WO2017187121A1 - Underfloor heating - Google Patents

Underfloor heating Download PDF

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Publication number
WO2017187121A1
WO2017187121A1 PCT/GB2017/050626 GB2017050626W WO2017187121A1 WO 2017187121 A1 WO2017187121 A1 WO 2017187121A1 GB 2017050626 W GB2017050626 W GB 2017050626W WO 2017187121 A1 WO2017187121 A1 WO 2017187121A1
Authority
WO
WIPO (PCT)
Prior art keywords
panel
layer
conductors
modular
heating element
Prior art date
Application number
PCT/GB2017/050626
Other languages
French (fr)
Original Assignee
Jet Blue Limited
Beattie, Alex
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jet Blue Limited, Beattie, Alex filed Critical Jet Blue Limited
Priority to CN201790000096.9U priority Critical patent/CN208075075U/en
Publication of WO2017187121A1 publication Critical patent/WO2017187121A1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24D—DOMESTIC- OR SPACE-HEATING SYSTEMS, e.g. CENTRAL HEATING SYSTEMS; DOMESTIC HOT-WATER SUPPLY SYSTEMS; ELEMENTS OR COMPONENTS THEREFOR
    • F24D13/00—Electric heating systems
    • F24D13/02—Electric heating systems solely using resistance heating, e.g. underfloor heating
    • F24D13/022—Electric heating systems solely using resistance heating, e.g. underfloor heating resistances incorporated in construction elements
    • F24D13/024—Electric heating systems solely using resistance heating, e.g. underfloor heating resistances incorporated in construction elements in walls, floors, ceilings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24D—DOMESTIC- OR SPACE-HEATING SYSTEMS, e.g. CENTRAL HEATING SYSTEMS; DOMESTIC HOT-WATER SUPPLY SYSTEMS; ELEMENTS OR COMPONENTS THEREFOR
    • F24D13/00—Electric heating systems
    • F24D13/02—Electric heating systems solely using resistance heating, e.g. underfloor heating
    • F24D13/022—Electric heating systems solely using resistance heating, e.g. underfloor heating resistances incorporated in construction elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/32—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
    • E04C2/322—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with parallel corrugations
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
    • E04C2/521—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling
    • E04C2/525—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits serving for locating conduits; for ventilating, heating or cooling for heating or cooling
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • H05B3/26—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2203/00—Specially structured or shaped covering, lining or flooring elements not otherwise provided for
    • E04F2203/02—Specially structured or shaped covering, lining or flooring elements not otherwise provided for having particular shapes, other than square or rectangular, e.g. triangular, hexagonal, circular, irregular
    • E04F2203/023—Specially structured or shaped covering, lining or flooring elements not otherwise provided for having particular shapes, other than square or rectangular, e.g. triangular, hexagonal, circular, irregular having triangular shapes
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/014—Heaters using resistive wires or cables not provided for in H05B3/54
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/016—Heaters using particular connecting means
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/026—Heaters specially adapted for floor heating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B30/00—Energy efficient heating, ventilation or air conditioning [HVAC]

Definitions

  • This invention relates to heated panels for flooring or walls, in particular to modular heated panels.
  • Typical systems comprise either electric or water based heating systems, which are installed under a floor or behind a wall and typically require an insulating layer.
  • Electric systems may comprise either single heating elements, which are arranged under flooring panels by the user, or pre-formed mats comprising multiple heating elements, which are simply put down before the panels are fitted.
  • Water based systems may comprise a network of pipes linked to a boiler and use a flow of heated water to transfer heat to the room.
  • Both electric and water based systems require that an insulating layer is put down before the electric or water heating elements are installed, and both systems need to be installed before the panels are put down and require space underneath the panels to be installed.
  • nano-carbon filament layers are known in the art.
  • the disadvantage of such layers is that over time, the integrity of the filament becomes worn out and burn marks can become visible on the surface of the panel, where hot spots occur. As well as being visibly unappealing, this can lead to inconsistent delivery of heat to the surface of the panel. It is desirable to have a system for heating flooring and/or wall panels, which is easy to install and does not require a separate insulating layer.
  • the present invention aims to address at least some of these problems.
  • one aspect of the present invention provides a modular heated panel for use in providing heating for a building, the panel having an upper layer, first and second middle layers and a lower layer; wherein: the upper layer comprises a first material; the first middle layer comprises a second material having one or more grooves or channels formed therein, a heating element being received within the grooves or channels; the second middle layer comprises a third material which is a thermally and/or electrically insulating material, the first middle layer being in between the upper layer and the second middle layer; and the lower layer comprises a fourth material having one or more grooves or channels formed therein, the channels or grooves receiving two power supplying conductors, wherein the conductors are configured such that the conductors are connectable to a power source, the heating element is connected to the power conductors to receive power from the conductors, the conductors are accessible from the exterior of the panel, and the conductors are releasably connectable to the conductors of a second identical flooring unit.
  • Another aspect of the present invention provides a modular heated panel for use in providing heating for a building, the panel having an upper layer, and a lower layer; wherein: the upper layer comprises a first material and the lower layer comprises a second material having one or more grooves or channels formed therein, a heating element and two power supplying conductors being received within the grooves or channels; wherein the conductors are configured such that the conductors are connectable to a power source, the heating element is connected to the power conductors to receive power from the conductors, the conductors are accessible from the exterior of the panel, and the conductors are releasably connectable to the conductors of a second identical flooring unit.
  • the heating element is a nano-carbon heating element.
  • the heating element comprises at least one composite strand, formed from a number of carbon nanotubes which are twisted together.
  • the number of carbon nanotubes which are twisted together to form the composite strand is between 500 and 1 ,500.
  • the number of carbon nanotubes which are twisted together to form the composite strand is around 1 ,000.
  • the grooves or channels that receive the heating element have a distance of 0.5 cm or greater between them.
  • the grooves or channels that receive the heating element have a distance of 8 cm or less between them.
  • the conductors are integral with at least one layer of the modular heated panel.
  • the heating element is powered through a physical connection with the conductors.
  • the second middle layer has one or more apertures formed therethrough to allow the physical connection between the heating element and the conductors.
  • the heating element is powered through an induction loop.
  • the groove or channel of the first middle layer is less than half the depth of the first middle layer.
  • one or more of the layers have male and female portions configured to join adjacent strips of connected panels together.
  • connectors comprise male and/or female end portions enclosed in a single unit
  • the single unit sited in a recess at the end of the panel and sealed within the recess.
  • the modular heated panel is waterproofed, such that liquid cannot reach the electric components.
  • At least some of the electric components contained within the panel are waterproof.
  • At least one of the first, second, third or fourth materials are wood.
  • At least one of the first, second, third or fourth materials are a ceramic.
  • At least one of the first, second, third or fourth materials are a polymer.
  • the first material is slate.
  • the first material is marble.
  • At least a part of the modular heated panel is made of elm, maple or walnut.
  • the power source is an external power source.
  • at least a part of the power is supplied by a piezoelectric generator.
  • the panel further comprises a pressure sensor, the pressure sensor configured to turn off the heating element if a pressure over a threshold pressure is detected.
  • the panel further comprises a joining element, wherein: the joining arrangement comprises two pairs of connectors on the same side of the joining arrangement, the pairs of connectors configured to receive a first pair of conductors of a first modular heating panel and a second pair of conductors of a second modular heating panel; the joining arrangement configured to conduct power to the second modular heating panel from the conductors of the first modular heating panel, such that only one power source is needed to power the first and second modular heating panels.
