Patent Abstract:
The invention is directed to modular radiant heat panel system. In the preferred embodiment, the system comprises multiple radiant heat transfer panels ( 16 ), each of the panels having a thermal mass ( 18 ) and a conduit channel ( 20 ); a fluid conduit ( 21 ), the conduit communicating with an apparatus ( 23 ) for heating fluid ( 22 ) in the conduit; the multiple panels positioned adjacent each other such that the conduit extends through a series of the conduit channels; the panels, conduit and apparatus so configured and arranged to permit heat transfer from the fluid to the thermal mass of the panel, whereby heat radiates from the panel. The present invention also discloses a radiant heat transfer panel for engagement with a fluid conduit comprising: a formed tray ( 24 ); the tray defining a thermal volume ( 17 ) and a conduit channel; the volume containing a thermal mass; and the channel, volume and thermal mass configured and arranged to permit heat transfer between the conduit and the thermal mass. The invention also discloses a method for installing a modular radiant heat panel system comprising the steps of: providing an under-layer having a given area ( 44 ); providing multiple panels having a thermal mass and a conduit channel; providing conduit; position the conduit over or under the under-layer in a predetermined pattern; and positioning the panels on or under the under-layer such that the conduit extends through at least a portion of the conduit channel of the panels.

Full Description:
TECHNICAL FIELD 
   The present invention relates generally to the field of in-floor radiant heating systems and, more particularly, to a new modular radiant heat panel system. 
   BACKGROUND ART 
   Hydronic in-floor radiant heat systems are known in the prior art. Such radiant heating systems utilize tubing within a floor structure to carry and disburse heat through the floor without any visible radiators or heating grills. They generally do so by embedding tubing in a single continuous horizontal concrete slab poured below the finished flooring. Warm water is then circulated through the tubing and the heat in the circulated fluid flowing through the tubing is transferred to the concrete slab by conduction. The concrete stores and radiates the heat, thereby warming objects in the room, rather than the air in the room, which can be more cost effective and can reduce heat loss. 
   It is known that such systems can be formed by providing a subfloor, running tubing over the subfloor, and then pouring a single continuous concrete or gypsum slab, such as Maxxon Corporation&#39;s THERMA-FLOOR®, around and over the tubing. A synthetic material is generally used for the tubing, such as polyethylene or polybutylene, which has the advantage of not expanding and contracting with fluxuations in temperature. When the concrete or gypsum hardens, it acts as the thermal mass for the system. The concrete or gypsum underlayment or slab is poured in liquid form across the entire surface area and cures to encase the tubing. 
   However, such systems have a number of drawbacks. First, the equipment required to pour the concrete slab is extensive and the process for installing the slab involves pumping the concrete through an elaborate delivery system, often at great effort and expense. Second, delays in construction are necessary to allow the concrete slab to set-up or cure. Third, the choice of materials that may be used as the thermal slab are limited. Fourth, the conditions in which the concrete slab cures or is formed varies from job site to job site and is dependent in large part on weather conditions. This can result in variations in the strength and characteristics of the slab. Fifth, because the underlayment is a continuous planar slab, if there is leakage in the piping or problems with the subfloor, the entire slab must be removed and replaced. Sixth, it is often difficult to properly align and then maintain the alignment of the piping when the slab is being poured and is curing. 
   Hence, it would be useful to provide a radiant heat system which allows for quick and easy installation, uniform characteristics and strength in the underlayment, uniform fabrication, options in the characteristics of the underlayment, greater standardization, and easy repair. 
   DISCLOSURE OF THE INVENTION 
   With parenthetical reference to the corresponding parts, portions or surfaces of the disclosed embodiment, merely for the purposes of illustration and not by way of limitation, the present invention provides an improved radiant heat transfer system ( 15 ) comprising: multiple radiant heat transfer panels ( 16 ), each of the panels having a thermal mass ( 18 ) and a conduit channel ( 20 ); a fluid conduit ( 21 ), the conduit communicating with an apparatus ( 23 ) for heating fluid ( 22 ) in the conduit; the multiple panels positioned adjacent each other such that the conduit extends through a series of the conduit channels; the panels, conduit and apparatus so configured and arranged to permit heat transfer from the fluid to the thermal mass of the panel, whereby heat radiates from the panel. 
