Radiation device and method of manufacturing the same

Abstract

The radiation device (1) for heating a workspace (SO) or an object (O) comprises a substrate material (11) configured to be attached to a surface of a structure or object (O) in the workspace (SO), and a conductor (10) associated with the substrate material (11) and configured to receive an electric current, the conductor (10) extending in a plane so as to define a radiation surface of the radiation device (1), the conductor (10) being a flat conductor made of a carbon-based material.

Description

[Technical Field]

[0001] The present invention relates to a radiation device and a method for manufacturing a radiation device.

[0002] A radiant device is a device configured to produce radiant heat by passing an electric current through a conductor, generating heat via the Joule effect.

[0003] These devices comprise a frame with associated conductors in paths that define a radiating surface, in which the surface that emits radiation is called the active surface and the surface that does not emit radiation and therefore does not contribute to heating is called the passive surface.

[0004] Generally speaking, these devices have a planar shape that defines a radiating panel. [Background technology]

[0005] In the field of radiating devices, two broad categories of radiating devices are known.

[0006] The first category of radiating panels comprises radial conductors, i.e. wire windings that form the radiating surface.

[0007] This type of panel has several drawbacks: on the one hand, the size of the active surface is limited, since the surface cannot be overfilled with circular conductors, and on the other hand, a lot of energy is lost, since the radial conductors generate radial radiation that is not orthogonal to the radiating surface. Therefore, in summary, the energy efficiency of these radiating panels is rather low, at around 40%.

[0008] On the other hand, the second category of radiating panels is made using a flat support sheet on which a conductive polymer is laid. This solution increases the size of the active surface, but has several almost negligible drawbacks. First of all, these devices usually have exposed electrical connections, making them unsuitable for exposed structures. Furthermore, and more importantly, their service life is relatively short, at around three or four years. In fact, the operating principle of this type of device is based on the movement (kinetic energy) of polymer particles, which generates heat. The fact that radiation is the result of a dynamic situation of molecular movement leads to relatively rapid wear of the polymer.

[0009] In this regard, it should be noted that in the field of building construction, current legislation requires the provision of a 10-year warranty on the installation of fixed components built into structures, and therefore these devices cannot be used in such situations, as their service life is much shorter.

[0010] Conventional devices with the above drawbacks are described in the following documents: GB2536214A, US2011056928A1, and CN111432507A. Summary of the Invention

[0011] SUMMARY OF THE INVENTION It is an object of the present invention to provide a radiation device and a method for manufacturing the same which overcomes the above-mentioned drawbacks of the prior art.

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

[0013] According to one aspect thereof, the present disclosure provides a radiant device for heating a workspace and / or an object, preferably the device being a radiant panel.

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

[0015] The device comprises a conductor, the conductor being associated with a substrate material, the conductor being configured to receive a current, the conductor extending in a plane and defining a radiating surface of the radiating device.

[0016] The conductor is configured to radiate heat generated by the Joule effect caused by the passage of electrical current through the conductor into a work space or object.

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

[0018] The use of a flat conductor allows the radiation of the entire surface to be directed into the workspace, rather than wasting energy by radiating in different directions, as occurs in the prior art.

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

[0020] This means that heating relies on the Joule effect caused by the passage of electrons rather than molecular motion, and is a "static" form of heating that allows the device (conductor) to have a longer service life in accordance with the 10-year warranty obligations of building structures.

[0021] In one embodiment, the conductor is made of graphene. In one embodiment, the substrate material is made of a polymer material. Preferably, the substrate material is fire resistant. Preferably, the substrate material is electrically insulating.

[0022] In one embodiment, the substrate material is made of polyimide. An example of a material that can be used is Kapton®.

[0023] In one embodiment, the conductors are formed by starting with a substrate material and (nanometric) thermally converting the substrate material into a carbon-based material, which allows for nanometer-based conductor structuring to achieve a very high level of flexibility in the manufacture of the conductors, with virtually no limitations on the shape of the conductors.

[0024] The use of a thermal conversion process provides the conductor with special structural properties that make it possible to distinguish the graphene thus formed from other types of graphene formed using different methods. The method used therefore has a direct impact on the graphene used and can be subject to product protection.

[0025] In one embodiment, the conductor comprises a continuous sheet that defines the radiating surface of the radiating device.

[0026] In one embodiment, the continuous sheet has a thickness of less than 50 microns, hi one embodiment, the continuous sheet has a thickness of less than 30 microns, preferably less than 25 microns.

