AU2014227518B2 - Heating panel - Google Patents

Abstract

Document4-19/09/2014 A heating panel including a base panel having a channel formed into a face of the base panel and an electric element laid to extend along the channel. B. Routed Channes C. ConTrol/ A. Base D. Routed corners comprise of non-right angle turnssuch as, but not limited to, Material D2 21F .n.

Description

HEATING PANEL

Field of the Invention

The invention relates to a heating panel and, more particularly, but not exclusively, to an electric panel heater of the kind generally known as an eco panel heater. The heating panel may be of the kind having no moving parts, and may be adapted for being mounted on an interior wall of a building for heating an interior space of the building, or as a free standing portable unit.

Background of the Invention

It is known to provide electric panel heaters commonly known as eco panel heaters. This type of heater typically comprises two halves joined together by adhesive with a heater element sandwiched between the two layers. Heaters of this type commonly include a protective thermal device wired in-line with a heating element wire which is embedded in the base material and/or sandwiched between the two layers.

The applicant has identified that existing heating panels of this kind have disadvantages owing to the manner in which the heating element is sandwiched within the panel, and due to one or more fuses being embedded within the base material and/or sandwiched between the two layers.

The applicant has identified that it would be advantageous for there to be provided a heating panel with improved resistance to stress on the heater element, minimising hot spots and reducing likely points of failure. It has also been identified as being desirable to provide a heating panel which provides improved accessibility to a thermal protection device for servicing and/or replacement.

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2014227518 01 Oct 2019

Examples of the invention seek to provide an improved heating panel which overcomes or at least alleviates disadvantages associated with existing heating panels.

Summary of the Invention

In accordance with one aspect of the present invention, there is provided a heating panel for an electric panel heater, the heating panel having a single base panel with a channel formed into a face of the base panel, wherein the heating panel also includes an electric element laid to extend along the channel, a mesh sheet covering the channel, and a settable material applied over the top of the mesh sheet, resulting in the settable material being embedded into the mesh sheet and the channel.

In accordance with another aspect of the present invention, there is provided a method of forming a heating panel for an electric panel heater, comprising the following steps in sequence: providing a single base panel, forming a channel into a face of the base panel, laying an electric element to extend along the channel, providing a mesh sheet to cover the channel, and applying a settable material over the top of the mesh sheet, thereby embedding the settable material into the mesh sheet and the channel.

Preferably, the channel forms a serpentine path across a major portion of the width and height of base panel. More preferably, the channel includes a plurality of comers, and each of said corners is in the form of a curve, or a junction of straight lines deviating from a continuous straight line by an angle less than 90 degrees. Even more preferably, each of said corners is in the form of a curve, or a junction of straight lines deviating from a continuous straight line by an angle less than 45 degrees.

More preferably, the serpentine path winds back and forth across the panel in substantially parallel linear sections, and each pair of adjacent linear sections is joined by a corner, the corner being formed of a curve, or a plurality of junctions, each junction being a junction of straight lines deviating from a continuous straight line by an angle less than 90 degrees. The substantially parallel linear sections may run vertically along the heating panel

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2014227518 20 Sep 2019

-3 In a preferred form, the channel is routed into the face of the base panel.

Preferably, the heating panel includes a control unit, and opposite ends of the channel terminate at the control unit. More preferably, the control unit houses a thermal protection device and/or a tilt switch device.

Preferably, the thermal protection device is arranged to be accessible from outside the base panel.

Preferably, the thermal protection device is located at a portion of the base panel outside of an area covered by mesh material such that an access path for servicing the thermal protection device is maintained.

Preferably, a settable cement material (which may be a blended cement material) is embedded into the mesh material to cover the channel.

Preferably, the heating panel includes a plurality of fuses/sensors spaced at different locations of the heating panel. More preferably, wiring to the fuses/sensors is in the form of said electric element. Even more preferably, wiring to the fuses/sensors is in the form of additional wiring, said additional wiring being additional to said electric element and said additional wiring being connected to the control unit.

Brief Description of the Drawings

The invention is described, by way of non-limiting example only, with reference to the accompanying drawings, in which:

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-4Figure 1 shows a heating panel in accordance with an example of the present invention, as well as detail of example configurations of a channel formed in the panel; and

Figure 2 shows the panel of Figure 1, with a channel of the panel covered by a mesh material;

Figure 3 shows a heating panel in accordance with another example of the present invention, the heating panel having a vertical electric element wire with sensors;

Figure 4 shows a heating panel in accordance with another example of the present invention, the heating panel having horizontal electric element wire; and

Figure 5 shows a cross-section of the element wire.

