U.S. patent application number 14/552167 was filed with the patent office on 2015-05-28 for in-floor heating apparatuses and associated methods.
The applicant listed for this patent is Schluter Systems, L.P.. Invention is credited to Josef Slanik.
Application Number | 20150144708 14/552167 |
Document ID | / |
Family ID | 52015832 |
Filed Date | 2015-05-28 |
United States Patent
Application |
20150144708 |
Kind Code |
A1 |
Slanik; Josef |
May 28, 2015 |
IN-FLOOR HEATING APPARATUSES AND ASSOCIATED METHODS
Abstract
A heated flooring assembly includes a base layer having a
plurality of studs arranged in a grid pattern, the base layer
operable to be coupled to a flooring surface. A screed layer is
bonded to an upper surface of the base layer. A length of tubing
has an outer surface and an inner surface, the length of tubing
operable to carry a fluid that creates a temperature differential
between the length of tubing and the screed layer. The length of
tubing is retained between at least some of the studs. At least the
outer surface of the length of tubing has at least one projection
extending outwardly therefrom, the projection increasing a rate at
which heat is transferred between the length of tubing and the
screed layer as the fluid travels through the length of tubing.
Inventors: |
Slanik; Josef; (Plattsburgh,
NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Schluter Systems, L.P. |
Plattsburgh |
NY |
US |
|
|
Family ID: |
52015832 |
Appl. No.: |
14/552167 |
Filed: |
November 24, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61907948 |
Nov 22, 2013 |
|
|
|
Current U.S.
Class: |
237/69 |
Current CPC
Class: |
F28F 1/40 20130101; Y02B
30/00 20130101; Y02B 30/24 20130101; F28F 1/08 20130101; F24D 3/14
20130101; F24D 3/146 20130101; F16L 55/02772 20130101 |
Class at
Publication: |
237/69 |
International
Class: |
F24D 3/14 20060101
F24D003/14 |
Claims
1. A heated flooring assembly, comprising: a base layer having a
plurality of studs arranged in a grid pattern, the base layer
operable to be coupled to a flooring surface; a screed layer bonded
to an upper surface of the base layer; and a length of tubing
having an outer surface and an inner surface, the length of tubing
operable to carry a fluid that creates a temperature differential
between the length of tubing and the screed layer, the length of
tubing being retained between at least some of the studs, at least
the outer surface of the length of tubing having at least one
projection extending outwardly therefrom, the projection increasing
a rate at which heat is transferred between the length of tubing
and the screed layer as the fluid travels through the length of
tubing.
2. The assembly of claim 1, wherein the at least one projection
extends radially outwardly from the outer surface of the length of
tubing.
3. The assembly of claim 2, wherein the at least one projection
includes a first base side and a second base side, the first base
side being displaced longitudinally along the length of tubing from
the second base side, with the projection extending radially
outwardly between the first and second base sides.
4. The assembly of claim 1, wherein the at least one projection
extends longitudinally along the outer surface of the length of
tubing.
5. The assembly of claim 4, wherein the length of tubing includes a
cross section having a series of peaks and valleys defined
therein.
6. The assembly of claim 1, wherein the inner surface of the length
of tubing includes a surface contour that substantially matches a
surface contour of the outer surface of the length of tubing.
7. The assembly of claim 1, wherein the at least one projection
extends along an area of the length of tubing that can be wrapped
about one or more of the studs.
8. A heated flooring assembly, comprising: a base layer having a
plurality of studs arranged in a grid pattern, the base layer
operable to be coupled to a flooring surface; a screed layer bonded
to an upper surface of the base layer; and a length of tubing
having an outer surface and an inner surface, the length of tubing
operable to carry a fluid that creates a temperature differential
between the length of tubing and the screed layer, the length of
tubing being retained between at least some of the studs, at least
the inner surface of the tubing having at least one projection
extending inwardly therefrom, the projection increasing a rate at
which heat is transferred between the tubing and the screed layer
as the fluid travels through the length of tubing.
