Driveway, walkway and roof snow and ice melting mat

• US 6,184,496 B1
• Filed: 05/31/2000
• Issued: 02/06/2001
• Est. Priority Date: 08/06/1998
• Status: Expired due to Fees

• Current Assignee: JCC, Ltd., Raleigh Enterprises, LLC, Technology Research Corporation (Southwire Company)
• Original Assignee: Clearpath Incorporated
• Inventors: Pearce, Richard J.
• Primary Examiner(s): Hoang, Tu Ba
• Application Number:
  US09/583,682
• Time in Patent Office: 251 Days
• Field of Search: 219/200, 219/202, 219/212, 219/213, 219/520, 219/528, 219/529, 219/535, 219/537, 219/538, 219/539, 219/541, 219/542, 219/543, 219/545, 219/549
• US Class Current: 219/213
• CPC Class Codes: E01C 11/265 Embedded electrical heating elements in floors F24D13/00; Mounting thereof
• CPC Class Codes: E04D 13/103 De-icing devices or snow melters for drainage outlets E04D13/0409, for gutters E04D13/0762, for down pipes E04D13/08
• CPC Class Codes: H05B 2203/005 using multiple resistive elements or resistive zones isolated from each other
• CPC Class Codes: H05B 2203/011 Heaters using laterally extending conductive material as connecting means
• CPC Class Codes: H05B 2203/013 Heaters using resistive films or coatings
• CPC Class Codes: H05B 2203/017 Manufacturing methods or apparatus for heaters
• CPC Class Codes: H05B 2203/026 Heaters specially adapted for floor heating
• CPC Class Codes: H05B 2203/033 Heater including particular mechanical reinforcing means
• CPC Class Codes: H05B 2214/02 Heaters specially designed for de-icing or protection against icing
• CPC Class Codes: H05B 3/36 heating conductor embedded in insulating material

Abstract

A relatively lightweight and easy to use flexible heating mat for melting snow and ice that can be cut in the field to custom length or to accommodate direction changes or avoid obstructions. The heating mat includes one or more planar flexible heaters sandwiched between two vulcanized polymer protective sheets. The heating mat may be activated remotely or manually and can be powered from either end of the heating mat. Nonskid patterns ate typically included in heating mats used on driveways and walkways.

Claims

1. A heating mat for melting snow and ice comprising:

at least one planar flexible electric heater;

the at least one planar flexible electric heater including a first elongated, flexible, electrically insulating substrate having an electrically insulated surface;

the at least one planar flexible electric heater further including a plurality of resistive heating elements comprising a plurality of resistive material traces deposited on said first insulating substrate in spaced apart relationship, a first and second electrical conductors, each disposed in proximity to each of respective opposing edges of said electric heater and a third electrical conductor disposed at an intermediate location between the first and second electrical conductors, each of said resistive material traces being in electrical communication with the first, second and third electrical conductors and extending therebetween;

the at least one planar flexible heater further including a second elongated, flexible, electrically insulating substrate having an electrically insulated surface, wherein the first insulating substrate is adhesively attached to the second insulating substrate with the resistive heating elements and electrical conductors disposed therebetween, the first insulating substrate and the second insulating substrate forming the at least one flexible electric heater'"'"'s two opposite planar surfaces; and

two protective sheets composed of abrasion resistant flexible material, each having an inner surface oriented towards and in face to face adherent engagement with the respective planar surfaces of the at least one flexible electric heater, said two protective sheets and said electric heater disposed therebetween forming the heater mat having two opposing end edges, and two opposing side edges,

wherein the resistive heating traces and electrical conductors are arranged such that a portion of the heating mat may be removed to accommodate a use by cutting the heating mat to remove said portion, the heating mat being adapted to maintain its electrical operative characteristics after removal of said portion.

2. The heating mat according to claim 1, wherein the at least one planar flexible heater further includes a grounding metallic substrate in a laminar relationship with the first insulating substrate, wherein the grounding metallic substrate is adhesively attached to the first insulating substrate.

3. The heating mat according to claim 1, wherein each of the first, second and third electrical conductors is an elongate strip comprising one of copper and copper alloys.

