US20240218611A1

US20240218611A1 - Heatable modular unit for use in pathways

Info

Publication number: US20240218611A1
Application number: US18/401,565
Authority: US
Inventors: Kamran BAKHTI SOROUSH
Original assignee: Individual
Current assignee: Individual
Priority date: 2023-01-04
Filing date: 2023-12-31
Publication date: 2024-07-04

Abstract

The present invention is a heatable pathway system comprising a prefabricated pathway block made by an insulator material. A plurality of open channels built inside the block forming a plurality of exposed surfaces on the top layer of the block and a plurality unexposed surfaces on the bottom of the open channels, wherein a set of heating elements are placed on the unexposed surfaces of the open channel, and the plurality of the open channels are filled by a thermally conductive material and disposed directly above the heating elements to allow for quick conduction of heat from a heating source through the top in order to permit quick melting of snow and ice.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority of U.S. Provisional Patent Application Ser. No. 63/437,075 entitled “HEATABLE MODULAR UNIT FOR USE IN PATHWAYS” filed Jan. 4, 2023 and naming Kamran BAKHTI SOROUSH as inventor. The contents of the above-referenced application are incorporated herein by reference into this disclosure.

FIELD OF THE INVENTION

The present invention relates in general to pre-fabricated pathway systems, and in specific to a pre-fabricated pathway block having a heating wire or heating pipe to efficiently transmit certain areas of upper portion of a pathway block without losing heat radiated from the heating wire/pipe to the either ground or to adjacent conductive compartment for melting snow and ice in walkways and driveways for vehicles and pedestrians.

BACKGROUND OF THE INVENTION

Snow accumulation in pathways is a challenge in winter time in cold climates. Driveways, walkways, parking lots and/or other areas where access and use can be impaired by snowfall or freezing water is an issue in cold climates. In areas where there is a lot of snow, the snow on the roads and passages should be removed during the snowfall period in winter to ensure transportation and maintain the living environment.
During winter, traditional pavement blocks can become slippery when covered in snow or ice, posing a hazard of injury. To ensure pedestrian safety, salt can be applied to dissolve the ice, or heating wires can be installed beneath the pavement to eliminate snow and frost. However, when heating wires are positioned under conventional pavement blocks, the heat generated may not be under control to heat up the pathway efficiently and causes waste of energy.
Construction operation for existing methods for melting snow and ice is time consuming and costly. Existing methods need heavy maintenance care and in case of failure whole system needs to be redone. Many utility providers and governments require electricity to be distributed from generators to consumers. Using above ground wires mounted on poles may lead to weather related outages and are unreliable.
Other existing method pours a thick layer of rock salt or calcium chloride. Concrete slabs powered by electric heating wires easily crack by thermal fluctuation and create puddles over time. These methods are not energy efficient systems. The use of various chemicals to address wintery conditions lead to pollution. All these methods need heavy maintenance and leave huge carbon footprint impact which are not nature friendly.
U.S. Pat. No. 7,578,102, entitled Electric Tile Modules, discloses an electrically connectable tile module that includes a porous substrate having a top side, a bottom side, and at least two side edges. At least one connector is integrated into the porous substrate allowing adjoining electrically connectable tile modules to be electrically connected to the porous substrate. At least one electrical element is disposed over the top side of the porous substrate and electrically connected to the at least one connector. Thermo-voltaic elements and photovoltaic elements are housed within the disclosed tile module for generating electricity from heat and light, respectively. There is no teaching of a system to serve two roles simultaneously as an insulator and conductive system which efficiently distributes the electrical power.
U.S. patent Ser. No. 10/968,572 entitled Frost resistant surface, discloses methods, systems and devices for making a pedestrian, vehicular, or other surface resistant to frost, snow and ice by use of heat. A composite base or deck element includes a recess to accommodate heating element. A thermal insulator has an upward facing layer of heat-conductive aluminum foil, above the heating element. On top is a pedestrian, vehicular, or other exposed surface, for example a tactile warning surface. There is no teaching of efficiently distributing the electrical power to the various electrical elements.
U.S. patent Ser. No. 11/505,899 entitled Anti-icing surface with polymeric support discloses a cassette for connection to a substrate. The cassette includes a panel having a top, an underside, and a plurality of edges. The top of the panel configured as a walking surface. The cassette further includes a heating system secured in thermal contact with the underside of the panel. Additionally, the cassette includes a polymeric support system fastened to at least one edge of the panel and configured to support the panel and provide the panel at least one of thermal insulation or galvanic insulation from the substrate. However, this application further lacks of reducing the energy needed for warming the surface.
Therefore, there is a need for heatable modules, such as modular blocks, modular tiles and the like, for constructing pathways, such as pedestrian walkways and vehicular driveways that are energy efficient, easy to install and cost effective to install.