  • the joining arrangement comprises two pairs of connectors on the same side of the joining arrangement, the pairs of connectors configured to receive a first pair of conductors of a first modular heating panel and a second pair of conductors of a second modular heating panel; the joining arrangement configured to conduct power to the second modular heating panel from the conductors of the first modular heating panel, such that only one power source is needed to power the first and second modular heating panels.
  • the joining element is sited on a first and/or second side of the modular heated panel and is parallel to the upper layer.
  • the present invention may also relate to a joining arrangement for use with modular heated panels according to any of the above, wherein: the joining arrangement comprises two pairs of connectors on the same side of the joining arrangement, the pairs of connectors configured to receive a first pair of conductors of a first modular heating panel and a second pair of conductors of a second modular heating panel; the joining arrangement configured to conduct power to the second modular heating panel from the conductors of the first modular heating panel, such that only one power source is needed to power the first and second modular heating panels.
  • kits comprising two or more panels according to any of the above, in combination with the above joining arrangement.
  • the present invention may also provide a method of making a modular heated panel, comprising the steps of: providing a first, surface layer, providing a second layer, forming a groove in a second layer, placing a heating element in the groove of the second layer, joining the first layer and the second layer, providing a third insulating layer, joining the third layer to the first and second layer, providing a fourth layer, configured to receive power cables, joining the fourth layer to the first, second and third layers.
  • Fig. 1 is a schematic view of a heating panel according to an embodiment of the present invention.
  • Fig. 2 is a schematic view of panel layer with a heating element according to an embodiment of the present invention.
  • Fig. 3 is a schematic view of a panel layer for receiving a heating element according to an embodiment of the present invention.
  • Fig. 4 is a schematic view of the underside of a heating panel according to an embodiment of the present invention.
  • Fig. 5 is a schematic view of power cable connectors according to an embodiment of the present invention.
  • Fig. 6 is a schematic view of a room with heating panels and joining sections according to an embodiment of the present invention.
  • Fig. 7 is a schematic view of a room with heating panels and joining sections according to another embodiment of the present invention.
  • Fig. 8 is a schematic view a heating panel according to another embodiment of the present invention.
  • Fig. 9 is a schematic view of panel layer with a heating element according to an embodiment of the present invention.
  • Fig. 10 is a schematic view of a connector unit according to another embodiment of the present invention.
  • the embodiment shown in Fig. 1 comprises a multi-layered panel, in accordance with the present invention, made up of a first (i.e. uppermost) layer 5, a second layer 1 , a third layer 6 and a fourth (i.e. lowermost) layer 7. All the layers 5, 1 , 6, 7 are preferably substantially the same length and width.
  • the panel is 1210 mm long, 165 mm wide and 18.5 mm deep, although panels may be made to any suitable size.
  • One or more of the layers may have a male portion, such as a protruding rib, running along one side edge 13 of the panel and a corresponding female portion, such as a groove, running along the opposite edge of the panel (not shown). These male and female portions may join two adjacent strips of panels together, and/or help to maintain adjacent strips of panels in relative positions so that the first layers 5 of the panels are at the same level.
  • FIG. 8 Another embodiment shown in Fig. 8 comprises a dual-layered panel, in accordance with the present invention, made up of a first (i.e. uppermost) layer 16, and a second (i.e. lowermost) layer 17.
  • the layers 16, 17 are preferably substantially the same length and width.
  • the panel is 1210 mm long, 165 mm wide and 18.5 mm deep, although panels may be made to any suitable size.
  • One or more of the layers may have a male portion, such as a protruding rib, running along one side edge of the panel and a corresponding female portion, such as a groove, running along the opposite edge of the panel (not shown). These male and female portions may join two adjacent strips of panels together, and/or help to maintain adjacent strips of panels in relative positions so that the first layers 16 of the panels are at the same level.
  • the layers 5, 1 , 6, 7, 16, 17 are closely stacked upon one another and are joined to one another by any suitable joining method, such as by glue.
  • the first layer 5, 16 typically comprises a robust and presentable material such as wood, slate, marble, a ceramic, a polymer or any other material suitable for floor or wall panels. In use, the first layer 5, 16 will comprise the visible surface of the panel. In preferred embodiments, the first layer 5, 16 comprises a high density wood.
  • the second layer 1 comprises a thermally insulating material such as wood, a ceramic or a polymer and holds a heating element, such as a nano-carbon heating element.
  • the second layer 1 is described in greater detail below.
  • the second layer 1 comprises an engineered wood, such as plywood or MDF.
  • the grain of the second layer 1 is at 90° to the first layer 5.
  • the third layer 6 comprises an electrically and/or thermally insulating material such as wood, a ceramic or a polymer.
  • the third layer 6 comprises an engineered wood, such as plywood or MDF.
  • the grain of the third layer 6 is at 90° to the second layer 1 .
  • the fourth layer 7 comprises a material such as wood, a ceramic or a polymer and further comprises at least one channel 8, for receiving a power cable. The fourth layer 7 is described in greater detail below.
  • the fourth layer 7 comprises an engineered wood, such as plywood or MDF.
  • the grain of the fourth layer 7 is at 90° to the third layer 6.
  • the second layer 17 comprises a thermally insulating material such as wood, a ceramic or a polymer and holds a heating element, such as a nano-carbon heating element and a power cable.
  • the second layer 17 is described in greater detail below.
  • the second layer 17 comprises an engineered wood, such as plywood or MDF.
  • the grain of the second layer 17 is at 90° to the frst layer 5.
  • An advantage of having layers wherein the grain of the wood of a layer is at 90° to the layer above is that it reduces the oxyt that the wood can swell or shrink and increases the overall strength of the panel.
  • Fig. 2 shows the second layer 1 of the multi-layered panel in more detail.
  • the second layer 1 comprises a rectangular layer 2 of substantially constant thickness with a first major surface (shown here as the upper surface), and the rectangular layer 2 has one or more grooves 4 in the upper surface of the rectangular layer 2, which are deep enough to receive the nano-carbon heating element 3.
  • the groove 4 runs from a first end of the second layer 1 , along the length of the second layer 1 to a second end of the second layer 1 , travels in a perpendicular direction to the length of the second layer 1 and then returns towards the first end of the second layer 1 .
  • the groove runs up and down the length of the second layer 1 , in order to allow a length of the heating element 3 that is substantially longer than the length of the second layer 1 to be placed in the groove 4.
  • the groove 4 therefore "zig zags" across the upper surface of the second layer 1 . It should be understood that any other suitable arrangement of grooves may be used. In the embodiment shown in Fig.
  • the nano-carbon heating element 3 is in the order of six times the length of the second layer 1 , however other multiples such as two, nine, twelve and twenty times are contemplated. In some embodiments, wider panels will have larger multiples of length of nano-carbon heating element. In other embodiments, the multiple of nano-carbon heating element length is independent of the width of the panel.
  • An advantage of using a nano-carbon heating element is that the panel can distribute the heat in a more controlled manner than a nano-carbon heating layer and prevents hot spots from occurring due to worn out filament layers.
  • the heating element 3 has two free ends. Power can be supplied across the free ends in use, as explained below.
  • Fig. 3 shows a cross sectional view of the second layer 1 of the multi-layer panel, without the heating element 3.
  • the grooves 4 for receiving the heating element 3 are less than half the depth of the second layer 1 .
