Integrally-formed die-casting aluminum alloy graphene heating floor and manufacturing method thereof

Abstract

The invention discloses an integrally-formed die-casting aluminum alloy graphene heating floor and a manufacturing method thereof.The aluminum alloy graphene heating floor comprises an aluminum alloy plate, the aluminum alloy plate comprises a horizontal plate body and ribs integrally arranged on the back face of the horizontal plate body, and the ribs and the horizontal plate body jointly define a plurality of mounting cavities; and heat transfer glue, a graphene heating plate and heat insulation glue are sequentially arranged in each mounting cavity from inside to outside. According to the integrally-formed die-casting aluminum alloy graphene heating floor, the heat conduction efficiency of the floor structure can be improved, and the convenience of the mounting process is enhanced through a modular structure.

Description

Technical Field

[0001] This invention relates to the field of building floor radiant heating technology, specifically to an integrally molded die-cast aluminum alloy graphene heating floor. Background Technology

[0002] In the field of building heating technology, radiant floor heating systems are widely used, mainly including hydronic floor heating, electric heating cable floor heating, and graphene heating film floor heating. Existing radiant floor heating systems typically employ the following installation process: First, the base floor is leveled; then, extruded polystyrene foam boards are laid as an insulation layer, followed by a metal reflective film; heat transfer or heating units are installed on the reflective film; subsequently, fine aggregate concrete or mortar and other cement-based filling materials are poured on top of the overall structural layer to form a heat storage layer; after the filling layer has cured, floor finishing materials such as ceramic tiles or wooden flooring are laid on its surface.

[0003] While this type of structure provides a comfortable heating method, it has the following drawbacks in use: 1. Complex installation: Numerous procedures (leveling, multi-layer laying, pouring, finishing), resulting in a long construction period and high costs. 2. Slow heating: The large heat capacity of the infill layer delays the system response, typically requiring about 6 hours or more for a significant rise in room temperature. 3. Insufficient long-term reliability: Risks such as pipe corrosion and aging, insulation failure of the heating element, and connection point failures generally limit the actual service life of the system to less than 15 years. 4. Difficult maintenance: The heating unit is deeply buried under the infill and finishing layers, requiring large-scale destructive construction for fault location and repair. Summary of the Invention

[0004] In view of this, the present invention provides an integrally molded die-cast aluminum alloy graphene heating floor and its manufacturing method. Addressing the problems of low heat transfer efficiency and complex installation in existing floor radiant heating systems, this invention integrates graphene heating material with a die-cast aluminum alloy matrix, utilizing the high thermal conductivity of aluminum alloy and the efficient electrothermal conversion properties of graphene to improve heat transfer efficiency. Simultaneously, a modular quick-installation structure simplifies the complex construction procedures of traditional floor heating, enabling rapid floor assembly and enhancing installation convenience, thus effectively solving the shortcomings of existing technologies in terms of construction cycle and performance.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: An integrally molded die-cast aluminum alloy graphene heating floor includes an aluminum alloy plate. The aluminum alloy plate includes a horizontal plate body and ribs integrally disposed on the back of the horizontal plate body. The ribs and the horizontal plate body together form multiple mounting cavities. Each mounting cavity is provided with heat transfer adhesive, a graphene heating plate and heat insulation adhesive in sequence from the inside to the outside.

[0006] To better achieve the above technical solution, the rib further includes transverse ribs, longitudinal ribs and diagonal ribs. There are multiple transverse ribs and longitudinal ribs, which together form multiple rectangular structures. There are multiple diagonal ribs that are intersected with each other, and their two ends are respectively connected to the transverse ribs, longitudinal ribs or adjacent diagonal ribs.

[0007] Furthermore, the heat-insulating adhesive covers the outer contour line of the back of the rib.

[0008] Furthermore, the thickness of the horizontal plate is 1.3-3mm.

[0009] Furthermore, the thickness of the transverse ribs, longitudinal ribs, and diagonal ribs is consistent, and all are 16-20mm.

[0010] A method for manufacturing a one-piece die-cast aluminum alloy graphene heating floor includes the following steps: S10. Melt the heat-free aluminum alloy ingot and maintain it at 660±3℃; S20 liquid alloy is injected into a special mold cavity by a large vacuum die casting machine and then solidified and cooled. S30. Remove the formed blank and trim and straighten the edges; S40. Use blue light to inspect the blank to determine if there are cracks or other defects; S50. Perform laser trimming on the blank; S60. Spray coating is applied to the blank to obtain the final aluminum alloy sheet. S70. Apply heat transfer adhesive to the top surface of the mounting cavity, place the graphene heating plate inside the mounting cavity, and initially fix it with heat transfer adhesive. S80. Fill the remaining space in the mounting cavity with heat insulation adhesive until the heat insulation adhesive covers the outer contour line of the back of the rib. S90. Conduct overall quality inspection and packaging of the products.