4. The heating mat according to claim 1, wherein the planar flexible electric heater further includes an elongate conductive film disposed between each of the first, second and third electrical conductors and the first insulating substrate, the elongate conductive film comprising one of silver and silver alloys.

5. The heating mat according to claim 1, wherein the respective inner surfaces of said protective sheets are bonded onto respective planar surfaces of the electric heater with a pressure sensitive hot melt adhesive.

6. The heating mat according to claim 1, wherein at least one of said protective sheets includes an outer surface with a nonskid pattern impressed thereupon.

7. The heating mat according to claim 6, wherein the nonskid pattern includes a plurality of ribs protruding therefrom, the ribs forming a cyclic V-pattern extending transversely to the side edges of the heating mat and the ribs further forming drainage channels in the spaces therebetween.

8. The heating mat according to claim 1, further comprising a thermal cutout switch electrically connected in series with said at least one flexible electric heater.

9. The heating mat according to claim 1, further comprising one of a ground fault circuit interrupter or an equipment leakage circuit interrupter electrically connected in series with the at least one flexible electric heater, the one of the ground fault circuit interrupter or the equipment leakage circuit interrupter being located in an electrical power supply cable for connecting the heating mat to a source of electrical power.

10. The heating mat according to claim 1, wherein the two opposing side edges of the heating mat are bound by stitching an elongate generally water and mildew resistant material to each of said opposing side edges.

11. The heating mat according to claim 1, wherein the first and second insulating substrates are made from a thermoplastic laminate material.

12. The heating mat according to claim 1, further comprising an elongated sealing bracket having a substantially U-shaped cross section forming an elongated opening dimensioned to receive each of the opposing end edges of said heating mat within said opening for protecting said opposing end edges and for protecting electrical connections at each opposing end edges for connecting the at least one flexible electric heater to a source of electric power.

13. The heating mat according to claim 12, wherein the elongated sealing bracket is attached with sealing means for bonding each end edge of the heating mat and for encapsulating each end edge thereby preventing submersion, exposure from weather hazards, and injury due to electrocution.

14. The heating mat according to claim 12, further comprising means for connecting the source of electric power from either side edge of the elongated sealing bracket protecting the electrical connections.

15. The heating mat according to claim 1, wherein the at least one planar flexible electric heater comprises two planar flexible electric heaters in parallel with each other.

16. The heating mat according to claim 1, wherein the at least one planar flexible electric heater comprises three planar flexible electric heaters in parallel with each other.

17. The heating mat according to claim 1, wherein the at least one planar flexible electric heater comprises four planar flexible electric heaters in parallel with each other.

18. The heating mat according to claim 1, wherein the at least one planar flexible electric heater comprises five planar flexible electric heaters in parallel with each other.

19. The heating mat according to claim 1, wherein at least one of the two protective sheets is reinforced by one of fibrous or woven material, embedded therein.

20. The heating mat according to claim 1, further comprising means for securing and for providing positional stability of the heating mat on a surface to be protected from snow and ice.

21. The heating mat according to claim 20, wherein the means for securing and providing positional stability of the heating mat on a surface to be protected from snow and ice includes a plurality of grommets located in a predetermined spaced-apart relationship along the respective side edges of the heating mat.

22. The heating mat according to claim 21, wherein when a heating mat is to be located on a roof edge, the means for securing and providing positional stability of the heating mat on a surface to be protected from snow and ice further comprises:

at least one elongate metallic strap having a plurality of spaced-apart angularly directed slots, each strap being of sufficient length for sliding said strap under a roofing shingles and to engage a roof shingle nail into one of said slots; and

each strap further including a plurality of apertures in a spaced-apart relationship along the length of said strap,

wherein the heating mat may be attached to the strap by placing a fastener through one of said apertures into one of said grommets, thereby securing the heating mat in place.

23. The heating mat according to claim 22, wherein when a heating mat is to be located on a roof edge, the means for securing and providing positional stability of the heating mat on a surface to be protected from snow and ice further comprises:

at least one elastomeric strap with connecting means at each end for connecting one end of said strap to one of said grommets and for connecting an opposite end of said strap to a predetermined portion of a building near the roof edge.

24. The heating mat according to claim 1, wherein the heating mat may be electrically connected with one or more heating mats for use on steps and other staggered surfaces.

