Patent Application
20220010974
The present invention relates to a panel as defined in the preamble of claim 1. The present invention also relates to an electrical end connector for electrically and mechanically coupling the panel to an adjacent panel, to a method for coupling a panel to an adjacent panel, and a heating system.
The following background information is a description of the background of the present invention, which thus not necessarily has to be a description of prior art.
One of our times big challenges is to reduce the overall energy consumption in the world. In many parts of the world, houses, apartments, offices, shops, factories and/or other public or non-public spaces, need to be heated in order to provide an acceptable environment for people spending time in these spaces. Such heating thus needs to provide a comfortable temperature at the same time as the energy consumption should be kept at a minimum.
Underfloor heating may be used for reducing the energy consumption at the same time as an acceptable temperature/environment is provided. It is nowadays common to install underfloor heating using warm water or electricity as a heat source when stone and/or ceramic tiles are used for covering the floor. Also, underfloor heating may be used when wooden floors, such as e.g. parquet flooring, are used for covering the floors.
Traditionally, the heat used for providing the underfloor heating has been created by warm water flowing in pipes/tubes under the floor boards and/or by electricity flowing through resistance in sheet materials arranged under the floor boards. Such a known solution is described in US2008/0210679, in which a mat/sheet “denoted heating device 1” in the document is arranged under a “floor covering 12”, i.e. under the actual floor boards. These pipes/tubes and/or sheet materials are thus arranged underneath the wooden floor, or underneath the stone and/or ceramic tiles. These traditional solutions have a disadvantage in that they are not very efficient in providing the heat into the space where it is actually needed, i.e. into the space above the wooden floor, and/or above the stone and/or ceramic tiles. This is due to the fact that the heat is created underneath the wooden floor, or underneath the stone and/or ceramic tiles, and thus needs to be transported through the entire wooden floor, and/or through the entire stone and/or ceramic tiles to reach the space where the e.g. people are to be present, i.e. to reach the space which should be heated. Also, a large part of the created heat is transported in the opposite direction, i.e. away from the wooden floor, or the stone and/or ceramic tiles, which also means away from the space which should be heated. Thus, a lot of the created heat is lost in such traditional heating systems, wherefore the heating system is inefficient and wastes energy.
In a prior art solution shown in US20060289144, a flooring board is instead provided with an embedded heating foil within the board, which is arranged for creating heat when being supplied with electrical energy. Hereby, the created heat is much more efficiently provided to the space in which it is needed, since the heat is created within the actual flooring board, instead of underneath it.
The flooring board shown in US20060289144 has, however, a number of problems related to the power supply to the flooring boards. The flooring board has electrical connecting means arranged on the grooves and tongues of the quick coupling joints being used for mechanically coupling the flooring board together with other flooring boards. Since the electrical connecting means are arranged on the grooves and tongues of the joint, the electrical connecting means will also experience small movements when pressure is applied on the flooring boards. The parts of the joints, i.e. the grooves and the tongues of the joints, move slightly every time for example a person walks on the flooring boards. Hereby, the electrical connecting means in US20060289144 will become worn out after some use. Also, even a lost contact may result from the wear of the electrical connecting means, whereby the heating function is lost. Also, a short circuit may be caused by the wear of the electrical connecting means, which may be hazardous due to e.g. a risk of fire. These possible problems are of course very unfortunate, especially for a floor having a long expected life time. Such a floor may have to be exchanged after a considerably shorter time than expected due to a malfunctioning heating function of the floor.
It is therefore an object of the present invention to provide a panel, an electrical end connector, a method, and a heating system that solve at least some of the above stated problems and/or disadvantages.
The object is achieved by the above mentioned panel according to the characterizing portion of claim 1. The panel may in this disclosure be understood to correspond to a panel assembly comprising the panel and an electrical end connector mounted on/attached to the panel for coupling the panel to an adjacent panel.
The panel/panel assembly includes:
Thus, the first and second end panel coupling means include first and second end panel grooves, respectively, the first and second end panel grooves at least partly extending between the first and second opposite longitudinal sides, and the at least one electrical end connector is arranged in one or more of the first and second end panel grooves.
According to an embodiment of the present invention, the at least partly resilient portion of the at least one electrical end connector is arranged to protrude at least partly from the one or more of the first and second end panel grooves in its relaxed state.
According to an embodiment of the present invention, the at least partly resilient portion is arranged to protrude at least partly more than a width Wend_con of the at least partly resilient portion of the at least one electrical end connector.
According to an embodiment of the present invention, the at least partly resilient portion of the at least one electrical end connector is arranged to be pressed into at least one of the first and second end panel grooves by at least one of first and second end panel coupling means of an adjacent panel when the panel is being coupled to the adjacent panel.
According to an embodiment of the present invention, the at least partly resilient portion of the at least one electrical end connector is arranged to relax into, i.e. to at least partly return towards its relaxed state by relaxing into, at least one of the first and second end panel grooves of the adjacent panel when the panel is coupled to the adjacent panel.
According to an embodiment of the present invention, the at least partly resilient portion of the at least one electrical end connector is arranged to be snapped into at least one of first and second end panel grooves of the adjacent panel, thereby mechanically locking the panel to the adjacent panel.
According to an embodiment of the present invention, the first and second end panel grooves have a height Hend_groove essentially equal to a height Hend_con of the at least partly resilient portion of the at least one electrical end connector; Hend_groove=Hend_con.
According to an embodiment of the present invention, at least one of the first and second end panel grooves have a first depth Dend_groove1 essentially equal to or larger than a width Wend_con of the at least partly resilient portion of the at least one electrical end connector; Dend_groove1≥Wend_con.
