U.S. patent application number 11/200960 was filed with the patent office on 2006-01-05 for method of installing a radiant density floor heating system.
This patent application is currently assigned to Sealed Air Corporation (US). Invention is credited to Charles Kannankeril, Dale Tokarski.
Application Number | 20060000184 11/200960 |
Document ID | / |
Family ID | 34116575 |
Filed Date | 2006-01-05 |
United States Patent
Application |
20060000184 |
Kind Code |
A1 |
Kannankeril; Charles ; et
al. |
January 5, 2006 |
Method of installing a radiant density floor heating system
Abstract
A method of installing a radiant density floor heating system,
in which a multi-layer conductive/insulation pad is disposed atop
the ground or a subfloor, a heating element is placed atop the pad,
a concrete or cement layer is laid atop the heating element and
pad, and a flooring material is laid atop the cement layer. The pad
comprises a first polymer layer having a first side that forms an
outer surface of the multi-layer conductive/insulation pad, a
conductive layer laminated to an opposite second side of the first
polymer layer, a second polymer layer laminated to the side of the
conductive layer opposite the first polymer layer, and a first air
cellular cushioning layer laminated to the side of the second
polymer layer opposite the conductive layer. The pad can also
include a second air cellular cushioning layer and/or a protective
polymer layer.
Inventors: |
Kannankeril; Charles; (North
Caldwell, NJ) ; Tokarski; Dale; (Carmel, IN) |
Correspondence
Address: |
ALSTON & BIRD LLP;BANK OF AMERICA PLAZA
101 SOUTH TRYON STREET, SUITE 4000
CHARLOTTE
NC
28280-4000
US
|
Assignee: |
Sealed Air Corporation (US)
|
Family ID: |
34116575 |
Appl. No.: |
11/200960 |
Filed: |
August 10, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10637282 |
Aug 8, 2003 |
|
|
|
11200960 |
Aug 10, 2005 |
|
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Current U.S.
Class: |
52/741.1 |
Current CPC
Class: |
B32B 2307/206 20130101;
B32B 2307/202 20130101; E04F 15/18 20130101; B32B 27/08 20130101;
E02D 27/01 20130101; E04F 15/182 20130101; B32B 15/08 20130101;
B32B 27/20 20130101; B32B 15/20 20130101; Y10T 428/24661 20150115;
E04B 1/78 20130101 |
Class at
Publication: |
052/741.1 |
International
Class: |
E04B 1/00 20060101
E04B001/00 |
Claims
1. A method of installing a radiant density floor heating system,
the method comprising the steps of: (a) disposing on a substrate a
multi-layer conductive/insulation pad comprising: (i) a first
polymer layer having a first side that forms an outer surface of
the multi-layer conductive/insulation pad; (ii) a conductive layer
laminated to an opposite second side of said first polymer layer;
iii) a second polymer layer laminated to the side of said
conductive layer opposite said first polymer layer; and (iv) a
first air cellular cushioning layer laminated to the side of said
second polymer layer opposite said conductive layer; (b)
positioning a heating element atop said pad so that when said
heating element is activated, heat generated from said heating
element is reflected away from said pad; and (c) providing a layer
of cementitious material on said heating element and said pad.
2. The method of claim 1, further comprising the step of: (d)
placing a flooring material on said layer of cementitious
material.
3. The method of claim 1, wherein said pad further comprises: (v) a
protective polymer layer laminated to the side of said first air
cellular cushioning layer opposite said second polymer layer;
wherein the pad is disposed with the protective polymer layer
against a substrate or subfloor on which the radiant density floor
heating system is supported.
4. The method of claim 1, wherein said pad further comprises: a
third polymer layer laminated to the side of said first air
cellular cushioning layer opposite said second polymer layer, and a
second air cellular cushioning layer laminated to the third polymer
layer on the side opposite said first air cellular cushioning
layer.
5. The method of claim 4, wherein said pad further comprises: a
protective polymer layer laminated to the side of said second air
cellular cushioning layer opposite said third polymer layer;
wherein the pad is disposed with the protective polymer layer
against a substrate or subfloor on which the radiant density floor
heating system is supported.
6. The method of claim 1, wherein the layer of cementitious
material is provided by pouring wet cementitious material atop the
heating element and pad, such that the heating element and pad are
at least partially embedded in the layer of cementitious
material.
7. The method of claim 1, wherein said conductive layer comprises a
thin foil of metal or a metallized thermoplastic layer.
8. The method of claim 1, wherein said conductive layer comprises
aluminum.
9. The method of claim 1, wherein said first polymer layer and said
second polymer layer each comprises at least one of polyethylene,
low density polyethylene, linear low density polyethylene,
co-polymers of polyethylene and polypropylene, polyethylene
terephthalate, polyamide, and polyvinyl chloride.
