RADIANT HEAT MODULE WITH PCM

Abstract

 A module for radiant heating, having a studded plate for holding a tube with heating and/or cooling fluid. The studded plate has studs arranged as pockets for being filled with PCM, whereby the PCM exchanges heat with said tube. A stud filled with the PCM, is air- and watertight sealed with a sealing sheet, independently of a sealing of other studs on the plate. The studded plate comprises an inner section filled with the PCM, and an outer section of studs situated around at least one side of the studded plate, whereby these outer studs are left empty and open at the side of the plate, thereby allowing studs of a second studded plate, to be releasably clickable into the open studs of the studded plate. The plate may be provided with an insulating EPS underlayer.

Description

TECHNICAL FIELD

[0001] The invention relates to radiant heating systems. More particular the invention relates to radiant heating systems with improved heating or cooling properties using Phase Changing Materials (PCM). More particular the invention relates to radiant heating systems using heat conduits (i.e. tubes), such as floor, wall or ceiling heating systems, provided with PCM.

BACKGROUND

[0002] Integration of PCM into existing and improved floor heating concepts increases heating and cooling efficiency of otherwise in principle conventional radiant heating systems. The challenge is to optimize heat exchange between fluids running through conduits (tube) of the heating system and the PCM. Several solutions have been proposed, in for example patent publications, which are discussed hereinafter.

[0003] Japanese patent application JP2009074743A is summarized as a heat pump type floor heating device having a heat insulating board mounted on lower faces of joists. A hollow container is disposed on a top face of the heat insulating board. A floor board lies on the container. A hot water pipe runs in a groove formed on the top face of the hollow container constituting a panel. A latent heat storage material in the container is heated by the hot water flowing in the hot water pipe, and the heat of a temperature of 25-35°C is stored in the latent heat storage material.

[0004] Dutch patent NL1038152C2 by Unifloor B.V. is summarized as a floor comprising a support construction and provided with means for controlling the temperature of said floor, said means comprising conduits for liquid either electric current and containers containing a heat storage material, such as PCM. Said containers have an oblong flat shape and are positioned on the conduits, such that their top surfaces form part of the floor surface.

[0005] A disadvantage of the current art solutions, such as described above is, that they are costly, labor-intensive and do not match the wishes and needs of the general user and market.

DISCLOSURE OF INVENTION

[0006] It is an object of the present invention to provide a cost efficient, flexible and environmentally friendly radiant heating device which is easy to install, ergonomically designed, and provides effective heating and/or cooling of an environment such as in a building.

[0007] The object is realized by the following clauses and further embodiments.

1. A module for radiant heating for heating or cooling of a floor, wall or ceiling, comprising a studded plate arranged for supporting a tube configured for having a heating and/or cooling fluid respectively, flowing therethrough, the studded plate comprising a sheet with an array of protruding studs, wherein, when used on a floor, the plate is facing the bottom and the studs are facing upward, whereby the studs are configured with means for holding a part of the tube in close contact, characterized in that,

• one or more of the studs of the studded plate are arranged as pockets of various volumes between 15 and 25 cl., arranged for being filled with a Phase Changing Material (PCM), such as a salt;
• the PCM of a filled stud of the one or more studs is arranged for exchanging heat with the fluid of said tube, mainly at the location of the close contact area between the filled stud and the tube;
• each filled stud of the one or more studs is individually sealed airtight and/or water vapor diffusion tight with a sealing sheet, independently of a sealing of other studs of the studded plate.

2. The module according to clause 1, characterized in that the studded plate comprises an inner section of studs and an outer section of studs situated around at least one side of the studded plate, wherein a substantial number of studs of the inner section is filled with the PCM and sealed, whereas a number of the studs of the outer section is left empty and open at the side of the plate, thereby configured to receive one or more studs of a second studded plate, and making the second studded plate releasably clickable to the studded plate.

3. The module according to clause 1 or 2, characterized in that the studded plate is configured with an underlayer made of Expanded Polystyrene (EPS) made in various thickness with acoustical and/or thermal insulation characteristics.

4. The module according to any one of the preceding clauses, characterized in that the sealing sheet is made of polystyrene, such as a polystyrene foil.

