Radiation device and manufacturing method thereof

Abstract

A radiation device (1) for heating a work space (SO) or an object (O), comprising:-a substrate material (11) configured to be attached to a structure of the work space (SO) or to a surface of the object (O); -a conductor (10) associated with the base material (11) and configured to receive an electrical current, the conductor (10) extending in a plane to define a radiation surface of the radiation device (1), characterized in that the conductor (10) is a flat conductor made of a carbon-based material.

Description

Technical Field

[0001] The invention relates to a radiation device and a method for producing the radiation device.

[0002] A radiation device is a device configured to generate radiant heat by flowing an electric current through a conductor and generating heat by the Joule effect.

[0003] These devices comprise a frame to which conductors are associated in a path defining a radiating surface. In radiating devices, the radiation emitting surfaces are called active surfaces and the surfaces which do not emit radiation and thus do not contribute to heating are called passive surfaces.

[0004] Generally speaking, these devices have a planar shape defining a radiating panel. Background Art

[0005] In the field of radiation devices, two major categories of radiation devices are known.

[0006] The first type of radiating panels comprises radial conductors, essentially coiled wires forming a radiating surface.

[0007] Such panels have several disadvantages. On the one hand, the size of the active surface is limited, since this surface cannot be oversaturated with circular conductors, and on the other hand, the radial radiation produced by the radial conductors is not orthogonal to the radiating surface, with the result that a lot of energy is lost. In short, therefore, the energy efficiency of these radiating panels is rather low, of the order of 40%.

[0008] On the other hand, the second type of radiant panels is made using a flat support sheet on which a conductive polymer is laid. This solution, although increasing the size of the active surface, has some almost negligible disadvantages. First of all, these devices are usually provided with exposed electrical connections and therefore cannot be applied to exposed structures. In addition, and more importantly, the working life of these devices is relatively short, of the order of three or four years. In fact, the operating principle of such devices is based on the movement (kinetic energy) of polymer particles, to generate heat. The fact that radiation is the result of a dynamic situation of molecular motion leads to a relatively rapid wear of the polymer.

[0009] In this regard, it should be remembered that in the field of building construction, the current state of legislation regarding the installation of fixed components in structures requires a ten-year warranty. Therefore, these devices cannot be used in such cases, as their working life is much shorter.

[0010] Prior art devices having the above-mentioned disadvantages are described in documents GB2536214A, US2011056928A1 and CN111432507A. Summary of the invention

[0011] The object of the present invention is to provide a radiation device and a method for manufacturing the radiation device to overcome the above-mentioned disadvantages of the prior art.

[0012] This object is fully achieved by the device and method of the present disclosure as characterized in the appended claims.

[0013] According to one aspect of the present disclosure, the present disclosure provides a radiation device for heating a workspace and / or an object. Preferably, the device is a radiation panel.

[0014] The device includes a base material configured to be attached to a surface of a structure or object in a workspace.

[0015] The device includes a conductor. The conductor is associated with a substrate material. The conductor is configured to receive an electric current. The conductor extends in a plane to define a radiating surface of the radiating device.

[0016] The conductor is configured to radiate heat from a workspace or object using a Joule effect generated by current passing through the conductor.

[0017] Preferably, the conductor is a flat conductor.

[0018] The use of a flat conductor makes it possible to direct the radiation over the entire surface into the workspace without wasting energy due to radiation in different directions as in the prior art.

[0019] In an embodiment, the conductor is made of a carbon-based material.

[0020] This means that the heating does not depend on molecular motion but on the Joule effect created by the passage of electrons, a "static" form of heating that allows the device (conductor) to have a longer operating life, more in line with the ten-year warranty requirements for building construction.

[0021] In an embodiment, the conductor is made of graphene. In an embodiment, the base material is made of a polymer material. Preferably, the base material is fireproof. Preferably, the base material is electrically insulating.

