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 having a groove 4 for piping housing disposed on the upper surface, a hot water pipe 3 housed in the groove 4, and a soaking sheet 5 disposed on the upper surface of the substrate 2. An auxiliary joist arrangement omitting part A in which an auxiliary joist is not arranged is disposed. Six pipings are arranged in a range of 303 mm with an array pitch of a linear part thereof of 40-65 mm, and may be partially uneven between 40-65 mm. A width b of the auxiliary joist arrangement omitting part is between 40-80 mm. A thickness of the soaking sheet 5 is 70-130 μm. A heat transfer member 7 is disposed in the linear part of the groove 4, and a heat transfer member 10 is disposed in the curve part. A thickness of the heat transfer member 10 is smaller than a thickness of the soaking sheet 5 and is 30-100 μm, b / a is 1.1 or more, and (t1+t2) / b is 1.6 (μm / mm) or more.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a floor heating mat for heating a 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, one in which a hot water pipe is arranged in a groove on the upper surface of a substrate made of foamed synthetic resin 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 via 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, one in which grooves are 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, a rib for forming a groove is provided.

[0011] A floor heating mat with joists is manufactured by combining a substrate, joists, a hot water pipe, and a 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] A 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 a substrate, a hot water pipe, and a heat dissipation sheet. When manufacturing the substrate of a floor heating mat without joists, there are cases where a mold with ribs provided at a uniform pitch is used, and cases where the substrate of a 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 becomes 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, and the mold cost becomes high.

[0014] In the latter case, since it is also used as a 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 capable of reducing temperature unevenness in a floor heating mat of a type in which there is no groove for arranging a hot water pipe in the 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. In the floor heating mat, an omitted part of the joist arrangement where the joist is not arranged is provided, the hot water pipe is not provided in the omitted part of the joist arrangement, and the arrangement pitch a of the linear part of the hot water pipe is 40 to 65 mm, and 6 hot water pipes are arranged within a range of 303 mm. Even if there is some variation within the range of 40 to 65 mm, the width b of the omitted part of the joist arrangement is between 70 and 85 mm, the thickness of the heat dissipation sheet is 70 to 130 μm, a heat transfer member is provided in the groove, and the heat transfer member has a part arranged in the groove and a part overlapping the upper surface of the substrate. The groove has a linear part extending linearly in parallel with one side of the substrate and a curved part extending in a curved shape so as to connect the ends of the linear parts, and the heat transfer member is provided in both the linear part and the curved part. The thickness of the heat transfer member is smaller than the thickness of the heat dissipation sheet and is 30 to 100 μm.

[0017] In one aspect of the present invention, the heat transfer member arranged in the curved part has a horizontal part overlapping the upper surface of the heat dissipation sheet and a vertical piece part hanging downward from the horizontal part and arranged in the groove.

[0018] 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 pipe outside the omitted part of the joist arrangement is 1.1 or more, and the value (t1 + t2) / a obtained by dividing the sum of the thickness t1 (μm) of the heat dissipation sheet and the thickness t2 (μm) of the heat transfer member by the pitch a (mm) is 1.6 (μm / mm) or more.

[0019] In one aspect of the present invention, 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 with a thickness of 40 mm (expanded polystyrene, thermal conductivity 0.040 W / (m·K)), 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 at a hot water passing 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 unevenness of the floor surface temperature (high temperature part - low temperature part) photographed from a height of 120 cm with an infrared thermography camera (manufactured by Nippon Avionics Co., Ltd., model: InfReC R450S) in a 20 cm square area centered on the omitted joist arrangement part is within 4 °C.

Effect of the Invention

[0020] In the floor heating mat of the present invention, heat transfer members are provided in both the straight and curved portions of the groove. The thickness of the heat transfer member 10 in the curved portion is smaller than the thickness of the heat dissipation sheet and is 30 to 100 μm. Further, the thickness of the heat dissipation sheet is as large as 70 to 130 μm.

[0021] In such a floor heating mat of the present invention, the temperature unevenness on the upper surface of the floor heating mat having an omitted joist arrangement portion is reduced, the output is increased, and thus the energy saving property is improved. In the present invention, since the mold for manufacturing the floor heating mat can be shared with the mold for manufacturing the 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

[0022]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiments for Carrying Out the Invention

[0023] 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.

[0024] 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 linear portion 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. Note that in Fig. 1, the heat equalizing sheet 5 and the heat transfer member 10 are not shown. This floor heating mat 1 does not have joists.

[0025] In the linear portion 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 disposed, and the hot water pipe 3 is disposed via the heat transfer member 7. In the curved portion of the groove 4, as shown in Figs. 5 and 6, the hot water pipe 3 is disposed via a heat transfer member 10 formed by weaving a pre-attached aluminum foil 10' inward along the groove 4. Details of the configurations of the heat transfer members 7 and 10 will be described later.