Detailed Description

With reference to Figures 1 and 2, there is shown a heating panel 10 having a heating element which follows a curved path to avoid sharp corners so as to reduce the stress on the heater element, thereby minimizing hot spots and reducing likely points of failure. The heating panel 10 has a different construction process which avoids problems associated with existing heating panels. In particular, existing heating panels use two cement sheets (which may be formed of blended cement material) which are sandwiched together with a heating element inside, and the applicant has identified that such existing heating panels over time develop cracks in the joins where the two cement sheets have been fixed together. In contrast, the present heating panel uses only one cement sheet (which may be formed of blended cement material) with a channel routed for the heating element. A mesh is placed over the surface of the base panel to provide additional strength, then blended cement material and/or plaster may be applied over the top of the mesh.

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-5More specifically, with reference to Figure 1, there is shown a heating panel 10 including a base panel 12 having a channel 14 formed into a face of the base panel 12, and an electric element 16 laid to extend along the channel 14. The channel 14 forms a serpentine path across a major portion of the width and height of the base panel 12, so that a large proportion of the surface area of the base panel 12 is heated by the electric element 16. The channel 14 includes a plurality of comers 18, and each of the corners 18 is in the form of a curve, or a junction of straight lines deviating from a continuous straight line by an angle less than 90°. The lower part of Figure 1 shows detail of alternative examples of a configuration of a path of the channel 14 around the corners 18 whereby sharp corners are avoided. In particular, the corner 18 may be formed as a continuous curve, or as a series of junctions in which right angles are avoided. In one form, each of the corners 18 may be in the form of a curve, or a junction of straight lines deviating from a continuous straight line by an angle less than 90°, and more preferably less than 45°, per junction.

As can be seen, the serpentine path winds back and forth across the base panel 12 in substantially parallel linear sections, and each pair of adjacent linear sections is joined by a corner 18. Each corner is formed as a curve 20, or as a plurality of junctions 22, each junction 22 being a junction of straight lines deviating from a continuous straight line by an angle less than 90°.

It will be appreciated that the angle of each junction may be more than 45° at the start (or end) of the plurality of junctions, but that each junction between the start and end would preferably be 45° or less. Accordingly, the plurality of curves can be made up of angles less than 90° and more preferably less than 45°.

The channel 14 may be routed into the face of the base panel 12. More specifically, the base panel 12 may be formed from a blended cement mixture that is dried hard into a sheet, with the channel 14 being routed using an industrial router. The electric element 16 may be either a single core metal wire or an insulated single core metal wire. The wire is covered over by a top layer of blended cement material similar in composition

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-βίο that of the base panel 12. Subsequently, the base panel 12 may be smoothed/finished and painted.

The heating panel 10 may also include a control unit 24, with opposite ends of the channel 14 terminating at the control unit 24. The control unit 24 may house a thermal protection device 26 and/or a tilt switch device. Depending on the heater criteria (mainly power rating), it is also possible that no fuses would be used.

The heating panel 10 may also include a mesh sheet 28 covering the channel 14 (see Figure 2). The heating panel 10 may include a settable material embedded into the mesh sheet 28 and the channel 14. The mesh can be either placed on both sides or only one side of the cement material (in both cases the mesh is embedded in the cement material when the cement material is a paste-like consistency before hardening). In the case of one side, the mesh will be placed over the element wire and routed channels to fill in any space and provide a protective top layer. The mesh can be a glass fibre material such as fibreglass or the like, however other mesh materials may be used.

The control unit 24 may be in the form of a separate plastic box which is attached to the base panel 12 after the panel is finished, i.e. after the blended cement material is cured with the element wire 16 and mesh sheet 28 embedded in the blended cement material, and possibly also after painting. The control box may be opened or removed from the heating panel 10 if required, and the control box can be any shape or at any position in the panel.

Advantageously, examples of the present invention provide a heating panel having curved angles of the routed channels, an embedded mesh and inclusion of thermal switches and/or a tilt switch device in the control box area.

Various changes in the form and detail can be made within the scope of the invention, as will be appreciated by persons skilled in the art. In particular, a number of bends/comers and the routing arrangement may depend of a variety of factors including,

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-7but not limited to, the size of the panel, the material of the heater element, and the power of the panel. Advantageously, the construction according to the present invention improves panel strength, seals in the heater element, and holds the unit together in the event of impact damage. The construction of the present invention minimizes exposure of live internal wires. The mesh can consist of various sizes or shapes. Typically, the mesh patterns are square or rectangular and made from a non-conducting material.

