RECIPROCATING PANEL FOR CAPILLARY HYDRONIC MATS

Description

FIELD OF THE INVENTION

The present invention relates to hydronic capillary mats for building conditioning. In particular, the invention relates to a modular reciprocating panel system that supports a capillary hydronic mat.

BACKGROUND TO THE INVENTION

Capillary hydronic mats over the last few decades are providing for a new method of installing radiant systems into spaces. Often, capillary mats are embedded into plasterboard panels in one of two methods; either manufactured into the plaster itself or routed to the back of the plasterboard. The attractiveness of a lightweight conditioning system, as well as one which involves a ‘dry mounting’ as opposed to a traditionally ‘wet’ system that involved concrete pouring on site, is driving interest into capillary mat systems. Furthermore, these lightweight systems are becoming very dynamic and responsive in their conditioning capacity.

There are several prior art disclosures, such as U.S. Pat. No. 5,957,378A (Fiedrich), which discloses radiant hydronic floor and wall heating principles and their functioning in great detail. Often, these traditional systems apply plastic (PEX) tubing embedded into a concrete slab. More recently, ‘dry mounted’ systems have been developed that do not require ‘weť’ concrete to be poured. These systems are placed after a floor is constructed, for example underneath a plywood subfloor where metal or aluminium plates support the tubing. Systems for supporting the tubing are also placed on top of the subfloor using lightweight grooved insulated boards, for example as disclosed in U.S. Pat. No. 4,865,120A (Shiroki), DE3411339A1 (Weenen), and U.S. Pat. No. 3,037,746A (Williams). Many of the prior art to this point disclose using a ‘serpentine’ tubing arrangement.

AU199861912B2 (Alsberg), takes the concept further in producing a structural subfloor panel with grooves that accommodate a heat-conducting (metal) embossed pan with a matching groove pattern that house the hydronic tubing. Messana of Italy, manufacture an insulated ceiling panel with a metal pan to which hydronic plastic tubing is integrated in a serpentine manner. Systems and methods of coupling such panels together are disclosed for example in US20170089500A1 (Messana).

Many such prior art systems utilise a ‘serpentine arrangement’ of tubes, which relies on a supply inlet to the floor in the room, winding in a serpentine pattern, to an outlet. This often yields a significantly different water temperature between the inlet and the outlet. Nevertheless, this variability in temperature is the nature of the traditional design and its functioning. Traditional ‘serpentine’ methods with larger diameter and wider spaced tubing can experience significant temperature variations in the finishing surface.

However, more recent hydronic conditioning mats may often comprise a different arrangement also known as a ‘canopy-to-canopy’ arrangement. In these arrangements, the inlet water temperature enters a manifold vessel (tube) which then equally distributes the water to an array of smaller (capillary) tubes running perpendicular to the manifold tube. This capillary tubing array has the advantage of delivering the supplied water directly across a surface (floor, wall or ceiling). The result is a water flow with almost the same temperature at the beginning to what it is at the end. Furthermore, due to the closely spaced tubing, the finished substrate is rather uniform and balanced in temperature. This principle is critical when hydronic cooling is applied because of the narrow range of supplied water temperature to its dewpoint (condensation).

For example, DE102018111136A1 (Schludermann), illustrates a canopy-to-canopy design. This prior art illustrates a moulded metal conductive pan as a unit. However, the system disclosed suffers from inadequate insulation, which results in less efficient building conditioning. The prior art also suffers from an inflexible construction method, which the present invention attempts to ameliorate as will be discussed further herein.

The methods of mounting existing capillary mats during construction, often yield results that are less effective in their heat transfer mechanism than planned. The prior art has not explored the heat transfer process in the final installation of their product. Applicant has discovered that a consistent installation needs to be assured, guaranteeing a prescribed heat transfer. For a consistency in heat transfer to take place, a prefabricated metal (conductive) encapsulated hydronic capillary mat has been devised. The devised system can then further be heavily insulated onto one side, by a reciprocating insulated board, while becoming highly conductive to the other side with an affixed finished surface.

