Kitchen overhead floor heating module capable of being opened for maintenance and dry type construction method thereof

Abstract

The invention discloses a kitchen overhead floor heating module capable of being opened for maintenance and a dry construction method thereof, and belongs to the technical field of fabricated building floors. According to the module, an 18-mm calcium silicate board serves as a panel, U-shaped and rectangular metal supporting pieces and threaded sleeves are integrated on the bottom face of the module, the module is directly supported on a structural floor through M10 adjustable foundation bolts, an extruded polystyrene board heat preservation layer, a floor heating pipe and an 8-mm calcium silicate balance board are sequentially laid on the module, and an overall raised floor system with the thickness of 46 mm is formed. During construction, cement mortar and concrete filling is not needed, paving is completed only through seven steps of base layer cleaning, heat preservation plate paving, floor heating pipe fixing, bolt installing, module leveling, balance plate bonding and polystyrene foam injecting, wet-free operation is achieved, the construction period is shortened by 70%, temperature rising is fast, and energy consumption is low; and the balance plate can be undamaged to overhaul or replace the floor heating pipe in the later period, and no garbage is maintained. The system is suitable for small wet areas such as kitchens and toilets, and meets the requirements of industrialization, greenization and maintainability.

Description

Technical Field

[0001] This invention relates to the field of prefabricated building floor engineering technology, specifically to an openable and maintainable overhead underfloor heating module for wet areas of kitchens and its dry construction method with no wet work involved. Background Technology

[0002] The current residential kitchen flooring generally uses the traditional wet construction process of "cement mortar leveling, laying water and electricity pipes, concrete filling layer, and floor finishing layer". This process has the following inherent defects: 1) Long construction period: Each floor requires curing, which significantly extends the overall construction period; 2) Many common quality problems: Material shrinkage and improper construction can easily cause hollow spots and cracks in the floor, and long-term dampness in the kitchen can easily lead to leakage; 3) Difficult pipeline maintenance: Water, electricity and underfloor heating pipelines are completely buried in concrete. Later inspection or renovation must be carried out by destructively removing the ground, which results in high maintenance costs and a great disturbance to residents. 4) High resource consumption: On-site mixing of cement mortar requires a large amount of water and generates a large amount of construction waste, which does not meet the requirements of green building.

[0003] Therefore, there is an urgent need for a new type of kitchen floor heating technology that can be industrially produced, dry-assembled on-site, can be opened and repaired without damage in the later stages, and has excellent thermal performance. Summary of the Invention

[0004] This invention aims to provide an openable and maintainable kitchen underfloor heating module and its dry construction method. By using factory-prefabricated underfloor heating modules in conjunction with adjustable anchor bolts, a dry-work-free underfloor layer is established on the structural floor slab. The underfloor heating pipes are laid openly on top of the extruded polystyrene insulation layer, and a balance board and finishing are directly laid on top. This achieves the goals of rapid installation of kitchen floors, non-destructive opening in the later stage, excellent thermal performance, and green environmental protection.

[0005] To achieve the above objectives, the present invention is implemented as follows: A dry construction method for an openable and maintainable kitchen underfloor heating module includes: forming a dry-work-free elevated layer on the structural floor slab using adjustable anchor bolts; laying the underfloor heating pipes above the extruded polystyrene insulation layer; using the interlocking metal supports on the bottom of the factory-prefabricated elevated module to achieve self-positioning and overall leveling; and laying a balance plate on the upper surface of the module to form a non-destructive opening surface base, thereby taking into account rapid installation, pipeline maintenance, controllable thickness, and thermal performance.

[0006] Furthermore, the aforementioned dry construction method for the kitchen overhead underfloor heating module that can be opened for maintenance specifically includes the following steps: cleaning the base layer, laying 30 mm extruded polystyrene board, fixing the underfloor heating pipes with clips, installing M10 adjustable anchor bolts through the insulation layer, placing and leveling the prefabricated overhead module, laying 8 mm calcium silicate balance board, and injecting expanding foam at the base of the wall.

[0007] Furthermore, a 30 mm gap is left between the extruded polystyrene board insulation layer and the exterior wall, and a gap of more than 20 mm is left between it and the interior partition wall. The underfloor heating pipes are fixed at a spacing of 45 mm, with the first pipe 400 mm from the center of the main pipe of the manifold. The spacing between anchor bolts is no more than 300 mm, and the bolt length is selected according to the height of the finished surface, using specifications of 50 mm, 70 mm, 100 mm or 120 mm.

