CONCAVE-CONVEX METAL PLATE AND FLOOR HEATING USING THE SAME

Abstract

A concave-convex metal plate of a floor heating system according to the present disclosure includes repeatedly bent concave and convex portions to transmit a load from an upper portion of a finishing material to a floor slab. Because the concave-convex metal plate includes the repeatedly bent concave and convex portions, resistance to the load from the upper portion is significantly improved, thus functioning as a floor structural material that may sufficiently withstand the load, while transferring the load from the upper portion of the finishing material to the floor slab.

Claims

1. A concave-convex metal plate in which concave and convex portions are repeatedly bent to transfer a load from an upper portion of a finishing material to a floor slab, wherein the concave portion is formed to have a size for accommodating a linear heating element, while contacting the linear heating element on a lower surface and left and right sides.

2. The concave-convex metal plate of claim 1, wherein any one of a lower portion of the concave portion or an upper portion of the convex portion is formed to have a flat surface.

3. The concave-convex metal plate of claim 1, wherein the concave portion is rounded so as to be in contact with lower portions of the left and right sides of the linear heating element.

4. The concave-convex metal plate of claim 1, wherein the concave and convex portions of the concave-convex metal plate are formed in both directions.

5. The concave-convex metal plate of claim 1, wherein the concave-convex metal plate is formed of a material selected from an iron plate, a color steel plate, a synthetic resin coated steel plate, a galvanized iron plate, a galvalume steel plate, a galvanized steel plate, a tin-plated iron plate, aluminum, duraluminium, an aluminum alloy plate, a copper plate, brass, and bronze.

6. The concave-convex metal plate of claim 1, wherein the concave-convex metal plate is formed by any one of gear forming, roller forming, and press forming.

7. A floor heating system comprising: an insulator preventing heat from a heating element from being transferred to a floor slab; a lower thermal diffusion plate positioned above the insulator and allowing heat conducted from the heating element to be transferred in a horizontal direction; the concave-convex metal plate of claim 1, positioned above the lower thermal diffusion plate and accommodating the heating element; a heating element accommodated in a concave portion of the concave-convex metal plate; and an upper thermal diffusion plate positioned above the concave-convex metal plate and transferring heat conducted from the heating element in a horizontal direction and to a finishing material.

8. The floor heating system of claim 7, wherein the lower thermal diffusion plate or the upper thermal diffusion plate is selected from a metal panel such as a galvalume steel sheet, a galvanized steel sheet, a color steel sheet, a tin-plated steel sheet, a galvanized steel sheet, an aluminum sheet, a stainless steel sheet, a copper sheet, or a synthetic resin panel, a wood panel, an inorganic panel.

9. A floor heating system comprising: an insulator preventing heat from a heating element from being transferred to a floor slab; a lower thermal diffusion plate positioned above the insulator and allowing heat conducted from the heating element to be transferred in a horizontal direction; the concave-convex metal plate of claim 2, positioned above the lower thermal diffusion plate and accommodating the heating element; a heating element accommodated in a concave portion of the concave-convex metal plate; and an upper thermal diffusion plate positioned above the concave-convex metal plate and transferring heat conducted from the heating element in a horizontal direction and to a finishing material.

10. A floor heating system comprising: an insulator preventing heat from a heating element from being transferred to a floor slab; a lower thermal diffusion plate positioned above the insulator and allowing heat conducted from the heating element to be transferred in a horizontal direction; the concave-convex metal plate of claim 3, positioned above the lower thermal diffusion plate and accommodating the heating element; a heating element accommodated in a concave portion of the concave-convex metal plate; and an upper thermal diffusion plate positioned above the concave-convex metal plate and transferring heat conducted from the heating element in a horizontal direction and to a finishing material.

11. A floor heating system comprising: an insulator preventing heat from a heating element from being transferred to a floor slab; a lower thermal diffusion plate positioned above the insulator and allowing heat conducted from the heating element to be transferred in a horizontal direction; the concave-convex metal plate of claim 4, positioned above the lower thermal diffusion plate and accommodating the heating element; a heating element accommodated in a concave portion of the concave-convex metal plate; and an upper thermal diffusion plate positioned above the concave-convex metal plate and transferring heat conducted from the heating element in a horizontal direction and to a finishing material.

