Patent Application
20090314848
Radiant heating is an increasingly popular alternative to forced air heating for homes and business alike due to a more uniform distribution of heat, lower operational cost, and capacity to warm surfaces that otherwise feel cold to the touch, such as wood, tile or stone flooring. A radiant heating system can be installed as part of a laminar floor construction, with a heat radiating layer interposed between a subfloor and a top cover or finished layer. In one type of system, the heating layer consists mainly of electrically conductive heating elements held in place by a fabric mat or other supporting structure. In another approach, known as hydronic radiant heating, flexible tubes or conduits distributes hot water throughout the heating layer. Heat is conducted from the water to metal plates, sheets or foil in contact with the tubing, then radiated by the metal component.
The heating components, either electric elements or hot water tubing, can be embedded in wet concrete or another matrix when installed. In an alternative “dry installation” technique, prefabricated modular panels incorporating channels for supporting and guiding the hot water tubing are secured directly to the subfloor or wall. This approach is described in U.S. Pat. No. 5,292,065 to Fiedrich. According to a more recent improvement disclosed in U.S. Pat. No. 6,270,016 also to Fiedrich, separate panels are coupled to each other by hinges, either side by side or end to end. The foregoing referenced Fiedrich '065 and Fiedrich '016 patents are hereby incorporated herein by reference.
According to another known dry installation approach, hydronic radiant heating panels consist of an expanded foam base molded with grooves in its top or outer surface, and a metal sheet or plate formed with channels corresponding to the grooves for a conforming fit of the plate against the top surface of the base. The channels are sized to receive the hot water conduit. The expanded foam base is thermally insulative. As a result, more of the radiated heat is directed upwardly or outwardly into the room for more effective and efficient use of the heat. However, the expanded foam lacks the strength of wood and other structural materials. It is more susceptible to damage from concentrated forces due to screws or other fasteners. In fact, screws or other fasteners preferably are installed through the metal plate as well as the base, with the plate being better suited to withstand the screw force. Consequently, a relatively thick and rigid metal plate is required. Further, the expanded foam base is not well suited for use as an anchor for securing the cover or finished layer.
The present invention addresses the foregoing problems while retaining the benefits that arise from using expanded foam. In addition, the invention provides a heating panel assembly with a folded configuration suitable for transportation and storage, and provides a more convenient method of installing a radiant heating system.
According to the invention, a radiant heating panel assembly includes a plurality of thermally insulative panels. Each panel is elongate in a longitudinal direction and has an obverse panel service, a reverse panel service, and a panel thickness defined by a transverse distance between the obverse and reverse panel surfaces. The obverse surface is contoured to accommodate a radiant heating element. The panel assembly also includes a plurality of structural members. Each structural member is elongate in a longitudinal direction and has an obverse structural member surface, a reverse structural member surface, and a structural member thickness determined by a transverse distance between the obverse and reverse structural member surfaces. The panel assembly further includes a coupling structure adapted to support the panels and the structural members in a working configuration, in which the longitudinal directions of the panels and structural members are substantially parallel, and the reverse panel surfaces and reverse structural member surfaces are substantially coplanar.
The present description is directed primarily to floor installations, in which the reverse panel and structural member surfaces confront the subfloor beneath the panel assembly, and the obverse surfaces of the panels and structural members cooperate to provide a top surface of the assembly. It should be recognized that the present invention is equally applicable to wall or other surface installations, in which case the reverse surfaces confront the wall or other supporting surface.
Typically the obverse surface of each panel is contoured to provide a groove running longitudinally along the panel and recessed inwardly (downwardly in floor installations) from the rest of the obverse surface. This shapes the surface to accommodate a radiant heating element in the form of a metal plate that is generally planar except for a longitudinally running channel. The panel groove accommodates the channel, which in turn accommodates the hot water tubing.
The panels preferably are formed of expanded polystyrene (EPS) or other polymeric foam. The resulting panels are sturdy but lightweight, highly thermally insulative, resistant to moisture and easily shaped by molding to provide the desired obverse surface contour and other features. In addition, expanded foam panels are relatively inexpensive.
The structural members can be formed of a high density polyethylene (HDPE) known as “plastic lumber.” The structural members can bear considerable weight, and can withstand the concentrated forces applied locally by screws or other fasteners. As a result, the panel assembly can be secured to a subfloor of concrete or wood, solely with screws directed through the structural members. There is no need to secure the panels directly with screws, nor is there any need for an adhesive between the assembly and subfloor. Once secured, the structural members provide the lateral stability necessary to secure the panels as well. In addition, the structural members can serve as anchors for securing a covering or finished floor over the panel assembly. The HDPE structural members are resistant to moisture.
The preferred coupling structure is capable of supporting the panels and structural members alternatively in the working configuration, and in a storage or transport configuration in which the panels and structural members are folded against one another in accordion-like fashion. To this end, the coupling structure can include strips of film or tape, each strip running longitudinally and secured to adjacent members, e.g. adjacent panels or a panel and its adjacent structural member. Each strip positions longitudinal side edges of its associated members in contiguous, confronting relation in the working configuration, and acts as a living hinge to allow the adjacent members to pivot relative to each other about a longitudinal axis. Strips can be applied alternatively to obverse surfaces and reverse surfaces of adjacent members, to provide accordion-like folding. If desired, the fastening strips can be metallic, and may contact the radiant heating elements to augment heat conduction and radiation.
