JP3671176B2 - Hot water mat for floor heating and manufacturing method thereof - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a process for the production of hot water mat and its use in floor heating to heat the room from the floor. Particularly, a method for manufacturing a hot water mat and its floor heating that can reduce the manufacturing cost of the mat.
[0002]
[Prior art]
First, the structure of a conventional hot water mat will be described.
Floor heating is a heating system that warms the room from the floor by flowing warm water (for example, 60 ° C.) through a radiator pipe in a warm water mat laid under a floor board (flooring) or tatami mat. It is popular because it can effectively warm the bottom of a room, which is difficult to warm with general heating, and is being installed in many homes in recent years.
FIG. 5 is a plan view showing the structure of a conventional warm water mat for floor heating. FIG. 2 is a schematic cross-sectional view originally showing the structure of the hot water mat for floor heating of the present invention, but the conventional hot water mat for floor heating of FIG. 5 also has the same cross-sectional structure, so see FIG. However, it will be explained.
[0003]
As shown in FIG. 2, a piping groove 41 is dug in the upper surface of the mat plate 5 which is made of a heat insulating material such as foamed polyethylene and should be called a hot water mat body. The pipe groove 41 has a substantially U-shaped cross section, and a heat radiating pipe (hot water pipe) 2 is laid therein. In the heat radiating tube 2, hot water of about 60 ° C. flows. The upper surface of the heat radiating tube 2 is substantially flush with the upper surface of the mat plate 5. The heat radiating tube is made of cross-linked polyethylene and is flexible. The mat plate 5 is cut out in some places, and small joists 7 are embedded therein. The small radish 7 is a strip-like plate made of plywood or the like, and plays both the role of reinforcing the hot water mat and the role of a nailing member.
[0004]
A heat radiating sheet 6 made of aluminum foil is attached to the upper surface of the mat plate 5 including the piping grooves 41 and the upper surface of the small joists 7. The heat radiating sheet 6 transmits heat released from the hot water in the heat radiating pipe 2 to the upper surface of the hot water mat and radiates heat from the hot water mat toward the upper room. The hot water mat 1 is placed on the floor structure of the building (concrete or wooden floor). On the hot water mat 1, floor materials (flooring, tatami mats, carpets) according to the type of the room are laid.
[0005]
Next, a planar structure of a conventional hot water mat will be described with reference to FIG. FIG. 5 shows a state where the heat dissipating sheet on the upper surface is peeled off. In the hot water mat 101, eight small joists 107 are placed in the vertical direction of the figure. The small joist 107 at the leftmost end of the figure extends downward from the upper side 130 of the hot water mat 101 in a comb shape and reaches the vicinity of the lower side 131 of the hot water mat 101. The second small joist 107 from the left extends upward from the lower side 131 and reaches the vicinity of the upper side 130. In this way, the small joists are arranged like two interdigitated teeth.
[0006]
A portion of the surface of the hot water mat 101 other than the small joist 107 is provided with a mat plate 103, and a heat radiating tube 102 is laid in a loop shape on the mat plate 103. That is, in the left half of the hot water mat 101, the two heat radiating pipes 102a come out from the hot water inlet header 119 disposed at the center of the upper side 130 of the hot water mat 101 and extend between the small joists 107 in the direction of the lower side 131. The pipe crossing path 113 between the tip 108 of the joist 107 and the mat lower side 131 is advanced to the left, and further rises between the small joists 107 and descends. It reaches the turn-up portion 123 at the upper left corner of the mat 101, makes a U-turn, proceeds downward near the left side 132 of the mat, then proceeds to the right along the pipe crossing path 113, and then rises to sew the small joists 107, It descends and rises and enters the outlet header 121 (heat radiation pipe 102b).
