KR20230069083A - Plasterboard-Like Building Panel Radiant Heater - Google Patents

Abstract

The present invention relates to a heating panel comprising a thermally conductive (e.g., metal) layer, a layered heating element disposed on a framing-facing side of the thermally conductive layer, an insulating layer disposed over the layered heating element, and a thermally conductive material. and a room-facing surface layer disposed on at least the room-facing side of the layer. A method for heating a room may include installing at least one heating panel on the ceiling of the room and providing power to a heating element to generate heat radiating into the room. The panel may be part of a heating system that includes a controller, such as a thermostat, to regulate power to the heating panel. A plurality of heating panels or a plurality of heating zones in one or more panels may be independently controllable.

Description

Plasterboard-Like Building Panel Radiant Heater

This application claims priority to U.S. Provisional Patent Application No. 63/042,217, filed on June 22, 2020, entitled "PLASTERBOARD LOOKALIKE BUILDING PANEL RADIANT HEATER", the contents of which are for all purposes the entirety of which is incorporated herein by reference.

Efficient heating systems for housings that keep the carbon footprint to a minimum are desirable. Modern houses are now well insulated, leading to heating systems that do not require high power capacity. Infrared (IR) radiant heating panels use 35% to 40% less energy compared to conventional convection heating radiators or commonly used underfloor heating.

Placing heating panels on or in the ceiling can provide flexibility in strategically placing heat where heat is desired, with fewer restrictions than when using other types of heating units. Freestanding IR heating panels can be suspended or suspended from existing ceilings, but are often obtrusive (ie, protrude and stand out in unwanted ways), and thus may not be visually acceptable in the marketplace.

Existing heater applications in ceilings can be installed behind ceiling surface panels in cavities between ceiling joists to be concealed. This may involve using electric cable heater mats or films, wet hydronic pipes, and the like. Typical ceiling constructions include surface panels of 12.5 mm thick plasterboard or gypsum wallboard sheetrock, which are usually attached with drywall screws to the structure of the wood ceiling joists, and drywall along seams between the panels. They are integrated together into a continuous ceiling contour by using tape and spackle. These installations are relatively inefficient and, according to inspection data, result in heat transfer of only 70% to 75% of the input energy when radiating heat into a room.

The efficiency of IR thermal radiation is a function of temperature, where higher temperatures produce more efficient radiation. Existing plasterboard or sheetrock panels are typically limited to surface temperatures below 55°C.

Accordingly, there is a need in the field to provide efficient and aesthetically pleasing IR heating.

One aspect of the invention includes a heating panel having a framing-facing surface and a room-facing surface. The heating panel includes a thermally conductive layer having a room-facing side and a framing-facing side, at least one layered heating element disposed over the framing-facing side of the thermally conductive layer, an insulating layer disposed over the at least one layered heating element, and a thermally conductive layer. and a room-facing surface layer disposed on at least the room-facing side of the conductive layer. A power cord is connected to the layered heating element and is configured to connect to a power source.

The protective framing-facing surface layer may be disposed over the insulating layer and may define at least a portion of the framing-facing surface of the panel. In some embodiments, the thermally conductive layer can include metal, the protective framing-facing surface layer can include a gypsum-reinforced polyester mesh layer bonded to the insulation layer, and the insulation layer can include foam. and/or the room-facing surface layer may include paper. The thermally conductive layer may include a tray having peripheral sidewalls. In such constructions, the room-facing surface layer may surround the sidewalls of the tray and may define at least a portion of the framing-facing surface of the panels as well as peripheral edge surfaces of the panels.

The panel may include a power cutout switch configured to cut out power to the tiered heating elements upon detecting a temperature at the heating panel greater than a predetermined maximum, such as 80°C. The heating panel may include a plurality of holes extending from the room-facing surface of the panel to the framing-facing surface of the panel, each hole sized to receive a fastener for fastening the panel to the framing of the structure. is determined The insulated region may extend between the periphery of the panel and the at least one heating element.

The heating panel may include two heating elements and may have an insulated region extending between the two heating elements. An electrical enclosure cutout may be defined in the insulating layer, where the power cords are connected to the busbars of the layered heating element, and may have a cover flush with the framing-facing surface of the panel.

Another aspect of the invention includes a heating system comprising a heating panel as described herein, wherein a power cord is connected to a controller, such as a thermostat, to regulate power to the heating panel. A plurality of heating panels or a plurality of heating zones in one or more panels may be independently controllable by a controller.

