Floor heating mat

Abstract

To provide a floor heating mat capable of reducing temperature unevenness in the floor heating mat of a type without the existence of a hot water pipe arrangement groove in an auxiliary joist arrangement omitting part.SOLUTION: A floor heating mat 1 includes a substrate 2, a hot water pipe 3 housed in a groove 4 via a heat transfer member 7, and a soaking sheet 5. Six pipings at 40-65 mm are arranged in a range of 303 mm with an array pitch of the hot water pipe 3 excluding in an auxiliary joist arrangement omitting part A. A width b of the auxiliary joist arrangement omitting part is between 70-85 mm. A thickness of the soaking sheet 5 is 70-130 μm. A width w of a flange part 7f of the heat transfer member 7 is 60-120% of a width of the groove 4. A ratio b / a of the width b of the auxiliary joist arrangement omitting part to the array pitch a of the hot water pipe excluding in the auxiliary joist arrangement omitting part is 1.1 or more. A value t / b obtained by dividing a thickness t (μm) of the soaking sheet 5 by the pitch a (mm) is 1.1 (μm / mm) or more.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a floor heating mat for heating the floor of a building by passing hot water therethrough, and particularly to a type of floor heating mat without joists.

[0002] In the following description, the upper surface of the floor heating mat refers to the upper surface when the floor heating mat is laid on the floor, and the lower surface of the floor heating mat refers to the lower surface when the floor heating mat is laid on the floor.

Background Art

[0003] As a floor heating mat using hot water, a mat in which a hot water pipe is arranged in a groove on the upper surface of a foamed synthetic resin substrate is widely used.

[0004] Normally, the substrate is rectangular, and the grooves are provided so as to extend in a direction parallel to the long side direction of the substrate. After the hot water pipe is arranged in the groove, a heat dissipation sheet made of an aluminum foil sheet is provided so as to cover the upper surface of the substrate.

[0005] In some cases, a heat transfer member called U-shaped aluminum made of aluminum foil is disposed in the groove. In this case, the hot water pipe is disposed in the groove through the heat transfer member.

[0006] There are floor heating mats with joists and those without joists.

[0007] A floor heating mat without joists is fixed to the floor base using an adhesive or the like. In the case of a floor heating mat with joists, the floor heating mat can be fixed to the floor base by nailing through the joists. The width of the joist is usually 45 mm.

[0008] As an example of a floor heating mat without joists, a mat having grooves provided at a substantially uniform pitch is shown in FIG. 1 of Patent Document 1. Patent Document 1 describes that the arrangement pitch is preferably 30 to 60 mm.

Prior Art Documents

Patent Document

[0009]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0010] The substrate of the floor heating mat is manufactured by foam molding using a mold. On the inner surface of the mold, ridges for forming grooves are provided.

[0011] The floor heating mat with joists is manufactured by combining the substrate, joists, hot water pipe, and heat dissipation sheet so that it can be nailed to the floor base through the joists. Since no hot water pipe is arranged in the joist part, temperature unevenness occurs on the upper surface of the floor heating mat.

[0012] The floor heating mat without joists is fixed to the floor base using an adhesive or the like on the slab surface (the floor surface of the building structure) and does not need to be nailed to the floor base through the joists. Therefore, it is manufactured by combining the substrate, hot water pipe, and heat dissipation sheet. When manufacturing the substrate of the floor heating mat without joists, there are cases where a mold with ridges provided at a uniform pitch is used, and cases where the substrate of the floor heating mat with joists is also used and the joist part is replaced with the substrate for manufacturing.

[0013] In the former case, since the mold is a dedicated mold for manufacturing a substrate of the type without joists, two types of molds for the substrate of the floor heating mat with joists are required, resulting in high investment costs.

[0014] In the latter case, since it is also used as the mold for manufacturing the substrate of the floor heating mat with joists, the mold cost can be reduced. However, in this case, the part where the joist part is omitted is composed only of the substrate and no hot water pipe is arranged, so the temperature unevenness on the upper surface of the floor heating mat becomes large.

