A class a non-combustible electric heating floor and a preparation process thereof

Abstract

The application discloses a kind of A-grade non-combustible electric floor and its preparation process, comprising the following steps: substrate preparation: inorganic non-combustible material is selected as the main body of substrate;Fireproof layer composite: at least one fireproof insulation layer is compounded on the substrate by one-time hot press forming process;Heating layer setting: heating layer is set on the fireproof insulation layer, and the heating layer is driven by 36V and below safe voltage;Surface layer press pastes: decorative layer and wear-resistant layer are sequentially pressed and pasted on the heating layer to form floor blank;Connection structure processing: straight insertion type lock catch connection structure is processed on the side edge of the floor blank, which realizes circuit conduction while connecting floor, and inorganic non-combustible material is selected as the main body of substrate, which significantly simplifies production process, reduces chemical reagent consumption and wastewater treatment cost, and at the same time, inorganic material does not release toxic smoke at high temperature, and there is no melting phenomenon, which fundamentally eliminates secondary hazards caused by material decomposition in fire.

Description

Technical Field

[0001] This invention belongs to the field of electric heating floor technology, specifically relating to a Class A non-combustible electric heating floor and its preparation process. Background Technology

[0002] Non-combustible electric heating floor is a high-tech building material that combines flooring, heating, and health functions. Its core value lies in its "non-combustible" characteristics, which fundamentally improve the safety of electric heating. Through a special structure and non-combustible materials, it achieves self-limiting temperature, self-extinguishing upon removal of flame, non-combustibility at high temperatures, and leakage protection, thus taking into account both heating and fire safety.

[0003] Currently, existing fire-resistant and non-combustible electric heating floors mainly adopt the following technical approaches: First, they use wood-based materials (such as multi-layer solid wood boards or high-density fiberboard) as the main body, impregnating the wood with phosphorus-based, nitrogen-based, or inorganic flame retardants to achieve the B1 fire-retardant standard; second, they install an independent non-combustible insulation layer (such as mica sheets or fiberglass cloth) inside the floor to physically isolate the heating element from other parts of the floor; third, they incorporate temperature sensors and leakage current protectors in the electrical control system to achieve overheat protection. However, these existing technologies still have the following shortcomings in practical applications: First, the process is relatively complex. The non-combustible treatment of wood-based substrates typically requires multiple impregnation, drying, and curing processes, which are lengthy. Secondly, it consumes a large amount of materials. To ensure the non-combustible effect, traditional solutions often rely on increasing the thickness of the non-combustible layer or the amount of flame retardant, leading to increased material costs. Thirdly, fire safety depends on external devices. The overheat protection of most products relies entirely on thermostats and temperature sensors. Once the sensor fails or the control logic malfunctions, the heating element may continue to heat up and cause a fire. Fourthly, maintenance is difficult. If the internal wiring of the pre-embedded wiring structure fails, the entire flooring will be scrapped. Therefore, this paper proposes a Class A non-combustible electric heating floor with better fire resistance and heat resistance, as well as its preparation process. Summary of the Invention

[0004] The purpose of this invention is to provide a Class A non-combustible electric heating floor and its manufacturing process to solve the problems mentioned above.

[0005] To achieve the above objectives, the present invention provides a Class A non-combustible electric heating floor and its manufacturing process, comprising the following steps:

[0006] Substrate preparation: Inorganic non-combustible materials are selected as the main substrate;

[0007] Fireproof layer composite: At least one fireproof insulation layer is laminated onto the substrate through a one-time hot pressing molding process;

[0008] Heating layer configuration: A heating layer is configured above the fireproof insulation layer, and the heating layer is driven by a safe voltage of 36V or below;

[0009] Surface layer bonding: A decorative layer and a wear-resistant layer are bonded sequentially over the heating layer to form a floor blank;

[0010] Connection structure processing: A straight-insertion locking connection structure is processed on the side of the floor blank, which enables circuit conduction while connecting the floor.