Another aspect of the present invention includes a method for heating a room comprising installing at least one heating panel as described herein on a ceiling of a room, and generating heat radiating into the room. and providing power to at least one heating element. The plurality of heating panels may be connected to a thermostat controller mounted in the room, where the method includes controlling heat in the room to achieve a set temperature of the room. The ceiling includes at least one heating panel and at least one non-heating panel, and installing the at least one ceiling panel includes at least one heating panel and at least one unheating panel to form a continuous coverable ceiling layer. It may include applying a plaster material between the panels.

1 is a schematic diagram of a cross-section of an exemplary heating panel embodiment.
2 is a schematic diagram of a partially transparent top view of an exemplary heating panel embodiment, showing a schematic diagram of control and power elements and locations of heating elements relative to the periphery of the panel.
3 is a schematic diagram of an exemplary installation of a heating panel as described herein on an insulated ceiling.
4 is a schematic diagram of an exemplary installation of a heating panel as described herein on an uninsulated ceiling.
5A depicts an exemplary enlarged portion of the framing side of an exemplary panel, showing an enclosure for electrical connections with a closure lead fastened to the enclosure.
FIG. 5B depicts a portion of the framing side of an exemplary panel as depicted in FIG. 5A , without a lid on the enclosure.

One aspect of the present invention includes a heating panel capable of generating useful usable radiant heat at greater than 90% of the input energy. The panel can achieve operating surface temperatures of 80°C or less. The panels have the look and behavior of gypsum or plasterboard panels, and are constructed to be attached to ceilings in exactly the same way as sheetrock panels. The panel is configured as a “plug-and-play” application, where the heater is configured to be plugged into an available line voltage supply of 110/230v in a house or building.

A system comprising one or more of these ceiling panels can be connected to any standard thermostat to control the temperature of a room. Panels can be placed in desired positions and tailored to maximize the heating requirements of a particular room layout.

Benefits of systems incorporating these panels include over 90% energy conversion into radiant heat directed into a room, which can represent energy savings of 30% to 40% compared to existing concealed ceiling installations. Additionally, the construction of the ceiling panels allows the ceiling panels to be installed in the same way as conventional insulated boards or sheetrock panels, and the active panel surface to be painted or covered with any type of suitable ceiling surface layer. A suitable continuous surface may be covered with a rendering plaster or any coating similar to plasterboard to allow integration into the ceiling. Although the panels can achieve temperatures of 80°C, the panels are constructed to meet fire requirements. Plug-and-play connectivity simplifies installation and allows flexibility in positioning the panels wherever they are needed. The overall cost of the heating system is competitive with most or all other technologies on the market, and may be less expensive.

An exemplary heating panel is depicted in FIGS. 1 and 2 . The panel comprises a heat conducting layer 10, preferably in the form of a tray with a bottom 9 and a peripheral side wall 11. While a tray structure that includes sidewalls is desirable for structural/esthetic/edge protection functionality, in other embodiments, the thermal laminate layer may not have sidewalls without adversely affecting thermal performance. In an exemplary embodiment, the tray is formed of metal (eg, having a thickness of 0.5 mm in one embodiment), preferably steel, more preferably galvanized or galvanized steel. Steel is preferred because of its low heat capacity, stiffness, good fire/smoke/toxic properties combined with low cost, but the present invention is not limited to any particular materials of construction. In particular, other metals that are good thermal conductors such as (but not limited to) aluminum and copper may be particularly suitable, and non-metal materials such as ceramics, carbon-fibre-reinforced or other conductive fibrous polymeric materials. It can also be used for a heat conduction layer. The thermal conducting layer may include a multilayer composite of more than one type of thermal conducting material.

The thermally conductive layer comprises a framing-facing surface 13 (intended to be installed facing the framing of the ceiling to which the thermally conductive layer is attached) and (intended to be installed facing the room to which radiant heat is intended to be supplied) It has a room-facing surface (15). A heating film 12, such as a LaminaHeat Comfort heating film, is disposed over the framing-facing surface and is preferably in contact with the thermally conductive layer. In one embodiment, the layered heating film may be rated for 160W at 230v or 110v, and may have a power density of 300W/m 2 . An insulation core 14, such as foam, may be disposed over the heating film and bonded to the inner sidewalls of the thermally conductive tray. In one embodiment, the foam includes rigid polyurethane (PU) foam that is 11 mm thick, but the present invention is not limited to foam insulation or any particular type of foam or thickness thereof. In general, insulating materials having thermal conductivity values (k=0.028W/mK to 0.035W/mK) and densities of 30 kg/m ³ to 250 kg/m ³ are preferred. Additional suitable materials include, without limitation, acrylic and extruded polystyrene (XPS). In one embodiment, the insulation is a vacuum insulation panel such as VIP comprising a silica powder core known commercially as va-Q-plus™ supplied by va-Q-tec AG, which delivers high-hardness. insulated panel (VIP), which delivers a final performance k value of 0.0035, which is approximately 10 times better than standard foam insulation.