[0015] An object of the present invention is to provide a floor heating mat that can reduce temperature unevenness in a floor heating mat of a type in which there is no groove for arranging a hot water pipe in an omitted part of the joist arrangement.

Means for Solving the Problems

[0016] The floor heating mat of the present invention is a floor heating mat having a substrate provided with a groove for accommodating a pipe on the upper surface, a hot water pipe accommodated in the groove, and a heat dissipation sheet provided so as to cover the upper surface of the substrate and the upper side of the hot water pipe. An omitted part of the joist arrangement where the joists are not arranged is provided. The hot water pipes are arranged in parallel such that a part of the arrangement pitch is different. The arrangement pitch a of the hot water pipes outside the omitted part of the joist arrangement is 40 to 65 mm, and 6 pipes are arranged within a range of 303 mm. There may be some variation as long as it is between 40 and 65 mm. The width b of the omitted part of the joist arrangement is between 70 and 85 mm. The thickness t of the heat dissipation sheet is 70 to 130 μm. A heat transfer member is provided in the groove. The heat transfer member has a portion arranged in the groove and a flange portion overlapping the upper surface of the substrate. The width w of the flange portion is 60 to 120% of the width of the groove.

[0017] In one aspect of the present invention, the ratio b / a of the width b of the omitted part of the joist arrangement to the arrangement pitch a of the hot water pipes outside the omitted part of the joist arrangement is 1.1 or more, and the value t / a obtained by dividing the thickness t (μm) of the heat dissipation sheet by the pitch a (mm) is 1.1 (μm / mm) or more.

[0018] In one aspect of the present invention, when the floor heating mat is laid on a floor base configured by arranging a plywood with a thickness of 12 mm on a heat insulating material (expanded polystyrene, thermal conductivity 0.040 W / (m·K)) with a thickness of 40 mm, and a soundproof floor with a thickness of 13.5 mm is provided to cover the floor heating mat to form a floor heating system, when operating under the conditions of a passing hot water temperature of 60°C at a room temperature of 20°C and a flow rate of 0.5 L / min flowing through each pipe, the temperature unevenness (high temperature part - low temperature part) of the floor surface photographed from a height of 120 cm with an infrared thermographic camera (model: InfReC R450S, manufactured by Nippon Avionics Co., Ltd.) in a 30 cm square area centered on the omitted joist arrangement part is within 4°C.

Effects of the Invention

[0019] In the floor heating mat of the present invention, the temperature unevenness on the upper surface of the floor heating mat having an omitted joist arrangement part is reduced, and the output increases, so the energy saving performance is improved. Since the mold for manufacturing the floor heating mat of the present invention can be shared with the mold for manufacturing a substrate with joists, the mold cost can be reduced, and the manufacturing cost of the floor heating mat can be reduced.

Brief Description of the Drawings

[0020]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Modes for Carrying Out the Invention

[0021] Hereinafter, embodiments will be described with reference to the drawings. Note that each of the following embodiments is an example of the present invention, and the present invention can take forms other than the following embodiments.

[0022] This floor heating mat 1 includes a rectangular substrate (base) 2, a hot water pipe 3 arranged in a groove 4 (Fig. 3) provided on the upper surface of the substrate 2, headers 8 and 9 (Fig. 1) to which the hot water pipe 3 is connected, a heat transfer member 7 arranged in the straight part of the groove 4, a heat transfer member 10 arranged so as to cover the upper surfaces on both ends in the longitudinal direction of the substrate 2, a heat equalizing sheet 5 attached so as to overlap the entire upper surface of the substrate 2, etc. In Fig. 1, the heat equalizing sheet 5 and the heat transfer sheet member 10 are not shown. This floor heating mat 1 does not have joists.

