Note: Descriptions are shown in the official language in which they were submitted.
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SUPPORT STRUCTURE FOR ELECTRIC CABLES OF A SURFACE HEATER
PRIORITY CLAIM
Priority is claimed of and to German utility model application number 20
2014 104 792.1, filed October 7, 2014.
FIELD OF THE INVENTION
The present invention relates to support structures for facilitating the
arrangement of electric heating cables.
BACKGROUND OF THE INVENTION
Support structures for facilitating the arranging of electric heating cables
are already known in the prior art. Their purpose is to facilitate the
arranging of
electric heating cables of a surface heater. In contrast to conventional
surface
heaters that use water as a heating fluid, electric surface heaters have the
advantage that they are of significantly smaller height, which is why they are
particularly suitable for retrofitted installation, for example during
renovations, to
name only one example. Another advantage of electric surface heaters is that
they have much shorter heat-up times compared to conventional surface heating
means, such that they can produce a detectable effect in a very short time
after
they are turned on. With this in mind, it is not uncommon for an electric
surface
heater to be installed in addition to a conventional surface heater in order
to react
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quickly to variable temperatures, particularly in the spring and fall, without
having
to turn on the primary heater.
SUMMARY OF THE INVENTION
The present invention provides improvements to existing electric surface
heating systems, in particular with regard to even shorter heat-up times.
Toward this end, the present invention provides a support structure of the
type mentioned above, the structure characterized in that a thermal barrier
layer
is attached to the bottom of the support layer. The advantage of the thermal
barrier layer according to the invention is that the great majority of the
thermal
energy given off by an electric heating cable held in the heating cable
receiving
channels during the heat-up period of an electric surface heater is dissipated
toward the top of the support structure. This allows the heat-up time of an
electric
surface heater to be greatly reduced thanks to the thermal barrier layer.
Investigations in this regard have shown that the heat-up phase can be
shortened by up to 40%. On the other hand, the thermal barrier layer according
to the invention has almost no affect on the long-term operation of an
electric
surface heater. As soon as the heat given off by the heating cables has
penetrated the thermal barrier layer, equilibrium sets in such that heat is
dissipated evenly in both directions; that is to say toward the room and
toward
the lower base. The thermal barrier layer can be glued to the bottom of the
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support layer using a suitable adhesive. Alternatively, it can also be
laminated or
otherwise attached.
According to one embodiment of the present invention, the thermal barrier
layer has a height in the range of Ito 3 mm, in particular in the range of 1.5
to
2.5 mm. Investigations have shown that thermal barrier layers with a height of
less than 1 mm do not achieve any significant shortening of the heat-up time.
Heights of more than 3 mm only result in minor improvement of the heat-up
times. Moreover, 3 mm should not be exceeded since otherwise the height of the
support structure will be too much overall, which is not desirable,
particularly
when used in renovation work.
In one embodiment, the thermal barrier layer is made of a foam material or
a fleece material.
It is advantageous that an adhesion promoting layer is provided at the
bottom side of the support structure. An adhesive or mortar used to fasten the
support structure to a lower base clings to such an adhesion promoting layer.
This ensures a secure attachment of the support structure during installation.
The
adhesion promoting layer can be fastened to the thermal barrier layer as a
separate layer. For example, it can be glued to the thermal barrier layer.
Alternatively, the thermal barrier layer and the adhesion promoting layer can
be
designed as a single piece. For example, the bottom of a thermal barrier layer
made of fleece material can also simultaneously be used as an adhesion
promoting layer.
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It is advantageous to design the thermal barrier layer as being stable
against pressure. As such, outside loads can be easily transferred to the
lower
base.
The edge areas of the protrusions can have indentations as viewed from
above, the indentations defining part of the heating cable receiving channels.
Such indentations facilitate the attachment of the electric heating cables to
the
support structure.
