STRUCTURAL COMPOSITE PANEL WITH HEATING LAYER FOR FLOORINGS OR WALLS AND SYSTEM

Abstract

 The invention refers to a structural composite heating panel (10) that may or may not be installed under an interior coating layer (19) of a compartment where users remain, for example, under a flooring of a train or of a coach, and to a heating system comprising one such panel. The panel comprises a first layer of thermally-conductive skin (11A) preferably made of metal material, a heating layer (15), a core layer (12) and a second skin layer (11B) also preferably made of metal material. The heating layer (15) comprises a mesh or net support substrate made of a mechanically-resistant material on which an electric conductor wire is embroidered, wherein the wire is sufficiently thin to allow sharp curvatures which enable a heating area of up to 99% of the total area and consequently a lower temperature gradient in the compartment.

Description

TECHNICAL DOMAIN

[0001] The subject matter of the present application is comprised within the field of the composite structural heating panels of interior spaces and heating systems that comprise it. More particularly, the subject matter of the present application refers to composite structural heating panels and heating systems of rail or road vehicles and other spaces of public or private use, such as, for example, hotel bathrooms.

BACKGROUND

[0002] Over recent decades, accompanying the evolution in the sector of transports, we have witnessed substantial development in the comfort provided to passengers on board trains and coaches, among other means of transport. In particular, in cities and regions with more extreme temperatures, either in very low temperature zones or in areas of great heat, the market has seen a rise in the degree of discernment relating to the comfort provided to the passengers, for example, in trains and coaches, concerning the temperature level inside the carriages and in the road vehicles.

[0003] Also relative to other type of interiors, such as, for example, in hotels, comfort is each increasingly a characteristic considered basic, particularly in terms of interior temperature. Current air-conditioning systems are broadly used both in hotels, public spaces in general and private homes, as in transport vehicles. However, these systems are often noisy and require careful maintenance in order to prevent the development of bacteria and other infectious agents.

[0004] Therefore, the heated floorings have gained in popularity, by being high energy efficiency and not entailing disadvantages relative, for example, to noise and/or creation of infectious agents. However, the heated flooring systems of today, especially those that are installed in passenger transport vehicles, use systems with heating panels that include layers of heating comprising means of heating that hamper the scope of a heated area near the whole area of the flooring to be heated and consequently generates relatively high differences in temperature inside the cabin or in the space intended for heating. This fact is undesirable from the point of view of the comfort and also from the point of view of consumption of energy to compensate these differences in temperature.

PRIOR ART

[0005] The current systems of composite structural heating panels are based on two main concepts. One of these concepts includes films with printed resistances that are also subdivided into two categories, namely resistances in aluminum, recorded, encapsulated in polyester film, and resistances in carbon fibers. The other concept is based on electric conductor cables, which meander inside the core and intermediary layers of the composite structural panel, which requires specific machining of said core layer and, on the other hand, the electric conductor cables or wires are not capable of being submitted to very sharp curvatures and accordingly have limitations in managing to reach smaller areas or corners of the flooring intended for heating.

[0006] Moreover, adding a heating layer under the flooring of a transport vehicle, for example, will compulsorily cause an increase in weight of this transport vehicle, which is undesirable from the point of view of the economy of the vehicle's form locomotion energy and, on the other hand, from the environmental point of view. Accordingly, it is highly desirable and advantageous that the heating layer of the panel be the lightest weight possible.

[0007] European patent EP 2432673B1 refers to a heating device for rail vehicles comprising at least one heating element which forms a sandwich structure to sustain loads, jointly with edge profiles and a core layer. According to the invention, a plurality of heating units and sandwich structures form, each one, modular construction components that can be installed and fastened to each other on the rail vehicle by means of fastening elements. The heating element that is the object of this patent is not capable of covering over about 70% of the area of the cabin intended for heating, due to its geometry, which does not allow it to reach smaller areas such as, for example, nooks or non-rectangular geometries.

[0008] Patent application US 2007/215589 A1, by Craig M. Berger, U.S.A., discloses a system for generating radiant heat in a transit vehicle that includes at least one floor panel having at least one heating element disposed therein, and a power switch disposed to operate between one source of power supply and the heating element to selectively supply and discontinue a preset value of power supply generated by said source of power supply of one such heating element. Said heating element is a cable with an electric conductor with a diameter of approximately 10 mm, a layer of insulation, a hem and a metal braid involving the hem, which does not enable this heating element to make sharp curvatures and reach all the points, namely those of a smaller surface area to heat.

[0009] Therefore, today there is no technical solution that solves the technical problem of high temperature gradient in the volume of the cabin or space that is intended for heating without increasing, at the same time, the weight of the heating panel which is an important characteristic when passenger transport vehicles are concerned.

SUMMARY OF THE INVENTION

[0010] The invention refers to a structural composite heating panel which may or may not be installed under an interior coating layer of a compartment where users remain, for example and without limitation, under a flooring or an inner wall of a train or of a coach, or also, for example, of a hotel bathroom, and a heating system comprising one such panel. The panel according to the invention comprises at least one first skin layer made of a preferably metal thermo-conductor material, a heating layer, a core layer preferably made of a polymer material and a second skin layer also preferably made of metal material. The heating layer comprises a mesh or net support substrate made of a mechanically-resistant material, for example, fiberglass, on which an electric conductor wire is embroidered, wherein the wire is sufficiently thin to allow sharp curvatures without losing physical characteristics, for example, the wire can be made of filaments of tin-plated copper.

[0011] In a first aspect, the present invention refers to a structural composite heating panel for installation under a flooring or an inner wall of a cabin comprising a first layer of thermally-conductive skin, a heating layer, a core layer, a second skin layer, at least one first structural connection edge and at least one second structural connection edge, wherein the heating layer comprises a mesh or net support substrate and an electric current conductor wire embroidered in the support substrate of mesh or net, whereby in making the electric current pass through the conductor wire embroidered in the substrate, the heating layer, by Joule effect and by conduction, makes the top layers of said panel heat up, transmitting heat to the first layer of thermally-conductive skin which in turn transmits heat to the surface which is in contact with the users, for example, the flooring of a train carriage or of a coach.

