Patent Application
20250143470
N/A
The present invention relates in general to heated furniture and decking, but more particularly to modular heated board system.
Outdoor decking and furniture have long been popular choices for homeowners and commercial establishments to extend their living or operational spaces. Traditional decking systems and outdoor furniture are typically constructed using wood, composite, or other materials. Despite their popularity, these conventional systems and furniture pieces lack heating capabilities, limiting their usability during colder months.
Various attempts have been made to introduce heating elements to outdoor spaces. These include patio heaters, heated cushions, and heated mats primarily designed for melting snow and ice on outdoor flooring. However, retrofitting existing decks or furniture with these heating solutions can be cumbersome and costly. Also, they may not always align with the desired aesthetic or functional outcomes. Many of these heating solutions are not tailored to integrate seamlessly with standard decking materials or outdoor furniture designs, leading to potential aesthetic inconsistencies and functional challenges. These challenges can manifest as uneven surfaces, tripping hazards, or discomfort when using the furniture or walking on the decking.
Given these challenges, there is a clear need for a modular outdoor heated board system. Such a system should seamlessly integrate with conventional decking materials and outdoor furniture, offering efficient and uniform heating. This would significantly enhance the comfort and usability of outdoor spaces and seating, making it a viable solution for both new constructions and retrofit applications.
The following presents a simplified summary of some embodiments of the invention in order to provide a basic understanding of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some embodiments of the invention in a simplified form as a prelude to the more detailed description that is presented later.
It is a primary objective of the invention to offer a modular heated board system that can seamlessly integrate with conventional decking, be configured in various arrangements resembling furniture, and be interconnected to operate from a single power source.
In order to do so, a modular heated board system is provided, comprising a plurality of modular heated boards configurable in any desired arrangement, each of the modular heated boards comprising: an outer surface layer that is exposed to external elements and that forms the main structural element of the modular heated board; a heating layer located within the modular heated board, the heating layer including a heating element and electrical leads, wherein the electrical leads provide for power input and output, and wherein each modular heated board can be electrically connected to an adjacent modular heated board via the electrical leads; an insulating layer positioned within the modular heated board to direct heat from the heating layer towards the outer surface layer; and an enclosing and fastening layer configured to enclose the insulating layer and to attach the modular heated board to a supporting structure.
In one embodiment, the outer surface layer comprises a composite material. In another embodiment, the composite material is a glass fiber reinforced composite material. In one embodiment, the outer surface layer comprises aluminum. In another embodiment, the aluminum is capped or veneered with a decorative material. In one embodiment, the insulating layer comprises fiberglass insulation. In one embodiment, the insulating layer comprises rigid foam insulation. In another embodiment, the plurality of modular heated boards can be integrated with conventional decking or arranged to resemble furniture. In yet another embodiment, each of the electrical leads of the heating layer comprises a first pair of leads for power input to the modular heated board and a second pair of leads for power output from the modular heated board to enable electrical connection to an adjacent modular heated board. In one embodiment, a transformer/control box electrically connected to the modular heated boards is provided, wherein the transformer/control box regulates voltage to each heating element and facilitates the distribution of power across the plurality of modular heated boards.
The foregoing has outlined rather broadly the more pertinent and important features of the present disclosure so that the detailed description of the invention that follows may be better understood and so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the disclosed specific methods and structures may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should be realized by those skilled in the art that such equivalent structures do not depart from the spirit and scope of the invention as set forth in the appended claims.
Other features and advantages of the present invention will become apparent when the following detailed description is read in conjunction with the accompanying drawings, in which:
The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the general principles of the present invention have been defined herein to specifically provide a modular heated board system.
It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. The terms “a” or “an,” as used herein, are defined as to mean “at least one.” The term “plurality,” as used herein, is defined as two or more. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). The term “providing” is defined herein in its broadest sense, e.g., bringing/coming into physical existence, making available, and/or supplying to someone or something, in whole or in multiple parts at once or over a period of time. These terms generally refer to a range of numbers that one of skill in the art would consider equivalent to the recited values (i.e., having the same function or result). In many instances these terms may include numbers that are rounded to the nearest significant figure.
