GB2573505A

GB2573505A - Improvements in underfloor heating methods

Info

Publication number: GB2573505A
Application number: GB1805586.3A
Authority: GB
Inventors: Andrew Ellis Stuart
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-04-05
Filing date: 2018-04-05
Publication date: 2019-11-13
Also published as: GB201805586D0

Abstract

An underfloor heating mat and pipe holding system consists of a series of foil backed rectangular mats 1C made from recycled vehicle tyre rubber and adhesive resin and having pressed channels (8-13, 15, 17, Fig. 1) for holding water pipes (18, 19, Fig. 2). The channels may have a ‘U’ shaped profile and may have a clipping system to hold the water pipes in the ‘U’ shaped channels. The clipping system may have protruding clip ridges 22, 25, 26 provided alternately along the upper open edge of the channels and may also have edging 24, 28 alternately between each protruding clip ridge along the upper open edge of the ‘U’ shaped channel. The body may be compressible to allow water pipes of various diameters to be held in the channels. The ‘U’ profile channels may be of sufficient depth to prevent any part of the pipe from protruding above a top surface of the mat. The mats (F, G, Fig.7) may be laid adjacent each other on the floor to cover a desired floor area. Sections of the mats may be trimmed away to suit fitting needs.

Description

IMPROVEMENTS IN UNDERFLOOR HEATING METHODS

Field of the Invention

The present invention relates to underfloor heating using water filled pipes and a floor matting arrangement system for installation.

Background

The use of water filled piping arranged on the floor of a dwelling is known in the practice of underfloor heating. Underfloor heating and cooling is a form of central heating and cooling which achieves indoor climate control for thermal comfort using conduction, radiation and convection.

The terms radiant heating and radiant cooling are commonly used to describe this approach because radiation is responsible for a significant portion of the resulting thermal comfort but this usage is technically correct only when radiation composes more than 50% of the heat exchange between the floor and the rest of the space. Hydronic systems. Hydronic systems use water or a mix of water and anti-freeze such as propylene glycol· as the heat transfer fluid in a closed loop that is recirculated between the floor and the boiler.

Various types of pipes are available specifically for hydronic underfloor heating and cooling systems and are generally made from polyethylene including PEX, PEX-AI-PEX and PERT. Older materials such as Polybutylene (PB) and copper or steel pipe are still used in some locales or for specialized applications.

Hydronic systems require skilled designers and tradespeople familiar with boilers, circulators, controls, fluid pressures and temperature. The use of modem factory assembled sub-stations, used primarily in district heating and cooling, can greatly simplify design requirements and reduce the installation and commissioning time of hydronic systems.

Hydronic systems can use a single source or combination of energy sources to help manage energy costs. Hydronic system energy source options are boilers (heaters) including Combined heat and power plants heated by natural gas or methane industry-wide is considered the cleanest and most efficient method of heating water, depending on availability.

Underfloor heating can have a positive effect on the quality of indoor air by facilitating the choice of otherwise perceived cold flooring materials such as tile, slate, terrazzo and concrete. These masonry surfaces typically have very low VOC emissions (volatile organic compounds) in comparison to the various other flooring options.

In conjunction with moisture control, floor heating also establishes temperature conditions that are less favourable supporting mould, bacteria, viruses and dust mites. By removing the sensible heating load from the total HVAC (Heating, Ventilating, and Air Conditioning) load, ventilation, filtration and dehumidification of incoming air can be accomplished with dedicated outdoor air systems having less volumetric turnover to mitigate distribution of airborne contaminates. There is recognition from the medical community relating to the benefits of floor heating especially as it relates to allergens.

Low temperature underfloor heating is embedded in the floor or placed under the floor covering. As such it occupies no wall space and creates no bum hazards, nor is it a hazard for physical injuries due to accidental contact leading to tripping and falling. This has been referenced as a positive feature in healthcare facilities including those serving elderly clients and those with dementia. Anecdotally, under similar environmental conditions, heated floors will speed evaporation of wetted floors (showering, cleaning, and spills). Additionally, underfloor heating with fluid filled pipes is useful in heating and cooling explosion proof environments where combustion and electrical equipment can be located remotely from the explosive environment.

The prior art shows us that many of these types of floor embedded systems take a long period of time to heat up from cold and use high amounts of energy over long periods, in some examples. There are also issues with pipes and their aftercare or maintenance when they have been fixed under concrete or floor screeding. Including damage to them and access following completion of works.

The present invention aims to provide an improved system to enable the underfloor heating system to heat more rapidly using less energy and time. The enclosed invention also uses a multiple mat system which is produced using completely recycled materials with an improved pipe holding method thereto.