In one particularly preferred panel assembly, pairs of the panels are disposed between neighboring structural members. The fastening strips that secure the adjacent panels are applied to their obverse surfaces, while the fastening strips that join panels to adjacent structural members are applied to the respective reverse surfaces.
Another aspect of the present invention is a process for installing a radiant heating system, including the following steps:
(a) providing a panel assembly composed of elongate members coupled side by side, wherein the elongate members include a plurality of thermally insulative panels and a plurality of structural members;
(b) selectively positioning the panel assembly in a working configuration against a subfloor or other selected surface with reverse surfaces of the members confronting and contiguous with the selected surface and with obverse surfaces of members facing away from the selected surface;
(c) with the panel assembly so configured and selectively positioned, installing fasteners through the structural members and into the subfloor, to secure the structural members and the panels against the selected surface; and
(d) mounting radiant heating elements along obverse surfaces of the panels.
Depending on the application, the radiant heating elements may be mounted to the panels after the panel assembly is secured to the subfloor or other selected surface, or in part before securing the assembly. For example, electrical heating elements can be installed after the panel assembly is secured. In hydronic radiant heating systems including such radiant heating elements as metal sheets or plates, and conduit for conducting hot water past the sheets or plates, the plates are advantageously applied to the panels before the panel assembly is secured, while the conduit is best installed after securement.
Although the screws or other fasteners are installed only through the structural members, they secure the entire assembly. There is no need for further screws through the panels, nor for any adhesive between the reverse surfaces and the subfloor or other selected surface. Not only is installation easier, but should the need arise to remove a panel assembly, e.g. for inspection or repair, detachment is accomplished simply by removing the screws. There is no adhesive to contend with, and no resulting damage to the subfloor or panel assembly.
Further features and advantages will become apparent upon consideration of the following detailed description and drawings, in which:
Turning now to the drawings,
At opposite ends of the system, edge panels 30 are joined to the panel assemblies. Each of the edge panels has arcuate grooves designed for alignment with longitudinal (the horizontal direction in
The tubing 32 may be any suitable material. In the preferred embodiment, however, the tubing is preferably a flexible tubing, and more specifically, cross-linked polyethylene (PEX) flexible tubing. Tubing 32 includes a supply section 34 coupled to a water supply 36, and a return section 38 through which water is returned to supply 36. A heater 39 heats the water, and a pump 40 circulates the heated water through the conduit to transfer heat from the water to a series of aluminum plates or sheets 42, which, in turn, transfers heat to a cover or finished floor (not shown), that acts as a radiator to heat the room.
In similar fashion, an adhesive backed strip 46, attached to the obverse surfaces of panel 26a and panel 26c, allows these panels to pivot relative to one another about a longitudinal axis. Complete folding involves rotating panel 26c 180 degrees relative to panel 26a.
Panels 26 preferably are formed of an expanded polymeric foam such as expanded polystyrene (EPS). The panels preferably are formed by injection molding, each with its obverse (top) surface contoured to accommodate a radiant heating element. More particularly, a relatively shallow recess 48 and a U-shaped groove 50 extend longitudinally along the complete length of the panel. These features accommodate an elongate longitudinal extending radiant heating element or plate 42, preferably formed of aluminum or another thermally conductive material. Plate 42 is composed of opposite coplanar side sections 52 and 54, and further is formed to include a central longitudinal channel 56 sized to contain tubing 32 for conducting heated water throughout the system. The inside diameter of channel 56 is slightly larger than the outside diameter of the tubing. However, an upper neck of the channel has a lateral dimension less than the tubing diameter, to require slight elastic compression of the flexible tubing as it is installed into the channel. As a result, the channel is better adapted to contain the tubing. Each plate 42 is attached to its associated panel 26 with an adhesive, applied between side sections 52 and 54 and the panel obverse surface along the flat bottom of recess 48.
Structural members 28 extend longitudinally, and are substantially uniform in lateral cross section. Each structural member is beveled near its obverse surface 58, as indicated at 60. The preferred material for the structural members is a high density polyethylene (HDPE) known as “plastic lumber,” which imparts strength, durability, and moisture resistance.
As seen in
The top of each panel assembly, visible in
As shown schematically in
In addition to the panel assemblies, edge panels 30 are installed typically along the walls of the room and properly aligned with the panel assemblies to form the desired serpentine path for the heated water tubing. Strips 46 are used to couple adjacent panel assemblies side-by-side. End-to-end couplings are as shown in
Once the panel assemblies and edge panels are secured, tubing 32 is installed into channels 56 along the panel assemblies and arcuate grooves along the edge panels. Linear grooves in the edge panels accommodate supply section 34 and return section 38. The tubing is gently pressed downwardly into the channels, undergoing a slight elastic deformation as it enters the channels, resulting in containment within the channel as illustrated in
Finally, a cover or finished floor layer 66, such as carpeting, tile, wood, etc., is installed over the panel assemblies and edge panels, as shown in
Although only exemplary embodiments of the invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims.
This application claims priority to Provisional Application No. 60/716,999 filed Sep. 14, 2005, which is incorporated herein in its entirety.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US06/35678 | 9/14/2006 | WO | 00 | 8/19/2008 |
| Number | Date | Country | |
|---|---|---|---|
| 60716999 | Sep 2005 | US |
