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US20080056694A1 - Radiant heater - Google Patents

Radiant heater Download PDF

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Publication number
US20080056694A1
US20080056694A1 US11/582,166 US58216606A US2008056694A1 US 20080056694 A1 US20080056694 A1 US 20080056694A1 US 58216606 A US58216606 A US 58216606A US 2008056694 A1 US2008056694 A1 US 2008056694A1
Authority
US
United States
Prior art keywords
resistive material
contact terminal
heating system
substrate
radiant heating
Prior art date
Legal status (The legal status 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 status listed.)
Abandoned
Application number
US11/582,166
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English (en)
Inventor
Richard Cooper
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Priority to US11/582,166 priority Critical patent/US20080056694A1/en
Priority to PCT/US2007/022102 priority patent/WO2008076167A1/fr
Publication of US20080056694A1 publication Critical patent/US20080056694A1/en
Abandoned legal-status Critical Current

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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
    • 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 heaters and in particular to a method of heating rooms and spaces through radiant heat from floors, walls and ceilings.
  • Some include circulating heated water or air through a piping system installed beneath the surface of the floor ( FIG. 1 ).
  • Others include electrically heated insulated wires that are enmeshed in a material placed in between the floor surface and the sub floor, or in a concrete layer that also serves as the finished floor.
  • a cement board is attached to the sub floor and a finish material such as tile, linoleum or wood are adhered to the cement board. In those systems efficiency is compromised as there is no intimate contact between the source of heat and the surface to be heated.
  • This invention overcomes these shortcomings of the prior art, and provides an improved system for heating surfaces such as floors and walls.
  • This invention meets the need for a more efficient, space saving, cost efficient and energy saving method to heat floors, walls, ceilings and surface areas such as countertops.
  • a resistive film such is applied directly to a backer board by means of spraying, painting or silk screening where the tile or outer surface material is to be applied.
  • the width and thickness of the resistive film is selected to provide the desired power as expressed in watts per square inch or watts per square foot.
  • the material requires a firing process for curing. During the curing process it is necessary to control the process so that the cement backer board is not heated sufficiently to degrade the materials within the backer board.
  • the resistive film is cured by the use of infra-red heat processing equipment.
  • the resistive film can be patterned onto an insulative material substrate such as mica, and the mica interposed between the subfloor and the finish surface material such as tile or linoleum.
  • the mica is installed by the use of an adhesive applied to the backer board and to the finish surface material.
  • the mica can be in the form of pre-cut tiles with the resistive material patterned onto each tile.
  • spaced apart electrodes or bus-bars are applied to apply a voltage across the patterned resistive material.
  • a protective coating such as Teflon® or silicon is then applied over the resistive material to protect it from moisture and to provide an electrically insulative layer.
  • overheating can be prevented by the use of a temperature sensor embedded in or placed atop the floor assembly.
  • the sensor sends a signal to a controller that reduces or cuts power if a maximum temperature is reached or exceeded.
  • FIG. 1 is a cross-sectional view of a prior art radiant heating assembly.
  • FIG. 2 is a top plan view of a preferred embodiment of the invention.
  • FIG. 3 is a cross-sectional view of the embodiment shown in FIG. 1 shown as part of a floor assembly.
  • FIG. 4 is a cross-sectional view of the embodiment shown in FIG. 4 and which also includes a decorative top layer over the heating unit.
  • FIG. 5 is a top plan view of a second embodiment of the invention which uses a different interconnect.
  • FIG. 6 is a top plan view of the embodiment of the invention shown in FIG. 2 in which multiple individual units are shown interconnected.
  • Backer board may be any of a number of materials, but in the preferred embodiment it is formed of a cementous material, and which is designed to underlay tile or other floor finish materials.
  • Hardy Board® One such product is known as Hardy Board®.
  • the patterned resistive film is a graphite impregnated sol-gel material such as that manufactured by either ThermoCeramix, Inc. of Shirley Mass. or Datec Coating Corporation of Milton, Ontario, Canada.
  • the resistive material is applied directly to the backer board through a means of spraying, painting or silk screening onto the surface of the substrate that will support the tile or other outer finish material.
  • Other methods of applying a resistor include the thermal spraying of the resistive material.
  • the resistive material could be a continuous layer covering the entire surface, but is preferably applied in a pattern to reduce the amount of material required to provide the necessary power.
  • thermal spray a material in powder or wire form is fed to a heat source where it is melted into fine droplets.
  • the heat source can be created by combustion of fuel gases, an electric arc, or ionized plasma.
  • the droplets are accelerated with a carrier gas and directed towards a prepared surface. The droplets impact the surface and freeze instantaneously. By traversing the spray apparatus repeatedly over the surface, a coating is built up.
  • the coatings are deposited using resistive metals or electro conductive ceramics.
  • metals which is the case when the substrate is mica