9. The assembly of claim 8, wherein the at least one projection
extends radially inwardly from the inner surface of the length of
tubing.
10. The assembly of claim 9, wherein the at least one projection
includes a first base side and a second base side, the first base
side being displaced longitudinally along the length of tubing from
the second base side, with the projection extending radially
inwardly between the first and second base sides.
11. The assembly of claim 10, wherein the at least one projection
extends both radially inwardly within the length of tubing, and
longitudinally along the length of tubing.
12. The assembly of claim 11, wherein the at least one projection
extends along a helical path within the length of tubing.
13. The assembly of claim 8, wherein the length of tubing includes
a cross section having a series of peaks and valleys defined
therein.
14. The assembly of claim 8, wherein the inner surface of the
length of tubing includes a surface contour that substantially
matches a surface contour of the outer surface of the length of
tubing.
15. The assembly of claim 8, wherein the at least one projection
extends along an area of the length of tubing that can be wrapped
about one or more of the studs.
16. A heated flooring assembly, comprising: a base layer having a
plurality of studs arranged in a grid pattern, the base layer
operable to be coupled to a flooring surface; a screed layer bonded
to an upper surface of the base layer; a length of tubing having an
outer surface and an inner surface, the length of tubing operable
to carry a fluid that creates a temperature differential between
the length of tubing and the screed layer, the length of tubing
being retained between at least some of the studs; and an insert,
disposed within the length of tubing, the insert being operable to
increase a rate at which heat is transferred between the tubing and
the screed layer as the fluid travels through the length of
tubing.
17. The assembly of claim 16, wherein the insert includes at least
a first planar member that twists helically along a length of the
planar member, the planar member inducing rotational fluid flow
through the length of tubing.
18. The assembly of claim 17, further comprising a second planar
member that twists helically along a length of the planar member,
the second planar member inducing rotational fluid flow through the
length of tubing.
19. The assembly of claim 18, wherein the first planar member and
the second planar member induce rotational fluid flow through the
length of tubing in the same direction of rotation.
20. The assembly of claim 18, wherein the first planar member and
the second planar member induce rotational fluid flow through the
length of tubing in different directions of rotation.
Description
PRIORITY CLAIM
[0001] This application claims priority and benefit of and to U.S.
Provisional Patent Application Ser. No. 61/907,948, filed Nov. 22,
2013, which is hereby incorporated herein by reference in its
entirety.
BACKGROUND
Field of the Invention
[0002] The present invention relates generally to radiant heat
systems. More particularly, the present invention relates to
radiant heat systems installed within a floor of a room to thereby
affect a temperature of the room.
SUMMARY OF THE INVENTION
[0003] In one aspect, the technology provides a heated flooring
assembly, including a base layer having a plurality of studs
arranged in a grid pattern. The base layer can be operable to be
coupled to a flooring surface. A screed layer can be bonded to an
upper surface of the base layer. A length of tubing can have an
outer surface and an inner surface, the length of tubing operable
to carry a fluid that creates a temperature differential between
the length of tubing and the screed layer. The length of tubing can
be retained between at least some of the studs, with at least the
outer surface of the length of tubing having at least one
projection extending outwardly therefrom, the projection increasing
a rate at which heat is transferred between the length of tubing
and the screed layer as the fluid travels through the length of
tubing.
[0004] In accordance with another aspect of the invention, a heated
flooring assembly is provided, including a base layer having a
plurality of studs arranged in a grid pattern, the base layer
operable to be coupled to a flooring surface. A screed layer can be
bonded to an upper surface of the base layer. A length of tubing
can have an outer surface and an inner surface, the length of
tubing operable to carry a fluid that creates a temperature
differential between the length of tubing and the screed layer. The
length of tubing can be retained between at least some of the
studs, with at least the inner surface of the tubing having at
least one projection extending inwardly therefrom, the projection
increasing a rate at which heat is transferred between the tubing
and the screed layer as the fluid travels through the length of
tubing.