[0007]
The inlet header 119 distributes the hot water supplied from the hot water inlet pipe 115 to the two inlet-side heat radiating pipes 102a. The outlet header 121 collects hot water from the two outlet side heat radiating pipes 102 b and sends the hot water to the hot water outlet pipe 117. The portion of the heat radiating tube 102 laid between the small joists 107 along the longitudinal direction of the small joists 107 is called a longitudinal portion, and a crossing path between the tip 108 of the small joists 107 and the upper and lower sides 130 and 131 of the mat. A portion laid on 113 is called a traversing portion.
[0008]
An example of the specifications of the conventional hot water mat of FIG. 5 is shown below.
Overall mat dimensions: Width 2,680mm, Length 1,770mm, Thickness 12mm
Matte board: Polyethylene foam, thickness 12mm
Effective heat radiation area: 4.74 m ²
Radiation tube: Cross-linked polyethylene tube, outer diameter 7.2mm, wall thickness 1.1mm, total extension 68m
Kokona: Plywood, width 45mm, thickness 12mm
[0009]
Conventionally, the mat plate 103 of the hot water mat shown in FIG. 5 is a single piece. That is, the mat plate 103 is connected to the entire sheet, although the portion into which the small joists 107 enter has long and narrow cuts from the upper side 130 and the lower side 131 toward the center. And the piping groove process of the mat | matte board 103 was performed with the processing machine (equivalent to the plano mirror in cutting) which can move the resin melting tool (equivalent to the end mill in cutting) three-dimensionally. In other words, a large piece of foamed polyethylene (or expanded polystyrene) plate is placed on the router table, and the resin melting tool is pushed into the plate to the depth of the piping groove, and the tool (or The pipe groove was processed by moving the table.
[0010]
[Problems to be solved by the invention]
The conventional manufacturing method has the following problems.
(1) Since the size of the mat plate is large (maximum 3.3 m × 2.4 m), it is necessary to install a router having a table corresponding to it in the factory, which requires high capital investment.
(2) Since the pipe grooves were processed one by one by the router, the production efficiency was poor and the processing cost was high.
(3) Since a material that matches the size of the mat plate may not be obtained, the yield of the material was poor when the offcuts were produced.
[0011]
The present invention aims to provide a hot water mat floor heating Ru can reduce the manufacturing cost and a manufacturing method thereof.
[0012]
[Means for Solving the Problems]
To solve the above problems, the hot water mat for floor heating according to the present invention comprises a heat insulating material, a matte having a loop-shaped piping groove on the surface, the hot water pipe laid in the pipe trench of the mats ( a heat radiation pipe), affixed to the upper surface of the mat, and heat dissipation sheet made of good thermal conductive material, provided with a hot water for floor heating which is placed on the floor structure of a building together was the entire a mat; the mat is divided into a portion how many of piping grooves are arranged in parallel in a straight line (vertical Gyobu mat plate), the other part (the transverse section mat board) and it is produced by combining each part mat plate laid radiator tube thereon are entirely integrated by adhering a heat radiation sheet to the mat board and the heat radiating tube on further places of the mat and small joists, which are strip-shaped plate embedded in the pipe cross path Free transverse portion mat plate, between the outer and the mat plate upper or lower side of the pipe cross path, and a small small joists which is arranged to come on the extension of the small joists, the vertical Gyobu mat The plates are separated from each other by the small joist , and the incision for the tip of the small joist and the incision for the small joist are formed in the traverse portion mat plate including the pipe crossing path, The small joists are arranged at both ends of the row portion mat plates or between the adjacent row portion mat plates, and the mat plates and small joists of each portion are attached to the upper surface of the mat. It is characterized in that it is integrated as a whole.
The method for producing a hot water mat for floor heating according to the present invention comprises a mat having a loop-shaped piping groove on the upper surface, a hot water pipe (radiation pipe) laid in the piping groove of the mat, affixed to the upper surface, and a heat dissipation sheet made of good thermal conductive material, with a whole a manufacturing method of the hot water mat heating to be placed on the floor structure of a building together thereof; the the mat, a portion how many of piping grooves are arranged in parallel in a straight line (vertical Gyobu mat board), divided and produced in the other parts (the transverse section mat plate), small joists and opposite ends thereof, cut the transverse portion mat board, or arranged so as to be positioned in transverse section the mat plates adjacent to combine each portion mat plate laid radiator tube thereon, the pipe cross The outside of the pipe crossing and the upper side of the mat board Or, between the lower side, place the small joist in the notch provided so as to be on the extended line of the small joist, and the mat plate and small joist of each part are integrated with the whole by a heat dissipation sheet that is attached to the upper surface of the mat It is characterized by doing.