[0022] In an embodiment, the substrate material is made of polyimide. Examples of materials that can be used are

[0023]

[0024] In an embodiment, starting from a base material, the conductor is manufactured by (nano)thermal conversion of the base material in a carbon-based material. This allows a very high level of flexibility in the manufacture of the conductor, with nanoscale-based conductor structures and virtually no restrictions on the shape of the conductor.

[0025] In particular, it is noted that the use of a thermal conversion process gives the conductor special structural properties, which allow the identification of the graphene thus produced, compared to other types of graphene produced using different methods. Therefore, the method used has a direct impact on the graphene used and can be an object of product protection.

[0026] In an embodiment, the conductor comprises a continuous sheet defining the radiating surface of the radiating device.

[0027] In an embodiment, the continuous sheet has a thickness of less than 50 microns. In an embodiment, the continuous sheet has a thickness of less than 30 microns, preferably 25 microns.

[0028] In an embodiment, the continuous sheet is flexible (pliable) so that it can conform to the surface of an object on which it is placed.

[0029] In an embodiment, the device comprises one or more attachment elements configured to attach the base material to the object to be heated. For example, the attachment element may be an adhesive strip that adheres to the object to be heated.

[0030] In an embodiment, the device comprises a frame on which the conductors are arranged (associated, attached, connected, fastened, supported). In particular, the frame is configured to support a continuous sheet. In an embodiment where a frame is provided, there may be a plurality of continuous sheets parallel to each other and spaced apart along the radiation direction to increase the amount of heat radiated by each panel.

[0031] In another embodiment, the conductor comprises a straight conductor. The straight conductor is preferably flat. The straight conductor is wound on (around) the frame to define a radiating surface.

[0032] In an embodiment, the frame includes a frame. The frame includes four side walls. The frame includes a plurality of through cavities. The plurality of through cavities are made in at least two side walls of the frame. A straight conductor is wound around the frame. The straight conductor is inserted into the through cavities of the frame to form a corresponding spiral. In this way, a coil that radiates heat is defined.

[0033] The through cavities are spaced apart along the radial direction to define respective spaces between respective turns defined by the straight wrapped conductors, thereby reducing heat transfer toward a side of the device opposite to where the working space is located.

[0034] Preferably, a straight conductor is manufactured according to the embodiments described below, which provides several advantages in terms of reducing noise generated by magnetic and / or electric fields.

[0035] In particular, the (flat) straight conductor comprises a first (flat) conductor. The first flat conductor is encapsulated (contained, accommodated, arranged, insulated) in a base material. The first flat conductor is passed through by a first alternating current.

[0036] The (flat) straight conductor includes a second flat conductor. The second flat conductor is encapsulated (contained, accommodated, arranged, insulated) in a base material. A second alternating current passes through the second flat conductor.

[0037] Preferably, the sense of the second alternating current is opposite to that of the first alternating current. The modulus of the first alternating current is the same as that of the second alternating current. In addition, the first conductor and the second conductor overlap each other along the axis (relative to the axis) of the heat flow emission to define a (flat) straight conductor. This configuration of conductors allows the magnetic field to be zeroed because the first alternating current and the second alternating current have opposite senses, which produce an induced magnetic field with opposite senses and equal modulus, thereby zeroing the induced magnetic field. In addition, the presence of an electrically insulating substrate material allows the electric field to be insulated.

[0038] It should also be noted that the present disclosure does not intentionally provide any solution for compensating for (or avoiding) eddy currents. In fact, eddy currents further increase conductor heating, thus contributing to improving the resulting heating efficiency to all intents and purposes.

[0039] According to one aspect of the present disclosure, the present disclosure provides a structural element for building construction, comprising a structure. The structural element comprises a heating device according to any of the features described in the present disclosure. The device is attached to the structure of the structural element. The structural element may be a floor, a column, a wall, a ceiling, a cabinet.

[0040] According to one aspect of the present disclosure, the present disclosure provides a method of manufacturing a radiation device for heating a workspace or an object.