[0005] In accordance with another aspect of the invention, a heated
flooring assembly is provided, including a base layer having a
plurality of studs arranged in a grid pattern, the base layer
operable to be coupled to a flooring surface. A screed layer can be
bonded to an upper surface of the base layer. A length of tubing
can have an outer surface and an inner surface, the length of
tubing operable to carry a fluid that creates a temperature
differential between the length of tubing and the screed layer, the
length of tubing being retained between at least some of the studs.
An insert can be disposed within the length of tubing, the insert
being operable to increase a rate at which heat is transferred
between the tubing and the screed layer as the fluid travels
through the length of tubing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Additional features and advantages of the invention will be
apparent from the detailed description which follows, taken in
conjunction with the accompanying drawings, which together
illustrate, by way of example, features of the invention; and,
wherein:
[0007] FIG. 1 is a side cross-sectional view of a radiant heat
flooring system according to one aspect of the present
invention;
[0008] FIG. 2 is a perspective view of an exemplary base layer
having a length of tubing embedded therein;
[0009] FIG. 3A and FIG. 3B are end and side views, respectively, of
a length of tubing having protrusions extending from an inner
surface thereof;
[0010] FIG. 4 is a radial cross sectional view of a length of
tubing having a series of peaks and valleys thereon;
[0011] FIG. 5A is a side view of a tube insert in accordance with
an embodiment of the invention;
[0012] FIG. 5B is a perspective, partially sectioned view of the
tube insert of FIG. 5A, with the insert positioned within a length
of tubing;
[0013] FIG. 5C is an end view of the length of tubing and tube
insert of FIG. 5B;
[0014] FIG. 6A is a side view of a pair of tube inserts in
accordance with an embodiment of the invention, the tube inserts
having the same directions of rotational flow;
[0015] FIG. 6B is a perspective, partially sectioned view of the
tube inserts of FIG. 6A, with the inserts positioned within a
length of tubing;
[0016] FIG. 6C is an end view of the length of tubing and tube
inserts of FIG. 6B;
[0017] FIG. 7A is a side view of a pair of tube inserts in
accordance with an embodiment of the invention, the inserts having
different directions of rotational flow;
[0018] FIG. 7B is a perspective, partially sectioned view of the
tube inserts of FIG. 7A, with the inserts positioned within a
length of tubing;
[0019] FIG. 7C is an end view of the length of tubing and tube
inserts of FIG. 7B;
[0020] FIG. 8A is a side view of a length of tubing in accordance
with an aspect of the technology;
[0021] FIG. 8B is a more detailed view of a section of the length
of tubing of FIG. 8A; and
[0022] FIG. 9 illustrates a matrix of thermally conductive rods
inserted into a mortar layer in accordance with an embodiment of
the invention.
[0023] Reference will now be made to the exemplary embodiments
illustrated, and specific language will be used herein to describe
the same. It will nevertheless be understood that no limitation of
the scope of the invention is thereby intended.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENT(S)
Definitions In describing and claiming the present invention, the
following terminology will be used in accordance with the
definitions set forth below.
[0024] Relative directional terms, such as "upper," "lower," "top,"
bottom," etc., are used herein to aid in describing various
features of the present system. It is to be understood that such
terms are generally used in a manner consistent with the
understanding one of ordinary skill in the art would have of such
systems. Such terms should not, however, be construed to limit the
present invention.
[0025] As used herein, the term "substantially" refers to the
complete, or nearly complete, extent or degree of an action,
characteristic, property, state, structure, item, or result. As an
arbitrary example, an object that is "substantially" enclosed would
mean that the object is either completely enclosed or nearly
completely enclosed. The exact allowable degree of deviation from
absolute completeness may in some cases depend on the specific
context. However, generally speaking the nearness of completion
will be so as to have the same overall result as if absolute and
total completion were obtained.