5. The module according to any one of the preceding clauses, characterized in that sealing sheet is glued around the edge of the stud, such as with a thermobond adhesive.

6. The module according to any one of the preceding clauses, characterized in that the PCM comprises a PCM with a phase change temperature in the range of 21 to 26 degrees Celsius.

7. The module according to any one of the preceding clauses, characterized in that the PCM comprises a gel.

8. The module according to any one of the preceding clauses, characterized in that the distance from heart to heart of two adjacent studs is 5 cm.

9. The module according to any one of the preceding clauses, characterized in that the studded plate is made of polystyrene having a thickness in the range of 0,9-1,4 mm.

10. The module according to any one of the preceding clauses, characterized in that the studded plate is configured with one or more reinforcing grooves and/or ribs.

11. The module according to any one of the preceding clauses, characterized in that the studded plate has a substantially rectangular shape and the reinforcing grooves and/or ribs are running diagonally.

12. The module according to any one of the preceding clauses, characterized in that the studs are made of a rigid material and/or are reinforced with grooves and/or ribs.

13. The module according to any one of the preceding clauses, characterized in that the underlayer is glued to the sealing sheet.

14. The module according to any one of the preceding clauses, characterized in that the studded plate is made of a single thermoplastic sheet which is vacuum molded.

15. The module according to any one of the preceding clauses, characterized in that the array of studs is configured to lead the tube in an at least partly straight line between any of the studs.

16. The module according to any one of the preceding clauses, characterized in that the module is configured for supporting a screed and the screed is optionally covered by a floor finish.

17. The module according to any one of the preceding clauses, characterized in that the module comprises the following elements:

• the insulation layer with on top of that
• the polystyrene sheet, with on top of that
• the studded plate, whereby the studs are facing outward.

18. The module according to clause 17, characterized in that any or all elements are made of regenerated or recycled material, and/or releasably joint and reusable.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The figures show views of embodiments in accordance with the present invention.

FIGURE 1

shows a perspective view of the invented module.

FIGURE 2

shows a top view of the studded plate comprised in the invented module.

FIGURE 3

shows a front view of the module.

FIGURE 4

shows a part of a cross section of the front view of figure 3.

DETAILED DESCRIPTION

[0009] The invention is now described by the following aspects and embodiments, with reference to the figures.

[0010] The invention discloses a modular system with a free laying pattern of studded plates with studs which are at least partly filled with PCM, and which are used for underfloor heating using tubes in a closed system, whereby the tubes are connected to the studs. This way, a closed and liquid-tight floor construction is offered. The transfer between tube and PCM is optimally carried out by clamping the pipe between the filled PCM studs. Furthermore, floor plates are divisible for optimal processing. The free and flexible pipe distances (i.e. a minimum of 50 mm) ensure sufficient heat coverage based on the heat demand in the room. The combination of these features and elements ensures that underfloor heating (or wall,- or ceiling heating systems based on the same principle), plays a leading role for the heat delivery (or cooling), due to its flexibility of laying patterns and the improved transfer to the PCM.

[0011] The invention integrates PCM technology with basic principles of radiant heating systems. Hereinafter a typical application in floor heating systems is described, but the present invention is also very suitable for applications in wall heating systems, or heating system integrated in ceilings. In a wall heating system the invented heating module is preferably placed in an upright/vertical position, whereby the heat radiation faces towards the room, whereas, when us in a ceiling system, the module may also be placed upside down, without losing functionality or compromising the structural integrity, or causing safety risks.

[0012] The invention proposes to use a studded plate as a basis of a heating module. By combining and connecting multiple studded plates a whole surface such as a floor may be covered. Such a studded plate may in principle be preferably dedicated for flexible conduits/tubes for leading a fluid through. Such fluid may comprise water or a special coolant or heating fluid. The advantage of using tubes comprises that the heating system may also be used as a cooling system, just by running cold fluid (such as treated water) through the tubes instead of hot fluid.

[0013] By adding PCM to the heating system in the invented manner, the heating and cooling properties of the heating (or cooling) system are largely improved.

[0014] The floor heating heats the room and at the same time will ensure that the PCMs are charged. After the room is up to temperature and there is again a heat demand in the room, the charged PCM will release heat to the room on the basis of floor surface temperature. This ensures that there are fewer switching moments and actions for the heat or cold source, which significantly extends the lifespan of the heating/cooling system, and results in energy savings of between 30 and 40%.