[0041] The method includes the step of providing a substrate material.

[0042] The method comprises the steps of arranging a conductor on a base material. The conductor is a flat conductor and / or is made of a carbon-based material.

[0043] Preferably, the step of providing the conductor on the base material is a step of nanothermal conversion, wherein parts of the base material are thermally converted into the carbon-based material of the conductor.

[0044] According to one aspect of the present disclosure, the present disclosure also provides a method for manufacturing a straight conductor, preferably a flat straight conductor.

[0045] The method for manufacturing a straight conductor comprises the following steps:

[0046] - providing a strip of substrate material, preferably made of a polymer material;

[0047] - thermally converting a portion of the base material into a conductor, wherein the conductor is formed on the surface of the base material and in the inner region of the strip such that the conductor is spaced apart from the peripheral edge of the base material;

[0048] - folding the strip around a longitudinal axis defined by the direction of extension of the strip;

[0049] - welding the covered edges of the base material to encapsulate or insulate the conductor;

[0050] - folding said strip about a transverse axis perpendicular to said longitudinal direction so as to define two layers of said conductor;

[0051] - welding (bonding) said two layers of conductor to define a linear conductor comprising a first straight conductor and a second straight conductor parallel to each other along a longitudinal direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] This and other features will become more apparent from the following description of a preferred embodiment, illustrated by way of non-limiting example in the accompanying drawings, in which:

[0053] - Figure 1A and Figure 1B Two schematic side views of embodiments of a radiation device for heating a workspace or object according to the present disclosure are shown;

[0054] - Figure 2 shows a schematic side view of another embodiment of the radiation device of FIG. 1 ;

[0055] - Figure 3 shows a schematic plan view of the radiation device of FIG1 ;

[0056] - Figure 4 Shows Figure 2 A schematic plan view of a radiation device;

[0057] - Figure 5 shows a schematic side view of a straight conductor that can be used in a radiating device according to the present disclosure;

[0058] - Figure 6 shows a schematic plan view of a strip of substrate material on which the conductors are thermally converted;

[0059] - Figure 7 shows a schematic side view of an embodiment of a radiation device according to the present disclosure;

[0060] - Figure 8 A working space is schematically illustrated in which a structural heating element is arranged. DETAILED DESCRIPTION

[0061] With reference to the drawings, numeral 1 denotes a radiation device for heating a workspace or an object. In particular, the radiation device is a radiation panel 1 .

[0062] The radiation panel 1 comprises a conductor 10. The conductor 10 is electrically conductive to allow an electric current to pass through it, thereby heating it by the Joule effect. In a first embodiment, the conductor 10 has the shape of a flat plate (flat plate, continuous sheet). Preferably, along the radiation direction DI, the thickness of the conductor is less than 100 microns, preferably less than 50 microns, more preferably, the thickness is between 23 microns and 28 microns.

[0063] In an embodiment, the conductor 10 directly faces the space to be heated. In some embodiments, there is an insulating layer between the conductor 10 and the surrounding space, but there is no base material to be heated between the conductor 10 and the surrounding space.

[0064] In an embodiment, the panel 1 includes an input connector 101 and an output connector 102. The input connector 101 is connected to the conductor 10 to supply power thereto. The output connector 102 is connected to the conductor 10 to receive power therefrom.

[0065] In an embodiment, the device 1 comprises a base material 11. The base material 11, besides having the function of supporting the conductor 10, also allows the conductor 10 to be insulated from the structure or object on which it is located.

[0066] In an embodiment, the base material 11 is flexible (non-rigid).

[0067] Thus, in an embodiment, the substrate material 11 is a panel whose dimensions are at least equal to those of the conductor 10 (when the conductor 10 is a continuous panel). The panel of substrate material 11 is arranged downstream of the conductor 10 in the radiation direction DI in the radiation direction VI. In other words, the conductor 10 faces the workspace to be heated, while the substrate material 11 faces the structure where the panel is located.

