The invention relates to a floor heating mat for realizing a floor heating and/or floor cooling in buildings. For such a heating and/or cooling use is usually made of a system wherein a heat transport medium such as water and/or glycol is applied. Use is here made of conduits so that the medium can be transported.

It is known in practice to install floor heating by casting a conduit system into a ground surface, particularly into a sub-floor. This must be carried out at the construction site, and is thereby labour-intensive. This work is further carried out under (ambient) conditions which are usually not optimal. This increases the chance of errors and also makes it possible that the conduits are positioned incorrectly or sub-optimally, so that cold corners are for instance created in a floor.

In order to obviate the stated problems a floor heating mat is known wherein conduits are secured in a desired pattern on a carrier material, such as a mesh, in a production environment.

This therefore happens under controlled conditions and with an optimal distribution of the conduits over the carrier. The prefabricated mats are then transported to the construction site. At the construction site the mats are laid at the desired position and are then connected. This reduces the amount of labour at the construction site and reduces the risk of incorrect installation.

A problem occurring in practice with such floor heating mats is that they do not remain flat, or at least not sufficiently flat, during placing at the construction site. This then causes problems when arranging the floor. In such cases it is thus still sometimes required to secure the mat manually in order to thereby position it sufficiently flat, and thereby enable arranging of a floor. Alternatively and/or additionally, it can be required to give the carrier a sufficiently stiff form so as to encourage the mat to lie flat. This increases costs and additionally has the drawback that transport is impeded in that the mat for instance cannot be rolled up.

The present invention has for its object to obviate or at least reduce the above stated problems and to provide an effectively and efficiently usable floor heating mat.

This object is achieved with a floor heating mat according to the invention for floor heating and/or cooling of a ground surface, wherein the floor heating mat comprises: a roll-up carrier mat; a conduit arranged on or at the carrier mat prior to placing of the carrier mat, wherein the conduit is provided with a deformation, such that the carrier mat with the conduit arranged thereon or thereat lies substantially flat during placing.

By providing a roll-up carrier mat it is possible to store and transport it in relatively simple manner. In practice the roll-up carrier mat can also be arranged in a space in relatively simple manner. Such a carrier mat preferably comprises a mesh construction. The carrier mat can be manufactured from different materials, including metals such as zinc-plated steel, plastic materials such as polyethylene, polypropylene, polyvinyl chloride and variants thereof.

Conduits for throughfeed of the transport medium, particularly water or glycol, are prearranged on the carrier mat in the factory. These conduits are likewise sufficiently flexible to also be rolled up along with the carrier mat. With this prefabrication of the one or more conduits a good positioning of the conduit over the space is realized, whereby cold corners are for instance avoided. The risk of connection errors is further also reduced further. The floor heating can hereby also be arranged in effective manner at the construction site. The conduits can be arranged on the inner side and/or the outer side of the rolled-up carrier mat.

According to the invention, the conduit is provided with a deformation such that the carrier mat with conduits arranged thereon or thereat lies substantially flat during placing at the construction site, or at least lies sufficiently flat to be able to arrange the floor in effective manner. Application of the deformation has been found to apply a kind of bias in the conduits so that they remain substantially flat in effective manner, particularly after the rolled-up carrier mat with the conduits attached thereto is unrolled in the space(s) intended therefor. The deformation here preferably comprises a plastic deformation. The deformation of the conduits is hereby implemented permanently.

The deformation is preferably a deformation of the conduit to a non-round cross-section. Conventionally, conduits are usually provided having a round cross-section and arranged on the carrier mat therewith. As a result of the deformation applied according to the invention, the round cross-section will transform to a non-round (cross-)section, and thereby realize the desired effect in respect of unrolled carrier mat remaining flat. The deformation can be applied during production and/or in a special intermediate step during the processing of the conduit. Use can be made here of specific moulds and/or guides for applying the desired deformation. The deforming can be performed in different ways. In possible embodiments according to the invention it is thus possible to deform the conduit such that a cross-section with a kind of egg shape is obtained, or a slightly dented form with a concave and convex side is obtained. It will be apparent that other forms are also possible according to the invention, for instance arranging a profile in the form of a type of groove in longitudinal direction of the conduit. The deformed conduit can in principle be arranged on the carrier mat in diverse orientations.

