Under floor heating systems are known in the art. In such applications, one or more heating wires are disposed between a subfloor surface and a main floor surface. Once activated, the heating wires transmit heat to the main floor surface, which may then be heated to a desired temperature. Floor heating systems may be particularly useful in cold weather climates. In other applications, heating wires may be disposed on or adjacent to a different surface to provide heat thereto. For example, a heating wire may be utilized on a roof surface to provide a snow melting and an ice dam prevention mechanism. Other applications may include heating wires within or adjacent to walkways, entryways, or gutter downspouts to provide de-icing capabilities.
To provide an effective and consistent heating area, the heating wires are arranged in a particular pattern to provide an efficient and uniform heating mechanism. To that end, one or more wire retaining apparatuses may be utilized to hold the heating wires in the desired orientation and spacing for uniform power output within a given area. In some instances, the wire retaining apparatus is provided in the form of a plurality of strips that may be coupled together and attached to the subfloor (or other surface). Once attached, the heating wires may be coupled to the wire retaining apparatus to maintain the heating wires in the desired orientation. After installation of the heating wires, the main floor (or other) surface may be installed on top of the heating wires such that the wire is positioned adjacent and/or is in contact with an underside of the main floor.
One wire retaining apparatus includes a support structure having a plurality of protrusions that extend from a surface. Pathways are formed between the protrusions that are adapted to receive a flexible heating wire. The support structure supports a main floor and is supported by a sub-floor. The support structure is constructed of a flexible material designed to accommodate shifting of the sub-floor to provide a flat and level main floor surface.
Another wire retaining apparatus includes a heating cable guide strip having curved sections for guiding the heating cable along a curved path. The curved sections include a top horizontal flexible flange that projects outwardly. The heating cable guide strip includes wave-shaped formations that provide alignment of guide strips to be lined up without interlocking or forming a secure connection.
Unfortunately, known wire retaining apparatuses have numerous drawbacks. For example, it may be difficult to secure heating wires of different sizes to the same wire retaining apparatus. As such, numerous different-sized wire retaining apparatuses may need to be utilized in a single installation to accommodate the difference in diameter, resulting in increased expense and effort during the installation process.
Another drawback is that wires of different sizes may not be attached to the wire retaining apparatus in a secure manner. In particular, the wire retaining apparatus may have one or more retaining elements that are shaped to accommodate a specifically dimensioned wire. In instances where a differently dimensioned (e.g., smaller or larger diameter) wire may be used, the retaining element may not grip or otherwise interact with the wire in a manner to secure the wire thereto. When smaller diameter wires are used, extra care and effort is necessary to keep the wire properly tensioned so as to prevent the wire from lifting away through curling. In other instances, the retaining elements may not be flexible enough to accommodate a wire with a larger diameter.
A further drawback to known wire retaining apparatuses is the mechanism by which the plurality of strips are coupled together. For example, some strips simply include a protrusion designed to loosely interact with an opening disposed in a different strip. In many instances, this interaction is not secure and may result in the strips becoming uncoupled from each other.
In light of the above issues, a need exists for a way in which to couple a plurality of strips together in a secure manner. A further need exists for a wire retaining apparatus designed to securely retain wires of different diameters.
Some embodiments provide a wire retaining apparatus including a base and a plurality of retention members. The base includes a first end and a second end opposite the first end, and an upper and a lower side. The plurality of retention members protrude outwardly from the upper side of the base. Each retention member includes a wall portion and a flange portion that circumscribes and extends outwardly from an upper peripheral portion of the wall portion. The flange portion is angled upwardly away from the upper side of the base and forms a retention gap configured to receive a wire.
Some embodiments provide a method of forming a wire retaining system. The method includes the step of providing a first and a second wire retaining apparatus, each including a plurality of retention members. The plurality of retention members of the first and second wire retaining apparatus each define a plurality of retention gaps for receiving one or more wires having a different diameter with respect to each other. The first wire retaining apparatus further includes a first portion of a coupling mechanism provided in the form of a lower protrusion and at least one coupling aperture. The second wire retaining apparatus further includes a second portion of a coupling mechanism provided in the form of at least one coupling post and an opening. The first and second wire retaining apparatuses are coupled together by pressing the at least one coupling post into the at least one coupling aperture, whereby the lower protrusion is retained within the opening in a coupled configuration.
