Segmented Heating Cable Splice for Floor Membrane Bosses
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Solution Overview
Problem
The existing heating cable installations for in-floor and in-wall heating systems face challenges due to the large size of the hot to cold splice, which requires cutting the base membrane to fit, leading to increased installation thickness, time consumption, and compromise of the moisture barrier.
Innovation Solution
A center splice design that can be snapped or woven between the bosses of the base membrane, with staggered electrical connections and bulges matching the gaps between the bosses, eliminating the need for membrane cutting and maintaining low installation thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a traditional hot to cold splice is used, then electrical connections are provided, but the splice size requires cutting the base membrane and increases installation thickness
Solution Approach 1:
The splice is divided into multiple sections (first section, second section, third section) with varying widths. The narrower first and third sections fit between bosses, while the wider second section provides space for electrical connections. This segmentation allows the splice to navigate through the boss gaps without cutting the membrane while still accommodating necessary electrical components.
Solution Approach 2:
The splice utilizes the vertical dimension by creating a three-dimensional structure that weaves between bosses. The alternating narrow-wid e-narrow pattern in the longitudinal direction, combined with vertical positioning between bosses, allows the splice to fit through the membrane structure without requiring horizontal cutting, effectively using spatial arrangement to solve the size constraint.
2Ease of operation
If the base membrane is cut to accommodate the splice, then the splice can be installed, but the moisture barrier characteristics are compromised and installation time increases
Solution Approach 1:
The splice is segmented into sections with alternating widths that correspond to the spacing between bosses. The narrow sections pass through gaps between bosses while the wide section contains electrical connections, allowing the entire splice to be installed by weaving through the boss pattern without cutting the membrane, thus preserving the moisture barrier.
Solution Approach 2:
The bosses act as intermediaries that guide and support the splice installation. The splice is designed to interact with the boss structure, using the gaps between bosses as pathways for installation. This intermediary relationship between the splice and boss structure eliminates the need for membrane cutting while maintaining installation feasibility.
3Ease of operation
If the splice is made larger to accommodate electrical connections, then electrical functionality is provided, but installation thickness and height increase
Solution Approach 1:
The splice has non-uniform width distribution with narrow sections for fitting between bosses and a localized wide section for electrical connections. This local quality variation allows the splice to maintain low overall profile while providing adequate space for electrical connections only where necessary, rather than increasing the size of the entire splice assembly.
Solution Approach 2:
The splice distributes its volume in the longitudinal direction rather than uniformly increasing thickness. The alternating width pattern extends the splice lengthwise while keeping the vertical profile low, allowing electrical connections to be accommodated in the wider section without significantly increasing the overall installation thickness.
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
This solution streamlines the installation process, reduces installation time, and preserves the moisture barrier integrity by accommodating the splice without cutting the membrane, allowing for quicker and more efficient installation with minimal thickness.
Implementation Method 1
The heated cable is made of a resistive element with high resistivity that heats up when electrified to provide the floor warming characteristics
Implementation Method 2
The cold lead is made of larger gauge copper wire with low resistivity such that the cold lead does not heat up when electrified
Data Source
AI summary
A heating cable splice having two bulges interspersed between three sections of the heating cable splice having a smaller width than a width of the two bulges, wherein first, second, third, fourth, and fifth sections of the heating cable splice are adapted to receive electrical cabling therein, and wherein the heating cable splice is adapted to be positioned between upwardly extending bosses on a base membrane. A heating cabling system and method of providing a method of forming a heating cabling system is also disclosed.