[0026] The use of "substantially" is equally applicable when used
in a negative connotation to refer to the complete or near complete
lack of an action, characteristic, property, state, structure,
item, or result. As another arbitrary example, a composition that
is "substantially free of" particles would either completely lack
particles, or so nearly completely lack particles that the effect
would be the same as if it completely lacked particles. In other
words, a composition that is "substantially free of" an ingredient
or element may still actually contain such item as long as there is
no measurable effect thereof.
[0027] As used herein, the term "about" is used to provide
flexibility to a numerical range endpoint by providing that a given
value may be "a little above" or "a little below" the endpoint.
[0028] Distances, forces, weights, amounts, and other numerical
data may be expressed or presented herein in a range format. It is
to be understood that such a range format is used merely for
convenience and brevity and thus should be interpreted flexibly to
include not only the numerical values explicitly recited as the
limits of the range, but also to include all the individual
numerical values or sub-ranges encompassed within that range as if
each numerical value and sub-range is explicitly recited.
[0029] As an illustration, a numerical range of "about 1 inch to
about 5 inches" should be interpreted to include not only the
explicitly recited values of about 1 inch to about 5 inches, but
also include individual values and sub-ranges within the indicated
range. Thus, included in this numerical range are individual values
such as 2, 3, and 4 and sub-ranges such as from 1-3, from 2-4, and
from 3-5, etc.
[0030] This same principle applies to ranges reciting only one
numerical value and should apply regardless of the breadth of the
range or the characteristics being described.
Invention
[0031] The present technology generally provides an in-floor
hydronic or hydraulic radiant heating system. The system can be
incorporated into a variety of flooring applications, for
installation over a variety of subfloor types, and beneath a
variety of finished flooring products. The present technology can
include multiple layers of material, as illustrated generally in
FIG. 1. This figure depicts one generalized embodiment of the
multi-layer hydronic radiant heating system, shown generally at 10.
While the term "heating system" is used throughout this
specification, it is to be understood that the system transfers
heat to and from various components. Thus, the system can be used
to both cool and warm a room, as is dictated by any particular
application.
[0032] In the example shown in FIG. 1, a bottom or base layer 20
can be provided for installation over a generalized subfloor 18.
This layer can be formed of a material such as expanded polystyrene
(EPS) foam. While any substrate material may be used, EPS foam has
been used with particular success, and particularly Schluter
Systems' proprietary Bekotec.RTM. can be utilized in many of the
examples provided herein. The EPS foam 20 provides a variety of
advantages: it minimizes the heat lost to the ground or the rest of
the building; it allows a good surface upon which a screed layer 40
can be installed; and it can minimize the amount of screed 40 that
needs to be heated. Using less screed 40 allows the system to
operate at lower temperatures because a reduction in screed
thickness also generally provides a reduction in the thermal
resistance of the screed layer 40.
[0033] In addition, the base layer 20 can include a variety of
studs or protrusions 22 that can be arranged in various grid
patterns. The grid pattern can result in spaces 24 that are formed
between each of the studs. These spaces are used for holding or
retaining lengths of hydronic pipe or tubing 30 (these spaces 24
can be referred to herein as embedding spaces). Hydronic pipes or
tubing 30 can be embedded in the embedding spaces 24 formed between
the studs 22 of the base layer 20. The lengths of tubing 30 allow
for heated or cooled water to be run through the pipes and thereby
heat or cool the flooring assembly 10. A generalize perspective
view of the base layer and tubing is illustrated in FIG. 2.
[0034] While the lengths of tubing or pipes 30 can be formed from a
variety of materials, in one aspect they are formed of
polypropylene. The polypropylene pipes function to allow the heated
(or cooled) water to flow through the floor and heat the
surrounding screed layer 40. The polypropylene provides structural
flexibility that enables installation of the pipes 30 around the
studs 22. The studs 22, and corresponding reduction in screed 40
thickness, allow the piping 30 to be positioned closer to the
surface, which results in a drastically reduced floor heating
response time. It should be appreciated that while polypropylene
piping has been utilized with a certain degree of success, any
suitable pipe material, as appreciated by one of ordinary skill in
the art, may be utilized.