In a currently preferred embodiment the deformation can be characterized by the ratio between the maximum sectional axis and the minimum sectional axis as seen in cross-section (throughflow surface) of the conduit. In a currently preferred embodiment this ratio lies in the range of 1.025-1.5, preferably 1.04-1.25, more preferably 1.05-1.15, and most preferably amounts to about 1.1. Tests have shown that such a ratio preserves a suitable throughflow of the medium through the conduit and simultaneously achieves the desired effect on remaining flat. In an advantageous embodiment according to the invention the conduit is arranged on or at the carrier mat, such that the height of the cross-section of a conduit perpendicularly of the carrier mat is greater than the width of the cross-section of the conduit in the direction at a right angle thereto. It is therefore preferred that the maximum sectional axis lies substantially perpendicularly of the carrier mat and the minimum sectional axis lies substantially parallel to the carrier mat. Orienting the deformed, non-round conduit on the carrier mat such that said height is greater than said width of the cross-section achieves in effective manner that the carrier mat remains flat and that the degree of flatness is increased further by said orientation of the deformed conduit on the carrier mat.

The non-round conduit functions here as deformation, and tests have shown that the conduit lies substantially flat during placing.

In an advantageous embodiment according to the invention the conduit is manufactured from polyethylene.

Providing the conduit from polyethylene material achieves on the one hand that a flexible conduit is obtained which can be rolled up together with the carrier mat, and on the other hand that a conduit is obtained which can be deformed in order to realize the desired effect on the flatness of the placed floor heating mat. The polyethylene is preferably so-called cross-linked polyethylene (PE-RT). It will be apparent that it is also possible to use other materials, optionally in combination with polyethylene.

In a further advantageous embodiment according to the invention the floor heating mat comprises an electrical cable attached thereto or thereat.

By also providing the floor heating mat with electrical cables, this in addition to conduits for the floor heating and/or cooling, an effective mat is provided whereby desired provisions in buildings can be arranged even more quickly. An arranged electrical cable preferably comprises one or more pluggable couplings for facilitating connection still further.

In a possible embodiment according to the invention a further conduit such as a sewer pipe is further also arranged, this in addition to the conduit for the heating and/or cooling and optionally in combination with the electrical cable. This increases the flexible utility of the floor heating mat according to the invention still further.

In a currently preferred embodiment the carrier mat is provided with a mesh or grid structure with a number of so-called longitudinal wires and transverse wires. Diameters used preferably lie in the range of 0.5-5.0 mm, and more preferably in the range of 1.0-3.0 mm. In a currently preferred embodiment the diameter of the longitudinal wire is smaller than the diameter of the transverse wire. It has been found that this further simplifies rolling up of the roll-up carrier mat. In addition, it is possible to provide the floor heating mat with an insulating layer. This increases the effectiveness of the floor heating mat according to the invention still further. The invention further also relates to a floor heating, floor and/or building wherein a floor heating is applied as according to an embodiment of the present invention.

Such a floor heating, floor and/or building provides similar advantages and effects as described for the floor heating mat. The floor heating mat according to the invention particularly provides for an effective placing for the floor heating, floor and/or building.

The invention further also relates to a device for manufacturing a floor heating mat in an embodiment according to the invention.

Such a device provides similar advantages and effects as described for the floor heating mat.

The device makes it possible to provide a prefabricated floor heating mat, which is preferably manufactured to specification of the desired construction site.

The invention further also relates to a method for manufacturing a floor heating mat, comprising the steps of: determining dimensions and configuration of the floor heating mat; deforming the conduit; and arranging the deformed conduit on a mat in accordance with the dimensions and configuration.

Such a method provides similar effects and advantages as described for the floor heating mat, floor heating, floor and a building and/or device. The conduits are preferably arranged on the carrier mat in (semi-) automatic manner using a device. After arranging, the prefabricated carrier mat is removed from the device.

In the method according to the invention use is optionally made of automatic reading of desired dimensions and a desired configuration of the conduits on the carrier mat. This means that the carrier mat can be manufactured specifically for a desired construction site. The provision is optionally made to couple the carrier mat and/or cut it at the locations intended therefor at the construction site, wherein a so-called enlarged loop or folding loop can optionally be arranged.