  • the grooves 4 are significantly less than the depth of the second layer 1 .
  • Fig. 4 shows the fourth layer 7 of the multi-layer panel in more detail.
  • the fourth layer 7 again comprises a rectangular layer 9 of substantially constant thickness, having two channels 10 running along the entire length of the fourth layer 7, extending between openings 8 at either end of the fourth layer 7.
  • the channels 10 are substantially straight and parallel.
  • the channels 10 are open at the underside of the fourth layer 7.
  • the channels 10 are wide enough and deep enough to receive power cables, for powering the heating element 3. The power cables are described in more detail below.
  • Fig. 5 shows the power cables 1 1 of the multi-layer panel in more detail.
  • the power cables 1 1 are positioned in the channels 10 of the fourth layer 7. There is a positive power cable in a first channel 10 and a negative power cable in a second channel 10.
  • the power cables 1 1 are used for delivering power to the heating element 3.
  • At each end of the power cables 1 1 there are connectors 12, used for connecting an end of a power cable 1 1 in the panel to the end of a power cable in a second such panel, such that multiple panels can be linked together and power can be delivered to the heating elements of multiple panels from a single power source, with power flowing through the cables 1 1 and the connectors 12 of the panels.
  • each panel can be attached to its own power source.
  • Fig. 9 shows the shows the second layer 17 of the dual-layer panel in more detail.
  • the second layer 17 comprises a rectangular layer of substantially constant thickness with a first major surface (shown here as the upper surface), and the rectangular layer has one or more heating element grooves in the upper surface of the rectangular layer, which are deep enough to receive the nano-carbon heating element 20. There are further power cable grooves which are deep enough to receive the power cable 18, 19.
  • the heating element groove runs from a first end of the second layer 17, along the length of the second layer 17 to a second end of the second layer 17, travels in a perpendicular direction to the length of the second layer 17 and then returns towards the first end of the second layer 17.
  • the heating element groove runs up and down the length of the second layer 17, in order to allow a length of the heating element 20 that is substantially longer than the length of the second layer 17 to be placed in the heating element groove.
  • the heating element groove therefore "zig zags" across the upper surface of the second layer 17. It should be understood that any other suitable arrangement of heating element grooves may be used. In the embodiment shown in Fig.
  • the nano-carbon heating element 20 is in the order of five times the length of the second layer 17, however other multiples such as two, nine, twelve and twenty times are contemplated. In some embodiments, wider panels will have larger multiples of length of nano-carbon heating element. In other embodiments, the multiple of nano-carbon heating element length is independent of the width of the panel.
  • the second layer 17 further two power cable grooves running along the entire length of the second layer 17, extending between openings at either end of the second layer 17.
  • the power cable grooves are substantially straight and parallel.
  • the power cable grooves are open at the topside of the second layer 17. The power cable grooves are wide enough and deep enough to receive power cables, for powering the heating element 20.
  • the heating element 20 has two free ends.
  • An advantage of having the heating element 20 and the power cables 18, 19 in the same layer is that it allows for thinner panels to be produced.
  • Another advantage of having both the heating element 20 and the power cables 18, 19 in the same layer is that such an arrangement is compatible with any number of overall layers.
  • the panels are typically used as flooring panels or wall panels.
  • Figs. 6 and 7 show the panels placed on the floor of a room.
  • the panels are modular and are connected in strips so that the whole or part of a floor or a wall of a room may be covered in strips of connected panels.
  • a power source or connections to a power source are only needed at one end of each strip, as shown in Fig. 6.
  • joining portions 15 join the ends of the strips of panels together, such that only one power source is needed to power all of the strips of panels, as shown in Fig. 7.
  • the joining portions 15 include connectors and power cables that allow an electrical connection between the power cables of one panel with the power cables of an adjacent, parallel panel.
  • the joining portion 15 may be sited on a first and/or second side of the panel and be parallel to the upper layer.
  • the power cables run an entire length of a strip of panels, the power cables of one panel continually connecting to the power cables of another panel.
  • the power cables are integral with more or one of the layers of the panel and do not form a "sub-layer" under the panels.
  • Fig. 10 shows another connector unit 21 for connecting the power cables 22 of two or more panels.
  • the male and/or female portions at one end of the panel are enclosed in a single unit.
  • the unit may be made, for example, from plastic.
  • the connector unit 21 may be sited in a recess at the end of a panel.
  • the connector unit 21 may be sealed within the recess by, for example, a resin.
  • a connector unit 21 may comprise two male connectors, two female connectors or a male connector and a female connector.
  • a connector unit 21 may comprise a mating face, the mating face comprising a first side of the connector unit 21 and the male and/or female connectors. In use, two mating faces may be placed together causing the male and/or female connectors to meet and electrically engage.
  • each strip of connected panels may terminate in an end connector 13, as shown in Fig. 6.
  • the end connector receives the ends of the power cables 1 1 , so that they are not exposed.
  • the end connector 13 may be of a same standard length as the other panels, or may be half length or a quarter length or any other suitable length so that the flooring panels fit the room in which they are installed. In preferred embodiments, a flooring panel without a heating element is used as an end connector 13.
  • joining portions 13, 15 may join the panels on the wall and the panels on the floor such that only one power supply is needed for a room.
  • the third layer 6 comprises an insulating layer, which separates the heating element 3 from the power cables 1 1 .
  • the insulating layer 3 provides added protection to a user.
  • the insulating layer 3 provides added protection to the user from receiving an electric shock.
  • one layer may be a thermally insulating layer and a second layer may be an electrically insulating layer, in other embodiments one or more layers that are both thermally and electrically insulating may be used.
  • the entire flooring panel may be waterproof, such that liquid cannot reach the electronic components (aside, possibly, from the connectors) and so exposure to, or even immersion in, liquid will not expose a user to the risk of an electric shock.
  • the waterproofing may arise from sealing the separate layers such that liquid cannot move between the layers or by coating and/or treating the panel arrangement as a whole.
  • the electronic components themselves may be waterproof, such that if any liquid that moves through the layers and reaches a live part of the panel, the user is not at risk of an electric shock.
  • Connections must be formed between the power cables 1 1 , 18, 19 and the heating element 3, 20.
  • the heating element 3 is routed down from the second layer 1 , through the third layer 6 and into the fourth layer 7, where it connects to the power cables 1 1 .
  • the heating element 3 is routed down from the second layer 1 into the third layer 6 and the power cables 1 1 are routed up from the fourth layer 7 into the third layer 6.
  • the heating element 3 is connected to the power cables 1 1 in the third layer 6.
  • the power cables 1 1 are routed up from the fourth layer 4, through the third layer 6 and into the second layer 1 , where they connect to the heating element 3.
  • the heating element 3 connects to the power cables 1 1 near an end of the panel.
  • one or more separate wires or other conductors are placed in between the second layer 1 and the fourth layer 7 and link the heating element 3 and the power cables 1 1 .
  • the heating element 3 is powered by an induction loop or another non-contact arrangement.
  • the heating element 20 is sited on the same layer as the power cables 18, 19 and the heating element 20 may connect directly to the power cables 18, 19 through a channel or groove.
  • the heating element 20 connects to the power cables 18, 19 near an end of the panel.
  • the heating element 20 is powered by an induction loop or another non-contact arrangement.
  • the heating element may be powered by an alternating current power source. In other embodiments the heating element may be powered by a direct current power source. In yet more embodiments, a converter may be provided such that an alternating current power source may be converted to a direct current power source, the direct current powering the heating element. A direct current to alternating current converter is also contemplated.
