Permeation-resistant heating module suitable for underground environment and manufacturing method thereof

Abstract

The invention discloses a permeation-resistant heating module suitable for an underground environment and a manufacturing method of the permeation-resistant heating module, and relates to the field of underground heating, the heating module comprises an inner-layer structure and an outer-layer sealing packaging body, the inner-layer structure sequentially comprises an upper shielding layer, a module body and a lower shielding layer from top to bottom, and the sealing packaging body completely wraps and seals the inner-layer structure; the module body sequentially comprises a cement surface layer, a heating film and an extrusion molding heat preservation plate from top to bottom, all the layers of structures are fully coated and bonded through double-component polyurethane glue and then pressurized and cured to form a rigid functional body, and no internal gap exists between all the layers. The heating module prepared by the method has high integrity and excellent anti-seepage and moisture-proof performance, and can resist underground water seepage pressure, so that the structural reliability, thermal stability and electrical safety of the heating module during long-term operation in underground and other severe and humid environments are ensured.

Description

Technical Field

[0001] This invention relates to the field of underground heating, specifically to a permeability-resistant heating module suitable for underground environments and its manufacturing method. Background Technology

[0002] Currently, electric underfloor heating module technology applied in building heating can be mainly divided into the following two categories based on its structural characteristics and application scenarios: The first type is conventional indoor underfloor heating modules, whose typical structure usually includes, from top to bottom, a decorative surface layer, a cement mortar protective layer, a heating layer, a heat insulation layer, and a moisture-proof pad.

[0003] These modules are designed with heat dissipation efficiency and comfort in dry indoor environments in mind, with the materials of each layer primarily bonded together using conventional building adhesives or physical interlocking. However, their structural integrity, sealing, and moisture resistance are insufficient, resulting in significant drawbacks when applied to basements, underground garages, direct burial in soil, or other environments that may be subject to prolonged dampness or even moisture infiltration pressure. First, ambient moisture can easily penetrate along interlayer gaps or material capillaries, causing the heating layer to become damp and its insulation performance to decline, leading to electrical safety hazards or functional failure. Secondly, moisture penetration reduces the effectiveness of the adhesive, causing the structural layers to detach and become hollow, thus compromising the structural integrity and heat transfer efficiency of the module.

[0004] The second category comprises heating devices improved for humid environments. Some technical solutions attempt to enhance moisture resistance by adding a partial waterproof shell to the heating element or by separately installing waterproof membranes above and below the heating layer. However, these improvements are mostly localized waterproofing and fail to achieve a systematic seal for the entire heating module. Moisture can still penetrate from the module edges, seams, or areas not covered by the waterproof layer, and the bonding interfaces between multiple layers of materials remain weak points in humid environments, compromising long-term reliability. Furthermore, these modules often lack specific designs to address groundwater seepage pressure; under continuous osmotic pressure, the moisture-proof layer may be breached, leading to waterproofing failure.

[0005] In summary, existing underfloor heating modules generally suffer from incomplete moisture and water resistance, insufficient long-term reliability, and structural failure under seepage pressure when applied to complex underground or high-humidity environments, which restricts their safe and stable application in a wider range of scenarios. Summary of the Invention

[0006] In view of the above situation and to overcome the defects of the prior art, the present invention provides a permeability-resistant heating module suitable for underground environments and its manufacturing method, which at least partially solves the problems mentioned in the background art.

[0007] The technical solution adopted in this invention is as follows: In a first aspect, the present invention provides a permeability-resistant heating module suitable for underground environments, comprising: The inner structure includes an upper shielding layer, a module body and a lower shielding layer arranged from top to bottom. The module body includes a cement surface layer, a heating film and an extruded insulation board from top to bottom. The layers of the module body are bonded together with a two-component polyurethane adhesive and then pressure-cured to form a rigid functional body with no internal gaps between the layers. The outer sealing package encapsulates and seals the inner structure.

[0008] In a further embodiment, the sealed encapsulation body is made of high-density polyethylene geomembrane by hot-melt welding, and its shape matches the inner layer structure.

