Low cost radiant floor comfort systems

Abstract

A rapidly assembled pre-fabricated array of heating elements, such as tubing or wire, on a rigid mesh, for use in radiant panel heating and/or cooling systems, reduce costs by streamlining both the design layouts and the labor operations to fabricate and install the systems. The pre-fabricated arrays may be installed with the mesh on the finish floor side for additional protection of the heating elements during and after installation.

Description

This invention was made with State of California support under California Energy Commission contract number 500-02-026. The Energy Commission has certain rights to this invention.

BACKGROUND

This subject matter of this application relates to radiant floor heating and cooling systems, and particularly to systems that place hydronic tubing or electrical heating cables in contact with indoor room or outdoor surfaces.

Radiant floors are widely recognized as the most comfortable choice among heating systems. As a result, the radiant floor market has grown rapidly. However, the market could be much larger if installed system costs could be lowered significantly. Installations have been largely limited to custom homes where the owners are willing to pay more for improved comfort. Current radiant heating systems are more likely to be installed at sites where cooling systems are not necessary. Cooling is generally provided by ducted forced air systems, which for a modest additional expense can deliver heating as well. By comparison, combining radiant heating with forced air cooling is much more expensive to install. However, there is the potential in dry climates to install ductless systems that can deliver cooling as well as heating through floor tubing. Many rapidly growing housing market areas are in the dry climates of the U.S. southwest and mountain states. Production builders construct more than 75% of new homes in these areas. These volume homebuilders are more likely to consider radiant systems if costs can be reduced, because homebuyers are attracted to many radiant system features including superior comfort, high energy efficiency, and low noise.

There are additional market opportunities for lower-cost outdoor panel heat transfer systems. These include snow-melt and patio heating systems, patio cooling systems, and swimming pool solar heating systems that circulate pool water through tubing in surrounding or nearby concrete paving.

The most economical radiant floor systems place linear tubing or electrical conductors (wires) in concrete slabs, where reinforcing steel provides a matrix for securing the linear heat transfer elements in a desired pattern. The concrete transfers heat laterally, allowing wider spacing of the elements. For concrete slab construction, a typical method involves a concrete crew placing steel reinforcing wire, which is typically a grid-type reinforcing mesh that arrives in a rolled form and then is straightened, cut, and laid throughout the formed area. A radiant floor specialty crew then manually secures the tubing or wire onto the top of the reinforcing grid at 2′ to 3′ intervals with wire or cable ties. Tying the tubes or wires in place is a labor intensive, time consuming, process. The installers must either repeatedly bend over or be on their hands and knees for extended periods of time. In addition to working for long periods in uncomfortable positions, the installers must have considerable dexterity to secure the ties without damaging the tubing or wires.

The heating elements typically arrive at the site in rolls, and if the element is hydronic tubing, its “memory” of the rolled shape complicates the task of securing it in straight runs on the mesh. Radiant floor designs typically use customized serpentine and rectangular spiral layouts. These layouts or circuits can be complex because interior wall locations must be marked before the circuits are placed. The layout patterns are usually configured room-by-room with connecting lines entering through doorways to avoid passing under interior walls, thereby minimizing the danger that wall framing fasteners will penetrate and damage the tubing or wire.

The ends of the heating elements ultimately meet at a manifold or panel that becomes the distribution point for a group of “circuits,” whether hydronic or electrical. After the circuits are run, the concrete crew that formed the slab edges returns to pour the slab over the heating elements. During the pour, they typically reach blindly through the wet concrete with “J-hooks” to pull the reinforcing mesh up near the horizontal centerline of the slab. Because the mesh is not typically flat, and the ties are widely spaced, this operation sometimes results in pulling heating elements too near the surface, where they are more vulnerable to damage. If the system is hydronic, the tubing is pressurized during the pour, and a sudden loss in pressure indicates that the tubing has been punctured.

