NL2023726B1

NL2023726B1 - Modular floor heating system

Info

Publication number: NL2023726B1
Application number: NL2023726A
Authority: NL
Inventors: Borsje Hazendonk Arie
Original assignee: Hazendonk Techniek B V
Priority date: 2019-08-29
Filing date: 2019-08-29
Publication date: 2021-05-11
Also published as: WO2021037888A1

Abstract

A floor heating system for hot water heating, constituted by interconnectable plastic modules (10, 60, 90), comprises 5 - at least one connector manifold module (10) comprising a supply channel (16) and at least one associated supply manifold channel (20), a return channel (18) and at least one associated return manifold channel (26), - a basic module (60) having at least one supply channel (72’), and at least one return channel (72”), 10 - a return module (90) having at least one return channel (92), wherein the supply channel (16) of at least one connector manifold module (10) is configured to allow connection to a supply conduit from a hot water source and the return channel (18) of at least one connector manifold module (10) is configured to allow connection to a return conduit to the hot water source. 15 Fig. 17

Description

P34137NLO0/JV Title: Modular floor heating system The present invention relates to a floor heating system for hot water heating.

Today floor heating is a frequently applied means for heating buildings by hot water, such as certain rooms, in particular a living room, a kitchen and hallway in houses. Such a type of floor heating may be used instead of radiator heating or may be applied in addition thereto. Typically a floor heating system is a circulation circuit, which comprises a manifold having a supply inlet for hot water from a boiler of a central heating and a return outlet for water to the boiler, a number of flexible hoses or tubes, that are embedded in the floor, and the ends of which are connected to the manifold. Typically the flexible hoses are arranged in grooves that are cut in the concrete bottom floor and after inserting the hoses the grooves are filled with fresh mortar or concrete. Generally the flexible hoses are arranged in a pattern wherein parallel hose parts are spaced at a distance of typically 10 cm. Installing such floor heating systems requires a lot of labour intensive activities. In addition the existing floor heating systems do heat up the whole concrete mass of the floor during use. This results in relative long heat up times and waste of heat into the mass of concrete. In addition, due to the distance between the hoses the occupants and other users experience local temperature variations. Furthermore, this kind of floor heating is less suitable for application with relative thin supporting floors, such as wooden floors, which may be present in older buildings, or between storeys, due to the typical diameter dimensions of the hoses. Moreover, in such wooden floors it is complicated to fixedly mount the hoses. Also space for arranging the manifold may be hard to find.

The invention aims at providing a floor heating system which is versatile such that it can be easily adapted and installed independent from the type of supporting floor and that allows for easy connection to existing pipework.

Another object is to provide such a system which enables to reduce the heat losses into the floor. According to the invention a floor heating system for hot water heating is provided that is constituted by interconnectable plastic modules, comprising - at least one connector manifold module comprising a supply channel having ends, wherein the ends are configured for connecting to the respective supply channel of an adjacent connector manifold module, at least one supply manifold channel, a first end thereof ending up in the supply channel and a second end thereof being configured for connecting to a basic module,

2. a return channel having ends, wherein the ends are configured for connecting to the return channel of an adjacent connector manifold module, at least one return manifold channel, a first end thereof being configured for connecting to a basic module and a second end thereof ending up in the return channel; - a basic module comprising a panel having at least one supply channel, and at least one return channel, wherein the at least one supply channel at one end is configured to be connected to the respective supply manifold channel of the connector manifold module and at the other end being is configured to be connected to a return module, and wherein the at least one return channel at one end is configured to be connected to the respective return manifold channel of the connector manifold module and at the other end being configured to be connected to the return module; -areturn module comprising a panel having at least one return channel, which return channel at one end is configured to be connected to the respective supply channel of the basic module and at the other is configured to be connected to the respective return channel of the basic module; wherein the supply channel of at least one connector manifold module is configured to allow connection to a supply conduit from a hot water source and the return channel of at least one connector manifold module is configured to allow connection to a return conduit to the hot water source.

The floor heating system according to the invention comprises three main modules, a connector manifold module that is typically arranged at an edge between the floor on which the modules are positioned and an upstanding wall, typically at the position of a plinth if any, one or more basic modules supported by the floor and extending from the connector manifold module in the direction of an opposite wall, and a return module arranged at the opposite wall.

The respective channels of a module are at their ends connectable to the corresponding channels of an adjacent module in a fluidly tight manner.

The connector manifold module receives hot water from a central heating unit such as a boiler or heat pump and returns water after circulation through the basic module and return module to the central heating unit.