According to an embodiment of the present invention, at least one of the first and second end panel grooves have a second depth Dend_groove2 smaller than a width Wend_con of the at least partly resilient portion of the at least one electrical end connector; Dend_groove2<Wend_con.
According to an embodiment of the present invention, the at least partly resilient portion of the at least one electrical end connector includes a first and a second electrically conducting tongue.
According to an embodiment of the present invention, the first and second electrically conducting tongues of the at least partly resilient portion are arranged to be in electrical contact with the heat providing layer of the panel and with a corresponding heat providing layer of an adjacent panel being coupled to the panel.
According to an embodiment of the present invention, the heat providing layer of the panel includes first and second electrically conducting parts adjacent to at least one of the first and second end panel grooves.
According to an embodiment of the present invention, the first and second electrically conducting tongues of the at least partly resilient portion are arranged to be in electrical contact with the first and second electrically conducting parts, respectively, of the heat providing layer of the panel and with corresponding first and second electrically conducting parts, respectively, of a corresponding heat providing layer of an adjacent panel being coupled to the panel.
According to an embodiment of the present invention, the first and second electrically conducting tongues are at least partly wave-formed.
According to an embodiment of the present invention, the at least partly resilient portion of the at least one end connector is arranged to be located closer to the first end portion than to the second end portion, or vice versa.
According to an embodiment of the present invention, the at least one end connector has a length L and a most protruding part of the at least partly resilient portion of the at least one electrical end connector is arranged to be located a first length L1 from at least one of the first and second end portions, wherein a ratio between the first length L1 and length L is at least one in the group of:
0.5<L1/L<0.15;
0.4<L1/L<0.2; and
L1/L=0.3.
According to an embodiment of the present invention, the at least partly resilient portion of the at least one electrical end connector includes a resilient material.
According to an embodiment of the present invention, the at least partly resilient portion of the at least one electrical end connector includes first and second portions being resiliently connected to each other.
According to an embodiment of the present invention, the first and second portions of the at least partly resilient portion are resiliently connected to each other by means of at least one in the group of:
a spring joint;
a resilient member.
According to an embodiment of the present invention, at least one of the first and second portions of the at least partly resilient portion includes a resilient material.
According to an embodiment of the present invention, the first and second portions of the at least partly resilient portion include first and second electrically conducting tongues, respectively.
According to an embodiment of the present invention, at least first and second longitudinal grooves are arranged in the base layer from the first end side to the second end side and facing the heat providing layer, the at least first and second longitudinal grooves being arranged in parallel with, and having at least first and second distances to the first and second longitudinal sides, respectively.
According to an embodiment of the present invention, the panel further includes:
According to an embodiment of the present invention, at least one insulating core is included in the base layer, the at least one insulating core having heat insulating and/or sound absorbing properties.
According to an embodiment of the present invention, the heat providing layer is arranged at a heat depth Dheat from the visible surface 104 being one in the group of:
0.1 mm to 3 mm;
0.4 mm to 1 mm;
0.5 mm to 0.8 mm; and
0.6 mm.
The above mentioned object is also achieved by the above mentioned electrical end connector. The electrical end connector being insertable into one or more of the first and second end panel grooves of the first and second end panel coupling means of a panel and characterized by the at least one electrical end connector including first and second end portions and an at least partly resilient portion located between the first and second end portions, the at least partly resilient portion at least partly including an electrically conductive material and at least partly protruding from the one or more of the first and second end panel coupling means, thereby providing an electrical connection between the heat providing layer of the panel and a corresponding heat providing layer of at least one adjacent panel coupled to the panel.
When the panel and an adjacent panel are mechanically coupled together, the at least partly resilient portion of the electrical end connector is, according to various embodiments, inserted/received in first and second end panel grooves of both the panel and the adjacent panel, whereby the at least partly resilient portion of the electrical end connector provides for the electrical connection between the heat providing layers of the panel and of the adjacent panel.
The above mentioned object is also achieved by a method for coupling a panel to a corresponding adjacent panel characterized in:
The above mentioned object is also achieved by a heating system. The heating system includes:
The panel and heating system according to the present invention provide for an energy efficient and durable heating of essentially all sorts of spaces.
By integrating the heat providing layer into a construction panel, such as e.g. a flooring panel, a wall panel and/or a ceiling panel, it is possible to efficiently, precisely and reliably regulate the indoor climate/temperature in spaces delimited by a floor, walls and a ceiling at least partly including such panels.
The heat providing layer is arranged very close to the space to be heated, since it is located directly under the covering/decorative layer. Hereby, the created heat may be very efficiently transported to the space to be heated when the panel according to the present invention is used. By this efficient heat transportation to the space to be heated, the consumption of electric energy being used for creating the heat is minimized.
The panel according to some embodiments of the present invention is cuttable in the sense of being possible to cut off and still be used for laying floors. This is due to the fact that the locations of the first and second longitudinal grooves are well defined, which also results in a well-defined placement of the first and second electrical power supply end connectors placed in the first and second grooves.
By usage of the present invention, a secure and reliable power supply to the panel is assured. Also, the design of the electrical end connector according to the present invention simplifies mechanical coupling of panels together, at the same time as a stable electrical coupling is provided.
Also, the electrical end connector of the panel according to the present invention provides for a reliable and secure electrical contact to adjacent panels. Hereby, electrical energy to be used for creating the heat in the heat providing layer reliably reaches each one of mechanically and electrically coupled panels, and therefor also reaches the heat providing layers of each one of the panels.