Radiant systems that are not placed in concrete slabs are relatively more expensive because they require the addition of a layout matrix to guide the layout patterns. Such systems usually require either closer spacing of the heating elements or additional components to spread heat laterally. The prior art includes several novel strategies for reducing the cost of “raised floor” radiant technologies that do not surround the linear heat transfer elements with concrete. For example, the Applicant's “low mass” radiant system shown in U.S. Pat. No. 4,782,889 uses a corrugated deck that spans across the framing members to hold the tubing, and spread heat laterally across the floor. A subsequent technology (U.S. Pat. No. 5,788,152) uses a composite plywood-aluminum deck to accomplish the same three functions. Both of these systems would benefit from use of a tubing product that arrives in a serpentine pattern rather than in rolls.

The above factors suggest a need and opportunity for improved radiant panel methods that reduce costs and enhance installation reliability.

SUMMARY

The subject matter of this application is directed to an improved heating element product and methods for fabricating and installing such elements, including radiant panel systems that reduce costs by streamlining both the design layouts and the labor operations to fabricate and install the systems. The improved products and methods include forming a heating element, such as hydronic tubing in a “figure-8” pattern that facilitates installation of the tubing in certain layouts. The subject matter of the application also provides, a method of rapidly assembling pre-fabricated arrays of heating elements, such as tubing or wire, on a rigid mesh. According to the subject matter of this application, the pre-fabricated arrays may be installed with the mesh on the finish floor side for purposes of protection of the heat transfer elements. These and other improvements will be further described in the following sections.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of this application will be described in detail with reference to the following drawings in which like reference numerals refer to like elements and where:

FIG. 1 is an isometric view showing an exemplary method for winding figure-8 tubing;

FIG. 2 is a plan view showing an exemplary method for deploying tubing from a narrow figure-8 pattern;

FIG. 3 is a plan view showing an exemplary method for deploying tubing from a wide figure-8 pattern;

FIG. 4 is an isometric view showing an exemplary method for pre-fabricating tubing in a narrow figure-8 pattern to a grid substrate;

FIG. 5 is a cross-sectional view showing an exemplary method for placing a pre-fabricated assembly and enclosing it in a concrete slab;

FIG. 6 is a cross-sectional view showing an exemplary method for placing the pre-fabricated assembly on a framed floor with cementitious topping; and

FIG. 7 is an isometric view showing an exemplary method for folding two pre-fabricated assemblies that form a single tubing circuit.

DETAILED DESCRIPTION OF EMBODIMENTS

Although features of the subject matter of this application may be implemented use in a variety of deployment patterns, standardization can be maximized using a serpentine pattern in which the linear heat transfer element, such as tubing or wire, enters near one corner of a rectangular grid and is placed in a repetitive back-and-forth alignment of parallel runs. The “memory” problem for plastic tubing wound on a spool can be minimized an/or eliminated with a “figure-8” winding, which can be accomplished according to the subject matter of this application.

FIG. 1 is an isometric view showing an exemplary method for winding figure-8 tubing. As shown in FIG. 1, tubing 1 is extruded from an extruder 2. The tubing 1 is received on a winder 6 having two mandrels 3a and 3b. Because the extruder 2 is typically a large machine that must remain fixed in position, a preferred exemplary embodiment uses a two-mandrel winder 6 with double-axis movement. The exemplary version of the winder 6 has two vertical mandrels 3a, 3b and a bed 6a that tilts about a horizontal axis 6b. The spacing between the mandrels 3a, 3b can vary from as little as about 3′ to as much as about 20′, as shown in exemplary applications further described with reference to FIGS. 2 and 3.

During the winding process, tubing 1 being produced by the extruder 2 is wound on two mandrels 3a and 3b of a winder 6 rather than on one larger mandrel as used in a standard tubing extrusion process. The diameter of the mandrels 3a, 3b will typically range from 6″ to 12″. As the tubing 1 from the extruder 2 is freshly wound about the mandrels 3a and 3b, the tubing 1 takes a “set” such that curved tubing segments 4 remain curved and straight sections 5 remain straight after removal from the winder 6. In an embodiment, the winder 6 tilts and rotates relative to the extruder 2 so that the tubing 1 clears the mandrels 3a, 3b as winding proceeds. As shown in FIG. 1, the winder 6 next rotates counter-clockwise about axis 9 as viewed from above. As rotation proceeds, the tubing 1 winds about the mandrel 3b and the winder 6 continues to rotate counterclockwise until the mandrel 3a approaches the tubing 1. An end 7 of winder 6 then pivots downward until the tubing 1 fully clears the top of mandrel 3a. The end 7 then pivots back up before rotation reverses, and clockwise rotation continues until the mandrel 3b approaches the tubing 1. An end 8 of the winder 6 then pivots downward until the tubing 1 fully clears above the mandrel 3b. The end 8 pivots back up, and rotation changes back to counter-clockwise.