[0026] As the material of the substrate 2, foamed synthetic resins such as foamed polypropylene, foamed polyethylene, foamed polystyrene, and foamed polyurethane having a density of about 10 to 100 kg / m 3 can be used. When the substrate is made of foamed polystyrene (EPS), the foaming ratio is preferably 5 to 25 times, particularly 15 to 20 times.

[0027] 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.

[0028] 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.

[0029] 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 is also 12 mm or less, particularly 10 mm or less, especially 9 mm or less.

[0030] The hot water pipe 3 is preferably made of cross-linked polyethylene, polyethylene, polypropylene, polybutadiene, or the like.

[0031] 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 shape at the other end side, and extends from the other end side to the one end side. Some of the grooves 4 are further curved in a substantially U shape at the one end side and extend in a zigzag shape.

[0032] 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.

[0033] 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.

[0034] The distance b between the center lines between the sixth and seventh grooves 4 from the left in FIG. 1 and the distance b between the center lines between the twelfth and thirteenth 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.

[0035] The distance from the center line of the first 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 eighteenth (rightmost) 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.

[0036] The reason why the distance b between the sixth and seventh, and twelfth and thirteenth grooves 4, 4 from the left in FIG. 1 is large is that this substrate 2 is manufactured using a die for forming a substrate with joists, and the joists are omitted. If it is a substrate with joists, the locations where the joists are arranged are also composed of the substrate (foamed synthetic resin).

[0037] That is, between the sixth and seventh, and twelfth and thirteenth grooves 4, 4 from the left, these are the parts where the joists are arranged in a floor heating mat with joists. However, since this joist arrangement part is also composed of foamed synthetic resin, this part has become the joist arrangement omission part A. The width of this joist arrangement omission part A is 70 - 85 mm.

[0038] The soaking 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. The soaking 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 soaking sheet 5.

[0039] For the adhesion of the soaking sheet 5, adhesives such as acrylic, ethylene - vinyl acetate, polyamide, and polyester can be used. However, these are just examples, and the present invention is not limited to these.

[0040] Among the grooves 4, in the linear portions, 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.

[0041] 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.

[0042] 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, of the width of the groove 4, and 120% or less, particularly 90% or less.

[0043] Among the grooves 4, in the portions (curved portions) that are curved in a substantially U-shape on both ends in the longitudinal direction of the substrate 2, as shown in FIG. 5, a heat transfer member 10 is disposed.

[0044] This heat transfer 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.

[0045] This heat transfer member 10 is formed as shown in FIG. 6(a) by attaching an aluminum foil 10' to the end areas (the areas between the ends of the heat transfer member 7 and the short side of the substrate 2) on both ends in the long side direction of the substrate 2, then forming a slit 10a along the center in the width direction of the groove 4 as shown in FIG. 6(b), and then pushing the hot water pipe 3 into the groove 4, resulting in the configuration shown in FIG. 5. Note that by pushing the hot water pipe into the groove 4, the aluminum foil 10' is bent downward along the corner edge of the groove 4, and the vertical piece portion 12 is formed.

[0046] The thickness of the aluminum foil constituting the heat transfer member 10 is smaller than the thickness of the heat spread sheet 5, and is 30 μm or more, preferably 40 μm or more, particularly 60 μm or more, and is also 100 μm or less, particularly 80 μm or less. In this case, it is preferable that the value (t1 + t2) / b obtained by dividing the sum of the thickness t1 (μm) of the heat spread sheet 5 and the thickness t2 (μm) of the heat transfer member 10 (aluminum foil 10') by the pitch a (mm) is 1.6 (μm / mm) or more.

[0047] In the floor heating mat 1 configured as described above, there is an omitted small joist arrangement portion A, but the heat transfer member 7 is provided in the linear portion of the groove 4 and the heat transfer member 10 is provided in the curved portion, and a thick heat spread 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 property is improved. Although the heat spreading property improves as the thickness of the heat spread sheet 5 increases, the effect gradually saturates, so that if it exceeds 130 μm, only the manufacturing cost increases.

[0048] In addition, by increasing the thickness of the heat spread sheet 5, damage to the hot water pipe 3 during the production or construction of the floor heating mat is prevented.

[0049] In 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 (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 flowing 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 thermographic camera (model: InfReC R450S, manufactured by Nippon Avionics Co., Ltd.) in a 20 cm square area centered on the omitted small joist arrangement portion can be within 4 °C.

Example

[0050] [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 arrangement pitch a of the hot water pipe 3 was 44.8 mm, the width b of the omitted part of the small rib arrangement was 79 mm, and 6 pipes were arranged within a range of 303 mm. The thickness of the heat transfer member 10 in the curved part was 40 μm, and the thickness of the heat equalizing sheet 5 was 100 μm.

[0051] [Comparative Example 1] It was the same as Example 1 except that the heat transfer member 10 in the curved part was eliminated and the thickness of the heat equalizing sheet 5 was 40 μm.

