GB2609437A

GB2609437A - A mouldable, heatable item

Info

Publication number: GB2609437A
Application number: GB2111000.2A
Authority: GB
Inventors: Pedley Andrew
Original assignee: Poured Project Ltd
Current assignee: Poured Project Ltd
Priority date: 2021-07-30
Filing date: 2021-07-30
Publication date: 2023-02-08
Anticipated expiration: 2041-07-30
Also published as: GB2609437B; GB202111000D0

Abstract

A heatable item 1 comprises a moulded body 2 shaped from a mouldable material such as cement, polymer, resin, etc; and a heating means 4a,4b encapsulated within the body. The heating means is configured to be in communication with a heat source and/or power source and ideally comprises a fluid conduit to receive heated water or air, or heating pads including an electrical heating element. Plastic retaining clips (114, figure 3) may be used to support the heating means in a desired arrangement during manufacture of the heatable item so that the heating means is located at least 5mm beneath a contact surface of the heatable item upon completion. The heatable item may take any conceivable form including that of a bath tub (figure 1), a heated bench (figures 5 and 6) or panels for use in swimming pools.

Description

A MOULDED, HEATABLE ITEM

FIELD

The present invention relates to a heatable item, in particular to a moulded item comprising at least one heating element and to a method of manufacturing the castable item.

BACKGROUND

Often it is desirable to retain heat in cast or concrete structures. A problem encountered with such cast or concrete structures has been that they are complex and require a substantial amount of heat energy in order to raise their temperature, even by a few degrees. This characteristic is known as the specific heat capacity and is a characteristic of materials.

For example in a bathroom, large concrete baths or plunge pools have tended to dissipate heat quite quickly with the consequence that water contained in them does not remain warm for sufficiently long periods in order to enjoy a bath.

A heated element to be cast into hard surface of the pool sides and base to help regulate the temperature.

PRIOR ART

United States patent US 5 950 396 (Fosdick) discloses a system and apparatus for factory built pan-making precast insulated concrete walls. The interior as well as the perimeter walls of a home are solid reinforced concrete. Concrete for the exterior walls is poured over a rigid insulation board so that when the walls are erected, they are insulated on the outside. This protects the concrete from the elements and makes the concrete available to the interior of the building for thermal mass to store heat.

Manufactured reinforcing panels are laid on casting slabs for concrete to be poured and finished. The casting slab is created to have the ability to pour walls of various heights.

Canadian patent application number CA 2 012 205 (Dahan) discloses a heating system for melting snow on driveways using heating cables. The heating cables are normally buried inside concrete slabs. The heating system is adaptable to different kinds of surface pavements especially stone pavement by creating a heat sink made of a double steel wire mesh around which a heating cable is wound.

International patent application number WO 2010/059169 (University of Nebraska) discloses a conductive concrete that contains various amounts of conductive materials. The conductive concrete is made by mixing cement, aggregate, water, and conductive materials. The conductive materials may include both metal fibres and metal particles. Particles made of carbon and graphite may be used to make the mixture easier to blend and pump.

A microwave heating system which efficiently heats the conductive concrete by utilizing radio frequency absorption properties of taconite is also disclosed.

UK patent GB 1 294 513 (Electricite Neuchateloise) discloses a radiant heating panel for floors, walls or ceilings which comprises a support plate made of low thermal conductivity material, such as expanded polystyrene or foamed polyurethane. Heating elements are housed in grooves formed in one surface of the plate and covered by a layer of electrical insulation. Cement retains elements in the grooves.

A disadvantage of many of the aforementioned systems is that they have been complicated to fabricate and to install.

In addition many existing systems are not suitable for use in cast structures which hold water.

The present invention arose in order to overcome problems associated with many prior art systems.

SUMMARY OF INVENTION

According to a first aspect of the present invention there is provided a moulded, heatable item comprising: a moulded body formed from at least one mouldable material; and at least one heating element encapsulated within the moulded body, in which the at least one heating element is configured to be in communication with a power source and/or heat source.

According to a second aspect of the present invention there is provided a method of manufacturing a moulded, heatable item as herein described, the method comprising: providing at least one heating element in a predetermined configuration; and encapsulating the heating element(s) in at least one mouldable material. In one embodiment, the moulded, heatable item is a household item.

In one embodiment, the moulded, heatable item may be a fixture or fitting of a building such as for example a radiator, foot spa or bath.

