DE2658673A1 - Prefabricated unit underfloor heating system - uses press to embed coil length and cover sheets in plastics foam insulation - Google Patents

Abstract

The underfloor heating system has a corrugated cardboard layer (1) on a concrete base, and supporting a plastics foam layer (2) in which is embedded a serpentine shaped heating coil (6) for water circulation. This coil is gripped in the folds (7) of a set of sheets (3) laid over the coil, overlapping each other. Over this is a plaster layer (4) carrying a suitable floor covering (5). The coil is made from continuous tube which is assembled continuously with the overlapping sheets (3) which are preformed with one fold down one side of each sheet, and with a cut out each end of the fold to clear the bends in the tube. They are then made into prefabricated units of a given length by moulding them onto their foam layers in a moulding press.

Description

Method of manufacturing an element

for a surface heating or cooling system The invention relates to a process for the production of an element for a surface heating or cooling system, which has a heat conducting plate on its upper side and a thermal insulation plate on its underside Has made of a foamable material and in which the heat conducting sheet in thermally conductive Contact iii with a pipe or hose coil carrying the heating or cooling medium is held by force-fit pressure That by means of the procedure Element produced according to the invention is intended in particular as a register element for Be suitable for underfloor heating or for heat pump systems.

The underfloor heating benefits equally for new buildings as well for the renovation of old buildings increasingly important. You should after the instant State of the art meet the following requirements: a) Register elements should be provided which have standardized dimensions and which can be easily joined together at the construction site permit; b) The top of each register cell should carry a heat conducting sheet, that is in intimate, thermally conductive contact with a pipe coil carrying the heating medium inflamed. This is to prevent the floor from becoming uneven is heated.

A temperature gradient between the central branches of the coil is perceived as unpleasant; c) The element should have a thermal insulation board on its underside that the required thermal insulation is guaranteed.

d) The element should have a relatively low overall height, for example of 2 to 3 cm, dalllil especially when renovating old buildings that of the earlier ones Floor coverings, including insulation, ingested and, for example, up to the door frames and the like. Reaching height is not exceeded.

Underfloor heating that largely meets these requirements is from DT-PS 23 46 155 became known. The named patent concerns a plate-shaped space heating element z. B. for soil, Wall or ceiling heating, which consists of a thermal insulation board, inserted in grooves of the same, the heat transfer medium, z. B. water-carrying lines, and one of the heat-conducting sheet lying on the heat insulation panel there is what the latter transfers the heat to a covering to be applied, the lines are laid in parallel loops.

In the known embodiment, a thermal insulation board must be provided Wertlen, which is provided with grooves. The grooves must either be at the lier division the thermal insulation board can be provided in a molding process or, for example, by Milling can be introduced in the Fahrik or at the construction site. In any case is a subsequent introduction of the grooves at the points of curvature of the pipe coil necessary. There forms in which thermal insulation panels are foamed with grooves can, are relatively expensive, one is in each case to the same groove spacing which then corresponds to the distance between the central branches of the pipe coil, tied. However, it is understandable that different distances may be more favorable for different building projects. So you can, for example, in factories, storerooms or the like. With a be satisfied with a larger distance, while, for example, a narrower distance in living rooms is desirable.

According to the specified prior publication, the grooves # -shaped. However, such a training can only go through Mill out the groove, otherwise the thermal insulation board will no longer come out of the Form could be taken - unless the form itself has detachable fittings for the formation of the groove.

However, the manufacturing process then becomes quite complicated because yes, after each ausschäunivorgang the shape for the purpose of removing the thermal insulation board must be dismantled. You will engrave accordingly, as in the drawings the patent is shown, content with semicircular grooves, in which then a appropriately shaped Heat conducting sheet is inserted. This results in However, the heating coil is only partially enclosed by the heat conducting plate.

Furthermore, according to the known embodiment, it is necessary that the areas of the thermal insulation board, which are not from the baffle. covered as well as the exposed line sections by additional cover plates to be covered. These are glued at one end to the guide plates.