Advantageously, in accordance with the example disclosed, the thermal protection device 26 in the form of a fuse may be included in the control unit 24 or outside the embedded region of the base panel 12 so that the thermal protection device 26 can be easily accessed or replaced if required. The control unit 24 can be positioned anywhere within the heater panel 10, but will usually be located towards an outer edge in one of the corners. The embedded fuse is not the thermostat for monitoring room temperature - this is part of the thermal protection system within the product which usually (but not always) includes two items, a resettable fuse/switch and a permanent fuse. The resettable fuse can reset itself after the exceeded temperature and reduces back to normal operating conditions. The permanent fuse is set higher than the resettable fuse and is a last line of defence if the resettable fuse fails.

The heater panel may have a tilt switch device. The applicant has identified that it would be advantageous for there to be provided an eco panel heater having a tilt switch. Currently available eco panel heaters do not have tilt switches due to the fact that most eco panel heaters available are exclusively wall mountable. Since examples of the present invention may have dual purpose (wall mountable and free standing), a mechanical or electronic tilt switch may be included in the control box.

With reference to Figure 3 of the drawings, there is shown a heating panel 10 in accordance with another example, wherein the heating panel 10 has a vertical element 16 with a plurality of sensors 30. The sensors 30 may be provided either in the control unit/box 24 or embedded within the body of the heater. The provision of this feature

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- 8 facilitates improvements in monitoring and controlling the temperature of the heating panel

10.

The applicant has identified that existing heating panels may have only two fuses (at most) embedded at the same location inside the panel and/or sandwiched between component panels of the heater. It has been determined by the applicant that it would be advantageous for there to be provided two or more sensors 30, or alternatively two or more fuses instead of the sensors 30, placed at different locations embedded within the heating panel 10 as per the arrangement shown in Figure 3. Accordingly, it will be understood by those skilled in the art that in the arrangement shown in Figure 3 the sensor image could represent both sensors and/or fuses.

Existing heating panels typically have no fuses or sensors, other than possibly a room ambient sensor for thermostat control, or a maximum of two fuses placed side-byside in the same location in the panel (at the centre of the panel or to one side). It has been identified by the applicant that it would be beneficial for a heating panel to have multiple fuses/sensors at clearly different locations. The wiring to the sensors (or fuses) could either use the existing heater element wiring or an additional wiring system that is connected to the control box/unit.

In the particular arrangement shown in Figure 3, the wiring to the sensors 30 is provided by the existing electric element 16. In particular, an upper length of the electric element 16 is diverted downwardly between parallel sections of the electric element 16 to communicate with the sensors 30. The sensors 30 are located at spaced locations across the heating panel 10. In particular, the sensors 30 are spaced vertically and horizontally. The horizontal spacing of the sensors 30 is such that the sensors 30 are separated by one or more sections of parallel serpentine electric element 16. In the arrangement shown in Figure 3, there is also one sensor 30 shown in (or on) the control unit 24.

With reference to Figure 4, there is shown a heating panel 10 in accordance with another example of the present invention, the heating panel 10 having a horizontal electric

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-9element wire. The heating panel 10 shown in Figure 4 is otherwise generally similar to the heating panel shown in Figure 2 and like features are indicated with like reference numerals. Accordingly, it will be understood by those skilled in the art that the substantially parallel linear sections of the electric element 16 may run generally vertically along the heating panel (as shown in Figures 1 to 3) or generally horizontally along the heating panel (as shown in Figure 4).

It is considered that horizontal routed lines may be preferable, though not essential, and this may be achieved by forming horizontal channels/grooves 14. The horizontal channels 14 may serve to strengthen the heating panel 10 so that when an impact occurs or people lean up against the heater in operation it is slightly less likely to break as the forces will likely, but not always, be in the vertical direction rather than horizontal. Accordingly, the horizontal routed channels/grooves 14 tend to improve resistance to the vertical forces reducing the likelihood of the panel cracking along the channels/grooves 14.

Turning to Figure 5, there is shown a detailed and enlarged diagrammatic crosssection of the element wire 16, depicting heating wire/conductor 32 (single or multistranded) surrounded by insulating material 34.