The basic module comprises at least two, but preferable a plurality of channels such as 6-12, wherein half of the number of the plurality of channels acts as a supply channel and the other half acts as a return channel.

The number of supply and return manifold channels in the connector manifold module is the same as the number of the supply and return channels in the basic module.

The at least one supply channel of the basic module is at its inlet end connected to the supply side of the connector manifold module, that is the respective end of

23. the supply manifold channel, and at the opposite side to the inlet end of the respective return channel of the return module. On its turn the outlet end of the return channel of the return module is connected to the at least one return channel of the basic module and via this return channel via the return manifold channel to the return channel of the connector manifold module. At least one of the connector manifold modules is connected to the hot water source, from which hot water is received and to which water, after circulation through the modules is returned. The plastic modular floor heating system according to the invention can be easily applied on existing floors, whether made from concrete, wood or other material, without the need for cutting grooves for inserting hoses or tubes. The plastic basic modules can be easily manufactured in one piece by extrusion at a standard length and can be cut to size in situ. The connector manifold module can be prepared by injection moulding and the like of its constituting parts, which possibly are assembled together. Also the return manifold may be manufactured by this technique. 3D printing may also be used for manufacturing the modules.

Preferably the plastic is a thermoplastic allowing mirror welding to connect the end of the channels of the basic module to those of the connector manifold module and the return module in order to establish the leak tight circulation loops comprised of the respective channels in the modules. Polyurethane is a preferred starting material in view of strength, rigidity and expansion coefficient. The internal surfaces of the channels may be coated, e.g.

with an oxygen barrier coating in order to avoid diffusion of oxygen through the plastic into the circulating water, which would result in a flow of corrosive oxygen-rich hot water through the system including the hot water source and (metal) connecting pipework. Another example is a heat transfer improving coating such as a thin metal coating. In a preferred embodiment the channels in the basic module and return module have a flat configuration. In other words these channels have a cross-section, which is typically rectangular, having a width that is larger than the depth, advantageously the depth is much smaller than the width. The thickness of the upstanding walls that delimit the channels in the depth direction is determined by the strength required and are designed as small as possible. The flat configuration of the channels due to their width offers a large heat exchanging surface covering substantially the whole floor surface in a contiguous way without the presence of large gaps between spaced apart hoses according to the prior art, thereby preventing local temperature difference. The system according to the invention also allows to operate the warm water source at a lower temperature compared to a floor heating system based on embedded hoses, because the system according to the invention does not need to heat up the concrete mass and because of the large heat exchanging surface. During operation of the system according to the invention the channels having a flat configuration, and the total of channels covering the whole surface of the respective floor a large volume of

-4- water (compared to prior art systems with hoses) is circulating. Such a large volume of water is favourable for use with a heat pump in view of stable operation thereof as well as optimal use of its heating and/or cooling capacity. The heating efficiency may further be enhanced by applying a suitable isolation such as a flattening underfloor for example from felt or cork, upon which the floor heating system according to the invention is positioned. The thickness of the module according to the invention in a flat bottom embodiment is preferably 7 mm or less. The thickness of the module according to the invention having supporting legs as explained below is preferably less than 10 mm. The total thickness including the isolation is less than 15 mm, such as 12 mm. Typically a further floor covering, such as carpeting, floor laminate or wooden floorboards, is laid on top of the floor modules according to the invention.

The supply channels of adjacent connector manifold modules can be connected by a connector, e.g. a short piece of straight tubing having embedded seals, such as O- rings, at both ends that are to be inserted in the supply channel ends of adjacent modules to be connected. The return channels can be connected in a similar way.

Atleast one of the connected connector manifold modules is connected to the hot water source. In renovation where the system according to the invention replaces conventional radiator heating the connections of existing supply and return pipes can be used. Typically the connector manifold module in the neighbourhood of these existing conduits is provided with additional connectors for connecting thereto, which connectors are in fluid communication with the supply channel and return channel of the respective module. Thus advantageously the supply channel of at least one connector manifold module is provided with an additional supply connector, which is configured to be connected to a hot water supply conduit from the hot water source. Similarly the return channel of at least one connector manifold module is provided with an additional return connector, which is configured to be connected to a return conduit to the hot water source. Depending on the position of these existing conduits the additional connectors may be provided as top connectors, side connectors or bottom connectors. Angled e.g. 90° (knee bend) connectors may be inserted in the ends of the supply channel and return channel if desired. Non-active ends of the supply and return channels of the connector manifold module can be easily blinded by inserting a suitable plug or stopper.