[0009] In a further embodiment, a waterproof threading seal is provided at the location where the power cord of the heating film passes through the sealed package, and the waterproof threading seal achieves a waterproof seal between the power cord and the sealed package by locking.

[0010] In a further embodiment, both the upper and lower shielding layers are 0.1mm thick aluminum foils, which are respectively attached to the upper and lower surfaces of the module body to form a symmetrical shielding and protection structure.

[0011] In one embodiment, the sealing enclosure is a composite geomembrane, which includes an inner HDPE membrane and an outer nonwoven geotextile.

[0012] In a further embodiment, a sensor is integrated within the cement surface layer. The sensor is a temperature and humidity sensor, a leakage monitoring electrode, or a stress optical fiber. The sensor cable and the power cable are led out together from the waterproof wiring seal.

[0013] Secondly, the present invention provides a method for manufacturing a permeability-resistant heating module suitable for underground environments, comprising the following steps: S1 module body molding: Two-component polyurethane adhesive is selected as the adhesive. First, the two-component polyurethane adhesive is fully applied to the surface of the extruded insulation board. After the heating film is pasted, the adhesive is applied again to the surface of the heating film for fixation. Then, the cement surface layer is bonded and the whole is pressure-cured to form a rigid functional body without internal gaps between the layers. S2 shielding layer bonding: 0.1mm thick aluminum foil is tightly bonded to the upper and lower surfaces of the rigid functional body to form an upper shielding layer and a lower shielding layer, which constitute the inner layer structure; S3 Sealing Encapsulation: A high-density polyethylene (HDPE) geomembrane is used to make a sealing encapsulation body. The shape of the sealing encapsulation body matches the inner layer structure. After the inner layer structure is placed in, the edges and seams of the geomembrane are tightly heat-fused to form a completely sealed package. S4 Power Cord Waterproof Sealing: The heating film power cord led out from the side of the extruded insulation board passes through the waterproof threading seal sleeve pre-set in the sealed enclosure, and the power cord and the sealed enclosure are waterproofed and sealed by locking, ensuring the overall waterproof integrity.

[0014] In a further implementation, before bonding the cement surface layer in step S1, a sensor mounting groove is pre-set in the cement surface layer, and the temperature and humidity sensor, leakage monitoring electrode or stress optical fiber is embedded in the mounting groove. The sensor cable is led out along the side of the extruded insulation board and the power line at the same time. In step S4, the sensor cable passes through the waterproof cable sealing sleeve together with the power line.

[0015] In one implementation, the high-density polyethylene (HDPE) geomembrane in step S3 can be replaced with a composite geomembrane, which includes an inner HDPE membrane and an outer non-woven geotextile. During sealing, the inner structure is directly placed into the encapsulation body made of the composite geomembrane, and the edges and seams of the composite geomembrane are hot-melt welded.

[0016] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: The heating module prepared by this method achieves complete sealing by using a geomembrane to encapsulate the entire structure, consisting of a cement surface layer, a heating membrane, and an extruded polystyrene insulation board. The geomembrane itself has extremely high impermeability and corrosion resistance, which can fundamentally isolate the intrusion of external liquid water and moisture, solving the drawbacks of traditional modules that rely on multiple layers of materials for waterproofing but are prone to leakage at joints and edges. The cement surface layer, heating film, and extruded polystyrene insulation board inside the heating module prepared by this method are bonded together using a two-component polyurethane adhesive. This two-component polyurethane adhesive possesses excellent water resistance, aging resistance, high bonding strength, and good compatibility with each layer of materials. Even inside the geomembrane encapsulation, each functional layer can remain permanently and firmly bonded in a humid environment, preventing failure due to interlayer delamination. This combination of internal reinforcement and external sealing makes the module a truly integrated structural unit with extremely strong resistance to mechanical stress and hydrolytic aging. The geomembrane sealing layer not only prevents seepage, but its flexible and high-strength properties also enable it to effectively resist hydrostatic and seepage pressures in the underground environment, preventing moisture from breaking through the moisture barrier under pressure. At the same time, the robust internal cement surface layer and extruded polystyrene board structure provide rigid support for the sealing, preventing the geomembrane from undergoing excessive deformation under backfill soil pressure or groundwater pressure, together forming a stable pressure-resistant sealing system. The heating module prepared by this method can be directly applied to areas where traditional underfloor heating modules cannot work reliably, such as: frost heave heating under building foundations, basement floor heating, tunnel snow melting, slope frost protection, and insulation of various facilities that need to be directly buried in the soil. Its complete sealing fundamentally eliminates the risk of leakage caused by moisture, significantly improving electrical safety while ensuring long-term stability of heating efficiency. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the permeability-resistant heating module suitable for underground environments proposed in an embodiment of the present invention; Figure 2 This is a schematic diagram of the cross-sectional structure of the permeability-resistant heating module suitable for underground environments proposed in an embodiment of the present invention; Figure 3 This is a flowchart illustrating the manufacturing method of a permeability-resistant heating module suitable for underground environments, as proposed in an embodiment of the present invention.