[0027] In one embodiment, the continuous sheet is flexible (pliable) so that it can conform to the surface of the object on which it is placed.

[0028] In one embodiment, the apparatus includes one or more attachment elements configured to attach the substrate material to the object to be heated. For example, the attachment elements may be adhesive strips that adhere to the object to be heated.

[0029] In one embodiment, the apparatus includes a framework to which the conductors are disposed (associated, attached, connected, secured, supported). In particular, the framework is configured to support a continuous sheet. In embodiments including a framework, there may be multiple continuous sheets arranged parallel to one another and spaced apart along the radial direction to increase the heat radiated from each panel.

[0030] In a further embodiment, the conductor comprises a linear conductor, which is preferably flat, wrapped around a framework to define a radiating surface.

[0031] In one embodiment, the framework comprises a frame. The frame comprises four side walls. The framework comprises a plurality of through cavities. The plurality of through cavities are formed in at least two of the side walls of the frame. A linear conductor is wound around the framework. The linear conductor is inserted into the through cavities of the frame to form respective spirals, thereby defining a coil that radiates heat.

[0032] The through cavities are spaced along the radial direction to define respective spaces between respective spirals defined by the linear wound conductor, thereby reducing heat transfer to a side of the apparatus opposite the side on which the working space is located.

[0033] Preferably, the straight conductors are manufactured according to the embodiments described below, which offer several advantages in terms of reducing noise caused by magnetic and / or electric fields.

[0034] In particular, the (flat) linear conductor comprises a first (flat) conductor, the first flat conductor being encapsulated (housed, contained, positioned, insulated) by a substrate material, and a first alternating current being passed through the first flat conductor.

[0035] The (flat) straight conductor comprises a second flat conductor, which is encapsulated (housed, contained, positioned, insulated) by a substrate material, and through which a second alternating current is passed.

[0036] Preferably, the second alternating current has a direction opposite to that of the first alternating current. The absolute value of the first alternating current is the same as that of the second alternating current. Furthermore, the first and second conductors are superimposed on each other along the axis of heat flow emission (relative to said axis) to define a (flat) linear conductor. This conductor configuration allows for zero magnetic field because the first and second alternating currents have opposite directions, which generates induced magnetic fields of opposite direction and equal absolute value, and therefore the induced magnetic field is zero. Furthermore, the presence of an electrically insulating substrate material allows for electric field isolation.

[0037] It should also be noted that the present disclosure intentionally does not provide a solution to compensate for (or avoid) eddy currents, which in fact further increase the heating of the conductor and thus actually contribute to the resulting increased heating efficiency.

[0038] According to one aspect, the present disclosure provides a structural element for a building construction, the structural element comprising a structure. The structural element comprises a heating device according to any of the features described herein. The device is attached to the structure of the structural element. The structural element may be a floor, a column, a wall, a ceiling, or a cabinet.

[0039] According to one aspect thereof, the present disclosure provides a method for manufacturing a radiant device for heating a workspace or object.

[0040] The method includes providing a substrate material.

[0041] The method includes disposing a conductor on a substrate material, the conductor being a flat conductor and / or made of a carbon-based material.

[0042] Preferably, the step of disposing the conductor on the substrate material is a step of nanometric thermal conversion in which part of the substrate material is thermally converted into a conductive carbon-based material.

[0043] The present disclosure also provides, according to one aspect thereof, a method for manufacturing conductors that are preferably flat and straight.

[0044] The manufacturing method of the straight conductor is as follows: - providing a strip of substrate material, preferably made of a polymer material; - thermally converting a portion of the substrate material into a conductor, the conductor being formed on the surface of the substrate material within an inner region of the strip such that the conductor is spaced from a periphery of the substrate material; - folding the strip about a longitudinal axis defined by the direction of development of the strip; - welding the overlapping edges of the substrate material to encapsulate or insulate the conductor; - bending the strip about a transverse axis perpendicular to the longitudinal direction to define two layers of conductor; - welding (bonding) two layers of conductor together to define a linear conductor comprising a first linear conductor and a second linear conductor parallel to each other along a longitudinal direction. [Brief explanation of the drawings]