[0012] In a second aspect, the present invention refers to a heating system that comprises at least one structural composite heating panel according to the first aspect of the invention and a source of electrical power supply to which the structural composite heating panel is electrically connected. Additionally, the heating system may comprise a temperature control module and at least one temperature measuring probe and/or at least one thermal fuse, wherein the heating panel system is adapted to be installed in a passenger transport vehicle or, in alternative embodiments of the present invention, in a fixed installation, such as, for example, a sanitary installation of a hotel.

[0013] In certain embodiments of the second aspect of the present invention, the panel is adapted to receive on it a flooring layer of a passenger transport vehicle or a wall coating layer of one such vehicle.

[0014] In some embodiments of the second aspect of the present invention, the panel is adapted to receive on it a fixed installation flooring layer, such as, for example, a ceramic flooring of a sanitary installation.

SOLUTION TO THE PROBLEM

[0015] The structural composite heating panel according to the invention provides a substantially homogenous ambient temperature in the space where it is installed and is heated thereby. For example, the panel according to the invention can be installed under the flooring of a train or of a coach. The electric conductor wire which is embroidered in the support substrate comprised by the heating layer of the panel, can be connected to the electrical system already existing in the train or in the coach. Additionally, this connection can be monophase, biphase or triphase, depending on the electrical system installed in the vehicle. The fact of having a triphase power supply, for example, may bring the advantage that, in the event of a failure of a phase in the electrical system of the vehicle, there will still be two phases powered that can contribute to heating the compartment.

[0016] The panel according to the present invention is comprised in a heating system of a train or of a coach that may comprise, in certain embodiments, a temperature control module and one or more temperature probes and/or temperature fuses, controlling the temperature inside the compartment of the train or coach, keeping it inside a certain desirable temperature range. This temperature control module may be, for example, included in the vehicle's air-conditioning system.

[0017] Advantageously, the system comprising the composite panel according to the invention can be installed in a used vehicle, quickly and easily, or plug-and-play, for example, in a refurbishment operation of a transport vehicle such as a train or a coach, not requiring to be installed solely in new vehicles. This means that the system comprising the panel according to the invention does not require any adaptation of the electrical power supply means, for example, of the train or coach, nor any other structural adaptation of the compartment, the system according to the invention can be installed and connected to be ready to operate, for example, under the flooring of a coach or train already existing.

[0018] Additionally, the system comprising the panel according to the invention enables greater heating efficiency of the compartment wherein it is installed. This advantage relative to the state of the art is provided by the capacity that the heating layer has in covering an almost total area of the space wherein it is installed, for example, under the flooring of a train or coach. This almost total occupation may be as much as 99% of the occupied area, and will preferably be 95% of the area occupied by the flooring or by the wall of the compartment. The innovative characteristic of the heating layer, which comprises a flexible substrate, in mesh or net, on which a relatively thin electric conductor wire is embroidered or sown, enabling, for example, narrower corners or spaces, around the feet of benches or contouring cabinets to be filled in with the embroidery carried out by the conductor wire of the panel heating layer according to the invention. Moreover, due to the light weight and flexibility of this heating layer, the total weight of the panel - relative to panels existing on the market today - may reduce to about 15%, due to its thin and flexible constitution in lighter materials.

[0019] The system comprising the panel according to the invention can also be installed in fixed installations, such as, for example, hotel bathrooms or pre-fabricated homes which are mounted with modules, besides other zones destined to users, such as, for purposes of illustration and without limitation, waiting rooms, consulting rooms, corridors or offices, or even any type of spaces for public or private use.

[0020] The panel according to the invention solves the previous problems of the art, namely the fact that the heating area covered by the prior heating panels manages to cover only about 70% of the total area of a surface in contact with the users, for example, the passengers of a train or coach. This fact makes the thermal gradient inside the carriage or of the space heated by the panel according to the invention, lower than the one obtained by the systems of prior art, the thermal gradient may be less than 3°C, while the thermal gradients achieved by the prior art is about 5°C. Consequently, the panel and the system according to the present invention provide savings in energy since there is no need to constantly correct the temperature gradient and consequently enables greater comfort for the users.

[0021] Additionally, the panels of the solution provided by the present invention have a snap-fit system between panels based on male-female encasement such that compared to the connections between heating panels existing on the market, it does away with various fastening components such as joining parts, and may reduce the number of screws required, which translates into an even greater reduction in the weight added by the panel to the structure of the compartment of the installation or of the vehicle where it is installed.

[0022] Additionally and advantageously, the panel according to the invention presents mechanical hardness about 50% superior to the panels of prior art, which enables a reduction in the thickness of the panel and consequently in its weight in applications wherein it is possible to maintain the hardness provided by prior art panels.

ADVANTAGEOUS EFFECTS OF THE INVENTION

[0023] As mentioned above, the panel and the system according to the invention offer the advantages of:

providing a heating area almost total, that is, to at least 95%, relative to the contact surface with the users, for example, passengers of trains or coaches, which provide more comfort to the users, but also savings on heating energy;

providing a temperature gradient measured in the heated area substantially lower than those provided by the panels and systems of the prior art, for example, by 2 to 5°C lower;

conferring an additional minimal weight to the vehicle or installation where it is installed, relative to prior art panels, and

being easy and quick to install, even on trains, coaches or other old or used infrastructures, for example, in refurbishment process, since it only requires a hook-up to the electrical system of the infrastructure where it is installed and may be suitable for a monophase, biphase or triphase connection;

having superior mechanical hardness, bending less than the panels in the state of the art by about 50%. This also means that to obtain a same hardness as with prior art panels, it is possible to use a panel according to the invention of lesser thickness, obtaining a significant reduction in its weight.

BRIEF DESCRIPTION OF THE FIGURES

[0024] With the purpose of providing an understanding of the principles according to the embodiments of the present invention, reference will be made to the embodiments illustrated in the figures and to the terminology used to describe them. In any case, it should be understood that there is no intention of limiting the scope of the present invention to the contents of the figures. Any subsequent alterations or modifications of the inventive characteristics illustrated herein, as well as any additional applications of the principles and embodiments of the invention illustrated, which would normally occur to a person skilled in the art having the knowledge of this specification, are considered as being within the scope of the claimed invention.