The panel according to the present invention may be produced and installed cost efficiently. Since the heat may be created by use of low voltages, such as 4-60 Volts, e.g. approximately 25 Volts or approximately 50 Volts, the panels may even be installed by a layman, i.e. by a non-professional. Thus, by installation of the panels according to the present invention, there may not be a need for an electrician to be present, depending on laws and regulations where the panel is to be installed/used, which dramatically reduces the total cost for an end user, e.g. a house owner. Prior art electrical underfloor heating systems are often driven by much higher voltages, e.g. 230 Volts, which must be installed by a certified electrician.
Some known underfloor heating systems include a lower voltage mat/sheeting creating the heat, which is arranged under the wooden floor or underneath the stone and/or ceramic tiles. One such example is the above-mentioned heating device 1 in US2008/0210679, which is arranged under the floor covering 12. This arrangement results in considerable energy losses as described above. Also, this prior art lower voltage mat/sheeting is often difficult to properly install, wherefore a skilled person often must adapt e.g. the size of the mat/sheeting to fit the area to be covered by the floor. This increases the costs for installation of the floors.
The panel according to the present invention, however, already itself includes the heat providing layer, and does thus not need any heat creating mats to be installed underneath it.
As a non-limiting example, a power per floor area in an interval of approximately, 10-40 W/M2, or 20-30 W/m2 may be used for creating the heat. The used power per floor area may be seen as a balance between differing characteristics for the floor and/or heating. Higher power generally results in shorter heat providing circuits, which is an advantage when cutting off the panels since the part of the panel without heating due to the cutting off becomes small. However, for lower powers per floor area, the resistances of the heat providing circuits are less critical than for higher powers and lower resistances.
Detailed exemplary embodiments and advantages of the panel, the heating system, and the method according to the invention is hereafter described with reference to the appended drawings illustrating some preferred embodiments.
Embodiments of the invention are described in more detail with reference to attached drawings illustrating examples of embodiments of the invention in which:
a-g, 3a-c, and 4a-c schematically show views of a panel 100 and/or an electrical end connector 150 according to various embodiments of the present invention.
As is shown e.g. in
The first longitudinal side 105, the second longitudinal side 106, the first end side 107, and the second end side 108 may be provided with panel coupling means, such as a groove/female and tongue/rabbet forming e.g. “click joints” 115, 116, 117, 118, respectively. The panel coupling means 115, 116, 117, 118 are, according to an embodiment, arranged in the base layer 101 at the first 105 and second 106 longitudinal sides of the panel 100, and at the first 107 and second 108 end sides of the panel 100, for mechanically coupling the panel 100 to at least one adjacent panel 201, 202, . . . 206, i.e. to at least one other corresponding panel 201, 202, . . . , 206 (as shown in
The panel 100 further includes a base/core layer 101 and a covering/visual layer 103. The covering/visual layer 103 has a surface 104 possibly being visible from the space to be heated, i.e. from within the room in which the panel 100 covers a floor, wall and/or ceiling. The covering/visual layer 103 may have a suitable appearance/look, including colors and/or patterns.
The panel 100 further includes a heat providing layer 102 attached to the base layer 101, i.e. arranged between the base layer 102 and the covering/visual layer 103. This also means that the heat providing layer 102 is arranged very close to the space to be heated, i.e. directly underneath the thin covering/visual layer 103. The heat providing layer 102 may include essentially any material being electrically conducting and having an electrical resistance suitable for creating heat, i.e. an increased temperature, when current flows through the material. The material may be formed as a heat generating element, which may have a large number of shapes. For example, the heat providing layer 102 may comprise printed electronics, a film, one or more resistors, a sheet, a tape, a paint, or may have essentially any other shape or form suitable for creating heat through its electrical resistance and for being included in the panel 100 according to the present invention. Thus, for example, the heat providing layer 102 may comprise at least one heat generating element including printed electronics having an electrical resistance, at least one film having an electrical resistance, and/or one or more resistors having an electrical resistance.
As a non-limiting example, it may be mentioned that, when the electric energy has a voltage of 25 V, i.e. when the electrical energy providing arrangement delivers a voltage of 25 V is used as power supply, 23 W/m2 may be created by the heat providing layer 102 according to an embodiment. The time constant for the temperature increase at the covering layer may be short, in the area of minutes, and a temperature increase of e.g. 3° C. may be quickly achieved.
The voltage drop increases with the squared length of the floor. For shorter floors, e.g. floors having a length shorter than 10 m, the voltage drop has little effect on the created heat. However, for longer floors, e.g. floor longer than 15 m, the voltage drop may noticeably affect the produced heat.
According to an embodiment of the present invention, the heat providing layer 102 is arranged at a heat depth Dheat from the visible surface 104 in an interval of 0.1 mm-3 mm, 0.4 mm-1 mm, or 0.5 mm-0.8 mm, and/or at a depth of 0.6 mm. This then also means that the covering layer 103 has a thickness Tcov being equal to the heat depth Dheat; Tcov=Dheat; which results in an efficient transport of heat energy into the space to be heated, since the heat providing layer 102 is very close to the heated space.
According to an embodiment of the present invention, the layers of the panel 100, i.e. the base layer 101, the heat providing layer 102 and the covering layer 103 are attached/fixed to each other by use of an adhesive, such as e.g. a glue.