SUMMARY OF THE INVENTION

The present invention discloses a heatable pathway system comprising a plurality of heatable units. The heatable units are compressed complex cube shape blocks made by synthetic rubber forming an insulator block. In one embodiment each block is a heavy duty prefabricated block having a rectangular shape. The blocks have a length and a width of about 4-6 feet and a thickness of 3.5 inches (versus 8 inches traditional slab). Due to the lower mass (volume) and lower conductive surface area, the blocks are suitable for the intended application which is cheaper and faster to construct and operate to preserve heat inside.
In one embodiment, each cube shaped block has a “W” shaped pre-fabricated channel constructed inside the block. The “W” shape channel is configured to receive the heating wire and other heating sources, such as heating pipe to pass hot liquid, to provide heat. The electrically powered heating wire and source is disposed within the channels. The channels are filed with conductive material. This makes each block partially insulated and partially conductive, i.e, the rubber part is insulated and channel part that is filled with conductive material is conductive. This multi-functional block may effectively and efficiently transmit heat through the upper portion of the block. The conductive parts transmit the heat to the surface of the block while the insulator part of the block prevents the heat transmission either to the ground or to the channel sections.
The heat conductive material allows for quick conduction and transmit of heat from the heating wire through the top layer in order to permit quick melting of snow and ice, and also allows for even distribution of the heat. Since the heat is trapped inside the channels, as channels are surrounded by rubber insulation, each block can keep heat for an extended time, thereby the whole block consumes less power to heat up in a short time when its needed. The blocks are each installed in place to form the pathway. The blocks may be installed in connected relation one to the next by flexible rubber joints to form a solid stable structure.
The blocks are pre-fabricated blocks, are light and wider than regular comparable paving materials. This allows contractors to install it 5 time faster so that it empower the contractors to work more efficient even in winter time.
By increasing the mass of the conductive part, the block can preserve more heat and be capable of melting snow for longer time. Many energy sources such as wind and sun can be used. Clean sources of energy keep the block warm so that in severe cold condition a smart control panel will decide to allow grid power into system or not. In this case its easy and faster to reach to the desired heat point because the block is already warmed up.
As can be understood from the above description, the present invention provides a heatable pathway system, that uses electrical power efficiently. The heatable blocks used to construct the heatable pathway system readily fit properly in place and are readily lay on any shape of subbase. The heatable blocks are lightweight and easy to manufacture.
In an embodiment the insulator block is made of molded synthetic rubber which is shaped under high pressure and heat in present of Aliphatic or Aromatic binder into desired shape and thickness. Majority parts of the block is made of tire recycling powder which helps cleaning the land fields and lower the pressure on natural resources like rivers and mountains. The conductive part preferably includes a heat conductive—material and a heat retentive polymer material. The heat conductive—material allows for quick conduction of heat from the heating source through the top layer in order to permit quick melting of snow and ice. In the manufacturing of the present invention, it is possible to use the method of compression molding to form the structure.
The key points of the present invention relies on two major facts: Duality insulation act which means that while eliminate thermal bridge, acts as a mold for conductive compartment. Conductive component to keep and/or transfer the heat to the face of block.
Unlike the existing methods the blocks can be repaired or substituted. The blocks are anti acid and mold resistance. It is therefore an object of the present invention to provide a heatable pathway system, such as pedestrian walkways and vehicular driveways that is modular.
It is another object of the present invention to provide a system and method for creating safe path way with a prefabricated blocks suitable for both walkway and drive way having heating wire and/or heating pipes in which an insulator controls the transmission of heat to the ground while control the conductive area on top.
It is another object of the present invention to provide pre-fabricated path way blocks having heating element within the conductive part and on top of the insulator preventing losing heat to the ground.
It is another object of the present invention to provide pre-fabricated path way blocks having heating element to create a safer pathway avoiding serious injuries in accidental falls.
It is another object of the present invention to provide prefabricated path way blocks having heating elements to be installed fast and easily.
It is another object of the present invention to provide prefabricated pathway blocks with heating elements which have low maintenance care characteristic.
It is another object of the present invention to provide a prefabricated pathway with heating element which apply environmental friendly ingredients and low Carbon footprint in production.
It is another object of the present invention to provide a system and method for melting the snow in the pathways with lower energy usage that maximize the lifetime while minimize the operating cost.
It is another object of the present invention to provide a system and method which helps to have a cleaner environment by consuming recycled tires and lower the pressure on natural resources.
It is another object of the present invention to provide heatable pathway system, that use electrical power efficiently.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments herein will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the scope of the claims, wherein like designations denote like elements, and in which:

FIG. 1 is a top plan view of the heatable block of the present invention;

FIG. 2A is a cross-sectional side elevational view of the present invention;

FIG. 2B is a cross-sectional side elevational view of the present invention;

FIG. 3 is a top plan view of another embodiment of the heatable block;

FIG. 4 is a top plan view of the heatable block, showing the block being heated during heating cycle;

FIG. 5 is a photo showing a top view of the block according to the present invention;

FIG. 6 is a photo showing the cover of the conductive compartment according to the present invention;

FIG. 7 , is a photo showing the installed pathway system, according to the present invention, and

FIG. 8 is a photo showing the installation system of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 1 to 5 show the heatable pathway system 100 according to the present invention. The heatable pathway system 100 comprises a plurality of heatable blocks 110. The heatable blocks 110 are used in constructing the heatable pathway system. Each heatable block 110 is a compressed material complex modular block. In one embodiment each block is prefabricated in a rectangular shape compartment having a length and a width of 4 feet and a thickness of 3.5 inches (versus 10 inches traditional slab) suitable for the intended application. However, it should be understood that the heatable block 110 can be of any other suitable shape and size.
The block 110 is made by an insulator material such as synthetic rubber. As shown clearly in FIG. 1 each block 110 has open channels pre-constructed inside the block 110 configured to receive the various parts of the system. Each block 110 can store heat energy, thereby the whole block 110 consumes less power to heat up in a short time.
The block 110 are cheaper to construct and faster to operate because it has lower mass (volume) and lower surface area to be heat up. Plurality of blocks 110 are installed in place to form a pathway. The blocks 110 may be installed in connected relation one to the next by flexible rubber joints to form a solid stable structure. Therefore, the installation and maintenance of the system is easier and faster.
According to FIGS. 1, 2A and 2B again, the block 110 has a novel pre-fabricated construction. Each block is made of two different layers. The bottom layer 120 b of the block is made of a synthetic rubber with lower density than the top layer 120 a. This provides a lower thermal conduction through the bottom layer 120 b of the block 110 and provides a greater tension, traction, and compression strength on the layer to handle passing of vehicles.
A plurality of channels are built inside the block 110 forming an insulator compartment 120 and a conductive compartment 130. In one embodiment, the channels are constructed in a “W” shape. However the channels can be in other shapes such as “H” shape as shown in FIG. 3 . The channels make the conductive section of each block. In addition, each compartment 130 may have recessed cable holders 118 on the bottom for accommodating electrical connectors and electrical wires therein.
The electrical wires 140 and heating pipes 115 can run from one heatable block 110 to the next. Each block 110 has a top 111 facing the surface in contact with the snow and ice and a bottom 112 facing the ground. The bottom layer 112 comprises of the insulator components while the top layer 111 consists of partially an insulator surface and partially conductive surface.
After the instalment of the blocks 110 and placing the wires 140, the conductive compartment 130 is filled with thermally conductive material. Therefore, each block 110 may have about 50% conductive surface area 116 on top that means the block tends to heat up only 50% of its surface and 50% is insulator part 117. Therefore, the block 110 serves two roles: it acts as both an insulator and a conductive compartment. The heatable block 110 has a high heat capacity material disposed within the conductive compartment 130. The block 110 provides more resistance to heat and cold and prevents of crack.
According to FIGS. 1 and 3 again each exposed surface has a heated width 116, and an insulated width 117. each heated width 116 is less than width of a tire of a vehicle. Vehicles weighing more than 2600 lbs require a minimum width of 8″ for their tires. By having a 6″ width for the conductive compartment 130, they don't have to bear the full load from the tires when the vehicle runs over each part. This allows that a part of the tire to always be on the insulator parts of the block, which are made of heavy duty compressed rubber with excellent shock-absorbent properties. This reduces the load per square inch and allows for a lower structural height for conductive department, resulting in less energy needed for warming the block 110.
Additionally, since the insulator compartments 120 are between the conductive compartments 130 they prevent the transfer of energy to adjacent conductive compartments. This is why there is a separation of 6″ insulated compartments between the 6″ conductive compartments. This design ensures efficient energy consumption and optimal durability.
FIGS. 2A and 2B show the cross section view of the heatable block 110. The lower half of the block 120 b has a lower density insulator, providing it with thermal resistance properties and acting as a cushion for the upper layer. The density of the insulator is higher in the top half of the block 120 a, giving it greater tension, traction, and compression strength. The compartments are divided by flexible rubber joints that allows the whole block to be thermal shock resistance and not to crack easily. It brings the whole block 110 to a point near to a maintenance free material. Each block 110 acts as a heat battery.
In the preferred embodiment the heating source are heating wires 140 (regular or self-regulated) which run through the conductive compartment 130. Heating wires 140 heat up the conductive compartment 130. Conductive compound preserves the generated heat in result of its high thermal capacity and accordingly conducts the excess to the top layer 111 which is either concrete or PGM layer (semi-conductor). On the other hand insulation all around the conductive compartment 130 does not allow heat to be transferred to the ground or sides.