Figure 1 - represents a cross-sectional view of an embodiment of a structural composite heating panel (10) according to the invention;

Figure 2A - schematically represents a top view of an embodiment of the heating layer (15) of the structural composite heating panel (10) according to the invention;

Figure 2B - schematically represents one detail of an embodiment of the mesh or net support substrate (16) of the heating layer (15) of the structural composite heating panel (10) according to the invention;

Figure 3A - schematically represents a top view of another embodiment of the heating layer (15) of the structural composite heating panel (10) according to the invention;

Figure 3B - schematically represents one detail of an embodiment of the wire (17) embroidered on the mesh or net support substrate (16) of the heating layer (15) of the structural composite heating panel (10) according to the invention;

Figure 4 - schematically represents a top view of yet another embodiment of the heating layer (15) of the structural composite heating panel (10) according to the invention;

Figure 5 - schematically represents a top view of an embodiment of the structural composite heating panel (10) according to the invention;

Figure 6 - schematically represents a top view of an embodiment of the structural composite heating panel (10) according to the invention, wherein the first layer of thermally-conductive skin (11A) and the heating layer have been removed;

Figure 7A - schematically represents a top view of a composition of various composite structural heating panels (10) according to the invention, joined to the structure of a train carriage and joined to each other;

Figure 7B - schematically represents a detailed, cross-sectional view, of an edge of a structural composite heating panel (10) according to the invention;

Figure 7C - schematically represents a cross-sectional view of a connection between two composite structural heating panels (10) according to the invention;

Figure 8A - represents an image obtained by temperature profile of a structural composite heating panel (10) according to the invention;

Figure 8B - represents an image obtained by temperature profile of a heating panel according to prior art.

DESCRIPTION OF THE EMBODIMENTS

[0025] The structural composite heating panel according to the invention and the heating system that the comprises will be described ahead, making reference to the accompanying figures.

[0026] Figure 1 represents a cross-sectional view of an embodiment of a structural composite heating panel (10) according to the invention, in which the various layers that make up the structural composite heating panel (10) are visible. The panel is comprised of a first layer of thermally-conductive skin (11A), a heating layer (15) which is immediately beneath the first layer of thermally-conductive skin (11A), a core layer (12) and a second skin layer (11B) which is the bottom layer of the structural composite heating panel (10) according to the invention. Figure 1 also shows an interior coating layer (19), which is that layer in contact with the users of the compartment where the panel is installed. For example, if the structural composite heating panel (10) is installed on the floor of a train or of a coach, the interior coating layer (19) will be the flooring of the train or of the coach. The first layer of thermally-conductive skin (11A) is made of a good thermal conductor material, for example, a metal material, in particular aluminum, aluminum coated by an anti-corrosion film, aluminum with epoxy treatment, steel, steel with anti-corrosion treatment, or a laminated composite, for example, made of fire-resistant polyester resin reinforced by fiberglass. Preferably, the first layer of thermally-conductive skin (11A) is made of aluminum and even more preferably of aluminum with epoxy treatment. The second skin layer (11B) can be made of the same material as the first layer of thermally-conductive skin or of a different material, since the second skin layer (11B) does not need to have thermal conduction properties. The first and the second skin layers (11A,11B) have thicknesses that can vary between 0.5 mm and 2 mm, wherein the first layer of thermally-conductive skin (11A) has a thickness preferably of 0.5 mm to 1.5 mm and more preferably the first layer of thermally-conductive skin is 1.5 mm in thickness, and the second skin layer (11B) has a thickness preferably of 0.5 mm to 1 mm and even more preferably of 1 mm. The core layer (12) is made of a material with adequate mechanical resistance and thermally insulating, which can be homogeneous and based on a structural foam polymer, for example, PET (polyethylene terephthalate), PVC (polyvinyl chloride), PUR (cross-linked polyurethane), phenol resin, cork, composite of agglomerated cork, balsa wood or mixtures or composites thereof and preferably the material of the core layer is PET. The core layer (12) has a thickness of 5 mm to 50 mm, preferably, from 5 mm to 25 mm. In certain embodiments, the core layer may also be heterogeneous (not shown), for example, it may be a stack of two or more sublayers of densities equal or different structural foam polymer-based, for example, PET (polyethylene terephthalate) PVC (polyvinyl chloride), PUR (cross-linked polyurethane), phenol resin, cork, composite of agglomerated cork, balsa wood or mixtures or composites thereof, wherein the densities of the sublayers fall into the range from 60 kg/m³ to 300 kg/m³. Preferably, the density of the material of the core layer (12) is 100 kg/m³ to 200 kg/m³, and more preferably the density is 100 kg/m³, so as to confer the lowest weight possible to the structural composite heating panel (10), maintaining at the same time good mechanical resistance of the structural composite heating panel (10). The core layer (12), besides having suitable mechanical resistance and hardness, is thermally insulating, which enables maximum heating efficiency to be obtained from the structural composite heating panel (10), since the heat produced by the heating layer (15), adjacent to the core layer (12), is substantially conducted in totality to the first layer of thermally-conductive skin (11A) due to the insulating characteristics - or poor thermal conduction - of the core layer (12). The first layer of thermally-conductive skin (11A) will be in direct contact with the interior coating layer (19) which in turn will be in contact with the users of the heated compartment. The heating layer (15) comprises a mesh or net support substrate, made of a suitable material, on which an electric conductor wire is sown and will be discussed in greater detail in reference to the following drawings. As clearly shown in Fig. 1, the heating layer (15) is placed beneath the first layer of thermally-conductive skin (11A). When the heating layer (15) heats by Joule effect action due to the passage of an electric current in the electric conductor wire embroidered on the mesh or net support substrate (16), the first layer of thermally-conductive skin (11A) is heated by thermal conduction, since this layer is made of a good heat-conducting material, for example, a metal material, as mentioned above. In turn, the interior coating layer (19) which is in contact with the users and with the space where the users remain, also heats by thermal conduction, which enables the air inside the compartment where the users are to be heated by convection, providing the desired comfort. Said interior coating layer (19) may be made of a material belonging to the group comprised of elastomer, compounds of PVC (polyvinyl chloride), linoleum, textile coatings, such as rugs or carpets, ceramic materials or mixtures thereof and said interior coating layer (19) has a thermal conductibility from 0.08 W/m.K to 1.5 W/m.K.

