US20180283711A1

US20180283711A1 - Hydronic Wall Panel

Info

Publication number: US20180283711A1
Application number: US15/472,144
Authority: US
Inventors: David R. Hall; Benjamin Jensen; Seth Myer
Original assignee: Hall Labs LLC
Current assignee: Hall Labs LLC
Priority date: 2017-03-28
Filing date: 2017-03-28
Publication date: 2018-10-04

Abstract

In various example embodiments, a multi-layer wall structure is described, comprising an interior wall layer, a waterproof channel layer comprising adjacent parallel channels running from an upper manifold down to a lower manifold which is fed by and a remote fluid source. The multi-layer wall structure further provides structural support for a building and may be a wall, ceiling, or floor, and wherein the multi-layer wall structure may heat or cool a living space.

Description

BACKGROUND

Field of the Invention

This invention generally relates to buildings and more particularly relates to heating and cooling a building.

Background of the Invention

There are many ways to heat or cool a living space. The current art includes furnaces, boilers, heat pumps, gas-fired space heaters, electric space heaters, wood-burning and pellet stoves, fire places, ductless, and radiant heating. Radiant heating is advantageous because it allows for greater efficiency and zoning, is silent, and doesn't circulate allergens.
Current art radiant heat systems are normally installed in floors, but are also installed in walls and the ceiling. Current art most often uses PEX pipes or another type of pipe. They are placed throughout the floor, wall, or ceiling. Water then circulates through the pipes varying in temperature to either heat or cool the surrounding living area. These systems offer no structural support for the buildings where they are installed. In addition, they represent a small portion of the surface area where they are installed. This can result in uneven heating, especially when objects are placed in front of or over top of the radiant heating/cooling system. For example, couches, bookshelves, and pictures or clocks that are hung on walls will impede the heating or cooling process.
Other known radiant flooring systems are configured such that the pipes are installed and concrete is laid over top of them to comprise the floor of the building or living area. This makes the installation process cumbersome and expensive, and also impedes the heating or cooling process. A radiant heat system is needed that may comprise the floor itself, so that minimal material is placed between the fluid—the source of the heating or cooling—and the living area.
A system is needed that comprises the entire surface area of a wall, ceiling or floor. Such a system will allow for more efficient and consistent heating and cooling. A system that can be easily manufactured with the fluid pathway integrated within the wall, floor, or ceiling panel could potentially simplify the manufacturing process, and reduce the total system cost. A radiant heat system which offers structural support for the building is also needed. Embodiments disclosed herein may improve performance of radiant heat systems.

SUMMARY

This invention has been developed in response to the present state of the art and, in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available systems and methods. Features and advantages of different embodiments of the invention will become more fully apparent from the following description and appended claims, or may be learned by practice of the invention as set forth hereinafter.
Consistent with the foregoing, a structure for heating or cooling a living area that simultaneously provides structural support for the building is disclosed. Rather than have pipes embedded inside the wall structure, the structural material itself is configured with parallel channels running through the panel. These channels allow fluid flow throughout the panel for heating or cooling the space.
The structure includes: A multi-layer wall structure, comprising an interior wall layer; a waterproof channel layer comprising adjacent parallel channels in communication with each other, a structural layer, a channel layer perpendicular to the waterproof channel layer, a thermal insulation layer, an outer layer, and an upper manifold and lower manifold in communication with the adjacent parallel channels and a remote fluid source.
The waterproof channel layer and channel layer perpendicular to the waterproof channel layer may be composed from different materials such as polycarbonate, acrylic, plastic, polypropylene, or non-wood materials. All these materials are waterproof and won't mold, mildew, or deteriorate when water or another hydronic fluid is run through the water proof channel layer. Additionally, the shapes of the channels may vary. The channels are parallel and evenly spaced, but the specific shape may be hexagon, octagon, triangle, quadrilateral, pentagon, heptagon, nonagon, decagon or another shape. The waterproof channel layer and channel layer perpendicular to it are designed such that the perpendicular channels add sheer strength to the structure.
The multi-layer wall structure also adds structural support for the building wherein it is placed. The sheer strength created by the waterproof channel layer and channel layer perpendicular to it, as well as the structural layer provide structural support. The fluid running from either the upper manifold to lower manifold or the lower manifold to the upper manifold is heated or cooled by a central water heating system. When it flows through the waterproof channel layer, the heat radiates into the living area in order to heat or cool the living space. The channel layer perpendicular to the waterproof channel layer and the thermal insulation provide insulation in the multi-layer wall structure. The air inside the channel layer perpendicular to the waterproof channel layer insulates. The thermal insulation layer may be a foam board, rigid foam, aluminum foil, or another insulating material that will reflect the heat inwards toward the living area. Furthermore, the structural layer will also reflect heat into the living area. It will be reflective itself, have a reflective coating, or a reflective film adhesively attached.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through use of the accompanying drawings, in which:

FIG. 1 is an isometric section view of a multi-layer wall structure, according to one example embodiment.

FIG. 1B is an isometric section view of a multi-layer wall structure, according to one example embodiment.

FIG. 2 is an isometric section view of certain sections of the wall structure, according to one example embodiment.

FIG. 3A is a partial wall section of the multi-layer wall structure illustrating how fluid flow through the waterproof channel layer, according to one example embodiment.

FIG. 3B is a partial wall section of the multi-layer wall structure illustrating how fluid flow through the waterproof channel, according to one example embodiment.

FIG. 4 is an isometric view of a room with a section view of a multi-layer wall structure next to it, according to one example embodiment.

FIG. 5 is an isometric view of the wall structure with an extended structural layer, according to one example embodiment.

FIG. 6 is an isometric view of a room with a section view of a multi-layer wall structure utilized as a ceiling structure, according to one example embodiment.

FIG. 7 is a flow diagram showing the wall structure connected to a heating and cooling system, according to one example embodiment.

FIGS. 8A, 8B and 8C are example embodiments of channels of various extruded shapes, according to certain example embodiments.

FIG. 9 is an isometric view of a multi-layer wall structure illustrating how fluid flows thru the channel layers, according to one example embodiment.

FIG. 10A is an isometric view of a multi-layer wall structure illustrating how fluid flows thru the channel layers, according to one example embodiment, according to one example embodiment.

FIG. 10B is an isometric view of a multi-layer wall structure illustrating how fluid flows thru the channel layers in another example embodiment.

FIG. 10C is an isometric view of a multi-layer wall structure illustrating how fluid flows thru the channel layers in an example embodiment.

