HEATED FLOOR MATS AND ARCHITECTURAL PANELS

Abstract

An apparatus includes first and second glass panes separated by a gap, a resistive layer in the gap adjacent to the first glass pane, a controller configured to supply electric current to the resistive layer to heat air in the gap, and first and second openings allowing air to enter and exit the gap. A method performed using the apparatus is also described.

Description

CROSS-REFERENCE TO A RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/510,651, filed Jul. 22, 2011, titled “Heated Floor Mats And Window Panels”, which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to electrically heated floor mats and architectural panels.

BACKGROUND

Localized heat sources can be used to improve personal comfort or to control energy costs. However, a need remains for improved heated floor mats and architectural panels, including personal heated floor mats for people and animals, and heated architectural panels that can provide warmth for personal comfort and/or to control energy costs.

SUMMARY

In one aspect, the invention provides an apparatus that include first and second glass panes separated by a gap, a resistive layer in the gap adjacent to the first glass pane, a controller configured to supply electric current to the resistive layer to heat air in the gap, and first and second openings allowing air to enter and exit the gap.

In another aspect, the invention provides a method including passing air through a gap between first and second glass panes, wherein the air is heated by electrical current in a resistive heating layer positioned in the gap.

In another aspect, the invention provides method including: passing an electrical current through a resistive heating layer adjacent to a glass panel to warm the glass panel, and controlling the electrical current to achieve a temperature of the glass panel that is substantially the same as a temperature of a wall in which the glass panel is mounted.

In another aspect, the invention provides a heat mat including a first panel, a resistive layer adjacent to the first panel, a non-conductive coating adjacent to the resistive layer, two bus bars electrically connected to the resistive layer, a motion sensor for detecting motion of a user, and a controller configured to enable the application of voltage to the bus bars in response to the motion sensor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a floor mat constructed in accordance with an aspect of the invention.

FIG. 2 is a plan view of the floor mat of FIG. 1.

FIG. 3 is a cross-sectional view of a floor mat constructed in accordance with another aspect of the invention.

FIG. 4 is a plan view of the floor mat of FIG. 3.

FIG. 5 is an elevation view of a window panel constructed in accordance with another aspect of the invention.

FIG. 6 is a cross-sectional view of the window panel of FIG. 5.

FIG. 7 is a cross-sectional view of a window panel constructed in accordance with another aspect of the invention.

FIG. 8 is a cross-sectional view of a window panel constructed in accordance with another aspect of the invention.

FIG. 9A is an elevation view of a window panel constructed in accordance with another aspect of the invention.

FIG. 9B is a top view of the window panel of FIG. 9A.

FIG. 10A is an elevation view of a window panel constructed in accordance with another aspect of the invention.

FIG. 10B is a top view of the window panel of FIG. 10A.

FIG. 11 is a cross-sectional view of a window panel constructed in accordance with another aspect of the invention.

FIG. 12 is schematic representation of a glass panel configured for use in combination with a display.

DETAILED DESCRIPTION

In various embodiments, this invention provides electrically heated apparatus and methods of using such apparatus to promote personal comfort and/or to control energy costs. Such apparatus can take the form of, for example, heated floor mats, windows, architectural panels, etc.

FIG. 1 is a cross-sectional view of a floor mat 10 (also called a personal heat mat) constructed in accordance with an aspect of the invention. FIG. 2 is a plan view of the floor mat of FIG. 1. The floor mat includes a first panel 12, which can be constructed of tempered glass, a resistive layer 14 positioned adjacent to the first panel, and an electrically insulating layer 16 positioned adjacent to the resistive layer 14 on a side opposite to the first panel. The insulating layer can be a non-conductive coating forming a laminate or hardened surface. Electrical current flowing in the resistive layer (also called a conductive layer) causes the resistive layer to heat up, thereby raising the temperature of the adjacent first panel.