The invention is now based on the object of a method for production to propose an element for a surface heating or cooling system, which differs from the known element in that cover plates or the like. can be omitted and in which a better heat transfer is guaranteed, with a later assembly of the thermal insulation board, the heat conducting plate and the cooling coil should be omitted, d. H. the elements are factory-made in a single operation connected with each other.

The method according to the present invention is characterized by the characterizing part of claim 1 listed features characterized.

The considerations on which the method according to the invention is based are as follows: The optimal thickness of the heat conduction plate is 0.5 mm (e.g. Copper sheet) up to 1 mm (e.g. galvanized sheet). Such sheets are inherently elastic. If they are provided with semicircular or # -shaped grooves, their diameter is slightly smaller than the pipe diameter of the heating coil, then the heat conducting plates lie in the area of the grooves under elastic spring tension on the lleizscIiL'Iiige through which a favorable heat transfer is already guaranteed will. The heat conducting sheet with the pressed-in heating coil can now be as suggested the invention directly as an element for the foaming of the heat insulation serve, the grooves in the thermal insulation board, so to speak, by themselves in the correct arrangement and size. According to the invention, the heat conducting plates arranged in mutual overlap. It is not necessary that the heat conducting plates z. B. by spot welding or the like.

be connected to each other. The overlapping points of the heat conducting plates are pressed together in the molding process and, for example, by the used Polyurethane foam glued together.

The polyurethane foam also penetrates behind the undercuts of the Q-shaped groove, whereby the heat conducting plates are fixed in such a way that they are not more of the thermal insulation board can be detached without the use of force. Farther during the foaming process under the surface pressure of at least 1 kg / cm², preferably of 3 kg / cm² the heat conducting plates are full and without air influences on the pipe coil pressed, which results in a surprisingly good heat transfer.

The distance between the central branches of the pipe coil can vary widely without the need for other form boxes. When using the same Sheet metal strips, the overlap can be selected larger or smaller. It can sheet metal strips can also be used, in each of which Ineltrerc # -shaped grooves are provided. In any case, the grooves are formed in the thermal insulation panel of alone in the desired place.

According to a preferred embodiment, a one-piece Pipe or hose loops used whose length and width are approximately the same as the length and length Width corresponds to the box shape, and in which the milky branches parallel to each other run and in their number the number of sheet metal strips or a multiple of which correspond.

In known processes, the Rolirschlange was produced by dali first straight pieces of pipe as central branches in parallel grooves of the thermal insulation board have been inserted. The exposed ends of these pieces of pipe were then passed through elbows connected with each other.

This requires expensive soldering work or a screw connection usual practices. In contrast, there is the particular advantage of the method of Invention is that you have a one-piece pipe coil for the production of each element can use. The costly connection of the pipe sections is therefore no longer necessary; aside from that the feared risk of leaks, especially with underfloor heating systems excluded at the connection points.

According to a further preferred embodiment, each has sheet metal strips near a side edge, i.e. either near the narrow edge or the Longitudinal edge, a single Q -shaped, parallel to this side edge or semicircular groove, the diameter of which is slightly smaller than the diameter the pipe or hose coil. The pipe or hose coil is inserted into the groove depressed. The sheet metal strips are arranged so that each of the groove opposite Side area of a sheet metal strip the groove area of the neighboring sheet metal strip overlaps. The side parts of each sheet metal strip lying in the overlapping area are then cut out.

In particular, according to a preferred mode of operation, the process is then carried out is carried out as follows, assuming a number of box shapes is available, the length and / or width of each over 1 m, z. B. 2 m x 3 m, and whose height is about 3 cm and which is designed in the form of an open lid are: a) In the box shape is a first sheet metal strip, whose Length e.g.