FIGS. 6 to 8 show the installation of the blocks 110. The blocks 110 are installed in place to form the pathway. The blocks 110 are installed in connected relation one to the next by flexible rubber joints to form a solid stable structure. The wires 140 are installed in the recessed cable holders 118 inside the channels and then the channels are covered with reinforcement bares (as shown in FIG. 6 ) and filled with conductive compounds. The conductive compound consists of polymeric sand, beach sand, crumb rubber (mesh14), pea gravel and Poly Gravel Mortar (PGM) or regular concrete. Further, lower thickness of conductive material (lower mass in comparison with existing concrete slabs) uses less energy to reach to desire melting point temperature. Moreover, based on the fact that sand has a large thermal capacity and is able to release it gradually.
The heat conductive material would allow for quick conduction of heat from the heating wires 140 through the top layer 111 in order to permit quick melting of snow and ice, and also would allow for even distribution of the heat. The heat retentive material would allow a portion of the heat from the heating wires 140 to be retained within the heatable block 110 for a period of time after the electrical power to the heating wires 140 is turned off, thereby allowing for a longer cycle time until electrical power needs to be applied again to retain sufficient heat to melt snow and ice.
The system 100 includes sensors and a control panel to sense and control the system. According to FIG. 4 the block 110 comprises a heating sensor 125 to control the electricity current and capable of sensing the heat and sending a signal to the control panel 170 to activate and deactivate the heating source and avoid of wasting of energy. The system may further include a snow sensing sensor 135. In one embodiment the system can be connected to a smart system on the mobile phone or connected to a weather temperature app system.
In one embodiment, according to FIG. 4 again, a combination of active and passive energy sources work together to meet the best efficiency. The heatable block 110 constantly receives energy from solar panel 171 or wind turbine 172 which are clean sources of energy to heat up conductive compartment 130 which acts as heat battery preserving heat inside. The heating wires 140 is connected to electrical power source through a control panel 170.
The electrical power source is operable to provide electrical power to the system 100. When the sensor, which may be a snow sensor 135, senses the snow, the control panel 170 will allow the power grid boosting the system that is already warmed up. Based on above mentioned facts, the efficiency goes up to about %500 in comparison with existing methods. In case heating wires 140 just use active energy, aforesaid sensors need to be neutralised and system can act as a battery to preserve energy and/or to be used for other purposes like transferring heat to inside an envelope by a fan coil system 150.
By increasing the mass of the conductive part, the heatable block 110 will be able to preserve more heat, capable of melting snow for longer time on its own using just active source of energy like wind and sun. This pre-fabricated blocks are light and wider than regular comparable paving materials. This allows contractors to install it 5 time faster so that it empowers the contractors to work more efficient even in winter time.
In instalment to form the heatable pathway 100, the heatable blocks 110 are placed in perimeter-edge to perimeter-edge relation one to the next, and are secured together one to the next. Since the blocks of the present invention are heavy enough, so they will be secured in removable and replaceable relation to the ground and to each other so that the blocks can be easily and quickly removed and replaced.
The present invention is constructed of a sustainable and recyclable material and is unique in method that minimizes carbon footprint and usage of natural resources in manufacturing process. As the block 110 is fabricated in mold, it can be designed in different shape with same principals either for melting snow or saving energy to be used on its own or to be transferred elsewhere. Moreover, the blocks 110 are flexible and design friendly, so they can be used in various topography and various complicated job site conditions.
As can be understood from the above description, the present invention provides a heatable pathway system 100, that uses electrical power efficiently, that is modular, wherein the heatable blocks used to construct the heatable pathway system readily fit properly in place and wherein the included heatable blocks are readily connectable one to the next and wherein the included heatable blocks are lightweight and easy to manufacture. The insulator 120 is made of molded synthetic rubber which is shaped under high pressure and heat in present of Aliphatic or Aromatic binder into desired shape and thickness.
Majority parts of the blocks 110 are made of tire recycling powder which helps cleaning the land fields and lower the pressure on natural resources like rivers and mountains. The conductive part 130 preferably includes a heat conductive polymer material and a heat retentive polymer material. The heat conductive polymer material allows for quick conduction of heat from the heating source through the top layer in order to permit quick melting of snow and ice. In the manufacture of the present invention, it is possible to use the method of compression molding to form the structure. Any parts inside must be stationary and in the proper place.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
With respect to the above description, it is to be realized that the optimum relationships for the parts of the invention in regard to size, shape, form, materials, function and manner of operation, assembly and use are deemed readily apparent and obvious to those skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.