The panel 100 according to the present invention may according to some embodiments include a first longitudinal groove 121 arranged in parallel with, and having at least a first distance 131 to, the first longitudinal side 105, and a second longitudinal groove 122 arranged in parallel with, and having at least a second distance 132 to, the second longitudinal side 106 (as shown in
The panel 100 according to the present invention further includes at least one electrical end connector 150 arranged at one or more of the first end panel coupling means 117 at the first end side 107, and the second end panel coupling means 118 at the second end side 108. More in detail, the first 117 and second 118 end panel coupling means include first 127 and second 128 end panel grooves, respectively. These first 127 and second 128 end panel grooves at least partly extend between the first 105 and second 106 opposite longitudinal sides of the panel. The at least one electrical end connector 150 is arranged in one or more of the first 127 and second 128 end panel grooves, respectively.
The at least one electrical end connector 150 includes first 151 and second 152 end portions and an at least partly resilient portion 153 located between the first 151 and second 152 end portions. The at least partly resilient portion 153 is at least partly electrically conductive, i.e. at least partly include an electrically conducting material, such as e.g. a suitable metal. Thus, the at least partly resilient portion 153 may include one or more sections being resilient, and may also include one or more non-resilient sections. Further, the at least partly resilient portion 153 may include one or more sections of a conductive material, and may also include one or more sections of a non-conductive material. The at least partly resilient portion 153 is further at least partly protruding from the one or more of the first 117 and second 118 end panel coupling means when being arranged at the one or more of the first 117 and second 118 end panel coupling means. Thus, one or more sections of the at least partly resilient portion 153 may protrude from the one or more of the first 117 and second 118 end panel coupling means when being arranged therein.
These features make it possible for the at least partly resilient portion 153 to provide an electrical connection between the heat providing layer 102 of the panel 100 and a corresponding heat providing layer 102′ of at least one adjacent panel 201, 202 coupled to the panel 100. Thus, the at least partly resilient portion 153 is arranged to make the heat providing layers 102, 102′ of at least two adjacent panels 100, 201, 202 (shown e.g. in
According to embodiments of the present invention, schematically illustrated e.g. in
When the at least one electrical end connector 150 is arranged in the one or more of the first 127 and second 128 end panel grooves, the at least partly resilient portion 153 of the at least one electrical end connector 150 is arranged to protrude at least partly from the one or more of the first 127 and second 128 end panel grooves in its relaxed state. When the panel 100 is being coupled to an adjacent panel 201, 202, the at least partly resilient portion 153 of the at least one electrical end connector 150 is arranged to be pressed into at least one of the first 127 and second 128 end panel grooves by at least one of first 117′ and second 118′ end panel coupling means of the adjacent panel 201, 202. Furthermore, the at least partly resilient portion 153 of the at least one electrical end connector 150 is arranged to relax, i.e. to at least partly return towards its relaxed/non-tensioned/normal state/form, into at least one of the first 127′ and second 128′ end panel grooves of the adjacent panel 201, 202 when the panel 100 is coupled to the adjacent panel 201, 202. In other words, when the panel 100 is coupled to the adjacent panel 201, 202, the at least partly resilient portion 153 of the at least one electrical end connector 150 is arranged to be snapped into at least one of the first 127′ and second 128′ end panel grooves of the adjacent panel 201, 202, thereby mechanically coupling/locking and electrically coupling the panel 100 to the adjacent panel 201, 202. The mechanically coupling/locking of the panel 100 to the adjacent panel 201, 202 using the electrical end connector 150 will now be further described with reference to
As described above and below, the at least partly resilient portion 153 of the at least one electrical end connector 150 is at least partly electrically conductive, i.e. includes one or more conductive sections, which provides an electrical connection between the panel 100 and the adjacent panel 202, i.e. between the heat providing layers 102, 102′ of the panel 100 and the adjacent panel 202. In embodiments, the at least partly resilient portion 153 of the at least one electrical end connector 150 provides the electrical connection between the heat providing layers 102, 102′ of the panel 100 and the adjacent panel 202 using electrically conducting tongues. Thus, the one or more conductive sections then include one or more electrically conductive tongues, respectively. The tongues are in this embodiment arranged to be in electrical contact with the heat providing layers 102, 102′ of the panel 100 and of the adjacent panel 202, respectively.
The first 171 and second 172 electrically conducting tongues of the at least partly resilient portion 153 are arranged to be in electrical contact with the heat providing layer 102 of the panel 100 and with a corresponding heat providing layer 102′ of the adjacent panel 201, 202 being coupled to the panel 100. When the first 171 and second 172 electrically conducting tongues are wave-formed, the first 171 and second 172 electrically conducting tongues may each comprise a first wave and a second wave, as illustrated in
According to embodiments of the invention, the heat providing layer 102 of the panel 100 includes first 181 and second 182 electrically conducting parts/sections, while the heat providing layer 102′ of the adjacent panel 201, 202 includes corresponding first 181′ and second 182′ electrically conducting parts/sections, as illustrated in
The first 127 and second 128 end panel grooves have a height Hend_groove essentially or approximately equal to a height Hend_con of the at least partly resilient portion 153 of the electrical end connector 150; Hend_groove=Hend_con or Hend_groove=Hend_con. Thus, the at least partly resilient portion 153 of the electrical end connector 150 is movable within the end panel grooves 127, 128 with limited play, e.g. essentially without play, thereby providing a solid mechanical coupling/locking and electrical coupling. Thereby, when the electrical end connector 150 is arranged in at least one of the first 127 and second 128 end panel grooves, the conductive parts/sections of the at least partly resilient portion 153 of the electrical end connector 150 will be in contact with the heat providing layer 102 of the panel 100 exposed to the inside of the first 127 and second 128 end panel grooves. Hence, for the electrical end connector 150 shown in
Furthermore, at least one of the first 127 and second 128 end panel grooves may have a first depth Dend_groove1 essentially equal to or larger than a width Wend_con of the at least partly resilient portion 153 of the at least one electrical end connector 150; Dend_groove1≥Wend_con; while at least one of the first 127 and second 128 end panel grooves may have a second depth Dend_groove2 smaller than the width Wend_con of the at least partly resilient portion 153 of the at least one electrical end connector 150, i.e. Dend_groove2<Wend_con. If the width Wend_con of the at least partly resilient portion 153 varies over the length of the at least partly resilient portion 153, the first depth Dend_groove1 may be selected based on the maximum width Wend_con of the at least partly resilient portion 153 and the second depth Dend_groove2 may be selected based on the maximum width Wend_con and/or the width Wcon_end of the at least partly resilient portion 153 at the location of the conductive parts/sections of the at least partly resilient portion 153.