[0027] Figure 2A schematically represents a top view of an embodiment of the heating layer (15) of the structural composite heating panel (10) according to the invention. The heating layer (15) comprises a mesh or net support substrate (16) in mesh or net which is made of a light and fire-resistant material, for example, fiberglass, polypropylene, other thermo-plastic materials, metals, mixtures and/or composites thereof, and preferably the substrate in mesh or net is made of fiberglass, on which an electric conductor wire (17) is embroidered or sown. The wire (17) may be any configuration of embroidery desired, wherein the embroidery is performed by methods existing in the art that allow the wire to be fixably coupled to the mesh or net support substrate (16) and the embroidery does not alter with use. The embroidery performed by the wire (17) may be denser in certain zones, for example, in peripheral zones of the structural composite heating panel (10) and less dense in other zones such as for example in the inner zones (not shown). The density of the embroidery performed by the wire (17) implies a greater or lesser localized calorific power, which in turn enables a desired homogeneity of temperatures to be obtained, through the entire surface. For example, the wire may substantially fill the whole area of the mesh or net support substrate (16) as shown in Figure 2A. The electric conductor (17) can be made of a metal core composed of filaments, wherein the metal core is made of a metal belonging to the group comprising copper, tin-plated copper, aluminum, gold, silver or alloys thereof, preferably the metal core is made of copper and even more preferably the metal core is made of tin-plated copper. As can be seen in Figure 2A, the wire (17) may make an embroidery composed of straight lines and of curved lines. The curved lines may have sharp curvatures, since the wire (17) has sufficiently thin diameters for this effect. For example, the outer diameter of the wire (17) can be from 0.75 mm to 1.2 mm, preferably, the conductor wire (17) has an outer diameter of 0.9 mm. The conductive electric wire (17) comprises a metal core (not shown) and a layer of insulation (not shown) surrounding said metal core. The metal core of the conductor wire (17) can have a diameter from 0.3 mm to 10 mm, preferably, the diameter of the metal core of the conductor wire (17) is 0.6 mm. Additionally, the metal core comprises a number of filaments between 10 and 50, preferably, the metal core comprises 32 filaments (not shown). Said filaments of said metal core of the conductor wire (17) may have a thickness between 0.05 mm and 0.10 mm, preferably, the filaments have a thickness of about 0.08 mm. The layer of insulation surrounding said metal core may be made of a polymer material belonging to the group comprised of MFA/PFA copolymer perfluoromethylalkoxy / perfluoroalcoxy alkane, other fluoroelastomers, other thermo-plastic materials, and wherein the conductor wire (17) may have an outer diameter from 0.75 mm to 1.2 mm, preferably, the conductor wire (17) has an outer diameter of 0.9 mm.

[0028] Figure 2B shows a detail of the mesh or net support substrate square (16). The mesh or net support substrate (16) comprises first wires (16A) and second wires (16B), forming cells (16C), and the first wires (16A) form an angle with the second wires (16B) which may be from 20° to 160°, preferably the first wires (16A) form an angle of approximately 90° with the second wires (16B). The first wires (16A) and the second wires (16B) have a thickness between 0.1 mm and 0.5 mm, preferably the wires (16A, 16B) have a thickness of about 0.2 mm. The cells (16C) of said mesh or net of the support substrate (16) have an area between 10 mm² and 30 mm², preferably, the cells (16C) of the mesh or net have an area of about 16 mm². The mesh or net support substrate square (16) is adequate for fastening thereon the electric conductor wire (17) performing a suitable embroidery at a desired heating in the space where the structural composite heating panel (10) according to the invention is installed.

[0029] Figure 3A schematically represents a top view of another embodiment of the heating layer (15) of the structural composite heating panel (10) according to the invention, wherein the wire (17) makes a different embroidery to the one shown in Figure 2A. In fact, the embroidery designed by the wire (17) can be any one. It may, for example, have greater wire density zones (not shown), when the intention is to obtain a greater concentration of heat output, for example, next to the door zone of a train or coach, which is a zone where there is greater cooling of the air caused by the opening of the doors.

[0030] Figure 3B represents a detail of the substrate (16) with the first wires (16A) and the second wires (16B) forming cells (16C) suitable for fixing thereon the embroidered or sewn wire (17), which is represented in Figure 3B designing a curve with sharp curvature. The curvatures designed by the wire (17) may have a radius from 1 mm to 4 mm, preferably from 2 mm to 3 mm. As already stated above, the sharp curves enable the structural composite heating panel (10) according to the invention to obtain the desired heating output concentration and also provided for a substantially uniform heating in the compartment where the users of the space to be heated remain, due to the geometric flexibility that the wire (17) embroidered on the mesh or net support substrate (16) offers, allowing it to reach all the points of the area to be heated, even the ones hardest to reach.

[0031] Figure 4 schematically represents a top view of yet another embodiment of the heating layer (15) of the structural composite heating panel (10) according to the invention, on which it is possible to see interruptions (17A) in the embroidered wire (17). These interruptions may correspond to zones where seats or lockers are installed on a train or coach, for example, and illustrate well the capacity of the heating layer (15) of the structural composite heating panel (10) to overcome obstacles and maintain the desired heating output, wherein the design of the embroidery of the wire (17) may be adapted to nooks or contours of zones where benches or lockers, for example, are installed.

[0032] Figure 5 schematically represents an embodiment of a top view of a structural composite heating panel (10) according to the invention, including structural connection edges (51,52). The structural connection edges (51,52) include first structural connection edges (51) and second structural connection edges (52). The structural composite heating panel (10) has, in the preferred embodiments, a quadrilateral geometry, wherein two opposite sides terminate in first structural connection edges (51) which may be fixably coupled to the first layer of thermally-conductive skin (11A), to the second skin layer (11B) or both the first and second skin layers (11,11B) (coupling not shown). The first structural connection edges (51) are coupled by adequate means to the structure of the compartment, for example, to the bodywork of a train or of a coach. The other two opposite sides of the structural composite heating panel (10) terminate at second connection edges (52) to adjacent composite structural heating panels (10) so as to make up a coverage for all the area intended to heat. For example, the structural composite heating panel (10) may also have other edges (not represented) connecting to elements existing in the space to heat, such as, for example, seat or cabinet leg structures. Figure 5 represents a preferred embodiment of the geometry of the structural composite heating panel (10).