DETAILED DESCRIPTION OF THE DRAWINGS

The description that follows includes systems, methods, techniques, instruction sequences, and computing machine program products that embody illustrative embodiments of the disclosure. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide an understanding of various embodiments of the inventive subject matter. It will be evident, however, to those skilled in the art, that embodiments of the inventive subject matter may be practiced without these specific details. In general, well-known instruction instances, protocols, structures, and techniques are not necessarily shown in detail.
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, but mean “one or more but not all embodiments” unless expressly specified otherwise. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise.
Furthermore, the described features, advantages, and characteristics of the embodiments may be combined in any suitable manner. One skilled in the relevant art will recognize that the embodiments may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments.
The liquid that flows through the waterproof channel layer may be water or any other hydronic fluid which includes oil.
There are many existing radiant heating systems which use PEX pipe or other similar piping. The multi-layer wall structure is advantageous because it uses the entire surface area of the wall to radiantly heat or cool a living area. This will allow for greater flexibility when individuals living in, renting, or using the living area would like to add furniture, decorations, clocks, paintings, light fixtures, book shelves, cabinets or other furniture to the living area. In pex pipe radiant heating systems, the listed furniture causes a lot of problems because when the pipes only cover a very small portion of the surface area. Using furniture then blocks a greater percentage of the heat or cooling.
The water or other hydronic fluid may be pumped from the bottom manifold to the top manifold or from the top manifold to the bottom manifold. There are advantages with each embodiment. When the water is pumped from the top manifold to the bottom manifold, the flow of water does not have to work against gravity. This will make pumping the water downwards more efficient and save more energy for owners of a building with a multi-layer wall structure. However, it may also be advantageous to pump water or another hydronic fluid from the bottom manifold to the top manifold because individuals in the living area are on the floor, and so the warmest part of that wall would be nearest the people by pumping from bottom manifold to top.
There are various shapes that the channels of the waterproof channels may be shaped into the channels are parallel to one another and evenly spaced and cover the surface area of the wall, ceiling, or floor where they are installed. One special advantage of the waterproof channels when compared to current art radiant heating systems is the issue of a leak. Current art radiant heating systems are extremely costly to install and are most often laid in floors and covered with a layer of concrete. Not only does this inhibit the heating or cooling effects, but makes repair very expensive whenever there is a leak in the pipes. the only option when there is a leak is to remove the concrete and repair the individual pipe that is the source of the problem. In contrast, in the multi-layer wall structure, the channels through which the liquid flows are in communication with one another. That is to say, when there is a leak or a break in one of the channels, the liquid will flow into the channel adjacent to it and not out into the wall (which could cause molding, deterioration) thus small leaks in the multi-layer wall structure do not require reparation. This also makes the multi-layer wall structure less expensive to maintain than current art radiant heating and cooling systems.
The multi-layer wall structure may be used as an exterior wall or interior wall. In either embodiment, the thermal insulating layer is designed to direct the heat into the room that the waterproof channel layer is nearest. The channel layer perpendicular to the waterproof channel layer also contributes to directing the heat towards the intended room. This way, heat does not escape into a room or outdoor area behind the multi-layer wall structure. By using a thermal insulating layer, owners of a multi-layer wall structure can also use zoning, that is they can heat specific rooms that they need to without leaking a lot of heat into surrounding rooms an insulating layer may be a foam board. The foam board is also useful in its ability to dampen sound traveling through rooms. It will help to control noise from traveling from room to room. The channel layer perpendicular to the waterproof channel layer can also provide the insulation necessary to direct the heat into the living area.
The structural layer may also contribute to insulating. In the preferred embodiment, the structural layer is made from a metal that has the natural attribute of being reflective to direct heat into the living area. In another embodiment, the metal sheet layer has a reflective coating so that the desired effect is still achieved. Another embodiment includes a reflective material being placed over the structural layer which has reflective properties and will also direct the heat into the living area.
