Note: Descriptions are shown in the official language in which they were submitted.
WO 2021/259896
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PLASTERBOARD LOOKALIKE BUILDING PANEL RADIANT HEATER
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to United States Provisional Application No.
63/042,217, filed June 22, 2020, entitled PLASTERBOARD LOOKALIKE BUILDING
PANEL RADIANT HEATER, the contents of which are incorporated herein by
reference in
their entireties for all purposes.
BACKGROUND OF THE INVENTION
Efficient heating systems for housing that keep the carbon footprint to a
minimum are desirable. Modern houses now are well insulated, leading to
heating
systems that do not require high power capacity. Infrared (IR) radiant heating
panels
typically use 35-40% less energy compared to conventional convection heating
radiators or commonly used underfloor heating.
Placing heating panels on or in the ceiling can provide flexibility in
strategically placing the heat where it is desired, with fewer restrictions
than with other
types of heating units. Standalone IR heating panels may be hung or suspended
from
an existing ceiling, but are often obtrusive (i.e prominent and noticeable in
an
unwelcome way) and therefore may not be visually acceptable to the market.
Existing heater applications in the ceiling may be installed behind the
ceiling surface panels in the cavity between the ceiling joists in order to be
concealed.
zo This can involve using electric cable heater mats or films, wet hydronic
pipes, and the
like. Typical ceiling constructions comprise surface panels of 12.5mm thick
plasterboard
or gypsum wallboard sheetrock, which are usually attached to a structure of
wood
ceiling joists with drywall screws, and are integrated together into a
continuous ceiling
appearance by using drywall tape and spackle along the seams between the
panels.
Such installations are relatively inefficient, resulting in heat transfer of
only 70-75% of
the input energy as radiating heat into the room, according to test data.
The efficiency of the IR heat radiation is a function of temperature, in
which higher temperature produces more efficient radiation. Existing
plasterboard or
sheetrock panels are typically limited to a surface temp of 55 degC or less.
Accordingly, there is a need in the field to provide IR heating that is
efficient and aesthetically pleasing.
SUMMARY OF THE INVENTION
One aspect of the invention comprises a heating panel having a framing-
facing surface and a room-facing surface. The heating panel comprises a
thermally
conductive layer having a room-facing side and a framing-facing side, at least
one
laminar heating element disposed over the framing-facing side of the thermally
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conductive layer, an insulation layer disposed over the at least one laminar
heating
element, and a room-facing surface layer disposed over at least the room-
facing side of
the thermally conductive layer. A power cord is connected to the laminar
heating
element and configured to connect to a power source.
A protective framing-facing surface layer may be disposed over the
insulation layer and may define at least a portion of the framing-facing
surface of the
panel. In some embodiments, the thermally conductive layer may comprise metal,
the
protective framing-facing surface layer may comprise a gypsum-reinforced
polyester
mesh layer bonded to the insulation layer, the insulation layer may comprise
foam,
and/or the room-facing surface layer may comprise paper. The thermally
conductive
layer may comprise a tray having peripheral sidewalls. In such configurations,
the
room-facing surface layer may wrap around the sidewalls of the tray and may
define at
least a portion of the framing-facing surface of the panels as well as the
peripheral
edge surfaces of the panels.
The panel may comprise a power cutout switch configured to cutout
power to the laminar heating element upon detecting a temperature in the
heating
panel greater than a predetermined maximum, such as at 80 degrees C. The
heating
panel may include a plurality of holes extending from a room-facing surface of
the
panel to a framing-facing surface of the panel, each dimensioned to receive a
fastener
zo for fastening the panel to framing of a building. An insulated area may
extend between
the periphery of the panel and the at least one heating element.
The heating panel may comprise two heating elements and may have an
insulated area extending between the two heating elements. An electrical
enclosure
cutout may be defined in the insulation layer, in which the power cord
connects to
busbars of the laminar heating element, and may have a cover that is flush
with the
framing-facing surface of the panel.