  • the materials that make up the panel are chosen such that they do not substantially expand when the heating element 3, 20 is powered.
  • high density woods such as elm, maple or walnut may be chosen for the first layer 5, 16. This is advantageous as it prevents the first layer 5, 16 from cracking or splitting after repeated heating cycles.
  • the heating elements are described as nano-carbon heating elements.
  • such heating elements are generally formed from carbon nanotubes, which are tubular structures formed from hexagonal arrangements of carbon atoms, with each carbon atom being covalently bonded to three other carbon atoms in the structure.
  • a carbon nanotube effectively takes the form of a tubular sheet of graphene.
  • the electrical properties of carbon nanotubes can either exhibit metallic or semiconducting properties along the tube axis.
  • it is preferred that the nanotubes are formed to have metallic electrical properties along the tube axis.
  • each nano-carbon heating element comprises a number of individual carbon nanotubes which are twisted together to form a composite strand.
  • the carbon nanotubes are electrically in parallel with one another.
  • the power source (as discussed above) will be connected so that current flows along all (or substantially all) of the nanotubes that form a composite strand. It has been found that the use of composite strands of this kind, comprising a number of individual carbon nanotubes which are twisted together, provides heating elements which have desirable properties for flooring panels and the like.
  • the resistance of the composite strands is well-suited to the application, particularly when used with mains electricity, and the heat generated by the composite strands is of a suitable level to provide warmth through one or more layers of wood, slate etc., without excessive heat being experienced by a user.
  • the number of individual nanotubes that are twisted together to form a composite strand is between 500 and 1 ,500. More preferably, the number of individual nanotubes that are twisted together to form a composite strand is between 800 and 1 ,200. Yet more preferably, the number of individual nanotubes that are twisted together to form a composite strand is around 1 ,000, or is 1 ,000.
  • Composite strands of this kind have been found to have particularly advantageous properties with regard to resistance and heating, in the context of flooring panels and the like. When using composite strands of this kind, the surface of a flooring panel has been found to heat to around 22-30°C. It has also been found that composite strands comprising more than 2,000 nanotubes twisted together generates excessive temperatures.
  • the nanotubes that are twisted together to form the composite strand each have a diameter of around 1 nm, although nanotubes having other diameters may also be used.
  • a length of composite strand is provided within a floor panel, where the length of the composite strand (when fully extended) is between 2 and 20 times the length of the floor panel.
  • a 5m length of composite strand may be used to form a long floor panel, having a length of around 1 .2m, and also to form a short floor panel, having a length of around 0.6m.
  • the strand is arranged into four parallel stretches, and in the short floor panel the strand is arranged into nine parallel stretches.
  • the channels that receive the heating element have a distance of between 0.5 cm and 8 cm between them.
  • the advantage of this range of distances is that if the channels are closer together than 0.5 cm then undesirably high temperatures may occur in the panel, potentially leading to discolouration of the surface of the panel. If the channels are further apart than 8 cm, then uneven heating and cold spots may occur. It is recognised that other distances may be appropriate for different situations. For example, in an abnormally cold environment, closer channels may be needed and in an abnormally hot environment, channels that are further apart from each other may be appropriate. If heating elements of a substantially different power rating are used, then different spacing may be appropriate.
  • the power source may be connected to a thermostat unit comprising at least a thermostat and a processor.
  • the power source may be turned on and off by the thermostat unit in order to keep the room or floor surface at a constant temperature.
  • the thermostat unit may be connectable to a remote device, such as a mobile phone or a table, via a network, such as the internet, so that a user can turn the power source on and off remotely via, for example, a computer program or app. This is advantageous as it allows a user to save energy or to pre-warm a room before the user enters the room.
  • the power source for the heated panel is generally mains electricity; however, other power sources are contemplated.
  • piezoelectric power generators which generate power from users walking on the floor, may provide a portion of the power to the heating element.
  • the panels may be connected to a ground source heat pump, an air source heat pump or renewable electricity source such as a solar panel or a wind turbine.
  • a pressure sensor is included in a flooring panel.
  • the pressure sensor may be connected to a logic circuit. If, for example, a heavy piece of furniture is placed on top of the flooring panel, the pressure sensor sends a signal to the logic circuit, which turns off the heating element (e.g. by opening a switch so that power is not supplied to the heating element).
  • the advantage of such an arrangement is that placing furniture on top of a flooring panel may cause it to overheat.
  • the pressure sensor is used to detect the furniture and the heating circuit is switched off, preventing overheating.
  • the heated panel may be mounted on a roof in order to melt, and prevent the build-up of, snow.

Abstract

A modular heated panel for use in providing heating for a building, the panel having an upper layer, first and second middle layers and a lower layer; wherein: the upper layer comprises a first material; the first middle layer comprises a second material having one or more grooves or channels formed therein, a heating element being received within the grooves or channels; the second middle layer comprises a third material which is a thermally and/or electrically insulating material, the first middle layer being in between the upper layer and the second middle layer; and the lower layer comprises a fourth material having one or more grooves or channels formed therein, the channels or grooves receiving two power supplying conductors, wherein the conductors are configured such that the conductors are connectable to a power source, the heating element is connected to the power conductors to receive power from the conductors, the conductors are accessible from the exterior of the panel, and the conductors are releasably connectable to the conductors of a second identical flooring unit.

Description

Title: Underfloor heating Description of Invention
This invention relates to heated panels for flooring or walls, in particular to modular heated panels. Typical systems comprise either electric or water based heating systems, which are installed under a floor or behind a wall and typically require an insulating layer.
Electric systems may comprise either single heating elements, which are arranged under flooring panels by the user, or pre-formed mats comprising multiple heating elements, which are simply put down before the panels are fitted.
Water based systems may comprise a network of pipes linked to a boiler and use a flow of heated water to transfer heat to the room.
Both electric and water based systems require that an insulating layer is put down before the electric or water heating elements are installed, and both systems need to be installed before the panels are put down and require space underneath the panels to be installed.
Further, nano-carbon filament layers are known in the art. The disadvantage of such layers is that over time, the integrity of the filament becomes worn out and burn marks can become visible on the surface of the panel, where hot spots occur. As well as being visibly unappealing, this can lead to inconsistent delivery of heat to the surface of the panel. It is desirable to have a system for heating flooring and/or wall panels, which is easy to install and does not require a separate insulating layer.
The present invention aims to address at least some of these problems.
Accordingly, one aspect of the present invention provides a modular heated panel for use in providing heating for a building, the panel having an upper layer, first and second middle layers and a lower layer; wherein: the upper layer comprises a first material; the first middle layer comprises a second material having one or more grooves or channels formed therein, a heating element being received within the grooves or channels; the second middle layer comprises a third material which is a thermally and/or electrically insulating material, the first middle layer being in between the upper layer and the second middle layer; and the lower layer comprises a fourth material having one or more grooves or channels formed therein, the channels or grooves receiving two power supplying conductors, wherein the conductors are configured such that the conductors are connectable to a power source, the heating element is connected to the power conductors to receive power from the conductors, the conductors are accessible from the exterior of the panel, and the conductors are releasably connectable to the conductors of a second identical flooring unit.