  • the metal is melted in a conventional thermal spray system and subjected to a reactive gas such as oxygen when the metal is in the molten state.
  • the metal forms reaction products such as metal oxides that are incorporated into the deposited coating.
  • the coating will then comprise the free metal starting material together with some proportion of metal oxides that will tend to boost the coating resistivity. In this way, a heater with substantially increase resistivity is formed into a coating.
  • Heater starting materials are typically nickel-chrome alloys, iron-chrome alloys, titanium, titanium oxide or zirconium diboride.
  • the heater coating is typically designed to form a pattern that determines the electrical resistance by balancing a combination of the geometric factors of element path length, element thickness, and element width with material factor of element resistivity.
  • the resistive film is selected to embody a resistance value that provides the necessary power as expressed in watts per square inch or watts per square foot.
  • This sheet resistance value is affected by a combination of material formulation and thickness of the sol-gel as is well-known to those of skill in the art, including the manufacturers of the material.
  • the sol-gel resistive material In most instances after the sol-gel resistive material is applied, it must be cured to a finished state by heating.
  • the parameters of the curing process vary according to the resistive material selected, and the invention is not limited to any particular curing process. Those of skill in the art will appreciate the heating/curing process must be controlled so to adequately heat the uncured resistive material on the surface of the cement backer board and also so as not to affect the composite materials within the underlying backer board.
  • One preferred curing method employs the use of an infra red heater, which is particularly well-suited as it can be readily controlled to heat primarily the resistive film and surface of the backer board without overheating the body of the backer board.
  • spaced apart electrodes or bus-bars are applied to apply a voltage across the resistor.
  • a protective coating 15 such as Teflon® or silicon is then applied over the resistor to protect from moisture and to provide an electrical insulation.
  • the backer board provides an excellent means of connectivity. Affixing fasteners such as threaded screws can be utilized to make safe and secure electrical connections.
  • the backer board serves as an excellent heat and electrical insulator in the invention.
  • mica coated heaters can also be utilized by placing the mica heater between the cement backer board and the outer material 18 such as tile, linoleum or laminate as shown in FIG. 4 , all of which are typically supported on a subfloor 17 .
  • This method requires an additional adhesive layer; one layer 19 adhering the mica to the backer board, and one adhesive layer 20 adhering the top layer 18 to the mica surface.
  • This method is still preferable to the existing products using heated water or wire woven fabrics that take up space and waste energy.
  • individual tiles are assembled into a heating assembly by placing two tiles adjacent each other with their respective electrical contacts 15 and 16 overlapping.
  • the connectors are connected by screw 23 which is driven through the contacts and into the underlying backer board.
  • the contacts could also be connected by adhesives or in any other suitable manner.
  • the resistive layer 52 is a rectilinear layer rather than a pattern as in the first embodiment.
  • the contacts 54 and 56 are in the form of long conductive strips that are placed in contact with the resistive material and held in place by a conductive adhesive. The individual tiles are assembled into a floor by placing the edges adjacent one another and interconnecting the conductive strips 54 and 56 .
  • Heating units receive current from one adjacent heating unit and provide current to another adjacent heating unit by connection of contacts as described above.
  • the heating units are connected to the power source in a parallel arrangement.
  • the advantage of connecting the heating units in parallel is apparent—the failure of a single heating unit will not adversely affect the remaining heating units.
  • the parallel connection of heating units can be achieved in any suitable manner, and various arrangements for doing so are well-understood by those of skill in the art.
  • the key distinction is that the electrical contacts on each heating unit are connected directly to an electrical supply rather than through an adjacent heating unit. This method of connection can also provide additional advantage in that a lower voltage is required to power the heating units.
  • each unit is electrically connected in parallel to a pair of transverse buses.
  • the heating unit includes a number of individual heating units adhered to the surface of an underlying support.
  • a series of alternating power and ground electrical buses ______ extend across the support and connect to supply and ground conductors ______ and ______.
  • Each of the individual heating units is connected in parallel to the electrical buses.
  • the transverse electrical buses are connected to a pair of conductors - - - and - - - , one on each side of the panel.
  • each lateral row of heating units is connected in parallel, preventing a significant loss of heating capacity in the event of a failure of one of the heating units.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Central Heating Systems (AREA)
  • Surface Heating Bodies (AREA)
  • Resistance Heating (AREA)
US11/582,166 2006-08-29 2006-10-16 Radiant heater Abandoned US20080056694A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US11/582,166 US20080056694A1 (en) 2006-08-29 2006-10-16 Radiant heater
PCT/US2007/022102 WO2008076167A1 (fr) 2006-10-16 2007-10-16 Appareil de chauffage par rayonnement amélioré

