Heating panel and method therefor

Abstract

A radiant heating panel, for typical use as cover for interior walls and ceilings, is provided, that is manufactured in a continuous process involving at least one sheet material, a settable material and a heating element. A method of installing such a heating panel is also provided, along with an apparatus and method required to terminate the heating panel.

1 . A method of manufacture of a heating panel comprising the steps of
 providing a continuous feed of a first sheet of material;   depositing a layer of settable material onto the first sheet of material in a continuous process to form a continuous open wallboard feed; and   wherein the method further includes one or more of the steps selected from
 continuously depositing at least one heating element substantially along the length of the continuous open wallboard feed; and 
 regularly depositing at least one heating element substantially along the length of the continuous open wallboard feed. 
   
     
     
         2 . A method as claimed in  claim 1  wherein the method includes one or more of the steps selected from
 continuously depositing at least one electrical conductor member substantially along the length of the continuous open wallboard feed, said electrical conductor member being relatively more conductive than the heating element; and 
 regularly depositing at least one electrical conductor member substantially along the length of the continuous open wallboard feed, said electrical conductor member being relatively more conductive than the heating element. 
 
     
     
         3 . A method as claimed in  claim 1  or  2 , wherein a plurality of heating elements are deposited. 
     
     
         4 . A method as claimed in  claim 2  or  3 , wherein a plurality of electrical conductor members are deposited. 
     
     
         5 . A method as claimed in any of  claims 2 - 4 , wherein the electrical conductor member is adapted to operate as a busbar at terminal points of the heating elements, and having a low resistance to flow of current relative to the heating element(s). 
     
     
         6 . A method as claimed in any of  claims 2 - 5 , wherein the electrical conductor member is deposited continuously along the sides of the length of the continuous open wallboard feed. 
     
     
         7 . A method as claimed in any of  claims 1 - 6 , wherein the layer of settable material is settable slurry. 
     
     
         8 . A method as claimed in any of  claims 1 - 7 , wherein the method includes the step of depositing at least one transverse conductor member, suitable for allowing termination of the heating panel at an opposed side of the heating panel from the heating element(s), along the length of the continuous wallboard feed. 
     
     
         9 . A method as claimed in any of  claims 1 - 8 , wherein the method includes the step of providing a continuous feed of a second sheet of material at an opposed side of the settable material layer to the first sheet of material to form a closed wallboard feed. 
     
     
         10 . A method as claimed in  claim 8  or  9 , wherein the transverse conductor member is at least partially incorporated in the settable material layer. 
     
     
         11 . A method as claimed in any of  claims 8 - 10 , wherein the transverse conductor member is integrally formed with the settable material layer 
     
     
         12 . A method as claimed in any of  claims 9 - 6 , wherein the method includes the step of sizing the closed wallboard feed by forcing it through a forming plate section of a predetermined size to form a pre-set continuously feeding heating panel of a consistent thickness. 
     
     
         13 . A method as claimed in any of  claims 2 - 12 , wherein the electrical conductor member is prefabricated as a continuous sheet of at least partially conductive material. 
     
     
         14 . A method as claimed in any of  claims 2 - 13  wherein the electrical conductor member is at least partially prefabricated together with at least one selected from
 the first sheet of material and 
 the second sheet of material. 
 
     
     
         15 . A method as claimed in any of  claims 2 - 14 , wherein the electrical conductor member is at least partially printed on at least one selected from
 the first sheet of material and   the second sheet of material.   
     
     
         16 . A method as claimed in any of  claims 7 - 15 , wherein the slurry layer is a gypsum slurry layer. 
     
     
         17 . A method as claimed in any of  claims 2 - 16 , wherein the electrical conductor member is arranged in a regular formation. 
     
     
         18 . A method as claimed in any of  claims 2 - 16 , wherein the electrical conductor comprises an irregular arrangement of electrically conductive fibres. 
     
     
         19 . A method as claimed in any of  claims 9 - 18 , wherein at least one selected from the first sheet of material and second sheet of material are composed of material that is at least partially porous to one or more selected from water vapour and liquid. 
     