Another aspect of the present invention provides a modular heated panel for use in providing heating for a building, the panel having an upper layer, and a lower layer; wherein: the upper layer comprises a first material and the lower layer comprises a second material having one or more grooves or channels formed therein, a heating element and two power supplying conductors being received within the grooves or channels; wherein the conductors are configured such that the conductors are connectable to a power source, the heating element is connected to the power conductors to receive power from the conductors, the conductors are accessible from the exterior of the panel, and the conductors are releasably connectable to the conductors of a second identical flooring unit.
Preferably, the heating element is a nano-carbon heating element.
Preferably, the heating element comprises at least one composite strand, formed from a number of carbon nanotubes which are twisted together.
Preferably, the number of carbon nanotubes which are twisted together to form the composite strand is between 500 and 1 ,500.
Preferably, the number of carbon nanotubes which are twisted together to form the composite strand is around 1 ,000. Preferably, the grooves or channels that receive the heating element have a distance of 0.5 cm or greater between them.
Preferably, the grooves or channels that receive the heating element have a distance of 8 cm or less between them.
Preferably the conductors are integral with at least one layer of the modular heated panel.
Preferably, the heating element is powered through a physical connection with the conductors.
Preferably, the second middle layer has one or more apertures formed therethrough to allow the physical connection between the heating element and the conductors.
Preferably, the heating element is powered through an induction loop. Preferably, the groove or channel of the first middle layer is less than half the depth of the first middle layer.
Preferably, one or more of the layers have male and female portions configured to join adjacent strips of connected panels together.
Preferably, wherein connectors comprise male and/or female end portions enclosed in a single unit, the single unit sited in a recess at the end of the panel and sealed within the recess.
Preferably, the modular heated panel is waterproofed, such that liquid cannot reach the electric components.
Preferably, at least some of the electric components contained within the panel are waterproof.
Preferably, at least one of the first, second, third or fourth materials are wood.
Preferably, at least one of the first, second, third or fourth materials are a ceramic.
Preferably, at least one of the first, second, third or fourth materials are a polymer. Preferably, the first material is slate. Preferably, the first material is marble.
Preferably, at least a part of the modular heated panel is made of elm, maple or walnut.
Preferably, the power source is an external power source. Preferably, at least a part of the power is supplied by a piezoelectric generator.
Preferably, the panel further comprises a pressure sensor, the pressure sensor configured to turn off the heating element if a pressure over a threshold pressure is detected.
Preferably, the panel further comprises a joining element, wherein: the joining arrangement comprises two pairs of connectors on the same side of the joining arrangement, the pairs of connectors configured to receive a first pair of conductors of a first modular heating panel and a second pair of conductors of a second modular heating panel; the joining arrangement configured to conduct power to the second modular heating panel from the conductors of the first modular heating panel, such that only one power source is needed to power the first and second modular heating panels.
Preferably, the joining element is sited on a first and/or second side of the modular heated panel and is parallel to the upper layer. The present invention may also relate to a joining arrangement for use with modular heated panels according to any of the above, wherein: the joining arrangement comprises two pairs of connectors on the same side of the joining arrangement, the pairs of connectors configured to receive a first pair of conductors of a first modular heating panel and a second pair of conductors of a second modular heating panel; the joining arrangement configured to conduct power to the second modular heating panel from the conductors of the first modular heating panel, such that only one power source is needed to power the first and second modular heating panels. Another aspect of the present invention may relate to a kit comprising two or more panels according to any of the above, in combination with the above joining arrangement. The present invention may also provide a method of making a modular heated panel, comprising the steps of: providing a first, surface layer, providing a second layer, forming a groove in a second layer, placing a heating element in the groove of the second layer, joining the first layer and the second layer, providing a third insulating layer, joining the third layer to the first and second layer, providing a fourth layer, configured to receive power cables, joining the fourth layer to the first, second and third layers. In order that the present invention may be more readily understood, embodiments thereof will now be described, by way of example, with reference to the accompanying drawings, in which:
Fig. 1 is a schematic view of a heating panel according to an embodiment of the present invention.
Fig. 2 is a schematic view of panel layer with a heating element according to an embodiment of the present invention. Fig. 3 is a schematic view of a panel layer for receiving a heating element according to an embodiment of the present invention.
Fig. 4 is a schematic view of the underside of a heating panel according to an embodiment of the present invention.
Fig. 5 is a schematic view of power cable connectors according to an embodiment of the present invention.
Fig. 6 is a schematic view of a room with heating panels and joining sections according to an embodiment of the present invention. Fig. 7 is a schematic view of a room with heating panels and joining sections according to another embodiment of the present invention.
Fig. 8 is a schematic view a heating panel according to another embodiment of the present invention.
Fig. 9 is a schematic view of panel layer with a heating element according to an embodiment of the present invention. Fig. 10 is a schematic view of a connector unit according to another embodiment of the present invention.
The embodiment shown in Fig. 1 comprises a multi-layered panel, in accordance with the present invention, made up of a first (i.e. uppermost) layer 5, a second layer 1 , a third layer 6 and a fourth (i.e. lowermost) layer 7. All the layers 5, 1 , 6, 7 are preferably substantially the same length and width. In one embodiment, the panel is 1210 mm long, 165 mm wide and 18.5 mm deep, although panels may be made to any suitable size. One or more of the layers may have a male portion, such as a protruding rib, running along one side edge 13 of the panel and a corresponding female portion, such as a groove, running along the opposite edge of the panel (not shown). These male and female portions may join two adjacent strips of panels together, and/or help to maintain adjacent strips of panels in relative positions so that the first layers 5 of the panels are at the same level.
Another embodiment shown in Fig. 8 comprises a dual-layered panel, in accordance with the present invention, made up of a first (i.e. uppermost) layer 16, and a second (i.e. lowermost) layer 17. The layers 16, 17 are preferably substantially the same length and width. In one embodiment, the panel is 1210 mm long, 165 mm wide and 18.5 mm deep, although panels may be made to any suitable size. One or more of the layers may have a male portion, such as a protruding rib, running along one side edge of the panel and a corresponding female portion, such as a groove, running along the opposite edge of the panel (not shown). These male and female portions may join two adjacent strips of panels together, and/or help to maintain adjacent strips of panels in relative positions so that the first layers 16 of the panels are at the same level.
In both the multi-layered and the dual-layered panels, the layers 5, 1 , 6, 7, 16, 17 are closely stacked upon one another and are joined to one another by any suitable joining method, such as by glue.
In both the multi-layered and the dual-layered panels, the first layer 5, 16 typically comprises a robust and presentable material such as wood, slate, marble, a ceramic, a polymer or any other material suitable for floor or wall panels. In use, the first layer 5, 16 will comprise the visible surface of the panel. In preferred embodiments, the first layer 5, 16 comprises a high density wood.
In the multi-layered panel, the second layer 1 comprises a thermally insulating material such as wood, a ceramic or a polymer and holds a heating element, such as a nano-carbon heating element. The second layer 1 is described in greater detail below. In preferred embodiments, the second layer 1 comprises an engineered wood, such as plywood or MDF. In some embodiments, wherein the second layer 1 comprises a layer made of wood, the grain of the second layer 1 is at 90° to the first layer 5.
In the multi-layered panel, the third layer 6 comprises an electrically and/or thermally insulating material such as wood, a ceramic or a polymer. In preferred embodiments, the third layer 6 comprises an engineered wood, such as plywood or MDF. In some embodiments, wherein the third layer 6 comprises a layer made of wood, the grain of the third layer 6 is at 90° to the second layer 1 . In the multi-layered panel, the fourth layer 7 comprises a material such as wood, a ceramic or a polymer and further comprises at least one channel 8, for receiving a power cable. The fourth layer 7 is described in greater detail below. In preferred embodiments, the fourth layer 7 comprises an engineered wood, such as plywood or MDF. In some embodiments, wherein the fourth layer 7 comprises a layer made of wood, the grain of the fourth layer 7 is at 90° to the third layer 6.