Some embodiments provide a wire retaining apparatus including a base having a first end and a second end opposite the first end, and further including an upper side and a lower side. A plurality of retention members extend from the base. Each retention member includes a wall portion and a flange portion that protrudes from an upper peripheral portion of the wall portion. The flange portion of each of the plurality of retention members form wire insertion gaps. The wire insertion gaps have a continuously variable gap length that has a minimum value at a central point.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.
Embodiments of the present disclosure provide a system and a method for installing and maintaining one or more heating wires in a pre-defined orientation using a plurality of wire retaining apparatuses that are designed to be securely coupled together. The wire retaining apparatuses can be used in a number of applications including residential and commercial flooring, roofing, walls, siding, and the like. Each application may include two substantially parallel surfaces defining a gap therebetween. The gap is sized to hold the heating wire such that the heating wire is in communication with one or both of the surfaces.
Referring to
Attachment guides 132 are centrally disposed within an orifice defining the interior volume 130 of each of the retention members 112. The attachment guides 132 extend outwardly from the upper face 108 of the base 102 and are each defined by a slightly raised cylindrical outer wall 134 and a sloped surface 136 that terminates at a substantially flat interior surface 138. The thickness of the base 102 may be reduced in an area adjacent the interior surface 138 in some embodiments. It is also contemplated that one or more of the attachment guides 132 may include an inner cylindrical wall 140 that defines a through hole 142 (see e.g.,
As shown in the embodiment depicted in
Certain embodiments may also include one or more types of attachment mechanisms (not shown) designed to be used in conjunction with the attachment guides 132 to secure the wire retaining apparatus 100 to a surface (not shown). Some non-limiting examples of attachment mechanisms may include screws, nails, rivets, and staples. In the present embodiment, the attachment guides 132 are configured to support a head of a screw or nail (not shown). One advantage of the present configuration is that the support provided by the attachment guides 132 prevents and/or reduces damage from over driving a screw or nail into the apparatus 100, which results in an easier and more efficient installation.
Still referring to
In some embodiments, one or more indicators 144 (see
In the embodiment shown in
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In the embodiments shown in
It is also contemplated that the insertion gap 150 may vary in size and shape between retention members 112 on a single wire retaining apparatus 100. For example, some of the retention members may be configured to form gaps 150 adapted to retain wires that are wide and flat while other retention members 112 on the same wire retaining apparatus 100 may be configured with different shaped and sized features to retain both large and small wires. Thus, a wire retaining apparatus 100 with a configuration as just described may be utilized in different applications (e.g., the retention of communication cables).
Now turning to
In some embodiments, the range of wire diameters that may be retained by the interaction of the wire and the wire retention pocket 156 may be from about 2.1 millimeters to about 4.2 millimeters. It is contemplated that by adjusting the dimension H1 and the angle A, the range of wires that may be retained can be increased or decreased as required. Further, a wire having a diameter smaller than the minimum diameter (e. g., about 1 millimeter) than the range for the retention pocket 156 may still be retained within the retention pocket with proper tensioning by the installer. Additionally, the present embodiment may accommodate wires oversized (not shown) for the retention pockets 156. Larger, oversized wires may require extra insertion force by the installer. The maximum wire size that the wire apparatus 100 may retain can be modified by adjusting the insertion gap 150, the dimension H1, and the angle A.
Wires 158, 160 of different diameters may be securely retained in the wire retention pocket 156 by contacting both the upper face 108 of the base 102 and lower surface 124 of the flange portion 116. It is contemplated that the faceted outer surface 122 of the wall portion 114 may be configured to grip a minimum diameter wire in some embodiments. Further, the shape of the wire retention pockets 156 may be configured to advantageously retain different sizes and shapes of wires for different applications. It is contemplated that the angle A, the spacing of the retention members 112, the shape and size of the faceted outer surface 122 of the wall portion 114, and the shape of the lower surface 124 may be adjusted individually or together to configure the retention capabilities of the wire retaining apparatus 100 for a variety of applications.