It is advantageous that the distances between the protrusions are narrow
relative to the outer diameter of the heating cables to be held in place such
that
the heating cables can be pressed into the heating cable receiving channels in
between two adjacent protrusions from above in the manner of a snap-on
connection, which widens said distance. In other words, the heating cables in
such an embodiment of the support layer can be simply clipped into the heating
cable receiving channels, providing an automatic means of attachment.
It is advantageous that depressions are formed inside the protrusions, the
base of said depressions being disposed at the height of the bottom side of
the
support layer. Such depressions inside the protrusions can improve the load
transfer to the bottom of the support structure.
The support structure can be a rollable mat. Rollable mats have the
advantage over conventional plates in that they can be transported more easily
and laid out more quickly.
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4a
Some embodiments disclosed herein provide a support structure for electric
heating cables of a surface heater, comprising: a film-like support layer; a
plurality of
protrusions extending upwardly from the support layer, each of the protrusions
having
an outer edge with open spaces defined between outer edges of adjacent
protrusions; the open spaces between outer edges of adjacent protrusions
defining a
plurality of heating cable receiving channels formed between adjacent outer
edges of
the plurality of protrusions for receiving the electric heating cables; and a
thermal
barrier layer, distinct from the film-like support layer and fastened to a
bottom side of
the film-like support layer, the thermal barrier layer having a height in the
range of 1
to 3 mm.
Some embodiments disclosed herein provide a support structure for electric
heating cables of a surface heater, comprising: a film-like support layer; a
plurality of
protrusions extending upwardly from the support layer, each of the protrusions
having
an inner depression formed therein and an outer edge circumventing said inner
depression; one or more open spaces defined between outer edges of adjacent
protrusions; the one or more open spaces defining a plurality of heating cable
receiving channels formed between adjacent outer edges of the plurality of
protrusions for receiving the electric heating cables; and a thermal barrier
layer
fastened to a bottom side of the film-like support layer, the thermal barrier
layer
having a height in the range of 1 to 3 mm.
Some embodiments disclosed herein provide a support structure for electric
heating cables of a surface heater, comprising: a film-like support layer; a
plurality of
protrusions extending upwardly from the support layer, each of the protrusions
having
an outer edge with open spaces defined between outer edges of adjacent
protrusions; the open spaces between outer edges of adjacent protrusions
defining a
plurality of heating cable receiving channels formed between adjacent outer
edges of
the plurality of protrusions for receiving the electric heating cables; and a
thermal
barrier layer, distinct from the film-like support layer and fastened to a
bottom side of
the film-like support layer, the thermal barrier layer having a height in the
range of 1
to 3 mm; the outer edge of each protrusion substantially circumscribing the
protrusion
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4b
and presenting an octagonal shape when viewed from above.
There has thus been outlined, rather broadly, relatively important features of
the invention so that the detailed description thereof that follows may be
better
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understood, and so that the present contribution to the art may be better
appreciated. Other features of the present invention will become clearer from
the
following detailed description of the invention, taken with the accompanying
drawings and claims, or may be learned by the practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially sectioned perspective view of a support structure
according to one embodiment of the present invention; and
FIG. 2 is a sectional view of the support structure of FIG. 1, as shown in
the installed state.
DETAILED DESCRIPTION
Before the present invention is disclosed and described, it is to be
understood that this invention is not limited to the particular structures,
process
steps, or materials disclosed herein, but is extended to equivalents thereof
as
would be recognized by those of ordinarily skilled in the relevant arts. It
should
also be understood that terminology employed herein is used for the purpose of
describing particular embodiments only and is not intended to be limiting.
It must be noted that, as used in this specification and the appended
claims, the singular forms "a" and "the" include plural referents, unless the
context clearly dictates otherwise. Thus, for example, reference to a "cable"
can
include one or more of such "cables."
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Definitions
In describing and claiming the present invention, the following terminology
will be used in accordance with the definitions set forth below.