Claims

1. A prefabricated block to build a heated pathway, the block comprising:

a) a bottom layer and a top layer,

i) wherein the bottom layer is made of a first synthetic rubber and the top layer is made of a second synthetic rubber, and

ii) wherein the density of the first layer is lower than the density of the second layer to provide a higher thermal conduction through the top layer and a lower thermal conduction through the bottom layer, and to provide a greater tension, traction, and compression strength on the second layer to withstand passing of vehicles;

b) a plurality of open channels built inside the block forming a plurality of exposed surfaces on the top layer of the block and a plurality of unexposed surfaces on the bottom of the open channels, wherein a set of heating elements are placed on the plurality of unexposed surfaces of the open channel, and the plurality of the open channels to be filled by a thermally conductive material disposed directly above the set of heating elements to allow for quick conduction of heat from the set of heating elements in order to permit quick melting of snow and ice, and allow for even distribution of heat, and

c) wherein each exposed surface has an insulated-block-width, and each channel has a heated-block-width, and wherein the heated-block-width is less than width of a tire of a vehicle.

2. The prefabricated block of claim 1, wherein the block is rectangular.

3. The prefabricated block of claim 2, wherein the block has a length and a width of 4 feet and a thickness of 3.5 inches.

4. The prefabricated block of claim 1, wherein the plurality of open channels are configured to form a W shaped open channels.

5. The prefabricated block of claim 1, wherein the plurality of open channels are configured to form H shaped open channels.

6. The prefabricated block of claim 1, wherein each channel has a width of 6 inches and each exposed surface has a width of 6 inches, thereby, the sum of each insulated-block-width and the heated-block-width is 12 inches to reduce the load per square inch and to cover a width of a tire.

7. The prefabricated block of claim 1, wherein each channel has a set of grooves to receive the set of heating wires and heating pipes and guide the set of heating wires from one block to the next through a set of apertures on side walls of each block.

8. The prefabricated block of claim 1, wherein the conductive material is selected from a group of thermally conductive material consisting of polymeric sand, beach sand, crumb rubber, pea gravel and Poly Gravel Mortar (PGM) or regular concrete.

9. The prefabricated block of claim 1, wherein the molded block is formed under high pressure and heat in present of Aliphatic or Aromatic binder into desired shape and thickness.

10. The prefabricated block of claim 1, further comprises a snow sensor.

11. The prefabricated block of claim 1, wherein the block is made of tire recycling powder.

12. The prefabricated block of claim 1, wherein the blocks are anti acid and mold resistance.

13. A method for making a heatable pathway system comprising:

a) making a plurality of prefabricated synthetic rubber blocks, wherein each block comprising:

i) a bottom layer and a top layer,

ii) wherein the bottom layer is made of a first synthetic rubber and the top layer is made of a second synthetic rubber, and

iii) wherein the density of the first layer is lower than the density of the second layer to provide a lower thermal conduction through the bottom layer, and to provide a greater tension, traction, and compression strength on the second layer to handle passing of vehicles;

iv) a plurality of open channels built inside the block forming a plurality of exposed surfaces on the top surface of the block and a plurality unexposed surfaces on the bottom of the open channels;

b) placing the plurality of prefabricated synthetic rubber blocks on a pathway in removable, replaceable and connected relation one to the next to form the heatable pathway;

c) placing a heating wire inside the channels of each block and passing the wire in a connected relation through the plurality of prefabricated synthetic rubber blocks,

d) connecting the heating wire to a smart control panel and then to a power supply to provide power to and heat the heating wires;

filling the open channels with a thermally conductive material disposed directly above the heating wire to allow for quick conduction of heat in order to permit quick melting of snow and ice, and allow for even distribution of heat, and whereby when the heating wire is heated, heat is conducted through the thermally conductive material to the top surface of the pathway.

14. The method of claim 13, wherein the plurality of prefabricated synthetic rubber blocks are connected one to the next by flexible rubber joints which allow the heatable pathway system to be thermal shock resistance and not to crack easily.

15. The method of claim 13, wherein the heating wire is connected to a power supply, and wherein the power supply is a combination of active and passive energy sources that work together to provide efficient and/or a clean energy source comprising solar panel or wind turbine.