JP7625987B2 - Panel for temperature control mat and its installation method - Google Patents

Description

The present invention relates to a panel for constructing a temperature control mat for floor heating. More specifically, the present invention relates to a panel for a temperature control mat having a groove on the upper surface for mounting a hot water pipe. The present invention also relates to a method for constructing the panel for a temperature control mat.

A panel for a temperature-control mat for underfloor heating has a groove on the upper surface for arranging hot water pipes, and a heat transfer member with an inverted Ω-shaped cross section is attached to the groove (Patent Document 1).

In Patent Document 1, a heat transfer sheet is attached to cover the groove and the heat transfer member. The heat transfer sheet has perforations along the center of the groove in the width direction.

After placing this temperature control mat panel on the building's floor structure, a hot water pipe is placed along the upper side of the groove, and the hot water pipe is pushed into the groove while breaking the heat transfer sheet along the perforations. A floor finishing material is then provided to cover the mat with the hot water pipe.

When hot water is passed through the hot water pipe, heat is transferred from the hot water pipe to the heat transfer sheet via the heat transfer member, providing underfloor heating.

JP 2009-52778 A

In Patent Document 1, the heat transfer member extends continuously from one end to the other end in the longitudinal direction of the groove. Therefore, when the panel is cut in a direction perpendicular to the groove direction to fit the on-site dimensions, the heat transfer member is also cut. This heat transfer member is made of thick aluminum with a thickness of about 0.8 mm (Patent Document 1, paragraph 0036), so burrs are generated when it is cut. Therefore, when a hot water pipe is attached to the groove of the cut panel, the hot water pipe may be damaged by the burrs.

The objective of the present invention is to provide a panel for a temperature control mat that does not produce burrs on the heat transfer member even when the panel is cut across the groove to adjust the panel dimensions, and a method for installing the panel.

The gist of the present invention is as follows:

[1] A panel for a temperature-controlled mat, comprising a plate-shaped substrate having a groove on the upper surface for arranging hot water pipes, and a heat transfer member attached to the groove, wherein a plurality of heat transfer members are installed at intervals in the longitudinal direction of the groove, and a cut line or slit extending perpendicular to the groove is provided on the lower surface of the substrate, and the cut line or slit is located on the lower surface of the substrate at a location where the heat transfer member is not present.

[2] The panel for a temperature control mat according to [1], characterized in that the groove extends linearly from one end edge to the other end edge of the substrate, the length of the substrate in the groove extension direction is an integer multiple of 303 mm, and the cut lines or slits are provided at a pitch of 303 mm.

[3] The length of the heat transfer member is 151.5 to 300 mm, and the distance between the heat transfer members is 10 to 100 mm. [2] A panel for a temperature control mat.

[4] The panel for a temperature control mat according to [2] or [3], characterized in that the slit is a main slit whose depth is 10-30% of the substrate, and a shallow slit whose depth is smaller than the main slit is provided along and parallel to the main slit on the underside of the substrate, and the shallow slit is disposed on the underside of the substrate in a portion where the heat transfer member is not present.

[5] The panel for a temperature control mat according to [4], characterized in that the shallow slits are provided on both sides of the main slit.

[6] A panel for a temperature control mat according to [4] or [5], characterized in that the distance between the shallow slit and the main slit is 20 to 50 mm.

[7] A panel for a temperature control mat according to any one of [2] to [6], characterized in that the end of the heat transfer member is spaced a predetermined distance from the side of the base material, and a shallow slit is provided on the underside of the base material, passing between the end of the heat transfer member and the side of the base material, in a direction perpendicular to the groove.

[8] A method for installing a panel for a temperature control mat, comprising laying a panel for a temperature control mat according to any one of [1] to [7] on a floor surface of a building body, the method including a step of cutting the panel for a temperature control mat along the slits to adjust the dimensions of the panel for a temperature control mat.