The method preferably comprises of transporting and actually arranging the floor heating mat at a desired location. This enables an effective process for arranging a floor heating. A further additional advantage is that the amount of construction waste is reduced and materials used can be processed in effective manner under controlled conditions. Effective placing of the floor heating mat according to the invention in the (future) ground surface therefore becomes possible thereby at the construction site.

Further advantages, features and details of the invention are elucidated on the basis of exemplary embodiments thereof, wherein reference is made to the accompanying figures, in which:

Figure 1 shows a view of a floor heating mat according to the invention with therein optionally an electrical cable and sewer pipe; Figure 2 shows a rolled-up carrier mat with floor heating mat according to figure 1 ; Figure 3 shows a view of an undeformed and deformed conduit applied on the floor heating mat according to figure 1 ;

Figures 4 and 5 show views of a device for manufacturing the floor heating mat according to figure 1.

Floor heating mat 2 (Figure 1) comprises a carrier mat 4 in the form of a mesh provided with longitudinal wires and transverse wires, to which first conduit 6 and second conduit 8 are secured using cable ties 10. In the longitudinal direction of carrier mat 4 conduits 6, 8 are arranged at mutual distance L and in transverse direction of mat 4 at mutual distance D in bends 12.

In the shown embodiment mat 2 is provided with first sub-section 16 and second sub section 18 connected via transition/connection 14. Sub-sections 16, 18 can be wholly or partially separated from each other by for instance cutting longitudinal wires of mat 2. Optionally provided in the shown embodiment is enlarged loop or folding loop 20, wherein during prefabrication first conduit 6 and second conduit 8 are positioned at a mutual distance smaller than the distance D.

This loop 20 is advantageous if sub-sections 16, 18 are positioned adjacently of each other in width direction during placing. Loop 20 makes it possible to have conduits 6, 8 continue without additional couplings being required.

Free strip B is optionally provided at the side edges of carrier mat 4. Insulating mat 21 is optionally arranged on the underside of carrier mat 4. In the shown embodiment insulating mat 21 is provided from a first part 21a and second part 21b which can be divided at transition 14.

Optionally further arranged in the shown embodiment is pipe 102, as well as electrical cable 104. Electrical cable 104 is preferably embodied as a flat conduit, optionally with plug or coupling 105. Pipe 102 is provided with coupling piece 106 which is slid with an outer part round rectangular tube 108 as a kind of sleeve. Outer part 110 can here be placed over rectangular tube 108, wherein coupling part 112 is slid into the interior of tubular profile 108. In the shown embodiment coupling piece 106 is provided with a decreasing internal diameter in a flow direction S so as to thereby reduce the risk of leakage.

Mat 2 (Figure 2) can be rolled up. Mat 2 is provided with rolled-up carrier 4 with arranged thereon on one side conduits 6, 8 and optionally on the other side insulating mat 21. Pipe 102 and electrical cable 104 are also arranged in the shown embodiment. Optionally provided on either side are conduits 6, 8, possibly provided with optional insulating mat 21. Conduits 6, 8, 104 can be arranged in a meander configuration, spiral configuration or another configuration, which is not shown.

Installation mat 2 can preferably be rolled up in both longitudinal direction and transverse direction. In a currently preferred embodiment carrier mat 2 is provided with a mesh or grid structure comprising longitudinal wires and transverse wires provided with a diameter in the range of 0.5 to 5.0 mm, preferably in the range of 1.0 to 3.0 mm. It has been found that application of such diameters provides a carrier mat which can be rolled up in practice, and a construction which is sufficiently stable and rigid after placing. In a currently preferred embodiment the longitudinal wires are slightly thinner than the transverse wires of mat 2. Rolling up in longitudinal direction is therefore simpler in this embodiment. This improves the possibility of rolling up the carrier mat for storage and transport, while stability and rigidity are maintained after placing. Alternatively and preferably additionally, the longitudinal wires and transverse wires are provided with material properties which differ to some extent by using different materials, including alloys. The longitudinal wire preferably takes a thinner and softer form than the transverse wire. This improves the flexibility for storage and transport and maintains stability and rigidity after placing.