[0018] Among them, 1. Inner structure, 11. Upper shielding layer, 12. Module body, 13. Lower shielding layer, 121. Cement surface layer, 122. Heating film, 123. Extruded insulation board, 124. Sensor; 2. Sealed encapsulation body; 21. Waterproof threaded sealing sleeve.

[0019] The accompanying drawings are provided to further understand the embodiments and form part of the specification. They are used together with the embodiments for explanation and do not constitute a limitation on the embodiments. Detailed Implementation

[0020] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection.

[0021] In the description of the embodiments, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the embodiments and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments.

[0022] Existing underfloor heating modules generally suffer from incomplete moisture and water resistance, insufficient long-term reliability, and structural failure under seepage pressure when applied to complex underground or high-humidity environments, which restricts their safe and stable application in a wider range of scenarios.

[0023] Recognizing the above problems, this application proposes and discloses a heating module with high integrity, excellent seepage and moisture-proof performance, and resistance to groundwater seepage pressure, ensuring its structural reliability, thermal stability and electrical safety during long-term operation in harsh and humid environments such as underground.

[0024] like Figure 1 and Figure 2 As shown, in a first aspect, the present disclosure provides a permeability-resistant heating module suitable for underground environments, including an inner layer structure 1 and an outer sealed encapsulation body 2. The inner layer structure 1 consists of an upper shielding layer 11, a module body 12, and a lower shielding layer 13 from top to bottom. The sealed encapsulation body 2 completely wraps and seals the inner layer structure 1. The module body 12 consists of a cement surface layer 121, a heating film 122, and an extruded insulation board 123 from top to bottom. The layers are bonded together with a two-component polyurethane adhesive and then pressure-cured to form a rigid functional body with no internal gaps between the layers.

[0025] In this embodiment, during the bonding process of the heating module body 12, adhesive is first applied to the upper surface of the extruded insulation board 123, the heating film 122 is then pasted and fixed with adhesive, and finally the cement surface layer 121 is bonded. Through pressure curing, the layers are firmly bonded into a single structure without internal gaps, ensuring the structural strength and heat transfer efficiency of the module itself.

[0026] Meanwhile, by using a two-component polyurethane adhesive, the durability of the interlayer bonding strength is ensured in a long-term humid microenvironment.

[0027] In this embodiment, the sealed encapsulation body 2 is made of high-density polyethylene geomembrane by hot-melt welding, and its shape matches the inner layer structure 1.

[0028] After the rigid functional body is inserted, the edges and seams of the geomembrane are tightly heat-fused to form a completely sealed enclosure. The geomembrane enclosure not only prevents seepage, but its flexibility allows it to fit well with the backfill soil, adapting to minor uneven settlement, while its high tensile strength effectively resists external pressure, thus protecting the internal structure.

[0029] like Figure 1 and Figure 2 As shown, a waterproof threading sealing sleeve 21 is provided at the position where the power cord of the heating film 122 passes through the sealed encapsulation body 2.

[0030] In this embodiment, the power cord leading out from the side of the extruded insulation board 123 of the heating module is locked and sealed when it passes through the waterproof threading sealing sleeve 21 of the sealed encapsulation body 2, forming a waterproof sealing structure to ensure the integrity of the overall anti-seepage.