[0033] Figure 6 schematically represents a top view of an embodiment of the structural composite heating panel (10) according to the invention, wherein the first layer of thermally-conductive skin (11A) and the heating layer (15) were removed leaving the core layer (12) visible. In the embodiment represented in Figure 6, the core layer (12) has a groove dug out to accommodate a temperature probe (21A) and a thermal fuse (21B) which cooperate in the control of the temperature of the heating layer (15). As can be seen in Figure 1, the core layer (12) is placed under the heating layer (15). Consequently, the temperature probe (21A) and the temperature fuse (21B) represented in Figure 6 are in physical contact with the heating layer (15). The temperature probe (21A) measures the temperature of the heating layer (15) and sends the values measured for a temperature control module (not shown) existing in the installation of the compartment, for example, the temperature control module can be a part of the air-conditioning system of a train, coach or of a hotel. In light of the temperature values received, the temperature control module compares these values with preset limits and, in view of the result of this comparison, it may decide to send an order to cut off the power supply of the conductor wire (17) as a way to lower the temperature, for example, if such was about to reach a maximum permitted ceiling value. The temperature control module is connected to source of electrical power supply (not shown) of the compartment and can be configured to turn on or off the power supply of the conductor wire (17), whereby being capable of controlling the temperature of the structural composite heating panel (10) within the limits of 20° and 50°C and preferably between 35°C and 42°C. Additionally, in embodiments that also comprise a thermal fuse (21B), such as the one represented in Figure 6, and for safety reasons, for example, the thermal fuse reacts to the temperature felt next to the heating layer, and may also cut the electrical power supply of the conductor wire (17). In embodiments that include the temperature probe (21A) and/or the thermal fuse (21B), is also supplied in the core layer (12) of the structural composite heating panel (10) a box (21) for the purpose of accessing the temperature probe (21A) and/or the thermal fuse (21B) for substitution or maintenance. The first connecting edges (51) and the second connecting edges (52) are also represented in Figure 6, as already discussed in relation to Figure 5.

[0034] Figure 7A schematically represents a top view of a composition of various composite structural heating panels (10) according to the invention, wherein the composite structural heating panels (10) are joined to the structure of a train carriage through the first structural connection edges (51) and joined to each other through the second structural connection edges (52). A structural composite heating panel (10) that is installed at the end of a train carriage (not shown) may have, for example, three connecting edges (51) (not shown) and one connecting edge (52). Since the heating layer (15) of the composite structural heating panels (10) comprises a conductor wire (17) embroidered in up to 99% of the area total of the panel, preferably about 95% of the area total of the panel, the coverage of the area of the train represented in Figure 7A will be, consequently, to 99%, preferably about 95%, of all the area of the train. As referred to above, this is one advantage of the structural composite heating panel (10) of the present invention which also provides a lower temperature gradient throughout the heated area of the compartment wherein it is installed. The first structural connection edges (51) are part of the prior art and will not be described in detail herein. In certain embodiments, the second structural connection edges (52) have a male-female type encasement. Figure 7B schematically represents one detail of a second structural connection female edge (52), in the interconnection zone of two composite structural heating panels (10), and Figure 7C represents the union zone between two composite structural heating panels (10) in which it is possible to see the male-female encasement between the second connecting edges (52) of two adjacent composite structural heating panels (10). The embodiment of the second structural edges (52) represented in Figures 7B and 7C comprises a male end and another female end of the structural composite heating panel (10) connected to female and male ends, respectively, of adjacent composite structural heating panels (10). In the embodiment represented in Figures 7B and 7C, each structural composite heating panel (10) has a second male structural edge (52) and a second female structural edge (52). Advantageously, this male-female encasement dispenses with intermediary joining parts of the two composite structural heating panels (10), consequently providing a significant reduction of the fastening elements necessary to the joining between composite structural heating panels (10) and, therefore, shorter installation time, and may also permit an additional decrease in the weight of the panels. The first and the second structural edges (51,52) of the composite structural heating panels (10) can be fixably coupled to the first layer of thermally-conductive skin (11A), can be fixably coupled to the second skin layer (11B), but can also be fixably coupled to the two skin layers (11A, 11B) and substantially have a thickness of the core layer (12), as represented in Figure 7B for a second female structural connection edge (52). In other embodiments not represented, the structural connection edges (51,52) can be included in another suitable layer of the structural composite heating panel (10).

[0035] Figure 8A represents an image obtained by temperature profile of a structural composite heating panel (10) according to the invention and Figure 8B represents an image obtained by temperature profile of a structural composite heating panel (10) according to prior art. Comparing the temperature profiles of the structural composite heating panel (10) represented in Figure 8A and of the panel according to the prior art represented in Figure 8B, it can be seen that, on the one hand, the area covered by the heated zone in the panel of Figure 8A is far superior to the area covered by the zone heated of the panel of the prior art of Figure 8B and, on the other hand, it is also visible that the temperature gradient measured in the structural composite heating panel (10) of the Figure 8A along the line P1 is less than the temperature gradient measured in the panel of Figure 8B along the line P1, where in Figures 8A and 8B the heated zone is represented by the light-colored areas. Figures 8A and 8B show a greater coverage of the heated area in the case of Figure 8A according to the invention, relative to the heated area of Figure 8B, with three heating elements covering a much smaller percentage of the total area of the panel. On the other hand, as already mentioned, the variation in temperature of the heated area in the case of Figure 8A (measured along the line P1), is less than the variation of the temperature in each one of the light zones, or heated zones of Figure 8B (where the central zone marked M1 highlights the P1 temperature measurement line).