[9] A method for installing a panel for a temperature control mat, comprising laying a panel for a temperature control mat according to any one of [2] to [7] on a floor surface of a building body, the method including a step of cutting the panel for a temperature control mat along the slit or shallow slit to adjust the dimensions of the panel for a temperature control mat.

[10] The method for constructing a panel for a temperature control mat according to [8] or [9], characterized in that after laying the panel for the temperature control mat, a hot water pipe is placed in the groove, and then a heat equalizing sheet is placed on the upper surface.

The dimensions of rooms in Japanese homes are measured in shaku (303 mm), so the length and width of commercially available panels for temperature control mats are also integer multiples of 303 mm. Therefore, when adjusting the dimensions of a panel for a temperature control mat to fit the dimensions of a room, the panel will be cut in increments of 303 mm.

The temperature control mat panel of the present invention has areas without heat transfer members at a predetermined interval (preferably 303 mm) in the groove extension direction, and cut lines or slits are provided in the temperature control mat panel so as to cross these areas without heat transfer members. Therefore, when adjusting the dimensions of the temperature control mat panel, the temperature control mat panel can be cut along these cut lines or slits to obtain a temperature control mat panel with the desired dimensions (length in the groove extension direction). Furthermore, since the heat transfer member is not cut during this cutting, no burrs are formed on the heat transfer member, and the hot water pipe is not damaged even when it is installed in the groove.

1 is a perspective view of a panel for a temperature control mat according to an embodiment, seen from the upper surface side. FIG. 2 is a perspective view of the panel for a temperature control mat according to the embodiment, seen from the bottom side. FIG. 3A and 3B are views taken along the arrows IIIa and IIIb in FIG. 2. FIG. 2 is an enlarged exploded perspective view of the temperature control mat panel of FIG. 1 . 2 is an enlarged sectional perspective view of a portion of the temperature control mat panel of FIG. 1 . FIG. 2 is a perspective view showing a panel for a temperature control mat and an end panel. 1A is a plan view of an end panel, and FIG. 1B is a plan view of the end panel with an aluminum sheet attached. FIG. 2 is a perspective view of a cut panel for a temperature control mat. FIG. 2 is a perspective view of a cut panel for a temperature control mat. FIG. 2 is a cross-sectional perspective view of a panel for a temperature control mat with a hot water pipe attached thereto.

The following describes in detail an embodiment of the present invention with reference to the drawings.

As shown in Figures 1 to 5, this temperature control mat panel 1 comprises a board-shaped base material 2 made of foamed synthetic resin, a small joist 3 made of plywood, and a heat transfer member 5 attached to a groove 4. In this embodiment, expanded polystyrene (EPS) is used as the foamed synthetic resin, and therefore, hereinafter, the foamed synthetic resin board-shaped base material 2 will be referred to as the EPS base material 2. Also, in this embodiment, the heat transfer member 5 is an aluminum member with a substantially U-shaped cross section, and therefore, hereinafter, this heat transfer member 5 will be referred to as the U-shaped aluminum 3. However, the materials of the base material 2 and the heat transfer member 5 are not limited to these.

The length L and width W of this temperature control mat panel 1 are both 909 mm (3 shaku). Each EPS base material 2 is 909 mm long and 258 mm wide, and three sheets are used. Each small joist 3 is 909 mm long and 45 mm wide, and three pieces are used.

A small joist 3 is arranged between the long sides of each EPS base material 2. In addition, a small joist 3 is arranged along one side of the temperature control mat panel 1, and this small joist 3 is parallel to the other two small joists 3.

The thickness of each EPS base material 2 and small joist 3 is preferably 1 to 5 mm, especially 2 to 3 mm, larger than the diameter of the hot water pipe 10 (Figure 10). The diameter of the hot water pipe 10 is usually 10 to 13 mm.

The upper surface of each EPS base material 2 is provided with two grooves 4 for attaching hot water pipes, which extend from one end to the other in the longitudinal direction.

