TEMPERATURE CONTROL SYSTEM

Abstract

A support structure for a heating or cooling system includes a plurality of projections designed to be capable of retaining one or more thermal elements positioned adjacent thereto. The projections are positioned so as to form a first set of substantially parallel undulating channels, each channel having one of the projections forming at least a part of the inner radius of each undulation, with each projection having a recess formed in a side wall thereof facing said channel. The undulations of the channel ensure that a thermal element positioned in the channel will make contact with the projections each time it has to bend around one, without requiring spacing of the projections to squeeze the thermal element. The thermal element can thus be held securely without any play (unwanted lateral movement) in a channel that is slightly wider than the thermal element. Recesses in the channels at the contact points also restrict movement in the vertical direction, thus preventing the thermal element from ‘popping out’ of the channel, while not requiring any restriction narrower than the thermal element.

Claims

1. A heating system comprising: a support structure having a plurality of projections formed thereon; and a heating wire; wherein the plurality of projections form a first set of substantially parallel undulating channels on the support structure, the undulations of each channel being formed by a series of constrictions that are alternately offset in opposite directions along a length of the respective channel; wherein the heating wire is configured to be retained within one or more of the substantially parallel undulating channels formed on the support structure; and wherein at least a portion of the support structure is textured.

2. The heating system of claim 1, wherein the texture on the support structure is formed by one of molding, surface imprinting, etching, or grit-blasting.

3. The heating system of claim 1, wherein the texture on the support structure comprises fibers adhered to or partially melted into the support structure.

4. The heating system of claim 3, further comprising a fabric stress mitigation layer on an underside of the support structure; wherein the fabric stress mitigation layer comprises fleece fibers; and wherein the fibers adhered to or partially melted into the support structure are fleece fibers of the same type as the fleece fibers of the fabric stress mitigation layer.

5. The heating system of claim 1, wherein: each projection of the plurality of projections comprises a side wall having a recess formed therein, the recess facing one of the substantially parallel undulating channels formed on the support structure; the heating wire undulates within the one or more of the substantially parallel undulating channels when the heating wire is retained therein; each undulation of each of the substantially parallel undulating channels has an amplitude that does not exceed a width of the respective channel; the projections of the plurality of projections are grouped into pairs; and the recesses of each pair of projections face adjacent undulating channels of either the first set of undulating channels or a second set of undulating channels.

6. The heating system of claim 5, wherein the projections of each pair of projections are separated by a portion of the support structure.

7. The heating system of claim 5, wherein: each pair of projections has one of two orientations, one orientation being a ninety degree rotation of the other orientation; the pairs of projections are arranged on the support structure in a rectangular grid with the orientations of the pairs of projections being set according to a checkerboard pattern; in a first one of the two orientations, the pairs of projections form a structure that is wider in a first dimension than in a second, perpendicular dimension; and in a second one of the two orientations, the pairs of projections form a structure that is wider in the second dimension than in the first dimension.

8. A heating system comprising: a castellated mat having a plurality of projections on an upper side thereof; and a heating wire; wherein the plurality of projections form a first set of channels on the castellated mat; wherein the heating wire is configured to be retained within one or more of the channels formed on the castellated mat; and wherein at least a portion of the castellated mat is textured.

9. The heating system of claim 8, wherein the texture on the castellated mat is formed by one of molding, surface imprinting, etching, or grit-blasting.

10. The heating system of claim 8, wherein the texture on the castellated mat comprises fibers adhered to or partially melted into the castellated mat.

11. The heating system of claim 10, further comprising a fabric stress mitigation layer on an underside of the castellated mat; wherein the fabric stress mitigation layer comprises fleece fibers; and wherein the fibers adhered to or partially melted into the castellated mat are fleece fibers of the same type as the fleece fibers of the fabric stress mitigation layer.