There are a number of ways to heat fluid in a building. Any current fluid heating system will work with the multi-layer wall structure. The hydronic fluid is pumped from the heating system to the upper or lower manifold. When the hydronic fluid exits the upper or lower manifold it is returned to the central water heating system and reheated or cooled to be circulated through the system again. Depending on the building type wherein the multi-layer wall structure is installed, one central fluid heating and cooling system may be preferred over another.
the multi-layer wall structure layers may be different than the order presented in various embodiments throughout the description contained herein. There are several embodiments that may be preferred depending on whether the multi layer wall structure is used as a ceiling, wall, or floor. The structural layer provides strength in addition to the sheer strength that is generated by the waterproof channel layer being perpendicular to the second channel layer. When the structure is used as a floor, the structural layer will be thicker to increase the maximum load bearing. The multi-layer wall structure as a floor will need to support more weight at any time because of furniture and a varying number of people in the room. The wall and ceiling will not need to bear that load. Additional sheer and loading strength is achieved by structurally or adhesively connecting vertical channel layers with adjacent horizontal channel layers. Many examples of this are shown both in these written specifications and drawings contained herein.
These features and advantages of the embodiments will become more fully apparent from the following description and appended claims, or may be learned by the practice of embodiments as set forth hereinafter.
FIG. 1 is an isometric section view of a multi-layer wall structure. The multi-layer wall structure 110 is shown with an interior wall layer 112 facing the interior space of the area to be heated or cooled. In certain embodiments, a metamaterial 114 is placed between the waterproof channel layer 120. The metamaterial 114 enhances the heat transfer from the waterproof channel layer 120 to the area to be heated or cooled. The vertical channels 118 open into the manifold to allow fluid to flow from the manifold into the channels. In one embodiment, fluid flows from the upper manifold 140 and through the channels 118 down to the lower manifold 142. In another embodiment, the fluid flows from the lower manifold 142 up to the upper manifold 140.
In the embodiment shown in FIG. 1, the structural layer 126 is between a channel layer 124 and a thermal insulation layer 130. In this embodiment, the insulation also insulates the upper and lower manifolds. As shown in this embodiment, the waterproof channel layer 118 is coated with a heat reflective material 122. An outer layer 132 is shown facing the exterior of the building in certain embodiments. In other embodiments, the outer layer 132 is facing another room inside a building. In this case, the wall structure 110 is an interior wall, and the heating or cooling is only required in the room it is facing. This allows each wall structure to serve individual rooms both within the interior space of the building, and where the wall structure is an exterior wall. An advantage of this configuration is that the heating and cooling of each room or area within the building that has a multi-layer wall structure can be controlled separately. This provides more control by allowing occupants of each individual room or space within the building to be able to adjust the temperature settings of the wall structure that serves their own area.
FIG. 1B is an isometric section view of a multi-layer wall structure. The multi-layer wall structure 110 is shown with an interior wall layer 112 facing the interior space of the area to be heated or cooled. In one embodiment, fluid flows from the upper manifold 140 and through the waterproof channel layer 120 down to the lower manifold 142.
In the embodiment shown in FIG. 1B, the structural layer 126 is extended from the bottom of the wall structure 150 up to the top of the wall structure 152. This provides continuous structural support from the bottom of the structure to the top. The channel layer 124 and a thermal insulation layer 130, and outer layer 132 may also be extended from the bottom of the wall structure all the way to the top as shown.
FIG. 2 is an isometric section view of certain sections of the wall structure showing the structural layer 126 in between the waterproof channel layer 120 and perpendicular channel layer 124. In this embodiment, the structural support layer is facing the waterproof channel layer and is coated with heat reflecting material 122.
FIG. 3A is a partial wall section of the multi-layer wall structure illustrating how fluid flow through the waterproof channel layer 120. Horizontal channel 124 is shown directly adjacent to the structural layer 126. These two layers may be adhesively attached to each other, and the structural layer 126 may be adhesively attached to the waterproof channel layer 120. In this example embodiment, fluid 310 flows from the upper manifold 140 down to the lower manifold 142.
FIG. 3B is a partial wall section of the multi-layer wall structure illustrating how fluid flow through the waterproof channel layer 120. Horizontal channel 124 is shown directly adjacent to the structural layer 126. These two layers may be adhesively attached to each other, and the structural layer 126 may be adhesively attached to the waterproof channel layer 120. In this example embodiment, fluid 310 flows from the lower manifold 142 up to the upper manifold 140.