In some applications, multiple wire retaining apparatuses 100 may be connected together to form a wire retaining system 178 (see
As shown in
As shown in
A method of connecting a plurality of wire retaining apparatuses 100 is also contemplated. A plurality of wire retaining apparatuses 100 may be used in some applications necessitating the connection of a plurality of the wire retaining apparatus 100 into long straps 190 (See
It is contemplated that disconnecting of the wire retaining apparatus 100 may be necessary in some instances. To do so, the first wire retaining apparatus 100a may be twisted with respect to the second wire retaining apparatus 100b until the components are disengaged from each other. A small amount of deflection of the wire retaining apparatus 100 may be required for the disconnection.
It is also contemplated that the wire retaining apparatus 100 as describe above may be reinforced when installed. The through hole 142b located within the attachment guide 132b of the retention member 162b aligns with the through hole 142a located in the second end 106a of the base 102a when the first wire retaining apparatus 100b is joined with the second wire retaining apparatus 100a. When installed, the attachment mechanism used in the installation (e.g., a nail) can be driven through the aligned through holes 142a, 142b to secured the wire retaining apparatuses 100a, 100b together and to the surface the system 178 is being mounted on (not shown).
It is contemplated that the wire retaining apparatus 100 may be constructed out of a variety of materials depending on the requirements of an application. Polymers may be used to provide flexibility and inexpensive manufacturing costs in some embodiments. Some non-limiting examples of materials that may be used for the wire retaining apparatus 100 are polypropylene and polyethylene. It is contemplated that different materials with different properties may impact the ease of trimming a wire retaining apparatus 100 to a specific length. Further, the force required to insert a wire into the wire retaining apparatus 100 may be controlled by adjusting the properties of the materials. Other embodiments of the wire retaining apparatus 100 may be constructed from metals or composite materials. It is contemplated that wire retaining apparatuses 100 may be used in applications having harsh environmental conditions that may require numerous types of materials.
Now turning to
The working distance between the straps may vary depending on the specific application and/or the floor plan of the room. In some embodiments, the working distances may vary for different areas of the same room. The working distance may be from a few centimeters to a few meters, for example. In some embodiments, the working distance is about 90 centimeters for most of the straps 190. The wire retaining system 178 may include single wire retaining apparatuses 100 that are secured individually that have a working distance larger or smaller than the rest of the wire retaining system 178. Further, in some embodiments, it may be necessary to place straps 190 in different orientations relative to each other so that the majority of the floor is heated. For example, straps 190 may be secured parallel, perpendicular, and/or any other orientation in between relative to each other to insure proper coverage of heating wires. After the straps 190 are secured, one or more heating wires 192 are inserted into the wire insertion gaps (not shown) and secured in the wire retaining pockets (not shown) so that the wires are spaced to cover a significant amount of the floor. Next, the straps 190 and wires 192 are covered by various flooring applications known to one having ordinary skill in the art and the installation of the under floor heating system is complete. In some embodiments, the wire retaining system 178 and wire 192 may be covered with a self-leveling floor compound, mortar, or thin-set and cured before a final flooring is added. In certain embodiments, the wire retaining system 178 and wire 192 may be covered by mortar, or thin-set as a final layer of flooring is applied. It is contemplated that the wire retaining system and/or wires may be in communication with a controller 194 that facilitates operation thereof. In one specific embodiment, the controller is a thermostat.
It is also contemplated that the wire retaining apparatus 100 may be different shapes. For example, an L-shaped wire retaining system (not shown) may be beneficial in the application described above for placing wire around corners. In some embodiments, the shape of the wire retaining system may be any geometric shape that can be advantageously used in a specific application.
It is also contemplated that the wire retaining apparatus 100 may be utilized for retaining different types of wires. Further, any type of device that may be used to transmit a signal, electrical power, or utilized for heating can be retained. In some embodiments, the wire 192 may be in the form of a multi-conductor cable such that a complete circuit is formed with the controller 194 with a single connection. The wire retaining apparatus 100 may also be utilized for retaining communications cables such as ethernet cables or coaxial cables in some embodiments. It is further contemplated that wire retaining apparatus 100 may be utilized for retaining any type of cables for computers or electronic equipment in some embodiments.
It will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the invention are set forth in the following claims.