U.S. patent application number 10/234787 was filed with the patent office on 2004-03-04 for in a dry installation of a radiant floor or wall hydronic heating system, metal radiating sheets that attach to the rough floor or wall adapted with a metal slot for holding hot water tubing.
Invention is credited to Fiedrich, Joachim.
Application Number | 20040040693 10/234787 |
Document ID | / |
Family ID | 31977468 |
Filed Date | 2004-03-04 |
United States Patent
Application |
20040040693 |
Kind Code |
A1 |
Fiedrich, Joachim |
March 4, 2004 |
In a dry installation of a radiant floor or wall hydronic heating
system, metal radiating sheets that attach to the rough floor or
wall adapted with a metal slot for holding hot water tubing
Abstract
In a hydronic heating system including a heating element that is
a length of tubing that conducts water mounted in a wall, floor or
ceiling of an area heated by the system against a radiating metal
sheet, the method of providing the radiating metal sheet including
the steps of: forming a unitary sheet of metal by bending and
folding it longitudinally to provide a first protuberance of double
thickness and bending and folding it longitudinally to provide a
second protuberance of double thickness, the protuberances being
evenly spaced apart providing a longitudinal metal slot for holding
the tubing, the rest of the metal sheet providing radiation
surfaces that extend away from the protuberances in a common plane,
whereby the protuberances are substantially perpendicular to the
common plane, and the metal slot accommodates the insertion therein
of the tubing from one side of the sheet so that the tubing is held
therein in intimate thermal contact with the sheet metal, whereby
the sheet is heated by conduction of heat from the tubing and
radiates heat from the one side to the area.
Inventors: |
Fiedrich, Joachim;
(Carlisle, MA) |
Correspondence
Address: |
Robert T. Dunn
4 Cedar Ridge Drive
Bedford
MA
01730
US
|
Family ID: |
31977468 |
Appl. No.: |
10/234787 |
Filed: |
September 4, 2002 |
Current U.S.
Class: |
165/56 ;
165/53 |
Current CPC
Class: |
F24D 3/14 20130101; Y02B
30/24 20130101; Y02B 30/00 20130101; F24D 3/148 20130101 |
Class at
Publication: |
165/056 ;
165/053 |
International
Class: |
F24D 005/10; F24H
009/06; F24D 019/02; F24H 001/00 |
Claims
1. In a hydronic heating system including a heating element that is
a length of tubing that conducts water mounted in a wall, floor or
ceiling of an area heated by said system against a radiating metal
sheet, the improvement comprising: (a) said metal sheet is formed
of a unitary sheet of metal bent and folded longitudinally to
provide a first protuberance of double thickness and bent and
folded longitudinally to provide a second protuberance of double
thickness, (b) said protuberances being evenly spaced apart
providing a longitudinal slot for holding said tubing, (c) the rest
of said metal sheet providing radiation surfaces that extend away
from said protuberances in a common plane, (d) whereby said
protuberances are substantially perpendicular to said common plane,
(e) said metal slot accommodates the insertion therein of said
tubing from one side of said sheet so that the tubing is held
therein in intimate thermal contact with said sheet metal, (f)
whereby said sheet is heated by conduction of heat from said tubing
and radiates heat from said one side to said area.
2. A hydronic heating system as in claim 1 wherein: (a) said sheet
has length, width and thickness and said length and width define
said radiating surfaces of said sheet and (b) said sheet is mounted
in said floor, wall or ceiling oriented with said radiation
surfaces thereof parallel to said floor or wall surface adjacent
thereto.
3. A hydronic heating system as in claim 1 wherein: (a) said
unitary sheet of metal is of uniform thickness.
4. A hydronic heating system as in claim 1 wherein: (a) said metal
sheets are modular so that a multitude of said sheets laid
end-to-end and side-by-side on a surface define a multitude of
courses for holding a continuous length of said tubing.
5. A hydronic heating system as in claim 4 wherein: (a) sleeper
boards are provided filling the spaces between the slots of said
side-by-side modular metal sheets to provide an even surface for
the finish material
6. A hydronic heating system as in claim 1 wherein: (a) said metal
slot is contoured to provide spaces between said inserted tubing
and said sheet metal in said slot for containing a resilient filler
material.