     
         20 . A method as claimed in any of  claims 9 - 19 , wherein at least one or more selected from the first sheet of material and second sheet of material are composed of paper. 
     
     
         21 . A method as claimed in any of  claims 2 - 20 , wherein the electrical conductor member is composed of one or more selected from
 a metal or metallic alloy;   a semi-conductor material; and   carbon fibre.   
     
     
         22 . A method as claimed in  claim 21  the semi conductor material is doped. 
     
     
         23 . A method as claimed in any of  claims 2 - 22 , wherein the electrical conductor is prefabricated in a regular formation. 
     
     
         24 . A method as claimed in  claim 23  wherein the regular formation of the electrical conductor is porous to one or more selected from water vapour and liquid. 
     
     
         25 . A method as claimed in any of  claim 23  or  24 , wherein the regular formation of the electrical conductor is a mesh. 
     
     
         26 . A method as claimed in any of  claims 2 - 25 , wherein the electrical conductor member is prefabricated in a regular formation together with a non-conductive material. 
     
     
         27 . A method as claimed in any of  claims 2 - 26 , wherein the electrical conductor member is prefabricated in a regular formation together with a flexible elongate material. 
     
     
         28 . A method as claimed in  claim 27 , wherein the flexible elongate material is one or more selected from glass fibre and plastic. 
     
     
         29 . A method as claimed in any of  claims 9 - 28 , wherein one or more selected from the first sheet of material and the second sheet of material is fed from a roll. 
     
     
         30 . A method as claimed in any of  claims 12 - 29 , wherein the method includes the steps of
 allowing the settable material in the pre-set continuously feeding heating panel to at least partially set; and   cutting the partially set continuously feeding heating panel to size.   
     
     
         31 . A method as claimed in  claim 30  wherein the method further includes the steps of stacking several similar cut heating panels in a heated environment to allow excess water to evaporate from the slurry and to allow the settable material layer to cure to form cured heating panels. 
     
     
         32 . A method as claimed in  claim 31  wherein the method further includes the step of finishing at least one edge of the cured heating panels. 
     
     
         33 . A heating panel made by the method of manufacture of a heating panel as claimed in  claims 1 - 32 . 
     
     
         34 . A heating panel comprising
 a wallboard portion including
 a layer of settable material having two opposed major faces, and 
 a first outer layer of sheet material disposed on a major face of the layer of settable material; and 
   at least one heating element incorporated with the wallboard portion.   
     
     
         35 . A heating panel as claimed in  claim 34  wherein the heating panel includes a plurality of heating elements. 
     
     
         36 . A heating panel as claimed in  claim 34  wherein the heating panel further comprises an electrical conductor member. 
     
     
         37 . A heating panel as claimed in  claim 36 , wherein the heating panel includes a plurality of electrical conductor members. 
     
     
         38 . A heating panel as claimed in  claim 36  or  37 , wherein the electrical conductor member(s) are adapted to operate as a busbar at terminal points of the heating elements. 
     
     
         39 . A heating panel as claimed in any of  claims 34 - 38 , wherein the heating panel further comprises a second outer layer of sheet material disposed on a major face of the settable layer opposed to the first layer of sheet material. 
     
     
         40 . A heating panel as claimed in  claim 39  wherein the sheet material of one or more of the first outer layer of sheet material and second outer layer of sheet material are porous. 
     
     
         41 . A heating panel as claimed in any of  claim 39  or  40 , wherein one or more of the first outer layer of sheet material and second outer layer of sheet material sheet material are fibrous. 
     
     
         42 . A heating panel as claimed in  claim 34  wherein one or more of the first outer layer of sheet material and second outer layer of sheet material sheet material is paper. 
     
     
         43 . A heating panel as claimed in any of  claims 34 - 42 , wherein the heating element is configured in a heating layer. 
     
     
         44 . A heating panel as claimed in any of  claims 43 - 43 , wherein the heating element is disposed in a heating layer between one or more selected from
 the first outer layer of sheet material and   the second outer layer of sheet material; and   the layer of settable material.   
     