A protective barrier layer 17 may be applied to the framing-facing surface of the insulating core layer. In one embodiment, the protective barrier layer comprises a gypsum-reinforced polyester mesh layer having a thickness of 0.8 mm. A protective surface is preferred on the frame side of the insulation to impart structural rigidity and toughness/protection to the foam, but may be omitted in some embodiments. Reinforced gypsum is compatible with existing building panels used in the building industry. However, other materials may also be used including, but not limited to, polyester mesh/woven glass fiber open fabric mesh and other fiber-reinforced-polymer coatings. A surface coating 16 (eg, paper) is applied to the room-facing surface of the thermally conductive layer and may be wrapped around the side of the panel and at least a portion of the framing-facing side of the panel. Paper is preferred because it is the same outer layer that is provided on standard plaster/gypsum sheetrock panels, but the present invention is not limited to any particular surface coating. In some embodiments, any of the above noted as suitable for the protective barrier layer 17, including embodiments in which the room-facing surface coating and the framing-facing protective barrier layer are the same materials, and embodiments in which the materials are different. Other surface coatings comprising a material of or all materials may be provided. A plurality of holes 18 for securing the panel to the framing may be provided passing through from the room-facing surface of the panel to the framing-facing surface of the panel.

As depicted in FIG. 2 , the panel may include a plurality of heating zones defined by layered heating elements, depending on the size of the panel. As depicted in Figure 2, the panel has two zones (each surrounded by an insulated perimeter region 20 having a width P between the lateral edges of the panel and the lateral edges of the layered heating element). 12A and 12B). The insulated perimeter region 20 may include, for example, a woven glass fiber E (electrical) grade, such as a 200 gsm plain weave construction, although the present invention is not limited to any particular materials. Each heating zone may have a thermal protection cutout switch 22 bonded to the heater in a central location. In an exemplary embodiment, the cutout switch may be set to cut off power to the tiered heating element whenever the detected heat exceeds a maximum of 80°C. However, the present invention is not limited to any particular cutout maximum.

A power input cord 24 is connected to the busbars 25 of the tiered heating units. An electrical connection enclosure 26 as depicted in more detail in FIGS. 5A and 5B surrounds the connection locations and includes cutouts in the insulating core layer. In one embodiment, the enclosure may include an electrical cover 56 of plastic (eg, a nylon/PVC blend), which is hollow on the inside (eg, the cover defines a top and sidewalls). ), and attached to the panel by two set screws 57 into corresponding nut plate inserts 58, so that when fastened the cover is flush with the planar surface of the framing-facing surface of the panel. The nut plate inserts may be bonded to the heater with, for example, hot glue. The electrical connection enclosure is not visible from the room-facing surface of the panel. In the embodiment depicted in FIGS. 5A and 5B , the thermally conductive layer is not in the form of a tray with sidewalls, but in a tray with sidewalls embodiment, the sidewalls typically define the outer edge of the enclosure and thus a more continuous forming a peripheral edge, at which continuous peripheral edge the cover is not visible from the periphery of the panel.

In an exemplary control scheme, controller 50 is connected to power cord 24, which may include ground/ground connections 54 (eg, to a thermally conductive layer), and and energized connections 52 and 53 respectively connected to the busbars 25 of the heating elements 12A and 12B. Connections may be made by any method known in the art, such as using a conductive adhesive, for example. A tape 59 having electrical insulating properties may cover the connections. The powered connections may ultimately be connected separately to the controller 50, allowing independent control of the zones, or both heating elements may be controllable together. The individual cutout switches are shown connecting to powered connectors 52 and 53, but electrically interposed schematically between the powered connections and the busbars so that the cutout switches will trip due to overheating ( trip), energy is not supplied to the heating element. In other embodiments, the cutout switches can be coupled back to the controller. The controller may be configured to log and/or generate an alarm condition and generate an audible and/or visible alarm when the cutout switch trips. Embodiments may be provided with remote controls, such as an embodiment in which the controller is connected to an in-home wireless communications network and configured to be controlled by application software on a computer, e.g., phone, tablet or other mobile device. there is. Alarms may be provided, for example, as notifications to a connected remote device by a controller.