[0045] This and other features will become more apparent from the following description of preferred embodiments, illustrated by way of non-limiting example in the accompanying drawings, in which: [Figure 1A-1B] 1A-1D show two schematic side views of an embodiment of a radiant device for heating a workspace or object according to the present disclosure; [Figure 2] 2 shows a schematic side view of a further embodiment of the radiation device of FIG. 1; [Figure 3] 2 shows a schematic plan view of the radiating device of FIG. 1; [Figure 4] 3 shows a schematic plan view of the radiating device of FIG. 2; [Figure 5] 1 shows a schematic side view of a straight conductor that can be used in a radiating device according to the present disclosure; [Figure 6] 1 shows a schematic plan view of a strip of substrate material onto which conductors are thermally converted. [Figure 7]1 shows a schematic side view of an embodiment of a radiation device according to the present disclosure; [Figure 8] 1 shows a schematic representation of a workspace in which structural heating elements are located; DETAILED DESCRIPTION OF THE INVENTION

[0046] With reference to the accompanying drawings, the numeral 1 designates a radiant device for heating a workspace or object. In particular, the radiant device is a radiant panel 1.

[0047] The radiating panel 1 comprises a conductor 10. The conductor 10 is electrically conductive in order to allow an electric current to flow through it, thereby heating it by the Joule effect. In a first embodiment, the conductor 10 has the form of a flat panel (flat sheet, continuous sheet). Preferably, along the radial direction DI, the conductor has a thickness of less than 100 microns, preferably less than 50 microns, and even more preferably between 23 and 28 microns.

[0048] In one embodiment, the conductor 10 directly faces the space to be heated.

[0049] In some embodiments, there is an insulating layer between the conductor 10 and the surrounding space, but no substrate material between the conductor 10 and the surrounding space that is heated.

[0050] In one embodiment, panel 1 comprises an input connector 101 and an output connector 102. Input connector 101 is connected to conductor 10 and supplies electrical energy to conductor 10. Output connector 102 is connected to conductor 10 and receives electrical energy therefrom.

[0051] In one embodiment, the device 1 comprises a substrate material 11. In addition to the function of supporting the conductor 10, the substrate material 11 also makes it possible to insulate the conductor 10 from the structure or object on which the conductor 10 is placed.

[0052] In one embodiment, the substrate material 11 is flexible (not rigid).

[0053] Thus, in one embodiment, the substrate material 11 is a panel whose size is at least equal to the size of the conductor 10 (if the conductor 10 is a continuous panel). The panel of substrate material 11 is positioned downstream of the conductor 10 along the radiation direction DI in the radiation orientation VI. In other words, the conductor 10 faces the work space to be heated, and the substrate material 11 faces the structure on which the panel is to be placed.

[0054] Preferably, the conductor 10 is made of (at least) graphene. Preferably, the graphene 10 is obtained by (nanometric) thermal conversion of a substrate material 11.

[0055] Preferably, the substrate material 11 is made of a polymer material, preferably polyimide.

[0056] The above-described device 1, made substantially of conductor 10 and substrate material 11, is flexible in both directions defining panel 1 so that it can conform to non-planar surfaces, such as, but not limited to, car interior trim, sofas, and other non-planar objects.

[0057] Thus, according to one aspect of the present disclosure, the panel 1 may also comprise mounting elements 13, which are configured to allow the (flexible) panel to be connected to a wall, structure or object. For example, the mounting elements 13 may be glue-in inserts formed using a heat-resistant adhesive. A solution is also conceivable in which the substrate material 11 has a contact surface facing away from the direction of radiation, the contact surface being sticky (with a heat-resistant adhesive). This allows the panel to be quickly and easily adapted to any type of surface.

[0058] In another embodiment, more specifically designed for fitting panels into a flat, rigid structure, the apparatus 1 comprises a framework 12 .

[0059] Framework 12 is preferably a rigid structure, which reduces the flexibility of device 1, but provides several important advantages.

[0060] In one embodiment, framework 12 comprises a frame 12'. Frame 12' comprises four side walls. In particular, frame 12' comprises a first side wall 121 and a second side wall 122 facing opposite each other. Frame 12' also comprises a third side wall 123 and a fourth side wall 124 facing opposite each other.

[0061] The side walls of the frame 12' extend along the radial direction DI.

[0062] In one embodiment, at least two side walls of the frame 12' include respective slots 14A configured to receive the continuous sheet of substrate material 11 of the conductor 10.

[0063] In particular, each pair of side walls 121, 122 or 123, 124 includes opposing slots 14A configured to receive respective opposing portions of the same substrate material 11 supporting the conductive sheet 10.

[0064] In one embodiment, the device 1 comprises a plurality of conductor units 1 ′, each including a respective continuous conductor sheet supported by a respective portion of substrate material 11 .

[0065] The frame 12' of the framework 12 also comprises a facing surface 125 facing the radiation direction VI and perpendicular to the radiation direction DI. The frame 12' comprises a contact surface 126 opposite the facing surface 125. Again, there may be a mounting element 13 arranged on the contact surface 126, or there may be an adhesive contact surface.