[0023] In the straight part of the groove 4, as shown in Figs. 1, 3, and 4, a heat transfer member 7 called U-shaped aluminum made of aluminum foil is arranged. Details of the configurations of the heat transfer members 7 and 10 will be described later.

[0024] As the substrate 2, foamed polypropylene, foamed polyethylene, foamed polystyrene (EPS), foamed polyurethane, etc. with a density of about 10 to 100 kg / m 3 can be used. When the substrate is made of foamed polystyrene, the foaming ratio is preferably 5 to 25 times, particularly 15 to 20 times.

[0025] The thickness of the substrate 2 is preferably 6 mm or more, particularly 9 mm or more, especially 10 mm or more, and also 24 mm or less, particularly 18 mm or less, especially 15 mm or less.

[0026] The depth of the groove 4 is preferably the sum of the diameter (outer diameter) of the hot water pipe 3 and the wall thickness of the heat transfer member 7.

[0027] The outer diameter of the hot water pipe 3 is preferably 3 mm or more, particularly 4 mm or more, especially 5 mm or more, and also 12 mm or less, particularly 10 mm or less, especially 9 mm or less.

[0028] The hot water pipe 3 is preferably made of cross-linked polyethylene, polyethylene, polypropylene, polybutene, etc.

[0029] The groove 4 extends parallel to the longitudinal direction of each substrate 2. Each groove 4 extends from one end side to the other end side in the longitudinal direction of the substrate 2, curves in a substantially U-shape in a U-turn at the other end side, and extends from the other end side to the one end side. Some of the grooves 4 further curve in a substantially U-shape at the one end side and extend in a zigzag shape.

[0030] As shown in FIG. 1, one end (the end on the hot water inflow side) of the three hot water pipes 3 is connected to the header 8, passed through the grooves 4 from the 1st to the 3rd from the left in FIG. 1, and then passed through the grooves 4 from the 4th to the 6th from the left. Each hot water pipe 3 is then routed in order through the grooves 4 from the 7th to the 9th from the left, the grooves 4 from the 16th to the 18th from the left, the grooves 4 from the 13th to the 15th from the left, and the grooves 4 from the 10th to the 12th from the left in the vicinity of the headers 8 and 9. And the other end (the end on the hot water outflow side) of each hot water pipe 3 is connected to the header 9.

[0031] In this embodiment, the intervals between the grooves 4 from the 1st to the 6th from the left in FIG. 1, the intervals between the grooves 4 from the 7th to the 12th from the left, and the intervals between the grooves 4 from the 13th to the 18th from the left may be the same or may vary. The pitch (the distance between the center lines of adjacent grooves 4) a of these grooves 4 is preferably 40 mm or more, particularly 44 mm or more, and 65 mm or less, particularly 60 mm or less.

[0032] The distance b between the center lines between the 6th and 7th grooves 4 from the left in FIG. 1 and the distance b between the center lines between the 12th and 13th grooves 4 from the left are larger than a, preferably 70 mm or more and 85 mm or less. b / a is preferably 1.1 or more.

[0033] The distance from the center line of the 1st groove 4 from the left in FIG. 1 to the left side of the substrate 2 and the distance from the center line of the 18th groove 4 from the left in FIG. 1 to the right side of the substrate 2 are smaller than a and 29 mm or less.

[0034] The reason why the distances b between the sixth and seventh, and the twelfth and thirteenth grooves 4, 4 from the left in FIG. 1 are large is that this substrate 2 was manufactured using a mold for forming a substrate with joists, and the joists were omitted. For a substrate with joists, the locations where the joists would be arranged are also composed of the substrate (foamed synthetic resin).

[0035] That is, between the sixth and seventh, and the twelfth and thirteenth grooves 4, 4 from the left are the parts where the joists would be arranged in a floor heating mat with joists. By replacing the joist part with the substrate, this part has become the joist arrangement omission part A. The width of this joist arrangement omission part A is between 70 and 85 mm.