Is it therefore an object of the present invention to overcome or ameliorate a problem of the prior art, or at least provide the public with a useful alternative.

SUMMARY OF THE INVENTION

According to a first aspect of the invention, there is provided an encapsulated capillary mat, comprising:

• • a first layer comprising a plurality of grooves;
  • a second layer comprising a capillary mat with a plurality of spaced apart parallel tubes;
  • wherein both longitudinal ends of the second layer comprises a manifold tube running perpendicular to the plurality of parallel tubes; and
  • a third layer comprising a substantially planar surface;
  • wherein the plurality of grooves are parallel, adapted to receive the plurality of spaced apart parallel tubes;
  • wherein the second layer is substantially enclosed in between the first metal layer and the third layer; and
  • wherein the first layer, the second layer, and the third layer are in thermal communication with each other.

In an embodiment, the plurality of parallel tubes and the manifold tubes of the second layer are plastic.

In an embodiment, the first layer is metal.

In an embodiment, a finished substrate material is applied onto the substantially planar surface of the third layer.

In an embodiment, the third layer comprises a plastic surface to which the finished substrate material is applied.

In an embodiment, the finished substrate material is a hydrophobic material.

In an embodiment, the finished substrate material is plasterboard, SPC vinyl panels, wood veneer, metal perforated sheeting, or rendering.

In an embodiment, the third layer is an aluminium layer having a thickness of approximately 0.1 mm.

In an embodiment, the third layer comprises an adhesive surface adapted to secure the third layer to the first layer.

In an embodiment, the encapsulated capillary mat further comprises a spigot adapted to be affixed to the manifold tubes of the second layer, the spigot comprising:

• • a tube section having a first end and a second end;
  • the first end comprising a taper; and
  • the second end comprising a sleeve region;
  • wherein the sleeve region is adapted to be affixed to the manifold tubes.

In an embodiment, the second end of the spigot comprises a first region with larger external diameter and a second region with smaller external diameter; wherein the first region comprises an abutment surface to securely position spigot against the manifold pipes as the second region is inserted into said manifold pipe.

In an embodiment, the abutment surface of the spigot is plastic welded to the manifold pipes.

In another aspect of the invention, there is provided a reciprocating panel, comprising:

• • an insulation layer comprising a plurality of machined grooves; and
  • the encapsulated capillary mat according to the first aspect of the invention;
  • wherein the plurality of machined grooves of the insulation layer are adapted to receive the plurality of machined grooves of the first layer of the capillary mat.

In an embodiment of the second aspect, the insulation layer and encapsulated capillary mat are adhesively affixed to each other.

In a third aspect of the invention, there is provided an array arrangement of the reciprocating panel according to the second aspect of the invention.

In an embodiment of the third aspect, wherein the reciprocating panels are in fluid communication with other reciprocating panels of the array.

In an embodiment of the third aspect, a finished substrate material is applied onto a substantially planar surface of the reciprocating panels of the array.

In a fourth aspect of the invention, there is provided a spigot, comprising:

• • a tube section having a first end and a second end;
  • the first end comprising a taper; and
  • the second end comprising a sleeve region;
  • wherein the sleeve region is adapted to be affixed to a tube.

In an embodiment of the fourth aspect, the second end of the spigot comprises a first region with larger external diameter and a second region with smaller external diameter; wherein the first region comprises an abutment surface to securely position spigot against the tube as the second region is inserted into said tube.

It should be noted that any one of the aspects mentioned above may include any of the features of any of the other aspects mentioned above and may include any of the features of any of the embodiments described below as appropriate.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned from the following detailed description which provides sufficient information for those skilled in the art to perform the invention. The detailed description is not to be regarded as limiting the scope of the preceding summary of the invention in any way. The detailed description will make reference to a number of drawings as follows.

FIG. 1 is an exploded view of an encapsulated capillary mat according to a preferred embodiment of the invention;

FIG. 2 is an insulation board adapted to be affixed to the encapsulated capillary mat;

FIG. 3 is a reciprocating panel according to another preferred embodiment of the invention;

FIG. 4 is a magnified perspective of a manifold tubing and its connective elements;

FIG. 5 provides views of a spigot according to another preferred embodiment of the invention;

FIG. 6 illustrates a connective clip to a manifold tubing; and

FIG. 7 illustrates an array of reciprocating panels according to another preferred embodiment of the invention.