[0013]
By dividing the mat into several mat plates , the mat plate processing (or molding) machine can be downsized. Further, the mat plate having only the parallel straight grooves can be produced by either forming the final product by extrusion molding once or by grooving at once by a router having multiple tools, so that the production efficiency is improved. In the case of the latter multi-tool router processing, the groove does not necessarily have to be a straight line.
[0014]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, it demonstrates more concretely, referring drawings. First, the structure of a hot water mat for floor heating suitable for realizing the manufacturing method of the present invention will be described.
FIG. 1 is a plan view showing the structure of a hot water mat for floor heating according to one embodiment of the present invention. FIG. 2 is a cross-sectional view schematically showing a cross-sectional structure of the hot water mat shown in FIG. FIG. 1 shows a state in which the mat before applying the heat dissipation sheet is viewed from above.
[0015]
The basic cross-sectional structure shown in FIG. 2 is not qualitatively changed from the conventional hot water mat. However, the size of the heat radiating tube is larger (10 mm) than the conventional outer diameter of 7.2 mm.
[0016]
Next, the planar structure of the hot water mat of this embodiment will be described with reference to FIG.
The hot water mat 1 in FIG. 1 is also arranged so that eight small joists 7 extend in the vertical direction, similarly to the conventional hot water mat in FIG. The pitch of the adjacent small joists 7 is 303 mm, which is the same as the conventional hot water mat. However, the planar shape of the small joists 7 is different from the hot water mat of FIG. That is, the hot water mat 1 of FIG. 1 has two types of small joists (two-end crossing path type small joists 7a and one-end crossing path type small joists 7b) having different shapes. For example, in the leftmost small joist 7a, both ends 23 and 25 remain in the mat plate and do not reach the upper side 19 or the lower side 21 of the mat. Between the upper and lower ends 23 and 25 of both small joists and the upper and lower sides 19 and 21, the pipe crossing path 13 a and the small joists 9 exist. As shown in FIG. 1, the small joists 7 are arranged at both ends of the cuts 53 (see FIG. 3) of the transverse portion mat plate 3 or between the adjacent transverse portion mat plates 3 .
[0017]
The pipe crossing path 13a in the upper left corner is a portion where the mat plate (the traversing portion mat plate 3a) remains, and one radiator pipe 2 passes through the central portion thereof. The small radish 9 is a small radish having a short length (for example, 40 mm). The small radish 9 is disposed on the extended line of the small radish 7a between the outside of the pipe crossing path 13a and the upper side 19 or the lower side 21. The small root joist 9 is installed from the viewpoint that the upper side 19 and the lower side 21 of the mat 1 are also required to be nailed.
[0018]
An auxiliary small joist 11 is installed in the vicinity (left side or right side) of the pipe crossing path 13a. The auxiliary small joist 11 has the same thickness and width as the small joists 7 and nine (12 mm, 45 mm), and the length is 175 mm, for example, and is parallel to the small joists 7 from the upper and lower sides 19 and 21 of the mat. Is provided so as to extend inside the mat. The main purpose of the auxiliary small joist 11 is to reinforce the pressure resistance of the pipe crossing passage 13a. That is, when a flooring material is placed on the pipe crossing path 13a in the horizontal direction in the figure, a plate material that supports the flooring material is required in the mat 1. In particular, since the pipe crossing paths 13a, 13b, and 13a exist in the upper part of the first row, the second row, and the third row of the jojita 7 in the upper left, there are three horizontal rows 13a, 13b, and 13a. If it does not exist, the load applied to the flooring material on the pipe crossing passages in the three rows is applied to the heat radiating pipe 2, and there is a risk of deformation (floor sinking).