7. A hydronic heating system as in claim 1 wherein: (a) said metal
sheet that extends away from said protuberances providing radiation
surfaces has a longitudinal edge and said longitudinal edge is bent
longitudinally to increase longitudinal rigidity of said sheet.
8. A hydronic heating system as in claim 7 wherein: (a) said
longitudinal edge is bent double.
9. In a hydronic heating system including a heating element that is
a length of tubing that conducts water mounted in a wall, floor or
ceiling of an area heated by said system against a radiating metal
sheet, the method of providing said radiating metal sheet including
the steps of: (a) forming a unitary sheet of metal by bending and
folding it longitudinally to provide a first protuberance of double
thickness and bending and folding it longitudinally to provide a
second protuberance of double thickness, (b) said protuberances
being evenly spaced apart providing a longitudinal metal slot for
holding said tubing, (c) the rest of said metal sheet providing
radiation surfaces that extend away from said protuberances in a
common plane, (d) whereby said protuberances are substantially
perpendicular to said common plane, (e) said metal slot
accommodates the insertion therein of said tubing from one side of
said sheet so that the tubing is held therein in intimate thermal
contact with said sheet metal, (f) whereby said sheet is heated by
conduction of heat from said tubing and radiates heat from said one
side to said area.
10. The method as in claim 9 wherein: (a) said sheet has length,
width and thickness and said length and width define said radiating
surfaces of said sheet and (b) said sheet is mounted in said floor,
wall or ceiling oriented with said radiation surfaces thereof
parallel to said floor or wall surface adjacent thereto.
11. The method as in claim 9 wherein: (a) said unitary sheet of
metal is of uniform thickness.
12. The method as in claim 9 wherein: (a) said metal sheets are
modular so that a multitude of said sheets laid end-to-end and
side-by-side on a surface define a multitude of courses for holding
a continuous length of said tubing.
13. The method as in claim 12 wherein: (a) sleeper boards are
provided filling the spaces between the slots of said side-by-side
modular metal sheets to provide an even surface for a finish
material
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to hydronic heating systems for
dwellings, offices, etc. having heating loops that consist of
tubing or pipes held in the floor or walls of a room by modular
metal radiation sheets that radiates heat to heat the room, the
tubing being secured in intimate thermal contact with the metal
radiation sheet; and, more particularly, where the modular metal
sheet is a unitary piece of metal sheeting shaped to provide a
radiation surface and a metal slot into which the tubing is
inserted and held in thermal contact with the sheet.
Dry Modular Panel Radiant Floor and Wall Hydronic Heating
[0002] Radiant floor heating (RFH) and radiant wall heating (RWH)
are techniques of heating rooms in a dwelling or commercial
building for human and creature comfort. It is believed by many
that radiant heating is the ideal way to warm the human body and
superior to forced hot air heating.
[0003] Typical hydronic heating systems require a supply of hot
water from a boiler and means for modulating the temperature of the
water from the supply that is fed to the heating loops of the
system, which include tubing and heating elements. This is
particularly the case where modular panels are used in a dry
installation on top of the floor for RFH or in the wall for RWH.
For example, if the supply water temperature is 180.degree. F. for
laundry, it must be modulated to about 100.degree. F. for RFH. A
suitable system for reducing and controlling the supply water
temperature for RFH is described in U.S. Pat. No. 5,119,988, issued
Jun. 9, 1992, entitled "Hydronic Heating Water Temperature Control
System", to Joachim Fiedrich, the inventor herein. In that patent a
three-way, modulated diverting or by-pass valve is provided in the
return line to the boiler, for diverting some of the cooler return
water to the hot supply water to reduce the temperature of the
supply water feeding the heating loop supply header. This is
sometimes called temperature dilution and the diverting valve is
modulated by a feedback signal derived from the diluted water
temperature.
[0004] A modular panel heating element for RFH or RWH is described
in U.S. Pat. No. 5,292,065, issued Mar. 8, 1994, entitled "Radiant
Floor And Wall Hydronic Heating Systems", to Joachim Fiedrich, the
inventor herein. It includes a metal radiation sheet or sheet
attached to two spaced apart boards for holding the tubing in the
space between the boards (the tube holding space) in intimate
thermal contact with the radiation sheet, so that the sheet is
heated by conduction of heat from the tubing, and the sheet has a
substantial radiating surface that radiates heat to the room.