[0011] The beneficial effects of this invention are: 1. The die-cast aluminum alloy plate in the one-piece die-cast aluminum alloy graphene heating floor is a large plate formed in one piece. Under the bonding of heat transfer adhesive and heat insulation adhesive, it forms an integral structure with the graphene heating plate. During on-site installation, only the heat insulation board and reflective film need to be laid, which shortens the installation cycle. 2. The die-cast aluminum alloy graphene heating floor has fast heat transfer, raising the room temperature in just about 10 minutes, compared to about 6 hours for traditional flooring, which is more than 30 times faster. 3. Installation can be completed in one go (traditionally it requires more than four times), which shortens the installation time.

[0012] 4. The graphene heating plate can be independently controlled to achieve localized digital control heating. It can also be remotely controlled via the Internet of Things to enable pre-activation and save energy. Attached Figure Description

[0013] Figure 1 This is a three-dimensional schematic diagram of an integrally molded die-cast aluminum alloy graphene heating floor according to an embodiment of the present invention; Figure 2 yes Figure 1 A sectional view; Figure 3 yes Figure 1 A three-dimensional example of a medium-sized aluminum alloy plate; Figure label: 10 aluminum alloy plate, 101 horizontal plate, 102 transverse ribs, 103 longitudinal ribs, 104 diagonal ribs, 20 heat transfer adhesive, 30 graphene heating plate, 40 heat insulation adhesive. Detailed Implementation

[0014] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. Identical components are indicated by the same reference numerals.

[0015] Please see Figures 1 to 3 This invention discloses an integrally molded die-cast aluminum alloy graphene heating floor, comprising an aluminum alloy plate 10 and a graphene heating plate 30.

[0016] like Figure 1 and Figure 3 As shown, the aluminum alloy plate 10 includes a horizontal plate body 101 and ribs integrally provided on the back of the horizontal plate body 101. Specifically, the aluminum alloy plate 10 adopts a die-casting process, which involves melting and die-casting a heat-free aluminum alloy ingot, followed by edge trimming, correction and other processes to form an integral structural component. The ribs and the horizontal plate body 101 together form multiple mounting cavities. Each mounting cavity is provided with heat transfer adhesive 20, graphene heating plate 30 and heat insulation adhesive 40 from the inside to the outside.

[0017] Furthermore, the ribs include transverse ribs 102, longitudinal ribs 103, and diagonal ribs 104. There are multiple transverse ribs 102 and longitudinal ribs 103, which are arranged perpendicularly to each other to form multiple rectangular structures. There are multiple diagonal ribs 104 that are intersected with each other, and the two ends of the diagonal ribs 104 are connected to the transverse ribs 102 or the longitudinal ribs 103 or to each other.

[0018] In an embodiment of the present invention, the transverse ribs 102 and the longitudinal ribs 103 form an outer rectangular structure along the edge of the horizontal plate 101 and two inner rectangular structures connected to one end of the outer rectangular structure. Diagonal ribs 104 are evenly distributed within the two inner rectangular structures and between the inner and outer rectangular structures. Multiple diagonal ribs 104 intersect to form a rhomboid arrangement. This rib layout not only enhances the overall rigidity and load-bearing capacity of the aluminum alloy plate 10 but also divides the plate into multiple mounting cavities, providing a structural foundation for the subsequent installation of the heat transfer adhesive 20, the graphene heating plate 30, and the heat insulation adhesive 40. Simultaneously, the rhomboid arrangement of the diagonal ribs 104 effectively disperses stress. In an embodiment of the present invention, the heat insulation adhesive 40 covers the outer contour line of the back of the rib, so that the back of the rib is covered by the heat insulation adhesive 40.

[0019] In an embodiment of the present invention, the thickness of the horizontal plate 101 is 1.3-3mm, the thickness of the transverse ribs 102, the longitudinal ribs 103 and the diagonal ribs 104 is the same, and all are 16-20mm, the thickness of the heat insulation adhesive 40 is 10-14mm, the thickness of the heat transfer adhesive 20 is 5-6mm, the thickness of the graphene heating plate 30 is generally 2mm, and the thickness of the heat insulation adhesive 40 covering the back of the ribs is preferably 1-2mm.