One key advantage of the present invention lies in its utilization of conductive heat transfer mechanisms, designed for optimized performance in outdoor settings. Unlike conventional outdoor heating solutions that largely rely on radiant heat transfer, the present invention allows for direct contact between the user and the heating surface, thereby enhancing the efficiency and effectiveness of heat transfer. This design sets the present invention apart in the marketplace as being especially tailored for direct heating via conductive heat transfer, although it also incidentally serves to warm the surrounding area. In particular, the invention is rooted in our standard line of conductive heat-based outdoor furniture, which has demonstrated superior performance in direct user heating as compared to radiant alternatives. While the invention does offer ancillary benefits, the primary objective is to provide efficient, direct heat to users, making it a uniquely effective solution for outdoor heating needs. The present invention will now be explained in detail below.
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The insulating layer 108 ensures the heat generated by the heating layer 106 is contained and efficiently directed towards the outer surface layer 103. In one embodiment, the insulating layer 108 is comprised of fiberglass insulation. In another embodiment, the insulating layer 108 is comprised of rigid foam insulation. In yet other embodiments, the insulating layer 108 may be comprised of any suitable insulation material known in the art. The enclosing and fastening layer 110 is dual purpose. First, layer 110 is configured to enclose and retain the insulation layer 108 within the modular heated board 102. Second, layer 110 is configured to be used as the direct surface for fastening the modular heated board 102 to another surface, such as floor joists, or framing for any desired arrangement. Any fastening means, fasteners, adhesives, etc. may be used for attaching each modular heated board to the desired surface.
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The modular heated board system is meticulously designed with a focus on both functionality and safety, especially given its outdoor application and integration with electrical components. Adhering to international standards, such as IP65, waterproofing techniques are employed for all electrical connections to and from each modular heated board. This encompasses seals at various connection points, including where the leads interface with the enclosing and fastening layer 110 and the terminals. In some embodiments, the leads might be sheathed in protective cables, with the possibility of the first and second pair of leads being consolidated into a singular electrical cable. Optimized for a standard nominal voltage (120V), the system's transformer/control box ensures consistent voltage regulation to each heating element. Emphasizing safety, in some embodiments, the system incorporates built-in thermal sensors to monitor board temperatures, preventing overheating by activating an automatic shut-off feature during temperature anomalies. All electrical connections, inclusive of leads and terminals, benefit from high-grade, flame-retardant encasements, mitigating potential electrical fire risks. Additionally, in some embodiments, the system is equipped with ground-fault circuit interrupters (GFCIs) to promptly cut off power during detected ground faults. Advantageously, the design inherently resists moisture ingress, ensuring that elements like water or snow do not jeopardize the electrical or heating components.
While not depicted in the figures, certain embodiments of the system feature both remote and manually activated power controls, allowing for precise temperature adjustments. In some configurations, users have the flexibility to activate or deactivate specific boards or designated zones, tailoring the heating to their immediate needs. The control mechanism can manifest as a manual switch, a sophisticated digital interface, or even a smartphone application. This smartphone application, beyond basic controls, could offer advanced features such as learning user preferences over time, providing insights into energy consumption, and sending alerts or notifications in case of board malfunctions or potential overheating risks. Such integrative features not only enhance user convenience but also ensure a safer and more informed operation of the system.
Ease of maintenance is a further advantage of the system. Should a modular board malfunction or wear out, it can be individually replaced without the need to overhaul the entire system. Additionally, in some embodiments, the system may include diagnostic features that alert users to any issues, simplifying the process of identification and repair. This modular approach not only ensures uninterrupted usage but also makes maintenance cost-effective.
Although the invention has been described in considerable detail in language specific to structural features, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features described. Rather, the specific features are disclosed as exemplary preferred forms of implementing the claimed invention. Stated otherwise, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. Therefore, while exemplary illustrative embodiments of the invention have been described, numerous variations and alternative embodiments will occur to those skilled in the art. Such variations and alternative embodiments are contemplated, and can be made without departing from the spirit and scope of the invention.
It should further be noted that throughout the entire disclosure, the labels such as left, right, front, back, top, bottom, forward, reverse, clockwise, counterclockwise, up, down, or other similar terms such as upper, lower, aft, fore, vertical, horizontal, oblique, proximal, distal, parallel, perpendicular, transverse, longitudinal, etc. have been used for convenience purposes only and are not intended to imply any particular fixed direction or orientation. Instead, they are used to reflect relative locations and/or directions/orientations between various portions of an object.
In addition, references to “first,” “second,” “third,” and etc. members throughout the disclosure (and in particular, claims) are not used to show a serial or numerical limitation but instead are used to distinguish or identify the various members of the group.