Summary of the invention

According to the present invention there is provided a mat which is made of 100% recycled material from used vehicle tyres. The rubber which is used to make tyres is shredded in fine fibres of no less than 3mm each in length and collected to form a mass. The collection of fibres is mixed with a second export of the tyre bi-product which is Poly 46-2P resin, an adhesive product. The two elements are pressed into a mould to form the rectangular shaping of the mat and its pattern of channels in the surface.

The fibres compress with the resin to set and form the mat which is allowed to dry prior to use or any further finishing works. A sufficient amount of the resin is required to ensure that the individual rubber fibres of the recycled tyres are held together and coated. This will aid the mat when it has to be cut during fittings, as the edges of the cut mat will hold together and prevent excessive loss of fibres or fall away.

To the body of the mat are pressed ‘U’ profiled cannels that run as two parallel lines, equally spaced, with a series of adjoining arched channels forming inlays for water pipes. As shown in the accompanying Figures.

The ‘U^! profiled channels are pressed by the mould press during manufacture and are always of sufficient depth to ensure that the pipes seat into the mat depth and none of the pipe is raised above the channel opening therefore.

The channels are elongated and also provide the fixing method or act as the ‘clip' for the pipes themselves, all from the single pressed mat.

The clipping action takes advantage of the flexible nature of the mats structure, made possible advantageously by the way the tyre fibres reply to gentle pressure. Along each of the elongated V profiled channels are intermediately provided clip ridges which protrude from each side of the channel. Each clip ridge is at least 100 millimetres in length and there is a 10 millimetre space between the end of each clip ridge and the start of the next, on the opposite side of the channel. As shown in the accompanying Figure 5. To the opposite side of the clip ridge is a more flat and only slightly raised upper edge to aid pipe insertion.

These clip ridges and their alternate spacing on either side of the channel continues throughout all channels pressed into the mat surface.

The pipe is pressed in a downward action, as shown in Figure 4 and presses past the flexing clip ridges into the ‘U’ profiled channel. The pipe seats within the channel fully and is not exposed above the mat surface level. As shown in Figure 6.

The pipes are laid into the channel of the mat surface and this is repeated throughout the entire floor area, with the return curve of the pipe accommodated in the curved channels on each mat, as shown.

Therefore, to complete a whole floor with piping, a number of mats are placed together to form the clipping and seating for the pipes.

The number of mats required to be laid on the ground would be determined by the size and shape of the room, mats can be trimmed owing to the advantageous design of the channels on the mats which are each identical.

A foil backing is also provided to each to mat on the rear side to provide insulation and protection.

Due to the use of recycled rubber tyres strands being used to create the underfloor heating mat body, the pipe is increasingly insulated within its deeper channel. This more rapid climb of heat from the insulated pipes in turn is reflected in the warming of the mat body simultaneously, which adds further heat insulation as the temperature rises. Therefore the underfloor heating reaches suitable temperatures more rapidly due to improved insulation and heat conduction. Examples of this are when a 3 kilowatt emersion heater is used to provide the heating of the water in the pipes, the heating temperature for suitable use is reached within 40 hours from cold. The same effect is reached with a 12 kilowatt boiler within 48 hours.

All known pipe sizes which are suitable to underfloor heating may be accommodated in the clipping system due to the size of the channel opening and depth, in combination with the clip ridges and their angle of internal delivery and angle against the outer surface of the pipes and its ability to slightly compress and therefore adjust to larger or smaller pope diameters therefore. A suitable layer of floor screeding is applied once the system has been tested to complete the floor finish.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

Further, the purpose of the foregoing abstract is to enable the Patent Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.

It is therefore an object of the present invention to provide a new and improved underfloor heating mat and pipe holding system which has all the advantages of the prior art underfloor heating methods and none of the disadvantages.

It is another object of the present invention to provide a new underfloor heating mat and pipe holding system which may be easily and efficiently manufactured and marketed.

It is a further object of the present invention to provide a new and improved underfloor heating mat and pipe holding system which is of durable and reliable construction.

An even further object of the present invention is to provide a new and improved underfloor heating mat and pipe holding system which is susceptible of a low cost of manufacture with regard to both materials and labour, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such a product available to the buying public.

Still yet another object of the present invention is to provide a new and improved underfloor heating mat and pipe holding system which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.

These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and detailed descriptive matter in which there is illustrated preferred embodiments of the invention.

Brief description of figures

Figure 1 shows a plan view of the underfloor heating mat and pipe holding system.

Figure 2 shows a plan view of the underfloor heating mat and pipe holding system with two parallel pipes installed.