[0036] In one preferred embodiment of a first aspect, the invention refers to a structural composite heating panel (10) comprising a first layer of thermally-conductive skin (11A), a heating layer (15), a core layer (12), a second skin layer (11B), and at least one first structural connection edge (51), wherein the heating layer (15) is disposed between the first layer of thermally-conductive skin (11A) and the core layer (12), the core layer (12) is disposed between the heating layer (15) and the second skin layer (11B), wherein the at least one first structural connection edge (51) is configured to fixably join the structural composite heating panel (10) to the structure of a compartment, and the at least one first structural connection edge (51) is fixably coupled to the first layer of thermally-conductive skin (11A), to the second skin layer (11B), or is fixably coupled to both the first and the second skin layers (11A,11B),
wherein

the heating layer (15) comprises a mesh or net support substrate (16) and at least one electric current conductor wire (17),

wherein

the mesh or net support substrate (16) comprises first wires (16A) and second wires (16B) forming a mesh or net with cells (16C) and is configured to fasten thereon an embroidery made by said conductor wire (17) and

the conductor wire (17) is configured to be embroidered on said mesh or net support substrate (16) forming a heating embroidery, wherein the heating embroidery comprises straight lines and/or curved lines.

[0037] In another embodiment of the first aspect, the invention refers to a structural composite heating panel (10) additionally comprising at least one second structural connection edge (52) comprising a male end and/or a female end, wherein the at least one second structural connection edge (52) is configured to fixably snap together, through said male end or said female end, the structural composite heating panel (10) to a female end or to a male end, respectively, of another adjacent structural composite heating panel (10) and wherein the at least one second structural connection edge (52) is fixably coupled to the first layer of thermally-conductive skin (11A), is fixably coupled to the second skin layer (11B), or is fixably coupled to both the first and the second skin layers (11A,11B) and preferably the at least one second structural connection edge (52) is fixably coupled to both the first and the second skin layers (11A, 11B).

[0038] In another embodiment of the first aspect, the invention refers to a structural composite heating panel (10) wherein the first wires (16A) and the second wires (16B) of the mesh or net support substrate (16) form angles between each other, said angles falling within the range from 20° to 160° and the first wires (16A) and the second wires (16B) forming said mesh or net of the mesh or net support substrate (16) has a thickness between 0.1 mm and 0.5 mm, and the cells (16C) of said mesh or net of the mesh or net support substrate (16) has an area between 10 mm² and 30 mm².

[0039] In yet another embodiment of the first aspect, the invention refers to a structural composite heating panel (10) wherein the at least one conductor wire (17) comprises a metal core with a diameter from 0.3 mm to 10 mm, wherein the metal core comprises a number of filaments between 10 and 50, wherein the filaments have a thickness between 0.05 mm and 0.10 mm, a layer of insulation surrounding said metal core, wherein the layer of insulation is made of a polymer material and wherein the at least one conductor wire (17) has an outer diameter from 0.75 mm to 1.2 mm.

[0040] In yet another embodiment of the first aspect, the invention refers to a structural composite heating panel (10) wherein the metal core of the at least one conductor wire (17) is made of a metal from the group comprised of copper, tin-plated copper, tin, aluminum, silver, gold or alloys thereof.

[0041] In yet another embodiment of the first aspect, the invention refers to a structural composite heating panel (10) wherein the curved lines of the heating embroidery performed by said at least one conductor wire (17) has a curvature radius from 1 mm to 4 mm, preferably the curved lines of the heating embroidery have a curvature radius from 2 mm to 3 mm.

[0042] In yet another embodiment of the first aspect, the invention refers to a structural composite heating panel (10) wherein the heating embroidery of said at least one conductor wire (17) occupies an area from 60% to 99% of the mesh or net support substrate (16), preferably, 80% to 99%, and more preferably the heating embroidery of the at least one conductor wire (17) occupies 95% of the area of the mesh or net support substrate (16).

[0043] In yet another embodiment of the first aspect, the invention refers to a structural composite heating panel (10) wherein the at least one conductor wire (17) is a conductor wire (17) simples, electrically connected to an electrical installation monophase, is a double conductor wire (17), electrically connected to an electrical installation biphase and/or is a triple conductor wire (17) electrically connected to an electrical installation triphase.

[0044] In yet another embodiment of the first aspect, the invention refers to a structural composite heating panel (10) wherein the material of the first layer of thermally-conductive skin (11A) and of the second skin layer (11B) is at least one chosen from the group comprised of: aluminum, aluminum coated by an anti-corrosion film, aluminum with epoxy treatment, steel, steel with anti-corrosion treatment, laminated composite, for example, made of fire-resistant polyester resin reinforced by fiberglass.

[0045] In yet another embodiment of the first aspect, the invention refers to a structural composite heating panel (10) wherein the material of the core layer is mechanically resistant and thermally insulating, homogeneous, polymer-based, phenol resin, cork, balsa wood, mixtures or composites thereof.

[0046] In yet another embodiment of the first aspect, the invention refers to a structural composite heating panel (10) wherein the material of the core layer has a density from 60 kg/m³ to 300 kg/m³.

[0047] In yet another embodiment of the first aspect, the invention refers to a structural composite heating panel (10) wherein the material of the core layer is mechanically resistant and thermally insulating, heterogeneous, that is, is composed of two or more sublayers, each of said sublayers being polymer-based, phenol resin, cork, balsa wood, mixtures or composites thereof and the sublayers are of equal densities or the sublayers are of different densities falling within the range of 60 kg/m³ to 300 kg/m³.

[0048] In a preferred embodiment of a second aspect, the invention refers to a heating system of a compartment that comprises at least one structural composite heating panel (10) according to the first aspect of the invention, configured to be electrically connected, through the conductor wire (17) of the heating layer (15) to a source of electrical power supply of the structure of the compartment, and a source of electrical power supply configured to make pass an electric current through the conductor wire (17) of the heating layer (15) of the at least one structural composite heating panel (10), wherein the at least one structural composite heating panel (10) is configured to be coupled to the structure of the compartment through the at least one first structural connection edge (51).

[0049] In another embodiment of the second aspect, the invention refers to a heating system of a compartment wherein the at least one structural composite heating panel (10) is configured to be additionally coupled, through the at least one second structural connection edge (52), to a second structural composite heating panel (10) or to a second and to a third composite structural heating panels (10).

[0050] In another embodiment of the second aspect, the invention refers to a heating system of a compartment that further comprises a temperature control module, and at least one temperature measuring probe (21A), and/or at least one thermal fuse (21B), wherein the at least one temperature measuring probe (21A) is disposed inside a furrow dug out in the core layer (12) of the at least one structural composite heating panel (10) and is electrically connected to said temperature control module, and for which it is configured to send temperature measurement data, the at least one thermal fuse (21B) is disposed inside a furrow dug out in the core layer (12) of the at least one structural composite heating panel (10) and is electrically connected to the power supply of the conductor wire (17) and said temperature control module is connected to said source of electrical power supply of the compartment and is configured to turn on or off the power supply of the conductor wire (17), whereby being capable of controlling the temperature of the structural composite heating panel (10).