[0005] Thermal conduction from the tubing to the sheet and
mechanical attachment of the tubing to the metal sheet can be
insured by a resilient thermally conductive filler material
inserted in the tube holding space before the tubing is inserted as
described in U.S. Pat. No. 5,579,996, issued Dec. 3, 1996, entitled
"Radiant Floor And Wall Hydronic Heating Systems", also to Joachim
Fiedrich, the inventor herein.
[0006] Thermal conduction from the tubing to the sheet is further
enhanced by under cutting the boards at their spaced apart edges to
widen the tube holding space at the sheet and so increase the
"thermal footprint" of the tubing on the radiation sheet as
described in pending U.S. Pat. No. 6,152,377, issued Nov. 28, 2000,
entitled "Radiant Floor And Wall Hydronic Heating System Tubing
Attachment To Radiant Plate", to Joachim Fiedrich, the inventor
herein.
[0007] The modular panel heating element described in the above
mentioned US patents and pending patent applications can be used to
cool as well as heat. In some installations, cooling is done by
feeding cool water to the tubing to reduce the temperature of the
sheet in the modular panel below room temperature so that heat
flows from the room to the sheet to the cool water, heating the
water slightly and the water is then fed to a heat exchanger where
it gives up the heat and is fed back to cool the panels. This
circulation of cool water is continuous and may be a closed system.
Several structures and adaptations of the RFH and RWH system for
cooling are described in U.S. Pat. No. 5,931,381, issued Aug. 3,
1999, entitled "For Radiant Floor, Wall And Ceiling Hydronic
Heating And/Or Cooling Systems Using Metal Plates That Are Heated
Or Cooled By Attached Tubing That Is Fed Hot Or Cold Water,
Techniques Of Improving Performance And Avoiding Condensation When
Cooling", to Joachim Fiedrich, the inventor herein.
[0008] When used for cooling, the floor installation is called
Radiant Floor Cooling (RFC), the wall installation is called
Radiant Wall Cooling (RWC) and the ceiling installation is called
(RCC). The floor installations are particularly effective for
heating and can also be used for cooling, the ceiling installations
are particularly effective for cooling and can also be used for
heating and the wall installations are effective for both heating
and cooling.
[0009] In any of the systems described in the aforementioned US
patents, patent applications and provisional applications, hot
and/or cold spots on the surface of the finished floor, wall or
ceiling that covers the modular panels sometimes occurs. These
spots are identified as being hotter during heating or cooler
during cooling than elsewhere on the finished surface, whereas
uniform surface temperature is preferred. Cold spots on the
finished covering during cooling can be particularly troublesome,
because when the temperature of the cold spot falls below the dew
point in the room, undesirable condensation occurs on the surface.
Techniques of eliminating or reducing such hot or cold spots are
described in said U.S. Pat. No. 5,931,381. The systems described in
that patent include floor, wall and ceiling installations of
modular panel elements and tubing.
[0010] In all of the above mentioned US patents, patent
applications and provisional applications, in which the modular
panel consists of two spaced apart holding boards that hold the
metal radiation sheet and the sheet is a unitary piece that
attaches to both boards and so fixes the uniform space between the
boards into which the tubing is inserted so that it is in intimate
thermal contact with the sheet. Several of the structures described
in the above mentioned patents and applications of the inventor
herein are shown in Figures A to H herein, denoted Prior Art.
[0011] Two types of modular panels are shown in Figures A to H, The
first type, shown in Figures A to D, has a flat sheet or sheet of
aluminum attached to one side of the two spaced apart boards. This
type of modular panel can be attached to the top of the sub-floor,
as shown in Figure A and B and the tubing inserted into the tube
holding space from the top and after insertion of the tubing in the
panels, a finished wall or ceiling can be installed; or it can be
attached to the bottom of the sub-floor between the floor joists as
shown in Figures C and D and the tubing inserted into the tube
holding space from beneath (from the floor below). The attachment
to the bottom of the sub-floor is often preferred where an finished
floor is already in place and/or where the added thickness
dimension of the panels on top of the sub-floor cannot be
tolerated.