In the dual-layered panel, the second layer 17 comprises a thermally insulating material such as wood, a ceramic or a polymer and holds a heating element, such as a nano-carbon heating element and a power cable. The second layer 17 is described in greater detail below. In preferred embodiments, the second layer 17 comprises an engineered wood, such as plywood or MDF. In some embodiments, wherein the second layer 17 comprises a layer made of wood, the grain of the second layer 17 is at 90° to the frst layer 5.
An advantage of having layers wherein the grain of the wood of a layer is at 90° to the layer above is that it reduces the amourt that the wood can swell or shrink and increases the overall strength of the panel.
Fig. 2 shows the second layer 1 of the multi-layered panel in more detail. The second layer 1 comprises a rectangular layer 2 of substantially constant thickness with a first major surface (shown here as the upper surface), and the rectangular layer 2 has one or more grooves 4 in the upper surface of the rectangular layer 2, which are deep enough to receive the nano-carbon heating element 3.
In the embodiment shown, the groove 4 runs from a first end of the second layer 1 , along the length of the second layer 1 to a second end of the second layer 1 , travels in a perpendicular direction to the length of the second layer 1 and then returns towards the first end of the second layer 1 . The groove runs up and down the length of the second layer 1 , in order to allow a length of the heating element 3 that is substantially longer than the length of the second layer 1 to be placed in the groove 4. The groove 4 therefore "zig zags" across the upper surface of the second layer 1 . It should be understood that any other suitable arrangement of grooves may be used. In the embodiment shown in Fig. 2, the nano-carbon heating element 3 is in the order of six times the length of the second layer 1 , however other multiples such as two, nine, twelve and twenty times are contemplated. In some embodiments, wider panels will have larger multiples of length of nano-carbon heating element. In other embodiments, the multiple of nano-carbon heating element length is independent of the width of the panel.
An advantage of using a nano-carbon heating element is that the panel can distribute the heat in a more controlled manner than a nano-carbon heating layer and prevents hot spots from occurring due to worn out filament layers.
In the embodiment shown, the heating element 3 has two free ends. Power can be supplied across the free ends in use, as explained below.
Fig. 3 shows a cross sectional view of the second layer 1 of the multi-layer panel, without the heating element 3. In this example, the grooves 4 for receiving the heating element 3 are less than half the depth of the second layer 1 . In preferred embodiments, the grooves 4 are significantly less than the depth of the second layer 1 . Fig. 4 shows the fourth layer 7 of the multi-layer panel in more detail. The fourth layer 7 again comprises a rectangular layer 9 of substantially constant thickness, having two channels 10 running along the entire length of the fourth layer 7, extending between openings 8 at either end of the fourth layer 7. In the embodiment shown, the channels 10 are substantially straight and parallel. In this example, the channels 10 are open at the underside of the fourth layer 7. The channels 10 are wide enough and deep enough to receive power cables, for powering the heating element 3. The power cables are described in more detail below.
Fig. 5 shows the power cables 1 1 of the multi-layer panel in more detail. The power cables 1 1 are positioned in the channels 10 of the fourth layer 7. There is a positive power cable in a first channel 10 and a negative power cable in a second channel 10. The power cables 1 1 are used for delivering power to the heating element 3. At each end of the power cables 1 1 , there are connectors 12, used for connecting an end of a power cable 1 1 in the panel to the end of a power cable in a second such panel, such that multiple panels can be linked together and power can be delivered to the heating elements of multiple panels from a single power source, with power flowing through the cables 1 1 and the connectors 12 of the panels. In other embodiments, each panel can be attached to its own power source.
Fig. 9 shows the shows the second layer 17 of the dual-layer panel in more detail. The second layer 17 comprises a rectangular layer of substantially constant thickness with a first major surface (shown here as the upper surface), and the rectangular layer has one or more heating element grooves in the upper surface of the rectangular layer, which are deep enough to receive the nano-carbon heating element 20. There are further power cable grooves which are deep enough to receive the power cable 18, 19.
In the embodiment shown, the heating element groove runs from a first end of the second layer 17, along the length of the second layer 17 to a second end of the second layer 17, travels in a perpendicular direction to the length of the second layer 17 and then returns towards the first end of the second layer 17. The heating element groove runs up and down the length of the second layer 17, in order to allow a length of the heating element 20 that is substantially longer than the length of the second layer 17 to be placed in the heating element groove. The heating element groove therefore "zig zags" across the upper surface of the second layer 17. It should be understood that any other suitable arrangement of heating element grooves may be used. In the embodiment shown in Fig. 9, the nano-carbon heating element 20 is in the order of five times the length of the second layer 17, however other multiples such as two, nine, twelve and twenty times are contemplated. In some embodiments, wider panels will have larger multiples of length of nano-carbon heating element. In other embodiments, the multiple of nano-carbon heating element length is independent of the width of the panel.
In the embodiment shown, the second layer 17 further two power cable grooves running along the entire length of the second layer 17, extending between openings at either end of the second layer 17. In the embodiment shown, the power cable grooves are substantially straight and parallel. In this example, the power cable grooves are open at the topside of the second layer 17. The power cable grooves are wide enough and deep enough to receive power cables, for powering the heating element 20.
In the embodiment shown, the heating element 20 has two free ends.
An advantage of having the heating element 20 and the power cables 18, 19 in the same layer is that it allows for thinner panels to be produced.
Another advantage of having both the heating element 20 and the power cables 18, 19 in the same layer is that such an arrangement is compatible with any number of overall layers.
In use, the panels are typically used as flooring panels or wall panels. Figs. 6 and 7 show the panels placed on the floor of a room. The panels are modular and are connected in strips so that the whole or part of a floor or a wall of a room may be covered in strips of connected panels. As the power cables 1 1 of the panels connect to one another and the panels are laid in strips, a power source or connections to a power source are only needed at one end of each strip, as shown in Fig. 6. In other embodiments, joining portions 15 join the ends of the strips of panels together, such that only one power source is needed to power all of the strips of panels, as shown in Fig. 7. The joining portions 15 include connectors and power cables that allow an electrical connection between the power cables of one panel with the power cables of an adjacent, parallel panel.
The joining portion 15 may be sited on a first and/or second side of the panel and be parallel to the upper layer. An advantage of such a power arrangement is that no separate power cables need to be laid down in order to power the heating element and that the panels can easily be laid in strips.
In some embodiments, the power cables run an entire length of a strip of panels, the power cables of one panel continually connecting to the power cables of another panel. In other embodiments the power cables are integral with more or one of the layers of the panel and do not form a "sub-layer" under the panels.