12. The heating system of claim 8, wherein: the first set of channels comprises a first set of substantially parallel undulating channels; the undulations of each channel are formed by a series of constrictions that are alternately offset in opposite directions along a length of the respective channel; each projection of the plurality of projections comprises a side wall having a recess formed therein, the recess facing one of the substantially parallel undulating channels; the heating wire undulates within the one or more of the substantially parallel undulating channels when the heating wire is retained therein; each undulation of each of the substantially parallel undulating channels has an amplitude that does not exceed a width of the respective channel; the projections of the plurality of projections are grouped into pairs; and the recesses of each pair of projections face adjacent undulating channels of either the first set of undulating channels or a second set of undulating channels.

13. The heating system of claim 12, wherein the projections of each pair of projections are separated by a portion of the castellated mat.

14. The heating system of claim 12, wherein: each pair of projections has one of two orientations, one orientation being a ninety degree rotation of the other orientation; the pairs of projections are arranged on the castellated mat in a rectangular grid with the orientations of the pairs of projections being set according to a checkerboard pattern; in a first one of the two orientations, the pairs of projections form a structure that is wider in a first dimension than in a second, perpendicular dimension; and in a second one of the two orientations, the pairs of projections form a structure that is wider in the second dimension than in the first dimension.

15. A method of forming a support structure for a heating system, the method comprising: forming a castellated mat having a plurality of projections on an upper side thereof, the plurality of projections forming a first set of channels that are configured to retain a heating wire; and texturing at least a portion of the castellated mat.

16. The method of claim 15, wherein the step of texturing at least a portion of the castellated mat comprises one of molding or surface imprinting the texture onto a surface of the castellated mat during a vacuum forming process.

17. The method of claim 15, wherein the step of texturing at least a portion of the castellated mat comprises one of etching or grit-blasting a surface of the castellated mat after the step of forming the castellated mat.

18. The method of claim 15, wherein the step of texturing at least a portion of the castellated mat comprises: applying fibers to a surface of the castellated mat after the step of forming the castellated mat; and allowing the fibers to partially melt into the surface.

19. The method of claim 18, further comprising the step of providing a fabric stress mitigation layer comprising fleece fibers on an underside of the castellated mat.

20. The method of claim 19, wherein the fibers applied to the surface of the castellated mat are fleece fibers of the same type as the fleece fibers of the fabric stress mitigation layer.

21. The method of claim 20, wherein the fibers applied to the surface of the castellated mat are supplied from off-cuts or wastage from the step of providing the fabric stress mitigation layer.

22. The method of claim 15, wherein the step of texturing at least a portion of the castellated mat comprises adhering fibers to a surface of the castellated mat after the step of forming the castellated mat.

23. The method of claim 22, further comprising the step of providing a fabric stress mitigation layer comprising fleece fibers on an underside of the castellated mat.

24. The method of claim 23, wherein the fibers adhered to the surface of the castellated mat are fleece fibers of the same type as the fleece fibers of the fabric stress mitigation layer.

25. The method of claim 20, wherein the fibers adhered to the surface of the castellated mat are supplied from off-cuts or wastage from the step of providing the fabric stress mitigation layer.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0045] Preferred embodiments of the invention will be described, by way of example only, and with reference to the accompanying drawings in which:

[0046] FIG. 1 shows a perspective view of a first embodiment of a castellated mat support structure;

[0047] FIG. 2 shows a plan view of the mat of FIG. 1;

[0048] FIG. 3 shows a side view of the mat of FIG. 1;

[0049] FIGS. 4a and 4b show cross-sections through a castellated mat;

[0050] FIG. 5 shows a perspective view of a second embodiment of a castellated mat support structure;

[0051] FIG. 6 shows a plan view of the mat of FIG. 5;

[0052] FIG. 7 shows a side view of the mat of FIG. 5;

[0053] FIG. 8 shows a perspective view of a third embodiment of a castellated mat support structure;

[0054] FIG. 9 shows a plan view of the mat of FIG. 8;

[0055] FIG. 10 shows a side view of the mat of FIG. 8;

[0056] FIG. 11 shows a pair of main projections with a central additional projection;

[0057] FIG. 12 shows the structure of FIG. 11 with a hole formed through the additional projection;

[0058] FIG. 13 shows an alternative to FIG. 12 with multiple holes formed through the additional projection;

[0059] FIG. 14 shows an alternative structure with projection through-holes;

[0060] FIG. 15 shows a single projection with a large central hole; and

[0061] FIG. 16 shows a textured mat.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0062] FIGS. 1-3 show a first embodiment of a castellated support structure 1 in the form of a mat. The mat may take the form of sheets that can be laid adjacent to one another or a roll that can be rolled out onto a desired surface. Either way the mat can be cut to size and shape for any particular installation.