corresponds approximately to the width of the box shape, inserted so that it is on a side boundary of the box shape rests, and that its groove on the side boundary is turned away, the sheet metal strip in the groove on each side one Owns cutout; b) the first central branch of a pipe coil, its length and width corresponds roughly to the length and width of the box shape, this is the first in ctie groove Sheet metal tire pressed in; c) a second metal strip is placed under the second The middle branch of the pipe coil is pushed until it is flush with its groove, whereby he overlaps the first sheet metal strip in such a way, claus the groove with the one inside Middle load of the pipe coil is covered; d) now becomes the second central branch pressed into the groove of the second sheet metal strip; e) a third sheet metal strip which is designed in the same way as the first sheet metal strip is under the third Central branch of the pipe snake scraped; the one that overlaps the second sheet metal strip The area covers its groove; the third central branch of the pipe coil is in pressed the groove of the sheet metal strip; f) it continues until all Central branches of the pipe coil lie in corresponding grooves in the sheet metal strips and thus the box shape is filled; g) a larger number of box forms prepared in this way; there is a precisely defined one in each box shape Amount of a foamable mixture, e.g. a polyurethane mixture, filled in; H) the box forms are stacked on top of each other, with the bottom lying on top Box shape covers the lower box shape; you can choose between the box shapes cover plates are also arranged; i) the arrangement thus produced is under drove a press; the box forms are pressed together so that they seal each other; k) now the mixture is foamed, with the Sheet metal strips a surface pressure of preferably 3 kg / cm² acts; the sheet metal strips are fully pressed against each other and against the pipe coil; the metal strips are through the polyurethane wet stuck together.

The elements extracted from the forms thus have a difference to known embodiments on their top a continuous, completely flat metal thermal conductive layer; the coil is apart from its inlet and Outlet end, completely foamed into the insulating plastic mixture.

Alternatively, the process can be carried out in such a way that the sheets to be pressed by ollen on the ear-snake; the arrangement is then reversed and placed in the loaf pan. It can also machine endless belts from a endless pipe coil and the sheet metal strips are produced.

The connection of the pipe coils of several elements with each other or having a manifold is made much easier if according to a preferred one Embodiment of the method of the invention in any box shapes a shaped block is placed on the ends of the pipe coil at two corners. Of the The shaped block is removed after the foaming process or when laying on the construction site In this way, two generally square ones are created on each element or rectangular recesses, which allow the connection of the coils of adjacent Make elements easier with each other or with a collector, e.g. by soft soldering.

The accompanying drawings serve to further explain the process according to the invention. There are shown: FIG. 1 a partial section of a completed Underfloor heating roughly on a natural scale; Fig. 2 on a reduced scale Cross-section to explain the production of the arrangement from a pipe coil and sheet metal strips; 3 and 4 cross sections to explain the spreading of the Groove a sheet metal strip on a pipe coil; Fig. 5 is a partial section for explanation the mutual overlap of the sheet metal strips; Fig. 6 is a cross section of a Box shape to explain the foaming process; Fig. 7 a cross section ilil enlarged scale to explain the mounting of the sheet metal strips in the foamed Thermal insulation board; Fig. 8 is a cross section of a press; Fig. 9 diagrammatically a sheet metal strip used according to the invention; Fig. 10 a Top view of the arrangement, from which in particular the course of the curvatures the pipe coil can be seen; 11 is a view of the junction of a Elements; 12 shows a cross section through the connection points of two elements; 13 schematically shows the connection of several elements in register form and FIG. 14 the overlapping connection of two elements.

An underfloor heating system made according to the method of the invention consists, as shown in Fig. 1, of a sound-absorbing layer placed on the rotlbetondecke Cardboard 1, an approximately 3 cm testicular thermal insulation board 2, one made of mutually overlapping Sheets 3 existing, continuous heat conducting sheet, one on the heat conducting sheet applied screed layer 4 and a floor covering 5, e.g. a carpet. Farther a continuous pipe coil 6 is provided, which in # -förmingen grooves 7 of the Sheet metal strip 3 lies. The arrangement is made so that the sheet metal strips 3 overlap each other, the area of the grooves 7 each from the adjacent Sheet metal strip is covered. Between the heat conducting sheet 3 and the screed layer 4 a protective film can be placed if it is feared that the E str i material the heat conducting sheet corrodes.