Bus bars 18 and 20 are positioned adjacent to opposite ends of the resistive layer, and form electrical contacts with the resistive layer. A control box 22 can be mounted on the first panel. The control box includes a control circuit 24 and may include a motion sensor 26. A power cord 28 is provided to connect the control circuit to a power source. Electrical conductors 30, 32 are provided to connect the control circuit to the bus bars.

These conductors can pass through a hole 34 in the first panel. An additional conductor 36 is provided between the control circuit and bus bar 18. This additional conductor can be insulated from the resistive layer. The edge of the resistive layer can be recessed with respect to the edge of the first panel and the edge of the electrically insulating layer 16, such that electrically conductive parts of the floor mat are not exposed.

Electric current flowing in the resistive layer causes the resistive layer to heat and the heat is transferred to the first panel. The motion sensor can be configured to detect the presence of a user on or near the mat. When a user is detected, the control circuit energizes the bus bars, causing current to flow in the resistive layer. The control circuit can be configured to energize the bus bars for a preset period of time after a user is detected and to de-energize the bus bars when a user is no longer detected.

FIG. 3 is a cross-sectional view of a floor mat 50 constructed in accordance with another aspect of the invention. FIG. 4 is a plan view of the floor mat of FIG. 3. The floor mat of FIGS. 3 and 4 is similar to that of FIGS. 1 and 2, but has a thinner glass layer and does not include a motion sensor. The mat includes a first panel 52, which can be constructed of tempered glass, a conductive layer 54 positioned adjacent to the first panel, and an electrically insulating layer 56 positioned adjacent to the conductive layer 54 on a side opposite to the first panel. Bus bars 58 and 60 are positioned adjacent to opposite ends of the conductive layer. A control box 62 is mounted on the first panel. The control box includes a control circuit 64. A power cord 66 is provided to connect the control circuit to a power source. Electrical conductors are provided to connect the control circuit to the bus bars. These conductors can pass through a hole in the first panel. An additional conductor 68 is provided between the control circuit and bus bar 60. This additional conductor can be insulated from the conductive layer. Electric current flowing in the conductive layer causes the conductive layer to heat and the heat is transferred to the first panel. The power cord is connects to an on/off switch 68 and a fuse 70.

In various embodiments, the personal heat mat can be designed for personal comfort in a work space or other location. The heat mat may warm to temperatures between about 80° F. and about 110° F., for example, between about 90° F. and about 100° F., to provide a warm radiant heat source. The temperature can be controlled in various ways. For example, a temperature sensor can be used to monitor the temperature of the mat and provide a signal to the controller indicative of the mat temperature. Then the controller can adjust the current accordingly. Alternatively, the controller can limit the maximum current and thereby limit the maximum temperature of the mat.

The heat mat can be designed and manufactured to any desired size or shape, e.g., to fit into unusual desk areas. Logos, designs or graphics can also be applied. The heat mat may have ANSI certification as a tempered and laminated safety glass unit. The heat mat can provide comfort and energy savings.

The personal heat mat can be designed and manufactured to provide personal comfort while sitting in a cool environment such as an office, work space, or any other cool area. In one embodiment, the heat mat is a personal glass heated mat that a person can stand on, or that could be used under a chair. The heat mat control circuit can include an automatic on/off control function. The heat mat can be designed such that when a user steps on the heat mat the heat will turn on and when the user steps off the heat mat the heat turns off. For example, a pressure sensor or motion detector can be provided to detect the presence of a user. Then the controller can control the electrical current in response to a signal from the sensor or detector. The controller and any associated sensors form a control system that can control the temperature of the mat. The heat mat can be a safety heat pad that cannot increase in temperature above the factory set temperatures.