[0066] Each conductor sheet of the conductor units 1' is supported by a respective slot in the side wall of the framework 12. The slots are spaced apart along the radial direction DI. Thus, the conductor units 1' are spaced apart along the radial direction DI, and respective spacings SP are defined between the conductor units 1'. These spacings act as thermal insulators, preventing the contact surfaces 126 from reaching very high temperatures.

[0067] If there are multiple conductor units 1 ′, each of these conductor units is connected to an electrical input collector, which is connected to an input connector 101 and distributes the current to all the conductor sheets 10 .

[0068] Similarly, each of the conductor sheets of the conductor unit 1' is connected to an electrical output collector, which is connected to an output connector 102 and receives current from all the conductor sheets 10.

[0069] Note that in one embodiment, the input connector 101 or the output connector 102 passes through the substrate material 11 along a direction perpendicular to the radial direction DI or along a direction parallel to the radial direction DI and emerges from the substrate material 11 on a contact surface. Similarly, if the framework 12 is present, the input connector 101 or the output connector 102 passes through the framework along a direction perpendicular to the radial direction DI and emerges from one of the side walls 121, 122, 123, or 124, or passes through the framework along a direction parallel to the radial direction DI and emerges from the contact surface 126 of the frame 12′.

[0070] In one embodiment, the device 1 differs significantly from the embodiment in that it is in sheet form, ie, preferably a flat, straight conductor 10'.

[0071] The straight conductor 10' comprises a conductor 10 and a substrate material 11 suitably integrated together to form the straight conductor 10'.

[0072] In a preferred embodiment, the linear conductor 10' is manufactured as follows: The linear conductor 10' comprises a first layer L1 and a second layer L2 juxtaposed along the longitudinal direction L of the main development of the linear conductor 10'.

[0073] The first layer L1 and the second layer L2 each comprise a flat, linear conductor, preferably made of graphene, encapsulated in a substrate material 11. In particular, around each conductor 10 of the first layer L1 and the second layer L2 there is a first layer of substrate material 11 and a second layer of substrate material 11 welded together to the sides of the conductor 10 interposed between the two layers.

[0074] An alternating current is passed through both the first layer L1 and the second layer L2. In particular, a first alternating current is passed through the first layer L1, the vector of which has a first magnitude and a first direction, while a second alternating current is passed through the second layer L2, the vector of which has a second magnitude and a second direction.

[0075] Preferably, the first magnitude is the same as the second magnitude and the first orientation is opposite to the second orientation, which allows for balancing of the induced magnetic field and allows for isolation of the electric field by the presence of the substrate material.

[0076] In one embodiment, the framework 12 includes a plurality of through cavities 14B that function similarly to the slots 14A in the continuous conductor sheet.

[0077] A plurality of through cavities 14B are provided in a first side wall 121 and a second side wall 122 that face each other.

[0078] The straight conductor 10' is supported by the framework by wrapping the straight conductor 10' around the framework 12 through the through cavity 14B. Upon attaching the straight conductor 10' to the framework, 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.

[0079] Thus, the straight conductor 10' is inserted from the outside to the inside of the frame 12' into one of the cavities 14B in the first side wall 121 and then brought to the next cavity 14B in the second side wall 122, passing from the inside to the outside of the frame 12'. The straight conductor 10' is then bent and its direction is reversed, allowing the straight conductor 10' to be reinserted from the outside to the inside of the frame 12' through another cavity 14B in the second side wall 122, away from the previous cavity along the radial direction DI.

[0080] This makes it possible to form coils extending along the radial direction DI to form several radiating layers.

[0081] It should be noted that the radiating panel 1 includes a plurality of linear conductors 10′ attached to a framework 12 and juxtaposed parallel to each other and along a direction perpendicular to the radiation direction DI.

[0082] In practice, the plurality of cavities 14B in the frame are also spaced apart along a direction perpendicular to the radial direction DI. In particular, the cavities 14B aligned along the radial direction DI serve the same linear conductor 10', while the cavities 14B aligned perpendicular to the radial direction DI serve separate linear conductors 10'.

[0083] The present disclosure also provides, according to one aspect thereof, a method for manufacturing the radiating device 1.

[0084] The method comprises a step of producing a conductor 10, preferably a step of (nanometric) thermal conversion, in which a support of a substrate material 11, preferably made of a polymer material (e.g. polyimide), is placed on a work surface and reconfigured nanometrically by electromagnetic waves, converting the polymer material into a carbon-based material, preferably graphene.