[0015] The conduits may comprise tubes, which have a relatively rigid wall for preventing collapsing and thereby blocking of the flow of the fluid, when e.g. a load is (accidentally) put on the tube, or when the tube is bend in a corner and put under some stress. The tubes are on the other hand flexible to a certain extent to enable laying the tubes in a winding pattern.

[0016] The tubes may also be configured with coupling pieces to connect at least one tube end to the heat pump system, or for coupling multiple tubes to each other. Coupling pieces for connecting special bended tube pieces may be used, but in principle the studded plate is designed such, and the tubes used are sufficient flexible to use a single tube in a winding pattern to cover as much of the floor which is to be heated.

[0017] The studded plates are configured as modules, and a floor covered with the invented modules is thereby comprised of a modular system. Connection of multiple modules is done in a manner described below and thereby form a complete floor heating system.

[0018] The present invention proposes to fill the studs of the studded plate module with PCM. This way, the stud, acting as connector of the tube and guiding the tube, acts also as heat exchange, whereby a close contact is established between the PCM and the tube connected to the stud.

[0019] Depending on the desired heat storage and release properties of the PCM, more or less PCM may be required in certain situations. For this purpose, the available amount of PCM may be varied in a couple of ways.

[0020] A First adaptation comprises that the stud is unchanged in size and volume, but the level of filling is be varied, preferably already in the production process of the module.

[0021] A second approach comprises that the size of the stud is varied, and thus the capacity of the filling level. Size may be varied in height and/or width.

[0022] A third way comprises that the number of filled studs is varied, which allows more or less use of PCM per surface.

[0023] Each module may be cut in a desired shape and reduced in size on location. By combining regular i.e. rectangular modules with customized modulus, virtually any room may be provided with complete floor covering heating system. No extra handling and work steps are required at location, because the PCM is integrated in the improved and flexible studded plate.

[0024] Positioning of the conduits (i.e. tubes) is very flexible because of the placement of the studs on the studded plate. Preferably, the studs are positioned in an array or matrix, leaving space between each stud to guide a tube straightly and unobstructed by other studs. For this purpose the distance, heart to heart between any two adjacent studs is preferably 50mm, considering a regular tube diameter of around 16 mm, i.e. 14, 16 or 17 mm as currently available. The distance between tubes is usually chosen anywhere between 100 mm and 150 mm, depending on the application. The invented module facilitates the use of these standard tubes and placements.

[0025] The placement of the studs also allows for bending the tubes in e.g. a winding pattern.

[0026] The studded plate is preferably made of a single polystyrene sheet, which is molded to form hollow studs. The sheet may e.g. made of High Impact Polystyrene (HIPS). Using a material like polystyrene, molding is easy and the produced studded plate is relatively light and flexible, yet sturdy and durable.

[0027] The plate may be offered in various colours, provided with embossed or indented markings, instructions and trademarks from the factory.

[0028] It is possible to produce the studded plates as flexible plates, when the application area requires flexibility around corners or bends, but in most cases a plate with a certain level of rigidity will be required to be laid on level floors. For this purpose, the plate may be provided with additional grooves, ridges and/or rims to increase rigidity and stability. These grooves etc. are be designed such that they do not obstruct the positioning of the tubes.

[0029] The studs themselves, apart form being flexible in shape and size in the production process, are preferably provided with some kind of clamping means to hold a tube in place and to ensure that the tube has maximal contact with a largest possible surface area of the stud, to ensure fast and maximum heat exchange between the tube's fluid content and the PCM contained by the stud.

[0030] A preferred clamping means comprises that the studs are provided with protrusion around the top of the stud, e.g. at four positions. The protrusions are somewhat flexible and configured to envelop at least a part of the diameter of a tube. A tube may in this way be clicked to the stud. The studs may be flat or flattened at one or more sides, and have rounded corners. On the one hand the flat sides provide maximum surface area contact with a clamped tube and on the other hand rounded corners allow bending of a tube around a corner without putting too much stress on the tube.

[0031] The studs are preferably designed such, that when multiple plates are stacked, the studs of the lower plate fit into the hollow underside of the plate laying on top of the lower plate. The studs are therefore designed slightly tapered towards the top. This saves space when stored or transported.