[0019]
The second small joist 7b from the left of the hot water mat in FIG. That is, the lower side of the small joist 7b reaches the mat lower side 21 and there is no pipe crossing path, and the upper side does not reach the upper side 19 and the pipe crossing path 13b and the small joe 9 Exists. These roles are the same as those of the leftmost small joist 7a. Note that two heat radiating pipes pass through the pipe crossing path 13b.
The third small joist 7a from the left is again a double-end crossing type, and the fourth small joist 7b is a single-end crossing type. Thereafter, the double-end crossing-type small joists 7a and the one-end cross-passing type small joists 7b are alternately arranged toward the right.
[0020]
The mat of the hot water mat 1 in FIG. 1 is divided into a number of blocks. First, as a vertical division, a line connecting the inner ends of the auxiliary small joists 11 on the upper side and the lower side (mat plate cut line 4) is connected to the longitudinal portion mat plate 5 at the central portion and the transverse portion mat plate 3 at both ends. It is divided. Further, the longitudinal portion mat plate 5 is divided in the left-right direction by the small joists 7. Further, the transverse portion mat plate 3 is divided in the left-right direction by the auxiliary small joists 11 and the small joists 7. This division is mainly from the viewpoint of manufacturing rationalization that improves the piping groove machining efficiency of the mat plate. In addition, the mat board and small joist of each part become the whole by the heat radiation sheet (6 of FIG. 2) affixed on the mat | matte upper surface.
[0021]
With reference also to FIGS. 3 and 4 for each block of the mat, it will be described in detail.
FIG. 3 is a plan view showing the planar shape of various traversing section mat plates used in the hot water mat for floor heating in FIG. FIG. 4 is a plan view showing a planar shape of a longitudinal portion mat plate used in the hot water mat for floor heating in FIG.
The traverse portion mat plate 3a shown in FIG. 3 (a) is a type of mat plate including a single groove pipe crossing path 13a. In the hot water mat 1 of FIG. 1, it is used in four places such as the upper left corner. A transverse part mat plate 3a 'is a transverse part mat plate 3a', which is used in four places such as the third from the left on the upper side in the hot water mat 1 in FIG. In FIG. 3, reference numeral 51 denotes a cut for small radish, and reference numeral 53 denotes a cut for the tip of the small radish.
[0022]
The traverse portion mat plate 3b shown in FIG. 3B is a type of mat plate including a two-groove pipe crossing path 13b. In the hot water mat 1 of FIG. 1, it is used in three places such as the second from the upper left side. The row portion mat plate 3e shown in FIG. 3 (e) is a type in which the width of the row portion mat plate 3b is slightly widened, and is used in the lower right corner of the hot water mat 1 of FIG. A traverse portion mat plate 3c shown in FIG. 3C is used at the upper right corner of the hot water mat 1 in FIG. A traversing mat plate 3d shown in FIG. 3 (d) is a type including a U-turn portion 31 of a heat radiating tube, and is used in the lower left corner of the hot water mat 1 in FIG.
[0023]
As shown in FIG. 4, there are only two types of longitudinal portion mat plates 5. That is, they are a longitudinal portion mat plate 5 a having three piping grooves 41 extending linearly in the vertical direction and a longitudinal portion mat plate 5 b having two piping grooves 41. In the hot water mat of FIG. 1, eight longitudinal portion mat plates 5a are used from the left end to the right, and only the rightmost one is the longitudinal portion mat plate 5b. Since the pipe groove 41 is straight and parallel in any of the longitudinal portion mat plates 5, the groove processing is easy. For example, even if extrusion of foamed resin or melt processing using a router is used, it is possible to efficiently form the three piping grooves 41 by providing three router heads at a certain pitch and making the head pass once. Can be processed.
[0024]
The arrangement of the heat radiating pipes in the hot water mat for floor heating in FIG. 1 will be described.