FIG. 4 is an isometric view of a room with a section view of a multi-layer wall structure next to it. Upper manifold 140 and lower manifold 142 are shown, along with outer layer 132. The heat 420 from heated fluid flowing through waterproof channel layer 120 penetrates the interior wall layer 112 and extends into the room 410. In certain embodiments, the interior wall layer 112 allows heat to flow thru the wall material into the room. In an embodiment, the interior further is sound dampening.
FIG. 5 is an isometric view of the wall structure with an extended structural layer. In this embodiment, the structural layer 510 extends beyond the other wall layers. This allows the wall structure to be structurally attached to adjacent structural members such as adjacent walls, floors or ceiling structures. Thermal insulation layer 130, interior wall layer 112, and outer layer 132 are shown, along with channel layer 124. In this embodiment, upper manifold 140 and lower manifold 142 are cylindrical in shape, and may be a pipe that allows fluid flow into the waterproof channel layer 120.
FIG. 6 is an isometric view of a room with a section view of a multi-layer wall structure utilized as a ceiling structure 610. Upper manifold 140 and lower manifold 142 are shown, channel layer 124, along with waterproof channel layer 120. In this embodiment, the ceiling structure 610 provides heating to a room. Wall 605 and floor 602 are shown defining the room space.
FIG. 7 is a flow diagram showing the wall structure connected to a heating and cooling system. Pump 720 pumps fluid from the heating and cooling system 710 via supply piping 726 into the wall structure lower manifold 142. Fluid flow 736 is represented by an arrow, showing the direction of flow entering the wall structure's lower manifold 142. The fluid continues up thru the waterproof channel layer, and to the upper manifold 140. Fluid flow 734 continues into return piping 724 to the heating and cooling system 710.
FIGS. 8A, 8B and 8C are example embodiments of channels of various extruded shapes. FIG. 8A shows square shaped channels 810, FIG. 8B shows triangular shaped channels 820, and FIG. 8C shows honeycomb shaped channels 830.
FIG. 9 is an isometric view of a multi-layer wall structure illustrating how fluid flows thru the channel layers. Fluid 910 enters supply piping 940 into horizontal channel layer 124. The fluid then flows towards openings 914 between the horizontal channel layer and the vertical waterproof channel layer 120, fluid 916 flowing down towards the lower manifold. In this embodiment, the horizontal channel layer is also waterproof, and serves as a pathway for the fluid to flow across the series of vertical waterproof channels. This allows for unique flow patterns to be configured as required. For certain applications it may be advantageous to have the fluid flowing both up the vertical channels and down adjacent vertical channels.
FIG. 10A is an isometric view of a multi-layer wall structure illustrating how fluid flows thru the channel layers, according to one example embodiment. Fluid 1010 enters supply piping 940 into upper horizontal channel layer 1012. The fluid then flows 1014 down to lower horizontal channel layer 1016, then out thru outlet piping 1040. Fluid flow 1020 shows the fluid exiting the wall structure.
FIG. 10B is an isometric view of a multi-layer wall structure illustrating how fluid flows thru the channel layers in another example embodiment. Fluid 1010 enters supply piping 940 into upper horizontal channel layer 1012. In this embodiment, fluid 1030 flows back up to the upper channel layer 1012, then the fluid 1032 flows back down to lower horizontal channel layer 1016, then out thru outlet piping 1040. Fluid flow 1020 shows the fluid exiting the wall structure.
FIG. 10C is an isometric view of a multi-layer wall structure illustrating how fluid flows thru the channel layers in an example embodiment. Fluid 1010 enters supply piping 940 into upper horizontal channel layer 1012. In this embodiment, fluid 1014 flows down to lower horizontal channel layer 1016, then fluid flows 1042 back up to the upper channel layer 1012, fluid 1044 flows back down to lower horizontal channel layer 1016, then fluid flow 1030 returns back up to upper horizontal channel layer 1012, and out thru outlet piping 1040. Fluid flow 1020 shows the fluid exiting the wall structure.
Regarding the structural layer materials, wherein sheet metal is used for the structural layer, fabrication applies to sheets comprising SPCC, SHCC, SECC, SGCC, copper plates, aluminum plate (6061,6063,5052,1020, etc), aluminum extrusion and stainless steel. Various materials with different specifications may be utilized as follows: Steel plate cold-rolled (SPCC). Mainly used for part need painted or electro-plating, thickness usually no more than 3.2 mm; Hot rolled steel (SHCC). T≥3.0 mm, treated with spraying or electro plating as SPCC; Electro or Galvanized steel (SECC/SGCC). SECC includes N and P type; Copper plate. Mainly applied for electricity conducting function, surface treated with chrome or nickel plating, or without any finish; Aluminum plate. Usually treated with chromate, anodize (conductive anodizing or chemical anodizing), may be silver or nickel plated; Aluminum extrusion are with complex structure from side view, its surface can be treated as what aluminum plates do; and stainless steel sheet.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. A multi-layer wall structure, comprising:

an interior wall layer;

a waterproof channel layer comprising adjacent parallel channels in communication with each other;

a structural layer;

one or more channel layers perpendicular to the waterproof channel layer;

a thermal insulation layer;

an outer layer;

an upper manifold in communication with the adjacent parallel channels;

a lower manifold in communication with the adjacent parallel channels;

a remote fluid source; and

wherein the upper manifold, lower manifold waterproof channel layer are in communication with the fluid of the remote fluid source.

2. The structure of claim 1, wherein the waterproof channel layer and the one or more channel layers perpendicular to the waterproof channel layer comprise one or more materials and composites of: polycarbonate; acrylic; plastic; polystyrene; polypropylene; PVC; ABS; fiberglass; resin; crystalline materials; amorphous materials; organic materials; and synthetic materials.

3. The structure of claim 1, wherein the remote fluid source flowing through the waterproof channel layer is a liquid.

4. The structure of claim 3, wherein the liquid flowing through the waterproof channel layer is at a temperature hot enough to radiantly heat a living area.

5. The structure of claim 3, wherein the liquid flowing through the waterproof channel layer is at a temperature cool enough to radiantly cool the living area.

6. The structure of claim 1, wherein the multi-layer wall structure provides structural support for a building wherein it is placed.

7. The structure of claim 1, wherein air is in the channel layer perpendicular to the waterproof channel layer to insulate the living area.

8. The structure of claim 3, wherein the liquid flowing through the waterproof channel layer enters and exits the waterproof channel layer via the upper manifold or lower manifold.

9. The structure of claim 1, wherein the waterproof channel layer is coated with heat reflective material comprising one or more of foil; paint; metamaterials; fabric and metal coatings.

10. The structure of claim 1, wherein the channels within the waterproof channel layer, and the channels within the one or more channel layers are evenly spaced.

11. The structure of claim 4, wherein the channels within the waterproof channel layer channels and the channels within the channel layer comprise extrusions of one or more of the shapes of: hexagon; octagon; triangle; quadrilateral; pentagon; heptagon; nonagon; decagon; shapes that enhance fluid flow; and shapes that facilitate the manufacturing of the channels.

12. The structure of claim 1, wherein the thermal insulation layer comprises one or more materials of a foam board, rigid foam, aluminum foil, and insulating material.

13. The structure of claim 1, wherein the structural layer reflects heat by one or more of the following methods: coated with a reflective material; is reflective itself; has a coating on it that is reflective; and a reflective film adhesively attached.

14. The structure of claim 1, wherein one or more adjacent channels of the waterproof channel layer are in communication with one or more channels of the one or more channel layers, and wherein the one or more channel layers are waterproof.

15. The structure of claim 1, wherein one or more layers of the multi-layer wall structure have sound damping effects.

16. The structure of claim 1, wherein the multi-layer wall structure is an interior wall, exterior wall, floor, or ceiling.

17. The structure of claim 1, wherein one or more layers of the multi-layer wall structure are coated with metamaterials comprising: glass-polymer hybrid materials with one or more properties of capturing heat; reflecting heat; shedding heat from the metamaterial; conducting heat; and transmitting heat.

18. The structure of claim 1, wherein one or more of each layer of the multi-layer wall structure is adhesively attached to another layer.

19. The structure of claim 1, wherein the structural layer comprises one or more materials and composites of: polycarbonate; acrylic; plastic; polystyrene; polypropylene; PVC; ABS; fiberglass; resin; crystalline materials; amorphous materials; organic materials; synthetic materials; steel; stainless steel; copper; aluminum; titanium; alloys and metal.

20. The structure of claim 1, wherein the thermal insulating layer is the channel layer perpendicular to the waterproof channel layer.