In a preferred embodiment the connector manifold module comprises a bottom portion and an upstanding portion, wherein the supply channel and the return channel are arranged parallel and above one another in the upstanding portion, and the at least one supply manifold channel and the at least one return manifold channel extend through the upstanding portion and the bottom portion wherein the ends configured to be connected to the basic module are arranged in the bottom portion. In this way the supply channel and the discharge channel are easily accessible for mutual coupling to adjacent connector manifolds using straight

-5. connector parts as explained above, while the bottom portion can be connected by mirror welding to the respective adjacent basic module.

In order to allow easy assembling and mutual positioning, in a further embodiment the basic modules are provided with couplings for interconnecting of these modules at the edges, typical the longitudinal sides, parallel to the channels in the basic modules, preferably tongue and groove couplings.

Similarly the return modules are provided with couplings for interconnecting of these modules at their edges.

Preferably these couplings are also tongue and groove couplings.

In yet a further embodiment the at least one return channel of the return module is a U shaped channel allowing a smooth bending of the flow of water.

Generally the basic module and return module are panels having a flat upper face, upon which a further floor covering can be laid.

This also holds for the bottom portion of the connector manifold module.

When no separate insulating underfloor is used, the opposite bottom face of the various modules is preferably provided with supporting legs, more preferably at the positions of the upstanding walls of the channels, which walls separate adjacent channels, whether adjacent channels in the same module or in a neighbouring module.

The supporting legs allow to balance any unevenness of the floor on which the system according to the invention is arranged.

Furthermore the air volume that is present between the legs functions as an isolation layer preventing full area contact of the bottom face of the module with the floor, which also contributes to reduction of heat loss to the floor.

In case a separate insulating underfloor is used, preferably the opposite bottom is flat.

It will be understood that the system according to the invention also can be used as a cooling system.

The invention is illustrated in more detail in the attached drawing, wherein:

Fig. 1is a diagrammatic view of an embodiment of a connector manifold module of a floor heating system for hot water heating according to the invention; Fig. 2 is a cross sectional view at a position of a supply manifold channel in Fig. 1; Fig. 3 is a cross sectional view at a position of a return manifold channel in Fig. 1 Fig. 4 is a diagrammatic view of an embodiment of a basic module of an underfloor heating system for hot water heating according to the invention; Fig. 5 is a cross sectional view of the basic module of Fig. 4; Fig. 6 is a diagrammatic top view of an embodiment of a return module of an underfloor heating system for hot water heating according to the invention; Fig. 7 illustrates the internal channels of the return module of Fig. 6;

Fig. 8 is a diagrammatic view of a second embodiment of a connector manifold module of an floor heating system for hot water heating according to the invention; Fig. 9 is a cross sectional view at a position of an additional supply connector in Fig. 8;

-6- Fig. 10 is a cross sectional view at a position of an additional return connector in Fig. 8; Fig. 11 is a diagrammatic view of a third embodiment of a connector manifold module of an floor heating system for hot water heating according to the invention; Fig. 12 is a cross sectional view at a position of an additional supply connector in Fig. 11; Fig. 13 is a cross sectional view at a position of an additional return connector in Fig. 11; Fig. 14 is a diagrammatic view of a fourth embodiment of a connector manifold module of an floor heating system for hot water heating according to the invention; Fig. 15 is a cross sectional view at a position of an additional supply connector in Fig. 14; Fig. 16 is a diagrammatic view of an embodiment of a connector part for mutual coupling adjacent connector manifold modules; and Fig. 17 is a diagrammatic view of a room, the bottom of which is provided with a system according to the invention.

In the drawing the same parts are indicated by the same reference numbers, except where indicated explicitly otherwise.