[0032] The studs are preferably filled with gel PCM in the production phase. Each stud is than sealed with a foil (or a sheet). The foil is made of material which is preferably durable, able to withstand some impact and sheer resistant. The foil is preferably bonded to the underside of the studded plate with an adhesive or thermobond. Each stud comprising PCM is sealed off individually. This has the major advantage that the plate may be cut along a stretch between studs and still leaving the sealing of the individual studs intact.

[0033] Another big advantage comprises that, when the seal, for whatever reason, is damaged at one position under the plate, this may only affect the studs immediately above the damage. PCM may leak out of that particular stud, but PCM in other not affected studs will securely remain sealed and safe. Using gel PCM largely reduces the risk of losing PCM in the case of micro damage. Would repair be necessary, repairing of the seal is possible. If the affected stud is not clamping a tube, it may even have little to none influence on the effectiveness of the invented device, would the seal not be repaired.

[0034] As a studded plate is preferably designed to be connectable to a second plate, the studs at e.g. the outer edge of the plate may be left empty, i.e. without PCM and without a sealing. These empty studs may then receive studs of a second plate in their hollow, thereby providing a means to connect two studded plates in an easy and secure manner.

[0035] Besides storing and exchanging of heat between tubes and PCM, additionally, an insulation layer may be provided covering the opposite side of the studs/tube side, i.e. at the underside of a module in a floor heating application. The main purpose of this insulation layer is to prevent that the heating system loses heat to the floor.

[0036] A secondary objective is that the insulation layer acts as sound or vibration dampening. The type of material of the insulation layer may be chosen depending on the desired properties, which may comprise heat insulation, sound dampening, vibration dampening, or any combination of properties.

[0037] Preferably the insulation layer is made of expanded polystyrene and even more preferably the EPS is made of recycled polystyrene components. High Density (HD) EPS in this case will provide extra rigidity and durability.

[0038] Additionally, when laid on a concrete floor for example, the insulation layer in itself contributes to the insulation of the building. In combination with existing floor insulation, the insulation properties of a floor is even more increased.

[0039] Listed below are references as used in the accompanying figures.

100 The invented heating module

101 Studded plate

102 Plate element of studded plate 101

103 A first stud of studded plate 101

104 A second stud of studded plate 101

105 Holding means for clamping tube 200

106 PCM

107 Stud wall

110 First row of studs at an outer section without PCM

111 Second row of studs at an outer section without PCM

120 Reinforcing groove or rib

130 Sealing sheet

140 Insulating layer

[0040] Referring now to the figures, wherein:

Figure 1 shows a perspective view of the invented module 100, wherein a studded plate 101 (reference shown in Figure 2) is configured with studs such as first stud 103 and second stud 104.

Figure 2 shows a top view of the studded plate 101 comprised in the invented module 100. Indicated by arrow 110 a first row of an outer section of plate 101 comprises studs which are left open, without a filling of PCM. A second row 111 of studs is open en empty as well. Both rows may accommodate insertion of a row of studs of a second plate (similar to the studded plate shown), in order to make a click-fastening and releasable connection. As an example stud 103 is indicated as a stud filled with PCM and sealed to keep the PCM secured inside.

[0041] The figure also shows reinforcing grooves and ribs such as indicated by reference 120. For example, the grooves may be laid out diagonally, whereas the ribs are laid out perpendicularly in relation to the shape of the preferably rectangular studded plate 101. These reinforcements provide rigidity and stability to studded plate 101 with a minimum use of material.

[0042] Figure 3 shows a front view of the module 100. Plate element 102 of studded plate 101 is configured with studs, for example studs 103 and 104. An insulating layer 140 is provided at the underside of studded plate 101. Between layer 140 and studded plate a sealing sheet 130 (see figure 4) is provided.