Fig. 10 shows another connector unit 21 for connecting the power cables 22 of two or more panels. The male and/or female portions at one end of the panel are enclosed in a single unit. The unit may be made, for example, from plastic. The connector unit 21 may be sited in a recess at the end of a panel. The connector unit 21 may be sealed within the recess by, for example, a resin. A connector unit 21 may comprise two male connectors, two female connectors or a male connector and a female connector. A connector unit 21 may comprise a mating face, the mating face comprising a first side of the connector unit 21 and the male and/or female connectors. In use, two mating faces may be placed together causing the male and/or female connectors to meet and electrically engage. The advantage of such a connector unit 21 is that it proves better water resistance than simply having two connectors exiting a panel. When the panels are installed, each strip of connected panels may terminate in an end connector 13, as shown in Fig. 6. The end connector receives the ends of the power cables 1 1 , so that they are not exposed. The end connector 13 may be of a same standard length as the other panels, or may be half length or a quarter length or any other suitable length so that the flooring panels fit the room in which they are installed. In preferred embodiments, a flooring panel without a heating element is used as an end connector 13. The advantage of such an end connector 13 is that if, for example, an area 14 of the end connector 13 needed to be removed so that the flooring fit a non- regular shaped room, the user would not need to worry about cutting through either a heating element 3 or a power cable 1 1 .
If the panels cover a wall and a floor of a room, joining portions 13, 15 may join the panels on the wall and the panels on the floor such that only one power supply is needed for a room.
In the embodiment comprising the multi-layer panel, the third layer 6 comprises an insulating layer, which separates the heating element 3 from the power cables 1 1 . In the case of a fault with the power cables 1 1 , the insulating layer 3 provides added protection to a user. Likewise, if a user, for example, spills a liquid on the panel, the insulating layer 3 provides added protection to the user from receiving an electric shock. In other embodiments there may be two, three, four or any other number of insulating layers between the heating layer and the power layer. For example, one layer may be a thermally insulating layer and a second layer may be an electrically insulating layer, in other embodiments one or more layers that are both thermally and electrically insulating may be used.
The entire flooring panel may be waterproof, such that liquid cannot reach the electronic components (aside, possibly, from the connectors) and so exposure to, or even immersion in, liquid will not expose a user to the risk of an electric shock. The waterproofing may arise from sealing the separate layers such that liquid cannot move between the layers or by coating and/or treating the panel arrangement as a whole. Alternatively, or in addition, the electronic components themselves may be waterproof, such that if any liquid that moves through the layers and reaches a live part of the panel, the user is not at risk of an electric shock.
Connections must be formed between the power cables 1 1 , 18, 19 and the heating element 3, 20.
In some multi-layer panel embodiments, the heating element 3 is routed down from the second layer 1 , through the third layer 6 and into the fourth layer 7, where it connects to the power cables 1 1 . In other embodiments, the heating element 3 is routed down from the second layer 1 into the third layer 6 and the power cables 1 1 are routed up from the fourth layer 7 into the third layer 6. In this embodiment, the heating element 3 is connected to the power cables 1 1 in the third layer 6. In other embodiments, the power cables 1 1 are routed up from the fourth layer 4, through the third layer 6 and into the second layer 1 , where they connect to the heating element 3. Preferably, the heating element 3 connects to the power cables 1 1 near an end of the panel. In some embodiments, one or more separate wires or other conductors are placed in between the second layer 1 and the fourth layer 7 and link the heating element 3 and the power cables 1 1 . In other embodiments, the heating element 3 is powered by an induction loop or another non-contact arrangement.
In the dual-layer embodiments, the heating element 20 is sited on the same layer as the power cables 18, 19 and the heating element 20 may connect directly to the power cables 18, 19 through a channel or groove. Preferably, the heating element 20 connects to the power cables 18, 19 near an end of the panel. In some embodiments, the heating element 20 is powered by an induction loop or another non-contact arrangement.
In some embodiments the heating element may be powered by an alternating current power source. In other embodiments the heating element may be powered by a direct current power source. In yet more embodiments, a converter may be provided such that an alternating current power source may be converted to a direct current power source, the direct current powering the heating element. A direct current to alternating current converter is also contemplated.
In preferred embodiments, the materials that make up the panel are chosen such that they do not substantially expand when the heating element 3, 20 is powered. For example, high density woods such as elm, maple or walnut may be chosen for the first layer 5, 16. This is advantageous as it prevents the first layer 5, 16 from cracking or splitting after repeated heating cycles.
In the discussion above, the heating elements are described as nano-carbon heating elements. As the skilled reader will understand, such heating elements are generally formed from carbon nanotubes, which are tubular structures formed from hexagonal arrangements of carbon atoms, with each carbon atom being covalently bonded to three other carbon atoms in the structure. A carbon nanotube effectively takes the form of a tubular sheet of graphene. Depending on the alignment of the atomic structure with respect to the tube axis, the electrical properties of carbon nanotubes can either exhibit metallic or semiconducting properties along the tube axis. In embodiments of the present invention, it is preferred that the nanotubes are formed to have metallic electrical properties along the tube axis.
In preferred embodiments of the present invention, each nano-carbon heating element comprises a number of individual carbon nanotubes which are twisted together to form a composite strand. In such a composite strand, the carbon nanotubes are electrically in parallel with one another. The power source (as discussed above) will be connected so that current flows along all (or substantially all) of the nanotubes that form a composite strand. It has been found that the use of composite strands of this kind, comprising a number of individual carbon nanotubes which are twisted together, provides heating elements which have desirable properties for flooring panels and the like. The resistance of the composite strands is well-suited to the application, particularly when used with mains electricity, and the heat generated by the composite strands is of a suitable level to provide warmth through one or more layers of wood, slate etc., without excessive heat being experienced by a user.
In preferred embodiments, the number of individual nanotubes that are twisted together to form a composite strand is between 500 and 1 ,500. More preferably, the number of individual nanotubes that are twisted together to form a composite strand is between 800 and 1 ,200. Yet more preferably, the number of individual nanotubes that are twisted together to form a composite strand is around 1 ,000, or is 1 ,000. Composite strands of this kind have been found to have particularly advantageous properties with regard to resistance and heating, in the context of flooring panels and the like. When using composite strands of this kind, the surface of a flooring panel has been found to heat to around 22-30°C. It has also been found that composite strands comprising more than 2,000 nanotubes twisted together generates excessive temperatures.
For these purposes it is preferred that the nanotubes that are twisted together to form the composite strand each have a diameter of around 1 nm, although nanotubes having other diameters may also be used.
In some known panels that employ nano-carbon heating elements, the heating elements are provided in a layer or membrane that is provided in a sheet-like form. Such panels have exhibited poor performance, and the use of composite strands of the kind described above confers significant advantages compared to this known approach. As discussed above, in preferred embodiments of the invention, a length of composite strand is provided within a floor panel, where the length of the composite strand (when fully extended) is between 2 and 20 times the length of the floor panel. By way of example, a 5m length of composite strand may be used to form a long floor panel, having a length of around 1 .2m, and also to form a short floor panel, having a length of around 0.6m. In the long floor panel, the strand is arranged into four parallel stretches, and in the short floor panel the strand is arranged into nine parallel stretches. These are given by way of example, however, and the skilled reader will appreciated that many other arrangements are possible.
In preferred embodiments, the channels that receive the heating element have a distance of between 0.5 cm and 8 cm between them. The advantage of this range of distances is that if the channels are closer together than 0.5 cm then undesirably high temperatures may occur in the panel, potentially leading to discolouration of the surface of the panel. If the channels are further apart than 8 cm, then uneven heating and cold spots may occur. It is recognised that other distances may be appropriate for different situations. For example, in an abnormally cold environment, closer channels may be needed and in an abnormally hot environment, channels that are further apart from each other may be appropriate. If heating elements of a substantially different power rating are used, then different spacing may be appropriate.