[0068] Preferably, the conductor 10 is made of (at least) graphene. Preferably, the graphene 10 is obtained by (nano)thermal conversion of a substrate material 11 .

[0069] Preferably, the base material 11 is made of a polymer material, preferably polyimide.

[0070] The above device 1, basically made of conductors 10 and base material 11, is flexible in both directions relative to the defining panel 1, so that it can adapt to non-planar surfaces, such as, as non-limiting examples, car interiors, sofas or other non-planar objects.

[0071] Therefore, according to one aspect of the present disclosure, the panel 1 may further comprise an attachment element 13. The attachment element 13 is configured to allow the (flexible) panel to be attached to a wall, a structure or an object. For example, the attachment element 13 may be an adhesive insert made using a heat-resistant glue. Also conceivable is a solution in which the base material 11 comprises a contact surface facing in a direction opposite to the radiation direction, wherein the contact surface is an adhesive (with a heat-resistant glue). This allows the panel to be quickly and easily assembled to any type of surface.

[0072] In other embodiments, more specifically designed for mounting a panel to a flat rigid structure, the device 1 includes a frame 12 .

[0073] The frame 12 is preferably a rigid structure which, although it reduces the flexibility of the device 1, provides a number of important advantages.

[0074] In an embodiment, the frame 12 includes a frame 12'. The frame 12' includes four side walls. In particular, the frame 12' includes a first side wall 121 and a second side wall 122 that are opposite and facing each other. The frame 12' also includes a third side wall 123 and a fourth side wall 124 that are also opposite and facing each other.

[0075] The side walls of the frame 12 ′ extend along the radiation direction DI.

[0076] In an embodiment, at least two side walls of the frame 12 ′ include respective grooves 14A configured to receive the base material 11 of the respective continuous conductor sheet 10 .

[0077] In particular, each pair of side walls 121 , 122 or 123 , 124 includes opposing grooves 14A configured to receive respective opposing portions of the same base material 11 supporting the respective conductor sheet 10 .

[0078] In an embodiment, the device 1 comprises a plurality of conductor units 1 ′, each conductor unit comprising a respective continuous conductor sheet supported by a respective portion of a base material 11 .

[0079] The frame 12' of the frame 12 also includes a facing surface 125 facing the radiation direction VI and perpendicular to the radiation direction DI. The frame 12' includes a contact surface 126 opposite to the facing surface 125. In this case, the attachment element 13 can also be arranged on the contact surface 126, or an adhesive contact surface can be arranged.

[0080] Each conductor sheet of the conductor unit 1' is supported by a corresponding slot in the side wall of the frame 12. The slots are spaced apart along the radial direction DI. Therefore, the conductor units 1' are spaced apart along the radial direction DI to define corresponding spaces SP between the conductor units 1' themselves. These spaces act as thermal insulators and prevent the contact surface 126 from reaching very high temperatures.

[0081] If there are several conductor units 1 ′, each of them is connected to an electrical input collector which is connected to the input connector 101 and distributes the current to all conductor sheets 10 .

[0082] In the same way, each conductor sheet of the conductor unit 1 ′ is connected to an electrical output collector which is connected to the output connector 102 and receives the electrical current from all conductor sheets 10 .

[0083] We note that in the embodiment, the input connector 101 or the output connector 102 passes through the base material 11, for example, in a direction perpendicular to the radiation direction DI or in a direction parallel to the radiation direction DI, so as to come out of the base material 11 on the contact surface. In the same way, when the frame 12 exists, the input connector 101 or the output connector 102 passes through the frame in a direction perpendicular to the radiation direction DI, so as to come out of one of the side walls 121, 122, 123 or 124, or passes through the frame in a direction parallel to the radiation direction DI, so as to come out of the contact surface 126 of the frame 12'.

[0084] In the embodiment, the device 1 differs greatly from the embodiment in the form of a sheet, that is to say a preferably flat straight conductor 10 ′.