[0012] The second type of modular panel, shown in Figures E to H,
has a slotd sheet or sheet of aluminum attached to one side of the
spaced apart boards with the metal slot projecting into the spacing
between the boards, (the tube holding space). This type of modular
panel can be attached to the top of the sub-floor, as shown in
Figure E and F and the tubing inserted into the metal slot from the
top; or it can be attached to the bottom of the sub-floor between
the floor joists as shown in Figures G and H and the tubing
inserted into the metal slot from beneath (from the floor below).
The preference for one or the other also depends on whether a
finished floor is already in place and/or where the added thickness
dimension of the panels on top of the sub-floor cannot be
tolerated.
[0013] Both types of these Prior Art modular panels can also be
mounted to a wall or a ceiling, in which case, the elongated space
between the boards and/or the metal slot in the sheet, (herein
called the tube holding space) into which the tubing is inserted,
provides access for the insertion on the room side of the wall or
ceiling so that the tubing can be inserted from that side after the
panels are attached to the wall studs or the ceiling rafters. After
insertion of the tubing in the panels, a finished wall or ceiling
can be installed.
[0014] As mentioned above, in all of these Prior Art modular
panels, the unitary piece metal sheet or metal sheet is fixedly
attached to the two spaced apart boards to provide the modular
panel ready for installation side by side and end to end on or
under a sub-floor or on a wall or ceiling for heating or for
cooling the room.
[0015] The inventor herein has found a need for an installation in
which the boards are provided in situs and in which all pairs of
boards may not be the same width and/or length or even where the
width of the metal radiation sheet may not be the same for all
courses of the inserted tubing.
[0016] Heretofore, to provide greater versatility and selections of
installations, the inventor herein has conceived and made modular
metal sheet structures in two separate pieces that are attached to
opposite edges of each board of the pair of spaced apart boards at
installation; thereby to provide metal radiation surfaces on each
board and a metal slot for holding the tubing between the boards.
These modular metal sheet structures are described in U.S. Pat. No.
6,330,980, issued Dec. 18, 2001, entitled "In a Dry Installation of
a Radiant Floor or Wall Hydronic Heating System, Metal Radiating
Plates That Attach to the Edges of Side-by-side Boards and Provide
Metal Slots for Holding Hot Water Tubing", to Joachim Fiedrich, the
inventor herein.
[0017] To provide greater versatility and selections of
installations in the use of modular sheet metal radiation surfaces
that include a longitudinal metal slot for holding the tubing, the
inventor herein has conceived and made a unitary metal sheet
structure formed from a single sheet of metal that provides two
extensive radiation surfaces, one on each side of two spaced apart
protuberances that define a longitudinal slot for holding the
tubing in intimate thermal contact with the metal, which can be
mounted on top of the sub-floor, on the bottom of the sub-floor, on
wall studs or on ceiling rafters and in all cases the slot is
readily accessible for insertion of the tubing. Also, in all cases
sleeper floor boards, wallboards or insulation can be installed in
situs after insertion of the tubing and the purpose of sleeper
floorboards or sleeper wallboards is to provide an even surface for
attaching or applying a finish floor, wall or ceiling.
[0018] For on top of the sub-floor installations and for wall or
ceiling installations, the choice of the sleeper boards can be made
in situs by the installer and all sleeper boards can be installed
before or after the tubing is inserted. For under the sub-floor
installations, no sleeper boards are needed and insulation is
installed after insertion of the tubing.
[0019] In preferred embodiments, the unitary piece metal sheet is
modular and adapted to be installed in an array that provide
several side-by-side courses of the slots for insertion of a
continuous length of tubing therein and the modular pieces are
provided in two types: straight pieces and 180 turn pieces
SUMMARY OF THE INVENTION
[0020] It is an object of the present invention to provide a
modular unitary piece metal radiation sheet, formed with a
longitudinal slot that projects from the radiation side of the
sheet, for receiving and holding securely the tubing that is
inserted therein from the radiation side, for "dry" installation of
RFH, RWH, RCH, RWC and/or RCC in a hydronic heating and/or cooling
system.
[0021] It is another object of the present invention to provide
such an installation in which sleeper boards may be provided in
situs between the metal slots to provide an even rough floor, wall
or ceiling surface for installation of finish floor, wall or
ceiling thereon.