As depicted, in an exemplary embodiment, the overall thickness (T) of the panels may preferably be 12.5 mm, but the thickness is not limited to any particular size, and ideally, the panels are interlocked so that the heating panels are interconnected. It may be available in any thickness consistent with the corresponding thickness of standard sheetrock or plaster panels that can be mixed. Similarly, the panels are of any length and width, in particular, for example, in at least one embodiment, a length (L) of 1200 mm and a width (W) of 600 mm, a full size piece of plasterboard or sheetrock. Instead, it may have lengths and widths configured to be inserted. In one embodiment of 1200 x 600 x 12.5 mm, the insulated peripheral area may have a width P of 25 mm.

An embodiment may include properties suitable for use as a similar panel of plasterboard or sheetrock, although embodiments are not limited to these constructions. For example, ceiling panels suitable for installation alongside standard drop ceiling tiles may also be formed having some or all of the layers as shown and described. In a ceiling tile embodiment, the room-facing layer of tile may include a material other than paper and/or may have a texture to match non-radiating ceiling tiles, which non-radiating ceiling tiles. Within the tiles, textures can be mixed with each other to form a cohesive ceiling panel system.

Exemplary layered heating elements referred to herein may be of the type described in PCT Publication Application No. WO 2016/113633 ("'633 WO publication), incorporated herein by reference in its entirety, which is incorporated herein by reference in its entirety. As described therein, the heating element may be a non-woven, wet material of individual non-entangled fibers including, for example, conductive fibers, non-conductive fibers (eg, glass fibers), or a combination thereof. - comprising external reinforcing or insulating layers on one or both sides of a resistive heater sheet layer comprising conductive fibers, such as carbon fibers, randomly oriented in a wet-laid layer (but not (but not limited thereto) may comprise a plurality of layers. In preferred embodiments, the fibers have an average length of less than 12 mm, and the fiber layer has no conductive particles. A typical density of such a layer is 8 grams/square meter to 60 grams/square meter, more preferably 15 grams/square meter to 35 grams/square meter.The heater layer is preferably (according to predetermined industry standards for uniformity) Has a uniform electrical resistance in any direction.The fiber layer may further comprise one or more binder polymers and/or flame retardant materials. Each of the conductive fibers and/or non-conductive fibers has a thickness ranging from 6 mm to 12 mm. length. One or more of the plurality of conductive fibers may include non-metallic fibers with a metallic coating. The fiber layer may consist essentially of individual unentangled fibers, and in particular in a fiber matrix However, the composition of layer 240 is not limited to any particular configuration, functional properties, or density.

The fibrous layer, or heating element, as a whole, may also include a plurality of perforations that increase the electrical resistance of the fibrous layer compared to a similar layer without such perforations. The fiber layer also contains at least two conductive strips (preferably copper) as busbars. Electrical wires connected to the busbars enable voltage to be applied to the heater.

Exemplary installations are depicted in FIGS. 3 and 4 . 3 depicts an exemplary insulated ceiling structure 30, in which the ceiling abuts the floor 32 of an adjacent story of a building. Floor 32 may include multiple layers such as subfloors and floor coverings (including but not limited to hardwood, carpet, tile, etc.), as well as other functional layers (underlays, leveling, etc., without limitation). Joists 34 (eg, nominal 2x4, 2x6, 2x8 inch construction wood, steel beams, aluminum framing, etc.) support the adjacent floor, and common building panels 37 (eg, sheetrock) as well as the present application. It receives fasteners 35 (eg, drywall screws, nails, etc.) that fasten the heating panels 36 as described in . Insulation 38 fills the cavities defined by joists 34 , floor 32 , and ceiling panels 36 and 37 . This configuration may be particularly useful in structures for multi-story, multi-family homes, where insulation is provided between adjacent layers for acoustic and heat containment insulating properties.

4 depicts another exemplary ceiling structure 40, where insulating layers 42 (eg, 25 mm to 30 mm thick mineral wool) abut heated panels 36, but typical drywall panels. It does not touch (37). In exemplary embodiments, insulating layer 42 may be bonded to a similarly heated panel to further help contain and direct the heat output of the panels.