   The system may further comprise an attachment spacer ( 25 ) and an edge spacer ( 26 ) which may be made of wood or a composite material. The system may further comprise an over-layer ( 28 ) and/or an under-layer ( 29 ). The over-layer may have a finished surface and may be selected from a group consisting of wood, carpet, tile or laminate. The panel may be attached to the under-layer by a mechanical bond or by a mechanical fastener and the over-layer may be attached to the attachment spacer or the edge spacer by a mechanical fastener. The system may further comprise a wall, the multiple panels may define an outer perimeter ( 31 ), the wall ( 33 ) may define an inner perimeter ( 32 ), and the edge spacer may be positioned between the outer perimeter and the inner perimeter. The panel may have an outer surface which may define a floor, wall or ceiling. 
   The present invention also discloses a radiant heat transfer panel for engagement with a fluid conduit comprising: a formed tray ( 24 ); the tray defining a thermal volume ( 17 ) and a conduit channel; the volume containing a thermal mass; and the channel, volume and thermal mass configured and arranged to permit heat transfer between the conduit and the thermal mass. The conduit may be plastic tubing and the tray may comprise a composition selected from the group consisting of polyvinyl chloride, polyethylene, polybutylene or thermoplastic material. The tray may comprise a fixture tower ( 34 ) and a side gusset ( 35 ). The conduit channel may be a U-shaped trough, may be cylindrical, and may comprise a linear section ( 36 ) and/or an arcuate section ( 38 ). The thermal mass may comprise a composition selected from the group consisting of cement, mortar, ceramic, concrete or stone, and may have an outer surface that is textured or is a finished flooring surface. 
   The invention also discloses a radiant heat transfer panel ( 60 ) for engagement with a conduit comprising: a thermal mass; the thermal mass having an outer surface ( 64 ) and a conduit channel ( 63 ); the thermal mass and the conduit channel configured and arranged to permit heat transfer between the conduit and the thermal mass; whereby heat radiates from the panel. 
   The invention also discloses a method for installing a modular radiant heat panel system comprising the steps of: providing an under-layer having a given area ( 44 ); providing multiple prefabricated thermal panels having a thermal mass and a conduit channel; providing conduit; position the conduit over the under-layer in a predetermined pattern; and positioning the panels on the under-layer such that the conduit extends through at least a portion of the conduit channel of the panels. 
   The method may further comprise the steps of attaching the panel to the under-layer, attaching the conduit to an apparatus for heating fluid flowing through the conduit, using a filler substance to fill a fault or irregularity in the under-layer, positioning an over-layer over the panels, providing an attachment spacer and positioning the attachment spacer adjacent to at least one of the panels, attaching the attachment spacer to the under-layer, providing an over-layer, and/or attaching the over-layer to the attachment spacer. 
   Accordingly, the general object of the present invention is to provide an improved radiant heat system in which modular panels are used to create the thermal mass for the system. 
   Another object of the invention is to provide an improved radiant heating system in which the thermal mass is light-weight. 
   Another object of the invention is to provide an improved radiant heating system in which the thermal mass is composed of a fire resistant cementitious material. 
   Another object of the invention is to provide an improved radiant heating system in which the thermal mass is water resistant. 
   Another object of the invention is to provide an improved radiant heating system in which the thermal mass provides sound deadening characteristics. 
   Another object of the invention is to provide a radiant heating system which requires less equipment, labor and time to install. 
   Another object of the invention is to provide an improved radiant heating system in which the thermal mass provides a predetermined and uniform routing channel for the tubing. 
   Another object of the invention is to provide an improved radiant heating system in which the thermal mass is cured prior to installation and remotely from the installation site. 
   Another object of the invention is to provide an improved radiant heating system in which the thermal mass may be installed regardless of work site conditions such as temperature or humidity. 
   Another object of the invention is to provide an improved radiant heating system in which the strength characteristics of the thermal mass may be standardized by controlling the conditions under which the thermal mass is poured, formed and cured. 
   Another object of the invention is to provide an improved radiant heating system in which the thermal mass is formed under highly controlled curing and pouring conditions. 
   Another object of the invention is to provide an improved radiant heating system in which the thermal mass operates as a finished floor after installation. 
   Another object of the invention is to provide an improved radiant heating system in which the top surface of the thermal mass is of finished quality. 
   Another object of the invention is to provide an improved radiant heating system in which the top surface of the thermal mass may have different finishes, shades, textures, preparations, coatings, colors, treatments or ornamental features. 