The winding process continues until the winder 6 is full. The tubing 1 is then cut and the cut end from the extruder 2 is connected to a second winder. The coiled tubing 1 is then removed from the first winder 6. If the heating element being extruded from the extruder 2 is a cross-linked polyethylene tubing (PEX), the coil of tubing then proceeds to a cross-linking operation. The completed coil of tubing may either be packaged for shipment or deployed and secured immediately to a grid in a process to be described below.

FIGS. 2 and 3 are plan views showing exemplary methods for deploying tubing from narrow and wide figure-8 patterns, respectively. In FIG. 2, tubing 1 from a bundle 10 is partially secured to a mesh grid 11. In FIG. 3, tubing 1 is shown secured to the grid 11. In various exemplary embodiments, the grid 11 will typically serve both as a base for attaching the tubing 1 and as a source of reinforcement for a concrete slab or other floor topping, and is usually made of steel in a square grid pattern, e.g., reinforcing wire. For example, a mesh of rigid #10 steel wires (approximately 0.10″ diameter) are often used in a 6″×6″ spacing arrangement, and the grid is typically produced in the U.S. in 5′ and 7′ widths. Heavier wire and/or tighter grid spacing can be used where stronger reinforcement is required. The mesh is relatively rigid but can be obtained in either rolls or flat sheets. Flat sheets are preferred for use with the subject matter of this application because such sheets more reliably retain the tubing 1 in a flat plane. The most common and appropriate sheet size is 7′ by 20′, as shown in FIGS. 2 and 3.

FIG. 2 shows how the bundle 10 of “figure-8” tubing 1 can be deployed into a narrow serpentine pattern 13a. Compared to a wide serpentine pattern 13b shown in FIG. 3, the narrow serpentine pattern 13a requires less factory space for the winding process, and facilitates pre-fabrication of the tubing/grid arrays, as discussed with reference to FIG. 4. The tubing 1 is sufficiently flexible that the curved tubing segments 4, which in packing make turns of more than 180°, quite easily open to 180° during deployment of the tubing 1. In an exemplary preferred layout, “tails” of the heating elements from each pattern 13 connect to a supply box or “manifold center”. Thus, it is beneficial to have both the supply end 16 and the return end 15 leaving the grid 11 in close proximity to one another. For example, FIG. 2 shows a “tail” 15 of the heating element that proceeds straight from the left end to the right end of the grid 11. When installed at the job site, the tail 15 will proceed with the second tail/supply end 16 to the manifold center connection point.

A common spacing of the tubing 1 on the grid 11 is 12″ on center. The configuration or pattern shown in FIG. 2 uses tubing nominally wound on 12″ mandrels with axes spaced 4′ apart, so that the “outside-to-outside” serpentine pattern is 5′ wide. Located on the grid 11 as shown, this pattern allows side-by-side grid placement that essentially maintains a spacing of about 12″ between the tubing 1 including the tail 15. In FIG. 2, tubing segments 17 and the tail 15 have already been secured to the grid 11 with ties 18. Various devices can be used for the ties 18. Field-placed tubing is typically held to the mesh grids 11 with either wire ties or (“zip”) cable ties placed by hand. An example of a motorized wire tie system is discussed with respect to FIG. 4. Spacing of the ties 18 varies with location of the tubing 1 on the grid 11. For example, along the straight segments 5, the ties may be spaced up to 36″ apart, but at the 180° curved segments 4, ties 18 are recommended at the intersection of the straight and curved segments 5, 4. A spacing of about 24″ between the ties 18 is recommended along the tail 15 (FIG. 2) where the curved segments 4 have been opened to form a continuous straight segment 5. The dotted line 19 shows where the “not yet secured” tubing will be placed, and how the other tail 16 will leave the grid parallel to the first tail 15.