In the shown embodiment the metal of carrier mat 4 is a zinc -plated metal, such as zinc- plated steel or zinc -plated iron, or a galvanized metal such as galvanized steel or galvanized iron. Alternatively, use can also be made of a plastic carrier mat of for instance polyethylene, polypropylene, polyvinyl chloride, chlorinated polyvinyl chloride and/or plastic film, such as polyethylene film. Carrier mat 4 can be embodied as an uninterrupted carrier or, in a currently preferred embodiment, as a mesh-like carrier. Further alternative materials are also possible according to the invention, including rubber, textile, bamboo and/or reed.

Conduit 6, 8 (Figure 3) is provided with a deformation whereby the usually substantially round shape with diameter d in cross-section (throughflow surface) transitions to a deformed shape. Minimum cross-sectional diameter or sectional axis d^ and maximum cross-sectional diameter or sectional axis d _m , _x are obtained by the preferably plastic deformation. In the shown embodiment d^ is about 15 mm and d _max about 16-17 mm in respect of the outer dimensions. In this embodiment the ratio between d _^ and d _mill thereby lies between 1.07 and 1.13. In the shown embodiment d _^ lies substantially in a direction perpendicularly of the surface of unrolled mat 2 and d _min lies substantially in a direction parallel thereto. It will be apparent that a slightly different dimensioning and/or orientation are likewise possible according to the invention.

Machine 800 (Figure 4) comprises roll 802 for the feed of a mesh-like carrier mat 804. For the sake of clarity the lattice of carrier mat 804 is not shown in the figure, however, carrier mat 804 has in reality preferably a mesh form.

Carrier mat 804 is guided from supply roll 806 to two conveyor belts 808a, 808b. A guide roller 810 is optionally provided to guide carrier mat 804 in the direction of conveyor belts 806a, 806b. Conveyor belts 806a, 806b are provided with studs so that the studs can hook into the meshes of the mesh-like carrier mat 804 in order to thus transport mesh-like carrier mat 804. Carrier mat 804 is transported by conveyor belts 804a, 804b in the direction of arrow P, after which carrier mat 804 is rolled up onto roll 812. Guide roller 814 is optionally provided on this output side. Guide rollers 810, 814 contribute toward holding carrier mat 804 on the conveyor belt. Pipes 102 and electrical cables 104 can be arranged in similar manner.

Conduit 816 (Figure 5) is supplied from roll 818. Arranged above carrier mat 804 is rail 820 along which carriage 822 can move reciprocally. Carriage 822 is provided with one or more guide rollers 824, 826 which position conduit 816 on carrier mat 804.

Machine 800 moreover comprises a cable tie gun or braiding machine (not shown) or hook and loop fastener machine (not shown), wherein conduits are for instance placed on a hook and loop carrier mat by means of hook and loop fastening tape for the purpose of thereby attaching conduit 816, which is laid in transverse direction on or over carrier mat 804 by guide rollers 814, 816, to mesh-like carrier mat 804. The cable tie gun or the braiding machine is for instance likewise provided on carriage 822. The cable tie gun or the braiding machine can alternatively also be located on the other side of carrier mat 804 relative to the carriage for the purpose of attaching conduit 816 to mesh-like carrier mat 804 from this side. Carriage 822 then moves in the opposite direction in order to place a new part of conduit 816 over the desired width on carrier mat 804, wherein the attaching means of the apparatus also attach this part of conduit 816 to carrier mat 804. An optional second conduit 824 for the floor part/mat is arranged in similar manner on carrier mat 804. It will be apparent that other embodiments are also possible for machine 800. It will be apparent that in machine 800 further process steps can also be included and/or be provided in other alternative manner.

If a building must be provided with an installation which is preferably also suitable for cooling, what is started with is designing an installation mat with a number of sections and sub sections. The specifications and other required information are for this purpose retrieved and preferably read into machine 800. The reading for instance takes place by reading AutoCAD drawings of the building in question, after which the production plans are made. According to the design, conduits 6, 8, 102, 104, 816 are then arranged in a production step, preferably using machine 800. After production, the floor heating mat is stored and transported, preferably on a roll and optionally in pressurized state. The prefabricated mat is then placed at the construction site in question, wherein the mat is cut into and folded where necessary on site. After positioning of the floor heating mat it is connected to other parts of an installation system. This connecting is simplified significantly with a mat according to the invention in that the number of couplings required is reduced significantly. After connection, use of the system follows.

The present invention is by no means limited to the above described embodiments thereof. The rights sought are defined by the following claims, within the scope of which many modifications can be envisaged.