   Another object of the invention is to provide an improved radiant heating system in which preformed modular panels of different shapes comprise the thermal mass. 
   Another object of the invention is to provide an improved radiant heating system in which the thermal mass is mixed, cured, tested and analyzed prior to installation and under controlled conditions. 
   Another object of the invention is to provide an improved radiant heating system which allows for simplified repair of discreet portions of the system. 
   Another object of the invention is to provide an improved radiant heating system which may be installed in existing structures without substantial structural modification. 
   Another object of the invention is to provide an improved radiant heating system in which finished flooring may be installed over the thermal mass. 
   Another object of the invention is to provide an improved radiant heating system in which finished flooring may be attached to the thermal mass by a mechanical or chemical bond. 
   Another object of the invention is to provide an improved radiant heating system in which the thermal mass is composed of a number of easily manipulated panels. 
   Another object of the invention is to provide an improved radiant heating system having a panel with numerous possible tube-routing combinations. 
   Another object of the invention is to provide an improved radiant heating system in which the thermal mass may vary widely in material composition. 
   Another object of the invention is to provide an improved radiant heating system which may be used indoors or outdoors. 
   Another object of the invention is to provide an improved radiant heating system which may be used in flooring, walls and ceilings. 
   Another object of the invention is to provide an improved radiant heating system having plastic encapsulation of plastic tubing. 
   Another object of the invention is to provide an improved radiant heating system which does not add moisture to the work site on installation. 
   Another object of the invention is to provide an improved radiant heating system which does not require construction delays to allow for curing of the thermal mass. 
   Another object of the invention is to provide an improved radiant heating system which allows for guaranteed batch analysis of the thermal mass. 
   Another object of the invention is to provide a modular panel with an internal form for shaping the thermal mass. 
   Another object of the invention is to provide a panel having an internal form with features that allow for connection to an under-layer. 
   Another object of the invention is to provide a radiant heat transfer panel having an internal form with features that allow for bonding with thermal mass material. 
   Another object of the invention is to provide a method for installing a radiant heat system. 
   These and other objects and advantages will become apparent from the foregoing and ongoing written specification, the drawings, and the appended claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a fragmentary sectional perspective view of a radiant heat system known in the prior art. 
       FIG. 2  is a fragmentary sectional perspective view of Applicant&#39;s improved modular radiant heat panel system. 
       FIG. 3  is a perspective view of the tray shown in  FIG. 2 . 
       FIG. 4  is a fragmentary sectional perspective view of the thermal panel shown in  FIG. 2 . 
       FIG. 5  is a top plan view of the tray shown in  FIG. 3 . 
       FIG. 6  is a front side elevation of the tray shown in  FIG. 5 . 
       FIG. 7  is a right side elevation of the tray shown in  FIG. 5 . 
       FIG. 8  is a bottom plan view of the thermal panel shown in  FIG. 2 . 
       FIG. 9  is a top plan view of the thermal panel shown in  FIG. 2 . 
       FIG. 10  is a vertical cross-sectional view of the thermal panel shown in  FIG. 9 , taken generally on line  10 — 10  of  FIG. 9 . 
       FIG. 11  is a top plan view of an alternate embodiment of the tray shown in  FIG. 5 . 
       FIG. 12  is a top plan view of a second alternate embodiment of the tray shown in  FIG. 5 . 
       FIG. 13  is a top plan view of a third alternate embodiment of the tray shown in  FIG. 5 . 
       FIG. 14  is a perspective view of a tray and spacer combination. 
       FIG. 15  is a perspective view of an alternate tray and spacer combination. 
       FIG. 16  is a vertical cross-sectional view of the tray and spacer combination shown in  FIG. 14 , taken generally on line  16 — 16  of  FIG. 14 . 
       FIG. 17  is a right side elevation of the combination shown in  FIG. 15 . 
       FIG. 18  is a schematic of conduit routing for a given area. 
       FIG. 19  is a schematic of the conduit routing shown in  FIG. 18  in combination with a modular radiant heat panel arrangement. 
       FIG. 20  is a schematic of the conduit routing shown in  FIG. 17  in combination with an alternate modular radiant heat panel arrangement, which includes attachment and edge spacers. 
       FIG. 21  is a fragmentary sectional perspective view of an alternate embodiment of the modular radiant heat panel system shown in  FIG. 2 . 