[0020] The present invention discloses a method for manufacturing an integrally molded die-cast aluminum alloy graphene heating floor as follows: S10. Melt the heat-free aluminum alloy ingot and maintain it at 660±3℃; S20 liquid alloy is injected into a special mold cavity by a large vacuum die casting machine and then solidified and cooled. S30. Remove the formed blank and trim and correct it using a trimming and correction mold; S40. Use blue light to inspect the blank to determine if there are cracks or other defects; S50. Perform laser trimming on the blank; S60. Spray coating is applied to the blank to obtain the final aluminum alloy plate 10. S70. Apply heat transfer adhesive 20 to the top surface of the mounting cavity, place the graphene heating plate 30 in the mounting cavity, and initially fix it with heat transfer adhesive 20. S80. Fill the remaining space in the mounting cavity with heat insulation adhesive 40 until the heat insulation adhesive 40 covers the outer contour line of the back of the rib. S90. Conduct overall quality inspection and packaging of the products.

[0021] The following is a comparison between a one-piece die-cast aluminum alloy graphene heating floor according to an embodiment of the present invention and a traditional heating system:

[0022] Technical advantages of an integrally molded die-cast aluminum alloy graphene heating floor according to an embodiment of the present invention: 1. The die-cast aluminum alloy plate is a large plate formed in one piece. With the bonding of heat transfer adhesive and heat insulation adhesive, it forms an integral structure with the graphene heating plate. During on-site installation, only the heat insulation board and reflective film need to be laid, which shortens the installation cycle. 2. The die-cast aluminum alloy graphene heating floor has fast heat transfer, raising the room temperature in just about 10 minutes, compared to about 6 hours for traditional flooring, which is more than 30 times faster. 3. Installation can be completed in one go (traditionally it requires more than four times), which shortens the installation time.

[0023] 4. The graphene heating plate can be independently controlled to achieve localized digital control heating. It can also be remotely controlled via the Internet of Things to enable pre-activation and save energy.

[0024] The technical solution of the present invention has been described in detail above with reference to specific embodiments. The specific embodiments described are used to help understand the concept of the present invention. Derivations and modifications made by those skilled in the art based on the specific embodiments of the present invention also fall within the scope of protection of the present invention.

Claims

1. A one-piece die-cast aluminum alloy graphene heating floor, characterized in that: The aluminum alloy plate (10) includes a horizontal plate (101) and ribs integrally provided on the back of the horizontal plate (101). The ribs and the horizontal plate (101) together form a plurality of mounting cavities. Each mounting cavity is provided with heat transfer adhesive (20), graphene heating plate (30) and heat insulation adhesive (40) in sequence from the inside to the outside.

2. The one-piece die-cast aluminum alloy graphene heating floor according to claim 1, characterized in that, The ribs include transverse ribs (102), longitudinal ribs (103), and diagonal ribs (104). There are multiple transverse ribs (102) and longitudinal ribs (103), which together form multiple rectangular structures. There are multiple diagonal ribs (104) that are intersecting each other, and the two ends of each diagonal rib (104) are connected to the transverse ribs (102) or longitudinal ribs (103) or adjacent diagonal ribs.

3. The one-piece die-cast aluminum alloy graphene heating floor according to claim 2, characterized in that, The heat insulation adhesive (40) covers the outer contour line of the back of the rib.

4. The integrally molded die-cast aluminum alloy graphene heating floor according to claim 2, characterized in that, The thickness of the horizontal plate (101) is 1.3-3mm.

5. The one-piece die-cast aluminum alloy graphene heating floor according to claim 2, characterized in that, The transverse ribs (102), longitudinal ribs (103), and diagonal ribs (104) have the same thickness, and are all 16-20mm.

6. A method for manufacturing an integrally molded die-cast aluminum alloy graphene heating floor as described in any one of claims 1-5, characterized in that, Includes the following steps: S10. Melt the heat-free aluminum alloy ingot and maintain it at 660±3℃; S20. Liquid alloy is injected into a special mold cavity through a large vacuum die casting machine and solidified and cooled. S30. Remove the formed blank and trim and straighten the edges; S40. Use blue light to inspect the blank to determine if there are cracks or other defects; S50. Perform laser trimming on the blank; S60. Spray coating is applied to the blank to obtain the final aluminum alloy plate (10); S70. Apply heat transfer adhesive (20) to the top surface of the mounting cavity, place the graphene heating plate (30) in the mounting cavity and fix it in place using heat transfer adhesive (20); S80. Fill the remaining space in the mounting cavity with heat insulation adhesive (40) until the heat insulation adhesive (40) covers the outer contour line of the back of the rib. S90. Conduct overall quality inspection and packaging of the products.

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