[0063] The mat 1 is typically used as an intermediate structure in underfloor heating installations and provides a structure around which a heating element can be wound while holding the heating element in place. The mat 1 also provides a rigid structure that can protect the heating element from being damaged, e.g. crushed during installation by installers walking around on the mat 1.

[0064] While the remainder of this description discusses a heating element in an underfloor heating installation, it will be appreciated that the mat is equally useful for a cooling element such as a conduit to carry a cold fluid and absorb heat from the room. It will also be appreciated that the installation is not limited to floors, but could equally well be installed on a wall or ceiling. It will also be appreciated that underfloor heating systems can either be fluid-based (often termed hydronic) in which a hot liquid is pumped through a fluid carrying conduit, or electrical in which an electrical current is passed through a heating wire to generate heat. The mat 1 can be used for any of these installations. The heating conduit, cooling conduit or heating wire are generally referred to as a thermal element.

[0065] FIG. 1 shows a support structure (mat) 1 with a thermal element (an electrical heating wire in this particular embodiment) 2 which is flexible and which has been laid in channels 3, 4 which are formed between projections 5. The projections have a side wall 6 with a height greater than the diameter of the thermal element 2 so that the channels 3, 4 are deeper than the thermal element 2 and the thermal element 2 is thus fully accommodated in the channels 3, 4. The thermal element 2 thus lies underneath the upper surface of the mat 1 and is protected from footfall on top of the mat 1.

[0066] As can best be seen in FIG. 2, the channels 3, 4 are undulating in the sense that the constrictions that form each channel 3, 4 are not all perfectly in line, but rather are offset alternately in opposite directions when viewed along the length of the channel 3, 4. Therefore a thermal element 2 laid in the channel 3, 4 undulates back and forth across a mid-line of the channel 3, 4 as it is deflected by the projections 5 on either side of the channel 3, 4. This undulation allows the thermal element 2 to be held in contact with the side walls 6 of a number of the projections 5, but without being pinched between them and without requiring overhanging lips to hold the thermal element 2 in the channel 3, 4. Instead, the channel 3, 4 can be formed to be wider than the diameter of the thermal element 2, thus avoiding pinching, while still ensuring that the thermal element 2 is contacted on both sides thereby holding it securely within the channel 3, 4. Without such grip on both sides there is a risk that the thermal element 2 could pop out of the channel 3, 4 which is inconvenient as it requires relaying of the thermal element 2 and also risks damage to the thermal element 2 underfoot while not protected in a channel 3, 4.

[0067] For added security, i.e. for better retention of the thermal element 2 within the channel 3, 4, it is preferred that a small recess 7 is provided on the projections 5 at the point of contact with the thermal element 2. This recess ensures that as the thermal element 2 is diverted around the projection 5, it sits in the recess 7 and is thus retained from above by a part of the projection 5 that overlies the thermal element 2. Note however that as this recess 7 is only ever present on one side of the channel 3, 4 at one time and as the channel 3, 4 is wider than the thermal element 2, the thermal element 2 is not pinched as it is pressed down into the channel 3, 4 and thus does not suffer any potential damage during this process.