[0085] The substrate material 11 may be in the form of a panel to form a continuous conductor sheet by heat converting the entire inner surface of the substrate material 11, or it may be in the form of a continuous strip to obtain a linear conductor 10' by heat converting the inner surface of the continuous strip.

[0086] After obtaining the graphene conductor 10, the method includes connecting the conductor 10 to an input connector 101 and an output connector 102.

[0087] Next, the method optionally includes placing the continuous sheet into slot 14A of framework 12.

[0088] On the other hand, for a straight conductor 10', the method involves winding the conductor 10' onto the framework 12 in the cavity 14B, as described above.

[0089] In addition to what has already been described, the present method also provides a method for manufacturing a straight conductor 10'.

[0090] The steps described here follow a step of thermal conversion of the continuous strip, thus providing a strip of substrate material 11 on which is also disposed a thermally converted conductor 10, spaced apart along the transverse direction T from the edges of the continuous strip of material 11 and defining a first weld edge BS1 and a second weld edge BS2.

[0091] At this point, the method includes a first step R1 of rotating the continuous strip about the longitudinal axis L so as to place the first weld edge BS1 on top of the second weld edge BS2. The first weld edge BS1 and the second weld edge BS2 are then welded, glued, or otherwise attached to one another to encapsulate the conductor 10 within the substrate material 11. This makes it possible to obtain a third weld edge.

[0092] In one embodiment, the method includes a second step R2 of rotating about the transverse direction T so as to fold the third weld edge onto itself.

[0093] The method then includes welding a third welding edge onto itself to define two conductive stretches juxtaposed along the longitudinal direction L, as described above with reference to the straight conductor 10'. [Prior art documents] [Patent documents]

[0094] [Patent Document 1] GB2536214A [Patent Document 2] US2011056928A1 [Patent Document 3] CN111432507A

Claims

1. A radiation device (1) for heating a working space (SO) or an object (O), comprising: a substrate material (11) adapted to be attached to a structure of said workspace (SO) or to a surface of said object (O), a conductor (10) associated with said substrate material (11) and configured to receive an electric current, said conductor (10) extending in a plane so as to define a radiating surface of said radiating device (1); A radiating device (1), wherein said conductor (10) is a flat conductor made of a carbon-based material.

2. 2. The device (1) according to claim 1, wherein the substrate material (11) is made of a fire-resistant, electrically insulating polymer material.

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

4. 4. The device (1) according to claim 1, wherein the conductor (10) is formed starting from the substrate material (11) by nanometric thermal conversion of the substrate material (11) into the carbon-based material.

5. 5. The device (1) according to any one of claims 1 to 4, wherein the conductor (10) comprises a continuous sheet defining the radiating surface of the radiating device (1).

6. 6. The device (1) according to claim 5, wherein the thickness of said continuous sheet is less than 30 microns.

7. 5. The device (1) of claim 4, comprising a framework (12) on which the conductor (10) is disposed, the conductor (10) comprising a flat, straight conductor (10') wrapped around the framework (12) to define the radiating surface.

8. 8. The apparatus (1) of claim 7, wherein the framework (12) comprises a frame (12') including four side walls (121, 122, 123, 124) and a plurality of through cavities (14B) formed in at least two of the four side walls (121, 122) of the frame (12'), and the flat, straight conductor (10') is wrapped around the framework (12) and inserted into the through cavities (14B) of the frame (12').

9. The flat and straight conductor (10') a first flat conductor (L1) encapsulated in said substrate material (11) and carrying a first alternating current; a second flat conductor (L2) enclosed within said substrate material (11) and carrying a second alternating current of opposite sense to said first alternating current, 5. The device (1) according to claim 4, wherein the first conductor (L1) and the second conductor (L2) are juxtaposed to each other along the longitudinal direction (L) of the main development to define the flat linear conductor (10').

10. A structural heating element for a building structure, comprising a structure and a heating device (1) according to any one of claims 1 to 9 attached to the structure of the structural element.

11. A method for manufacturing a radiant device (1) for heating a workspace (SO) or an object (O), the method comprising the steps of: - providing a substrate material (11); - placing a conductor (10) on said substrate material (11), said conductor (10) being a flat conductor made of a carbon-based material; The method, wherein the step of disposing the conductor (10) on the substrate material (11) is a nanometer thermal conversion step, in which a portion of the substrate material (11) is thermally converted into the carbon-based material of the conductor (10).

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