12. A floor heating system comprising: an insulator preventing heat from a heating element from being transferred to a floor slab; a lower thermal diffusion plate positioned above the insulator and allowing heat conducted from the heating element to be transferred in a horizontal direction; the concave-convex metal plate of claim 5, positioned above the lower thermal diffusion plate and accommodating the heating element; a heating element accommodated in a concave portion of the concave-convex metal plate; and an upper thermal diffusion plate positioned above the concave-convex metal plate and transferring heat conducted from the heating element in a horizontal direction and to a finishing material.

13. A floor heating system comprising: an insulator preventing heat from a heating element from being transferred to a floor slab; a lower thermal diffusion plate positioned above the insulator and allowing heat conducted from the heating element to be transferred in a horizontal direction; the concave-convex metal plate of claim 6, positioned above the lower thermal diffusion plate and accommodating the heating element; a heating element accommodated in a concave portion of the concave-convex metal plate; and an upper thermal diffusion plate positioned above the concave-convex metal plate and transferring heat conducted from the heating element in a horizontal direction and to a finishing material.

Description

DESCRIPTION OF DRAWINGS

[0033] FIG. 1 illustrates an example of a dry construction method.

[0034] FIG. 2 illustrates an example of a wet construction method.

[0035] FIG. 3 is a cross-sectional view showing an example of a wet construction method.

[0036] FIG. 4 is a cross-sectional view showing an example of dry construction.

[0037] FIG. 5 is a cross-sectional view showing an example of dry construction.

[0038] FIG. 6 is a perspective view of a concave-convex metal according to the present disclosure.

[0039] FIG. 7 is a state diagram in which a heating element is accommodated in a concave-convex metal plate according to the present disclosure.

[0040] FIG. 8 is a perspective view of a concave-convex metal according to another embodiment of the present disclosure.

[0041] FIG. 9 is a cross-sectional view of a floor heating system according to the present disclosure.

[0042] FIG. 10 is a cross-sectional view of a floor heating system according to another embodiment of the present disclosure.

[0043] FIG. 11 is a perspective view of a floor heating system according to the present disclosure.

[0044] FIG. 12 is a conceptual diagram of gear forming in a method of manufacturing a concave-convex metal plate according to the present disclosure.

[0045] FIG. 13 is a conceptual diagram of roller forming in a method of manufacturing a concave-convex metal plate according to the present disclosure.

[0046] FIG. 14 is a conceptual diagram of press forming in a method of manufacturing a concave-convex metal according to the present disclosure.

MODE FOR DISCLOSURE

[0047] FIG. 6 shows a concave-convex metal 30 of a floor heating system according to the present disclosure. In the concave-convex metal plate 30 of the floor heating system according to the present disclosure, a concave portion 31 and a convex portion 31 are repeatedly formed to be bent to transfer a load from an upper portion of a finishing material to a floor slab. Because the concave-convex metal plate has the repeatedly bent concave and convex portions, resistance to the load from the upper portion is remarkably improved, and it functions as a floor structural material that may withstand sufficient load while transferring the load from the upper portion of the finishing material to the floor slab.

[0048] As shown in FIG. 7, a linear heating element 40 is accommodated in the concave portion 30 of the concave-convex metal plate 30, and heat is transferred from the linear heating element, while in contact with a lower surface and left and right sides with the linear heating element 40. In the present disclosure, the heating element 40 is a general name for a heating material that provides heat in a floor heating system while having a circular cross-section and a relatively long linear shape, and includes an XL pipe, a heating pipe, an electric heating cable, and the like. Since the concave portion of the concave-convex metal plate and the heating element are in contact on the lower surface and left and right sides, heat may be transmitted very effectively from the heating element.