FIG. 3 also shows the tubing 1 placed 12″ on center. In this exemplary embodiment, the tubing 1 having a figure-8 pattern was wound on 12″ diameter mandrels spaced 17′ apart, and the “outside” serpentine dimension is 18′. Most features of this wide figure-8 pattern 13b are similar to those discussed with respect to FIG. 2, including tails 15 and 16 leaving the grid 11 at the same corner. However, this wide or “long serpentine” pattern 13b would better integrate with grid sheets 11 of even footage width increments (for example, 6′ or 8′ wide) so that identical grid/tubing panels 11 could provide even spacing of the tubing 1 in side-by-side placement. With the 7′ grid 11 or other “odd” footage widths, uniform spacing of the tubing 1 across multiple panels can only be achieved by adding an extra serpentine element to each alternate sheet 11. For example, alternating 7′ panels can have four serpentine pairs each, and their alternating neighbors can have three pairs, like the panel shown in FIG. 3.

FIG. 4 is an isometric view showing an exemplary method for pre-fabricating tubing 1 in the narrow figure-8 pattern 13 to a grid substrate 11. The pre-fabricated tubing/grid panel 24, shown in FIG. 4, is similar to the grid 11 discussed with respect to FIG. 2. In an exemplary embodiment of the method, the grid 11 is supported in a vertical position so that the tubing installer 20 can work in a more convenient and comfortable position compared to installing the tubing 1 on the floor or at a horizontal table. In the embodiment, the grid 11 is hung from above its horizontal centerline on pegs 21 that project from a support rail 22. The support system may also include a lower support rail (not shown) to stabilize the grid during assembly. Assembly proceeds starting with placement of the grid 11 onto the pegs 21 of the support rail 22. The tubing bundle 10 (not shown) is then deployed onto the grid 11 by hanging the curved segments 4 over the pegs 21, with one peg 21 per serpentine loop. The installer 20 may preferably use a motorized tie gun 23 to quickly attach the tubing 1 to the grid 11 at ties 18. The top tail 15 may be tied to the grid 11 either before or after the serpentine loops are tied. After all ties 18 are completed, the “off panel” tubing in the tails 15 and 16 may be bundled and lightly secured to the edge of tubing/grid panel 24 for transporting. The assembled grid/tubing arrays 24 may be stacked in any position for storage and delivery.

FIG. 5 is a cross-sectional view showing an exemplary method for placing pre-fabricated panels in a concrete slab. In a typical slab-on-grade application, edge forms 25 confine the concrete pour, and are partially supported by a concrete footing 26. Grid/tubing panels 24 are supported by standoffs 27 above a prepared base layer 28. In an exemplary embodiment, the panels 24 are placed with the tubing 1 at an underside of, rather than above, the grid 11. Locating the tubing 1 below the grid 11 is an advantage of the pre-assembly process as it keeps the tubing 1 lower in the concrete slab where it is less vulnerable to puncture from above, and it keeps the tubing 1 from floating upward between its tie points 18. Before a slab 29 is poured, the tails 15, 16 (not shown) from the panels 24 are deployed to the manifold center (not shown) and connected for a leakage test. Typically, the tubing 1 remains pressurized during the pour, and pressure is monitored to verify continuing integrity during the labor activities. In a typical 4″ thick slab, the grid panels 24 are placed at a vertical centerline of the slab 29. Several types of standoffs 27 are available and are well known in the art. Alternatively, instead of using standoffs, the panels 24 may be placed directly on the base layer 28, and then lifted using a “J-hook” during the pour, to place the panels 24 near the vertical centerline of the concrete slab 29.