[0022] It is another object of the present invention to provide
greater versatility and selections of sleeper boards and materials
for such installations.
[0023] It is another object of the present invention to provide
such metal sheet structures that allow the sleeper boards to be cut
to suit at installation and the lengths and widths of the metal
radiation sheets can be cut to suit at installation.
[0024] These and other objects and features of the present
invention are apparent from the following descriptions of specific
embodiments of the invention described in conjunction with the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Figure A (Prior Art) is a perspective view of a modular
panel of the first type which is an assembly of a metal radiation
or heat transfer sheet and holder boards according to the above
mentioned U.S. Pat. Nos. 5,292,065 and 5,579,996, positioned for
attachment to the top of a sub-floor;
[0026] Figure B (Prior Art) is an enlarged end view showing the
panel of the first type of metal radiation sheet and holders with
tubing inserted and adhered thereto with compliant thermally
conductive filler material, on top of the sub-floor;
[0027] Figure C (Prior Art) is a perspective view of a modular
panel of the first type, positioned for attachment to the bottom of
the sub-floor;
[0028] Figure D (Prior Art) is an enlarged end view showing the
panel of the first type attached to the bottom of the sub-floor
between floor joists;
[0029] Figure E (Prior Art) is a perspective view of a modular
panel of the second type which is an assembly of a metal radiation
or heat transfer sheet having a metal slot and holder boards
according to the above mentioned U.S. Pat. Nos. 5,292,065 and
5,579,996, positioned for attachment to the top of a sub-floor;
[0030] Figure F (Prior Art) is an enlarged end view showing the
panel of the second type of metal radiation sheet and holders with
tubing inserted in the metal slot on top of the sub-floor;
[0031] Figure G (Prior Art) is a perspective view of a modular
panel of the second type, positioned for attachment to the bottom
of the sub-floor; and
[0032] Figure H (Prior Art) is an enlarged end view showing the
panel of the second type attached to the bottom of the sub-floor
between floor joists.
[0033] According to the present invention:
[0034] FIG. 1 is an enlarged end view of an on top of the sub-floor
installation, showing a course of a unitary metal sheet formed
according to the present invention with two radiation surfaces and
a slot rising from the radiation side for holding the tubing that
is inserted into the slot from the radiation side, the sheet being
formed from a flat sheet of metal that is bent and folded double
longitudinally to form each spaced apart protuberance that together
define the slot for holding the tubing in intimate thermal contact
therewith over a majority of the outside surface of the tubing, and
with suitable sleeper boards filling the spaces between the slots
to provide an even surface for the finish floor;
[0035] FIG. 2 shows the same unitary metal sheet formed according
to the present invention, as in FIG. 1, attached underneath the
sub-floor between floor joists, with tubing inserted and covered
from below with thermal insulation;
[0036] FIG. 3 is an enlarged cross-section end view of the same
unitary metal sheet formed according to the present invention, as
in FIG. 1, that has been formed using sheet forming tools and
special dies to provide the two longitudinal folded (double layer)
protuberances so shaped and spaced apart to provide the slot on the
radiation side of the sheet for holding the tubing in intimate
thermal contact with the metal;
[0037] FIG. 4 is the same view as FIG. 3 illustrating a
modification of the embodiment in FIG. 3, providing spaces in the
slot for a resilient filler material, such as silicon caulking,
between the tubing and the metal, for mechanical and thermal
improvements such as described in the above mentioned U.S. Pat. No.
6,152,377.
[0038] FIG. 5 is an end view of the RFH installation on top of the
sub-floor showing several side-by-side courses of same unitary
metal sheet formed according to the present invention, as in FIG.
1, ready for insertion of the tubing, with an arrangement of
sleeper boards bringing the floor level to the top of the slot;
[0039] FIG. 6 is a perspective view of the RFH installation on top
of the floor shown in FIG. 5, with the tubing inserted, providing
many side-by-side courses across the floor and an arrangement of
sleeper boards;
[0040] FIG. 7 is an end view of another RFH installation on top of
the sub-floor showing several side-by-side courses of same unitary
metal sheet formed according to the present invention, as in FIG.