LIST OF COMPONENTS

The drawings refer to the following reference numerals:

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description of the invention refers to the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts. Dimensions of certain parts shown in the drawings may have been modified and/or exaggerated for the purposes of clarity or illustration.

In certain embodiments, the present invention provides for a reciprocating panel that can accommodate a separately metal encased capillary mat, of known size, and assures its contact effectiveness with its finishing substrate. Contact adhesive systems have provided for effective heat transfer between the capillary enclosed mat surface and the finishing substrate. Consequentially, a reliable and tested performance product and its installation method for accommodating the capillary mat into a comprehensive conditioning panel has been developed.

It is also to be noted here that almost all other innovations in ‘dry-mounted’ radiant systems are a kit-of-parts installation and do not provide a finished prefabricated modular product. There are only two truly prefabricated panelised systems for installation that are on the market. The first, is from capillary manufacturers themselves that embed the tubing into plasterboard sheets. The second is an insulated modular panel produced by Messana of Italy.

In the first, capillary embedded product, the installer is restricted to the finishing material being the plasterboard. In the second, panelised product by Messana, Italy, a serpentine tubing configuration is applied as well as the product reliant upon its insulating board and metal pan inserted material. The limitations of serpentine configurated conditioning have previously been discussed in this document. Furthermore, both solutions do not provide for the diversity and flexibility that is proposed with the present invention:

• • the present invention allows for an insulated board to be applied or not applied;
  • the present invention allows for various finishing substrates to be affixed to its surface; and
  • the present invention is prefabricated prior to installation on site only requiring a hydronic connection.

Referring to FIG. 1, there is provided an exploded view of an encapsulated capillary mat 14. The encapsulated mat 14 comprises three layers may be affixed together into an integral unit.

A second layer comprises an inner capillary mat 1 having a plurality of parallel plastic tubes 16 is sandwiched between a first layer and a third layer. The first layer is a moulded rigid layer 2, which in a preferred embodiment is a metal pan which has been moulded to feature parallel spaced grooves 18, the position of grooves 18 conform to the position of tubing 16 present on the capillary mat 1, thereby allowing for intimate contact between the mat 1 and the metal pan 2. Metal pan 2 is a highly thermally conductive layer, facilitation thermal heat transfer between capillary mat 1 and the metal pan 2. The metal pan 2 and capillary mat 1 is capped and affixed to a third layer of a uniform metal sheet 3, thereby encapsulating plastic tubing 16 in a highly thermally conductive environment. When assembled, metal sheet 3 results in an exposed uniform planar surface 20 to which finishing substrates may be applied. Alternatively, exposed planar surface 20 may comprise a plastic film to which a hydrophobic surface finishing substrate may be applied. Preferably, the hydrophobic finishing surface may be a plastic such as but not limited to vinyl, polyvinyl chloride, polypropylene, polyethylene, and polypropylene random copolymers.

The use of a hydrophobic finishing surface aids in preventing condensation on the exposed surface of metal sheet 3. In turn, this lowers the panel surface temperature during operation to be lower than the dew point of the surrounding environment. Applicant has demonstrated typical surface temperatures 5-6 degrees Celsius lower than dew point while in operation.

In a preferred embodiment, uniform metal sheet 3 is constructed from a thin layer of aluminium, which may be approximately 0.1 mm thick, having an adhesive layer adapted to secure sheet 3 to the underlying capillary mat 1. The adhesive layer may initially be covered by a protective layer to be peeled off by the user prior to joining sheet 3 with capillary mat 1. The thin aluminium layer presents an extremely lightweight encapsulated mat 14 for ease of transportation and installation into desired locations. By using an adhesive layer to, sheet 3 may be applied onto exposed capillary mat 1 in a manner similar to applying wallpaper onto walls. Although preferably the encapsulated mat 14 is provided to users prefabricated, the ease of installation of sheet 3 presents the user with a simple assembly method for the encapsulated capillary mat 14 if required.