As used herein, the terms "upper," "lower," "elevation," "height," and the
like, are to be understood to refer to relative locations and/or displacements
of
various elements or components relative to a condition in which a veneer
system
is oriented in its usable orientation. These terms are used to more clearly
claim
and describe the various elements or components of the invention and, unless
the context clearly indicates otherwise, are not to be construed as limiting
the
invention to any particular embodiment.
= As used herein, the term "substantially" refers to the complete or nearly
complete extent or degree of an action, characteristic, property, state,
structure,
item, or result. As an arbitrary example, an object that is "substantially"
enclosed
is an object that is either completely enclosed or nearly completely enclosed.
The exact allowable degree of deviation from absolute completeness may in
some cases depend on the specific context. However, generally speaking the
nearness of completion will be so as to have the same overall result as if
absolute and total completion were obtained.
The use of "substantially" is equally applicable when used in a negative
connotation to refer to the complete or near complete lack of an action,
characteristic, property, state, structure, item, or result. As an arbitrary
example,
a composition that is "substantially free or particles would either completely
lack
particles, or so nearly completely lack particles that the effect would be the
same
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as if it completely lacked particles. In other words, a composition that is
"substantially free of" an ingredient or element may still actually contain
such item
as long as there is no measurable effect thereof.
As used herein, the term "about" is used to provide flexibility to a
.. numerical range endpoint by providing that a given value may be "a little
above"
or "a little below" the endpoint.
As used herein, a plurality of items, structural elements, compositional
elements, and/or materials may be presented in a common list for convenience.
However, these lists should be construed as though each member of the list is
individually identified as a separate and unique member. Thus, no individual
member of such list should be construed as a de facto equivalent of any other
member of the same list solely based on their presentation in a common group
without indications to the contrary.
Concentrations, amounts, and other numerical data may be expressed or
presented herein in a range format. It is to be understood that such a range
format is used merely for convenience and brevity and thus should be
interpreted
flexibly to include not only the numerical values explicitly recited as the
limits of
the range, but also to include all the individual numerical values or sub-
ranges
encompassed within that range as if each numerical value and sub-range is
explicitly recited. As an illustration, a numerical range of "about 1 to about
5"
should be interpreted to include not only the explicitly recited values of
about 1 to
about 5., but also include individual values and sub-ranges within the
indicated
range. Thus, included in this numerical range are individual values such as 2,
3,
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and 4 and sub-ranges such as from 1-3, from 2-4, and from 3-5, etc., as well
as
1, 2, 3, 4, and 5, individually. This same principle applies to ranges
reciting only
one numerical value as a minimum or a maximum. Furthermore, such an
interpretation should apply regardless of the breadth of the range or the
characteristics being described.
Invention
The figures show a support structure 1 according to an embodiment of the
present invention for electric heating cables 2 of a surface heater, such as a
floor
or wall heater. The support structure 1 is in the form of a rollable mat and
comprises a film-like support layer 3 on the top side, the layer being made of
polypropylene in this case, wherein other plastics can be used as well. The
support layer 3 comprises a plurality of upward-pointing protrusions 4
distributed
over the surface thereof, the protrusions forming heating cable receiving
channels 5 therebetween for holding the electric heating cables 2. The edge
areas of the protrusions 4 comprise indentations as observed from above, the
indentations defining part of the heating cable receiving channels 5. The
distances between the protrusions 4 are selected to be narrow relative to the
outer diameter of the heating cables 2 being held in place in such a way that
heating cables 2 located between two adjacent protrusions 4 can be pushed from
above into the heating cable receiving channels 5 in the manner of a snap-on
connection, causing the distances to expand so that the heating cables 2 can
be
held securely in the corresponding heating cable receiving channels 5.
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Depressions 6 are made inside the protrusions 4, the base 7 of the depressions
being disposed at the height of the bottom of the support layer 3. A pressure-
stable thermal barrier layer 8 is fastened to the bottom of the support layer
3, the
layer being made of a fleece material in this case, with a height in the range
of
1.5 to 2.5 mm. Alternatively, the height can also be selected within a range
of 1
to 3 mm. According to another embodiment of the support structure 1 according
to the invention, the thermal barrier layer 8 can also be made of a foamed
material and provided with a fleece or fabric at the bottom thereof, although
this
in not shown in the present case.