[0051] In yet another embodiment of the second aspect, the invention refers to a heating system of a compartment that additionally comprises an interior coating layer (19), wherein said interior coating layer (19) is configured to be placed on the first layer of thermally-conductive skin (11A) of the structural composite heating panel (10) according to the first aspect of the invention; and
wherein said interior coating layer (19) is at least one of the group comprised of: interior flooring, interior wall coating, or a combination thereof.

[0052] In yet another embodiment of the second aspect, the invention refers to a heating system of a compartment wherein said interior coating layer (19) is made of a material belonging to the group comprised of an elastomer, a polymer, linoleum, textile coatings, ceramic materials or mixtures thereof and said interior coating layer (19) has a thermal conductibility from 0.08 W/m.K to 1.5 W/m.K.

[0053] In yet another embodiment of the second aspect, the invention refers to a heating system of a compartment configured to be installed in a compartment of a passenger transport vehicle belonging to the group comprised of: train, coach, car, boat, plane, more preferably, belonging to the group comprised of: train, coach.

[0054] In yet another embodiment of the second aspect, the invention refers to a heating system of a compartment configured to be installed in a compartment of an installation belonging to the group comprised of: sanitary installation, bedroom, living room, meeting room, office, kitchen, spa, corridor, store, public space.

DEFINITIONS

[0055] As used throughout this patent application, the expression "or" is used in the inclusive sense instead of the exclusive sense, unless the exclusive sense is clearly defined in a specific situation. In this context, a sentence of the type "X uses A or B" must be interpreted as including all the pertinent inclusive combinations, for example "X uses A", "X uses B" and "X uses A and B".

[0056] As used throughout this patent application, the indefinite article "a", "an" or "one" must be interpreted generally as "one or more", unless the sense of a singular embodiment is clearly defined in a specific situation.

[0057] As used throughout this patent application, the fastening of the electric conductor wire embroidery or sown on the substrate in mesh or net should be interpreted as being fastening by way of sewing or embroidery with needle and thread, by pins, glue or any other suitable fastening means.

[0058] As presented in this specification, the expressions listed with examples must be interpreted with the purpose of illustrating an example and not indicating a preference.

[0059] The subject matter described above is provided as an illustration of the present invention and must not be interpreted so as to limit it. The terminology used with the purpose of describing specific embodiments, according to the present invention, must not be interpreted to limit the invention. As used in the specification, the definite and indefinite articles, in their singular form, aim at the interpretation of also including the plural forms, unless the context of the description indicates, explicitly, the contrary. It will be understood that the expressions "comprise" and "include", when used in this description, specify the presence of the characteristics, the elements, the components, the steps, and the related operations, however, they do not exclude the possibility of other characteristics, elements, components, steps, and operations also being contemplated.

[0060] All the alterations, providing that they do not modify the essential characteristics of the claims that follow, must be considered as being within the scope of protection of the present invention.

LIST OF REFERENCE INDICATIONS

[0061] 

10 - structural composite heating panel

11A - first layer of thermally-conductive skin

11B - second skin layer

12 - core layer

15 - heating layer (mesh or net support substrate with conductor wire embroidered)

16 - mesh or net support substrate

16A - first wires of the mesh or net support substrate

16B - second wires of the mesh or net support substrate

16C - cells of the mesh or net support substrate

17 - conductor wire embroidered on the mesh or net support substrate of the heating layer

17A - interruptions in the embroidery of the conductor wire

19 - interior coating layer

21 - access box for maintenance or substitution of the temperature probe and/or of the thermal fuse

21A - temperature probe

21B - thermal fuse

51 - first structural connection edges

52 - second structural connection edges

AA - detail of the heating layer blown-up in Figure 3B

M1 - reference point indicating the heating panel in question

P1 - temperature profiled obtainment line on a panel

LIST OF CITATIONS

PATENT LITERATURE

[0062] 

European patent EP 2432673 B1 by 3A Technology / Management Ltd., published on August 24, 2016.

Patent application US 2007/215589 A1 by Craig M. Berger, U.S.A., published on September 20, 2007.

Claims

1. A structural composite heating panel (10) comprising:

- a first layer of thermally-conductive skin (11A);

- a heating layer (15);

- a core layer (12);

- a second skin layer (11B); and

- at least one first structural connection edge (51);

wherein

the heating layer (15) is disposed between the first layer of thermally-conductive skin (11A) and the core layer (12);

the core layer (12) is disposed between the heating layer (15) and the second skin layer (11B);

the at least one first structural connection edge (51) is configured to fixably join the structural composite heating panel (10) to the structure of a compartment, and the at least one first structural connection edge (51) is fixably coupled to the first layer of thermally-conductive skin (11A), to the second skin layer (11B), or is fixably coupled to both the first and second skin layers (11A,11B);

characterized in that the heating layer (15) comprises:

- a mesh or net support substrate (16); and

- at least one electric current conductor wire (17);

wherein

the mesh or net support substrate (16) comprises first wires (16A) and second wires (16B) forming a mesh or net with cells (16C) and is configured to be fixed thereon an embroidery made by said conductor wire (17); and

the conductor wire (17) is configured to be embroidered on said mesh or net support substrate (16) forming a heating embroidery, wherein the heating embroidery comprises straight lines and/or curved lines.

2. The structural composite heating panel (10) according to the preceding claim characterized by further comprising

- at least one second structural connection edge (52) comprising a male end and/or a female end, wherein the at least one second structural connection edge (52) is configured to fixably snap together, through said male end or of said female end, the structural composite heating panel (10) to a female end or to a male end, respectively, of another adjacent structural composite heating panel (10) and wherein the at least one second structural connection edge (52) is fixably coupled to the first layer of thermally-conductive skin (11A), is fixably coupled to the second skin layer (11B), or is fixably coupled to both the first and the second skin layers (11A, 11B) and preferably the at least one second structural connection edge (52) is fixably coupled to both the first and the second skin layers (11A,11B).