As can be seen from Fig. 2, the sheet metal strips 3 are each with their side edge opposite the groove under a central branch of the pipe coil 6 pushed until the groove 7 is aligned with the adjacent central branch of the pipe coil 6. Then, as indicated by the arrow 8, the groove 7 on the corresponding Branch of the pipe coil 6 pressed on. In this process, the groove 7 becomes temporary spread out, which with the preferred sheet metal thicknesses of 9, 5 to 1mm is possible. Dader the diameter of the coil 6 is kept slightly larger than the diameter of the groove 7 in the relaxed state is, as can be seen from FIG is, the groove 7 is full and resilient on the Rotirschlange 6. The overlap is as can be seen from Fig. 5, chosen so that the opening of the @ -formigen Groove 7 is covered. The assembly can be done in a box shape will. However, the arrangement can also be made separately and then be placed in a box shape. It is also possible to machine the assembly or to be carried out semi-automatically. An endless, i.e.

very long pipe coil use, which after reaching the the desired length of the element is cut.

Referring to Fig. 6, it can be seen that the arrangement is placed on the bottom 9 of a box shape, which is preferably hydraulically adjustable Has side walls 10. The box shape is closed by a lid 11, which seals the side walls 10 under the pressure of a press ram 12. Afterward a foamable synthetic resin mixture, e.g.

a urethane mix or a styrene mix into the loaf pan Filled in a partial amount. The amount is preferably measured in such a way that that a pressure of at least 1 kg / cm², preferably 3 kg / cm², during the foaming process developed. Under this pressure the synthetic resin penetrates into the undercuts 14 of the 1 -förinigen groove 7 and solidifies there, referring to FIG. 7. The sheet metal strips 3 could accordingly only be deducted from the thermal insulation panel 2 if the Undercuts 14 would be broken out. Furthermore, the so far only from the Coiled pipe 6 held sheet metal strips 3 fixed by the thermal insulation plate 2. About that In addition, the I3lechstreifeii 3 under the pressure mentioned on the overlapping Places tightly pressed together. Any air inclusions are expelled Likewise, the # # -shaped groove 7 is pressed tightly onto the pipe coil 6. In order to is an ideal heat flow from the coil 6 to the # -förniige groove 7 and from a sheet metal strip 3 on the subsequent sheet metal stiffeners 3 guaranteed. This is not only important for good heat dissipation. Rather, practice shows that different floor temperatures in a living room are perceived as uncomfortable even if they are deliberately not registered.

Most of the Kullrt resin mixes in question are adhesive on sheet metal when, as in the method according to the invention, directly on a Sheet can be foamed. The metal strips are mechanically carried out accordingly the adhesive effect of the synthetic resin foam connected to one another, from Flg .. 8 it can be seen that in the practical manufacture several box shapes are stacked on top of one another. The box shapes are accordingly each shaped by the bottom of the subsequent box shape locked. To avoid contamination of the floor during the foaming process can also be inserted between the form cover plates.

From Fig. 9 it can be seen that each sheet metal strip 3 in the area its groove 7 has two lateral recesses 15. The pipe coil lies accordingly, as can be seen from Fig. 10, at their Krümniungsstellen 16 on the previous one Sheet metal strip and then runs onto a side flange 17 of the groove assigned to it Sheet metal strip 3. This is made possible by the recess 15. Despite the Recesses 15, however, the bottom of the box shape is fully covered with the sheet metal strips or, in other words, the element has a continuous uninterrupted heat conducting surface made of sheet metal. This special training makes the use of a continuous Pipe coil allows. Any precautions, such as milling grooves or Like., are not required. The downwardly exposed side branches of the pipe snake are expanded by the synthetic resin and are therefore protected in the thermal insulation board 2.

Referring to Figures 11 and 12, it can be seen that the connection the free ends of the pipe coils of two elements is made much easier, if by sliding a molding block or a molding box 18 onto the end the coil a cuboid recess 19 is made. The ends of the both pipe coils can then be soldered together. However, it can also As shown in Fig. 12, a sleeve 20 can be glued into the pipe ends.

Fig. 13 shows an example of the connection of four elements in register form on collecting lines 21.