In the heat radiating pipe 2 of the hot water mat 1 shown in FIG. 1, a hot water inlet 15 and an outlet 17 are provided close to each other in the upper right corner. The heat radiating pipe 2a extends from the entrance 15, snakes up and down so as to sew between the small joists 7, reaches the U-turn part 31 at the lower left corner of the mat, and then returns to the heat radiating pipe 2b, similarly at the upper right corner of the mat. Return to exit 17. More specifically, the outgoing heat radiating tube 2a started from the upper right corner proceeds in the downward direction of the figure in parallel with the small joist 7b to near the lower side 21 of the mat (this portion is referred to as the longitudinal portion 33), and the transverse portion mat plate 3e. Turn 90 ° to the left at the part and pass through the pipe crossing path 13b in the horizontal direction (this part is referred to as the traversing part 35). Next, proceed upward in the longitudinal portion mat plate 5a, make a U-turn at the transverse portion mat plate 3a ', proceed downward along the small joist 7a (second from the right), and at the transverse portion mat plate 3a' Turn and proceed left through the pipe crossing 13a. Then, it goes up along the third small joist 7b from the right and makes a U-turn in the pipe crossing path 13b of the traverse mat plate 3b, and goes down along the small joist 7b. Then proceed in the same way.
[0025]
Next, details of the mat manufacturing method will be described.
(1) Welding method:
The production efficiency of the parallel groove mat plate is the highest when it is produced by this welding method. That is, a plurality of polyethylene (or polystyrene) rod-shaped members constituting the side wall portions of the grooves are attached to one thin sheet (made of the same material) constituting the bottom portions of the grooves by welding. In addition, the rod-shaped member is produced by slitting an extruded plate. In addition, at the time of welding, a rod-shaped member and a sheet can be simultaneously extruded and molded. An example of the specifications of the extrusion process is as follows.
Extrusion temperature: 170 ° C
Extrusion speed: 3m / sec
[0026]
(2) Simultaneous multi-grooving method (router):
Polyethylene foam (or polystyrene foam) is partially melted with a plurality of heated router heads, and a plurality of rows of grooves are simultaneously processed. At this time, the material plate is fixed to a vacuum (decompression) chuck table and sent in the longitudinal direction of the groove. Examples of specifications are as follows.
Head temperature: 200-300 ° C
Table feed speed: 1-2m / sec
[0027]
(3) Machining:
It is a method of scraping grooves with an end mill or a grinder instead of a router. The specifications are as follows.
Cutting edge rotation speed: 5,000 to 6,000 rpm
Table feed speed: 1-2m / sec
[0028]
(4) In-mold foam molding method:
This is a method capable of producing a curved groove mat plate with high production efficiency. Molten polyethylene (or polystyrene) containing a foaming agent is injected and cooled into a mold cavity having a shape of a mat plate with a curved groove, and is molded in one shot. The specifications are as follows.
Mold temperature: 130-140 ° C
[0029]
(5) Baking type pressing method:
This method is also used for the groove processing of the curved groove mat plate. In this method, a mold having a pipe groove-shaped concave portion is pressed against the surface of a foamed polyethylene flat plate to process the cutouts for R and small joists. Although the groove cross-sectional shape tends to be slightly sharp, it is one of the methods that can be used.
[0030]
【The invention's effect】
As apparent from the above description, the manufacturing method of the floor heating hot water mat and its of the present invention exhibits the following effects.
A) The size of the mat plate to be manufactured or processed can be small, so the manufacturing equipment can be small.
B) If each part has a standard shape, hot water mats with various shapes and dimensions can be produced as a combination of standard parts.
C) A highly efficient production method suitable for the shape can be taken by dividing the portion into a shape (for example, a linear parallel groove) that is easy to manufacture.
D) As a result of a) to c) , the manufacturing cost of the mat for the hot water mat can be reduced.
E) Since the mat is divided, the pitch of the small joist can be accurately defined (an example is 303 mm).
F) In the case of a wide single-piece mat, the mat may be deformed during the router processing, but this is not the case with the mat of the present invention, and the accuracy of the external dimensions is improved.