1, ready for insertion of the tubing, with another arrangement of
sleeper boards bringing the floor level to the top of the slot;
[0041] FIG. 8 is a perspective view of the RFH installation on top
of the floor shown in FIG. 7, with the tubing inserted, providing
many side-by-side courses across the floor and said other
arrangement of sleeper boards;
[0042] FIG. 9 is a perspective view of a RWH installation on the
wall studs showing several course of the same unitary metal sheet
formed according to the present invention, as in FIG. 1, with an
arrangement of sleeper wallboards between the slots, ready for
installation of the tubing in the slots; and
[0043] FIG. 10 is an enlarged end view of the RWH installation on
the wall studs shown in FIG. 9, with the tubing inserted.
DESCRIPTION OF PRIOR ART
Tube Holding Modular Panels of the First Type Prior Art Figs. A and
B--Panels On Top of the Sub-Floor
[0044] A configurations of a module panel, which is an assembly of
a radiation sheet 12 and tube holding boards 16 and 17 is shown in
Figures A and B. This configuration is also described in
aformentioned US patents, patent applications and provisional
applications. This panel is shown in Figure B on top the sub-floor
70 of a room for RFH. The holder boards 16 and 17 may be plywood,
particle board or other rigid material that is not thermally
conductive and preferably is the same thickness as the outside
diameter of the tubing 1 that it holds. The two lengths 16 and 17
of wood holder boards of the panel hold the heat conduction and
radiation sheet 12 and provide the tube holding space 14, the
length thereof for holding the tubing 1 against the sheet 12.
[0045] As shown in Figure B, the tube holding space 14 is the space
between boards 16 and 17 and is closed on one side (the bottom side
in this Figure) by the sheet 12 and so the tubing must be inserted
into this space from the top side of the space. Thus, the open end
of the tube holding space 14 is separated from the sub-floor by the
sheet.
[0046] The sheet is made of highly thermally conductive material
such as aluminum, copper or steel. For example, it can be made of a
relatively thin sheet of 0.008 gage, 3003 alloy aluminum; and is
attached to holder boards 16 and 17 by a suitable glue or epoxy or
by nailing or stapling or by staking as described in pending U.S.
application Ser. No. 08/746,458, filed Nov. 12, 1996 by the
inventor herein. Sheet 12 can also be made of heavier thermally
conductive material so that it conducts heat from the tubing more
readily.
Tube Holding Modular Panels of the First Type Prior Art Figs. C and
D--Panels Under the Sub-Floor
[0047] An installation of the same modular panel as shown in
Figures A and B installed under the sub-floor between floor joists
in shown in Figures C and D, Here, as in Figure A and B, the
assembly of a radiation sheet 12 and tube holding boards 16 and 17
is attached to the bottom of the sub-floor 70 of a room for
RFH.
[0048] In all other respects this kind of installation is the same
as described above with respect to Prior Art Figures A and B,
except the radiating sheet is immediately against the bottom of the
sub-floor instead of on top of it and the tubing is not against the
finished floor that would be installed, but is separated from the
finished floor by the sub-floor. This installation eliminates any
likelihood of hot spots in the finished floor that occur with
installations as in Figures A and B.
Tube Holding Modular Panels of the Second Type Prior Art Figs. E
and F--Panels on Top of the Sub-Floor
[0049] A configurations of a modular panel, which is an assembly of
a radiation sheet 33 and tube holding boards 31 and 32 is shown in
Figures E and F. This configuration is also described in the above
mentioned US patents and patent applications. This panel is shown
in Figure E and F is installed on top the sub-floor 70 of a room
for RFH. The holder boards 31 and 32 may be plywood, particle board
or other rigid material that is not thermally conductive and
preferably is the same thickness as the outside diameter of the
tubing 1 that it holds.
[0050] The two lengths 31 and 32 of spaced apart wood holder boards
of the panel hold the heat conduction and radiation sheet 33 and
provide the tube holding space 37, the length thereof, into which a
slot 34 in the metal sheet projects, substantially filling the
space between the boards. The tubing 1 is inserted into the metal
slot 34 and fits snugly therein holding the tubing 1 against the
metal of the sheet in intimate thermal contact therewith.
