Heating Element Underlayment Layout for Secure Floor Routing
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Solution Overview
Problem
Existing in-floor heating systems face issues with uneven heating and wire damage due to unsecured wires between studs, and hydronic systems require a hot water storage tank, which is less efficient than electric systems.
Innovation Solution
The underlayment system features protrusions forming routing hubs with receiving cavities to securely route and contain heating elements, allowing for efficient installation and reducing thermal loss, and includes a pad layer for additional support and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wires are not secured between adjacent studs, then installation is simpler, but uneven heating and wire damage occur
Solution Approach 1:
The underlayment is divided into modular sections with protrusions at regular intervals that create discrete routing locations. Each protrusion acts as an independent routing hub that segments the wire path into controlled sections, ensuring proper spacing and securing without requiring continuous attachment mechanisms.
Solution Approach 2:
Protrusions serve as intermediary elements between the underlayment and heating wires. These protrusions provide a mechanical interface that guides and secures wires at appropriate intervals, mediating between the simple underlayment structure and the need for wire retention to prevent uneven heating.
2Productivity
If a continuous mat is used, then installation speed increases, but subsequent adhesive layers cannot interact with previously placed layers
Solution Approach 1:
The continuous mat is segmented by protrusions that create discrete interaction zones. These protrusions allow adhesive to be applied at specific locations and provide mechanical keys for subsequent layers to bond to, maintaining bonding capability while preserving the overall continuous structure for fast installation.
Solution Approach 2:
The protrusions add a vertical dimension to the otherwise flat continuous mat. By creating raised features, the system enables multi-layer adhesive bonding in the vertical dimension while maintaining horizontal continuity, allowing subsequent layers to interact with previous layers at specific elevated points.
3Power
If hydronic systems are used, then heating capacity increases, but a hot water storage tank is required which reduces efficiency
Solution Approach 1:
The invention extracts the water storage tank component from the heating system by transitioning to electric heating elements. This removes the source of thermal loss associated with maintaining a hot water reservoir while retaining the heating function through direct electric cable or mat elements that convert electrical energy directly to heat at the installation location.
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 provides secure routing and efficient heat transfer, reducing the risk of uneven heating and wire damage while eliminating the need for a hot water storage tank, enhancing the overall efficiency and installation speed of in-floor heating systems.
Implementation Method 1
In-floor and in-wall heating and cooling is well known that utilizes heat conduction and radiant heat
Implementation Method 2
In-floor and in-wall heating and cooling is well known that utilizes heat conduction and radiant heat
Implementation Method 3
Carbon film systems are normally installed under the wire and onto a thin insulation underlay to reduce thermal loss to the sub floor
Data Source
AI summary
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.