[0031] In this embodiment, the upper shielding layer 11 and the lower shielding layer 13 are both 0.1mm thick aluminum foils, which are respectively attached to the upper and lower surfaces of the module body 12 to form a symmetrical shielding and protection structure.

[0032] In other embodiments, the sealed enclosure 2 also employs a composite geomembrane, which comprises an inner HDPE membrane and an outer nonwoven geotextile.

[0033] The outer non-woven geotextile can provide physical protection for the inner HDPE membrane, preventing damage to the membrane during backfilling. On the other hand, it can enhance the friction coefficient between the sealed enclosure 2 and the backfill sand, further improving the structural stability of the module in the underground environment.

[0034] like Figure 2 As shown, a sensor 124 is integrated within the cement surface layer 121. The sensor 124 is a temperature and humidity sensor 124, a leakage monitoring electrode, or a stress optical fiber. The sensor 124 cable and the power cable are led out together from the waterproof wiring sealing sleeve 21.

[0035] In this embodiment, the sensor 124 cable and the power cord are led out from the sealed cable sleeve and connected to the monitoring system, realizing real-time online monitoring and early warning of the module's internal dryness, temperature field, and whether the working environment is experiencing abnormal seepage. It upgrades from passive durability to active sensing, and is suitable for infrastructure projects with extremely high safety requirements, such as nuclear power plants and data centers.

[0036] Secondly, see Figure 3 This embodiment provides a method for manufacturing a permeability-resistant heating module suitable for underground environments, the method comprising: S1 module body molding: Two-component polyurethane adhesive is selected as the adhesive. First, the two-component polyurethane adhesive is fully coated on the upper surface of the extruded insulation board 123. After the heating film 122 is pasted, the adhesive is applied again on the upper surface of the heating film 122 for fixation. Then, the cement surface layer 121 is bonded and the whole is pressure-cured to form a rigid functional body without internal gaps between the layers. S2 Shielding layer bonding: 0.1mm thick aluminum foil is tightly bonded to the upper and lower surfaces of the rigid functional body to form an upper shielding layer 11 and a lower shielding layer 13, constituting the inner layer structure 1; S3 Sealing Encapsulation: A high-density polyethylene (HDPE) geomembrane is used to make a sealing encapsulation body 2. The shape of the sealing encapsulation body 2 matches the inner layer structure 1. After the inner layer structure 1 is placed in, the edges and seams of the geomembrane are tightly heat-fused to form a completely sealed package. S4 Power Cord Waterproof Sealing: The power cord of the heating film 122, which is led out from the side of the extruded insulation board 123, passes through the waterproof threading sealing sleeve 21 preset in the sealed encapsulation body 2, and achieves a waterproof seal between the power cord and the sealed encapsulation body 2 by locking, ensuring the overall waterproof integrity.

[0037] Before bonding the cement surface layer 121 in step S1, a sensor 124 mounting groove is preset in the cement surface layer 121. The temperature and humidity sensor, leakage monitoring electrode or stress optical fiber is embedded in the mounting groove. The sensor 124 cable is led out along the side of the extruded insulation board 123 and the power line at the same time. In step S4, it passes through the waterproof wiring sealing sleeve 21 together with the power line.

[0038] In another embodiment, the high-density polyethylene (HDPE) geomembrane in step S3 is replaced with a composite geomembrane, which includes an inner HDPE membrane and an outer non-woven geotextile. During sealing, the inner structure 1 is directly placed into the encapsulation body 2 made of the composite geomembrane, and the edges and seams of the composite geomembrane are hot-melt welded.

[0039] The method for manufacturing a permeable heating module suitable for underground environments proposed in this invention can produce heating modules as described in the above embodiments, achieving the same effect, and will not be repeated here.

[0040] It should be noted that, in this document, relational terms such as “first” and “second” are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.

[0041] Although embodiments have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit.

[0042] The embodiments have been described above, and such description is not restrictive. The figures shown are only one embodiment, and the actual structure is not limited to this. In short, if a person skilled in the art is inspired by this description and designs a similar structure and embodiment without departing from the inventive spirit, such design should fall within the scope of protection.