[0049] The concave-convex metal plate 30 may be formed so that a lower portion of the concave portion or an upper portion of the convex portion has a flat surface. In the floor heating system according to the present disclosure, a thermal diffusion plate 20 is provided on the upper and lower portions of the concave-convex metal plate. When the lower portion of the concave portion or the upper portion of the convex portion is formed to have a flat surface, the concave-convex metal plate 30 and the thermal diffusion plate 20 may be in surface contact with each other to be combined more stably.

[0050] In addition, as shown in FIGS. 7 and 10, the concave portion of the concave-convex metal plate may be formed to be rounded 80 so as to be in contact with the lower portions of the left and right sides of the linear heating element. If the concave portion is formed to be rounded, a contact surface with the heating element is widened, so that heat may be transmitted more effectively from the heating element.

[0051] In addition to this, in the concave-convex metal plate according to the present disclosure, it is also possible to form only the concave portion in which the linear heating element is accommodated is rounded 80. That is, although depression and protrusions are repeatedly formed on the concave-convex metal plate, the heating element is not accommodated in all concave portions and, since a concave portion in which the heating element should be accommodated and a concave portion in which the heating element is not accommodated among the concave portions of the concave-convex metal plate may be planned in advance according to a total heating area, the type of heating element, and the degree of bending, only the concave portion in which the heating element is to be accommodated may be formed to be rounded 80.

[0052] Meanwhile, unlike the concave-convex metal plate described so far in which the concave and convex portions are formed in one direction, the concave and convex portions may be continuously formed in both directions. FIG. 8 shows a concave-convex metal plate in which concave portions and convex portions are continuously formed in both directions according to another embodiment of the present disclosure.

[0053] Since the heating element is accommodated along the concave portion, if the concave portion and the convex portion are formed in one direction, the direction for receiving the heating element is limited to one direction, but since the concave portion and the convex portion of the concave-convex metal plate are formed in both directions as shown in FIG. 8, the heating element may be received in both directions, and therefore, an installation direction of the heating element may be more easily adjusted.

[0054] The concave-convex metal plate according to the present disclosure may be formed of a material selected from iron plate, color steel plate, synthetic resin coated steel plate, galvanized iron plate, galvalume steel plate, galvanized steel plate, tin-plated iron plate, aluminum, duraluminium, aluminum alloy plate, copper plate, brass, and bronze.

[0055] The concave-convex metal plate may be formed by any one of gear forming, roller forming, and press forming.

[0056] Gear forming is a method of arranging two gears 90 as shown in FIG. 12 and allowing a metal plate to pass through between the gears 90. In this method, the machine manufacturing cost is low, the productivity is good, and a steel plate structure is formed by the shape of a gear structure.

[0057] In roller forming, a continuous long iron plate having an appropriate size is transported as shown in FIG. 13, gradually and continuously formed through pressure of several stages so as to be curved or bent in a desired shape using a plurality of rollers 91, and cut to have an appropriate size.

[0058] Press forming is to manufacture a mold 92 having a concave-convex shape of a concave-convex metal plate as shown in FIG. 14 and work through a press operation.

[0059] A method of constructing a floor heating system using a concave-convex metal according to the present disclosure will be described. As a material for floor construction according to the present disclosure, 1: heating element 40, 2: thermal diffusion plate 20 having a width of 600 mm and a length of 600 mm, 3: silicone for bonding, 4: bolts 50 for iron plate, 5: concave-convex metal plate 30 are required.