An end panel groove 127, 128 having the first depth Dend_groove1 allows the full width Wend_con of the at least partly resilient portion 153 of the electrical end connector 150 to be received in the end panel groove 127, 128. Thereby, during the coupling of the panel 100 to the adjacent panel 201, 202 the at least partly resilient portion 153 of the electrical end connector 150 can be fully pressed into the end panel groove 127, 128 having the first depth Dend_groove1. Hence, an end panel groove 127, 128 having the first depth Dend_groove1 is suitable to be fitted with the electrical end connector 150 in its relaxed state before coupling the panel 100 to the adjacent panel 201, 202.
On the other hand, an end panel groove 127, 128 having the second depth Dend_groove2 can not receive the full width Wend_con of the at least partly resilient portion 153 of the electrical end connector 150. Therefore, at least a portion of the at least partly resilient portion 153 of the electrical end connector 150 will protrude from the end panel groove 127, 128 with the second depth Dend_groove2. Hence, an end panel groove 127, 128 having the second depth Dend_groove2 is suitable to receive the corresponding at least partly resilient portion 153′ of the electrical end connector 150′ of the adjacent panel 201, 202 when coupling the panel 100 to the adjacent panel 202, 201.
In the embodiment shown in
In embodiments where the at least partly resilient portion 153 of the electrical end connector 150 includes the first 155 and second 156 portions, the first 155 and second 156 portions of the at least partly resilient portion 153 may include first 171 and second 172 electrically conducting tongues, respectively, as shown in
In embodiments, the at least partly resilient portion 153 of the electrical end connector 150 may instead be a single part (not shown). In this case, the at least partly resilient portion 153 of the at least one electrical end connector 150 may include a resilient material, i.e. the at least partly resilient portion 153 of the electrical end connector 150 is in itself resilient/flexible.
It is the resilience of the at least partly resilient portion 153 of the electrical end connector 150 that allows the electrical end connector 150 to be used to mechanically couple/lock the panel 100 to the adjacent panel 201, 202, as well as provide the electrical connection between the panel 100 and the adjacent panel 201, 202. The shape and resilience of the at least partly resilient portion 153 of the electrical end connector 150 may be selected such that a smooth mechanical coupling/locking is achieved. For example, by arranging the at least partly resilient portion 153 towards one of the ends of the electrical end connector 150, the force required to press down the adjacent panel 201, 202 towards that end during the coupling to the panel 100 can be reduced. Thereby, the risk of breaking the electrical end connector 150, the panel 100, and/or the adjacent panel 201, 202 during the coupling is reduced. Hence, in embodiments the at least partly resilient portion 153 of the at least one electrical end connector 150 is arranged to be located closer to the first end portion 151 than to the second end portion 152, or vice versa.
In embodiments, the most protruding part 157 of the at least partly resilient portion 153 of the electrical end connector 150 may instead be located closer to or further away from the first end portion 151. Hence, the length L of the electrical end connector 150 and the first length L1 between the most protruding part 157 and the first end portion 151 may be selected such that the ratio between the first length L1 and the length L is at least one interval in the group (or an interval based on the limiting values in the group) of:
0.5≤L1/L≤0.15,
0.4<L1/L<0.2,
L1/L=0.3.
The location of the most protruding part 157 of the at least partly resilient portion 153 of the electrical end connector 150 along the electrical end connector 150 may be selected based on factors such as e.g. the strength of at least one of the first 117 and second 118 end panel coupling means, a desired strength of the mechanical coupling/locking etc. For example, if the first 117 and second 118 end panel coupling means are made of a strong material, e.g. solid wood, the most protruding part 157 of the at least partly resilient portion 153 of the electrical end connector 150 may be located in the middle or close to the middle of the electrical end connector 150. Thereby, the electrical end connector 150 can provide a strong mechanical coupling/locking. On the other hand, if the first 117 and second 118 end panel coupling means are made of a less strong material, e.g. wood fiber board, the most protruding part 157 of the at least partly resilient portion 153 of the electrical end connector 150 may be located closer to one end of the electrical end connector 150, e.g. 15%-25% of the length L from the end of the electrical end connector 150. Thereby, reducing the force required for the mechanical coupling/locking and hence the risk of breaking the first 117 and second 118 end panel coupling means and/or the electrical end connector 150 during the mechanical coupling/locking.
Furthermore, the shape and resilience of the at least partly resilient portion 153 of the electrical end connector 150 may be selected such that in its relaxed state the at least partly resilient portion 153 is arranged to protrude at least partly more than its width, i.e. more than the width Wend_con of the at least partly resilient portion 153 of the electrical end connector 150, as shown e.g. in
The sandwich/insulating core 160 may e.g. include polyurethane, for example in form of a polyurethane foam being injected at and/or after assembly of the layers of the panel 100.
