Protrusion Underlayment for Precise Floor Heating Wire Positioning
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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, while electric systems have low installation costs but may suffer from thermal loss.
Innovation Solution
The underlayment system features protrusions forming routing hubs with receiving cavities to securely route and contain heating elements, allowing for efficient routing and minimizing thermal loss, and includes a pad layer for added strength and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wires are spaced at specific locations using studs, then even heating is facilitated, but wires may separate from studs causing uneven heating or wire damage
Solution Approach 1:
The underlayment is divided into modular sections with integrated wire positioning features. Each module contains recesses and protrusions that segment the wire routing path, ensuring wires remain securely positioned at specific locations throughout the installation without relying on separate studs that could fail.
Solution Approach 2:
The wire positioning function is merged directly into the underlayment structure itself. The recesses and protrusions are integrated features of the underlayment material, combining the support function with the insulation layer, eliminating the need for separate stud components that could separate from wires.
2Temperature
If hydronic systems use pipes to circulate hot water, then heating is provided, but floor thickness increases and hot water storage tanks are required
Solution Approach 1:
The heating function is extracted from the traditional hydronic pipe system and integrated directly into the underlayment material. The phase change material capsules are embedded within the underlayment itself, removing the need for separate pipe layers and reducing overall floor thickness while maintaining heating capability.
Solution Approach 2:
The heating mechanism transitions from hydraulic (hot water circulation) to thermodynamic (phase change material). By using phase change material that absorbs and releases heat during phase transitions, the system eliminates the need for continuous water circulation and large storage tanks, achieving thin-floor heating with reduced infrastructure.
3Length of moving object
If electric cables are installed directly onto sub floor or installation board, then installation height is minimized, but thermal loss may occur without proper insulation
Solution Approach 1:
The insulation function is merged with the heating function in a single integrated underlayment layer. The phase change material capsules are embedded within the insulating underlayment, combining thermal insulation with active heating capability, thereby minimizing thermal loss while maintaining low installation height.
Solution Approach 2:
The underlayment uses composite material construction with phase change material capsules embedded in an insulating matrix. This composite structure provides both insulation properties to prevent thermal loss and heating properties through phase change, achieving energy efficiency in a thin profile suitable for direct installation over sub floors.
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 system provides secure and efficient routing of heating elements, reducing thermal loss and installation thickness, while maintaining low installation costs and efficient heating performance.
Implementation Method 1
The underlayment may include phase change material configured to absorb and/or release heat
Implementation Method 2
The underlayment may include a reflective material
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.