[0052] [Comparative Example 2] The diameter (inner diameter) of the hot water pipe 3 was 5 mm (5A), the arrangement pitch a of the hot water pipe 3 was 68 mm, the width b of the omitted part of the small rib arrangement was 100 mm, and 4 pipes were arranged within a range of 303 mm. The thickness of the heat equalizing sheet 5 was 40 μm. (The dimensions of the hot water mat were the same as those in Example 1)

[0053] [Comparative Example 3] It was the same as Comparative Example 2 except that the thickness of the heat equalizing sheet 5 was 100 μm.

[0054] [Comparative Example 4] The diameter (inner diameter) of the hot water pipe 3 was 6 mm (6A), the arrangement pitch a of the hot water pipe 3 and the width b of the omitted part of the small rib arrangement were 48 mm, and 6 pipes were arranged within a range of 303 mm. The thickness of the heat equalizing sheet 5 was 40 μm. (The dimensions of the hot water mat were the same as those in Example 1)

[0055] [Comparative Example 5] It was the same as Comparative Example 4 except that the thickness of the heat equalizing sheet 5 was 100 μm.

[0056] [Comparative Example 6] The diameter (inner diameter) of the warm water pipe 3 was set to 5 mm (5A), four pipes were arranged within a range of 303 mm with the arrangement pitch a of the warm water pipe 3 and the width b of the omitted joist arrangement part being 75.8 mm, and the thickness of the soaking sheet 5 was set to 40 μm. (The dimensions of the warm water mat were the same as in Example 1)

[0057] [Comparative Example 7] It is the same as Comparative Example 6 except that the thickness of the soaking sheet 5 was set to 100 μm.

[0058] For Example 1 and Comparative Examples 1 to 7, the ratio b / a of the width b of the omitted joist arrangement part to the arrangement pitch a of the warm water pipe outside the omitted joist arrangement part, the value t1 / b obtained by dividing the thickness t1 (μm) of the soaking sheet by the pitch a (mm), the value (t1 + t2) / b obtained by dividing the sum of the thickness t1 (μm) of the soaking sheet 5 and the thickness t2 (μm) of the heat transfer member 10 by the pitch a (mm), and the floor surface temperature unevenness (measurement method is as follows) and the judgment results of the soaking property are shown in Table 1.

[0059] <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 to cover the floor heating mat to form a floor heating system.

[0060] 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 thermographic camera (manufactured by Nippon Avionics Co., Ltd., model: InfReC R450S) in a 20 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.

[0061]

Table 1

[0062] As shown in Table 1, in Example 1, the unevenness of the floor surface temperature is smaller and the heat uniformity is better than in Comparative Examples 1 to 3. In addition, since the substrate of the floor heating mat having joists is also used and the joist part is replaced with the substrate for manufacturing, there is no investment cost for a dedicated mold.

[0063] In addition, in Comparative Examples 4 to 7, the unevenness of the floor surface temperature is small and the heat uniformity is good, but a dedicated mold with an equal conventional arrangement pitch is required, resulting in a high investment cost.

Explanation of Reference Signs

[0064] 1 Floor heating mat 2 Substrate 3 Hot water pipe 4 Groove 5 Heat uniform sheet 7, 10 Heat transfer member 8, 9 Header A Omitted part of joist 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 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 joists are not arranged, The hot water pipe is not provided in the joist arrangement omission portion, Six hot water pipes are arranged within a range of 303 mm with an arrangement pitch a of the linear portion of the hot water pipe being 40 to 65 mm. There may be some variation as long as it is between 40 and 65 mm. The width b of the joist arrangement omission portion is between 70 and 85 mm, and the thickness of the heat dissipation sheet is 70 to 130 μm and A heat transfer member is provided in the groove. The heat transfer member has a portion arranged in the groove and a portion overlapping the upper surface of the substrate. The groove has a linear portion extending linearly parallel to one side of the substrate and a curved portion extending curvilinearly to connect the ends of the linear portion. The heat transfer member is provided in both the linear portion and the curved portion. The thickness of the heat transfer member is smaller than the thickness of the heat dissipation sheet and is 30 to 100 μm. A floor heating mat characterized in that the ratio b / a of the width b of the joist arrangement omission portion to the arrangement pitch a of the hot water pipe outside the joist arrangement omission portion is 1.1 or more.

2. The heat transfer member arranged in the curved portion has a horizontal portion overlapping the upper surface of the heat dissipation sheet and a vertical piece portion hanging downward from the horizontal portion and arranged in the groove. The value (t1 + t2) / b obtained by dividing the sum of the thickness t1 (μm) of the heat dissipation sheet and the thickness t2 (μm) of the heat transfer member by the pitch a (mm) is 1.6 (μm / mm) or more. The floor heating mat according to Claim 1.

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 with a thickness of 40 mm (expanded polystyrene, thermal conductivity 0.040 W / (m·K)), 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 hot water passing 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 20 cm square area centered on the omitted joist arrangement part is within 4 °C when photographed from a height of 120 cm with an infrared thermographic camera (manufactured by Nippon Avionics Co., Ltd., model: InfReC R450S). The floor heating mat according to claim 1 or 2.

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