[0043] Figure 4 shows a part of a cross section of the front view of figure 3. Studs 103 and 104 are filled with PCM 106. A tube 200 is clamped between studs 103,104. To clamp tube 200 holding means 105 are provided. Tube 200 comprises a tube wall 201 and accommodates flow of a heating or cooling fluid 202. Studded plate 101 is sealed at the underside to individually seal stud 103 and 104 by seal 130. This way, studded plate 101 may be cut to size at any point between studs without compromising the liquid-tightness of the studs. The figure is without indication of perspective. Stud 104, however, preferably lies at a distance backward, when looked at from the front, as the overview shows in figure 1. This enables to insert tube 200 between two adjacent studs in a known manner. Studs 103,104 are preferably designed to increase the contact between studs and tube 200 to a maximum. This construction also increases the clamping effectiveness of the studs. Therefore, the studs are provided with concave walls 107, which may at least partly envelop a side of tube 200.

[0044] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that a person skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb "to comprise" and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The term "and/or" includes any and all combinations of one or more of the associated listed items. The article "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The article "the" preceding an element does not exclude the presence of a plurality of such elements. In the device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

Claims

1. A module for radiant heating for heating or cooling of a floor, wall or ceiling, comprising a studded plate arranged for supporting a tube configured for having a heating and/or cooling fluid respectively, flowing therethrough, the studded plate comprising a sheet with an array of protruding studs, wherein, when used on a floor, the plate is facing the bottom and the studs are facing upward, whereby the studs are configured with means for holding a part of the tube in close contact,
characterized in that,

- one or more of the studs of the studded plate are arranged as pockets of various volumes between 15 and 25 cl., arranged for being filled with a Phase Changing Material (PCM), such as a salt;

- the PCM of a filled stud of the one or more studs is arranged for exchanging heat with the fluid of said tube, mainly at the location of the close contact area between the filled stud and the tube;

- each filled stud of the one or more studs is individually sealed airtight and/or water vapor diffusion tight with a sealing sheet, independently of a sealing of other studs of the studded plate.

2. The module according to claim 1, characterized in that the studded plate comprises an inner section of studs and an outer section of studs situated around at least one side of the studded plate, wherein a substantial number of studs of the inner section is filled with the PCM and sealed, whereas a number of the studs of the outer section is left empty and open at the side of the plate, thereby configured to receive one or more studs of a second studded plate, and making the second studded plate releasably clickable to the studded plate.

3. The module according to claim 1 or 2, characterized in that the studded plate is configured with an underlayer made of Expanded Polystyrene (EPS) made in various thickness with acoustical and/or thermal insulation characteristics.

4. The module according to any one of the preceding claims, characterized in that the sealing sheet is made of polystyrene, such as a polystyrene foil.

5. The module according to any one of the preceding claims, characterized in that sealing sheet is glued around the edge of the stud, such as with a thermobond adhesive.

6. The module according to any one of the preceding claims, characterized in that the PCM comprises a PCM with a phase change temperature in the range of 21 to 26 degrees Celsius.

7. The module according to any one of the preceding claims, characterized in that the PCM comprises a gel.

8. The module according to any one of the preceding claims, characterized in that the distance from heart to heart of two adjacent studs is 5 cm.

9. The module according to any one of the preceding claims, characterized in that the studded plate is made of polystyrene having a thickness in the range of 0,9-1,4 mm.

10. The module according to any one of the preceding claims, characterized in that the studded plate is configured with one or more reinforcing grooves and/or ribs.

11. The module according to any one of the preceding claims, characterized in that the studded plate has a substantially rectangular shape and the reinforcing grooves and/or ribs are running diagonally.

12. The module according to any one of the preceding claims, characterized in that the studs are made of a rigid material and/or are reinforced with grooves and/or ribs.

13. The module according to any one of the preceding claims, characterized in that the underlayer is glued to the sealing sheet.

14. The module according to any one of the preceding claims, characterized in that the studded plate is made of a single thermoplastic sheet which is vacuum molded.

15. The module according to any one of the preceding claims, characterized in that the array of studs is configured to lead the tube in an at least partly straight line between any of the studs.

16. The module according to any one of the preceding claims, characterized in that the module is configured for supporting a screed and the screed is optionally covered by a floor finish.

17. The module according to any one of the preceding claims, characterized in that the module comprises the following elements:

- the insulation layer with on top of that

- the polystyrene sheet, with on top of that

- the studded plate, whereby the studs are facing outward.

18. The module according to any one of the preceding claims, characterized in that any or all elements are made of regenerated or recycled material, and/or releasably joint and reusable.

Drawing