25. The heating mat according to claim 14, further comprising means to remotely electrically activate and electrically deactivate the heating mat.

26. The heating mat according to claim 14, further comprising means to manually electrically activate and electrically deactivate the heating mat, the means comprising an inline switch between the heating mat and the source of electric power.

27. The heating mat according to claim 9, further including means to remotely electrically activate and electrically deactivate the heating mat, the means including a Radio Frequency signal receiver connected between the equipment leakage circuit interrupter and the source of electric power, the signal receiver receiving a signal from a Radio Frequency transmitter remotely located from the heating mat.

28. The heating mat according to claim 9, further comprising means to manually electrically activate and electrically deactivate the heating mat, the means comprising an inline switch between the one of the ground fault circuit interrupter or the equipment leakage circuit interrupter and the source of electric power.

57. The heating mat according to claim 1, wherein at least one of said protective sheets is made from a roofing material.

58. The heating mat according to claim 57, wherein the roofing material is one of a roof shingle material and single coverage rolled roof material.

59. The heating mat according to claim 57, wherein the roofing material is colored to match standard roof coverage materials.

29. A heating mat for melting snow and ice comprising:

at least one planar flexible electric heater;

the at least one planar flexible electric heater including a first elongated, flexible, electrically insulating substrate having an electrically insulated surface;

the at least one planar flexible electric heater further including a uniform layered resistive heating element comprising a generally uniform layer of resistive material traces deposited on said first insulating substrate, a first and second electrical conductors, each disposed in proximity to each of respective opposing edges of said electric heater and a third electrical conductor disposed at an intermediate location between the first and second electrical conductors, the resistive material traces being in electrical communication with the first, second and third electrical conductors and being in an underlying relationship;

the at least one planar flexible heater further including a second elongated, flexible, electrically insulating substrate having an electrically insulated surface, wherein the first insulating substrate is adhesively attached to the second insulating substrate with the resistive heating element and electrical conductors disposed therebetween, the first insulating substrate and the second insulating substrate forming the at least one flexible electric heater'"'"'s two opposite planar surfaces; and

two protective sheets composed of abrasion resistant flexible material, each having an inner surface oriented towards and in face to face adherent engagement with the respective planar surfaces of the at least one flexible electric heater, said two protective sheets and said electric heater disposed therebetween forming the heater mat having two opposing end edges, and two opposing side edges,

wherein the resistive heating traces and electrical conductors are arranged such that a portion of the heating mat may be removed to accommodate a use by cutting the heating mat to remove said portion, the heating mat being adapted to maintain its electrical operative characteristics after removal of said portion.

30. The heating mat according to claim 29, wherein the at least one planar flexible heater further includes a grounding metallic substrate in a laminar relationship with the first insulating substrate, wherein the grounding metallic substrate is adhesively attached to the first insulating substrate.

31. The heating mat according to claim 29, wherein each of the first, second and third electrical conductors is an elongate strip comprising one of copper and copper alloys.

32. The heating mat according to claim 29, wherein the planar flexible electric heater further includes an elongate conductive film disposed between each of the first, second and third electrical conductors and the first insulating substrate, the elongate conductive film comprising one of silver and silver alloys.

33. The heating mat according to claim 29, wherein the respective inner surfaces of said protective sheets are bonded onto respective planar surfaces of the electric heater with a pressure sensitive hot melt adhesive.

34. The heating mat according to claim 29, wherein at least one of sa id protective sheets includes an outer surface with a nonskid pattern impressed thereupon.

35. The heating mat according to claim 34, wherein the nonskid pattern includes a plurality of ribs protruding therefrom, the ribs forming a cyclic V-pattern extending transversely to the side edges of the heating mat and the ribs further forming drainage channels in the spaces therebetween.

36. The heating mat according to claim 29, further comprising a thermal cutout switch electrically connected in series with said at least one flexible electric heater.

37. The heating mat according to claim 29, further comprising one of a ground fault circuit interrupter or an equipment leakage circuit interrupter, electrically connected in series with the at least one flexible electric heater, the one of the ground fault circuit interrupter or the equipment leakage circuit interrupter being located in an electrical power supply cable for connecting the heating mat to a source of electrical power.