10. The method of claim 1, wherein said first polymer layer
comprises a pigmented polymer film.
11. A method of constructing a heated floor, comprising the steps
of: disposing a multi-layer conductive/insulation pad atop a
substrate, the pad comprising: (a) a first polymer layer having a
first side that forms an outer surface of the multi-layer
conductive/insulation pad for placement directly against a building
structure; (b) a conductive layer laminated to an opposite second
side of said first polymer layer; (c) a second polymer layer
laminated to the side of said conductive layer opposite said first
polymer layer; (d) a first air cellular cushioning layer laminated
to the side of said second polymer layer opposite said conductive
layer; (e) a second air cellular cushioning layer laminated to the
side of said first air cellular cushioning layer opposite said
second polymer layer; and (f) a protective polymer layer laminated
to the side of said second air cellular cushioning layer opposite
said first air cellular cushioning layer; the pad being disposed
with the protective layer against the substrate; placing a heating
element atop the pad; and pouring a layer of cementitious material
atop the heating element and pad and allowing the layer to harden.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application
Ser. No. 10/637,282 filed on Aug. 8, 2003, currently pending, the
entire disclosure of which is hereby incorporated herein by
reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to a multi-layer
conductive/insulation material having both conductive and
insulating properties that is particularly suitable for use under a
concrete slab, and in particular relates to a method of installing
a radiant density floor heating system incorporation such a
multi-layer conductive/insulation material.
[0003] Materials to control the movement of heat have been used for
many years and in many forms depending upon the desired use. For
example, a variety of materials such as sawdust, straw, wool
blankets and bats of foam or fiberglass have been used for
insulation. However, special uses require materials having special
insulating characteristics. One of these special uses is to prevent
radiant heat transfer under concrete slabs. In many parts of the
country houses, driveways and the like are constructed on concrete
slabs laid either directly on the ground or on sub-flooring. Many
of these types of structures are heated through hot water systems
or electrical circuits embedded in the concrete. When such
construction is used the radiant heating goes upward into the room
and downward through the ground or sub-flooring. It is therefore
desirable to prevent or substantially reduce the amount of heat
lost to the ground. One such means for reducing heat loss is to
install a system of reflective cushioning material with sealed
pockets of air.
[0004] Numerous suggestions for insulating materials for use under
concrete slabs have been made. For example, U.S. Pat. No. 6,188,839
to Pennella discloses a two-layer insulation assembly for use under
a concrete slab in a radiant heating system. These assemblies
include a rigid honeycomb panel forming a plurality of insulating
pockets alternatively disposed on the top and bottom surfaces of
the honeycomb and a reflective layer above the honeycomb to reflect
heat away from the honeycomb panel.
[0005] In U.S. Pat. No. 6,514,596 to Orologio there is described
the use of separating sheets to thermally separate construction
materials from underground soils to retain the soil in place and to
serve as moisture barriers. This patent discloses an insulating
material having thermal and moisture resistance. The sheet includes
a structure in which a metal foil is bonded between two bubble-wrap
layers. The foil is separated from the concrete by an insulation
air cellular cushioning layer. The insulating material described in
this patent is stated to reduce heat transfer.
[0006] U.S. Pat. No. 6,248,433 to Annestad discloses a multi-layer
thermal material used, for example, to cover ice skating rinks. The
multi-layered material includes an outer polyester sheet, an
insulation layer and an aluminum film layer positioned between an
inner surface of the polyester sheet and an outer surface of the
insulation layer. The aluminum film may be coated onto the
polyester sheet. The thermal material of Annestad is used to keep
cold in and heat out.
[0007] In view of the state of the art, there is a desire to
provide a conductive/insulation pad suitable for use under a
concrete pad that prevents or substantially reduces the radiant
energy from spreading out under the concrete slab.
BRIEF SUMMARY OF THE INVENTION
[0008] Despite numerous attempts to provide an effective product
that can be used to insulate under concrete slabs, the materials
presently used in the art are not altogether effective. Although
there is ample evidence that air cellular cushioning products work
in insulating under concrete slabs, it has been further suggested
that the performance is from the foil reflecting radiant energy. It
has been found that this theory is incorrect as it is a well-known
fact that coating the foil surface or applying a film to it will
substantially reduce the reflectivity of the foil. Moreover, it has
been found that the use of the conductive/insulation pad of this
invention reduces or eliminates ground water intrusion into the
concrete slab. Cold ground water will reduce the performance of a
radiantly heated slab. Secondly, the aluminum foil does not act as
a reflector as well as it does a conductor of heat allowing radiant
energy to spread out under the slab improving performance.