[0036] The heat dissipation sheet 5 is preferably an aluminum foil with a thickness of 70 μm or more, particularly 90 μm or more, especially 100 μm or more, and also 130 μm or less, particularly 120 μm or less, especially 110 μm or less. In this case, it is preferable that the value t / a obtained by dividing the thickness t (μm) of the heat dissipation sheet 5 by the pitch a (mm) is 1.1 (μm / mm) or more. The heat dissipation sheet 5 is provided over the entire upper surface of the substrate 2, and the heat transfer members 7, 10 are also covered with the heat dissipation sheet 5.

[0037] For attaching the heat dissipation sheet 5, adhesives such as acrylic-based, ethylene-vinyl acetate-based, polyamide-based, and polyester-based adhesives can be used. However, these are just examples, and the present invention is not limited to these.

[0038] In the straight portions of the grooves 4, as shown in FIGS. 1, 3, and 4, a heat transfer member 7 called U-shaped aluminum made of aluminum foil is disposed, and the hot water pipe 3 is disposed in the groove 4 via the heat transfer member 7. The thickness of the aluminum foil constituting the heat transfer member 7 is preferably 40 μm or more, particularly 60 μm or more, and also 100 μm or less, particularly 80 μm or less.

[0039] The heat transfer member 7 has a U-shaped portion 7u and a flange portion 7f that projects in a direction away from the upper end of the U-shaped portion 7u. The flange portion 7f overlaps the upper surface of the substrate 2 and is in contact with the lower surface of the heat dissipation sheet 5.

[0040] The width w of the flange portion 7f (the width in the direction orthogonal to the longitudinal direction of the groove 4) is preferably 60% or more, particularly 70% or more, and 120% or less, particularly 90% or less of the width of the groove 4.

[0041] In the groove 4, in the portions (curved portions) that are substantially U-shaped and curved at both ends in the longitudinal direction of the substrate 2, as shown in FIG. 5, the hot water pipe 3 is disposed in the groove 4 via the heat transfer sheet member 10 made of aluminum foil. The thickness of the aluminum foil constituting the heat transfer sheet member 10 is preferably 40 μm or more, particularly 60 μm or more, and 100 μm or less, particularly 80 μm or less.

[0042] This heat transfer sheet member 10 has a horizontal portion 11 that overlaps the upper surface of the substrate 2 and a vertical piece portion 12 that hangs downward from one side edge of the horizontal portion 11. The vertical piece portion 12 has a length that contacts the outer peripheral surface of the hot water pipe 3 in the groove 4.

[0043] This heat transfer member 10 is configured as shown in FIG. 5 by attaching aluminum foil to the end areas on both ends in the long side direction of the substrate 2 (the area between the end of the long heat transfer member 7 in FIG. 1 and the short side of the substrate 2), then forming a slit along the center in the width direction of the groove 4, and then pushing the hot water pipe 3 into the groove 4. By pushing the hot water pipe into the groove 4, the aluminum foil is bent downward along the corner edge of the groove 4, and the vertical piece portion 12 is formed.

[0044] In the floor heating mat 1 configured as described above, although the width (pitch b) of the omitted joist arrangement portion A is larger than the pitch a, the pipe arrangement pitch a of the hot water pipe is 40 to 65 mm, and 6 pipes are arranged within a range of 303 mm. There may be some variation within the range of 40 to 65 mm. The width b of the omitted joist arrangement portion is between 70 and 85 mm, the width w of the flange portion 7f is 60 to 120% of the width of the groove 4, and the heat transfer member 7 is provided (particularly in this embodiment, the heat transfer member 7 and the heat transfer sheet member 10 are provided). In addition, a thick heat dissipation sheet 5 is provided. Therefore, the temperature unevenness on the upper surface of the floor heating mat 1 is reduced, the output increases, and the energy saving performance is improved. Although the heat dissipation performance improves as the thickness of the heat dissipation sheet 5 increases, the effect gradually saturates. Therefore, if it exceeds 130 μm, only the manufacturing cost increases.