Another aspect of the invention comprises a heating system comprising a
heating panel as described herein, in which the power cord is connected to a
controller,
such as a thermostat, for regulating power to the heating panel. A plurality
of heating
panels or a plurality of heating zones in one or more of the panels may be
independently controllable by the controller.
Still another aspect of the invention includes a method for heating a
room, comprising installing at least one heating panel as described herein on
a ceiling
of the room, and providing power to the at least one heating element to
generate heat
that radiates into the room. A plurality of heating panels may be connected to
a
thermostat controller mounted in the room, in which the method comprises
controlling
heat in the room to achieve a set temperature in the room. The ceiling may
include at
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least one heating panel and at least one non-heating panel, wherein installing
the at
least one ceiling panel comprises applying a plaster material between the at
least one
heating panel and the at least one non-heating panel to form a continuous
coverable
ceiling layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a cross section of an exemplary
heating panel embodiment.
FIG. 2 is a schematic illustration of a partially transparent plan view of an
exemplary heating panel embodiment, showing locations of heating elements
relative
to the periphery of the panel, and a schematic of control and power elements.
FIG. 3 is a schematic illustration of an exemplary installation of a heating
panel as described herein on an insulated ceiling.
FIG. 4 is a schematic illustration of an exemplary installation of a heating
panel as described herein on an uninsulated ceiling.
FIG. 5A depicts an exemplary enlarged portion of the framing side of an
exemplary panel, showing an enclosure for electrical connections with a
closing lid
fastened thereto.
FIG. 56 depicts the portion of the framing side of the exemplary panel as
depicted in FIG. 5A, without the lid on the enclosure.
DETAILED DESCRIPTION OF THE INVENTION
One aspect of the invention comprises a heating panel capable of
producing useful available radiant heat at 90% or more of the input energy.
The panel
is capable of achieving operating surface temperatures of up to 80 degC. The
panel has
the appearance and behaviour of a gypsum or plasterboard panel and is
configured to
be attached to the ceiling in exactly in the same way as a sheetrock panel.
The panel
is configured as a "plug-and-play" application in which the heater is
configured to be
plugged into the available line voltage supply of 110/230v in the house or
building.
A system comprising one or more such ceiling panels may be connected
to any standard thermostat to control temperature of the room. Panels may be
placed
in desirable positions and tailored to maximise the heating requirements of a
particular
room layout.
Advantages of systems comprising such panels include 90% or more
energy conversion to radiant heat directed to the room, which may represent 30
-40%
energy savings as compared to existing concealed ceiling installations.
Additionally, the
construction of the ceiling panels permits them to be installed in the same
manner as
existing insulation boards or sheetrock panels, and the active panel surface
may be
covered with rendering plaster or any coating similar to plasterboard to
permit
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integration into a continuous surface ceiling suitable for painting or
covering with any
type of suitable ceiling surface layer. Although the panels may achieve a
temperature
of 80 degC, the panels are constructed to meet fire requirements. The plug-and-
play
connectability simplifies installation and allows flexibility in positioning
of the panels
wherever they are needed. The overall cost of heating system is competitive
with, and
may be less expensive, with most or all other technologies on the market.
An exemplary heating panel is depicted in FIGS. 1 and 2. The panel
comprises a thermal conductive layer 10, preferably in the form of a tray
having a
bottom 9 and a peripheral sidewall 11. While a tray structure including a
sidewall is
preferred for structural / aesthetics / edge protection functionality, in
other
embodiments, the thermal layer may have no sidewall, without a negative impact
on
thermal performance. In an exemplary embodiment, the tray is formed of a metal
(e.g.
having a thickness of 0.5 mm in one embodiment), preferably steel, more
preferably
zinc-plated steel or galvanized steel. Steel is preferred because of low
thermal capacity,
stiffness, excellent fire/smoke/toxity properties combined with low cost, but
the
invention is not limited to any particular materials of construction. In
particular, other
metals that are good thermal conductors, such as but not limited to aluminum
and
copper may be particularly suitable, and non-metal materials, such as ceramic,
carbon-
fiber-reinforced, or other conductive fiber polymeric materials, may also be
used for the
zo thermal conductive layer. The thermal conductive layer may comprise a
multi-layer
composite of more than one type of thermal conducting material.