[0060] The construction process using this will be described. An insulator 10 is attached to a horizontally leveled floor slab by shooting silicone for bonding having a thickness of wooden chopsticks at intervals of about 200 mm. The insulator 10 prevents heat from a heating element from being transferred in the direction of the floor slab. The insulator 10 may be any type, but a hard compressed Styrofoam (isopink) type is preferable so as not to be compressed and contracted. Again, the silicone for bonding is shot on the insulator, and the lower thermal diffusion plate 20 is attached. After attaching the lower thermal diffusion plate 20 entirely to the floor, the concave-convex metal plate 30 is attached with an adhesive. The heating element 30 is installed on the concave-convex metal 20 according to an installation interval, and the heating element and the concave-convex metal are fixed to the bottom of the iron plate by using the iron plate bolts 50. For a space of a portion where the heating element is bent and rotated, the concave-convex metal plate is cut to fit the space and fixed in the space. After installing both the heating element and the concave-convex metal, a gap between the heating element and the concave-convex metal is filled with a curable mortar such as silicone, tile bond, or cement. When the gap filling process is finished, the adhesive silicone is shot at intervals of about 100 mm, and the upper thermal diffusion plate 20 of 600 mm in width and 600 mm in length is attached to the entire construction area with an interval of 1 to 2 mm. After attaching all of the upper heat diffusion plate, a finishing material is constructed on an upper portion of the upper heat diffusion plate, thereby completing the construction of the dry floor heating system according to the present disclosure.

[0061] The floor heating system of the present disclosure completed by such a construction method includes: an insulator 10 preventing heat from a heating element from being transferred to a floor slab; a lower thermal diffusion plate 20 positioned above the insulator and allowing heat conducted from the heating element to be transferred in a horizontal direction; a concave-convex metal plate 30 positioned above the lower thermal diffusion plate and accommodating the heating element; a heating element 40 accommodated in a concave portion of the concave-convex metal plate; and an upper thermal diffusion plate 20 positioned above the concave-convex metal plate and transferring heat conducted from the heating element in a horizontal direction and to a finishing material.

[0062] In the present disclosure, the upper thermal diffusion plate and the lower thermal diffusion plate may be selected from metal panels such as galvalume steel plate, galva steel plate, color steel plate, tin-plated steel plate, galvanized steel plate, aluminum plate, stainless steel plate, copper plate, or the like, or selected from a synthetic resin panel, wood panel, and inorganic panel. In addition, by selecting the material of the upper heat diffusion plate and the material of the lower heat diffusion plate differently, the upper heat diffusion plate may be selected from metal panels, and the lower heat diffusion plate may be selected from synthetic resin panels, wood panels, and inorganic panels.

[0063] Since the concave-convex metal plate has a three-dimensional structure with concave and convex portions to withstand pressure properly, it may sufficiently withstand a load of about 1 ton or more per 1 m.sup.2 of weight of a refrigerator, etc., when installed as an ondol floor.

[0064] In addition, when having the same mass, the cement mortar has a heat storage capacity of about one-third or less of that of the metal and a thermal conductivity of one-fifth or sixth or less of that of the metal. When a plate-shaped structure is made of the metal having characteristics superior to cement and used in a heating system, heat of the heating element 40 may be transferred in four directions and thermal conductivity is 5 times faster than that of cement mortar, and therefore, the heat from the heating element conducts faster than the cement mortar floor and enters the room, increasing the efficiency of heat energy inflow by at least 2 to 3 times.

[0065] In addition, if the lifespan of floor heating with cement is more than 30 years, zinc plating, one of the materials of the concave-convex metal, is plated with zinc, which has a faster ionization than the quality, on the iron plate to prevent oxygen corrosion, and thus, corrosive life is semi-permanent for more than 30 years and there is no difference from construction with cement mortar.

[0066] As a material for heat diffusion plate or concave-convex metal plate, galvanized iron plate is the most common type of iron plate we see around us, dismantling is simple and recycling is possible, so there is less concern about waste generation.

[0067] The floor heating system according to the present disclosure may construct final finishing materials such as plywood flooring in just one day after construction, shortening the construction period, making it thinner and lighter in weight compared to conventional cement wet construction. Since all construction is completed in one day and the metal plate may be recycled after dismantling, it may solve the problems of conventional wet cement construction, such as reducing waste occurrence.

INDUSTRIAL APPLICABILITY

[0068] The present disclosure is used in the field of floor heating industry, and by constructing a floor heating system using a concave-convex metal plate, the construction efficiency and heating efficiency may be increased, while being simple.