       FIG. 22  is a bottom perspective view of the thermal panel shown in  FIG. 21 . 
       FIG. 23  is a schematic of the positioning of conduit and panels. 
       FIG. 24  is a top plan view of the schematic shown in  FIG. 23 . 
       FIG. 25  is a fragmentary sectional perspective view of an alternate embodiment of the modular radiant heat panel system shown in  FIG. 2 . 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, portions or surfaces, consistently throughout the several drawing figures, as such elements, portions or surfaces may be further described or explained by the entire written specification, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read (e.g., cross-hatching, arrangement of parts, proportion, degree, etc.) together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up” and “down”, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “rightwardly”, “upwardly”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly” and “outwardly” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate. 
   Referring now to the drawings and, more particularly, to  FIG. 2  thereof, this invention provides an improved modular radiant heat panel system, of which the presently preferred embodiment is generally indicated at  15 . The system is shown as broadly including an under-layer  29 , multiple radiant heat transfer panels  16 , conduit  21  winding through certain of conduit channels  20  in panels  16 , and an over-layer  28 . In the embodiment shown in  FIG. 2 , over-layer  28  is tongue and groove wood flooring positioned over panels  16 . However, it is contemplated that numerous other types of flooring may be employed as over-layer  28 . Examples of such types of flooring include conventional carpeting, tiling, or wood laminate such as Pergo®. 
   As shown in  FIG. 4 , panel  16  broadly includes tray  24 , conduit channels  20  and thermal mass  18 . As shown in  FIG. 3 , tray  24  is a rectangular tray-like member generally having four vertical side-walls  45 ,  46 ,  48  and  50  and a bottom member  52 . The side-walls are rear side-wall  45 , front side-wall  46 , right side-wall  48  and left side-wall  49 . The left vertical edge of side-wall  45  is joined to the rear vertical edge of side-wall  49 , the front vertical edge of side-wall  49  is joined to the left vertical edge of side-wall  46 , the right vertical edge of side-wall  46  is joined to the front vertical edge of side-wall  48 , and the rear vertical edge of side-wall  48  is joined to the right vertical edge of side-wall  45 . 
   As shown in  FIGS. 3 and 8 , conduit channel  20  is defined by a number of interconnected upside-down U-shaped troughs  36  and  38 – 43 . The ∩-shaped troughs are exit right trough  38 , exit left trough  39 , exit straight trough  40 , straight trough  36 , entrance right trough  41 , entrance left trough  42 , and entrance straight trough  43 . These troughs are in open communication with each other at junctions  50  and  51 , respectively, and define conduit channel  20 . As shown in  FIGS. 8 and 10 , troughs  36  and  38 – 43  have a depth  61  (distance up from bottom member  52 ) at least as great as the diameter of conduit  21  and have a width  62  at least as great as the diameter of conduit  21 . Bottom member  52  is joined to the horizontally extending edges of troughs  36 ,  38 – 43  and the bottom horizontally extending edges, respectively, of side-walls  45 ,  46 ,  48 ,  49 . The inner surfaces of side-walls  45 ,  46 ,  48 ,  49 , the upper surface of bottom member  52 , and the upper ∩-shaped surfaces of troughs  36  and  38 – 43  define a thermal volume  17 . 
   As shown in  FIG. 3 , tray  24  is fabricated to provide nine possible conduit channel configurations. Relative to axis x—x, these conduit combinations are flow-directed entering straight and exiting straight, flow-directed entering straight and exiting left, flow-directed entering straight and exiting right, flow-directed entering left and exiting left, flow-directed entering left and exiting straight, flow-directed entering left and exiting right, flow-directed entering right and exiting left, flow-directed entering right and exiting straight, or flow-directed entering right and exiting right. 
   In the preferred embodiment, tray  24  is two feet in length and six inches in width. However, as can be appreciated, the dimensions of the panels may be readily varied as required to fit a given area. The shape of the tray may also be readily varied to fit desired non-rectangular areas or to provide a non-rectangular floor pattern. Also, the thickness of the tray, and therefore the thickness of thermal mass  18 , may vary depending on desired parameters. 
