Protrusion-Based Underlayment for Secure Heating Element 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 thick floors and inefficient hot water storage tanks.
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 even heat distribution, and includes a pad layer for additional support and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If wires are spaced at specific locations using studs, then even heating is achieved, but wires may separate from studs causing uneven heating or wire damage
Solution Approach 1:
The heating wire is nested within a groove formed in the stud, creating a secure fit that prevents separation. The groove acts as a containment structure that holds the wire in place while maintaining the stud's positioning function for even heat distribution.
Solution Approach 2:
The stud is segmented to include a groove that specifically accommodates the heating wire. This segmentation allows the stud to perform multiple functions: positioning for even heating and securing the wire through the groove structure, preventing wire damage.
2Temperature
If hydronic systems use pipes to circulate hot water, then heating is provided, but thick floors are required which may be undesirable
Solution Approach 1:
The patent replaces the mechanical hydronic pipe system with an electrical heating cable system installed within thinset mortar. This substitution eliminates the need for thick floors required by hydronic pipes while maintaining heating capability through electrical resistance heating.
Solution Approach 2:
The heating system transitions from hydraulic parameters (water circulation, pipe diameter) to electrical parameters (cable resistance, current flow). This parameter change allows for a much thinner installation profile since electrical cables require minimal clearance compared to hydronic pipes.
3Duration of action of stationary object
If hydronic systems use hot water storage tanks, then continuous heating is maintained, but system efficiency decreases
Solution Approach 1:
The electrical heating cable system provides on-demand heating without requiring a storage tank. The system activates only when heating is needed, eliminating the energy waste associated with maintaining hot water in storage tanks while still providing continuous heating capability through direct electrical connection.
Solution Approach 2:
The patent extracts and eliminates the hot water storage tank component from the heating system. By removing this energy-inefficient element and replacing it with direct electrical heating, the system maintains continuous heating capability while significantly improving overall energy efficiency.
4Ease of operation
If adhesive layers are placed over studs, then wire positioning is guided, but subsequent adhesive layers cannot interact with previously placed layers
Solution Approach 1:
The stud groove provides a localized pathway for the heating wire that extends through the adhesive layer. This local structural feature ensures wire positioning guidance while maintaining adhesive bonding continuity, as the groove allows the adhesive to flow around and bond to the wire-stud assembly rather than creating a barrier.
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 installation costs and eliminating the need for thick floors, while ensuring even heating and minimizing wire damage.
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
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.