In Fig. 1 a diagrammatic view of an embodiment of a connector manifold module of an underfloor heating system for hot water heating according to the invention is shown. Fig. 2 and 3 show cross-sections at the position of a supply manifold channel, respectively at the position of a return manifold channel thereof. The connector manifold module is indicated in its entirety by reference numeral 10. The module 10 comprises an upstanding portion 12 and a bottom portion 14. The upstanding portion 12 comprises a supply channel 16 and a return channel 18, which both extend in the length direction of the module 10 and parallel to one another. At its respective ends 17 the supply channel 16 can be connected to an adjacent module, for example by means of a connection part as shown in Fig. 16. Similarly the ends 19 of the return channel 18 can be coupled to the end of the return channel in an adjacent module. In this embodiment the bottom portion 14 comprises ten channels, of which five adjacent supply manifold channels 20 (left hand side) are in fluid communication with the supply channel 16 via channels 22 and respective openings 24 in the upstanding portion 12. Similarly five adjacent return manifold channels 26 (right hand side) are in fluid communication with the return channel 18 via channels 28 and respective openings 30 in the upstanding portion 12. The channels 20 and 26 are separated by upstanding walls 32. These channels have a rectangular cross-section. As can be seen, the top face 34 of the bottom portion 14 is substantially flat and in this non-flat design the bottom face 36 is provided with supporting legs 38 at the position of the walls 32. At one side (left hand side) the bottom portion 14 has a groove part 40 and the opposite side (right hand side) is provided with a tongue part 42 for coupling to matching coupling parts of adjacent modules. In the embodiment shown the upper portion 12 comprises supporting legs 44 which carry the channels 16 and 18. Two supporting legs 44 are provided with slotted holes 46, which allow

-7- to fix the module 10 to a wall e.g. using a metal back support and screws (both not shown). In this embodiment the front faces 48 of the supporting legs 44 have projections 50 and recess 52 that extend in the length direction of the module 10. A further recess 54 is present in the top face 56. These projections 50 and recesses 52 and 54 can be used for coupling to a cover or plinth. In Fig. 4 a diagrammatic view of an embodiment of a basic module of an underfloor heating system for hot water heating according to the invention is shown. Fig. 5 shows a cross- section thereof. The basic module 60 has a panel like body 61 that corresponds to that of the bottom portion of the connector manifold module. The module 60 has a top 62 having a substantially flat upper face and - in the non-flat design as shown - a bottom 64 provided with supporting legs 66 extending over the length of the module 60 at the position of upstanding walls 68, that together with the top 62 and bottom 64 delimit parallel internal channels 72 having a rectangular cross-section similar to the channels 20 and 26 of the module 10. Half of these channels 72 are supply channels 72’ that can be connected to the ends 21 of the supply manifold channels 20. The other half are return channels 72” that can be connected to the ends 27 of the return manifold channels 26. The longitudinal side 74 is provided with a groove part 78 defined by recess 79 between projecting edges 80 and 82 of the top 62 and bottom 64. The opposite side 84 has a tongue part 86 for insertion into a matching groove part of an adjacent module. The recess 79 is configured to receive a matching tongue part 86.

In Fig. 6 a diagrammatic top view of an embodiment of a return module of an underfloor heating system for hot water heating according to the invention is shown. Fig. 7 illustrates the outlines of the internal channels thereof. The return module 20 has a panel like body 91 having an external configuration that corresponds to that of the basic module 60. The module 90 is provided with internal channels 92 separated by walls 94. The channels 92 have an inlet end 96 and outlet end 98 at the same side of the module 90, of which the cross-section corresponds to that of the internal channels 72 to receive the flow of water from the supply channels 72’ in the basic module 60 and to return the flow of water to the return channels 72” in the basic module 60. A return module 90 is provided with similar coupling means for coupling adjacent return modules.

Figs. 8-10 show a second embodiment of a connector manifold module according to the invention, similar to Fig. 1. Similar parts are indicated by the same reference numerals. In this embodiment the supply channel 16 is provided with an additional upper connector 100 for coupling to a source of heat water such as a heat pump or boiler of a central heater. The connector 100 may for example have internal screw thread. Similarly the return channel 18 is provided with an additional upper connector 102 for circulating back the flow of water to the source thereof.

-8- Fig. 11-13 show a third embodiment of a connector manifold module according to the invention, similar to Fig. 1 and 8, wherein however the respective additional connectors 100 and 102 are directed to the bottom of the module 10. Fig. 14-15 show a fourth embodiment of a connector manifold module according to the invention, similar to Fig. 1, 8 and 11, wherein however the respective additional connectors

100 and 102 project from the front of the upstanding portion 12 of the module 10. In this specific embodiment these additional connectors 100 and 102 have an end that is positioned where otherwise twa openings and channels would have been situated.

The number of internal channels is reduced to six, three as supply manifold channels 20 and three as return manifold channels 26. Fig. 16 shows an embodiment of a connector part 110 for mutual coupling adjacent connector manifold modules 10 .The connector part 110 comprises a length of tubing provided at both ends 112 with a suitable seal, in this case circumferential recesses 114 in the outer periphery of the tubing for receiving O-rings (not shown). The ends 112 have a diameter that allows insertion in a sealing manner into the corresponding ends of the supply channels 16 and the corresponding ends of discharge channels 18 in adjacent modules that are to be coupled.