[0009] In accordance with the present invention, there is provided
a multi-layered conductive/insulation pad. In a first embodiment of
the invention a multi-layer conductive/insulation pad is provided
having, in order, a first polymer layer, a conductive layer, such
as a thin foil of metal or a metallized thermoplastic film,
laminated to the first polymer layer, a second polymer layer
laminated to the side of the conductive layer opposite the side of
the first polymer layer. At least one air cellular cushioning layer
is laminated to the side of the second polymer film opposite the
conductive layer. Optionally, a protective polymer layer is
laminated to the first air cellular cushioning layer on the
opposite side of the second polymer layer. The first and second
polymer layers are laminated to the opposite sides of the
conductive layer to protect the layer from oxidizing and to protect
the layer from the lime in the curing concrete, and, when used
directly on the soil, the alkali content in the soil. The
insulation component (air cellular cushioning material) prevents
the ground water intrusion into the concrete slab, as well as heat
loss into the cold ground water. The conductive layer, i.e., foil
or metallized film, conducts the heat throughout the layer allowing
radiant energy to spread out under the slab.
[0010] For the product to be efficient, the conductive layer needs
to be as close as possible to the concrete slab, without having any
insulation between the slab and the conductive layer. An advantage
of the pad of the present invention is that the air cellular
cushioning layer insulation between the conductive layer and the
concrete slab is eliminated which makes the conductive layer a more
effective conductor of heat allowing radiant energy to spread out
under the concrete slab.
[0011] In another embodiment of the present invention the
multi-layer construction of the pad of the first embodiment has
added thereto a second air cellular cushioning layer laminated to a
third polymer layer on the side opposite the first air cellular
cushioning layer. Optionally, a protective polymer layer is
laminated to the second air cellular cushioning layer on the side
opposite the third polymer layer.
[0012] After the ground or sub-flooring has been prepared for
pouring a concrete slab, the conductive/insulation pad of one of
the embodiments of the present invention is placed directly on the
soil or the sub-flooring. Typically, a heating element is placed on
the conductive/insulation pad, generally slightly above the layer,
so that some of the concrete may settle under the heating element
and so that when the heating element is activated, heat generated
from the heating element is conducted away from the pad allowing
radiant energy to spread out under the concrete pad. After the
concrete slab with the heating element embedded therein dries, a
floor surfacing such as tile or the like may be laid.
[0013] It is, therefore, an object of the present invention to
provide a conductive/insulation pad having a conductive component
consisting of a foil or metallized film protected by polymer films
on both sides and an insulation component consisting of at least
one air cellular cushioning layer.
[0014] Another object of the present invention is to provide a
reflective layer that conducts heat throughout the layer allowing
radiant energy to spread out under the slab and preventing
dispersal of heat below the reflective surface.
[0015] An additional object of the present invention is to provide
a concrete pad having a foil or metallized film that is protected
by pigmented polyethylene on one side for surface identification
purposes.
[0016] Yet another object of the present invention is to provide a
concrete pad in which the insulation layer is protected from sharp
ground objects by an additional layer of heavy-duty polymer
film.
[0017] Other objects, features and advantages of the present
invention will become apparent from the following detailed
description of the invention taken in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Having thus described the invention in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0019] FIG. 1 is a perspective view in partial section of the
conductive/insulation pad of the present invention as it is used to
conduct radiant heating across a concrete floor;
[0020] FIG. 2 is a diagramic enlarged sectional view of a first
embodiment of the conductive/insulation pad of the present
invention taken along line 2-2 of FIG. 1;
[0021] FIG. 3 is a diagramic enlarged sectional view of a second
embodiment of the conductive/insulation pad of the present
invention also taken along line 2-2 of FIG. 1; and
[0022] FIG. 4 is another perspective view in partial section of the
conductive/insulation pad of the present invention illustrating use
in another environment.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present inventions now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some, but not all embodiments of the invention are shown. Indeed,
these inventions may be embodied in many different forms and should
not be construed as limited to the embodiments set forth herein;
rather, these embodiments are provided so that this disclosure will
satisfy applicable legal requirements. Like numbers refer to like
elements throughout.
[0024] Referring more particularly to the drawings, there is shown
in FIG. 1 a perspective view of a radiant heating assembly 10
showing a conductive/insulation pad 20 overlaying the ground 12. A
heating element 14 is placed above the conductive/insulation pad 20
and positioned so that the heating element 14 may be surrounded by
the slab 16. The slab 16 comprises a layer of concrete or other
cementitious material and is poured so that it covers the
conductive/insulation pad 20 and embeds the heating element 14.
After the concrete slab 16 dries, the slab may be covered with tile
18 or other type of flooring material.
[0025] In FIG. 2 there is shown a first embodiment of the
multi-layer conductive/insulation pad 20 of the present invention.