[0008] Furthermore, the overhead module uses 18 mm thick calcium silicate board with a planar size of 600 mm × 600 mm or 600 mm × 1200 mm, and U-shaped and rectangular metal support plates are alternately set on the bottom surface. After the adjacent modules are plugged in, they form a horizontal constraint. After leveling, the surface flatness is no more than 2 mm, and the joint width deviation is ±0.5 mm.

[0009] Furthermore, the balance plate and the module are bonded together to form an integral composite section by applying structural adhesive in spots. Polyurethane single-component foam is injected into the gaps at the base of the wall to half to two-thirds of the gap depth to form an elastic sealing sound insulation strip, so as to eliminate rigid collisions caused by thermal expansion and contraction and reduce impact noise.

[0010] Furthermore, the present invention provides an openable and servicable kitchen underfloor heating module, comprising an 18 mm thick calcium silicate board panel, U-shaped and rectangular metal supports integrated on the bottom surface, and threaded sleeves for connecting adjustable anchor bolts. The module is supported on the structural floor slab by bolts, the space below accommodates extruded polystyrene board and underfloor heating pipes, and a balance plate is bonded on top to form a floor system that can be opened without damage.

[0011] Furthermore, the standard planar dimensions of the above modules are 600 mm × 600 mm or 600 mm × 1200 mm, with a thickness of 18 mm. The metal support plates are arranged alternately along the four sides, so that adjacent modules can be self-positioned in the horizontal direction and bear the load together, meeting the requirements for rapid assembly and rigidity.

[0012] Furthermore, the adjustable anchor bolts adopt an M10 fully threaded galvanized structure, with lengths of 50 mm, 70 mm, 100 mm, or 120 mm selected according to the finished surface height. The bolt washers directly press against the extruded polystyrene board, eliminating the need for additional sleeves, simplifying the construction and ensuring accurate height of the raised floor.

[0013] Furthermore, the balance board is made of 8 mm thick calcium silicate board, which is bonded to the module to form a 26 mm double-layer cross section, improving the overall elastic modulus and preventing local indentation under concentrated loads of the furniture, while maintaining the openable function.

[0014] Furthermore, polyurethane foam is injected into the expansion joints at the base of the wall. After curing, it forms a continuous elastomer that can absorb the thermal expansion and contraction displacement of the module and block the transmission path of footsteps, achieving a triple effect of sealing, vibration reduction, and sound insulation.

[0015] Compared with existing wet-installation underfloor heating systems, this invention uses adjustable anchor bolts to form an elevated layer and lays the underfloor heating pipes on extruded polystyrene boards, eliminating the need for cement mortar leveling and concrete filling. No on-site curing is required, and the construction period is significantly shortened. At the same time, the interlocking metal supports on the bottom of the elevated modules ensure that the ground can achieve the required flatness under dry conditions, avoiding common problems such as hollowness and cracking. Later, only the balance plate needs to be lifted to inspect or replace the pipelines, and the maintenance process does not generate construction waste.

[0016] Due to the synergistic effect of the insulation layer, reflective layer and overhead air cushion, the system heats up faster and reduces operating energy consumption. The modules, bolts and balance plates are all prefabricated in the factory, and no secondary processing is required for on-site assembly, which significantly reduces the amount of cement and construction water, meets the requirements of green building, and is suitable for industrialized rapid paving of small wet areas such as kitchens and bathrooms. Attached Figure Description

[0017] Figure 1 This is a cross-sectional view of the kitchen overhead underfloor heating module that can be opened for inspection and maintenance, as described in this invention.

[0018] Figure 2 This is a flowchart of the construction method involved in the present invention. Detailed Implementation

[0019] The following combination Figure 1 , Figure 2 The embodiments of the present invention will be described in detail. Figure 1 This is a cross-sectional view of the system structure in this embodiment, showing the complete combination of structural floor slab, base waterproofing, 30 mm extruded polystyrene board as aluminum foil reflective layer, adjustable anchor bolts, 18 mm overhead module, 8 mm balance board and floor tile finish, and showing the expansion joints at the base of the wall and the location of the foam filling, which is used to explain the core structure of the present invention that allows for wet operation and can be opened for maintenance.

[0020] Example 1: Standard 600 mm × 600 mm modular system 1. Grassroots processing After cleaning the surface of structural floor slab 1, apply a layer of polymer cement waterproof coating with a thickness of about 1.2 mm to form a continuous moisture-proof layer and prevent kitchen water from seeping into the insulation layer.