Structural rigidity and strength may be increased by webbing
support 36 that is attached to the opposite side of both boards
[0051] As shown in Figure F, the tube holding space 37 is the space
between boards 31 and 32 and is closed on one side (the bottom side
in this Figure) by the sheet slot 34 that projects into the space
and so the tubing must be inserted into this space from the top
side of the space. In this case, the metal radiation sheet 33 is on
top of the installation and so is immediately against the finished
flooring and sometimes requires a thermal barrier as in the above
mentioned pending U.S. patent application Ser. No. 08/862,441,
filed May 23, 1997 by the inventor herein, to reduce hot spots in
the finished flooring.
[0052] Here again, the metal sheet is made of aluminum, copper or
steel. For example, it can be made of a relatively thin sheet of
0.008 gage, 3003 alloy aluminum; and is attached to holder boards
by a suitable glue or epoxy or by nailing or stapling or by staking
as described in pending U.S. application Ser. No. 08/746,458, filed
Nov. 12, 1996 by the inventor herein. Sheet 33 can also be made of
heavier thermally conductive material so that it conducts heat from
the tubing more readily.
Tube Holding Modular Panels of the Second Type Prior Art Figs. G
and H--Panels Under the Sub-Floor
[0053] An installation of the same modular panel as shown in
Figures E and F installed under the sub-floor between floor joists
in shown in Figures G and H. Here, as shown in Figure H, the
assembly of a radiation sheet 33 and tube holding boards 31 and 32
is attached to the bottom of the sub-floor 70 of a room for
RFH.
[0054] In all other respects this kind of installation is the same
as described above with respect to Prior Art Figures E and F,
except the radiating sheet is separated from the bottom of the
sub-floor by the thickness of holder boards 31 and 32 and is
further separated from the finished floor by the sub-floor. This
installation completely eliminates any likelihood of hot spots in
the finished floor that occur with installations as in Figures E
and F.
DESCRIPTION OF EMBODIMENTS OF THE PRESENT INVENTION
[0055] FIG. 1 is an enlarged end view of an on top of the sub-floor
70 installation, showing a course 46 of a unitary metal sheet 40
formed according to the present invention with two radiation
surfaces 41 and 42 and a slot 45 rising from the radiation side for
holding the tubing 1 that is inserted into the slot from the
radiation side, the sheet being formed from a flat sheet of metal
that is bent and folded double longitudinally to form each spaced
apart protuberance 43 and 44 that together define the slot 45 for
holding the tubing in intimate thermal contact therewith over a
majority of the outside surface of the tubing, and with suitable
sleeper boards 47 and 48 filling the spaces between the slots to
provide an even surface for the finish floor.
[0056] The longitudinal edges of the metal sheet that provide the
radiation surfaces 41 and 42 are folded (or "hemmed") at 51 and 52
to increase the longitudinal rigidity of the sheet FIG. 2 shows the
same unitary metal sheet 40 formed according to the present
invention, as in FIG. 1, attached underneath the sub-floor 70
between floor joists 71, with tubing 1 inserted and covered from
below with thermal insulation 49.
[0057] FIG. 3 is an enlarged cross-section end view of the same
unitary metal sheet 40 formed according to the present invention,
as in FIG. 1, that has been formed using sheet forming tools and
special dies to provide: two extensive radiation surfaces 41 and 42
and two longitudinal folded (double layer) protuberances 43 and 44
so shaped and spaced apart to provide the slot 45 on the radiation
side of the sheet for holding the tubing 1 when inserted therein in
intimate thermal contact with the metal.
[0058] FIG. 4 is the same view as FIG. 3 illustrating a
modification of the embodiment in FIG. 3, providing spaces 155 and
156 in the slot 145 for a resilient filler material 160, such as
silicon caulking, between the tubing 1 and the metal, for
mechanical and thermal improvements such as described in the above
mentioned U.S. Pat. No. 6,152,377. The caulking enables the tubing
1 to move longitudinally within the slot 145 while it is still held
securely therein and can improve thermal conductivity between the
tubing and the sheet 140.