The load carrying elements 170 may be casted/moulded together with base layer 101 material in order to improve the load carrying capabilities of the panel 100, i.e. to improve the load/weight carrying capabilities of the base layer 101 material. Hereby, a less stable and more porous material may be used for the rest of the base layer 101 material, which lowers the production costs.
According to an aspect of the present invention, an electrical end connector 150 is presented. The electrical end connector 150 and its embodiments are described in this document, and is illustrated e.g. in
As previously described and shown in e.g.
As described above with reference to
According to embodiments, the electrical end connector 150 also provides a mechanical coupling to at least one adjacent panel 201, 202, e.g. by snap locking.
As mentioned above, and also being illustrated e.g. in
According to an embodiment, the first 171 and second 172 electrically conducting tongues have a form being suitable for creating a solid electrical contact with the heat providing layers 102, 102′. The first 171 and second 172 electrically conducting tongues may e.g. be at least partly wave-formed, with the peaks of the wave form pointing towards the heat providing layers 102, 102′.
The electric energy being conveyed to the heat providing layer 102, 102′ by the at least partly resilient portion 153 may have a voltage in the interval of 5 Volts-60 Volts, or in the interval of 10 Volts-55 Volts, or in the interval of 15 Volts-50 Volts, or in the interval of 25 Volts-50 Volts. The panel 100 according to the present invention may be supplied with such low voltages since the electrical contact between adjacent panels, and possibly also the heat providing layers, and therefore of the panel 100 itself, are very good, i.e. have low losses.
According to an example embodiment of the present invention, the electric energy being supplied to the heat providing layer 102 in order to create the heat has a voltage V of 25 Volts; V=25 volt, which in many regions and/or countries may be handled by a layman, i.e. by a non-electrician.
According to another example embodiment of the present invention, the electric energy has a voltage V of 50 Volts; V=50 volt, which in some regions and/or countries may be handled by a layman.
As described above, at least first 121 and second 122 longitudinal grooves may be arranged in the base layer 101 of the panel 100, as shown in
The at least first 121 and second 122 longitudinal grooves may in embodiments be used to provide electrical connection between the panel 100 and an electrical energy providing arrangement 810. In such embodiments, the panel 100 further comprises at least first 161 and second 162 electrical power supply end connectors arranged in the at least first 121 and second 122 longitudinal grooves, respectively, at the first end side 107 or the second end side 108, the at least first 161 and second 162 electrical power supply end connectors being arranged to provide an electrical connection between the heat providing layer 102 of the panel 100 and an electrical energy providing arrangement 810. The electrical energy providing arrangement 810 may be part of a heating system 800, as will now be described with reference to
According to an aspect of the present invention, a heating system 800 is presented. The heating system 800, is schematically illustrated in
According to the embodiment shown in
According to another embodiment of the present invention, the electric energy has a voltage of 50 Volts; V=50 Volts; which in some regions and/or countries may be handled by a layman, i.e. by a non-electrician. A heating system 800 is schematically illustrated in
The electrical energy providing arrangement 810 may include contact means 811, 812, 813, 814, 815, 816, each one being arranged for providing one polarity P1, P2 to the panel 100, 203, 207 by use of a contact protrusion 817 and/or first 161 and second 162 electrical power supply end connectors. The contact means 811, 812, 813, 814, 815, 816 and/or the panels 100, 203, 207 may also include a stability protrusion 818.
When the contact means 811, 812, 813, 814, 815, 816 are assembled with, i.e. are inserted into, the panels 100, 203, 207, the electrical energy is provided to the panels 100, 203, 207 by the contact protrusions 818, and the panels 100, 203, 207 are held in place by the stability protrusions 817. Also, the electrical energy, i.e. the voltage creating the heat in the panels 100, 203, 207, is encapsulated within the panels 100, 203, 207 by the contact means 811, 812, 813, 814, 815, 816. The risk for getting an electric shock is therefore minimized for the heating system 800 illustrated in
Also, the voltage drop over the heat providing layer 102 is approximately reduced by 50% when the two polarities P1, P2 are provided to opposite sides of a floor.
According to an embodiment of the present invention, schematically illustrated in
Also, the second polarity P2 may be supplied to the first 161 or second 162 electrical power supply end connectors of a corresponding first end side 107′ of an adjacent panel 202 coupled directly or indirectly to the first end side 107 of the panel 100, as illustrated in
The electrical energy providing arrangement 810 thus supplies the electric energy to the first 161 and second 162 electrical power supply end connectors on two opposite end sides of the at least one panel 100, 203, 207. In
The at least one first contact means 911 may here e.g. be arranged as an electrically conducting contact strip, possibly in metal, being arranged horizontally in the electrical energy providing arrangement 910, such that it provides for a contact surface for the slightly upwardly tilted first 161 and second 162 electrical power supply end connectors. Thus, a vertical contact force Fcon is created when the at least one panel 100 and the electrical energy providing arrangement 910, e.g. in the form of a mounting base, are mounted together.
Also, the electrical energy providing arrangement 910, e.g. included in the mounting base 920 described in this document may, as mentioned above, be used for supplying electrical energy to essentially any electrically heated panel, i.e. not only to the herein described panel 100, and/or to any other electrical energy consuming device 930, such as e.g. a wall or ceiling heating panel, a lamp or the like. The electrical energy providing arrangement 910 may for this reason include at least one second contact means 912.
According to an embodiment, the at least one first contact means 911 may be provided with first polarity P1, and the at least one second contact means 912 may be provided with another second polarity P2.
Hereby, the electrical energy providing arrangement 910 may supply electrical energy to essentially any electrical device 930 driven by the voltage provided by the electrical energy providing arrangement 910. For example, many kinds of lamps are driven by lower voltages, such as e.g. 25 Volt or 50 Volt, and may therefore be directly supplied with this voltage from the electrical energy providing arrangement 910.