A U-shaped aluminum piece 5 is attached to each groove 4. As shown in FIG. 4, the U-shaped aluminum piece 5 has a U-shaped portion 5a and a pair of flange portions 5b, 5b that extend in opposite directions from the upper end of the U-shaped portion 5a. The U-shaped portion 5a is fitted into the groove 4, and the U-shaped aluminum piece 5 is attached to the EPS base material 2 so that the flange portions 5b overlap the upper surface of the EPS base material 2 along both edges of the groove 4.

In this embodiment, the length of the U-shaped aluminum 5 is 243 mm, but it can be 151.5 to 300 mm. Three U-shaped aluminum pieces 5 are attached to one groove 4 with a gap between them. The distance between the U-shaped aluminum pieces 5 is 60 mm, but it can be 10 to 100 mm. The distance between the ends of the U-shaped aluminum pieces 5 arranged on both ends of the groove 4 in the longitudinal direction and the edge of the EPS base material 2 is 30 mm, but it can be 1 to 75 mm.

Two slits (main slits) 6 are provided on the back surface of each EPS substrate 2 in the width direction, i.e., perpendicular to the grooves 4. The slits 6 extend from one long side of the EPS substrate to the other long side. The distance between the slits 6 is 303 mm. The distance between the short side of the EPS substrate 2 and the slit 6 closest to the short side is also 303 mm. Each slit 6 extends between two U-shaped aluminum pieces 5.

The depth of the slits 6 is preferably 10 to 30%, and more preferably 15 to 25%, of the thickness of the EPS substrate 2. The slits 6 and shallow slits 7 described below can be formed using a cutter or the like, but the method of formation is not limited to this.

In this embodiment, as shown in Figures 2 and 3, shallow slits (hereinafter referred to as shallow slits) 7 are provided parallel to the slits 6. A shallow slit 7 is provided on both sides of each slit 6. The distance between the shallow slits 7 and the slits 6 is preferably 303/24 = approximately 13 mm to 303/6 = approximately 50 mm, and particularly preferably 303/12 = approximately 25 mm to 303/8 = approximately 38 mm, and is set to 25.25 mm in this embodiment.

Shallow slits 7 are also provided along each short side of the EPS substrate 2, between the short side and the U-shaped aluminum 5. The distance between the shallow slits 7 and the EPS substrate and the short side is preferably 303/24 = approximately 13 mm to 303/6 = approximately 50 mm, and particularly preferably 303/12 = 25 to 303/8 = approximately 38 mm, and is set to 25.25 mm in this embodiment.

As shown in FIG. 5, the EPS base material 2 and the small joist 3 are connected with aluminum tape 8. The aluminum tape 8 is attached across the upper surface of the longitudinal edge of the small joist 3 and the upper surface of the edge of the EPS base material 2 that runs along the small joist 3.

When laying and constructing this temperature control mat panel 1, the end panel 11 is placed along the side of the temperature control mat panel 1 in the width W direction, as shown in Figure 6.

As shown in Figures 6 and 7(a), this end panel 11 is composed of three EPS base materials 12 and three small joists 13. The width of this end panel 11 is 909 mm, and the length is 151.5 mm (half a foot).

Small joists 13 are arranged between each pair of EPS substrates 12. In addition, a small joist (small small joist) 13 is arranged along one side of the end panel 11, and this small joist 13 is parallel to the other two small joists 13.

The thickness of the end panel 11 is the same as the thickness of the temperature control mat panel 1.

The upper surface of each EPS substrate 12 is provided with vertical grooves 14a, 14b, horizontal grooves 14e, semicircular arc grooves 14c, and quarter-circular arc grooves 14d.

The vertical grooves 14a, 14b are arranged in a positional relationship that is continuous in a straight line with the two grooves 4, 4 of the EPS substrate 2. The horizontal groove 14e extends from one side edge of the EPS substrate 12 to the other side edge. The semicircular groove 14c is arranged so as to reach from the vertical groove 14a to the vertical groove 14b. The midpoint of the semicircular groove 14c intersects with the horizontal groove 14e. The quadrant groove 14d is arranged so as to reach from the vertical grooves 14a, 14b to each side edge of the EPS substrate 12. The depth of each of the grooves 14a to 14e is the same as groove 4.