[0045] In addition, by increasing the thickness of the heat dissipation sheet 5, damage to the hot water pipe 3 during the production or construction of the floor heating mat is prevented.

[0046] In the present invention, when the floor heating mat is laid on a floor base configured by arranging a 12-mm-thick plywood on a 40-mm-thick heat insulating material (expanded polystyrene, thermal conductivity 0.040 W / (m·K)), and a 13.5-mm-thick soundproof floor is provided to cover the floor heating mat to form a floor heating system, when operating under the conditions of a flowing water temperature of 60°C at a room temperature of 20°C and a flow rate of 0.5 L / min flowing through each pipe, the floor surface temperature unevenness (high temperature part - low temperature part) photographed from a height of 120 cm with an infrared thermography camera (model: InfReC R450S, manufactured by Nippon Avionics Co., Ltd.) in a 30-cm square area centered on the omitted joist arrangement portion can be within 4°C.

Example

[0047] [Example 1] The base material 2 of the floor heating mat 1 shown in Fig. 1 was made of polystyrene foam with a thickness of 12 mm (foaming ratio: 20 times). The dimension of the long side of the floor heating mat 1 was 1818 mm, and the dimension of the short side was 864 mm. The diameter (inner diameter) of the hot water pipe 3 was 6 mm (6A). The pipe arrangement pitch a of the hot water pipe 3 was 44.8 mm, the width b of the omitted part of the narrow strip arrangement was 79 mm, and 6 pipes were arranged within a range of 303 mm. The thickness of the heat equalizing sheet 5 was 100 μm.

[0048] [Comparative Example 1] It was the same as Example 1 except that the thickness of the heat equalizing sheet 5 was 40 μm.

[0049] [Comparative Example 2] It was the same as Example 1 except that the diameter (inner diameter) of the hot water pipe 3 was 5 mm (5A), the pipe arrangement pitch a of the hot water pipe 3 was 68 mm, the width b of the omitted part of the narrow strip arrangement was 100 mm, and 4 pipes were arranged within a range of 303 mm, and the thickness of the heat equalizing sheet 5 was 40 μm.

[0050] [Comparative Example 3] It was the same as Example 2 except that the thickness of the heat equalizing sheet 5 was 100 μm.

[0051] [Comparative Example 4] It was the same as Example 1 except that the diameter (inner diameter) of the hot water pipe 3 was 6 mm (6A), the pipe arrangement pitch a of the hot water pipe 3 and the width b of the omitted part of the narrow strip arrangement were 48 mm, and 6 pipes were arranged within a range of 303 mm, and the thickness of the heat equalizing sheet 5 was 40 μm.

[0052] [Comparative Example 5] It is the same as Example 4 except that the thickness of the heat equalizing sheet 5 was 100 μm.

[0053] [Comparative Example 6] It is the same as Example 1 except that the diameter (inner diameter) of the hot water pipe 3 was 5 mm (5A), the pipe arrangement pitch a of the hot water pipe 3 and the width b of the omitted part of the narrow strip arrangement were 75.8 mm, and 4 pipes were arranged within a range of 303 mm, and the thickness of the heat equalizing sheet 5 was 40 μm.

[0054] [Comparative Example 7] This is the same as Example 6 except that the thickness of the soaking sheet 5 was 100 μm.

[0055] Table 1 shows the ratio b / a of the width b of the omitted joist arrangement part and the arrangement pitch a of the hot water pipes other than the omitted joist arrangement part, the value t / a obtained by dividing the thickness t (μm) of the soaking sheet by the pitch a (mm), the floor surface temperature unevenness (the measurement method is as follows), and the judgment result of the soaking property for Examples and Comparative Examples 1 to 7.