   As shown in  FIGS. 3–5  and  10 , tray  24  includes fixture towers  34   a – 34   d  and side gussets  35   a – 35   d . Fixture towers  34   a – 34   d  are conventional screw towers that have a central throughbore allowing for the panel to be attached to under-layer  29  by a mechanical screw without damaging thermal mass  18 . Side gussets  35   a – 35   d  extend perpendicularly from side-walls  45  and  46  to fixture towers  34   a – 34   d , respectively. Side gussets  35   a – 35   d  support towers  34   a – 34   d , reinforce and stiffen side-walls  45  and  46 , and assist in bonding thermal mass  18  to tray  24 . 
     FIGS. 11–13  show panels having alternate conduit channel configurations.  FIG. 11  shows a panel  56  having a conduit channel configuration which allows: in a first orientation, for flow-directed entering straight and exiting straight, flow-directed entering straight and exiting right, or flow-directed entering straight and exiting left; and in the opposite orientation, for flow directed entering straight and exiting straight, flow-directed entering left and exiting straight, or flow directed entering right and exiting straight.  FIG. 12  shows a panel  58  having a single conduit channel configuration defined by a single straight trough  37 , which only allows for a straight pass.  FIG. 13  shows a panel  59  having a conduit channel configuration which allows: in a first orientation, for flow-directed entering straight and exiting straight, flow-directed entering left and exiting straight, or flow-directed entering right and exiting straight; in a second orientation, for flow-directed entering straight and exiting straight, flow-directed entering straight and exiting right, or flow-directed entering straight and exiting left; and in a third crossing orientation, for flow-directed entering left and exiting right or flow-directed entering right and exiting left. Trays  24 ,  56 ,  58  and  59  may be used interchangeably in system  15  depending on the desired routing for conduit  21 . Also, while a number of configurations for conduit channel  20  have been shown and described, persons skilled in this art will appreciate that various alternative and/or additional configurations may be employed. 
   In the preferred embodiment, tray  24  is composed of conventional thermoplastic material formed by plastic injection molding. However, alternative molding processes may be used. For example, tray  24  may be vacuum molded. It is contemplated that tray  24  may be formed of various types of materials. Examples include polyethylene, polyamide, polycarbonate, polyethylene terephthalate, acrylonitrile butadiene styrene, polyethylene high density copolymer, high impact polystyrene, polypropylene, polypropylene copolymer, polypropylene homopolymer, and polyvinyl chloride. In addition, recycled materials, such as recycled plastic, may be used. The type of material may be varied depending on the geographic region in which the material will be used as well as desired colors and textures. In addition, the tray may be formed such that it has a rough texture which allows for increased bonding between the tray and the thermal mass. 
   As shown in FIGS.  4  and  9 – 10 , thermal volume  17  of tray  24  is filled with thermal mass  18 . In the preferred embodiment, thermal mass  18  is conventional cementitious material. It is mixed to provide for a desired weight, thermal conductivity, strength, density, absorption, fire resistance, surface coloring, surface texture and/or surface finish. The concrete mix manufactured by Pine Hill Concrete Corp. of 2255 Bailey Ave., Buffalo N.Y. 14211 may be employed in the preferred embodiment. The composition of thermal mass  18  may be readily varied to provide different weight, conductivity, strength, or surface characteristics. While the preferred embodiments employs a conventional cementitious material, it is contemplated that other material may be used as a thermal mass such as ceramic, cement, synthetic cement, synthetic gypsum, bata hemi hydrate, polystyrene, gypsum, ash, ceramic, mortar, or carbon. For example, if the system is to be installed in an existing building that is not capable of supporting heavy floor loads, the composition of the thermal mass may be designed and fabricated to be of lighter weight, depending on the carrying capacity of the structure. 
   Tray  16  is filled with cementitious material in a controlled indoor environment under controlled curing conditions. Tray  16  acts as the form-work for thermal mass  18 . Because tray  24  is filled with cementitious material which is cured in a controlled indoor environment removed from the site at which the panels will be installed, a greater variety of choices in the composition of the thermal mass are available. Also, because the conditions under which the thermal mass is poured, formed and cures is highly controlled, the characteristics of thermal mass  18  may in turn be more easily controlled and more uniform, and the panel can be readily tested or analyzed using state of the art equipment and techniques to confirm strength, density or other design criteria prior to installation. Furthermore, panel  22  will not add moisture to the installation site. 
   Trays  16  are filled with thermal mass  18  by a fully automated process. Filled trays  24  are then moved to an automated palletizer, which stacks panels  16  on pallets  38  to  42  rows high. Panels  16  are allowed to cure on the pallet. A pallet can generally contain 620 square feet of panels and weigh between 1,870 and 1,932 pounds. The panels are then transported to the installation site on standard shipping pallets. The number of panels on a pallet and resulting weight of a pallet can be readily varied depending on transportation abilities. 