A recess 13a is provided on the top surface of the small joist 13. The depth of this recess 13a is the same as the grooves 14a to 14e. The recess 13a is provided so as to cross the small joist 13 in the width direction.

The lateral groove 14e and the quadrant arc groove 14d are provided on the side of the EPS substrate 12 so as to face this recess 13a.

Although not shown in the figure, aluminum tape is attached to the EPS base material 12 and the upper surface of the edge of the small joist 13 (excluding the recess 13a). Aluminum tape is also attached to the lower surface of the edge of the EPS base material 12 and the small joist 13. This connects the EPS base material 12 and the small joist 13.

When constructing a heated floor using this temperature control mat panel 1, the temperature control mat panel 1 is placed on the floor surface of the building's structural frame, and then an end panel 11 is placed.

A number of temperature control mat panels 1 are arranged in the L direction in Figure 1, and also in the W direction. If the on-site dimensions (the dimensions of the floor surface to be constructed) are not an integer multiple of 909 mm in the W direction, a temperature control mat panel 1 with a width of 303 mm or 606 mm is required. In this case, as shown in Figures 8(a) and (b), by cutting the temperature control mat panel 1 along the small joists 3, a temperature control mat panel 1A with a width of 303 mm and a temperature control mat panel 1B with a width of 606 mm can be obtained.

In addition, due to on-site dimensions, a temperature control mat panel 1 with a length of 303 mm or 606 mm may be required. In this case, as shown in Figures 9(a) and (b), by cutting the temperature control mat panel 1 along the slit 6, it is possible to obtain temperature control mat panels 1C and 1D with a length of 303 mm or 606 mm.

Although not shown in the figure, by cutting the temperature control mat panel 1 along the small joists 2 and also along the slits 6, a temperature control mat with a length of 303 mm or 606 mm and a width of 303 mm or 606 mm can be obtained.

If the on-site dimensions are slightly shorter or longer than an integral multiple of 303 mm in the L direction, the temperature control mat panel 1 can be cut along the shallow slits 7 to obtain a temperature control mat with dimensions slightly shorter or longer than an integral multiple of 303 mm.

The slits 6 and 7 do not intersect with the U-shaped aluminum 5, so even if the temperature control mat panel 1 is cut along the slits 6 and 7, no burrs are created in the U-shaped aluminum 5.

If necessary, not only the temperature control mat panel 1 but also the end panel 11 can be cut along the small joists 13 to fit the on-site dimensions and adjust the width.

After laying the temperature control mat panel 1 and end panel 11 and fixing the panels 1, 11 to the structural floor by nailing them to the small joists 3, 13, the hot water pipe 10 is fitted into the groove 4 of the temperature control mat panel 1 and the grooves 14a, 14b of the end panel 11 as shown in Figure 10.

The hot water pipe 10, which is pulled from the groove 4 to the vertical groove 14a, is pulled through the semicircular groove 14c to the adjacent vertical groove 14b, or through the quadrant groove 14d and recess 13a. The hot water pipe 10, which has passed through the recess 13a, is then pulled from the quadrant groove 14d of the adjacent EPS base material 2 through the vertical groove 14b to the groove 4. The inflow and outflow ends of the hot water pipe are pulled out to the side of the array from the recess 13a, or the vertical groove 14a (or 14b), or the quadrant groove 14d located on the side of the array of the temperature control mat panel 1 and the end panel 13, and connected to a hot water header (not shown).

After the hot water pipes 10 are installed, an aluminum sheet (heat equalizing sheet) with a thickness of about 30 μm to 100 μm is placed on the top surface to cover the temperature control mat panel 1 and the end panel 11, and a floor finishing material is applied on top to create a heated floor.

The end panel 11 may have a heat spreader sheet placed on the upper surface in advance. Figure 7 (b) shows an example. The aluminum sheet 15 has the same dimensions as each EPS substrate 12. An adhesive is applied to the back surface of the aluminum sheet 15, and release paper is attached to it. The release paper is removed from the edge portion 15a along one side of the EPS substrate 12, and this edge portion 15a is attached to the EPS substrate 12.