[0035] The fourth layer can include a decoupling membrane 50 which
can be bonded to an upper surface of the screed layer 40. While any
decoupling membrane may be used, Schluter Systems' proprietary
DITRA.RTM. membrane has been utilized with a particular level of
success. The decoupling membrane 50 can be mechanically bonded to
the screed using mortar. Mortar can also be used on the top surface
of the decoupling membrane 50 in order to install the tile 60 or
other exposed flooring surface. The decoupling membrane 50 isolates
the differential movement stresses that occur between the plane of
the tile 60 and the substrate which prevents cracking of the grout
and tiles in the event the floor is required to shift. The
decoupling membrane 50 can be waterproof and be designed in a way
that it allows an exit path for excess moisture contained in the
substrate to escape through channels on its underside.
[0036] Lastly, a series of cut-back cavities can be provided in the
upper surface of the decoupling membrane 50 in order to allow
mortar spread therein to provide a series of column-like shapes
that transfer loading directly from the flooring surface to the
screed layer. These are some of the many benefits of using the
Schluter Systems Ditra.RTM. decoupling membrane: Ditra.RTM.
provides all of these features and is therefore able to distribute
heavy loads without compromising the structural integrity of the
exposed flooring surface.
[0037] One feature of the present invention is to increase the rate
at which heat is transferred between the fluid within the hydronic
tubing 30 to the flooring surface 60, which in turn will improve
the response time of the overall system. A series of embodiments
will be discussed herein which provide an increased thermal
reaction time in the overall system, which thereby provides and an
increase of heat transfer to the exposed flooring surface 60.
[0038] The response time can be improved by increasing the
convective heat transfer coefficient between the fluid and the
tubing, or alternatively, the convective heat transfer coefficient
can be improved by increasing the surface area over which heat
transfer occurs.
[0039] Currently employed systems utilize cylindrical polyethylene
tubes. These tubes typically have an outer diameter of 16 mm and an
inner diameter of 11 mm, with a sidewall thickness of approximately
2.5 mm. The polyethylene has fair thermal conductivity, and good
mechanical properties: meaning that it can be easily deformed and
placed into base layer 20.
[0040] The first aspect of the present invention involves using
polyethylene tubes having a thickness reduced to somewhere between
about 2 mm and about 1.5 mm. The reasoning for this can be
explained by Equation (1) known as Newton's law of heat
conduction.
q'=hA.DELTA.T (1)
[0041] It suggests that heat transfer rate q' can be increased by
one of three ways: first, by increasing the heat transfer
coefficient "h," second, by increasing the area "A" over which the
heat transfer occurs, or third, by increasing the temperature
difference between the solid and the fluid.
[0042] Reducing the thickness causes an improvement in two of these
categories:
[0043] First, it increases the area over which heat transfer
occurs. This can be demonstrated through the following concept:
[0044] The inner surface area is given by the Equation (2):
A.sub.s=.pi.D.sub.iL (2)
[0045] as the inner diameter is allowed to increase (thus providing
a thinner sidewall), the surface area of the inside wall is
increased thus increasing the surface area exposed to the heated or
cooled fluid.
[0046] Second, by reducing the thickness of the tubing sidewall,
heat transfer is improved because the heat transfer coefficient is
affected by distance the heat must travel through a substance.
Therefore, the rate of the heat flow from fluid to its surroundings
is increased, as the thickness of the material through which the
heat must travel is decreased, thus reducing the thermal
resistance.
[0047] This implementation of providing a multi-layered heated
flooring assembly is achieved by providing a bottom or base layer
20 having a plurality of studs 22 arranged in a grid pattern
wherein the studs 22 define embedding spaces 24 therebetween. As
shown by example in FIGS. 3A and 3B, a length of tubing 30 can be
provided having an outer surface 33 and an inner surface 35. The
length of tubing 30 can be embedded within at least one of the
embedding spaces of the bottom or base layer, as described
above.