[0011] In one or more embodiments of the present invention, the inorganic non-combustible material is selected from one or more combinations of magnesium oxide board, magnesium oxychloride cement board or microcrystalline stone, and no additional flame retardant is required.

[0012] In one or more embodiments of the present invention, in the one-time hot pressing molding process, a layered coating method is used to simultaneously hot press the fireproof insulation material, adhesive and substrate, the hot pressing temperature is controlled at 120℃-180℃, the pressure is controlled at 8-15kg / cm², and the hot pressing time is 60-180 seconds.

[0013] In one or more embodiments of the present invention, the heating layer is made of a positive temperature coefficient (PTC) self-regulating temperature material, the resistance of which automatically increases when the temperature rises, thus limiting the current flow.

[0014] In one or more embodiments of the present invention, a heat-conducting element is further provided between the fireproof insulation layer and the heating layer, the heat-conducting element being used to uniformly conduct heat and reduce the amount of fireproof insulation material used.

[0015] In one or more embodiments of the present invention, a sealing layer integrating waterproofing, insulation and heat preservation is formed in one step at the electrical connection part of the floor blank using a polyurethane foaming process.

[0016] In one or more embodiments of the present invention, the wear-resistant layer and / or decorative layer are prepared using a sand-free process to reduce production steps and material waste.

[0017] In one or more embodiments of the present invention, the heating layer is a structural layer with pre-fabricated wire channels, which are reserved during the preparation and the heating wires are inserted when the floor is assembled.

[0018] Compared with the prior art, the beneficial effects of the present invention are:

[0019] (1) The Class A non-combustible electric heating floor and its preparation process use inorganic non-combustible materials such as glass magnesium board, magnesium oxychloride cement board or microcrystalline stone as the main body of the floor substrate. No additional flame retardant is required to make the overall combustion performance reach the Class A2 (non-combustible material) standard specified in GB8624. The process of flame retardant preparation, impregnation treatment and subsequent drying is eliminated, which significantly simplifies the production process and reduces the consumption of chemical reagents and wastewater treatment costs. At the same time, the inorganic materials do not release toxic fumes at high temperatures and do not have melting drip phenomenon, which fundamentally eliminates the secondary hazards caused by material decomposition in the fire.

[0020] (2) The Class A non-combustible electric heating floor and its preparation process adopt a one-time hot pressing molding process to composite the fireproof insulation layer, the heating layer and the surface layer. The hot pressing temperature is 120-180℃, the pressure is 8-15 kg / cm², and the time is 60-180 seconds. The layer coating method is used to press and cure the materials of each layer simultaneously. Compared with the traditional step-by-step pressing, multiple hot pressing processes are combined into one step, the production cycle is shortened by more than 50%, the number of hot press start-ups and shutdowns and intermediate transfer links are greatly reduced, and the production energy consumption is reduced.

[0021] (3) The Class A non-combustible electric heating floor and its manufacturing process eliminate the risk of high-voltage arc igniting the floor or breaking down the insulation layer from the source by low-voltage drive. It does not require complex leakage protection isolation switches and high-voltage insulation reinforcement layers, simplifying the electrical design. It eliminates the need for temperature sensors, complex control circuits and a large number of connecting wires, reducing material costs. It also eliminates the need to write control software and calibration programs, significantly reducing the difficulty of the process, while achieving intrinsically safe passive fire protection.

[0022] (4) The Class A non-combustible electric heating floor and its manufacturing process do not require fine operations such as wire positioning, welding, and insulation wrapping, which avoids the short circuit and wire breakage scrap rate caused by pre-buried wires and improves the production qualification rate. At the same time, the polyurethane foaming process is used to form a waterproof, insulating and heat-insulating integrated sealing layer in the electrical connection part. The post-threading process allows the wires to be cut on site according to the actual distance, reducing material waste. And once the wires fail, they can be directly pulled out and replaced without scrapping the whole floor, reducing maintenance costs. Attached Figure Description

[0023] Figure 1 This is a process flow diagram of the present invention. Detailed Implementation

[0024] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings, but it should be understood that the scope of protection of the present invention is not limited to the specific embodiments.