FIG. 2 shows a possible design using the support structure 1 shown in
Figure 1. The design comprises a supporting lower base 9 as a lowermost layer,
the layer possibly being a concrete floor, for example. Positioned on the
lower
base 9 is a conventional insulating layer 10, consisting of individual
insulating
plates. The insulating plates can be placed loosely onto the lower base 9 as
is
presently the case. However, they can also be fixed to the lower base 9 using
a
mortar or adhesive. Instead of insulating plates, poured insulation can also
be
used to form the insulating layer 10. Above the insulating layer 10 is a
screed
layer 11 for gluing the bottom of the support structure 1. The adhesive 12
used
here can be a tile cement or the like, for example. Due to the fact that the
thermal
barrier layer 8 is made of a fleece material, the adhesive clings well to the
thermal barrier layer 8 as the support structure 1 is being glued into place,
resulting in a secure hold. The same applies when the bottom of the support
structure 1 is made up of the fleece adhesion promoting layer mentioned above
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or of a fabric. One or more heating cables 2 are held at the top of the
support
structure 1 in some of the heating cable receiving channels 5 provided for the
same. Above the support structure 1 is a floor covering 13 that is glued to
the top
of the support structure 1 using a suitable adhesive 14 which reaches into the
indentations provided at the protrusions 4. The adhesive 14 can be a tile
cement,
to name just one example. In this case, the floor covering is formed by panel
elements 15, which can be tiles, stone plates or the like, wherein the joints
16
present between the panel elements 15 are filled with a suitable joint
material.
Alternatively, however, a wood floor can also be installed as a floor
covering.
A significant advantage associated with the use of the support structure 1
according to the invention is that thanks to the thermal barrier layer 8, the
great
majority of the thermal energy given off from the electric heating cables as
the
surface heater is starting up is dissipated toward the top of the support
structure
1 and thereby in the direction of the room. This allows the heat-up time of an
electric surface heater to be greatly reduced thanks to the thermal barrier
layer 8.
Investigations have shown that in this way, improvements of up to 40% can be
achieved. Because of the small thickness of the thermal barrier layer 8, a
relatively low total design height of the support structure 1 is maintained
despite
this fact, such that the structure can also be installed onto previously
existing
screeds as part of renovation or restoration work. The film material of the
support
layer 3 and the material selected for the thermal barrier layer 8 provide the
support structure 1 overall with an elasticity that acts to decouple the
screed
layer 11 and the floor covering 13 and prevents the transfer of stresses
caused
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by different expansions of the screed layer 11 and the floor covering 13
because
of different coefficients of thermal expansion, for example. The large surface
area
taken up by the cable receiving channels 5 and the respective base 7 of the
depressions 6 relative to the overall surface area of the support structure
provides good load transfer for the screed layer 11, which results in a very
durable arrangement.
It is to be understood that the above-described arrangements are only
illustrative of the application of the principles of the present invention.
Numerous
modifications and alternative arrangements may be devised by those skilled in
the art without departing from the spirit and scope of the present invention
and
the appended claims are intended to cover such modifications and
arrangements. Thus, while the present invention has been described above with
particularity and detail in connection with what is presently deemed to be the
most practical and preferred embodiments of the invention, it will be apparent
to
those of ordinary skill in the art that numerous modifications, including, but
not
limited to, variations in size, materials, shape, form, function and manner of
operation, assembly and use may be made without departing from the principles
and concepts set forth herein.
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LIST OF PARTS
1 Support structure
2 Heating cable
3 Support layer
4 Protrusion
5 Heating cable receiving channel
6 Depression
7 Base
8 Thermal barrier layer
9 Lower base
10 Insulating layer
11 Screed layer
12 Adhesive
13 Floor covering
14 Adhesive
15 Panel element
16 Joint