G) It can respond to the production of mats of various dimensions by changing the length of the straight groove part.
[Brief description of the drawings]
FIG. 1 is a plan view showing the structure of a hot water mat for floor heating according to one embodiment of the present invention.
FIG. 2 is a cross-sectional view schematically showing a cross-sectional structure of the hot water mat in FIG.
3 is a plan view showing a planar shape of various traversing portion mat plates used in the hot water mat for floor heating in FIG. 1. FIG.
4 is a plan view showing a planar shape of a longitudinal section mat plate used in the hot water mat for floor heating in FIG. 1. FIG.
FIG. 5 is a plan view showing the structure of a conventional warm water mat for floor heating.
[Explanation of symbols]
1 Hot water mat 2 Hot water pipe (radiation pipe)
3 Traverse portion mat plate 4 Mat plate cut 5 Longitudinal portion mat plate 6 Heat radiation sheet 7 Kokonita 9 Kokonita 11 Auxiliary Kokonita 13 Pipe crossing passage 15 Hot water inlet 17 Hot water outlet 19 Upper side 21 Lower sides 23, 25, 27 End portion 31 U-turn portion 33 Longitudinal portion 35 Transverse portion 41 Piping groove 51 Small radish cut 53 Small radish cut 101 Hot water mat 102 Radiation pipe 103 Mat plate 107 Small radish 108 Small radish tip 113 Piping crossing passage 115 Hot water inlet Pipe 117 Hot water outlet pipe 119 Inlet header 121 Outlet header 123 Folded part 130 Mat upper side 131 Mat lower side 132 Mat left side 133 Mat right side

Claims (2)

Made of insulating material, a matte having a loop-shaped piping groove on the surface, the hot water pipe laid in the pipe groove of the mat (radiator tube), affixed to the upper surface of the mat, good heat a heat dissipation sheet made of conductive material, with a, a hot water mat for floor heating which is placed on the floor structure of a building together was the whole;
The mat is divided into a part (vertical part mat plate) in which several piping grooves are arranged in parallel in a straight line, and the other part (transverse part mat plate). ,
Combining each part mat plate, laying a heat radiating tube on it, and pasting the heat radiating sheet on the mat plate and heat radiating tube, the whole is integrated,
further,
Oneda, which is a strip-shaped plate embedded in the mats,
The small radish arranged so as to be on the extended line of the small joist, between the outer side of the pipe crossing lane and the upper or lower side of the mat plate, including the pipe crossing passage,
With
The longitudinal portion mat plates are divided from each other by the small joists,
The traversing portion mat plate including the pipe crossing path is formed with a cut for the tip of the small joist and the cut for the small joist,
The both ends of the small joists are arranged between the incisions of the traverse portion mat plate or between adjacent traverse portion mat plates,
The hot water mat for floor heating is characterized in that the mat plate and small joists of each part are integrated as a whole by a heat radiation sheet attached to the upper surface of the mat. Made of insulating material, a matte having a loop-shaped piping groove on the surface, the hot water pipe laid in the pipe groove of the mat (radiator tube), affixed to the upper surface of the mat, good heat comprising a heat dissipation sheet made of conductive material, and a hot water mat manufacturing method for heating to be placed on the floor structure of a building together was the whole; the mat, what this or pipe groove Produced by dividing into a portion arranged in parallel in a straight line (longitudinal mat plate) and the other portion (transverse portion mat plate),
The small joists are arranged so that both ends thereof are located between the incisions in the above-mentioned traverse portion mat plate or between the adjacent traverse portion mat plates,
Combine each part mat plate and lay a heat sink on it,
Between the outer side of the pipe crossing path of the traversing mat plate including the pipe crossing path and the upper or lower side of the mat plate, the small joists are arranged in a notch provided so as to be on the extended line of the small joists,
A method for producing a hot water mat for floor heating, characterized in that the mat plate and small joists of each part are integrated as a whole by a heat-dissipating sheet that is attached to the upper surface of the mat.

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