   The area in which the radiant heat system is being installed is provided with an under-layer  29 . As shown in  FIG. 25 , under-layer  29  may be a plywood subfloor. In other situations, as shown in  FIGS. 2 and 21 , it may be a concrete subfloor. Under-layer  29  is leveled, with any imperfections in the subfloor filled with an epoxy or other appropriate filler, and swept clean. 
   The length of conduit  21  needed for given area  44  is determined. Based on the area, dimensions, and anticipated conduit routing, the appropriate number and types of panels are transported to the installation site. The number of panels required is based on the square footage of the subject area and the dimensions of the panels to be used. The types of panels used will depend on the channel configurations which are most appropriate for the predetermined routing of conduit  21 . Also, the dimensions of channel  20  must be appropriate for the size and dimensions of conduit  21  being used. As shown in  FIG. 19 , different types of panels and channel configurations may be used depending on the desired routing of the conduit through the subject area. 
   Because of the small size and modular nature of the panels, they can be transported fairly easily and in manageable numbers, as circumstances such as the location of the installation site dictate. For example, if the system is being installed on the remote upper floors of a building, the panels can be carried to the site in smaller quantities, depending on the load capabilities of the transporter. This allows for the installation of the system in remote areas where it would otherwise be too cost prohibitive to install radiant heat. 
   The entrance  54  and exit  53  for the conduit tubing is determined and conduit  21  is passed through entrance  54 . Two alternatives are available with respect to placing the panels and conduit in place. One alternative is to unroll conduit  21  in stages and to place conduit  21  and panels  16  in place as conduit  21  is unrolled from a spool. A schematic of this type of approach is shown in  FIGS. 23 and 24 . In this approach, conduit  21  is held in place as it is unrolled by the positioning of panels  16  over conduit  21  and the subsequent attachment of panel  16  to under-layer  29  with conduit  21  in the appropriate channel  20  of panel  16 . Thus, panels  16  and conduit  21  are placed on under-layer  29  such that conduit  21  bends through conduit channel  20  in the routing configuration required for that portion of the subject area  44 . 
   Alternatively, the full length of conduit  21  may be unrolled in a serpentine pattern on under-layer  29 , extending from inlet  54  to outlet  53 , before panels  16  are positioned and conduit  21  and panels  16  aligned such that conduit  21  extends through appropriate conduit channels  20 . 
   Whether conduit  21  is unrolled in short lengths just ahead of the placement and alignment of panels  16  or is unrolled in its entirety over the subject area,  FIGS. 18–20  show conduit  21  in a final routing pattern for a subject area  44 . As shown, conduit  21  is configured in a series of straight parallel sections  100 ,  102 ,  104 ,  106 ,  108 ,  110 ,  112 , and  114 , which are separated by semi-circular sections  101 ,  103 ,  105 ,  107 ,  109 ,  111  and  113 . In  FIGS. 18–20 , the system is installed in a rectangular room having four walls  33   a – 33   d  and a perimeter  31  The walls define the subject heating area  44 . 
   In  FIG. 19  panels  16  are placed adjacent each other such that conduit channels  20  allow for the desired routing pattern of conduit  21 . Thus, as shown in  FIG. 19 , the right side-wall  48  of bottom right panel A is positioned against wall  33   b  such that conduit  21  extends from inlet  54  and is held in place by troughs  43 ,  36  and  40 . Next, the right side-wall  48  of bottom middle panel B is positioned against the left side-wall  49  of panel A and panel B and conduit  21  are aligned so that conduit  21  extends straight through trough  37  of panel B. The right side-wall  48  of bottom left panel C is positioned against the left side-wall  49  of panel B and panel B and conduit  21  are aligned so that conduit  21  extends straight through troughs  43  and  36  before bending right at junction  50  through trough  38  of panel C, thereby completing the first ninety degrees of semi-circular bend  101  . The left side-wall of  49  of panel C is positioned against wall  33   d  and the front side-walls  46  of panels A, B and C are positioned against wall  33   c . As can be seen, not all the troughs of channel  20  in panels A and C are used to hold conduit  21 . 