     
         45 . A heating panel as claimed in any of  claims 34 - 44 , wherein the heating element is disposed in a prefabricated layer. 
     
     
         46 . A heating panel as claimed in  claim 44 , wherein the prefabricated layer is of a mesh configuration. 
     
     
         47 . A heating panel as claimed in any of  claims 34 - 45 , wherein the heating element is composed of a loose agglomeration of conductive or semi-conductive fibres. 
     
     
         48 . A heating panel as claimed in any of  claims 34 - 47 , wherein the heating element is integrally formed within the layer of settable material. 
     
     
         49 . A heating panel as claimed in claim any of  claims 43 - 48 , wherein the heating layer comprises a mesh configuration of strands of conductive material. 
     
     
         50 . A heating panel as claimed in any of  claims 43 - 49 , wherein the heating layer comprises a mesh of strands of conductive and non-conductive material. 
     
     
         51 . A heating panel as claimed in any of  claims 43 - 50 , wherein the heating layer is disposed as a regular arrangement of parallel strands of conductive material extending across the width of the heating panel. 
     
     
         52 . A heating panel as claimed in any of  claims 43 - 51 , wherein the heating layer is disposed as a zigzag arrangement of one or more strands of conductive material extending from side to side along the length of the heating panel. 
     
     
         53 . A heating panel as claimed in any of  claims 43 - 52 , wherein the heating layer is printed on one or more selected from
 the first outer layer of sheet material and   the second outer layer of sheet material.   
     
     
         54 . A heating panel as claimed in any of  claims 43 - 53 , wherein the heating layer is at least partially impregnated into one or more selected from
 the first outer layer of sheet material and   the second outer layer of sheet material.   
     
     
         55 . A heating panel as claimed in any of  claims 43 - 54 , wherein the heating layer is at least partially porous to water vapour and/or liquid. 
     
     
         56 . A heating panel as claimed in any of  claims 34 - 55 , wherein the heating element is composed of one or more selected from
 a metal or metallic alloy   a semi-conductor material   carbon fibre; and   any other conductive or semi-conductive material.   
     
     
         57 . A heating panel as claimed in  claim 56 , wherein the semi conductor material is doped. 
     
     
         58 . A heating panel as claimed in any of  claims 34 - 57 , wherein the heating panel includes a transverse conductor member for allowing termination of the heating panel at an opposed side of the heating panel from the heating element(s). 
     
     
         59 . A heating panel as claimed in  claim 58 , wherein the transverse conductor member is at least partially incorporated in the settable material layer. 
     
     
         60 . A heating panel as claimed in any of  claim 58  or  59 , wherein the transverse conductor member is integrally formed with the settable material layer. 
     
     
         61 . A method of installing a heating panel, comprising the steps of
 providing a heating panel;   cutting the heating panel to size,   terminating the heating panel; and   securing the heating panel to a structural frame.   
     
     
         62 . A method as claimed in  claim 61 , wherein the structural frame is one or more selected from
 a. ceiling joists; and   b. wall studs.   
     
     
         63 . A method as claimed in any of  claims 61 - 62 , wherein the method of installing a heating panel includes a method of termination of the heating panel as claimed in any of  claims 76 - 80 . 
     
     
         64 . A construction including an installed heating panel as claimed in any of  claims 33 - 60 . 
     
     
         65 . A heating panel termination kit comprising
 a heating panel as claimed in any of  claims 1 - 60 ; and   a heating panel termination apparatus according to any of  claims 68 - 75 .   
     
     
         66 . A kit as claimed in  claim 65  wherein the heating panel termination kit further includes a scoring tool for scoring of one or more of the outer layers of sheet material. 
     
     
         67 . A kit as claimed in any of  claims 65 - 66 , wherein the heating panel termination kit further includes fasteners for fastening the heating panel to a support joist. 
     
     
         68 . A heating panel termination apparatus comprising
 a termination formation adapted to connect with at least one heating element in a heating panel; as claimed in any of  claims 33 - 60 ; and   a connecting formation adapted to connect with an electrical cable.   
     