RFH Installation of Many Courses of Continuous Tubing
[0059] FIG. 5 is an end view of the RFH installation on top of the
sub-floor 70 supported by floor joists 71, (as shown enlarged in
FIG. 1) showing several side-by-side courses 46 of same unitary
modular metal sheets pieces 40 formed according to the present
invention, as in the embodiments of FIG. 3 or 4, ready for
insertion of the tubing 1, with an arrangement of sleeper boards 47
and 48 bringing the floor level to the top of the slots 45 in the
metal sheets.
[0060] FIG. 6 is a perspective view of the RFH installation on top
of the sub-floor 70 shown in FIG. 5, with a continuous length of
the tubing 1 inserted, providing many side-by-side courses across
the floor. The unitary modular metal sheet pieces 40 are provided
in two types: straight pieces, like 40 providing courses 46 and
1800 turn pieces, like 40', providing 180.degree. turn courses like
46' at an end of two side-by-side straight courses. The sleeper
boards between the slots of side-by-side straight courses are
denoted 47 and 48 and the sleeper boards between a 180.degree. turn
course, like 46', and the straight courses are denoted 47' and 48'
FIG. 7 is an end view of another RFH installation on top of the
sub-floor 70 supported by floor joists 71, showing several
side-by-side courses 46 of same unitary modular metal sheets pieces
40 formed according to the present invention, as in the embodiments
of FIGS. 3 and 4, ready for insertion of the tubing 1, with another
arrangement of sleeper boards 47 and 48 bringing the floor level to
the top of the slots 45 in the metal sheets.
[0061] FIG. 8 is a perspective view of the RFH installation on top
of the sub-floor 70 shown in FIG. 7, with a continuous length of
the tubing 1 inserted, providing many side-by-side courses across
the floor. The unitary modular metal sheet pieces 40 are provided
in two types: straight pieces, like 40 providing courses 46 and
180.degree. turn pieces, like 40', providing 180.degree. turn
courses like 46' at an end of two side-by-side straight courses.
The sleeper boards in this arrangement between the slots of
side-by-side straight courses are denoted 50 and the sleeper boards
between a 180.degree. turn course, like 46', and the straight
courses are denoted 471 and 48' RWH Installation of Many Courses
Horizontal Over Wall Studs Part of a typical wood frame
construction wall structure is shown in FIGS. 9 and 10 and
includes, studs 189 usually spaced apart 16" on center. FIG. 9 is a
perspective view of a RWH installation on the wall studs showing
several courses 46 of the same unitary modular metal sheet 40
formed according to the present invention, as in FIG. 3 or FIG. 4,
with an arrangement of sleeper wallboards 57 between the slots 45,
ready for installation of the tubing in the slots. Here, as shown,
the modular metal sheets 40 are installed on a sub-wall 52 for
added support. However, the modular metal sheets 40, formed as
described herein, can be made sufficiently rigid so that they can
be mounted directly on the studs to eliminate the sub-wall 52. In
either case, the sleeper wallboards 57 provide an even surface for
attaching the finished wall. For example the wallboard may be
blueboard and the finish wall may be a hard plaster skim coat
applied thereto covering the blueboard and the slots and inserted
tubing
[0062] FIG. 10 is an enlarged end view of the RWH installation on
the wall studs 189 shown in FIG. 9, with the tubing inserted and
ready for the finish wall. The finish wall may be any finished
board or panel, or it may be a skim coat of plaster 58 that is
applied uniformly to cover the blueboard 57 and the courses 46 and
tubing 1.
RCH/RCC--Modular Metal Sheets and Tubing Across Rafters
[0063] Radiant hydronic cooling described herein is effective when
installed in the ceiling, because the cooled air against the
ceiling falls to the floor creating a convection flow that is
favorable to providing even cooling throughout the room. In typical
wood frame construction the ceiling of a room before the finished
ceiling is installed is bare rafters, joists or strapping. Such a
ceiling installation would be essentially the same as the wall
installation shown in FIGS. 9 and 1, except it would be on the
rafters, joists, etc. of the ceiling instead of the wall studs as
in those Figures.
CONCLUSIONS
[0064] While the invention described herein is described in
connection with several preferred embodiments, it will be
understood that it is not intended to limit the invention to those
embodiments. It is intended to cover all alternatives,
modifications, equivalents and variations of those embodiments and
their features as may be made by those skilled in the art within
the spirit and scope of the invention as defined by the appended
claims.
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