Figure 3 shows a plan view of the underfloor heating mat and pipe holding system with a curved pipe installed.

Figure 4 shows a dimensional view of a pipe being inserted into the clipping system.

Figure 5 shows a plan view of the clipping system.

Figure 6 shows an end elevation view of the clipping system with a pipe installed.

Figure 7 shows a plan view of two mats fitted together on a floor.

Detailed description of figures

A typical embodiment of the underfloor heating mat and pipe holding system is shown in Figure 1. It comprises a mat 1 which is made from recycled compressed and moulded rubber tyre strands 7 and a resin binding. The mat 1 has ‘IT profiled channels pressed into its surface 5. These are shown as parallel ‘IT profiled channels 2 and 4 which have extending curved channels 8, 9, 10, 11, 12, 13 and 17. The water pipes are pressed into these channels on installation, as shown in the following Figures.

The end openings of the ‘IT profiled channels are shown as 3, 6, 14 and 16.

Two horizontal channels 10 and 15 pass across the mat with channels 2 and 4 perpendicular to them.

Water pipes 18 and 19 are inserted into ‘IT profile channels 2A and 4A in mat 1A surface 5A. Rubber tyre strands 7A form mat 1 A, as shown in Figure 2.

Water pipe 18B is inserted into ‘IT profiled channels 2B and 4B by way of curved channels 20 and 21 as shown in Figure 3.

‘IT profiled channel 2C provided in mat 1C, has holding means for water pipe 18C as shown in Figure 4. Clip ridges 22, 25 and 26 and edging 24 and 28, flex to allow pipe 18C to enter ‘IT profile channel 2C, as shown. Water pipe opening 23 provides water flow. This Figure shows a short section of the clipping system only. Pipe thickness 27 may vary.

Figure 5 shows a plan view of the clipping system, derived of clip ridges 22D, 25D, 26D, 29 and 30. Edging 24D is alternately located between each clip ridge along the upper ‘IT profiled channel 2D. A holding means for water piping is provided therefore.

Figure 6 shows a profile view of the ‘IT profiled channel 2E, this is the arrangement of all channels on the mats 1E.

The water pipe 18E is held in the ‘IT profiled channel 2E by clip ridge 25E and edging 28E.

Mats F and G are laid on the floor together, this is repeated throughout the floor area until covers and sections of the mats may be trimmed away to suit fitting needs.

Claims

1) An underfloor heating mat and pipe holding system, which is a constituted by a series of foil backed rectangular mats made from recycled vehicle tyre rubber and adhesive resin for heat insulation and conduction, with impressed channels for holding water pipes which cover a floor area.

2) An underfloor heating mat and pipe holding system as claimed in claim 1 wherein, rectangular mats are made by shredding recycled vehicle rubber tyres and infusing the strands with a Poly 46-2P resin adhesive for binding means.

3) An underfloor heating mat and pipe holding system as claimed in claim 2 wherein, a manufacturing press is used to shape the mat and create straight and curved ‘IT profiled channels in the mat surface.

4) An underfloor heating mat and pipe holding system as claimed in claim 3 wherein, ‘IT shaped channels in a rubber mat surface are sized to accommodate water pipes for underfloor heating.

5) An underfloor heating mat and pipe holding system as claimed in claim 4 wherein, water pipes are held by a clipping system which is provided in all areas of the ‘IT profiled channels in a rubber mat.

6) An underfloor heating mat and pipe holding system as claimed in claim 5 wherein, protruding clip ridges are provided alternately along the upper edge of the ‘LT shaped channel to hold water pipes in place in the channel.

7) An underfloor heating mat and pipe holding system as claimed in claim 6 wherein, slight edging is provided alternately between each protruding clip ridge along the upper edge of the ‘LT shaped channel to hold water pipes in place in the channel.

8) An underfloor heating mat and pipe holding system as claimed in claim 7 wherein, water pipes of various diameters can be held by the clipping system due to it being slightly flexible when compressed on downward insertion of the pipes in the channels.

9) An underfloor heating mat and pipe holding system as claimed in claim 8 wherein, water pipes can be laid into the mat surface in ‘IT profiled channels which are of sufficient depth to prevent any part of the pipe from being raised above the top surface of the mat.

10) An underfloor heating mat and pipe holding system as claimed in claim 1 wherein, a foil backed mat insulates more due to them being made of shredded recycled tyre rubber, holding in water pipe heat to provide accelerated mat heating and floor heating therefore.

11) An underfloor heating mat and pipe holding system as claimed in claim 1 wherein, a foil backed mat conducts heat more rapidly to warm a floor due to them being made of shredded recycled tyre rubber fibres.