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US51271706A 2006-08-29 2006-08-29
US11/582,166 US20080056694A1 (en) 2006-08-29 2006-10-16 Radiant heater

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US51271706A Continuation-In-Part 2006-08-29 2006-08-29

Publications (1)

Publication Number Publication Date
US20080056694A1 true US20080056694A1 (en) 2008-03-06

Family

ID=39536604

Family Applications (1)

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US11/582,166 Abandoned US20080056694A1 (en) 2006-08-29 2006-10-16 Radiant heater

Country Status (2)

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US (1) US20080056694A1 (fr)
WO (1) WO2008076167A1 (fr)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090242538A1 (en) * 2008-03-26 2009-10-01 Dennis Porzio Decorative trim heating device
US20090297132A1 (en) * 2008-05-30 2009-12-03 Abbott Richard C Radiant heating using heater coatings
US20100065542A1 (en) * 2008-09-16 2010-03-18 Ashish Dubey Electrical heater with a resistive neutral plane
WO2011055330A1 (fr) * 2009-11-05 2011-05-12 Winstone Wallboards Limited Panneau de chauffage et procede associe
US20110188838A1 (en) * 2008-05-30 2011-08-04 Thermoceramix, Inc. Radiant heating using heater coatings
US20110286724A1 (en) * 2010-05-19 2011-11-24 Travis Goodman Modular Thermal Energy Retention and Transfer System
US20130071716A1 (en) * 2011-09-16 2013-03-21 General Electric Company Thermal management device
CN109084366A (zh) * 2018-08-16 2018-12-25 海南正诚立世科技有限公司 一种基于物联网的室内供暖管理系统
US20200113020A1 (en) * 2018-10-05 2020-04-09 Serendipity Technologies Llc Low power high-efficiency heating element
US20210048198A1 (en) * 2018-02-05 2021-02-18 Ecovolt Ltd A radiant heater and method of manufacture

