Floor heating system including membranes that are configured to be joined together to house a heating cable, and membrane system including such membranes
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Solution Overview
Problem
Traditional floor heating systems require a second layer of thinset to encapsulate the heating cable and form a flat surface for tile installation, which is time-consuming, costly, and heavy, and repairing damage is complex due to the need to reapply and replace thinset.
Innovation Solution
A membrane system comprising a base membrane with studs and a cover membrane that snap-fit together to hold the heating cable in place, eliminating the need for a second layer of thinset and allowing for easier installation and repair by using a lightweight, flexible material that uncouples the subfloor and tiles, reducing weight and installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a second layer of thinset is used to encapsulate the heating cable and form a flat surface for tile installation, then the heating cable is securely enclosed and a flat surface is formed, but the installation time increases due to curing requirements and the system weight increases significantly
Solution Approach 1:
The patent uses a flexible uncoupling membrane (thin film) to replace the traditional thinset mortar layer for encapsulating the heating cable. The membrane is laid over the heating cable and adhered to the subfloor, providing secure enclosure without requiring curing time. This directly resolves the contradiction by eliminating the time-consuming curing process while maintaining reliable cable enclosure.
2Reliability
If a second layer of thinset is used to encapsulate the heating cable and form a flat surface for tile installation, then the heating cable is securely enclosed and a flat surface is formed, but the system weight increases by approximately 30%
Solution Approach 1:
The patent replaces heavy thinset mortar with a lightweight flexible membrane to encapsulate the heating cable. This thin film structure provides the necessary enclosure and support while dramatically reducing the overall system weight by approximately 30%, directly addressing the weight concern while maintaining reliable cable enclosure.
3Reliability
If traditional thinset application is used to encapsulate the heating cable, then secure enclosure is achieved, but repair complexity increases due to the need to reapply and replace thinset
Solution Approach 1:
The patent segments the flooring system into distinct layers: subfloor, uncoupling membrane, heating cable, and tile layer. The uncoupling membrane acts as a separate, removable component that can be easily detached and replaced without affecting the subfloor or requiring reapplication of adhesive materials. This segmentation dramatically simplifies repair processes compared to traditional thinset-based systems.
Solution Approach 2:
The flexible membrane provides a removable enclosure for the heating cable that can be easily peeled back and reinstalled during repairs. Unlike rigid or adhesive-based systems, the flexible film allows for simple removal and reinstallation, reducing repair complexity while maintaining secure cable enclosure during normal operation.
4Reliability
If traditional floor heating installation methods are used with thinset, then heating cable enclosure is achieved, but installation cost increases due to material and labor requirements
Solution Approach 1:
The patent uses a flexible uncoupling membrane that can be quickly laid over the heating cable and adhered to the subfloor, eliminating the need for mixing, applying, and curing thinset mortar. This reduces both material costs (no expensive adhesive required) and labor costs (faster installation without curing wait times), directly addressing the cost concern while maintaining reliable cable enclosure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The membrane system reduces installation time and cost by eliminating the need for thinset application and curing, decreases system weight by approximately 30%, and simplifies repairs by allowing for direct access and replacement of the heating cable without reapplying thinset.
Implementation Method 1
The heating cable generates heat when electrical current is passed through the heating cable
Implementation Method 2
the uncoupling membrane uncouples the floor covering and the subfloor from one another to allow the floor covering and the subfloor to move in a horizontal plane relative to one another
Data Source
AI summary
A membrane system includes a base membrane and a cover membrane. The base membrane is configured to be installed between a subfloor and floor tiles to allow movement of the floor tiles relative to the subfloor. The base membrane includes a base layer and studs projecting from the base layer. The studs are configured to hold a heating cable in place when the heating cable is positioned between adjacent ones of the studs. The studs have free ends that define pockets therein. The cover membrane is configured to be coupled to the base membrane to encapsulate the heating cable between the base membrane and the cover membrane. The cover membrane includes a cover layer and studs projecting from the cover layer. The studs on the cover membrane are configured to fit within the pockets in the base membrane to couple the cover membrane to the base membrane.