FIG. 6 is a cross-sectional view showing an exemplary method for placing the pre-fabricated assembly on a framed floor with a cementatious topping in conjunction with metal fins that improve heat transfer. The floor construction includes joists 30 that support the subfloor 31 and a cement topping 32. This floor construction method is used where the mass of a concrete or gypsum cement topping is valued for its thermal and/or acoustical benefits. The topping 32 does not as effectively spread heat laterally compared to the full slab shown in FIG. 5, and the absence of a steel mesh grid also reduces lateral heat transfer. Aluminum channel fins 33 may be secured to the subfloor 31 in close contact with the tubing 1 to improve heat transfer and to minimize the likelihood that occupants will feel “hot lines” on the floor surface 34 directly above the tubing 1. The channel fins 33 are only placed over straight sections 5 of the tubing 1.

Another advantage of the figure-8 tubing 1 is apparent in considering installation of the channel fins 33. For example, conventional rolled tubing must first be secured to a subfloor to straighten the tubing before the channel fins can be placed. With the figure-8 tubing 1, the tubing 1 need not be secured to the subfloor 31 before the channel fins 33 are placed. Instead, the tubing 1 can be held by the channel fins 33 which are secured to the subfloor 31. This process works because the channel fins 33 can readily be snapped over the straight sections 5 of the figure-8 tubing 1.

The figure-8 tubing 1 may also benefit installations of the “Low Mass Hydronic Radiant Floor System” shown in U.S. Pat. No. 4,782,889 (1988). In this application (not shown), tubing is held by and in the grooves of a corrugated metal deck that replaces the subfloor in framed construction. As with respect to FIG. 6, the pre-formed serpentine patterns afforded by the figure-8 tubing 1 simplify installation by eliminating the need to wrestle with continuously curved tubing. Instead, the tubing 1 can be quickly deployed in its approximate final position, and then secured by pushing it down into the grooves in the corrugated metal deck.

In practice, one of the most cost-effective radiant heat designs combines low piping and manifold costs with relatively low pressure drop to minimize pump size and energy use. Optimal circuit lengths, tubing sizes, and tube spacings often dictate arrays that require two grid panels. For example, two 7′×20′ grids may be placed end-to-end to form a 7′×40′ assembly, or side-by-side to form a 14′×20′ assembly. For U.S. markets where ½ diameter (nominal) tubing is most common, the resulting 280 square foot area is appropriate for the optimal circuit. FIG. 7 shows a folded panel with a tubing circuit pattern known as a “spiral pair.” This pattern is similar to the “long serpentine” shown in FIG. 3. For both patterns, folding a “two grid” panel in the middle requires bends in all the parallel tubes in the array. The narrow serpentine pattern shown in FIG. 2 only requires two bends, but in either event, the tubing must not be damaged by bending. Tubing manufacturers typically specify minimum bend radii for their products. For example, the minimum bend radius for most cross-linked polyethylene (PEX) tubes is 10 diameters. Thus, a ½″ tube (actually 0.625″ diameter) can be formed to a 6.25″ bend radius- or roughly to a 12″ semi-circle in a serpentine pattern.

FIG. 7 is an isometric view showing a method for folding two grid sections that support a single tubing circuit. With two end-to-end grids 11a, 11b joined only by the tubing 1, and with the tubing 1 not joined to the grids 11 near the intersection of the grids 11a, 11b, one grid 11 may be offset with respect to the other grid 11 by a predetermined bend diameter. A folded width of the assembled grids 11a, 11b is then the width of the grid plus the tubing bend diameter. As shown in FIG. 7, the tubing 1 is secured to a folded pair of grids 11a and 11b. The two grids 11a, 11b are folded about line 37. When the pair of grids 11a, 11b is unfolded, the top corner 40 on the left grid 11a will meet the top corner 41 on the right grid 11b. When folded, the tubing 1 is contained between the two grids 11a and 11b. With the grids 11a, 11b in the folded position, the two top corners 40 and 41 are displaced by a length 19 (typically the minimum tubing bend diameter), allowing the tubing 1 to form arcs 17 without crimping the tubing 1. In the case shown where the bend radius equals the grid wire spacing, the arcs 17 are inset by a distance 18 equal to approximately 0.57 times the bend radius. For the 6″ spacing and bend radius shown, the distance 18 equals approximately 3.4″. Thus, the ties 38 and 39 should be no closer than 9.4″ (6″+3.4″) to the fold line 37. After unfolding and placement in the prepared foundation, the grids 11a and 11b may be wired together along the fold line 37, with the corners 40 and 41 intersecting.