The encapsulated mat 14 may be affixed to a rigid insulation board 4, said board illustrated in FIG. 2. The insulation board 4 is formed from an insulative material, such as but not limited to XPS, polyurethane, PIR, Styrofoam, or similar insulating materials as would be known to a person skilled in the art. Insulation board 4 comprises a plurality of parallel moulded grooves 5 which extend across the length of the board 4, said grooves adapted to receive the grooves 18 of the metal pan 2, thereby ensuring a close fit between the encapsulated mat 14 and insulation board 4.

Insulation board 4 comprises larger end grooves 6, which are adapted to receive manifold pipes 22 located at the longitudinal ends of capillary mat 1, the manifold pipes 22 positioned at both ends of the parallel tubes 16 and run substantially perpendicular to the parallel tubes 16. Grooves 5, 6 as present on insulation board 4 facilitates sufficient contact with metal pan 2 and capillary mat 1 of the encapsulated mat 14, thereby sufficiently insulating said encapsulated mat 14, to facilitate the mat to efficiently provide conditioning through thermal communication with metal sheet 3 when a coolant, such as water, is pumped through the pipes 16, 22, thereby conditioning the surrounding environment through exposed planar surface 20.

A fully assembled reciprocating panel 24, comprising the insulation board 4 and encapsulated capillary mat 14 used for building conditioning, is illustrated in FIG. 3. The metal encapsulated capillary mat 14 affixed to insulation board 4 through means known in the art, such as but not limited to glue. A finishing surface substrate, such as but not limited to plasterboard, vinyl SPC hybrid tiling, metal perforated pans, wood veneers, and the like, may then be applied to the exposed surface of metal sheet 3 as desired.

Referring now to FIG. 4, axial ends of the manifold pipe 22 are adapted to receive a plastic welded spigot 7 to which an exemplary pneumatic push-fit pipe connector 8 can be accommodated. This enables the reciprocating panel 24 to be joined in fluid communication with other reciprocating panels in a desired arrangement, such as a grid formation. Spigot 7 and connector 8 also enables the reciprocating panel 24 and/or arrangement of reciprocating panels to connect to an external piping network, such as return and supply pipes, to facilitate movement of coolant throughout the panels.

Spigot 7, as illustrated in FIG. 5, features a cylindrical tube region 26 having an internal fluid communication channel adapted to facilitate movement of coolant. A first end of spigot 7 is adapted to be received by connector 8 comprises a taper 28 to enable ease of fit into the connector 8. A second end of spigot 7 is adapted for secure abutment to ends of a manifold pipe 22, wherein tube region 26 expands into a sleeve region comprising a first region 30 with larger external diameter, and a second region 34 with smaller external diameter.

The first region 30 comprises an abutment surface 32 to securely position spigot 7 against manifold piping 22 as the second region 34 is inserted into the manifold pipe. In a preferred embodiment, the spigot 7 is secured to the manifold piping 22 through plastic welding between its abutment surface 32 and an internal rim, or internal diameter, of the piping 22. Once welded, the spigot tube region 26 serves as a transition piece between a larger diameter open-ended tubing, and a smaller diameter push-fit connector, allowing for conventional hydronic plumbing fixings to be installed.

Spigot 7 is specialised in its design to simplify and assure a solid welded connection to the manifold pipe 22 and to accommodate a pneumatic push-fit connector 8, which can be rotated to the required direction of a further pipe connection. In an embodiment, spigot 7 may be constructed from plastic, as is plastic welded to manifold tubing 22. The internal fluid communication channel within spigot 7 expands in a substantially conical fashion within the sleeve region.

