Method and apparatus for positioning heating elements
An underlayment system is provided that includes a plurality of protrusions that extend from a common base member. The protrusions and base member can include an opening therethrough that allows for subsequent layers of material, such as adhesive, to interact and bond to each other. The protrusions are arranged in such a way to contain a wire, string, or heating element, within a receiving area. The arrangement of the protrusions allow for routing of the wire, string, or heating element in a variety of angles, bends, and other routing layouts.
1. A support structure for electric heating cables, comprising:
a base having a first side and a second side opposite the first side;
a matrix of routing hubs extending from the first side of the base, each routing hub comprising a plurality of protrusion arranged in an equally-spaced circular array about array axis, each of the plurality of protrusions comprising an outer wall, an upper surface, and an inner wall sloping continuously away from the outer wall and toward the base, the outer walls of the protrusions defining a plurality of receiving cavities configured to receive a heating element; and
a pad layer attached to the second side of the base.
2. The support structure of claim 1 , wherein the pad layer comprises a heat reflective material, an energy reflective material, or a combination thereof.
3. The support structure of claim 1 , wherein the pad layer comprises a sound dampening material, an insulative material, or a combination thereof.
4. The support structure of claim 1 , wherein the pad layer comprises a porous substrate, a vapor barrier, a waterproof material, or a combination thereof.
5. The support structure of claim 1 , wherein the pad layer comprises foil, cork, rubber, plastic, concrete, wood, organic material, inorganic material, composite material, a compound, or a combination thereof.
6. The support structure of claim 1 , wherein the pad layer is attached to the second side of the base via adhesive, thermal bonding, welding, mechanical attachment, or a combination thereof.
7. The support structure of claim 1 , wherein the pad layer comprises adhesive on a side thereof opposite the second side of the base material, the adhesive capable of affixing the support structure to a surface.
8. The support structure of claim 1 , wherein the pad layer is configured to receive adhesive for affixing the support structure to a surface.
9. The support structure of claim 1 , wherein the support structure comprises a plurality of pad layers in a stacked configuration.
10. A floor underlayment comprising:
a base having a first side and a second side;
a plurality of routing hubs arranged in rows and columns on the base, each routing hub comprising a plurality of protrusions extending from the first side of the base, each one of the plurality of protrusions comprising a curved outer wall, a curved inner wall, and a top surface substantially parallel to the base, the curved outer walls of the plurality of protrusions of each routing hub forming a non-continuous circle, and the curved inner walls of the plurality of protrusions of each routing hub forming a non-continuous circle; and
a plurality of holes in the base,
wherein the plurality of routing hubs define a plurality of receiving cavities adapted to receive a heating element therein.
11. The floor underlayment of claim 10 , wherein at least one of the plurality of holes is located outside of the outer walls of the plurality of protrusions of any one of the plurality of routing hubs.
12. The floor underlayment of claim 10 , further comprising a heating element positioned in at least one of the receiving cavities.
13. The floor underlayment of claim 10 , further comprising a pad layer attached to the second side of the base.
14. The floor underlayment of claim 13 , wherein the pad layer comprises a heat reflective material, an energy reflective material, or a combination thereof.
15. The floor underlayment of claim 13 , wherein the pad layer comprises an insulative material, a porous substrate, or a combination thereof.
16. The floor underlayment of claim 13 , wherein the pad layer comprises foil, cork, rubber, plastic, concrete, wood, organic material, inorganic material, composite material, a compound, or a combination thereof.
17. The floor underlayment of claim 13 , wherein the pad layer is attached to the second side of the base via adhesive, thermal bonding, welding, mechanical attachment, or a combination thereof.
18. The floor underlayment of claim 13 , wherein the pad layer comprises adhesive on a side thereof opposite the second side of the base material, the adhesive useful for affixing the support structure to a surface.
19. A floor heating system, comprising:
a base member comprising a plurality of holes; and
a plurality of routing hubs extending from a first side of the base member, each one of the plurality of routing hubs comprising a plurality of protrusions arranged in an equally-spaced circular array about an array axis, each of the plurality of protrusions comprising a curved outer wall, a curved inner wall, and a top surface parallel to the base member,
wherein the curved inner wall slopes continuously away from the curved outer wall and toward the base member, and
wherein the plurality of routing hubs are arranged into rows and columns, and adjacent ones of the plurality of routing hubs define channels for securing a heating element.
20. The floor heating system of claim 19 , wherein at least one of the plurality of holes is located outside of any one of the plurality of routing hubs.