38. The heating mat according to claim 29, wherein the two opposing side edges of the heating mat are bound by stitching an elongate generally water and mildew resistant material to each of said opposing side edges.

39. The heating mat according to claim 29, wherein the first and second insulating substrates are made from a thermoplastic laminate material.

40. The heating mat according to claim 29, further comprising an elongated sealing bracket having a substantially U-shaped cross section forming an elongated opening dimensioned to receive each of the opposing end edges of said heating mat within said opening for protecting said opposing end edges and for protecting electrical connections at each opposing end edges for connecting the at least one flexible electric heater to a source of electric power.

41. The heating mat according to claim 40, wherein the elongated sealing bracket is attached with sealing means for bonding each end edge of the heating mat and for encapsulating each end edge thereby preventing submersion, exposure from weather hazards, and injury due to electrocution.

42. The heating mat according to claim 40, further comprising means for connecting the source of electric power from either side edge of the elongated sealing bracket protecting the electrical connections.

43. The heating mat according to claim 29, wherein the at least one planar flexible electric heater comprises two planar flexible electric heaters in parallel with each other.

44. The heating mat according to claim 29, wherein the at least one planar flexible electric heater comprises three planar flexible electric heaters in parallel with each other.

45. The heating mat according to claim 29, wherein the at least one planar flexible electric heater comprises four planar flexible electric heaters in parallel with each other.

46. The heating mat according to claim 29, wherein the at least one planar flexible electric heater comprises five planar flexible electric heaters in parallel with each other.

47. The heating mat according to claim 29, wherein at least one of the two protective sheets is reinforced by one of fibrous or woven material, embedded therein.

48. The heating mat according to claim 29, further comprising means for securing and for providing positional stability of the heating mat on a surface to be protected from snow and ice.

49. The heating mat according to claim 48, wherein the means for securing and providing positional stability of the heating mat on a surface to be protected from snow and ice includes a plurality of grommets located in a predetermined spaced-apart relationship along the respective side edges of the heating mat.

50. The heating mat according to claim 49, wherein when a heating mat is to be located on a roof edge, the means for securing and providing positional stability of the heating mat on a surface to be protected from snow and ice further comprises:

at least one elongate metallic strap having a plurality of spaced-apart angularly directed slots, each strap being of sufficient length for sliding said strap under a roofing shingles and to engage a roof shingle nail into one of said slots; and

each strap further including a plurality of apertures in a spaced-apart relationship along the length of said strap,

wherein the heating mat may be attached to the strap by placing a fastener through one of said apertures into one of said grommets, thereby securing the heating mat to the roof edge.

51. The heating mat according to claim 50, wherein when a heating mat is to be located on a roof edge, the means for securing and providing positional stability of the heating mat on a surface to be protected from snow and ice further comprises:

at least one elastomeric strap with connecting means at each end for connecting one end of said strap to one of said grommets and for connecting an opposite end of said strap to a predetermined portion of a building near the roof edge.

52. The heating mat according to claim 29, wherein the heating mat may be electrically connected with one or more heating mats for use on steps and other staggered surfaces.

53. The heating mat according to claim 42, further comprising means to remotely electrically activate and electrically deactivate the heating mat.

54. The heating mat according to claim 42, further comprising means to manually electrically activate and electrically deactivate the heating mat, the means comprising an inline switch between the heating mat and the source of electric power.

55. The heating mat according to claim 37, further including means to remotely electrically activate and electrically deactivate the heating mat, the means including a Radio Frequency signal receiver connected between the equipment leakage circuit interrupter and the source of electric power, the signal receiver receiving a signal from a Radio Frequency transmitter remotely located from the heating mat.

56. The heating mat according to claim 37, further comprising means to manually electrically activate and electrically deactivate the heating mat, the means comprising an inline switch between one of the ground fault circuit interrupter or the equipment leakage circuit interrupter and the source of electric power.

60. The heating mat according to claim 29, wherein at least one of said protective sheets is made from a roofing material.

61. The heating mat according to claim 60, wherein the roofing material is one of a roof shingle material and single coverage rolled roof material.

62. The heating mat according to claim 60, wherein the roofing material is colored to match standard roof coverage materials.