   The front side-wall  46  of second from the bottom left side panel D is then positioned against the rear side-wall  45  of panel C and the left side-wall  49  of panel D is positioned against wall  33   d  and panel D and conduit  21  are aligned so that conduit  21  enters and bends through trough  39  of panel D and extends straight through troughs  36  and  43  of panel D, thereby completing the second ninety degrees of semi-circular bend  101 . The left side-wall  49  of panel E is then positioned against the right side-wall  48  of panel D and the front side-wall  46  of panel E is positioned against the rear side-wall  45  of panel B and panel E and conduit  21  are aligned so that conduit  21  extends straight through trough  37  of panel E. The left side-wall  49  of panel F is positioned against the right side-wall  48  of panel E and the front side-wall  46  of panel F is positioned against the rear side-wall  45  of panel A and panel F and conduit  21  are aligned so that conduit  21  extends straight through troughs  40  and  36  before bending left at junction  51  through trough  41 , thereby completing the first ninety degrees of semi-circular bend  103 . The right side-wall  48  of panel F is positioned against wall  33   b.    
   This pattern is followed until area  44  is covered with panels  16 . In this manner, panels  16  hold conduit  21  in place as it extends from inlet  54  through sections  100 – 114  to outlet  53 . Thus, panels  16  are placed to enclose conduit  21  in the appropriate channel configurations of panels  16  given the conduit routing pattern desired. 
   As shown in  FIG. 19 , alternately configured panel  58  may be used in panel locations B, E, H, K, N, Q, T or W. Alternately configured panel  56  may be used in panel locations C, D, I, J, O, P, U or V. As the panels are positioned, they are attached by screws to under-layer  29 . The fasteners are screwed down through the guide-holes of fixture towers  34   a – 34   d  of each panel. 
     FIG. 20  depicts an alternate pattern for positioning the panels in area  44 . This embodiment uses a combination of panels together with attachment spacers  25  and edge spacers  26 . As shown in  FIG. 14 , an attachment spacer having properly aligned channels  55  may be positioned between two rows of panels  16 . 
   In  FIG. 20 , four edge spacers  26  are positioned between the inner perimeter  32  of walls  34   a – 34   d  and the outer perimeter  31  of panels  16  and attachment spacers  25 . In addition, five attachment spacers  25  are positioned between rows of panels  16 . Attachment spacers  25  have at least one channel  55  aligned to allow conduit  21  to pass through it where conduit  21  passes from one row of panels to the next. In this embodiment, edge spacers  26  and attachment spacers  25  are made of wood and are attached to under-layer  29  by mechanical fasteners such as screws. This allows for an over-layer  28  to be fastened at periodic intervals to attachment spacers  25  and edge spacers  26 , thereby securing over-layer  28  to under-layer  29  without damaging the integrity of thermal mass  18 . 
   As not all areas in which the modular radiant heat panel system might be employed are perfectly rectangular, it is contemplated that alternate routing of conduit may be necessary, in which case a different configuration of panels, edge spacers, or attachment spacers can be employed. Attachment spacers should be positioned intermittently to allow the attachment of over-layer  28  to under-layer  29 . In addition, edge spacers  26  may be used not only to attach the outer perimeter edge of over-layer  28  to under-layer  29 , but also to fill any irregular spaces between panels  16  and the vertical walls or other structure in the subject area. By using wood or other easily cut or shaped material, nonstandard spaces or irregular spaces may be easily filled. 
   Alternatively, a panel having no conduit channels but of the same substance as thermal mass  18  may be cut to fit irregular spaces between panels  16  and any vertical walls or other structure in the subject area. Thus, the outer edges of a room where the panels do not fit perfectly against the walls of the room may be filled by cutting such a panel to the dimensions and shape needed to fill such space. As a further alternative, cementitious non-shrink grout may be used to fill such irregularly-dimensioned spaces. 
   Once the tubing has been positioned in channels  20  of panels  16 , conduit  21  is attached to a conventional zone regulator, which allows for independent control of the temperature in different zones of a structure The regulator is then connected to a conventional boiler  23 , which heats the fluid running through conduit  21 . In the preferred embodiment, water is used as the conducting fluid. However, other fluid such as an antifreeze mix or glycol may be employed. The fluid is heated by boiler  23  and pumped through the circuit of conduit  21 . As it flows through conduit  21  where conduit  21  passes or extends through channels  20 , heat in the circulated fluid is conducted to thermal mass  18  of panels  16 . The heat is stored in and radiates from thermal mass  18 . 