[0025] like Figure 1The image shows an embodiment of a Class A non-combustible electric heating floor and its manufacturing process, comprising the following steps:

[0026] Substrate preparation: Inorganic non-combustible materials are selected as the main substrate;

[0027] Fireproof layer composite: At least one fireproof insulation layer is laminated onto the substrate through a one-time hot pressing molding process;

[0028] Heating layer configuration: A heating layer is installed above the fireproof insulation layer, and the heating layer is driven by a safe voltage of 36V or below;

[0029] Surface layer lamination: A decorative layer and a wear-resistant layer are laminated sequentially over the heating layer to form a floor blank;

[0030] Connection structure processing: A direct-insertion locking connection structure is processed on the side of the floor blank, which enables electrical conduction while connecting the floor; the inorganic substrate itself is non-combustible, and it can achieve the A2 non-combustible standard without the addition of flame retardants, which significantly improves fire safety; one-time hot pressing molding replaces multi-layer step composite, reducing the number of processes; low-voltage direct-insertion connection eliminates high-voltage insulation treatment and complex wiring, reducing process difficulty and material consumption, while making installation safer and more convenient.

[0031] Inorganic non-combustible materials are selected from one or more combinations of magnesium oxide board, magnesium oxychloride cement board, or microcrystalline stone, and no additional flame retardants are required. This eliminates the need for multiple processes such as flame retardant preparation, impregnation, and drying, greatly simplifying the production process. It also avoids the high cost of flame retardants, saving on material expenses. At the same time, inorganic materials do not release toxic fumes at high temperatures, are environmentally friendly, and have good dimensional stability, further enhancing the long-term safety and durability of the flooring.

[0032] In the one-time hot pressing process, a layered coating method is used to simultaneously hot press the fire-retardant insulation material, adhesive, and substrate. The hot pressing temperature is controlled at 120℃-180℃, the pressure is controlled at 8-15 kg / cm², and the hot pressing time is 60-180 seconds. Compared with the traditional step-by-step pressing, one-time hot pressing can improve the composite efficiency by more than 50% and significantly shorten the production cycle. It reduces the number of hot press start-ups and shutdowns and intermediate transfer losses, saving electricity and manpower. The optimized parameters ensure that there are no bubbles or delamination between the fire-retardant insulation layer, adhesive, and substrate, resulting in high bonding strength and stable and reliable fire-retardant insulation effect. At the same time, it eliminates the need for multiple independent hot pressing equipment, simplifying the production line.

[0033] The heating layer is made of positive temperature coefficient (PTC) self-regulating material. The resistance of the material automatically increases when the temperature rises, limiting the current flow. Even if the external thermostat fails, the PTC material itself will not overheat and catch fire, fundamentally improving fire safety. It eliminates the need for temperature sensors, complex control circuits, and a large number of connecting wires, reducing material costs and process complexity. At the same time, the PTC material has no mechanical contacts and no electric arc generation, ensuring high reliability in long-term operation and extending the service life of the floor.

[0034] A heat-conducting component is also installed between the fireproof insulation layer and the heating layer. The heat-conducting component is used to evenly conduct heat and reduce the amount of fireproof insulation material used. The heat-conducting component rapidly diffuses the heat from the heating layer laterally, eliminating local hot spots. Therefore, the thickness of the fireproof insulation layer can be reduced by 30%-50%, saving flame-retardant materials. At the same time, the floor heats up faster and has a more sensitive thermal response. The surface temperature uniformity is improved, reducing the risk of cracking caused by thermal stress. Overall, although the cost of the heat-conducting component is increased, the savings in flame-retardant materials are greater, and the total manufacturing cost is actually reduced.