[0085] The straight conductor 10 ′ includes a conductor 10 and a base material 11 , which are appropriately integrated with each other to form the straight conductor 10 ′.

[0086] In a preferred embodiment, the straight conductor 10' is made as follows: The straight conductor 10' comprises a first sheet layer L1 and a second sheet layer L2 placed side by side along the longitudinal direction of the main extension L of the straight conductor 10'.

[0087] The first plate layer L1 and the second plate layer L2 each include a flat straight conductor, preferably made of graphene, which is encapsulated in a base material 11. In particular, around each conductor 10 of the first plate layer L1 and the second plate layer L2, there is a first layer of base material 11 and a second layer of base material 11 welded together on one side of the conductor 10 between the two layers.

[0088] An alternating current is passed through each of the first layer L1 and the second layer L2. In particular, the first layer L1 is passed through by a first alternating current whose vector includes a corresponding first modulus and a corresponding first orientation, while the second layer L2 is passed through by a second alternating current whose vector includes a corresponding second modulus and a corresponding second orientation.

[0089] Preferably, the first modulus is the same as the second modulus, while the first orientation is opposite to the second orientation. This allows balancing the induced magnetic field, while the presence of the substrate material allows insulating the electric field.

[0090] In an embodiment, the frame 12 comprises a plurality of through cavities 14B having the same function as the slots 14A of the continuous conductor sheet.

[0091] A plurality of through cavities 14B are located on the first side wall 121 and the second side wall 122 , facing each other.

[0092] The straight conductor 10' is supported in the frame by wrapping the straight conductor 10' around the frame 12 and passing through the through cavity 14B. When the straight conductor 10' is mounted to the frame, a first end of the straight conductor 10' is connected to the input connector 101 and the other end is connected to the output connector 102.

[0093] Therefore, the straight conductor 10' is inserted into one of the multiple cavities 14B on the first side wall 121 from the outside to the inside of the frame 12', and then brought to the next cavity 14B on the second side wall 122 to pass from the inside of the frame 12' to the outside of the frame 12'. Next, the straight conductor 10' is folded and its direction is reversed to allow the straight conductor 10' to be reinserted from the outside of the frame 12' to the inside of the frame 12', passing through another cavity 14B on the second side wall 122, which is spaced apart from the previous cavity along the radial direction DI.

[0094] This allows forming coils extending in the radiation direction DI to form several radiation layers.

[0095] It should be noted that the radiation panel 1 comprises a plurality of straight conductors 10 ′ mounted on a frame 12 , parallel to each other and juxtaposed along a direction perpendicular to the radiation direction DI.

[0096] In fact, the plurality of cavities 14B on the frame are also spaced apart along a direction perpendicular to the radiation direction DI. In particular, the cavities 14B arranged along the radiation direction DI are used for the same straight conductor 10', while the cavities 14B arranged perpendicular to the radiation direction DI are used for different straight conductors 10'.

[0097] According to one aspect thereof, the present disclosure also provides a method for manufacturing a radiation device 1 .

[0098] The method comprises a step of manufacturing a conductor. The step of manufacturing a conductor 10 is preferably a step of (nano)thermal conversion. In the thermal conversion step, a carrier of a base material 11, preferably made of a polymer material (e.g. polyimide), is placed on a working surface and nano-reconstructed by electromagnetic waves, thereby converting the polymer material into a carbon-based material, preferably graphene.

[0099] The base material 11 may be in the form of a panel to produce a continuous conductor sheet by heat converting all inner surfaces of the base material 11, or may be in the form of a continuous strip to obtain a straight conductor 10' by heat converting the inner surface of the continuous strip.

[0100] After obtaining the graphene conductor 10 , the method includes connecting the conductor 10 to an input connector 101 and an output connector 102 .

[0101] Next, the method optionally includes positioning the continuous sheet in the slot 14A of the frame 12 .