The thermal conductive layer has a framing-facing surface 13 (intended
to be installed facing the framing of the ceiling onto which it is attached),
and a room-
facing surface 15 (intended to be installed facing the room to which the
radiant heat is
intended to be supplied). A heating film 12, such as a LaminaHeat Comfort
heating
film, is disposed above the framing-facing surface, and preferably in contact
with, the
thermally conductive layer. In one embodiment, the laminar heating film may be
rated
for 160 W at 230v or 110v, and may have a power density of 300 W/m2. An
insulation
core 14, such as foam, is disposed above the heating film, and may be bonded
to the
inner sidewalls of the thermally conductive tray. In one embodiment, the foam
comprises a rigid polyurethane (PU) foam 11 mm thick, but the invention is not
limited
to foam insulation or to any particular type of foam or thickness thereof. In
general,
insulation materials having thermal conductivity values k=0.028-0.035 W/mK and
a
density of 30 -250 kg/m3 are preferred. Additional suitable materials, without
limitation, include acrylic and extruded polystyrene (XPS). In one embodiment,
the
insulation may comprise a vacuum insulated panel (VIP), such as a VIP
comprising a
silica powder core, commercially known as vaQplusTM, supplied by va-Q-tec AG,
which
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delivers a high-end performance k value of 0.0035, which is approximately ten
times
better than standard foam insulation.
A protective barrier layer 17 may be applied to the framing-facing
surface of the insulation core layer. In one embodiment, the protective
barrier layer
comprises a gypsum-reinforced polyester mesh layer having a thickness of 0.8
mm. A
protective surface is preferred on the framing side of the insulation to
impose structural
stiffness and toughness /protection to the foam, but may be omitted in some
embodiments. Reinforced gypsum is compatible with existing building panels
used in
the building industry. Other materials may also be used, however, including
but not
limited to a polyester mesh / woven glass fiber open fabric mesh and other
fiber-
reinforced-polymer coatings. A surface coating 16 (e.g. paper) is applied to
the room-
facing surface of the thermally conductive layer, and may wrap around to the
side of
the panel, and at least over a portion of the framing-facing side of the
panel. Paper is
preferred as identical to the outer layer provided on standard plaster /
gypsum
sheetrock panels, but the invention is not limited to any particular surface
coating. In
some embodiments, other surface coatings may be provided, including any or all
of the
materials noted above as suitable for the protective barrier layer 17,
including in
embodiments in which the room-facing surface coating and framing-facing
protective
barrier layer are the same materials, and embodiments in which the materials
are
zo different. A plurality of holes 18 for fixing the panel to the framing
may be provided
that penetrate from the room-facing surface of the panel to the framing-facing
surface
of the panel.
As depicted in FIG. 2, the panel may comprise a plurality of heating
areas defined by the laminar heating elements, depending upon size of the
panel. As
depicted in FIG. 2, the panel has two zones 12A and 12B, each surrounded by an
insulated perimeter area 20, having a width P. between the lateral edges of
the panel
and the lateral edges of the laminar heating element. Insulated perimeter area
20 may
comprise, for example, a woven glass fiberE (electrical) grade, such as a 200
gsm plain
weave construction, but the invention is not limited to any particular
materials. Each
heating zone may have a thermal protection cutout switch 22 bonded to the
heater in a
central location. In an exemplary embodiment, the cutout switch may be set to
cut off
power to the laminar heating element whenever the detected heat exceeds an 80
degC
maximum. The invention is not limited to any particular cutout maximum,
however.
A power input cord 24 is connected to the busbars 25 of the laminar
heating units. An electrical connection enclosure 26, such as is depicted in
more detail
in FIGS. 5A and 5B, surrounds the connection locations, and comprises a cutout
within
the insulation core layer. In one embodiment, the enclosure may include a
plastic (e.g.