The power source may be connected to a thermostat unit comprising at least a thermostat and a processor. The power source may be turned on and off by the thermostat unit in order to keep the room or floor surface at a constant temperature. The thermostat unit may be connectable to a remote device, such as a mobile phone or a table, via a network, such as the internet, so that a user can turn the power source on and off remotely via, for example, a computer program or app. This is advantageous as it allows a user to save energy or to pre-warm a room before the user enters the room. The power source for the heated panel is generally mains electricity; however, other power sources are contemplated. For example, if the panels are used as flooring, piezoelectric power generators, which generate power from users walking on the floor, may provide a portion of the power to the heating element. In other embodiments, the panels may be connected to a ground source heat pump, an air source heat pump or renewable electricity source such as a solar panel or a wind turbine.
In some embodiments, a pressure sensor is included in a flooring panel. The pressure sensor may be connected to a logic circuit. If, for example, a heavy piece of furniture is placed on top of the flooring panel, the pressure sensor sends a signal to the logic circuit, which turns off the heating element (e.g. by opening a switch so that power is not supplied to the heating element). The advantage of such an arrangement is that placing furniture on top of a flooring panel may cause it to overheat. The pressure sensor is used to detect the furniture and the heating circuit is switched off, preventing overheating.
In other embodiments, the heated panel may be mounted on a roof in order to melt, and prevent the build-up of, snow.
When used in this specification and claims, the terms "comprises" and "comprising" and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.
The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

Claims

Claims
1 . A modular heated panel for use in providing heating for a building, the panel having an upper layer, first and second middle layers and a lower layer; wherein:
the upper layer comprises a first material;
the first middle layer comprises a second material having one or more grooves or channels formed therein, a heating element being received within the grooves or channels;
the second middle layer comprises a third material which is a thermally and/or electrically insulating material, the first middle layer being in between the upper layer and the second middle layer; and
the lower layer comprises a fourth material having one or more grooves or channels formed therein, the channels or grooves receiving two power supplying conductors, wherein the conductors are configured such that the conductors are connectable to a power source, the heating element is connected to the power conductors to receive power from the conductors, the conductors are accessible from the exterior of the panel, and the conductors are releasably connectable to the conductors of a second identical flooring unit.
2. A modular heated panel for use in providing heating for a building, the panel having an upper layer, and a lower layer; wherein:
the upper layer comprises a first material; and
the lower layer comprises a second material having one or more grooves or channels formed therein, a heating element and two power supplying conductors being received within the grooves or channels;
wherein the conductors are configured such that the conductors are connectable to a power source, the heating element is connected to the power conductors to receive power from the conductors, the conductors are accessible from the exterior of the panel, and the conductors are releasably connectable to the conductors of a second identical flooring unit.
3. The modular heated panel of claims 1 or 2 wherein the heating element is a nano-carbon heating element.
4. The modular heated panel of claim 3, wherein the heating element comprises at least one composite strand, formed from a number of carbon nanotubes which are twisted together.
5. The modular heated panel of claim 4, wherein the number of carbon nanotubes which are twisted together to form the composite strand is between
500 and 1 ,500.
6. The modular heated panel of claim 5, wherein the number of carbon nanotubes which are twisted together to form the composite strand is around 1 ,000.
7. The modular heated panel of any preceding claim, wherein the grooves or channels that receive the heating element have a distance of 0.5 cm or greater between them.
8. The modular heated panel of any preceding claim, wherein the grooves or channels that receive the heating element have a distance of 8 cm or less between them.
9. The modular heated panel of any preceding claim, wherein the conductors are integral with at least one layer of the modular heated panel.
10. The modular heated panel of claims 1 - 9 wherein the heating element is powered through a physical connection with the conductors.
1 1 . The modular heated panel of claim 10 wherein the second middle layer has one or more apertures formed therethrough to allow the physical connection between the heating element and the conductors.
12. The modular heated panel of claims 1 - 9 wherein the heating element is powered through an induction loop.
13. The modular heated panel of claims 1 - 12 wherein the groove or channel of the first middle layer is less than half the depth of the first middle layer.
14. The modular heated panel of claims 1 - 13 wherein one or more of the layers have male and female portions configured to join adjacent strips of connected panels together.
15. The modular heated panel of claims 1 - 14 wherein connectors comprise male and/or female end portions enclosed in a single unit, the single unit sited in a recess at the end of the panel and sealed within the recess.
16. The modular heated panel of claims 1 - 15 wherein the modular heated panel is waterproofed, such that liquid cannot reach the electric components.
17. The modular heated panel of claims 1 - 16 wherein the at least some of the electric components contained within the panel are waterproof.
18. The modular heated panel of any preceding claim, wherein at least one of the first, second, third or fourth materials are wood.
19. The modular heated panel of claims 1 - 17, wherein at least one of the first, second, third or fourth materials are a ceramic.
20. The modular heated panel of claims 1 - 17, wherein at least one of the first, second, third or fourth materials are a polymer.
21 . The modular heated panel of claims 1 - 20, wherein the first material is slate.
22. The modular heated panel of claims 1 - 20, wherein the first material is marble.
23. The modular heated panel of any preceding claim, wherein at least a part of the modular heated panel is made of elm, maple or walnut.
24. The modular heated panel of any preceding claim, wherein the power source is an external power source.
25. The modular heated panel of any preceding claim, wherein the at least a part of the power is supplied by a piezoelectric generator.
26. The modular heated panel of any preceding claim, wherein the panel further comprises a pressure sensor, the pressure sensor configured to turn off the heating element if a pressure over a threshold pressure is detected.
27. The modular heated panel of any preceding claim, wherein the panel further comprises a joining element, wherein:
the joining arrangement comprises two pairs of connectors on the same side of the joining arrangement, the pairs of connectors configured to receive a first pair of conductors of a first modular heating panel and a second pair of conductors of a second modular heating panel;
the joining arrangement configured to conduct power to the second modular heating panel from the conductors of the first modular heating panel, such that only one power source is needed to power the first and second modular heating panels.
28. The modular heated panel of claim 27, wherein the joining element is sited on a first and/or second side of the modular heated panel and is parallel to the upper layer.
29. A joining arrangement for use with modular heated panels according to claims 1 - 26, wherein:
the joining arrangement comprises two pairs of connectors on the same side of the joining arrangement, the pairs of connectors configured to receive a first pair of conductors of a first modular heating panel and a second pair of conductors of a second modular heating panel;
the joining arrangement configured to conduct power to the second modular heating panel from the conductors of the first modular heating panel, such that only one power source is needed to power the first and second modular heating panels.
30. A kit comprising two or more panels according to any one of claims 1 to 26, in combination with a joining arrangement according to claim 29.
31 . A method of making a modular heated panel, comprising the steps of: providing a first, surface layer,
providing a second layer,
forming a groove in a second layer,
placing a heating element in the groove of the second layer,
joining the first layer and the second layer,
providing a third insulating layer,
joining the third layer to the first and second layer,
providing a fourth layer, configured to receive power cables,
joining the fourth layer to the first, second and third layers.
32. A modular heated panel substantially as hereinbefore described with reference to the accompanying drawings.
33. A joining arrangement substantially as hereinbefore described with reference to the accompanying drawings.
34. A kit substantially as herein before described with reference to the accompanying drawings.
35. Any novel feature or combination of features disclosed herein.
PCT/GB2017/050626 2016-04-29 2017-03-08 Underfloor heating WO2017187121A1 (en)

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GB1607605.1A GB2552292A (en) 2016-04-29 2016-04-29 Underfloor heating

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