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2521540A (en) * 1946-09-17 1950-09-05 Max C Richardson Prefabricated panel and warming means therefor
US2889439A (en) * 1955-07-29 1959-06-02 Albert C Nolte Electric heating devices and the like
US3277419A (en) * 1963-11-20 1966-10-04 Du Pont Laminated heating unit
US3564200A (en) * 1969-01-09 1971-02-16 Elektra Systems Inc Electric radiant heating panel
US3657516A (en) * 1969-11-10 1972-04-18 Kansai Hoon Kogyo Kk Flexible panel-type heating unit
US3686472A (en) * 1969-03-06 1972-08-22 Barbara Joan Harris Space heating apparatus
US3697728A (en) * 1968-12-13 1972-10-10 Air Plastic Service Gmbh Heating devices
US3757087A (en) * 1970-09-11 1973-09-04 Smiths Industries Ltd Heating elements
US3767895A (en) * 1971-12-01 1973-10-23 Infra Red Circuits & Controls Portable electric radiant space heating panel
US3973103A (en) * 1975-04-21 1976-08-03 Universal Oil Products Company Wood veneer radiant heating panel
US4071737A (en) * 1974-06-21 1978-01-31 Kennecott Copper Corporation Heating panel
US4384401A (en) * 1979-12-07 1983-05-24 Sierracin Corporation Method for forming a heater element
US4587402A (en) * 1982-06-24 1986-05-06 Matsushita Electric Industrial Co., Ltd. Planar heating unit
US5177341A (en) * 1987-02-25 1993-01-05 Thorn Emi Plc Thick film electrically resistive tracks
US5380988A (en) * 1992-04-29 1995-01-10 Dyer; C. William Heated mat structure for melting ice and snow
US5910267A (en) * 1997-09-24 1999-06-08 Stricker; Jesse C. Infrared heater
US6080974A (en) * 1996-10-01 2000-06-27 All 4 House S.P. Clothes- and linen-warming or dehumidification apparatus
US20020040898A1 (en) * 2000-08-18 2002-04-11 Theodore Von Arx Wound and themoformed element and method of manufacturing same
US6556779B1 (en) * 1998-11-12 2003-04-29 Cadif Srl Pultrusion process to form specially shaped pieces for transforming electric current into diffused heat
US20040190882A1 (en) * 2003-03-28 2004-09-30 Richard Cooper Radiant heater
US20050002659A1 (en) * 2001-10-09 2005-01-06 Stylianos Panaghe Radiant electric heating element
US6963054B2 (en) * 1999-12-17 2005-11-08 Jean-Claude Tourn Device for heating air, fluids and materials, in dry or wet environment, powered with low voltage current or alternating or direct very low safe allowable voltage
US20060051079A1 (en) * 2004-09-09 2006-03-09 Gerhardinger Peter F Method and apparatus for a cloth heater

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US5408069A (en) * 1993-09-28 1995-04-18 Mischel, Jr.; James V. Self-defogging mirror
US6031967A (en) * 1999-02-17 2000-02-29 S. C. Johnson & Son, Inc. Device for dispensing volatile materials

Patent Citations (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2521540A (en) * 1946-09-17 1950-09-05 Max C Richardson Prefabricated panel and warming means therefor
US2889439A (en) * 1955-07-29 1959-06-02 Albert C Nolte Electric heating devices and the like
US3277419A (en) * 1963-11-20 1966-10-04 Du Pont Laminated heating unit
US3697728A (en) * 1968-12-13 1972-10-10 Air Plastic Service Gmbh Heating devices
US3564200A (en) * 1969-01-09 1971-02-16 Elektra Systems Inc Electric radiant heating panel
US3686472A (en) * 1969-03-06 1972-08-22 Barbara Joan Harris Space heating apparatus
US3657516A (en) * 1969-11-10 1972-04-18 Kansai Hoon Kogyo Kk Flexible panel-type heating unit
US3757087A (en) * 1970-09-11 1973-09-04 Smiths Industries Ltd Heating elements
US3767895A (en) * 1971-12-01 1973-10-23 Infra Red Circuits & Controls Portable electric radiant space heating panel
US4071737A (en) * 1974-06-21 1978-01-31 Kennecott Copper Corporation Heating panel
US3973103A (en) * 1975-04-21 1976-08-03 Universal Oil Products Company Wood veneer radiant heating panel
US4384401A (en) * 1979-12-07 1983-05-24 Sierracin Corporation Method for forming a heater element
US4587402A (en) * 1982-06-24 1986-05-06 Matsushita Electric Industrial Co., Ltd. Planar heating unit
US5177341A (en) * 1987-02-25 1993-01-05 Thorn Emi Plc Thick film electrically resistive tracks
US5380988A (en) * 1992-04-29 1995-01-10 Dyer; C. William Heated mat structure for melting ice and snow
US6080974A (en) * 1996-10-01 2000-06-27 All 4 House S.P. Clothes- and linen-warming or dehumidification apparatus
US5910267A (en) * 1997-09-24 1999-06-08 Stricker; Jesse C. Infrared heater
US6556779B1 (en) * 1998-11-12 2003-04-29 Cadif Srl Pultrusion process to form specially shaped pieces for transforming electric current into diffused heat
US6963054B2 (en) * 1999-12-17 2005-11-08 Jean-Claude Tourn Device for heating air, fluids and materials, in dry or wet environment, powered with low voltage current or alternating or direct very low safe allowable voltage
US20020040898A1 (en) * 2000-08-18 2002-04-11 Theodore Von Arx Wound and themoformed element and method of manufacturing same
US20050002659A1 (en) * 2001-10-09 2005-01-06 Stylianos Panaghe Radiant electric heating element
US20040190882A1 (en) * 2003-03-28 2004-09-30 Richard Cooper Radiant heater
US20060051079A1 (en) * 2004-09-09 2006-03-09 Gerhardinger Peter F Method and apparatus for a cloth heater
US7039304B2 (en) * 2004-09-09 2006-05-02 Engineered Glass Products Llc Method and apparatus for a cloth heater

Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009120788A3 (fr) * 2008-03-26 2010-03-25 Marley Engineered Products Llc Dispositif de chauffage d'élément de finition décoratif
US20090242538A1 (en) * 2008-03-26 2009-10-01 Dennis Porzio Decorative trim heating device
US8306408B2 (en) 2008-05-30 2012-11-06 Thermoceramix Inc. Radiant heating using heater coatings
US20110188838A1 (en) * 2008-05-30 2011-08-04 Thermoceramix, Inc. Radiant heating using heater coatings
US20090297132A1 (en) * 2008-05-30 2009-12-03 Abbott Richard C Radiant heating using heater coatings
US8039774B2 (en) 2008-09-16 2011-10-18 United States Gypsum Company Electrical heater with a resistive neutral plane
US20100065542A1 (en) * 2008-09-16 2010-03-18 Ashish Dubey Electrical heater with a resistive neutral plane
US8618445B2 (en) 2008-09-16 2013-12-31 United States Gypsum Company Heating system
US10184670B2 (en) 2009-11-05 2019-01-22 Winstone Wallboards Limited Heating panel and method therefor
WO2011055330A1 (fr) * 2009-11-05 2011-05-12 Winstone Wallboards Limited Panneau de chauffage et procede associe
US20120228280A1 (en) * 2009-11-05 2012-09-13 Richard Dod Coates Heating panel and method therefor
CN102713447A (zh) * 2009-11-05 2012-10-03 温斯顿计算机板有限公司 供暖板及用于供暖板的方法
AU2010316620B2 (en) * 2009-11-05 2016-06-02 Winstone Wallboards Limited Heating panel and method therefor
KR101763963B1 (ko) * 2009-11-05 2017-08-14 윈스톤 월보즈 리미티드 난방 패널 및 그 제조 방법
US20110286724A1 (en) * 2010-05-19 2011-11-24 Travis Goodman Modular Thermal Energy Retention and Transfer System
US20130071716A1 (en) * 2011-09-16 2013-03-21 General Electric Company Thermal management device
US20210048198A1 (en) * 2018-02-05 2021-02-18 Ecovolt Ltd A radiant heater and method of manufacture
US11982449B2 (en) * 2018-02-05 2024-05-14 Ecovolt Ltd Radiant heater and method of manufacture
CN109084366A (zh) * 2018-08-16 2018-12-25 海南正诚立世科技有限公司 一种基于物联网的室内供暖管理系统
US20200113020A1 (en) * 2018-10-05 2020-04-09 Serendipity Technologies Llc Low power high-efficiency heating element

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