This embodiment is a four or five layer construction wherein there
is a first polymer layer 22. Layer 22 is a clear or pigmented
polymer layer. Following the first polymer layer 22 is a conductive
layer 24 laminated to the first polymer layer 22. The next layer is
a second polymer layer 26 laminated to the side of the conductive
layer 24 opposite the side of the first polymer layer 22. The next
layer is at least one air cellular cushioning layer 28 laminated to
the side of the second polymer layer 26 opposite conductive layer
24. An optional protective layer of polymer material 30 is
laminated to the air cellular cushioning layer 28 to the side
opposite the second polymer layer 26. The protective layer 30 is a
heavy-duty polymer layer to protect the air cellular cushioning
layer from sharp ground objects. The concrete pad 20 conducts
radiant the heating provided by heating element 14 upward through
the concrete allowing radiant energy to spread out under the
concrete pad. The pad is flexible allowing easy installation and
may be rolled up so that it can be easily transported.
[0026] FIG. 3 illustrates another preferred embodiment of the
conductive/insulation pad of the present invention, pad 20a. This
embodiment the uses the five-layer construction of the first
embodiment and adds a second air cellular cushioning layer 32
laminated to the third polymer layer 34 on the side opposite the
first air cellular cushioning layer 28. An optional protective
polymer layer 30 is laminated to the second air cellular cushioning
layer 32 on the side opposite side of the third polymer layer
34.
[0027] The polymer layers may be a polyolefin, such as polyethylene
(PE), low density polyethylene (LDPE), polypropylene (PP),
co-polymers of polyethylene and polypropylene, polyethylene
terephthalates (PET), polyamide, and polyvinyl chloride. A
preferred polymer layer is a PETROTHENE.RTM. NA345-013, a low
density polyethylene film extrusion grade from Equistar Chemicals,
LP. These films are preferably extruded at a thickness of about 0.5
mil to about 3.0 mils. The first and second polymer films are
coated or attached to both sides of the conductive layer to protect
the layer from oxidization and the lime in the curing concrete. The
optional protective layer is a heavy-duty layer to protect the air
cellular cushioning layer from sharp ground objects and alkaline
content in the soil. The first polymer layer may be colored or
pigmented. The heavy-duty protective layer may also be a durable
non-woven polymer film scrim. By coloring the first polymer layer
the user may readily be able to determine which side of the pad to
have facing upward toward the slab.
[0028] The conductive layer is material that will reflect heat. In
particular a thin foil metal or metallized thermoplastic film
having conductive/reflective properties may be used. Preferably the
foil is aluminum, which has a lower emissive value of less than
five percent on each surface to essentially eliminate heat transfer
by radiation. The polymer layers on either side of the reflective
layer reduce the oxidation of the conductive layer helping to
retain the reflectivity of the layer. The conductive/reflective
layer, i.e., foil or metallized film, conducts the heat allowing
radiant energy to spread out under the slab.
[0029] The air cellular cushioning layer or layers provide both
thermal conduction and convection insulation and, in combination
with the conductive/reflective surface, excellent radiation
insulation. The air cellular cushioning layer has a first
thermoplastic film having a plurality of portions wherein each of
said portions defines a cavity and a second thermoplastic layer in
sealed engagement with said first layer to provide a plurality of
closed cavities. Such air cellular cushioning layers are well known
in the industry and are readily available from Sealed Air
Corporation. The insulation component (air cellular cushioning
layer) prevents the ground water intrusion into the concrete slab
as well as heat loss into the cold, water/ground layer.
[0030] The conductive/insulation pads 20 and 20a offer significant
resistance to heavy loading, whereby appreciative non-breakage of
air bubbles is often found. Preferably, outer polymer layers are
made slightly thicker than the inner layers to better resist
abrasion.
[0031] The multi-layer conductive/insulation pads are lightweight
and thin. For example, a typical pad weights about 1.20 to 1.50
ounces per square foot. The pads are typically from about 0.2 cm to
about 0.8 cm thick, preferably about 0.3 to about 0.35 cm. thick.
The thinness and flexibility of the pads facilitates the
manufacture, transportation and handling of rolls of different
desired sizes.
[0032] Referring now to FIG. 4, there is provided an alternative
embodiment of a radiant heating assembly 10a showing a
conductive/insulation pad 20 installation overlaying the a
sub-flooring 12a. The pad 20 is the same pad used in the embodiment
of FIG. 1. As in FIG. 1, a heating element 14 is placed above the
pad 20 and positioned so that the element 14 is surrounded by the
concrete slab 16. The concrete slab 16 is poured so that it covers
the pad 20 and embeds the heating element 14. After the concrete
slab dries, the slab may be covered with tile 18 or other type of
flooring material.
[0033] Many modifications and other embodiments of the inventions
set forth herein will come to mind to one skilled in the art to
which these inventions pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. Therefore, it is to be understood that the inventions are
not to be limited to the specific embodiments disclosed and that
modifications and other embodiments are intended to be included
within the scope of the appended claims. Although specific terms
are employed herein, they are used in a generic and descriptive
sense only and not for purposes of limitation.
* * * * *