[0035] It also includes the use of polyurethane foaming technology to form a waterproof, insulating, and heat-insulating integrated sealing layer at the electrical connection points of the floorboard blank in one step; combining multiple manual steps such as cutting, wrapping, and fixing into one foaming process, greatly simplifying the production process; the polyurethane foam layer is seamless and bubble-free, with a waterproof rating of up to IP68 and excellent insulation performance; at the same time, the foam material itself has low density and low usage, and simultaneously replaces three different functional materials, reducing material consumption and inventory management difficulty; in addition, the foam layer also has good heat insulation properties, reducing heat loss at the connection points.

[0036] In the preparation of the wear-resistant layer and / or decorative layer, a sanding-free process is adopted to reduce production steps and material waste; it eliminates the need for sanding machines, dust removal equipment and related manual operations, thus reducing the number of steps; it avoids the sanding process from removing approximately 0.1-0.3mm of surface material, improving material utilization; it eliminates defects caused by sanding scratches and dust pollution, improving product yield; at the same time, it reduces sanding energy consumption and dust emissions, making it more energy-efficient and environmentally friendly.

[0037] The heating layer is a prefabricated structural layer with wire channels. These channels are reserved during manufacturing, and the heating wires are inserted during floor assembly. This eliminates the need for precise operations such as wire positioning, welding, and insulation wrapping in the factory, greatly simplifying the manufacturing process and reducing the scrap rate. During on-site installation, the wire length can be cut according to actual needs, avoiding material waste of fixed-length wires for each floor. More importantly, if a wire fails, the old wire can be pulled out from the channel and replaced with a new one, without replacing the entire floor, greatly reducing the cost and difficulty of later maintenance.

[0038] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0039] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A Class A non-combustible electric heating floor and its manufacturing process, characterized in that, Includes the following steps: Substrate preparation: Inorganic non-combustible materials are selected as the main substrate; Fireproof layer composite: At least one fireproof insulation layer is laminated onto the substrate through a one-time hot pressing molding process; Heating layer configuration: A heating layer is configured above the fireproof insulation layer, and the heating layer is driven by a safe voltage of 36V or below; Surface layer bonding: A decorative layer and a wear-resistant layer are bonded sequentially over the heating layer to form a floor blank; Connection structure processing: A straight-insertion locking connection structure is processed on the side of the floor blank, which enables circuit conduction while connecting the floor.

2. The Class A non-combustible electric heating floor and its manufacturing process according to claim 1, characterized in that, The inorganic non-combustible material is selected from one or more combinations of magnesium oxide board, magnesium oxychloride cement board or microcrystalline stone, and no additional flame retardant is required.

3. The Class A non-combustible electric heating floor and its preparation process according to claim 2, characterized in that, In the one-time hot pressing molding process, the fireproof insulation material, adhesive and substrate are simultaneously hot pressed using a layer coating method. The hot pressing temperature is controlled at 120℃-180℃, the pressure is controlled at 8-15 kg / cm², and the hot pressing time is 60-180 seconds.

4. The Class A non-combustible electric heating floor and its manufacturing process according to claim 3, characterized in that, The heating layer is made of a positive temperature coefficient (PTC) self-regulating temperature material. The resistance of the material automatically increases when the temperature rises, thus limiting the current flow.

5. The Class A non-combustible electric heating floor and its manufacturing process according to claim 4, characterized in that, A heat-conducting component is also provided between the fireproof insulation layer and the heating layer. The heat-conducting component is used to uniformly conduct heat and reduce the amount of fireproof insulation material used.

6. The Class A non-combustible electric heating floor and its manufacturing process according to claim 5, characterized in that, It also includes the use of polyurethane foaming technology to form a waterproof, insulating, and heat-insulating integrated sealing layer at the electrical connection points of the floor blank in one step.

7. The Class A non-combustible electric heating floor and its manufacturing process according to claim 6, characterized in that, The wear-resistant layer and / or decorative layer are prepared using a sand-free process to reduce production steps and material waste.

8. The Class A non-combustible electric heating floor and its manufacturing process according to claim 7, characterized in that, The heating layer is a structural layer with prefabricated wire channels. These wire channels are reserved during the manufacturing process, and the heating wires are inserted during the floor assembly.

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