In various embodiments, the first layer can be glass having a thickness ranging from about ⅛″ to about ½″ thick. The resistive or conductive layer can have a resistance ranging from about 1 ohm to about 1000 ohm between the bus bars. The glass layer can be heat tempered to ANSI certifications for safety. The insulating layer can be a laminate of. for example, polyvinyl butyral (PVB) and urethane. The bus bars can be constructed of silver nitrite or zinc powder. The controller can be a solid state controller, that can be powered by a voltage source of 110 volts to 220 volts single phase AC or DC volts. The current can range from about 1 amp to about 4 amps.

The bus bars work as conductive strips that apply voltage (and current) to the glass surface and cause the resistive/conductive layer to heat up. The resistance and the length of the bus bars can be designed to provide control of the heated surface. Wires may be connected to the bus bars on one end that leads to the controller, which controls power on or power off when a sensor detects movement.

The heat mat can be a heat tempered and laminated device. If the glass layer were to break, the pieces should stay intact due to the lamination process used to assemble the layers.

Another embodiment of the invention provides a heated mat for animals that may have the same construction and operation as the personal heat mats described above, but may be smaller in size. The personal pet mat will typically heat up to temperatures between about 70° F. and about 85° F. The pet mat can also have a controller and control system that operates similar to the control system of the personal heat mat.

In another aspect, the invention can provide a warm window system designed for the office or home use, in either retrofit or new construction applications. FIG. 5 is an elevation view of a window system 90 constructed in accordance with an aspect of the invention. FIG. 6 is a cross-sectional view of the floor mat of FIG. 5. The window system includes a first panel 92, which can be constructed of tempered glass, a resistive or conductive layer 94 positioned adjacent to the first panel, and an electrically insulating layer 96 positioned adjacent to the conductive layer 94 on a side opposite to the first panel. Bus bars 98 and 100 are positioned adjacent to opposite ends of the conductive layer. A controller 102 is provided control the temperatures of the window. The controller connects the bus bars to a power source. Electrical conductors 104, 106 are provided to supply power to the bus bars. These conductors can pass through holes 108, 110 in the first panel. Electric current flowing in the conductive or resistive layer causes the conductive or resistive layer to heat and the heat is transferred to the first panel.

FIGS. 7-10 illustrate and describe details of window systems in accordance with other aspects of the invention.

FIG. 7 shows an embodiment of a heated window 120 mounted in an opening 122. The heated window includes a first glass pane 124 and a second glass pane 126, separated by a space 128. A resistive layer 130 is positioned adjacent to the second glass pane, and within the space. The resistive layer can be connected to two bus bars, not shown in this view, that are similar to the bus bars of FIGS. 6 and 7. When electrical current flows through the resistive layer, heat is produced that passed through the second pane 126 and into the room as illustrated by arrows 132. Panes 124 and 126 can both be constructed of low-e glass. Heat from outside the building is reflected by pane 124 as shown by arrows 134. The glass panes are separated by spacers 136, 138. A window frame 140 surrounds the heated window and is mounted in a wall 142. This configuration stops practically all heat loss from the room though the window.

FIG. 8 shows a window system 150 for a retrofit installation including a previously existing exterior window 152 and a heated window 154. The heated window is positioned in a window opening 156 on the interior side of the opening. The heated window includes a first glass pane 158 and a second glass pane 160, separated by a space 162. A resistive layer 164 is positioned adjacent to the second glass pane, and within the space 162. The resistive layer can be connected the bus bars, not shown in this view, that are similar to the bus bars of FIGS. 6 and 7. When electrical current flows through the resistive layer, heat is produced that passes through the second pane 160 and into the room as illustrated by arrows 166.

FIG. 9A shows a fixed frame window 180 including a frame 182, which can be aluminum, and a glass pane 184. A resistive layer 186 is positioned adjacent to the glass pane. The resistive layer can be connected to two bus bars 188, 190 that are similar to the bus bars of FIGS. 6 and 7. A controller 192 supplies electrical current to the bus bars. When electrical current flows through the resistive layer, heat is produced that passes through the pane 184 and into the room. FIG. 9B shows a top view of the window 180.

