METHOD AND APPARATUS FOR POSITIONING HEATING ELEMENTS

• US 20160047131A1
• Filed: 08/18/2015
• Published: 02/18/2016
• Est. Priority Date: 08/18/2014
• Status: Active Grant

• Current Assignee: Progress Profiles SPA
• Original Assignee: DZT Industries, LLC
• Inventors: Larson, David D.
• Granted Patent: US 9,625,163 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: E04B 5/48 Special adaptations of floors for incorporating ducts, e.g. for heating or ventilating in block-shaped elements E04C1/39; in slab- or sheet-shaped elements E04C2/52
• CPC Class Codes: E04F 15/02 Flooring or floor layers composed of a number of similar elements of webs E04F15/16
• CPC Class Codes: E04F 15/182 Underlayers coated with adhesive or mortar to receive the flooring
• CPC Class Codes: E04F 15/185 Underlayers in the form of studded or ribbed plates
• CPC Class Codes: E04F 2290/023 for heating
• CPC Class Codes: F24D 13/02 solely using resistance heating, e.g. underfloor heating
• CPC Class Codes: F24D 3/141 Tube mountings specially adapted therefor
• CPC Class Codes: Y02B 30/00 Energy efficient heating, ventilation or air conditioning [HVAC]

Abstract

An underlayment system is provided that includes a plurality of protrusions that extend from a common base member. The protrusions and base member can include an opening therethrough that allows for subsequent layers of material, such as adhesive, to interact and bond to each other. The protrusions are arranged in such a way to contain a wire, string, or heating element, within a receiving area. The arrangement of the protrusions allow for routing of the wire, string, or heating element in a variety of angles, bends, and other routing layouts.

Claims

1. An underlayment adapted to receive and secure at least one heating element of a radiant heating assembly, comprising:

a base material defining an area and having a first side and a second side disposed opposite the first side;

a first protrusion disposed on the first side of the base material, the first protrusion configured as a geometric shape having at least two sides, wherein one or more of the at least two sides includes an element receiving surface; and

a second protrusion disposed on the first side of the base material and adjacent to the first protrusion, the second protrusion configured as a geometric shape having at least two sides, wherein one or more of the at least two sides includes an element receiving surface, and wherein the element receiving surface of the second protrusion is offset from and facing the element receiving surface of the first protrusion forming an element receiving cavity therebetween; and

wherein the element receiving cavity is configured to contain at least one heating element of the radiant heating assembly.

2. The underlayment of claim 1, further comprising:

at least two routing hubs disposed adjacent to one another forming a routing element receiving cavity therebetween, wherein each routing hub comprises at least four protrusions equally-spaced in a circular array about an array axis.

3. The underlayment of claim 2, wherein the at least two routing hubs are configured to contain the at least one heating element via the element receiving cavity and the routing element receiving cavity.

4. The underlayment of claim 1, wherein said first protrusion and said second protrusion further have at least one cutout portion.

5. The underlayment of claim 4, wherein said cutout portions are adapted to receive one of at least adhesive, epoxy, grout, cement, glue, and plastic.

6. The underlayment of claim 1, wherein said element receiving surface is one of an arcuate receiving surface and an angular receiving surface.

7. The underlayment of claim 1, wherein said first protrusion and said second protrusion are formed from said base material.

8. A floor assembly, comprising;

an underlayment layer having a base material defining an area and having a first side and a second side disposed opposite the first side, a first protrusion disposed on the first side of the base material, the first protrusion configured as a geometric shape having at least two sides, wherein one or more of the at least two sides includes an element receiving surface, and a second protrusion disposed on the first side of the base material and adjacent to the first protrusion, the second protrusion configured as a geometric shape having at least two sides, wherein one or more of the at least two sides includes an element receiving surface, and wherein the element receiving surface of the second protrusion is offset from and facing the element receiving surface of the first protrusion forming an element receiving cavity therebetween; and

wherein the element receiving cavity is configured to contain at least one heating element of the radiant heating assembly; and

a heating member positioned between protrusions wherein the protrusions secure the heating member.

9. The floor assembly of claim 8, further comprising:

a pad layer, wherein said pad layer is attached to said base layer.

10. The floor assembly of claim 9, wherein said pad layer is attached to said base layer by at least one of adhesive, thermal bonding, welding, and mechanical attachment.

11. The floor assembly of claim 8, wherein said heating member is one of a wire and a fluid conduit.

12. The floor assembly of claim 9, wherein said pad layer is at least one of foil, cork, rubber, plastic, concrete, wood, organic materials, inorganic materials, composites, and compounds.

13. The floor assembly of claim 9, further comprising a sub floor, wherein said sub floor is attached to a bottom side of said pad layer.

14. An underlayment adapted to receive and secure at least one heating element of a radiant heating assembly, comprising:

a base material defining an area and having a first side and a second side disposed opposite the first side;

a plurality of routing hubs disposed on said first side of said base material and adapted to receive a heating element, each of said routing hubs further comprising four protrusions; and

a first and second heating element receiving cavity wherein said first heating element receiving cavity is formed by said protrusions and said second heating element receiving cavity being formed by said routing hubs.

15. The underlayment of claim 14, wherein said protrusions have at least one cutout portion.

16. The underlayment of claim 15, wherein said cutout portions are adapted to receive one of at least adhesive, epoxy, grout, cement, glue, and plastic.

17. The underlayment of claim 14, wherein said protrusions are formed from the base material.

18. The underlayment of claim 14, wherein said routing hubs are arranged in a matrix configuration.

19. The underlayment of claim 14, wherein said first and second heating element receiving cavities further comprise a receiving surface adapted to retain a heating element.

20. The underlayment of claim 19, wherein said receiving surface is one of an arcuate receiving surface and an angular receiving surface.