3. The structural composite heating panel (10) according to any one of preceding claims characterized in that the first wires (16A) and the second wires (16B) of the mesh or net support substrate (16) form angles between each other, said angles falling within the range from 20° to 160° and

in that the first wires (16A) and the second wires (16B) forming said mesh or net of the mesh or net support substrate (16) have a thickness between 0.1 mm and 0.5 mm, and

in that the cells (16C) of said mesh or net of the mesh or net support substrate (16) have an area between 10 mm² and 30 mm².

4. The structural composite heating panel (10) according to any one of the preceding claims characterized in that the at least one conductor wire (17) comprises

- a metal core with a diameter from 0.3 mm to 10 mm, wherein the metal core comprises a number of filaments between 10 and 50, wherein the filaments have a thickness between 0.05 mm and 0.10 mm;

- a layer of insulation surrounding said metal core, wherein the layer of insulation is made of a polymer material; and

wherein the at least one conductor wire (17) has an outer diameter from 0.75 mm to 1.2 mm.

5. The structural composite heating panel (10) according to any one of preceding claims characterized in that the metal core of the at least one conductor wire (17) is made of a metal from the group comprised of copper, tin-plated copper, tin, aluminum, silver, gold or alloys thereof.

6. The structural composite heating panel (10) according to any one of preceding claims characterized in that the curved lines of the heating embroidery performed by said at least one conductor wire (17) have a curvature radius from 1 mm to 4 mm, preferably the curved lines of the heating embroidery have a curvature radius from 2 mm to 3 mm.

7. The structural composite heating panel according to any one of preceding claims characterized in that the heating embroidery of said at least one conductor wire (17) occupies an area from 60% to 99% of the mesh or net support substrate (16), preferably, 80% to 99%, and more preferably the heating embroidery of the at least one conductor wire (17) occupies 95% of the area of the mesh or net support substrate (16).

8. The structural composite heating panel according to any one of preceding claims characterized in that the at least one conductor wire (17) is a simple conductor wire (17), electrically connected to a monophase electrical installation, is a double conductor wire (17), electrically connected to a biphase electrical installation and/or is a triple conductor wire (17) electrically connected to a triphase electrical installation.

9. The structural composite heating panel according to any one of preceding claims characterized in that the material of the first layer of thermally-conductive skin (11A) and of the second skin layer (11B) is at least one chosen from the group comprised of: aluminum, aluminum coated by an anti-corrosion film, aluminum with epoxy treatment, steel, steel with anti-corrosion treatment, laminated composite, for example, made of fire-resistant polyester resin reinforced by fiberglass.

10. The structural composite heating panel according to any one of preceding claims characterized in that the material of the core layer is mechanically resistant and thermally insulating, homogeneous, polymer-based, phenol resin, cork, balsa wood, mixtures or composites thereof.

11. The structural composite heating panel according to any one of preceding claims characterized in that the material of the core layer has a density from 60 kg/m³ to 300 kg/m³.

12. The structural composite heating panel according to any one of claims 1 to 9 characterized in that the material of the core layer is mechanically resistant and thermally insulating, heterogeneous, that is, is composed of two or more sublayers, each one of said sublayers being polymer-based, phenol resin, cork, balsa wood, mixtures or composites thereof and in that the sublayers are equal densities or the sublayers are different densities falling within the range of 60 kg/m³ to 300 kg/m³.

13. A heating system of a compartment, characterized in that the heating system comprises

- at least one structural composite heating panel (10) as defined in any of the preceding claims, configured to be electrically connected, through the conductor wire (17) of the heating layer (15) to an electrical power source of the compartment structure; and

- an electrical power supply configured to make pass an electric current through the conductor wire (17) of the heating layer (15) of the at least one panel (10);

wherein
the at least one structural composite heating panel (10) is configured to be coupled to the structure of the compartment through the at least one first structural connection edge (51).

14. The heating system of a compartment according to the preceding claim, characterized in that the at least one structural composite heating panel (10) as defined in any of claims 2 to 12, is configured to be additionally coupled, through the at least one second structural connection edge (52):

- the one second structural composite heating panel (10); or

- the one second and the one third composite structural heating panels (10).

15. The heating system of a compartment according to any one of claims 13 or 14, characterized in that the system further comprises

- a temperature control module and

- at least one temperature measuring probe (21A); and/or

- at least one thermal fuse (21B);

wherein

the at least one temperature measuring probe (21A) is disposed inside a furrow dug out in the core layer (12) of the at least one structural composite heating panel (10) and is electrically connected to said temperature control module, for which it is configured to send temperature measurement data;

the at least one thermal fuse (21B) is disposed inside a furrow dug out in the core layer (12) of the at least one structural composite heating panel (10) and is electrically connected to the power supply of the conductor wire (17); and

said temperature control module is connected to said source of electrical power supply of the compartment and is configured to turn on or off the power supply of the conductor wire (17), whereby being capable of controlling the temperature of the heating panel (10).

16. The heating system of a compartment according to any one of claims 13 to 15, characterized in that the system further comprises

- an interior coating layer (19);

wherein said interior coating layer (19) is configured to be placed on the first layer of thermally-conductive skin (11A) of the structural composite heating panel (10) as defined in any of claims 1 to 12; and

wherein said interior coating layer (19) is at least one of the group comprised of: interior flooring, interior wall coating, or a combination thereof.

17. The heating system of a compartment according to claim 16, characterized in that said interior coating layer (19) is a material pertaining to the group comprised of an elastomer, a polymer, linoleum, textile coatings, ceramic materials or mixtures thereof and in that said interior coating layer (19) has a thermal conductibility from 0.08 W/m.K to 1.5 W/m.K.

18. The heating system of a compartment according to any one of claims 13 to 17, characterized in that the system is configured to be installed in a compartment of a passenger transport vehicle belonging to the group comprised of: train, coach, car, boat, plane, more preferably, belonging to the group comprised of: train, coach.

19. The heating system of a compartment according to any one of claims 13 to 17, characterized in that the system is configured to be installed compartment of an installation belonging to the group comprised of: sanitary installation, bedroom, living room, meeting room, office, kitchen, spa, corridor, store, public space.

Drawing