     FIG. 21  shows an alternate embodiment to the modular radiant heat panel system shown in  FIG. 2 . The system shown in this alternate embodiment broadly includes an under-layer  29 , multiple radiant heat transfer panels  60 , and conduit  21  winding through certain of conduit channels  63  in panels  60 . Unlike the embodiment shown in  FIG. 2 , this embodiment does not include an over-layer. Instead, outer surface  64  of panels  60  operates as the finished floor surface. Panels  60  are formed with an outer surface  64  which is appropriate for a finished floor. This finished outer surface is formed by impregnating surface  64  with tile or another suitable finished surfacing material. 
   Also, in contrast to panels  16 , panels  60  do not include a tray  24 . As shown in  FIG. 22 , panels  60  have a thermal mass  18 , an outer surface  64 , and a conduit channel  63 . The panel shown in  FIG. 22  is formed by pouring thermal mass  18  into an appropriate mold, allowing thermal mass  18  to cure, and then removing thermal mass  18  from the mold to provide panel  60  with conduit channel  64 . Much like panel  16 , panel  60  may be molded to have a variety of different conduit channel configurations, examples of which are provided in  FIGS. 11–13 . By using panel  60 , which does not include tray  24 , the vertical sides of the panels may be positioned against each other or against spacers or walls without being separated by a thickness of plastic, which may be desired in certain applications. In this embodiment, conduit  21  contacts thermal mass  18  directly, rather than being in physical contact with channels  20  of tray  24 . Heat in the circulated fluid in conduit  21  where conduit  21  passes or extends through channels  63  is conducted directly to thermal mass  18 . The heat is stored in and radiates from panel  60  directly into the room, rather than through an over-layer  28 . 
   A third embodiment is shown in  FIG. 25 . This embodiment is especially suited to situations in which radiant heat is being installed with an existing finished floor. In this application, panels  16  are placed upside down against the underside of the existing flooring system. Typically, panels  16  are designed to fit between the floor joists  65  of the subfloor or under-layer  29 . Thus, panels  16  are oriented, as in  FIG. 8 , with the open portion of the troughs of conduit channel  20  facing up. Conduit  21  is routed with parallel sections  100 ,  102 ,  104 ,  106 ,  108 ,  110 ,  112  and  114  running between and parallel to the floor joists  65 , and with holes drilled at appropriate intervals in floor joists  65  for conduit  21  to pass through when making bends  101 ,  103 ,  105 ,  107 ,  109 ,  111  and  113 . Thus, the floor joists  25  are oriented similar to attachment spacers  25  in  FIG. 20  with respect to panels  16  and conduit  21 . 
   Panels  16  are positioned with bottom member  52  in contact with the underside  66  of floor  29  and with conduit  21  aligned in the appropriate channels  20  of panels  16 . The panels are attached by screwing fasteners up through the guide holes of fixture towers  34   a – 34   d  of each panel into the underside  66  of the existing floor  29 . Panels  16  are in essence hung from the existing floor and the existing floor holds the panels in place. Depending on the spacing between floor joists and the panel dimensions, one, two (as shown in  FIG. 25 ) or more rows of panels may be run between each set of floor joists. Panels  16  may be provided with alternate channel configurations depending on the conduit routing required. In this embodiment, heat in circulated fluid is conducted to and stored in thermal mass  18  of panels  16 , and radiates therefrom. 
   As can be appreciated, alternate panel  60  may be employed in this third embodiment. Also, as a further alternative, panels  16  may be positioned with outer surface  19  against or in contact with the underside  66  of floor  29  and with conduit  21  separated from the underside  66  of floor  29  by thermal mass  18 . In this orientation, conduit  21  may be held in channels  20  by appropriate fasteners to provide efficient conductivity. Panels  16  are attached to the underside  66  of floor  29  by fasteners screwed through fixture towers  34   a – 34   d  in the opposite direction to the direction shown and described in  FIG. 2 . 
   The present invention contemplates that many changes and modifications may be made. Therefore, while the presently-preferred form of the modular radiant heat panel system has been shown and described, and several modifications and alternatives shown or discussed, persons skilled in this art will readily appreciate that various additional changes and modifications may be made without departing from the spirit of the invention, as defined and differentiated by the following claims.

Technology Classification (CPC): 5