[0068] The portion of the thermal element 2 that lies in channel 4a in FIG. 2 is caused to undulate by four projections 5 which have been labeled A, B, C and D in FIG. 2. The projections A and C lie on one side of the thermal element 2, deflecting it in one direction (towards the top of the page), while projections B and D lie on the opposite side of the thermal element 2, deflecting it in the opposite direction (towards the bottom of the page). Therefore, with reference to the page of FIG. 2, the thermal element undulates from left to right over projection A, under projection B, over projection C and under projection D. The contact points of the projections A, C interleave with those of projections B, D along the length of the thermal element 2. It can be appreciated from this illustration that the outer radius of each projection A, B, C, D forms the inner radius of the undulations of thermal element 2 placed in channel 4a. The outer radius of the thermal element 2 does not make contact with the projections that are adjacent to it (best seen in FIG. 4).

[0069] As can be seen in FIGS. 1 and 2, two sets of undulating channels 3, 4 are formed the first set 3 is perpendicular to the second set 4. The first set of channels 3 comprises a number of substantially parallel channels, e.g. 3a, 3b, 3c. Similarly, the second set of channels 4 comprises a number of substantially parallel channels, e.g. 4a, 4b, 4c. The term “substantially” here allows for the fact that adjacent channels in a set or not exactly parallel. For example, in the design of FIGS. 1-3, the undulations in two adjacent channels 3a, 3b are a mirror image of each other such that they undulate towards and away from each other as they pass along the length of the mat, i.e. there are points in adjacent channels that are closer together than other points in the same adjacent channels. Thus the adjacent channels 3a, 3b (and also 4a, 4b or 3b, 3c or 4b, 4c) are not exactly parallel.

[0070] The two sets of channels 3, 4 together encompass a rectangular grid 8 which is shown in FIGS. 1-3 by way of illustration but need not actually take any form or be marked on the mat 1 in any way. The grid 8 is formed from straight lines at right angles to each other and illustrates the relative positioning of the projections 5 and how they form the undulating channels 3, 4. Looking at the grid line that lies in the channel 4a at the top of FIG. 2, it can be seen that the left-most projection 5a that lies above the grid line is much closer to the grid line than the two left-most projections 5b, 5c that lie below the grid line. Together these three projections 5a, 5b, 5c form the left-most constriction that defines the channel 4a. The next left-most constriction is again formed by three projections 5d, 5e, 5f, but this time projection 5d lies below the grid line while projections 5e and 5f lie above it and the projection 5d below the grid line is much closer to the grid line than the two projections 5e, 5f above it. Thus these two left-most constrictions are centered on opposite sides of the grid line and hence cause the channel 4a to undulate or oscillate along the grid line as it passes from left to right.

[0071] The projections 5 are arranged in pairs. For example projections 5b and 5c form a pair. Similarly projections 5e and 5f form a pair. Each pair of projections 5 lies between two adjacent channels of the first set of channels 3 and also between two adjacent channels of the second set of channels 4. Each projection 5 of the pair forms a contact point on a channel 3, 4 such that the two projections 5 of the pair form contact points on adjacent channels 3, 4 of one set of channels, but not both. Thus if a pair of projections 5 form contact points on a channel of the first set 3, they do not form contact points on a channel of the second set 4 and vice versa. Recesses 7 are formed at these contact points as discussed above. Each pair of projections is thus together slightly elliptical, having a wider dimension between the outer radii of the two projections 5 that form contact points with the adjacent channels (and have recesses 7 formed therein) than the dimension that does not contact the perpendicular channels.

[0072] The two projections 5 of a pair are curved such that each forms an arc around a central region 9. The two projections 5 of each pair are separated from each other so as to form a pathway 10 into the central region 9. These pathways 10 allow heat to be conducted from the thermal element 2 more evenly across the surface of the mat 1 as a whole, avoiding cold spots that might otherwise be formed between channels 3, 4. The curved nature of the projections 5 allows them to guide the thermal element smoothly between channels 3 of one set and channels 4 of the perpendicular set, thus allowing changes of direction of the thermal element 2 so that it can be laid back and forth across the mat 1 to cover a whole floor.

[0073] It may be noted that the rectangular grid 8 lies entirely within the channels 3, 4, i.e. the undulations caused by the projections 5 do not cause a thermal element 2 placed within the channel 3, 4 to deviate by more than the width of the thermal element 2. This puts a restriction on the amplitude of the undulations so as to minimize the stress placed on the thermal element 2, while also minimizing the increase in length of thermal element 2 that is required by the undulations but also ensuring that the thermal element 2 is still securely held in place.