[0021] 2. Insulation layer laying 30 mm thick XPS extruded polystyrene board 2 is directly laid on the waterproof layer. The board joints are staggered, leaving a 30 mm gap with the inner side of the exterior wall and a 20 mm gap with the interior partition wall. The gaps are filled with expanding foam later to form a buffer zone for thermal expansion and contraction.

[0022] 3. The reflective layer is fixed to the underfloor heating pipe. Cover the XPS surface with a 0.1 mm aluminum foil reflective film, and then lay Φ16 PE-RT underfloor heating pipes 3 according to the design direction with a pipe spacing of 45 mm. The first pipe is 400 mm away from the center of the main pipe of the manifold. Use plastic clips to directly fix the pipes to the XPS surface to form an integrated "pipe-plate" structure without the need for concrete filling.

[0023] 4. Adjustable anchor bolt installation M10×70 mm fully threaded galvanized bolts were selected as adjustable foot 4. They were positioned according to a 600 mm×600 mm grid. Holes were drilled in the XPS and floor slab with an electric hammer, and nylon expansion sleeves were embedded before the bolts were screwed in. The top of the bolts was about 25 mm above the XPS surface. Bolts were installed at all four corners of the same module, with the spacing controlled within 300 mm to ensure the accuracy of subsequent leveling.

[0024] 5. Placement and leveling of overhead modules The factory-prefabricated 600 mm × 600 mm × 18 mm calcium silicate overhead module 5 is placed on top of the bolt. Threaded sleeves are pre-embedded at the four corners of the module's bottom surface. After aligning with the bolt, hexagonal adjusting nuts are screwed in. Using a laser leveling instrument, the flatness of the module's upper surface is checked by rotating the nuts to ensure it is ≤2 mm. The U-shaped and rectangular support plates on the edges of adjacent modules interlock to achieve horizontal self-locking, preventing subsequent displacement due to stepping.

[0025] 6. Laying of balance boards Water-resistant structural adhesive is applied to the surface of the leveled module at 200 mm intervals. Then, an 8 mm thick calcium silicate balance board 6 is laid, with the board seam offset from the module seam by half to form a 26 mm double-layer composite cross section, which improves the overall rigidity and isolates the heat from the underfloor heating system from escaping upwards.

[0026] 7. Finishing installation and gap treatment Lay floor tiles 7 on the surface of the balance board using the conventional thin-set method, with a thickness of 8-10 mm. Leave a 20 mm expansion joint between the balance board and the wall. After the facing tiles are laid, inject polyurethane single-component foam into the joint to 2 / 3 of its depth. After the foam cures, it forms a continuous elastic band that can absorb the thermal expansion and contraction of the module and reduce footstep noise, thus achieving the triple functions of sealing, vibration reduction, and sound insulation.

[0027] Example 2: 600 mm × 1200 mm Modular System for Narrow Kitchens When the kitchen has a long and narrow layout, a 600 mm × 1200 mm × 18 mm long strip module is used. The bolt spacing is maintained at 300 mm along the long side and 600 mm along the short side. The bolt length is M10 × 100 mm. The rest of the structure is exactly the same as in Example 1. The long strip module can reduce the number of seams and improve the paving efficiency. At the same time, the metal support plates are densely arranged along the long side to ensure that the deflection in the middle of the slab is ≤1 mm, which meets the requirements for thin-laying of large slab floor tiles.

[0028] Example 3: Low Finish Height System When the kitchen and living room need to be delivered with "zero height difference", M10×50 mm short bolts are selected, the thickness of XPS is reduced from 30 mm to 20 mm, the thickness of the balance plate is reduced to 6 mm, and the overall structural height is compressed from 68 mm to 44 mm. Sufficient rigidity is still maintained through double-layer calcium silicate composite and interlocking of support plates. The residual deformation under a concentrated load of 1.5 kN is less than 0.2 mm, which meets the highest service level of residential buildings.

[0029] As can be seen from the above embodiments, based on the structure shown in the only accompanying drawing, the present invention can adapt to different finished surface heights and apartment layout requirements simply by changing the bolt length, module size, or insulation layer thickness. It can be repeatedly implemented without additional drawings, and all variations fall within the scope of protection of the claims.