In one embodiment, the moulded, heatable item may be an item of furniture. The item of furniture may for example be an internal or an external item of furniture. In one embodiment, the moulded, heatable item may be one or more of: seating and/or table, for example a table top.

In one embodiment, the mouldable material comprises one or more of: sand, aggregate(s), cement, pozzolan(s), polymer(s), reinforcing fibre(s), resin(s), or any combination thereof.

The mouldable material may comprise a plurality of different materials at any suitable ratio and/or amount depending on the requirements for the item.

In one embodiment, the power source may be an electrical power source.

In one embodiment, the heating element comprises one or more heating pads comprising an electrical heating element.

In one embodiment, the heating element(s) comprises at least one fluid conduit configured to be in communication with a fluid source, preferably a heated fluid source. The fluid source may for example be liquid (for example water) or gas (for example air).

The item may further comprise a pump configured to transport heated fluid from the fluid source through the fluid conduit(s). The item may further comprise a heat source configured to supply heat to the fluid source. The item may further comprise a thermostat configured to control the temperature of the heating element, for example of the fluid source.

In one embodiment, the item further comprises a support structure encapsulated within the moulded body. In one embodiment, the support structure comprises one or more fixation devices configured to engage and retain at least a portion of the at least one heating element in a predetermined location and/or orientation relative to the structure and/or moulded body.

The one or more fixation devices may comprise one or more clips, for example plastic clips. The clip(s) preferably comprise a first end secured to a portion of the support structure and a second end configured to engage and retain a portion of the heating element.

The term "encapsulated" is used herein to refer to a heating element(s) and support structure which are entirely surrounded by the moulded body such that the heating element(s) and support structure are not exposed to the external environment.

The item preferably comprises at least one contact surface through which heat is to be transmitted.

In one embodiment, the heating element(s) is located at a depth of at least 5 mm, preferably at least 10 mm, for example about 20 mm beneath the contact surface. In one embodiment, the heating element is located at a depth of no more than 2 m, preferably no more than 1 m A preferred embodiment of the invention will now be described by way of example only and with refence to the drawings in which:

BRIEF DESCRIPTION OF FIGURES

Figure 1 is a schematic illustration of a moulded, heatable item according to one embodiment of the present invention; Figure 2 is a schematic illustration of a view from above of a portion of a moulded, heatable item according to a further embodiment of the present invention; Figure 3 is a schematic illustration of a side view of a portion of the moulded, heatable item of Figure 2; Figure 4 is a schematic illustration of a clip of a moulded, heatable item according to a further embodiment of the present invention; Figure 5 is an overall view of a heated bench; and Figure 6 is a diagrammatical view of a cast heated chair with table chairs. DETAILED DESCRIPTION With reference to Figures 1 and 2, the moulded, heatable item 1, 101 comprises a moulded body 2, 102 formed from at least one mouldable material.

The mouldable material may comprise for example one or more of: sand, aggregate(s), cement, pozzolan(s), polymer(s), reinforcing fibre(s), resin(s), or any combination thereof in any suitable amounts and ratios. It is however to be understood that the material may comprise any material which is capable of being moulded and shaped to provide an item having predetermined shape and dimensions.

The moulded body 2, 102 has at least one contact surface 6, 8, 106 through which heat is to be supplied from at least one heating element 4a, 4b,104.

As shown in Figure 1, the item 1, in this case a bath tub, comprises two heating elements 4a,4b. A first heating element 4a is provided within the base 6 of the item 1. A second heating element 4b is provided within the side portions 8 of the item 1. It is however to be understood that the item may comprise any suitable number of heating elements. For example, the item 1 may comprise a single heating element 104 (as shown in Figure 2) or more than two heating elements. The heating element 4a, 4b, 104 is located preferably at about 5 mm beneath the contact surface 6, 8, 106.

The heating elements 4a, 4b, 104 are encapsulated within the moulded body 2, 102 such that the heating elements 4a, 4b, 104 are isolated from an external environment.

The heating elements 4a, 4b, 104 are in communication with a power source (not shown).

In the illustrated embodiments, the heating elements 4a, 4b, 104 are provided in a wave-like manner, for example sinusoidal manner. It is however to be understood that the heating elements 4a, 4b, 104 may be provided in any suitable arrangement.

As shown in Figures 2 and 3, the item 101 comprises a support structure 112. The support structure 112 is encapsulated within the moulded body 102. The support structure 112 provides a rigid framework for retaining and engaging portions of the heating element 104 in the desired arrangement during manufacture.