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nylon / PVC blend) electrical cover 56 that is hollow inside (e.g. the cover
defines a top
and sidewalls) and is attached to the panel by two fixing screws 57 into
corresponding
nut plate inserts 58 so that when fastened, the cover is flush with the planar
surface of
the framing-facing surface of the panel. The nut plate inserts may, for
example, be
bonded to the heater with high temperature adhesive. The electrical connection
enclosure is not visible from the room-facing surface of the panel. In the
embodiment
depicted in FIGS. 5A-5B, the thermally conductive layer is not in the form of
a tray
having sidewalls, but in a tray embodiment with sidewalls, the sidewall
typically defines
the outer edge of the enclosure, thus forming a more continuous peripheral
edge in
which the cover is not visible from the periphery of the panel.
In an exemplary control scheme, controller 50 is connected to the power
cord 24, which may comprise a ground / earth connection 54 (e.g. to the
thermally
conductive layer) and energized connections 52 and 53 connected to the busbars
25 of
heating elements 12A and 125, respectively. The connections may be made by any
method known in the art such as with a conductive adhesive. Tape 59 with
electrically
insulating properties may cover the connections. The energized connections may
ultimately connect separately to controller 50 to permit independent control
of the
zones, or both heating elements may be controllable together. The respective
cutout
switches are shown connecting to the energized connectors 52, 53, but
schematically
zo electrically are interposed between the energized connections and the
busbars so that
when the cutout switches trip for overheating, no energy is supplied to the
heating
element. In other embodiments, the cutout switches may be connected back to
the
controller. The controller may be configured to log and/or create an alarm
condition,
and produce an audible and/or visible alarm, when the cutout switch has
tripped.
Embodiments with remote controls may be provided, such as an embodiment in
which
the controller is connected to an in-home wireless communication network and
configured to be controlled by application software on a computer, such as on
a phone,
tablet, or other mobile device. Alarms may be provided, for example, as
notifications to
the connected remote device by the controller.
As depicted, in an exemplary embodiment, the full thickness T of the
panel may preferably be 12.5 mm, but the thickness is not limited to any
particular
size, and ideally, panels may be available in any thickness consistent with
the
corresponding thicknesses of standard sheetrock or plaster panels into which
the
heating panels are to be intermixed. Similarly, the panels may have any length
and
width, particularly lengths and widths configured for being inserted in place
of a full
size piece of plasterboard or sheetrock, such as in at least one embodiment,
having a
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length L of 1200 mm and a width W of 600 mm. In one 1200 x 600 x 12.5 mm
embodiment, the insulated perimeter area may have a width P of 25 mm.
While one embodiment may comprise characteristics suitable for use as a
lookalike to a panel of plasterboard or sheetrock, embodiments are not limited
to such
constructions. For example, ceiling panels suitable for installation alongside
standard
drop ceiling tiles may also be formed having some or all of the layers as
shown and
described. In a ceiling tile embodiment, room-facing layer of the tile may
comprise a
material other than paper, and/or may have a texture to match non-radiant
ceiling tiles
within which it may be intermingled to form a cohesive ceiling panel system.
Exemplary laminar heating elements referred to herein may be of the
type described in PCT Published Application No. WO 2016/113633 ("the '633 WO
Publication), incorporated herein by reference, which is incorporated herein
by
reference in its entirety. As described therein, the heating element may
comprise a
plurality of layers including but not limited to outer reinforcing or
insulating layers on
either or both sides of a resistive heater sheet layer comprising randomly
oriented
conducting fibers, such as carbon fibers, such as in a non-woven, wet-laid
layer of
individual unentangled fibers comprising conductive fibers, non-conductive
fibers (such
as glass fibers), or a combination thereof. In preferred embodiments, the
fibers have
an average length of less than 12mm and the fiber layer has an absence of
conductive
particles. Typical density of this layer may be in a range of 8-60, more
preferably in
the range of 15-35, grams per square meter. The heater layer preferably has a
uniform electrical resistance (in accordance with predetermined industry
standards for
uniformity) in any direction. The fiber layer may further comprise one or more
binder
polymers and/or a fire retardant. Each of the conductive fibers and/or each of
the non-
conductive fibers may have a length in the range of 6-12 mm. One or more of
the
plurality of conductive fibers may comprise a non-metallic fiber having a
metallic
coating. The fiber layer may consist essentially of individual unentangled
fibers, and
may, in particular, be marked by a lack of conductive particles in the fiber
matrix The
composition of layer 240 is not limited to any particular construction,
functional
characteristics, or density, however.