[0056] [Measurement Method of Floor Surface Temperature Unevenness] A floor base was constructed by arranging a 12 mm thick plywood on a 40 mm thick heat insulating material (expanded polystyrene, thermal conductivity 0.040 W / (m·K)). The floor heating mats of Example 1 and Comparative Examples 1 to 7 were laid on this floor base, and a 13.5 mm thick soundproof floor was provided so as to cover the floor heating mat to constitute a floor heating system.

[0057] When operating under the conditions of a hot water temperature of 60 °C and a flow rate of 0.5 L / min flowing through each pipe at a room temperature of 20 °C, the floor surface temperature unevenness (high temperature part - low temperature part) photographed from a height of 120 cm with an infrared thermographic camera (manufactured by Nippon Avionics Co., Ltd., model: InfReC R450S) in a 30 cm square area centered on the omitted joist arrangement part was measured. And those with a floor surface temperature unevenness within 4 °C were determined to have good soaking property. ○ in Table 1 indicates good soaking property, and × indicates poor soaking property.

[0058] [Table 1]

[0059] As shown in Table 1, Example 1 has less floor surface temperature unevenness and better soaking property than Comparative Examples 1 to 3. In addition, since the substrate of the floor heating mat with joists is also used and the joist part is replaced with the substrate for manufacturing, there is no investment cost for a dedicated mold.

[0060] Comparative Examples 4 to 7 have little unevenness in the floor surface temperature and good heat uniformity, but require a dedicated mold with a conventional uniform array pitch, resulting in high investment costs.

Explanation of Signs

[0061] 1 Floor heating mat 2 Substrate 3 Hot water pipe 4 Groove 5 Heat dissipation sheet 7 Heat transfer member 8, 9 Header 10 Heat transfer member A Omitted part of the small root arrangement

Claims

1. A substrate having a groove for accommodating pipes on its upper surface, a hot water pipe accommodated in the groove, and a heat dissipation sheet provided so as to cover the upper surface of the substrate and the upper side of the hot water pipe In a floor heating mat having, There is provided a joist arrangement omission portion where no joist is arranged, The hot water pipes are arranged in parallel such that a part of the arrangement pitch is different, The arrangement pitch a of the hot water pipes other than the joist arrangement omission portion is in the range of 40 to 65 mm, and 6 pipes are arranged within 303 mm. Even if there is some variation within 40 to 65 mm, it is acceptable, The width b of the joist arrangement omission portion is between 70 and 85 mm, The thickness t of the heat dissipation sheet is 70 to 130 μm, A heat transfer member is provided in the groove, The heat transfer member has a portion arranged in the groove and a flange portion overlapping the upper surface of the substrate, and the width w of the flange portion is 60 to 120% of the width of the groove A floor heating mat characterized by the above.

2. The ratio b / a of the width b of the joist arrangement omission portion to the arrangement pitch a of the hot water pipes other than the joist arrangement omission portion is 1.1 or more, The floor heating mat according to Claim 1, characterized in that the value t / a obtained by dividing the thickness t (μm) of the heat dissipation sheet by the pitch a (mm) is 1.1 (μm / mm) or more.

3. When the floor heating mat is laid on a floor base configured by arranging a plywood with a thickness of 12 mm on a heat insulating material (foamed polystyrene, thermal conductivity 0.040 W / (m·K)) with a thickness of 40 mm, and a soundproof floor with a thickness of 13.5 mm is provided so as to cover the floor heating mat to form a floor heating system, when operating under the conditions of a passing water temperature of 60°C at a room temperature of 20°C and a flow rate of 0.5 L / min flowing through each pipe, the floor surface temperature unevenness (high temperature part - low temperature part) of a 30 cm square area centered on the joist arrangement omission portion photographed from a height of 120 cm with an infrared thermographic camera (model: InfReC R450S, manufactured by Nippon Avionics Co., Ltd.) is within 4°C. The floor heating mat according to Claim 1 or 2.

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