The applicant has determined that existing eco panel heaters do not, at least typically, use an insulated heater filament wire within the product, and that it would be beneficial to do so for a number of reasons outlined below. The insulation itself may be formed of various materials which are rated for high temperatures. It has been determined that the insulation material could possibly include, but is not restricted to, silicone composite or silicone rubber composite materials. The purpose of the insulated heater wire is primarily to reduce the risk of main voltage contact to the end user in case of failure of the product. This could include physical damage by impact when the panel cracks and exposes the heater element or when moisture penetrates the fibre/cement panel potentially allowing electrical leakage to occur. In typical eco panel heaters on the market the heater element has no insulation and relies on sheets of insulating material laid across the wire and also the fibre/cement material to insulate the product. However, in the case of physical

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- 10damage the insulation sheet can split allowing direct contact with the raw heater element. Also, in the case of water ingress, gaps between the insulating sheets can allow electrical leakage to occur. The insulated wire ensures that there are no points of electrical leakage along the wire as the wire is completely sealed by the insulation when the wire is manufactured. In addition, it has been determined by the applicant that existing fibre/cement panels often being constructed of two pieces glued together does not assist in preventing leakage as cracks in the joins may occur over time, creating gaps that potentially increase the likelihood of electrical leakage paths being formed. In the routed heater panel of examples of the present invention the applicant does not have this cracking or splitting at the edges as the panel 10 does not use two halves joined together but a single routed fibre/cement board which is then cemented/plastered over to fill the routed parts. Accordingly, there are three constructional advantages to reducing exposure to live parts and reducing electrical leakage being: a) reduced likelihood of mains voltage exposure to element in case of physical damage; b) reduced likelihood of electrical leakage owing to the element wire being insulated; and c) minimised paths of electrical leakage as no joined fibre/cement panels.

While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the present invention should not be limited by any of the above described exemplary embodiments.

The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

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2014227518 19 Sep 2014

- 11 Throughout this specification and the claims which follow, unless the context requires otherwise, the word comprise, and variations such as comprises and comprising, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or 5 steps.

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Claims (19)

1. A heating panel for an electric panel heater, the heating panel having a single base panel with a channel formed into a face of the base panel, wherein the heating panel also includes an electric element laid to extend along the channel, a mesh sheet covering the channel, and a settable material applied over the top of the mesh sheet, resulting in the settable material being embedded into the mesh sheet and the channel.

2. A heating panel as claimed in claim 1, wherein the channel forms a serpentine path across a major portion of the width and height of base panel.

3. A heating panel as claimed in claim 2, wherein the channel includes a plurality of corners, and each of said comers is in the form of a curve, or a junction of straight lines deviating from a continuous straight line by an angle less than 90 degrees.

4. A heating panel as claimed in claim 3, wherein each of said comers is in the form of a curve, or a junction of straight lines deviating from a continuous straight line by an angle less than 45 degrees.

5. A heating panel as claimed in any one of claims 2 to 4, wherein the serpentine path winds back and forth across the panel in substantially parallel linear sections, and each pair of adjacent linear sections is joined by a comer, the corner being formed of a curve, or a plurality of junctions, each junction being a junction of straight lines deviating from a continuous straight line by an angle less than 90 degrees.

6. A heating panel as claimed in any one of claims 1 to 5, wherein the channel is routed into the face of the base panel.

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7. A heating panel as claimed in any one of claims 1 to 6, wherein the heating panel includes a control unit, and opposite ends of the channel terminate at the control unit.

8. A heating panel as claimed in claim 7, wherein the control unit houses a thermal protection device.

9. A heating panel as claimed in claim 7 or claim 8, wherein the control unit includes a tilt switch device.

10. A heating panel as claimed in claim 7 or claim 8 where appended to claim 7, wherein the thermal protection device is arranged to be accessible from outside the base panel.

11. A heating panel as claimed in claim 10, wherein the thermal protection device is located at a portion of the base panel outside of an area covered by mesh material such that an access path for servicing the thermal protection device is maintained.

12. A heating panel as claimed in any one of the preceding claims, wherein the settable material is a settable cement material embedded into the mesh material to cover the channel.

13. A heating panel as claimed in any one of the preceding claims, wherein the heating panel includes a plurality of fuses/sensors spaced at different locations embedded within the heating panel.

14. A heating panel as claimed in claim 13, wherein wiring to the fuses/sensors is said electric element.

15. A heating panel as claimed in claim 13, wherein wiring to the fuses/sensors is in the form of additional wiring, said additional wiring being additional to said electric element and said additional wiring being connected to the control unit.

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2014227518 01 Oct 2019

16. A heating panel as claimed in claim 5, wherein the parallel linear sections are generally vertical in relation to the heating panel when fitted in situ.

5

17. A heating panel as claimed in claim 5, wherein the parallel linear sections are generally horizontal in relation to the heating panel when fitted in situ.

18. A method of forming a heating panel for an electric panel heater, comprising the following steps in sequence:

10 providing a single base panel, forming a channel into a face of the base panel, laying an electric element to extend along the channel, providing a mesh sheet to cover the channel, and applying a settable material over the top of the mesh sheet, thereby

15 embedding the settable material into the mesh sheet and the channel.

19. The method of claim 18, wherein the settable material is a settable cement material.