Also, the at least one first 911 and the at least one second 912 contact means of adjacent parts of the energy providing arrangement 910, e.g. in the form of adjacent mounting base parts mounted together, may be electrically coupled by means of coupling means 951, 952, e.g. in form of sheet metal, that may possibly correspond in form and/or function to the herein described first 161 and second 162 electrical power supply end connectors.
In
According to an embodiment of the present invention, a method for installing the heating system 800 is presented
When panels according to the present invention are to be assembled/laid to become e.g. a floor, the electrical energy providing arrangement 810, 910 described above may first be arranged/mounted at a mounting base 820, 920 and/or facing the base layer 101 on one or two sides of the room to be floored. For example, a lower voltage energy providing arrangement, providing e.g. 25 Volts may be arranged/mounted along one wall of a room and then provides both polarities P1, P2 of the voltage. A higher voltage energy providing arrangement, providing e.g. 50 Volts, may instead be arranged along two opposite sides of a room and then provides one polarity of the voltage from each opposite side of the room. Thus, the electrical energy is then available at one or two sides of the room.
A first panel 100 is then mechanically coupled to at least one second panel 201, 202 by use of the electrical end connector 150 of the panel 100, the first end panel coupling means 117 of the panel 100, and the second end panel coupling means 118′ of the at least second panel 201, 202. Hereby, a row of two or more panels 100, 201, 202 is created. The last second panel 202 in such a row of panels may have to be cut such that the length of the row corresponds to the length of the room.
At the same time as the panels of the row are mechanically coupled, an electrical connection of the first panel 100 and the at least one second panel 201, 202 is achieved by the at least one electrical end connector 150 of the first panel 100. Thus, as the panels 100, 201, 202 are pressed together by the mechanical coupling means 117, 118, also the at least partly resilient portion 153 of the at least one electrical end connector 150, of the panels 100, 201, 202 of the row are pressed into the first 127, 127′ and second 128, 128′ end panel grooves of the panels 100, 201, 202, thereby causing an electrical connection of the heat providing layers 102, 102′ of the panels 100, 201, 202.
Then, the row of the first panel 100 and the at least one second panel 201, 202 is supplied with electrical energy from the electrical energy providing arrangement 810, 910. According to an embodiment described above, which is useful e.g. for lower voltages, this is done by connecting both of the first 161 and second 162 electrical power supply end connectors of the first panel 100 to the electrical energy providing arrangement 810, 910, which then supplies both of the voltage polarities P1, P2 to the first end side 107 of the first panel 100.
According to another embodiment described above, which is useful e.g. for higher voltages, the row of the first panel 100 and the at least one second panel 201, 202 is supplied with electrical energy from the electrical energy providing arrangement 810, 910 by connecting one of the first 161 and second 162 electrical power supply end connectors on the first end side 107 of the first panel 100 to the electrical energy providing arrangement 810, 910. The electrical energy providing arrangement 810, 910 then provides the first side 107 of the first panel 100 of the row of panels with one polarity P1 of the electrical energy. Then, another one of the first 161 and second 162 electrical power supply end connectors on the second end side 108′ of the row, i.e. on the second side 108′ of the at least one second panel 201, 202 is connected to the electrical energy providing arrangement 810, 910. The electrical energy providing arrangement 810, 910 then provides the second side 108′ of the row with another polarity P2 of the electrical energy.
As mentioned above, to supply the row of panels 100, 201, 202 with one voltage polarity at each end of the row has an advantage in that the risk for a person laying the floor getting an electric shock by the electric energy being provided to the panels is considerably reduced. In order to get an electric shock, i.e. in order to come in contact with both polarities of the voltage, the person would have to reach across the entire room, along the whole length of the row of panels, which is not very likely. Thus, a higher voltage supply may be used with this embodiment of the invention.
In the following, some non-limiting examples descriptions of electrical properties and heating properties of a floor according to some of the herein described embodiments are presented.
A power consumption for the floor, P, is given as:
P=U*I; (eq. 1)
where U is the voltage applied on the heat providing layer, and I is the corresponding applied electrical current. The applied voltage U is given by the voltage Usupply provided by the power source minus a voltage drop ΔU between the power source and the heat providing layer, i.e.:
U=U
supply
−ΔU. (eq. 2)
The current I flowing through the heat providing layer is given by ohm's law:
U=R*I; i. e. (eq. 3)
I=U/R; (eq. 4)
where R is the resistance of the heat providing layer. The heat providing layer may be divided in heating modules/sections, where a multiple of modules/sections may be coupled in parallel. For one heat module/section the resistance is given by:
R=resistivity*Lc_heat/Ac_heat; (eq. 5)
where the resistivity is a material parameter, e.g. for pure aluminum approximately 2.82×10−8 ohm m, Lc_heat is the length of the heating conductor (resistor), and Ac_heat is the cross section area of the heating conductor. The cross section area of the conductor Ac_heat is e.g. for a thin film given as:
A
c_heat
=h
c_heat
*w
c_heat; (eq. 6)
where hc_heat is the height/thickness of the conductor (resistor), and w is the width of the conductor (resistor).
For example, for a heating module with a heating conductor length Lc_heat of 62.5 m, a width of the heating conductor Wc_heat of 0.642 mm, and a heating conductor film thickness of 9 micrometer, the resistance R is approximately 305 ohm for aluminum.
By combining equations 1 and 4 above, the power is given by:
P=U
2
/R; (eq. 7)
i.e. the power increases with the square of the voltage, U, and is decreased with the inverse of the resistance R.
