Under floor heating element

• US 7,193,191 B2
• Filed: 01/10/2006
• Issued: 03/20/2007
• Est. Priority Date: 05/18/2005
• Status: Expired due to Fees

• Current Assignee: Milliken & Company
• Original Assignee: Milliken & Company
• Inventors: Davis, Shawn, Child, Andrew D., Wilson, David B., Horvath, Joshua D., Deangelis, Alfred R., Green, Karen M.
• Primary Examiner(s): Evans; Robin
• Assistant Examiner(s): PATEL, VINOD D
• Application Number:
  US11/328,860
• Publication Number:
  US 20060261057A1
• Time in Patent Office: 434 Days
• Field of Search: 219/529, 219/212, 219/213, 219/505, 219/528, 219/549, 219543-545, 392435-437
• US Class Current: 219/529
• CPC Class Codes: H05B 2203/003 using serpentine layout
• CPC Class Codes: H05B 2203/004 using zigzag layout
• CPC Class Codes: H05B 2203/005 using multiple resistive elements or resistive zones isolated from each other
• CPC Class Codes: H05B 2203/014 Heaters using resistive wires or cables not provided for in H05B3/54
• CPC Class Codes: H05B 2203/026 Heaters specially adapted for floor heating
• CPC Class Codes: H05B 3/342 heaters used in textiles

Abstract

An under floor heating element incorporating a scrim having one or more pairs of heating and/or sensor wires arranged in a continuous pattern such that pair members are disposed in crossing relation to one another. The pair members may be cut and joined to establish electrical connections at defined crossing points to establish feedback loop circuits with a control element.

Claims

1. An under floor heating element comprising a scrim layer comprising a first elongate conductive wire structure operatively connected to a control element and at least a second elongate conductive wire structure operatively connected to the control element, wherein at least one of said elongate conductive wire structures is disposed in a switchback patterned arrangement within the scrim layer such that the first and second elongate conductive wire structures cross at defined positions along the length of the scrim layer, said first and second elongate conductive wire structures being operatively connected within the scrim layer remote from the control element such that a circuit is completed with the control element.

2. The under floor heating element of claim 1, wherein said first and second elongate conductive wire structures are heating wires adapted to selectively raise the temperature within the scrim layer.

3. The under floor heating element of claim 2, wherein said first and second elongate conductive wire structures comprise metallic wire disposed in wrapped relation to a textile fiber core with an insulating sleeve disposed in surrounding relation to the wrapped wire and fiber core.

4. The under floor heating element of claim 1, wherein said first and second elongate conductive wire structures are sensor wires adapted to monitor temperature within the scrim layer.

5. The under floor heating element of claim 4, wherein said first and second elongate conductive wire structures comprise metallic wire disposed in wrapped relation to a textile fiber core with an insulating sleeve disposed in surrounding relation to the wrapped wire and fiber core.

6. The under floor heating element of claim 1, wherein said first and second elongate conductive wire structures are disposed in a substantially continuous switchback pattern in transverse orientation to a plurality of stabilizing yarn elements.

7. The under floor heating element of claim 6, wherein said first and second elongate conductive wire structures are disposed in non-perpendicular angled orientation to lateral edges of the scrim layer.

8. The under floor heating element of claim 6, wherein portions of said first and second elongate conductive wire structures are disposed along pathways in substantially perpendicular orientation to lateral edges of the scrim layer such that portions of said first and second elongate conductive wire structures are substantially parallel to one another at the interior of the scrim layer.

9. The under floor heating element of claim 6, wherein the first and second elongate conductive wire structures are adhesively bonded to said stabilizing yarn elements.

10. The under floor heating element of claim 1, further comprising at least one insulating layer.

11. The under floor heating element of claim 1, further comprising a non-skid layer.

12. The under floor heating element of claim 11, wherein the non-skid layer comprises a tackified foam layer or a high friction foam layer.

13. The under floor heating element of claim 1, wherein the control element is electrically connected to the first and second elongate conductive wire structures and at least partially regulates the temperature of the under floor heating element.

14. An under floor heating element system comprising at least 2 under floor heating elements of claim 1 electrically connected in a continuous circuit.

15. The under floor heating element system of claim 1, wherein the control element is electrically connected to the each elongate conductive wire structure and at least partially regulates the temperature of the under floor heating element.

16. The under floor heating element of claim 1, wherein the under floor heating element is encased in foam.

17. The under floor heating element of claim 1, wherein the under floor heating element is attached to a carpet pad.

18. The under floor heating element of claim 1, wherein the heating element is attached to a carpet substrate.

19. An under floor heating comprising a scrim layer comprising a first elongate conductive heating wire structure operatively connected to a control element, at least a second elongate conductive heating wire structure operatively connected to the control element, a first elongate conductive sensor wire structure operatively connected to the control element and at least a second elongate conductive sensor wire structure operatively connected to the control element, wherein said elongate conductive wire structures are disposed in a switchback patterned arrangement within the scrim layer such that the first and second elongate conductive heating wire structures cross at defined positions along the length of the scrim layer, and the first and second elongate conductive sensor wire structures cross at defined positions along the length of the scrim layer, said first and second elongate conductive heating wire structures being operatively connected within the scrim layer remote from the control element such that a heating circuit is completed with the control element and said first and second elongate conductive sensor wire structures being operatively connected within the scrim layer remote from the control element such that a sensing circuit is completed with the control element.

20. The under floor heating element of claim 19, wherein said first and second elongate conductive heating wire structures and said first and second elongate conductive sensor wire structures are disposed in non-perpendicular angled orientation to lateral edges of the scrim layer.

21. The under floor heating element of claim 19, wherein portions of said first and second elongate conductive heating wire structures and portions of said first and second elongate conductive sensor wire structures are disposed along pathways in substantially perpendicular orientation to lateral edges of the scrim layer such that portions of said first and second elongate conductive heating wire structures and portions of said first and second elongate conductive sensor wire structures are substantially parallel to one another at the interior of the scrim layer.

22. The under floor heating element of claim 19, further comprising at least one insulating layer.

23. The under floor heating element of claim 19, further comprising a non-skid layer.

24. The under floor heating element of claim 19, wherein the control element is electrically connected to the first and second elongate conductive wire structures and at least partially regulates the temperature of the under floor heating element.

25. An under floor heating element system comprising at least 2 under floor heating elements of claim 19 electrically connected in a continuous circuit.

26. The under floor heating element of claim 19, wherein the under floor heating element is encased in foam.

27. The under floor heating element of claim 19, wherein the under floor heating element is attached to a carpet pad.

28. The under floor heating element of claim 19, wherein the heating element is attached to a carpet substrate.