FIG. 14 shows a modification of FIG. 12. To ensure a good heat transfer from one element to the next, it is advisable to when the heat conducting sheet protrudes beyond the thermal insulation plate 2 on one side. This leaves easy to manage, if when foaming one in cross section Rectangular or square wooden strip on the sheet metal strips on one of the side borders 10 of the press is applied. The wooden bar can protect the heat conducting sheet remain at the construction site until they are laid. It will then be removed. The protruding one Part of the sheet metal strip 3 is then on the heat conducting sheet of the next element placed, covering the first groove.

This training is also suitable if smaller elements are to be filled in of a room should be attached to larger elements. In these elements k <inside then pipe coils or hoses can also be retrofitted. The grooves of this Pieces can also be used to hold the sanitary lines 21. Of course Elements can also be joined together in this way, especially in small rooms are, for example, each have only one groove. The pipe coils are then in this case pressed into the grooves on site.

The elements are not only suitable for underfloor heating, but also for ceiling, facade and other large area heating. As a cooling element, you can e.g. for cold rooms, artificial ice rinks. They are particularly suitable for use in connection with heat pump systems, preferably in the low temperature range and for solar heating systems. Due to the smooth, continuous metal surface, something flenlent can be insulated in such a way that it can also be used for lining and heating Swimming pool is suitable.

L e r s e i t e

Claims (8)

Claims 1. A method for producing an element for a surface heating or cooling system, which has a heat conducting plate on its top and has a thermal insulation board made of a schäunibaren material on its underside and in which the heat sheet is in thermally conductive contact with one of the heating or Coiled pipe or hose carrying the cooling medium by force-fit pressure is held, because it is shown that lower sheet metal strips, each at least have a groove for receiving a branch of the pipe or hose sole length, in mutual Overlap are placed in a box shape and that the remaining space of the box shape is filled with a certain amount of a foamable mixture, further that after closing the loaf pan, the mixture is foamed, with the amount the mixture is matched to the Ausscliäumvorgang so that on the sheet metal strips eib surface pressure of at least 1 kg / cm² is exerted and whereby through the hardening Synthetic resin connected the sheet metal strips to one another and to the strand be pressed against the pipe or hose coil. 2. The method according to claim 1, characterized in that a one-piece Pipe or hose coil is used, the length and width of which is approximately the same as the length and width corresponds to the box shape and in which the central branches are parallel to each other run and in their number the number of sheet metal strips or a multi-pool of which correspond. 3. The method according to claims 1 or 2, characterized in that g; each sheet metal strip near a side edge a single one, parallel to this Side edge has a # -shaped or semicircular groove, the diameter of which is slightly smaller than the diameter of the pipe or hose coil that into the Groove the pipe or hose snake is pressed in and that the sheet metal strips so be arranged that in each case the side area opposite the groove Sheet metal strip overlaps the groove area of the adjacent sheet metal strip. 4. Process according to Claims 1 to 3, characterized in that the side parts of each sheet metal strip lying in the overlapping area are cut out are or are bent downwards. 5 The method according to claim 4, characterized in that in the box shape a first sheet metal strip 30 is inserted that its groove in the Nälie a side boundary of the form, and in the area of the groove on one Side a cutout is provided that the first middle branch of the pipe coil in the groove of this sheet metal strip is pressed in that a second sheet metal strip, at a cutout is provided in the area of the groove on the opposite side is, is pushed under the second means of the pipe coil until this with his The groove is aligned after the second central branch has been pressed into the groove of the second Sheet metal strip a third sheet metal strip, which is designed in the same way as the first Sheet metal strip, is pushed under the third central branch of the pipe coil and so on until the box shape is filled. 6. The method according to claims 1 to 5, characterized in that g e k e n n z e i c N e t that, as a foamable mixture, a known synthetic material, a polymerizable urethane mixture is preferably used. 7. Process according to Claims 1 to 6, characterized in that in the box shape at two corners each a shaped block on the ends of the pipe coil is put on after the foaming process or when laying on the construction site be withdrawn and the one recess for connecting the coils of adjacent pipes Deliver elements. 8. Process according to Claims 1 to 7, characterized in that several box shapes placed on top of each other before foaming and in a clamping device or press are pressed together in a sealing manner.