The power P may be written as:
P=U
2
*w
c_heat
h
c_heat)/(Lc_heat×resistivity). (eq. 8)
Because the resistivity is a material parameter, and the conducting heat film thickness is a physical parameter to be chosen, the power may be written as:
P=U
2*(wc_heat/Lc_heat)*constant). (eq. 9)
This means that for a chosen type of heat film, the wanted power P is most easily controlled by the voltage, and then by the length Lc_heat and width wc_heat of the heating conductor (resistor).
Since all electrical power P is converted to Joule heat Q, Pheat=dQ/dt, Pheat is equal to P. The time derivative of Joule heat Q, dQ/dt, which corresponds to a flow of thermal energy. The heat flow, dQ/dt, will flow in the negative direction of the temperature gradient.
The power supplied P will be transformed into heat flow, dQ/dt, which will flow downwards dQ/dtdown to the under lay structure by conduction dQ/dtcond, and upwards, dQ/dtup, by convection dQ/dtconv and radiation, dQ/dtrad, and for non-equilibrium to the rise of the temperature of the board/panel, dQ/dtboard.
dQ/dt=dQ/dt
cond
+dQ/dt
conv
+dQ/dt
rad
+dQ/dt
board (eq. 10)
For equilibrium:
dQ/dt=dQ/dt
cond
+dQ/dt
conv
+dQ/dt
rad (eq. 11)
dQ/dt
down
=dQ/dt
cond (eq. 12)
dQ/dt
up
=dQ/dt
conv
+dQ/dt
rad (eq. 13)
For non-equilibrium the temperature of the board will be rised by dQ/dtboard.
Regarding the temporal behavior, the temperature derivative with regard to time of the board/panel is:
dT/dt=dQ/dt
board/(d*density*Cp); (eq. 14)
where dT/dt is hence proportional to dQ/dtboard, and obviously, the temperature will rise if dQ/dtboard is not zero.
If the board is well insulated from the underlay structure, dQ/dtcond will be small, and hence the temperature gradient in the board/panel will be small, therefore the temperature will approximately follow a first order differential equation. The time dependence of the board/panel will then be:
T
board
=T
initial+(Tend−Tinitial)*(1−e−t/tau)); (eq. 15)
where Tinital is the temperature of the board/panel before the voltage V is applied, Tend is the final temperature, and tau is the characteristic time constant.
T
end
=P*R
th_tot; (eq. 16)
and for tau per area unit:
tau=cp*density*d; (eq. 17)
where cP is the specific heat capacity, Rth tot is the total thermal resistance, density is the density of the board/panel, and d is the thickness of the board.
Regarding the heat flow dQ/dt and temperature rise of the board/panel, the temperature rise on the surface of the board/panel will be dependent on the power P, the ambient temperature Tamb, the thermal resistance downwards, Rth down (between the heat film and the ambient floor), the thermal resistance between the film and the ambient air Rth_up. Each layer of the board/panel has its own thermal resistance, i.e. for the board/panel substructure Rth_sub, any dampening layer under the board Rth_damp, the heating film substrate Rth_substrate, the covering layer, Rth_top, and for the interface between the covering layer and the ambient air, Rth_conv. The thermal resistances downwards add in series, and the thermal resistances upwards add also in a series. However, the total thermal resistance downwards and the total thermal resistance upwards is combined in a parallel manner to a total thermal resistance, Rth tot:
R
th down
=R
th_sub
+R
th_damp; (eq. 18)
R
th_up
=R
th_substrate
+R
th_top
+R
th_conv
+R
rad (eq. 19)
and
1/Rth_tot=1/Rth down+1/Rth_up (eq. 20)
Which may be written:
R
th_tot=(Rth_down*Rth_up)/(Rth_down+Rth_up). (eq. 21)
The temperature increase ΔTfilm in the heating film conductor (resistance) is given by:
ΔTfilm=P*Tth_tot. (eq. 22)
The thermal resistance for a solid material Rthcond due to thermal conduction is given as:
R
th_cond
=L
material/(Lambda*A). (eq. 23)
The thermal resistance convection is given as:
R
th_conv
=A/U
th_conv (eq. 24)
Some non-limiting examples of materials and thermal resistances are given in Table 1 below.
In the non-limiting example above, an equal heat flow, dQ/dt, in both directions, upwards and downwards, is provided, assuming that the underlay structure has the same temperature as the ambient floor.
The heat flow due to radiation dQ/dtheat is given by:
dQ/dt
heat=epsilon*SB*(Tsurface4−Tambient4); (eq. 25)
where epsilon is the emissivity factor and SB the Stefan-Boltzmann's constant.
For a surface in a cavity, the radiation has to consider the view factor F, so the heat flow due to radiation becomes:
dQ/dt
heat=epsilon*SB*(Tsurface4−Tambient4)*F(physical dimensions); (eq. 26)
where F ranges, i.e. is in the interval, from 0 to 1.
The surface temperature of the panel is thus dependent on heat leakage to the underlay structure. For a well insulated floor panel, e.g. for 18 mm expanded polystyrene (PS), the temperature rise will be approximately 6 degrees for a power supply of 50 W/m2, and 3 degrees for 25 W/m2. If the insulation is poor, however, such as e.g. 1 mm PS, the temperature increase will be less, for example 3 degrees at 50 W/m2, according to experiments.
The present invention is not limited to the above described embodiments. Instead, the present invention relates to, and encompasses all different embodiments being included within the scope of the independent claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1851449-7 | Nov 2018 | SE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/SE2019/051153 | 11/14/2019 | WO | 00 |