Claims

1. A heat generating module resistant to penetration suitable for use in an underground environment, characterized in that, include: The inner structure (1) includes an upper shielding layer (11), a module body (12) and a lower shielding layer (13) arranged from top to bottom. The module body (12) includes a cement surface layer (121), a heating film (122) and an extruded insulation board (123) from top to bottom. The layers of the module body (12) are bonded together by a two-component polyurethane adhesive and then pressure-cured to form a rigid functional body with no internal gaps between the layers. The outer sealing package (2) encloses and seals the inner structure (1).

2. The permeation resistant, heat generating module for use in a subterranean environment of claim 1, wherein, The sealed encapsulation body (2) is made of high-density polyethylene geomembrane by hot-melt welding, and its shape matches the inner structure (1).

3. The permeation resistant, heat generating module for use in a subterranean environment of claim 1, wherein, The power cord of the heating film (122) is provided with a waterproof threading seal sleeve (21) at the position where it passes through the sealed package (2). The waterproof threading seal sleeve (21) achieves waterproof sealing between the power cord and the sealed package (2) by locking.

4. The permeation resistant, heat generating module for use in a subterranean environment of claim 1, wherein, The upper shielding layer (11) and the lower shielding layer (13) are both 0.1mm thick aluminum foils, which are respectively attached to the upper and lower surfaces of the module body (12) to form a symmetrical shielding and protection structure.

5. The permeation resistant, heat generating module for use in a subterranean environment of claim 1, wherein, The sealed encapsulation body (2) is a composite geomembrane, which includes an inner HDPE membrane and an outer non-woven geotextile.

6. The permeation resistant, heat generating module for use in a subterranean environment of claim 3, wherein, The cement surface layer (121) integrates a sensor (124), which is a temperature and humidity sensor, a leakage monitoring electrode or a stress optical fiber. The sensor (124) cable and the power cord are led out from the waterproof threaded sealing sleeve (21).

7. A method of manufacturing a heat generating module for use in a subterranean environment resistant to permeation as claimed in claim 1, characterized in that, Includes the following steps: S1 module body molding: Two-component polyurethane adhesive is selected as the adhesive. First, the two-component polyurethane adhesive is fully coated on the upper surface of the extruded insulation board (123). After the heating film (122) is pasted, the adhesive is applied again on the upper surface of the heating film (122) for fixation. Then, the cement surface layer (121) is bonded and the whole is pressure-cured to form a rigid functional body with no internal gaps between the layers. S2 shielding layer bonding: 0.1mm thick aluminum foil is tightly bonded to the upper and lower surfaces of the rigid functional body to form an upper shielding layer (11) and a lower shielding layer (13), which constitute the inner layer structure (1). S3 Sealing Encapsulation: A sealing encapsulation body (2) is made of high-density polyethylene (HDPE) geomembrane. The shape of the sealing encapsulation body (2) matches the inner layer structure (1). After the inner layer structure (1) is placed in, the edges and seams of the geomembrane are tightly heat-fused to form a completely sealed package. S4 Power Cord Waterproof Sealing: The power cord of the heating film (122) drawn from the side of the extruded insulation board (123) passes through the waterproof threading sealing sleeve (21) preset in the sealed encapsulation body (2), and the power cord and the sealed encapsulation body (2) are sealed in a locking manner to ensure the overall waterproof integrity.

8. The manufacturing method according to claim 7, wherein Before bonding the cement surface layer (121) in step S1, a sensor (124) mounting groove is preset in the cement surface layer (121). The temperature and humidity sensor, leakage monitoring electrode or stress fiber is embedded in the mounting groove. The sensor (124) cable is led out synchronously with the power line along the side of the extruded insulation board (123). In step S4, it passes through the waterproof wiring sealing sleeve (21) together with the power line.

9. The production method according to claim 7, wherein The high-density polyethylene (HDPE) geomembrane mentioned in step S3 can be replaced with a composite geomembrane, which includes an inner HDPE membrane and an outer non-woven geotextile. During sealing, the inner structure is directly placed into the encapsulation body made of the composite geomembrane, and the edges and joints of the composite geomembrane are hot-melt welded.

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