[0074] As can best be seen in FIGS. 1 and 2, the projections 5 can be arranged into pairs in two different orientations so that one orientation provides contact points with one set of channels 3, while the other orientation provides contact points with the other set of channels 4. The projections 5 are arranged such that these two orientations are interleaved like the squares of a chequerboard, e.g. with one orientation occupying the black squares and the other orientation occupying the white squares. Thus each pair is directly adjacent (on the opposite side of a single channel) to a pair of the other orientation.

[0075] FIG. 4a shows a cross-section taken through two adjacent pairs of projections 5 and showing the thermal element 2 in contact with the projection 5d while not being in contact with the projection 5f. The thermal element 2 (e.g. heating wire) is seated in recess 7 in the outer diameter of curved projection 5d and is therefore constrained from upwards movement by the vertical overlap of the thermal element 2 and the projection 5 formed in this region. It can be seen that the thermal element 2 is not constrained by any similar overlap on the opposite side, i.e. adjacent to projection 5f. FIG. 4b shows a similar view, but taken at an angle (along the line IV-IV in FIG. 2) rather than substantially parallel to the channel 4 so as to take a section through the narrowest point of the channel between the outer radius of the large-radius part of one projection and the outer radius of the small-radius part of an adjacent projection (on the opposite side of the channel 3). It can be seen in FIG. 4b that the thermal element 2 is narrower than this narrowest part of the channel, i.e. the thermal element 2 is in contact with the large radius of the projection on the right, but there is a gap between the thermal element 2 and the small radius of the projection on the left.

[0076] FIGS. 5-7 are similar to FIGS. 1-3, except that for clarity the thermal element 2 is not shown in these figures. FIG. 7 is a side view looking down the length of channels 3. It will be appreciated that from this viewpoint two rows of pairs of projections can be seen, one behind the other. The wider dimension of a pair of projections in the rear row can be seen extending out beyond the narrower dimension of a pair of projections in the front row. This is highlighted on the right hand side of FIG. 7 where reference numeral 6′ shows the vertical side wall of the projection in the front row, while reference number 7′ shows the recess in the side wall of the projection in the rear row. It can clearly be seen that the width of the projection 5 between side walls 6′ in front is less than the distance between the recesses 7′ of the pair of projections behind. FIGS. 5-7 also show perforations 11 that are formed through the support structure 1 so as to provide a liquid transfer path from one side to the other of the support structure 1. These perforations 11 allow any adhesive that is applied above the support structure 1 to dry out by losing moisture through the perforations 11. As in existing installations, any evaporation path that allows moisture to escape upwards, e.g. between tiles, is still viable.

[0077] However, the perforations 11 allow wet-type adhesives to be used even when there is no (or there is insufficient) moisture escape route upwards from the support structure. Instead, moisture can escape by travelling across the membrane support structure 1 from a top side (tile side or floor side) to the bottom side (sub-floor side) and can escape through normal moisture escape paths e.g. through a wooden or concrete sub-floor structure.

[0078] The perforations 11 are formed in the structure 1 by punching or drilling through the finished structure. Thus the perforations 11 are formed through the support structure 1 itself as well as through any stress mitigation layer formed on the underside thereof (as best seen in FIG. 7). For example where a fabric layer such as a fleece layer 12 is formed on the back of the support structure 1, the perforations pass through the support structure 1 (typically plastic) and through the fabric layer 12. The diameter of the perforations 11 is kept sufficiently small that these through-holes do not allow adhesive to pass through from the top to the bottom and form a rigid connection across the support structure 1. Such a rigid connection would prevent the stress-mitigation layer from accommodating relative movement of the support structure 1 and the sub-floor, e.g. due to thermal expansion variations. The perforations are no more than 2 mm in diameter to ensure no such rigid connection.