As described above, the temperature control mat panel 1 of this embodiment has a portion in the extension direction of the groove 4 where there is no U-shaped aluminum 5, and the slit 6 and shallow slit 7 are provided so as to cross the portion where there is no U-shaped aluminum 5. Therefore, when adjusting the size of the temperature control mat panel 1, the temperature control mat panel 1 can be cut along the slit 6 or shallow slit 7 to obtain a temperature control mat panel of the desired size (length in the groove extension direction). Furthermore, since the U-shaped aluminum 5 is not cut during this cutting, no burrs are formed on the U-shaped aluminum 5, and even if a hot water pipe is attached to the groove, the hot water pipe will not be damaged. Furthermore, by providing the slit 6 or shallow slit 7, the temperature control mat panel 1 can be easily cut.

The above embodiment is an example of the present invention, and the present invention may be embodied in other forms. In the above embodiment, the dimensions of the temperature control mat panel are 909 x 909 mm, but they may also be 909 x 1818 mm, 606 x 2424 mm, etc. In the above embodiment, slits are provided, but cut lines made of ink or various markers may also be provided.

1 Panel for temperature control mat 2, 12 EPS base material 3, 13 Small joist 4 Groove 5 U-shaped aluminum (heat transfer member)
6 Slit 7 Shallow slit 8 Aluminum tape 10 Hot water pipe 11 End panel

Claims (8)

A plate-shaped base material having a groove for arranging a hot water pipe on an upper surface thereof;
A panel for a temperature control mat having a heat transfer member attached to the groove,
A plurality of heat transfer members are disposed at intervals along the length of the groove,
A cut line or slit extending in a direction perpendicular to the groove is provided on the lower surface of the base material,
The cut line or slit is a panel for a temperature control mat that is disposed on the lower surface of the base material at a portion where the heat transfer member is not present,
The groove extends linearly from one end side to the other end side of the base material,
The length of the substrate in the groove extending direction is an integer multiple of 303 mm,
The cut lines or slits are provided at 303 mm intervals,
the slit is a main slit having a depth of 10 to 30% of the substrate, and a shallow slit having a depth smaller than that of the main slit is provided along and parallel to the main slit on the lower surface of the substrate;
The shallow slits are disposed on the underside of the base material at locations where the heat transfer member is not present . 2. The temperature control mat panel according to claim 1 , wherein the heat transfer members are spaced apart from one another by a distance of 10 to 100 mm. 3. The panel for a temperature control mat according to claim 1 or 2 , wherein the shallow slits are provided on both sides of the main slit. 4. The temperature control mat panel according to claim 1, wherein the shallow slit and the main slit are spaced apart from each other by a distance of 13 to 50 mm. A panel for a temperature-controlled mat according to any one of claims 1 to 4, characterized in that the end of the heat transfer member is spaced a predetermined distance from the side of the base material, and the shallow slit is provided on the underside of the base material, passing between the end of the heat transfer member and the side of the base material , in a direction perpendicular to the groove. A method for installing a panel for a temperature control mat, comprising laying the panel for a temperature control mat according to any one of claims 1 to 5 on a floor surface of a building structure,
The method for installing a panel for a temperature control mat includes a step of cutting the panel for a temperature control mat along the slits to adjust the dimensions of the panel for a temperature control mat. A method for installing a panel for a temperature control mat, comprising laying the panel for a temperature control mat of any one of claims 1 to 5 on a floor surface of a structural body, the method comprising a step of cutting the panel for a temperature control mat along the slit or shallow slit to adjust the dimensions of the panel for a temperature control mat. 8. The method for constructing a panel for a temperature control mat according to claim 6 or 7 , characterized in that after the panel for a temperature control mat is laid, a hot water pipe is placed in the groove, and then a heat spreader sheet is placed on the upper surface.

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