Although the subject matter of this application has been described with reference to various exemplary embodiments, it is to be understood that the subject matter is not limited to the exemplary embodiments or constructions. To the contrary, the subject matter of this application is intended to cover various modifications and equivalent arrangements. In addition, while the various elements of the exemplary embodiments are shown in various combinations and configurations, others combinations and configurations, including more, less, or only a single element, are also within the spirit and scope of the invention.

Claims

1. A method of fabricating a heating/cooling element for a radiant comfort system, comprising:

forming the heating/cooling element of a material having a shape memory;

winding the heating/cooling element into a pattern of turn portions and straight portions onto a winding device;

removing the heating/cooling element from the winding device after a predetermined period so the heating/cooling element retains the pattern of turn portions and straight portions.

2. The method of claim 1, wherein winding the heating/cooling element includes receiving the heating/cooling element about two mandrels disposed on the winding device so that the turn portions turn more than 180 degrees about each mandrel and wind alternately clockwise and counterclockwise about the two mandrels, and the straight portions are disposed between the mandrels.

3. The method of claim 1, wherein the heating/cooling element is an extruded polymeric tube.

4. The method of claim 3, wherein the polymeric tube is comprised of one of a high density polyethylene or a cross-linked polyethylene.

5. The method of claim 1, wherein the heating/cooling element is a tube connectable to a fluid source to heat/cool an area.

6. The method of claim 1, further comprising:

securing the heating/cooling element to a substrate in a serpentine pattern with the turn portions open to approximately 180 degrees and the straight portions are substantially parallel to one another; and

placing a covering over the heating/cooling element and the substrate to protect the heating/cooling element and facilitate heating/cooling transfer.

7. The method of claim 6, wherein the heating/cooling element is a tube connectable to a fluid source to heat/cool an area.

8. The method of claim 6, wherein the substrate is a rectangular mesh grid and the straight portions are oriented transverse to a length of the rectangular mesh grid.

9. The method of claim 6, wherein the substrate is a structural sheet and the covering is a poured material that covers the substrate and the heating/cooling element and hardens after pouring.

10. The method of claim 6, further comprising placing at least one metallic heating/cooling transfer element in contact with the heating/cooling element before placing the covering.

11. The method of claim 6, wherein the substrate is a structural sheet and the covering is a rigid panel.

12. The method of claim 6, wherein the substrate is a corrugated metal sheet having troughs narrower than an outer dimension of the heating/cooling element and the heating/cooling element is placed into the troughs before placing the covering.

13. A method of installing a pre-fabricated radiant comfort system, comprising a mesh grid and a flexible linear heating/cooling element attached to one side of the grid to form a pre-fabricated assembly, the method comprising:

installing the pre-fabricated assembly at an installation location with the grid disposed between the heating/cooling element and the finish surface; and

covering the assembly with a finish surface.

14. The method of claim 13, wherein the grid element is held in a substantially vertical position while the element is being attached thereto to form the pre-fabricated assembly.

15. The method of claim 13, wherein the element is attached to the grid using a motorized wire-wrapping tool.

16. The method of claim 13, wherein the heating/cooling element is a flexible tube for conveying a liquid heating/cooling transfer fluid.

17. The method of claim 13, wherein the heating/cooling element is an electrical wire.

18. The method of claim 13, wherein the mesh grid is comprised of a metal and the finish surface is concrete.

19. The method of claim 13, further comprising joining at least two pre-fabricated assemblies by the heating/cooling element.

20. The method of claim 19, wherein the two assemblies are foldable about the joining element without damaging the element.

21. The method of claim 20 where the folded assembly allows a required minimum bend radius of the heat transfer element at the fold line.