[0030] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A dry construction method for an openable and maintainable kitchen overhead underfloor heating module, characterized in that: An adjustable anchor bolt is used to create a dry-work-free elevated layer on the structural floor slab. The underfloor heating pipes are laid openly on top of the extruded polystyrene board insulation layer. The metal supports on the bottom of the prefabricated elevated modules interlock to achieve self-positioning and overall leveling. A balance plate is laid on the upper surface of the module to form a non-destructive decorative base layer, thus taking into account rapid installation, pipeline maintenance, controllable thickness, and thermal performance.

2. The dry construction method for the operable and maintainable kitchen overhead underfloor heating module according to claim 1, characterized in that: Includes the following steps: Step 1: Clean the base layer of the structural floor slab; Step 2: Lay the extruded polystyrene board insulation layer on the base layer; Step 3: Fix the underfloor heating pipes to the upper surface of the extruded polystyrene board with clips to form an integrated pipe-board structure; Step 4: Install adjustable anchor bolts so that they penetrate the extruded polystyrene board and are anchored to the structural floor slab, with the top of the bolts protruding above the upper surface of the insulation layer; Step 5: Place the prefabricated overhead modules one by one on top of the anchor bolts, and level the whole by tightening the bolts and nuts; the overhead module is composed of an 18mm thick calcium silicate board and metal support plates integrated on its bottom surface. Adjacent modules are supported by interlocking U-shaped support plates and rectangular support plates on the edges. Step 6: Lay a balancing board on the upper surface of the leveled overhead module and bond it in place to form the finishing base layer; Step 7: Inject expanding foam into the expansion joints between the balance board and the surrounding walls to complete the sealing and sound insulation. Thus, the underfloor heating pipes are enclosed in the air gap between the structural floor slab and the balance plate, enabling dry construction, openable maintenance, and rapid heating.

3. The dry construction method for the openable and maintainable kitchen overhead underfloor heating module according to claim 1 or 2, characterized in that: The thickness of the extruded polystyrene board insulation layer is 30mm, with a 30mm gap between it and the exterior wall, and a gap of not less than 20mm between it and the interior partition wall; the fixed spacing of the underfloor heating pipes is 45mm, and the distance between the first underfloor heating pipe and the center line of the main pipe of the manifold is 400mm.

4. The method according to claim 1 or 2, characterized in that: The adjustable anchor bolts are M10 fully threaded galvanized bolts, with lengths of 50mm, 70mm, 100mm or 120mm, and the bolt spacing under the same module is no more than 300mm.

5. The dry construction method for the operable and maintainable kitchen overhead underfloor heating module according to claim 2, characterized in that: The standard planar dimensions of the overhead module are 600mm×600mm or 600mm×1200mm, with a thickness of 18mm. The metal support includes U-shaped support and rectangular support arranged alternately along the four sides of the module. The U-shaped opening is inserted into the rectangular support of the adjacent module to form a horizontal constraint.

6. The dry construction method for the operable and maintainable kitchen overhead underfloor heating module according to claim 1 or 2, characterized in that: The balance board is an 8mm thick calcium silicate board, which is bonded to the overhead module below by applying structural adhesive to form an integral composite board.

7. The dry construction method for the openable and maintainable kitchen overhead underfloor heating module according to claim 1 or 2, characterized in that: After leveling, the flatness of the entire overhead module surface is no more than 2mm, and the width deviation of the joint between adjacent module panels is no more than ±0.5mm.

8. The dry construction method for the openable and maintainable kitchen overhead underfloor heating module according to claim 1 or 2, characterized in that: The foam is a single-component polyurethane foam, injected to a depth of one-half to two-thirds of the gap depth, and forms an elastic seal after curing.

9. A kitchen overhead underfloor heating module that can be opened for inspection and maintenance, characterized in that, include: 18mm thick calcium silicate board is used as the panel; Metal support plates integrated into the bottom surface of the panel, the metal support plates include U-shaped support plates and rectangular support plates, and adjacent modules form horizontal support by interlocking the U-shaped support plates and rectangular support plates; A threaded sleeve located on the bottom surface of the panel is used to connect adjustable anchor bolts. Thus, the module is supported by the structural floor slab by anchor bolts, the extruded polystyrene insulation layer and the underfloor heating pipes are housed in the space below the module, and the balance board is laid and bonded to the upper surface of the module, forming a raised underfloor heating system that can be opened and maintained without damage.

10. The kitchen overhead underfloor heating module that can be opened for inspection and maintenance according to claim 9, characterized in that: The standard planar dimensions are 600mm×600mm or 600mm×1200mm, with a thickness of 18mm; metal support plates are arranged alternately along the four sides of the module, so that adjacent modules can be self-positioned in the horizontal direction and share the load.

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