     
         69 . A heating panel termination apparatus as claimed in  claim 68  wherein the termination formation is adapted to clamp onto a heating panel a claimed in any of  claims 33 - 60 , thereby connecting to at least one heating element. 
     
     
         70 . A heating panel termination apparatus as claimed in any of  claims 68 - 69 , wherein the termination formation is adapted to be inserted into the layer of settable slurry of the heating panel, thereby connecting to at least one heating element. 
     
     
         71 . A heating panel termination apparatus as claimed in any of  claims 68 - 70 , wherein the heating panel termination apparatus includes a securing formation for securing the heating panel termination apparatus to at least one support joist. 
     
     
         72 . A heating panel termination apparatus as claimed in any of  claims 68 - 71 , wherein the heating panel termination apparatus is configured and adapted to support the heating panel while connecting to at least one heating element. 
     
     
         73 . A heating panel termination apparatus as claimed in any of  claims 68 - 72 , wherein the termination formation is adapted to support the heating panel while connecting to at least one heating element. 
     
     
         74 . A heating panel termination apparatus as claimed in any of  claims 68 - 73 , wherein the termination formation includes a bonding face adapted and configured for adherence or bonding to at least one heating element in an electrically conductive manner. 
     
     
         75 . A heating panel termination apparatus as claimed in any of  claims 68 - 74 , wherein the termination formation provides a path for electrical current operationally that provides relatively less electrical resistance than the heating elements 
     
     
         76 . A method of terminating a heating panel, comprising the steps of
 scoring an outer layer of sheet material at least twice;   removing the sheet material from between the two scores;   mechanically fixing and/or adhering an electrically conductive terminal member to connect the terminal member to at least one or more heating elements disposed underneath the sheet material.   
     
     
         77 . A method as claimed in  claim 76  wherein the sheet material is paper. 
     
     
         78 . A method of terminating a heating panel, comprising the steps of:
 providing a heating panel as claimed in any of  claims 33 - 60 ;   providing a termination apparatus as claimed in any of  claims 68 - 75 ;   inserting a termination formation into the heating panel to make connection with at least one heating element disposed underneath the sheet material.   
     
     
         79 . A method of terminating a heating panel, comprising the steps of:
 providing a heating panel as claimed in any of  claims 33 - 60 ;   providing a termination apparatus as claimed in any of  claims 68 - 75 ;   clamping a termination formation onto the heating panel to thereby connect the termination formation to at least one heating element.   
     
     
         80 . A method of terminating a heating panel, comprising the steps of
 providing a heating panel as claimed in any of  claims 33 - 60 ;   providing a termination apparatus as claimed in any of  claims 68 - 75 ;   securing the termination apparatus to a supporting joist by at least one securing formation;   supporting a heating panel on the termination apparatus thereby connecting the heating elements to the termination apparatus.   
     
     
         81 . A panel sheet comprising or including
 a first outer layer;   a second outer layer spaced from the first outer layer,   a settable matrix interposed and attaching to each of the outer layers; and   a heating element introduced between the outer layers or positioned so as to be between the outer layers;   and wherein the electrical element may or may not be coextensive with the panel but the outer layers are at least substantially coextensive with the set suitable material.   
     
     
         82 . A panel sheet as claimed in  claim 81  wherein the panel sheet comprises a plurality of heating elements. 
     
     
         83 . A panel sheet as claimed in any of  claims 81 - 82 , wherein the panel sheet comprises a pair of electrical conductor members extending along opposed edges on a major face of the panel sheet. 
     
     
         84 . A panel sheet as claimed in  claim 83 , wherein the electrical conductor members have relatively little electrical resistance compared to the heating elements. 
     
     
         85 . A panel sheet as claimed in any of  claims 82 - 84 , wherein the plurality of heating elements extend parallel to each other between the electrical conductor members. 
     
     
         86 . A panel sheet as claimed in any of  claims 81 - 85 , wherein the heating element is introduced with the settable material. 
     
     
         87 . A panel sheet as claimed in any of  claims 81 - 86 , wherein at least one selected from first outer layer and the second outer layer are composed of paper.