[0079] As is shown in FIGS. 5-7, numerous perforations may be used to make up for their small size, regularly distributed across the surface of the support structure 1. In the embodiment of FIGS. 5-7 the perforations are formed along one set of channels 3 at a rate of three perforations per pair of projections 5 (i.e. two perforations between each perpendicular channel of the second set 4 and one on the intersection of perpendicular channels). However, it will be appreciated that this is purely an example and any other number and/or arrangement of perforations could equally well be used.

[0080] FIGS. 8-10 are similar to FIGS. 1-3, except that for clarity the thermal element 2 is not shown in these figures. Also, FIG. 10 is a cross-section through the support structure 1 rather than a side view as this better shows the construction. The different hatchings on the cross-section illustrate the different pairs of projections (the different orientations being represented by different hatching).

[0081] FIGS. 8-10 illustrate an alternative to FIGS. 5-7 (although the two techniques could be used together) which uses larger holes 13 for transferring moisture from one side of the support structure 1 to the other side. The larger holes 13 can have a larger area than the perforations 11 and can thus allow a faster rate of moisture transfer across the structure 1. However, a larger area hole means that there is a risk of adhesive bonding across the structure 1 which could prevent the stress-mitigation layer from operating correctly. Thus the larger holes 13 are formed only through the support structure 1 and not through the stress mitigation layer 12 (in this embodiment a fabric (fleece) layer bonded to the underside of the support structure 1). As the stress mitigation layer 12 remains unbroken, adhesive from the upper side of the structure 1 is prevented from bonding to the underlying sub-floor and thus the stress-mitigation layer remains in place to accommodate relative movement due to differing thermal expansion.

[0082] In order to allow the holes 13 to be formed without damage to the stress mitigation layer 12, the holes 13 are formed in projections 14 which project away from the stress mitigation layer 12. As a gap is present between the upper surface of the projection 14 and the stress mitigation layer 12, it is easy to cut, drill or otherwise rupture the top of the projection 14 without at the same time damaging the stress mitigation layer 12. In this embodiment the projection 14 is a separate projection formed in the central area 9 between each pair of projections 5, i.e. one such projection 14 can be formed for every two projections 5 on the mat 1.

[0083] In use, when adhesive is applied to the upper surface of the support structure 1, the adhesive can flow through the holes 13 where it collects between the stress mitigation layer 12 and the underside of the projection 14. This has an additional benefit of providing a good bond between the adhesive layer and the support structure 1.

[0084] FIG. 11 shows a close up of a pair of projections 5 with perforations 11 formed in the support structure 1. FIG. 12 shows a close up of a pair of projections 5 with an additional projection 14 and hole 13 formed therein. FIG. 13 shows an alternative version of FIG. 12 where instead of a single hole 13, a plurality of smaller holes 13′ are formed.

[0085] FIG. 14 shows another alternative to FIGS. 12 and 13. Instead of forming the hole 13 (or holes 13′) in a dedicated projection, holes 13″ are formed in the tops of the main projections 5. These holes 13″ can be formed particularly quickly and easily for example by cutting across the mat 1 after forming. However, the end result, while perfectly practical, is less aesthetically pleasing and for this reason may be less preferred.

[0086] FIG. 15 shows a variation in which a single large projection 15 is used in place of a pair of projections 5. All features of this single large projection 15 may be the same as for the combination of the pair of projections 5 except that there are no paths 10 to conduct heat into the central region of the projection 15. The single large projection 15 has the advantage of allowing a very large hole 16 to be formed in the top thereof for very efficient transfer of moisture across the structure 1.

[0087] FIG. 16 shows a textured version of the support structure 21 which is identical to the support structure 1 discussed above except with the addition of a textured upper surface (the surface that contacts the thermal element in use). The texture may be provided by adhering particles such as fibres to the surface of the mat. Fleece fibres are particularly suitable for this texturing and provide a keyed surface for good bonding of adhesive to the mat 21.

[0088] It will be appreciated that other variations and modifications may be made to the examples described above while still falling within the scope of the appended claims.