It should be noted that exemplary ceiling structures are described herein as examples only and that the present invention is not limited to any particular structure. Although not shown, ceiling panels are also ideal for use in suspended ceiling designs, such as those common in commercial environments, in which case the panels may be secured to thin profile steel beams. In the embodiments depicted in Figures 3 and 4, application of spackling and seaming tape across seams and seams visible or fastener divots, as is well known in the art. Additional finishing, such as additional processing to create a ceiling with an all-planar construction without fastener divots, may be performed as described above. Accordingly, the panel (and thus the corresponding thermally conductive layer) is formed in a plane mid-plane at the thickest part of the panel with a slightly beveled perimeter that is angled from the middle zone to the edges of the panel, which may have a slightly smaller thickness than the middle zone. It can be molded to have a zone. This slight beveling is done with seaming tape and spackling to cover the seams (within standard tolerances from planar, as well understood by those skilled in the art of drywall finishing) and create a substantially planar ceiling. Acceptance can help. This substantially flat ceiling includes a continuous coverable ceiling layer (suitable for painting or applying additional covering without visible seams between building panels (eg, including heating panels and general building panels)). do.

Besides the excellent thermal performance of the plasterboard-like radiant heating panels, another advantage is the plug-and-play simplicity that allows the heating panels to be connected very easily to existing or new power cables in the ceiling. includes

Although the invention has been illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Significantly, various modifications may be made in the details without departing from the invention and within the scope and scope of equivalency of the claims.

Claims (21)

A heating panel having a framing-facing surface and a room-facing surface, the heating panel comprising:
a thermally conductive layer having a room-facing side and a framing-facing side;
at least one layered heating element disposed on the framing-facing side of the thermally conductive layer;
an insulating layer disposed over the at least one layered heating element;
a room-facing surface layer disposed on at least a room-facing side of the thermally conductive layer; and
A power cord connected to the layered heating element and configured to be connected to a power source.
heating panel. According to claim 1,
a protective framing-facing surface layer disposed over the insulating layer and defining at least a portion of the framing-facing surface of the panel;
heating panel. According to claim 2,
wherein the framing-facing protective surface layer comprises a gypsum-reinforced polyester mesh layer bonded to the insulating layer.
heating panel. According to any one of claims 1 to 3,
The insulating layer comprises a foam,
heating panel. According to any one of claims 1 to 4,
wherein the room-facing surface layer comprises paper;
heating panel. According to any one of claims 1 to 5,
wherein the thermally conductive layer comprises a tray having peripheral sidewalls;
heating panel. According to claim 6,
the room-facing surface layer surrounds the sidewalls of the thermally conductive layer and defines at least a portion of the framing-facing surface of the panel;
heating panel. According to any one of claims 1 to 7,
Further comprising a power cutout switch configured to cutout power to the layered heating element upon detecting a temperature at the heating panel greater than a predetermined maximum.
heating panel. According to claim 8,
The predetermined maximum is 80 ℃,
heating panel. According to any one of claims 1 to 9,
and a plurality of holes extending from the room-facing surface of the panel to the framing-facing surface of the panel, the plurality of holes sized to receive fasteners for fastening the panel to the framing of the building. is determined,
heating panel. According to any one of claims 1 to 10,
an insulated region extending between the periphery of the panel and the at least one heating element;
heating panel. According to any one of claims 1 to 11,
Comprising two heating elements,
heating panel. According to claim 12,
further comprising an insulated region extending between the two heating elements;
heating panel. According to any one of claims 1 to 13,
further comprising an electrical enclosure cutout defined in the insulating layer, wherein the power cord is connected to busbars of the layered heating element within the enclosure, and wherein the enclosure faces the framing of the panel Including a cover that is flush with the surface,
heating panel. According to any one of claims 1 to 14,
The thermally conductive layer comprises a metal,
heating panel. As a heating system,
The heating system comprises the heating panel of any one of claims 1 to 15, wherein the power cord is connected to a controller for regulating power to the heating panel.
heating system. According to claim 16,
The controller includes a thermostat,
heating system. According to claim 16 or 17,
a plurality of heating panels or a plurality of heating zones in one or more of the panels, wherein one or more of the heating panels or heating zones are independently controllable by the controller;
heating system. A method for heating a room, said method comprising:
Installing at least one heating panel of any one of claims 1 to 15 on a ceiling of a room and providing power to said at least one heating element to generate heat radiating to said room. doing,
How to heat a room. According to claim 19,
connecting a plurality of heating panels to a thermostat controller mounted in the room, and controlling heat in the room to achieve a set temperature of the room.
How to heat a room. According to claim 19,
The ceiling includes at least one heating panel and at least one non-heating panel, and installing the at least one ceiling panel includes the at least one heating panel and the at least one heating panel to form a continuous coverable ceiling layer. comprising applying a plaster material between one unheated panel;
How to heat a room.

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