[0048] The tubing 30 can be sealed into the base layer 20 by using
a screed layer 40 bonded or otherwise applied to an upper surface
of the base layer 20. Additionally, a decoupling membrane layer 50
can then be bonded to an upper surface of the screed layer 40. The
upper surface can be defined by a plurality of upper surfaces of
each of the plurality of studs 22, thereby sealing the length of
tubing within the embedding spaces 24 of the base layer 20.
Finally, an exposed upper flooring surface 60 can be installed on
the decoupling membrane 50 by bonding the flooring surface using
mortar or some other suitable flooring adhesive.
[0049] In the example shown in FIGS. 3A-3B, the length of tubing
30a includes one or more protrusions 32 that extend from the inner
surface 35 of the tubing. In this aspect, the protrusions also
extend longitudinally within the tubing, and are configured in a
helical pattern along the length of the tube. In this example, two
gaps 37 are provided between two protrusions, projections or the
like 32. The protrusions or fins 32 increase the surface area in
which the fluid is in contact with, thereby increasing a rate at
which heat is transferred between the fluid and the tubing. In
addition, the fins or protrusions can promote mixing of the fluid
within the tubes. This can lead to portions of the fluid at higher
temperatures coming into contact with the walls of the tubes, and
driving portions of the fluid at lower temperatures toward the
center of the tube.
[0050] In the example shown in FIGS. 3A and 3B, the inner surface
35 of the length of tubing 30a includes protrusions or fins
extending inwardly therefrom. The outer surface 33, however, is in
the shape of a conventional tube, having a cylindrical shape. In
other embodiments, however, the protrusions can extend from the
outer surface and not the inner surface; from both the outer
surface and the inner surface; or the tube can include a cross
section in which a series of peaks and valleys extend alternately
inwardly and outwardly. One such example is shown in FIG. 4, where
outer surface 33a and inner surface 35a include substantially
matching contours. As this is a cross sectional view, it will be
apparent that the protrusions or projections in this example extend
along the length of the section of tubing (into the page of FIG.
4).
[0051] The "star" shape shown in FIG. 4 can increase the hydraulic
diameter of the tubing as well as increasing the surface area,
while not necessarily increasing the effective outer diameter. The
increased surface area and hydraulic diameter increases the heat
transfer rate using the same principles as discussed above
regarding increasing surface area as well as increasing the
hydraulic diameter. This can equate to more fluid passing through
the tubing with less resistance and at a higher speed, thus more
evenly distributing the heat through the length of tubing.
[0052] In the example shown in FIGS. 8A and 8B, a series of
projections or protrusions 32b extend from an outer surface of the
length of tubing 30b. As can be seen, a regular, repeating pattern
of protrusions is provided. In this example, the inner surface of
the tubing (not shown in detail) can include a substantially smooth
surface, or it can include a surface that substantially matches the
contour of the outer surface. This is somewhat analogous to
corrugated sheeting. This so-called corrugated tubing increases the
surface area and induces mixing with each of the corrugations. Heat
transfer rates are therefore increased using the same principles as
discussed above regarding mixing and increasing surface area.
Additionally, it is believed that such corrugated tubing can be
relatively inexpensively obtained and readily available, thus
providing a reduced cost and ease of access not realized by prior
art systems.
[0053] While the corrugations are shown in FIG. 6A as extending
along substantially the entire length of the tube, it is to be
understood that sections of the tubing can vary in geometry. For
example, in one aspect of the invention the tubing can include
sections of substantially "straight" or conventional tubing, with
alternating sections of "corrugated" tubing. Similar altering
patterns can be achieved with the other embodiments discussed
herein (e.g., straight sections can alternate with ribbon-tape
sections alternating with corrugated sections, etc.). Also, while
most of the figures illustrate relatively straight runs of tubing,
it is to be understood that the tubing will typically be routed
around and through the various studs shown. Thus, the various
projections, corrugations, modified cross sections, etc., of the
tubing sections can bend and turn about the studs, as dictated by
any particular application.