In an embodiment of the invention there is provided an end piece 9 adapted to conform to the contour of the manifold piping at either end of capillary mat 1 as illustrated in FIG. 6. When installed, end piece 9 extends the metal surface area of the panel encapsulated mat 14 and reciprocating panel 24, thereby allowing additional surface substrate to be applied and providing a larger surface area for conducting heat for building conditioning. Within the

Reciprocating panel 24 may be arranged in a grid-like array 36 of reciprocating panels as is illustrated in FIG. 7. Array 36 may be applied onto suspended ceiling grid 11, whereby planar surface 20 rests upon the grid 11 and faces downward into a room interior. It is understood that the array 36 is not limited to being installed onto ceiling grids, and those skilled in the art would be capable of installing array 36 as desired, such as into walls, flooring, and the like. Individual reciprocating panels 24 would typically comprise a finishing surface 10 applied to the exposed planar surface 20.

A hydronic pneumatic interconnection 12 with a substantially curved or semicircular profile connects the connectors 8 of the reciprocating panels 24, thereby joining the piping of said panels in fluid communication with each other. Interconnection 12 may also connect panels to a return and/or supply piping network 13, facilitating supply of coolant to each of the panels 24 in turn. Interconnection 12 is constructed from materials known in the art, such as but not limited to nylon tubing.

The present invention provides an improvement to an exemplary plastic capillary hydronic mat, significantly enhancing its thermal radiant capacity output through the encapsulating metal layers 2, 3. The encapsulated metal pan 2, which in turn is in thermal communication with metal sheet 3, is in close contact with parallel pipes 16 enabling it to become the primary thermal conductor of the panelised system. Applicant has found that thermal prototype testing indicates that virtually any finishing substrate can be affixed through adhesive systems to the planar metal surface of the capillary mat to provide for a successful conditioning panel.

The present invention provides for extremely uniform and balanced panel surface temperature, thereby achieving an optimised radiant energy transfer for building conditioning purposes. It is noted that other panels on the market, such as those comprising a serpentine flow design, experience greater temperature variation which limits their supply temperature due to condensation as would be understood by one skilled in the art.

Furthermore, the present invention represents a substantial departure from existing technologies, as it does not rely on a kit-of-parts to be assembled on-site but instead offers a fully prefabricated product. Whereas existing solutions typically utilise a U-shaped metal moulded pan to house tubing, the present invention, through grooves present on metal pan 2, completely encapsulates tubing within the conductive metal material. This encapsulation eliminates the need for (insulated) holding templates or separate snap-on spacing strips, as the design inherently ensures the proper on-centre (O.C.) spacing and secure placement of the tubing.

Furthermore, the invention is designed for smaller capillary tubing and differs from the conventional serpentine installation pattern common in many existing prior art solutions. Instead, it features a canopy-to-canopy tubing system with manifold pipes at each end. It is to be noted that while the encapsulated capillary mat 14 can incorporate an insulation board 4 if required, it is not dependent on it, making the product adaptable to various on-site assembly methods. It can be integrated with already constructed and insulated foundations and is compatible with a wide range of existing building materials and finishing surfaces, including rendering. The option to include an insulation board 4 is available if necessary, and the system's lightweight design makes it suitable for application in suspended ceilings.

Further advantages of the invention will also be made clear to the reader. The modularised panel design facilitates easy installation, particularly in retrofitting projects, and allows the panels to replace existing suspended ceiling tiles, transforming the ceiling into an effective conditioning surface. The present invention's superior temperature uniformity provides a 20-30% increase in conditioning capacity compared to serpentine tubing systems, which often suffer from significant temperature variations across the panel. This uniformity, together with the application of a hydrophobic substrate layer, reduces the risk of condensation and enhances heat transfer efficiency. The lightweight prefabrication of the system ensures ease of installation, and its dynamic, fast, and responsive conditioning capabilities deliver results within minutes, unlike traditional hydronic radiative systems. Additionally, the system is cost-competitive, offering an affordable alternative to other hydronic system installations.

The reader will now appreciate the advantages of present invention which provides for an improved reciprocating panel comprising a hydronic capillary mat for building conditioning.

Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognised that departure may be made therefrom within the scope of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus. Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of the common general knowledge in this field.

In the present specification and claims (if any), the word “comprising” and its derivatives including “comprises” and “comprise” include each of the stated integers but does not exclude the inclusion of one or more further integers.