[0102] On the other hand, in the case of a straight conductor 10 ′, as described above, the method includes winding the straight conductor 10 ′ around the frame 12 in the cavity 14B.

[0103] In addition to what has been described, the method also provides a method for producing a straight conductor 10 ′.

[0104] The steps described herein follow the steps of thermal conversion of a continuous strip. Thus, a strip of substrate material 11 is provided on which there is also a thermal conversion conductor 10 spaced from the edge of the continuous strip material 11 along a transverse direction T to define a first weld edge BS1 and a second weld edge BS2.

[0105] At this point, the method comprises a first step R1 of rotating the continuous strip about the longitudinal axis L so as to place the first welding edge BS1 on the second welding edge BS2. The first welding edge BS1 and the second welding edge BS2 are then welded, glued or otherwise attached to each other so as to enclose the conductor 10 within the base material 11. This allows obtaining a third welding edge.

[0106] In an embodiment, the method comprises a second step R2 of rotating about the transverse direction T so as to fold the third welding edge onto itself.

[0107] Next, the method comprises welding the third welding edge to itself so as to define two electrically conductive extensions placed side by side along the longitudinal direction L, as described above with reference to the straight conductor 10 ′.

Claims

1. A radiation device (1) for heating a workspace (SO) or an object (O), comprising: - a substrate material (11) configured to be attached to a structure of the workspace (SO) or to a surface of the object (O); a conductor (10) associated with the base material (11) and configured to receive an electric current, the conductor (10) extending in a plane to define a radiating surface of the radiating device (1), The invention is characterized in that the conductor (10) is a flat conductor made of carbon-based material.

2. The device (1) according to claim 1, wherein: The base material (11) is made of a polymeric, flame-proof, electrically insulating material.

3. The device (1) according to claim 2, wherein: The base material (11) is made of polyimide, and the conductor (10) is made of graphene.

4. The device (1) according to any one of the preceding claims, wherein: The conductor (10) is produced starting from the base material (11) by nanothermal conversion of the base material (11) in the carbon-based material.

5. The device (1) according to any one of the preceding claims, wherein: The conductor (10) comprises a continuous sheet defining the radiating surface of the radiating device (1).

6. The device (1) according to claim 5, wherein: The continuous sheet has a thickness of less than 30 microns.

7. The device (1) according to claim 4, comprising a frame (12), the conductor (10) being arranged on the frame (12), wherein the conductor (10) comprises a flat straight conductor (10') wound around the frame (12) to define the radiation surface.

8. The device (1) according to claim 7, wherein: The frame (12) comprises a frame (12'), the frame (12') comprises four side walls (121, 122, 123, 124) and a plurality of through cavities (14B), the plurality of through cavities (14B) being made in at least two side walls (121, 122) of the frame (12'), wherein the flat straight conductor (10') is wound around the frame (12) and inserted into the through cavities (14B) of the frame (12').

9. The device (1) according to claim 4, wherein: The flat straight conductor (10') comprises: - a first flat conductor (L1) which is encapsulated in the base material (11) and through which a first alternating current passes; a second flat conductor (L2) which is encapsulated in the base material (11) and through which a second alternating current passes, the second alternating current having a direction opposite to that of the first alternating current, The first conductor (L1) and the second conductor (L2) are placed side by side with each other along a main longitudinal direction (L) of extension to define the flat straight conductor (10').

10. A structural heating element for use in building construction, comprising a structure and a heating device (1) according to any one of the preceding claims, the heating device being attached to the structure of the structural element.

11. A method for manufacturing a radiation device (1) for heating a workspace (SO) or an object (O), the method comprising the following steps: - providing a substrate material (11); - arranging a conductor (10) on the base material (11), wherein the conductor (10) is a flat conductor made of a carbon-based material, The method is characterized in that the step of arranging the conductor (10) on the base material (11) is a step of nanothermal conversion, wherein a portion of the base material (11) is thermally converted into the carbon-based material of the conductor (10).

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