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.

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° F. for laundry, it must be modulated to about 100° 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° 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° 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° turn pieces, like 40′, providing 180° 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° 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.

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