FIG. 10A shows a casement window 200 including a frame 202, which can be aluminum, and a glass pane 204. A resistive layer 206 is positioned adjacent to the glass pane. The resistive layer can be connected to two bus bars 208, 210 that are similar to the bus bars of FIGS. 6 and 7. A controller 212 supplies electrical current to the bus bars. When electrical current flows through the resistive layer, heat is produced that passes through the pane 204 and into the room. The window is mounted in a casement frame 214. FIG. 10B shows a top view of the window 200.

In various embodiments, the glass panels of FIGS. 7-10 may be insulated or may be a one sheet laminated design to help eliminate heat loss through the window opening. The system may include aluminum extruded window profiles that are powder coated, with the optional application of wood grain to enhance the appearance. The glass may be low-e type that provides high energy savings. The interior glass of the insulated unit may be provided with a conductive or resistance coating that heats up when energized and radiates warmth into the room and stops any or all loss of heat through the window system.

In one aspect the invention provides a method in which the temperature of the heated window glass is controlled to be substantially the same as the temperature of the interior wall in which the window is mounted. For example, if any of the windows of FIGS. 7-10 are mounted in a wall of a room, where the interior surface of the wall is 70°, and the outside temperature is such that the window glass temperature would be 50°, the window glass can be heated such that the interior surface of the window glass is 70°. Then heat loss through the room walls matches the heat loss through the heated window. This can provide a more uniform distribution of temperatures in the room.

FIG. 11 shows a heated glass window 230 in accordance with another aspect of the invention. The window 230 includes a first glass pane 232 and a second glass pane 234, wherein the first and second glass panes are separated by a gap 236. A resistive layer 238 is positioned in the gap and adjacent to the second glass pane on the gap side. The resistive layer can be connected to two bus bars that are similar to the bus bars of FIGS. 6 and 7. A controller supplies electrical current to the bus bars. When electrical current flows through the resistive layer, heat is produced that passes through the pane 234 and into the room. The hot resistive layer also heats air in a gap 236 between the glass panes. In one example, the air in the gap can be heated to about 215° F. The glass panes are mounted in a frame 240 and spacers 242, 244 maintain the gap between the glass panes. Openings 246 and 248 can be provided to allow air flow into and out of the gap. Electrical current flow in the resistive layer heats the layer and thus heats the air in the gap. A fan or other blower 250 can be used to inject air into the gap or to extract air from the gap, so the heated air in the gap can be circulated into the room. The window is mounted in a wall 260.

FIG. 12 is schematic representation of a window 270 configured to be used in combination with a display 272, such as a simulated fireplace display. In the embodiment of FIG. 12, the window 270 can include two glass panes separated by a gap and a resistive layer adjacent to one of the panes as shown in FIG. 11. A controller can be provided to supply a current to the resistive layer to heat the air in the gap. Openings can be provided to allow air to be blown through the gap and into the room for example through opening 274. Air can enter a gap between the glass panes through an opening near the bottom of the window and can exit the gap through an opening near the top of the window. In one embodiment, the front glass radiates heat at about 210° F. and the air coming out of the top slot ranges from about 100° F. to about 125° F. In this manner heat produced by the heated layer in the window can be transferred to the room, simulating the heat from a fireplace. The window can be mounted on a decorative frame 276 that can be patterned to simulate a marble slab.

The warm window systems described above can provide one or more of the functions of radiating heat into a room; reducing up to 100% loss of heat through windows; lowering energy costs for operation; providing full clear view windows; and/or providing energy savings winter or summer.

The warm window systems can be adapted to various window frame types, such as: fixed window frame heated glass; casement operating window heated glass; project in window heated glass; and project out window heated glass.

The warm window systems can provide radiant heat of the same type provided by the sun, while allowing crystal clear viewing and eliminating condensation.