The fiber layer, or the heating element as a whole, may also include a
plurality of perforations that increase the electrical resistance of the fiber
layer relative
to a similar layer without such perforations. The fiber layer also includes at
least two
conductive strips (preferably copper) as busbars. Electrical wires connected
to the
busbars enable a voltage to be applied to the heater.
Exemplary installations are depicted in FIGS. 3 and 4. FIG. 3 depicts an
exemplary insulated ceiling construction 30, in which the ceiling adjoins a
floor 32 of an
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adjacent story of the building. Floor 32 may comprise multiple layers, such as
a
subfloor and a floor covering (hardwood, carpet, tile, etc., without
limitation), as well
as other functional layers (underlayment, leveling, etc., without limitation).
Joists 34
(e.g. wood of nominal 2x4, 2x6, 2x8 inch construction, steel beams, aluminum
framing, etc.) support the adjoining floor, and receive fasteners 35 (e.g.
drywall
screws, nails, etc.) that fasten the heating panels 36 as described herein as
well as
regular building panels 37 (e.g. sheetrock). Insulation 38 fills the cavities
defined by
the joists 34, the floor 32, and the ceiling panels 36, 37. This construction
may be
particularly useful in a construction for multi-level, multi-family dwellings,
in which
insulation is provided between adjacent stories for soundproofing and heat
containment
insulating properties.
Fig. 4 depicts another exemplary ceiling construction 40, in which
insulation layers 42 (e.g. 25-30 mm thick mineral wool) abut the heated panels
36, but
not the regular drywall panels 37. In exemplary embodiments, the insulation
layer 42
may be bonded to the lookalike heated panel to help further contain and direct
the heat
output of the panels.
It should be noted that the exemplary ceiling constructions are depicted
herein as examples only, and that the invention is not limited to any
particular
construction. Although not shown, the ceiling panels are also ideal for use in
zo suspending ceiling designs, such as are common in commercial
environments, in which
case the panels may be secured to thin profile steel beams. In the embodiments
depicted in FIGS. 3 and 4, additional finishing may be performed, as described
above,
such as the application of spackling and seaming tape over the seams and
further
processing to create a ceiling that has an overall planar configuration
without visible
seams or fastener divots, as is well known in the art. Accordingly, the panel
(and thus
the corresponding thermally conductive layer) may be shaped to have a planar
middle
region in a thickest portion of the panel with a slightly beveled periphery
angled from
the middle region to the edges of the panel, which may have a slightly lesser
thickness
than the middle region. This slight beveling may be helpful for accommodating
the
seaming tape and spackling to cover the seams and create a substantially
planar ceiling
(within standard tolerances from planar as are well understood by those of
skill in the
art of drywall finishing). Such a substantially planar ceiling comprises a
continuous
coverable ceiling layer (e.g. suitable for painting or applying further
coverings without
visible seams between the building panels (including heating panels and
regular
building panels).
In addition to the superior thermal performance of the plasterboard
lookalike radiant heating panel, another advantage includes the plug-and-play
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simplicity that permits the heating panels to be connected to existing or new
power
cables in the ceiling quite easily.
Although the invention is illustrated and described herein with reference
to specific embodiments, the invention is not intended to be limited to the
details
shown. Rather, various modifications may be made in the details within the
scope and
range of equivalents of the claims and without departing from the invention.
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