[0054] FIGS. 5A through 7C illustrate another aspect of the
invention. In these examples, an insert 34, 34a, 34b, 34a', 4b',
etc., is shown disposed within the lengths of tubing 30. The insert
can be formed of a generally planar sheet or strip of material that
twists in a helical pattern as it extends along the length of the
tubing. This aspect can be advantageous in that it does require a
change in the tubing dimensions. In this embodiment, as fluid
passes through the tubes 30 and over the twisted strips 34, the
convective heat transfer coefficient is increased by introducing
swirls into the motion of the fluid (forcing the fluid to
experience turbulent flow). This turbulent flow disrupts the
boundary layer of the fluid at the inside tube surface. The
turbulence and the vortex motion results in higher Nusselt number,
and therefore results in higher heat transfer coefficient because
new fluid is constantly coming into contact with the walls of the
pipe. Fluid that has had heat removed is constantly being exchanged
from the area near the pipe walls.
[0055] By altering the configuration of the strips or tapes 34,
different types of mixing can be achieved. For example, the
embodiment illustrated in FIGS. 5A-5C includes a single twisted or
helical tape insert 34 that can create a single helical flow.
Alternatively, in the example shown in FIGS. 6A-6C, a pair of
inserts 34a, 34b are utilized in a side-by-side arrangement to
create multiple helixes and further improve mixing. It should be
appreciated that the number of twisted tape inserts may have an
effect on the flow resistance and thereby cause an increased load
on the water pump. Pump pressure and flow capacities can therefore
be adjusted accordingly.
[0056] In the example shown in FIGS. 7A-7C, a pair of inserts 34a'
and 34b' are utilized. In this case, however, the inserts induce
flow in different (in this case, opposite) directions of
rotation.
[0057] In another aspect of the present invention, the radiant heat
flooring system's response time can be reduced by adding thermally
conductive materials to the mortar layer of the flooring system,
between the base layer and the decoupling membrane. This can
improve the thermal conductivity of the layers above the heating
pipes by reducing the thermal resistance of those layers. The
addition of the thermally conductive materials to the mortar layers
provides numerous low resistance paths by which heat can travel to
and thereby heat the flooring surface. While the following list is
not meant to be exhaustive, materials which may be added to the
mortar layers include, but are not limited to, copper, aluminum,
zinc, and steel, carbon fiber, fiberglass, and combinations
thereof.
[0058] The conductive materials can be added to the mortar layer in
a number of methods. In one exemplary aspect, shown in FIG. 9, the
conductive materials are provided throughout the mortar layer 40 by
providing a series of rods or posts 70 being formed of conductive
material and being spaced in a matrix throughout the mortar
layer.
[0059] Alternatively, conductive material may be added to the
mortar by adding conductive chips or flakes to the mortar compound
prior to it setting. While the rods or posts 70 would provide
complete thermal paths through which the heat will be able to flow
at various points throughout the mortar, the flakes or chips may
provide a more uniform heat dispersion across the entire flooring
surface. Additionally, the flake or chip method may be much less
labor intensive and more practical, and thus improve the value of
the modification. The behavior of the thermal conductivity in the
mortar when adding these chips can be tailored so as to differ from
the embodiment if the metal were added in the form of solid rods.
This is because complete thermal pathways through the mortar would
not be seen with the chips or flakes until some critical value of
metal (or other additive) concentration is achieved. At this
critical mixing point the thermal conductivity would be greatly
improved, and would improve further with a higher concentration of
conductive material; however below this critical value the increase
in thermal conductivity would be lower. It should be appreciated
that the amount of conductive material necessary will vary based on
the grain size of the chips or flakes and one of ordinary skill in
the art would recognize that some experimentation may be necessary
to find a proper balance for each type of conductive material.
[0060] While the forgoing examples are illustrative of the
principles of the present invention in one or more particular
applications, it will be apparent to those of ordinary skill in the
art that numerous modifications in form, usage and details of
implementation can be made without the exercise of inventive
faculty, and without departing from the principles and concepts of
the invention. Accordingly, it is not intended that the invention
be limited, except as by the claims set forth below.
* * * * *