For an end module an angled connector part, such as a 90° bend tubing may be a suitable alternative for the connector part 110. Fig. 17 shows a diagrammatic view of a room, the bottom of which is provided with a system according to the invention.

A series of connector manifold modules 10 of which the supply and return channels are interconnected using connector parts is arranged along a wall 110 of a room.

The bottom portions of the modules 10 are arranged on the floor 114 of the room with possible interstation of an insulating layer 116 of cork and welded to the basic modules 60, thereby connecting the supply manifold channels and return manifold channels of the modules 10 to the corresponding channels in the basic modules.

On its turn the other end of each basic module 10 is welded to the return module 60. As can be seen the connector manifold modules 10 and return modules 60 have a standard size, while the basic module is cut to size to achieve the required length.

The connector manifold modules are fixed by screws on a metal back support profile to prevent the modules from being pushed apart by the water pressure.

Claims

-9- CONCLUSIONS

An underfloor heating system for hot water heating, composed of interconnected plastic modules (10, 60, 90), comprising - at least one connector distribution module (10) including a feed channel (16) having ends (17), the ends being configured to be connected to the respective supply channel of an adjacent connector distribution module, at least one supply distribution channel (20), a first end of which terminates in the supply channel (16) and a second end (21) thereof is configured for connection to a base module (60), a return channel (18 ) having ends (19), the ends being configured for connection to the respective return channel of an adjacent connector distribution module, at least one return distribution channel (26), a first end (27) of which is configured for connection to a base module (80), and a second end (28) thereof terminates in the return channel (18); - a base module (60) comprising a body (61) having at least one supply channel (72), and at least one return channel (72"), the at least one supply channel (72') configured at one end to be connected with the respective supply distribution channel (20) of the connector distribution module (10) and configured at the other end to be connected to a return module {90}, and wherein the at least one return channel (72") is configured at one end to be connected connected to the respective return distribution channel (26) of the connector distribution module (10) and configured at the other end to be connected to the return module (90); - a return module (90) comprising a body (91) having at least one return channel (92), which return channel (92) at one end (94) is configured to be connected to the respective feed channel (72") of the base module (60) and at the other end (96) configured to connect to the respective return channel (727) of the base module (60), the feed channel (16) of at least one connector distribution module (10) being configured to connect to to allow a supply line from a hot water source and the return channel (18) of at least one connector distribution module (10) is configured to allow connection on a return line to the hot water source,

-10 - wherein the connector distribution module (10) comprises a bottom portion (14) and an upright portion (12), wherein the supply channel (16) and the return channel (18) are arranged parallel and one above the other in the upright portion (12), and the supply distribution channel (20) and the return distribution channel (26) extend through the upright portion (12) and the bottom portion (14), the ends (21; 27) configured to be connected to the base module (10), are arranged in the bottom portion (14).

Underfloor heating system according to claim 1, wherein the channels (72; 92) in the base module (60) and return module (90) have a rectangular cross-section with a width greater than the depth.

The underfloor heating system of claim 1 or 2, wherein the supply duct (16) of at least one connector distribution module (10) includes an additional supply connector (100) configured to be connected to a hot water supply line from the hot water source.

Underfloor heating system according to any one of the preceding claims, wherein the return channel (18) of at least one connector distribution module (10) is provided with an additional return connector (102) configured to be connected to a return line to the hot water source.

Underfloor heating system according to any one of the preceding claims, wherein the base modules (60) are provided with couplings for interconnecting these modules (60) at their edges (74; 84) parallel to the channels (72) in the base modules (10). ), preferably tongue and groove couplings (86; 78).

Underfloor heating system according to any one of the preceding claims, wherein the return modules (90) are provided with couplings for interconnecting these modules at their edges, preferably tongue and groove couplings (99).

Underfloor heating system according to any one of the preceding claims, wherein the at least one return channel (92) of the return module (90) is a U-shaped channel.

An underfloor heating system according to any one of the preceding claims, wherein the base module (60) and return module (90) have panel bodies (61; 91) having a flat top surface (62) and a flat bottom surface (64).

-11 -

Underfloor heating system according to any of the preceding claims 1-7, wherein the base module (60) and return module (90) have panel bodies (61; 91) with a flat top surface (62) and a bottom surface (64) provided with support legs ( 66).

An underfloor heating system according to claim 9, wherein in the base module (60) and return module (20) adjacent channels (72; 92) are separated by partition walls (38; 94) and the support legs (66) extend the length of the partition walls ( 38; 94) and at their positions.