The support structure 112 comprises a plurality of fixation devices 114 in the form of plastic retaining clips. These clips 114 (as shown in Figure 4) are positioned to engage and retain a corresponding portion of the heating element 104. The support structure 112 is configured to provide spaced apart fixation devices extending along the length of the moulded body 102. It is to be understood that the support structure 112 may be configured to provide spaced apart fixation devices extending in any suitable dimension(s) of the moulded body 102.

The support structure 112, and fixation devices 114, are placed within the desired mouldable in predetermined locations. The heating element 4a, 4b, 104 is inserted into the mouldable and engaged with the fixation devices 114 of the support structure 112. The mouldable material is then introduced into the mouldable to fully encapsulate the heating element(s) 4a, 4b, 104. The mouldable material is left to set under predetermined temperature and pressure conditions. Once set, the moulded, heatable item is removed from the mouldable.

The moulded, heatable item 1 is then connected with either a power source or a heat source (not shown) such that electricity or heated fluid is provided to the heating element(s) and heat is transmitted through the contact surface 6, 8, 106 as required.

The item may further comprise one or more layers of insulation adjacent surfaces of the moulded body 2, 102 through which heat is not to be transmitted from the heating element.

Figure 5 is an overall view of a heated bench. Figure 5 shows heated bench 44 with a seat 46 and a back rest 48. Heating elements 4a, 4b are embedded into the mouldable form and engaged by fixation devices (not shown). Like pads bear the same reference numerals as in Figures 1 to 4. Figure 6 is a diagrammatical view of another example of a cast heated bench 54 with cast legs 50 and a top 52 in which heating elements 4a are embedded. The heated bench 54 may be used as a chair or a heated table.

The present invention therefore provides a method of preparing an item of varying shape, which is able to provide at least one heated contact surface (of varying shape and dimension), for retaining heat or warming a person, animal or product, such as food or other items. As such, the present invention is versatile and can be used for a wide range of applications and is not to be limited to household items such as furniture.

Although the illustrated embodiments show the use of electrical heating elements, it is to be understood that the item may comprise other heating elements. For example, the item may comprise one or more fluid conduits configured to be in communication with a heated fluid source, such as for example hot water and/or hot air.

It will be appreciated that variation may be made to the invention, for example the invention may be included in infrastructure of panels for use in, pools, swimming pools and paddling pools.

Claims

CLAIMS1. A moulded, heatable item comprising: a moulded body formed from at least one mouldable material; and at least one heating element encapsulated within the moulded body, in which the at least one heating element is configured to be in communication with a power source and/or heat source.
2. An item as claimed in claim 1, in which the mouldable material comprises one or more of: sand, aggregate(s), cement, pozzolan(s), polymer(s), reinforcing fibre(s), resin(s), or any combination thereof.
3. An item as claimed in either of claims 1 or 2, in which the heating element comprises one or more heating pads comprising an electrical heating element.
4. An item as claimed in either of claims 1 or 2, in which the heating element(s) comprises at least one fluid conduit configured to be in communication with a fluid source.
An item as claimed in claim 4, in which the fluid source is water.
6. An item as claimed in any preceding claim, further comprising a support structure encapsulated within the moulded body.
7. An item as claimed in claim 6, in which the support structure comprises one or more fixation devices configured to engage and retain at least a portion of the at least one heating element in a predetermined location and/or orientation relative to the structure and/or moulded body.
8. An item as claimed in claim 7, in which the one or more fixation devices comprises one or more clips
9. An item as claimed in any preceding claim, in which the item comprises at least one contact surface through which heat from the heating element(s) is to be transmitted, and in which the heating element(s) is located at a depth of at least 5 mm beneath the contact surface.
10. An item as claimed in any preceding claim, in which the moulded, heatable item is a household item.
11. An item as claimed in any preceding claim, in which the moulded, heatable item is a radiator, foot spa or bath.
12. An item as claimed in any one of claims 1 to 10, in which the moulded, heatable item is an item of furniture.
13. An item as claimed in claim 12, in which the moulded, heatable item is a seat, stool or bench.
14. An item as claimed in claim 12, in which the moulded, heatable item is a seat, stool or bench.
15. An item as claimed in any of claims 1 to 11, in which the moulded, heatable item is a panel for a bath or a panel for a swimming pool.
16. A method of manufacturing a moulded, heatable item as claimed in any one of claims 1 to 15, the method comprising: providing at least one heating element in a predetermined configuration; and encapsulating the heating element(s) in at least one mouldable material.