealing the soaking sheet and the protective sheet at both ends of the planar PTC heater, outward polymerization of the soaking sheets and protective sheet from the sealing portion of the end portions with soaking seat floor heating surfaces, characterized in that both sides leading to the edge length of the communication output part comprising respectively formed at both ends of the substrate for each constituting a main body of the floor heating panel bring out the PTC heater.

2. The floor heating surface with a heat equalizing sheet according to claim 1, wherein the electrodes arranged at both ends of the sheet-shaped resistor are projected to the lower surface side without projecting to the upper surface side of the sheet-shaped resistor. PTC heater.

The planar PTC heater for floor heating with a soaking sheet according to claim 1 is laminated on the upper surface of the substrate, and the extended portions at both ends of the soaking sheet are laminated on both ends of the upper surface of the substrate. Floor heating panel using a flat PTC heater for floor heating with a soaking sheet.

The floor heating panel using a planar PTC heater for floor heating with a heat equalizing sheet according to claim 3, wherein an electric insulating sheet is laminated on the upper surface of the heat equalizing sheet.

The electrodes provided at both ends of the sheet-shaped resistor are projected to the lower surface side without projecting to the upper surface side of the sheet-shaped resistor, a concave portion is provided on the upper surface of the substrate, and the electrode of the planar PTC heater is provided in the concave portion of the substrate. The floor heating panel using the planar PTC heater for floor heating with a soaking sheet according to claim 3 or 4, wherein the floor heating panel is fitted.