In some embodiments, the warm window system can serve as a stand-alone heating system. The warm window system converts electricity into heat with an efficiency of close to 100% compared to between 50%-75% for gas heating systems. A programmable wireless thermostat can be used to control the temperature. There is no fuel stored in the warm window system, and thus risks such as carbon monoxide poisoning and explosions are avoided. Due to the “plug & play” nature of the warm window system, installation can be done in a matter of minutes. Radiant heat is more natural as compared to forced air heating, resulting in more comfort without fumes, dust or dryness.

Table 1 below lists specifications for a heated window system in accordance with one embodiment of the invention.

	TABLE 1
	Height - (Between Busbars)	45	inches
	Width - (Length of Busbars)	30	inches
	Edge delete	0.25	inches
	Volts	120	V
	Heated width	43.75	inches
	Heated height	29.75	inches
	Total sq. ft.	9.2
	Heated sq. ft.	9.0
	(Amps)	2.3
	(Watts) sq. ft.	2.3
	(Total Watts) Powder density	280
	(Ohms)	51
	(BTU) per hour	951

While the invention has been described in terms of various embodiments for purposes of illustration, it will be apparent to those skilled in the art that numerous changes can be made to the disclosed embodiments without departing from the scope of the claims set forth below. For example, elements of the various described embodiments can be used in combination with each other to form additional embodiments.

Claims

1. An apparatus comprising:

first and second glass panes separated by a gap;

a resistive layer in the gap adjacent to the first glass pane;

a controller configured to supply electric current to the resistive layer to heat air in the gap; and

first and second openings allowing air to enter and exit the gap.

2. The apparatus of claim 1, further comprising:

a blower configured to blow air into one of the first and second openings or to extract air from one of the first and second openings.

3. The apparatus of claim 1, further comprising:

a frame encompassing the first and second glass panes and the gap.

4. The apparatus of claim 1, wherein the first opening is position near a bottom of the gap and the second opening is positioned near a top of the gap.

5. The apparatus of claim 1, further comprising:

two bus bars electrically connected to the resistive layer.

6. The apparatus of claim 5, wherein the bus bars include silver nitrite or zinc powder.

7. A method comprising:

passing air through a gap between first and second glass panes, wherein the air is heated by electrical current in a resistive heating layer positioned in the gap.

8. The method of claim 7, wherein a blower is used to blow air into one of first and second openings into the gap or to extract air from one of the first and second openings.

9. The method of claim 7, wherein the first opening is position near a bottom of the gap and the second opening is positioned near a top of the gap.

10. The method of claim 7, wherein the first and second glass panes are encompassed by a frame that surrounds the gap.

11. A method comprising:

passing an electrical current through a resistive heating layer adjacent to a glass panel to warm the glass panel; and

controlling the electrical current to achieve a temperature of the glass panel that is substantially the same as a temperature of a wall in which the glass panel is mounted.

12. The method of claim 1, wherein the electrical current is supplied to the resistive layer through two bus bars electrically connected to the resistive layer.

13. The method of claim 5, wherein the bus bars include silver nitrite or zinc powder.

14. A heat mat comprising:

a first panel;

a resistive layer adjacent to the first panel;

a non-conductive coating adjacent to the resistive layer;

two bus bars electrically connected to the resistive layer;

a motion sensor for detecting motion of a user; and

a controller configured to enable the application of voltage to the bus bars in response to the motion sensor.

15. The heat mat of claim 14, wherein the controller turns the heat mat on when the user is on the heat mat and to turns the heat mat off after the user leaves the heat mat.

16. The heat mat of claim 14, wherein the first panel comprises a tempered and laminated safety glass panel.

17. The heat mat of claim 14, wherein the heat mat operates at temperatures between about 80° F. and about 110° F.

18. The heat mat of claim 14, wherein the heat mat operates at temperatures between about 70° F. and about 85° F.

19. The heat mat of claim 14, wherein the heat mat turns on when a user steps onto the heat mat and turns off when the user steps off of the heat mat.