초록 ▼

A radiant heating system comprises a thermally sprayed resistive heating layer bonded to an underlayment building material substrate. The substrate can comprise a sub-flooring material and the heating system can comprise a radiant floor heating system. The resistive heating layer can be thermally sp

A radiant heating system comprises a thermally sprayed resistive heating layer bonded to an underlayment building material substrate. The substrate can comprise a sub-flooring material and the heating system can comprise a radiant floor heating system. The resistive heating layer can be thermally sprayed directly onto a sub-floor or similar underlayment material, including a cementitious backing material or a sound reduction board. A finished floor surface, such as a tile, wood or laminate surface, can be provided over the substrate and thermally sprayed heater to provide a radiant floor heater. In other embodiments, a radiant heating system includes a thermally sprayed heater bonded to a flooring overlay, such as a laminate board, to a heater insert, such as a flexible polymer film or a mica-based material, or to a concrete substrate. Methods of fabricating radiant heating systems include thermally-spraying a resistive material on a sub-floor or flooring overlay.

대표청구항 ▼

1. A radiant heating system comprising: a laminate flooring board;a thermally sprayed resistive heating layer bonded to the laminate flooring board;at least one electrical connector for providing electrical power to the resistive heating layer;wherein the resistive heating layer is patterned to prov

1. A radiant heating system comprising: a laminate flooring board;a thermally sprayed resistive heating layer bonded to the laminate flooring board;at least one electrical connector for providing electrical power to the resistive heating layer;wherein the resistive heating layer is patterned to provide an electrical circuit, and at least two electrical connectors are in electrical contact with the resistive heating layer to provide a voltage across the circuit;wherein the laminate flooring board has a length and a width, and wherein the heating system comprises a pair of buses in electrical contact with the resistive heating layer and extending along the length of the flooring board; andwherein the resistive heating layer is patterned to provide a plurality of circuits extending along the length of the flooring board and connected in parallel by the pair of buses. 2. The radiant heating system of claim 1, wherein the pair of electrical connectors are located at one end of the flooring board and form an electrical connection with the pair of buses. 3. A radiant heating system comprising: a laminate flooring board;a thermally sprayed resistive heating layer bonded to the laminate flooring board; andat least one electrical connector for providing electrical power to the resistive heating layer;wherein the resistive heating layer comprises a first material and a second material, wherein the first material is an electrically conducting material and the second material is an electrically insulating material; andwherein the bulk resistivity of the resistive heating layer is higher than the resistivity of the conductive material by a factor of about 10 or more. 4. The radiant heating system of claim 3, wherein the bulk resistivity of the resistive heating layer is higher than the resistivity of the conductive material by a factor of about 10 to about 1000. 5. A radiant heating system comprising: a laminate flooring board;a thermally sprayed resistive heating layer bonded to the laminate flooring board; andat least one electrical connector for providing electrical power to the resistive heating layer;wherein the resistive heating layer comprises a first material and a second material, wherein the first material is an electrically conducting material and the second material is an electrically insulating material; andwherein the content of the electrically insulating material in the resistive heating layer comprises at least about 40% by volume. 6. The radiant heating system of claim 5, wherein the content of the electrically insulating material in the resistive heating layer comprises between about 40-80% by volume. 7. A radiant heating system comprising: a laminate flooring board;a thermally sprayed resistive heating layer bonded to the laminate flooring board; andat least one electrical connector for providing electrical power to the resistive heating layer;wherein the resistive heating layer comprises a first material and a second material, wherein the first material is an electrically conducting material and the second material is an electrically insulating material;wherein the electrically conductive material comprises a metallic material; andwherein the electrically insulating material comprises a reaction product of the metallic material. 8. The radiant heating system of claim 7, wherein the reaction product comprises at least one of an oxide, a nitride, a carbide and a boride. 9. The radiant heating system of claim 7, wherein the electrically insulating material comprises a thermally sprayed insulating material and a reaction product of the electrically conducting material. 10. A method of fabricating a radiant heater, comprising: providing a laminate flooring board;thermally spraying a material to form a resistive heating layer; andbonding the resistive heating layer to the laminate flooring board. 11. The method of claim 10 further comprising thermally spraying the material onto a surface of the laminate flooring board to bond the resistive heating layer to the laminate flooring board. 12. The method of claim 10 wherein the laminate flooring board comprises a decorative upper surface and an underside surface, and the resistive heating layer is bonded to the underside surface. 13. The method of claim 10 further comprising providing a protective layer over the resistive heating layer. 14. The method of claim 13 wherein the protective layer comprises one or more of a moisture barrier, a ground plane and a thermal barrier. 15. The method of claim 10 further comprising bonding the resistive heating layer to composite material and providing a decorative upper layer over the resistive heating layer and the composite material.