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.

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.