Infrared heating panels with non-linear heat distribution

• US 9,393,176 B2
• Filed: 02/03/2014
• Issued: 07/19/2016
• Est. Priority Date: 02/01/2013
• Status: Active Grant

• Current Assignee: Sauna360, Inc. (Masco Corporation)
• Original Assignee: TyloHelo Inc. (Masco Corporation)
• Inventors: Kao, Ragis H. C., Benda, Steven J., Benda, Chad M.
• Primary Examiner(s): Le, Huyen
• Assistant Examiner(s): SKUBINNA, CHRISTINE J
• Application Number:
  US14/170,967
• Publication Number:
  US 20140215708A1
• Time in Patent Office: 897 Days
• Field of Search: 452/4, 219476-478, 392/435, 392/407, 392/416
• US Class Current: 1/1
• CPC Class Codes: A61B 2018/00702 Power or energy
• CPC Class Codes: A61H 2201/10 with further special therapeutic means, e.g. electrotherapy, magneto therapy or radiation therapy, chromo therapy, infrared or ultraviolet therapy
• CPC Class Codes: A61H 33/063 Heaters specifically designed therefor
• CPC Class Codes: A61H 33/066 Cabins therefor
• CPC Class Codes: A61N 2005/0636 Irradiating the whole body
• CPC Class Codes: A61N 2005/0659 infrared
• CPC Class Codes: A61N 5/0625 Warming the body, e.g. hyperthermia treatment
• CPC Class Codes: H05B 2203/011 Heaters using laterally extending conductive material as connecting means
• CPC Class Codes: H05B 2203/032 Heaters specially adapted for heating by radiation heating
• CPC Class Codes: H05B 2203/037 Heaters with zones of different power density
• CPC Class Codes: H05B 3/26 heating conductor mounted on insulating base for transparent areas H05B3/84, H05B3/86

Abstract

Examples of infrared heating panels are described as having a non-linear power density profile along a length of the heating panel. The power density profile can include a first power density zone and a second power density zone, each zone corresponding to an area of the heating panel having a separate power density in response to a current flow. An infrared heating panel can include multiple heating elements arranged adjacently in a row and electrically connected together by at least two power buses extending perpendicularly across the heating elements. In one example, the first power density zone is located between a first power bus and an end of the heating elements. The second power density zone can be located between the first power bus and an opposite end of the heating elements. Infrared sauna systems and methods of generating heat for a sauna are also provided.

Claims

1. An infrared heating panel, comprising:

a first power density zone;

a second power density zone;

an electrically insulative planar substrate;

a plurality of infrared heating elements carried by the substrate, each heating element comprising a first end, a second end, and an elongated segment extending between the first end and the second end; and

at least a first power bus and a second power bus, each of the first and the second power buses extending perpendicularly across and electrically connecting with each of the plurality of heating elements;

wherein the first power bus is electrically connected to the elongated segments between the first end and the second end of each of the heating elements; and

wherein the elongated segment of each heating element comprises

an electrically resistive material adapted to emit infrared radiation in response to a current flow,

a first segment portion extending into the first power density zone between the first power bus and the first end of the heating element, the first segment portion configured to generate a first power density in response to a current flow, and

a second segment portion extending into the second power density zone between the first power bus and the second end of the heating element, the second segment portion configured to generate a second power density in response to a current flow, the second power density being separate from the first power density.

2. The infrared heating panel of claim 1, wherein the first power density zone is between the first power bus and the first ends of the elongated segments, and wherein the second power density zone is between the first power bus and the second ends of the elongated segments.

3. The infrared heating panel of claim 2, further comprising a bottom end proximate the first ends of the elongated segments and a top end proximate the second ends of the elongated segments, wherein the first power density of the first segment portions extending into the first power density zone is greater than the second power density of the second segment portions extending into the second power density zone.

4. The infrared heating panel of claim 3, wherein the first power density is between 1 and about 1.5 times greater than the second power density.

5. The infrared heating panel of claim 1, wherein the first power density is substantially uniform along the first segment portion and the second power density is substantially uniform along the second segment portion.

6. The infrared heating panel of claim 1, wherein the planar substrate comprises a first surface and an opposing second surface;

wherein the elongated segment is a first elongated segment attached to the first surface of the substrate;

wherein each heating element further comprises a second elongated segment electrically connected to the first elongated segment and attached to the second surface opposite from and in a parallel arrangement with the first elongated segment; and

wherein the second power bus is opposite the substrate from and in a parallel arrangement with the first power bus, and electrically connected to each of the elongated second segments between the first end and the second end of each of the heating elements such that the first and the second elongated segments of each heating element combine to form two current paths between the first and the second power buses.

7. The infrared heating panel of claim 1, further comprising a third power bus extending perpendicularly across and electrically connecting with each of the plurality of heating elements at the second ends of the heating elements, wherein the second power bus extends perpendicularly across and electrically connects with each of the plurality of heating elements at the first ends of the heating elements, and wherein the first power bus comprises a first electrical connection point and further comprising a second electrical connection point for connecting the heating panel to a power source.

8. The infrared heating panel of claim 7, further comprising a return segment attached to the substrate, the return segment electrically connecting the second power bus and the third power bus, wherein the second power bus or the third power bus provides the second electrical connection point.

9. The infrared heating panel of claim 7, further comprising a return segment attached to the substrate, the return segment electrically connecting the second power bus and the third power bus, wherein the return segment provides the second electrical connection point proximate to the first electrical connection point.

10. An infrared sauna, comprising:

an enclosed room comprising a floor, a ceiling, and a plurality of walls extending between the floor and the ceiling; and

at least a first infrared heating panel having a top edge and a bottom edge, the first heating panel mounted to one of the walls in a vertical orientation with the bottom edge nearest the floor and the top edge nearest the ceiling, the first heating panel comprising;

an electrically insulative planar substrate;

a plurality of infrared heating elements carried by the substrate, each heating element comprising a bottom end proximate the bottom edge of the heating panel, a top end proximate the top edge of the heating panel, and an elongated segment extending between the bottom end and the top end; and

at least a first power bus and a second power bus, each of the first and the second power buses extending perpendicularly across and electrically connecting with each of the plurality of heating elements;

wherein the first power bus is electrically connected to the elongated segments between the bottom end and the top end of each of the heating elements, thereby defining a first power density zone located between the first power bus and the bottom ends of the heating elements and a second power density zone located above the first power density zone between the first power bus and the top ends of the heating elements;

wherein the first power density zone generates a first power density in response to currents flowing through the heating elements between the first power bus and the bottom ends of the heating elements; and

wherein the second power density zone generates a second power density in response to currents flowing through the heating elements between the first power bus and the top ends of the heating elements.

11. The infrared sauna of claim 10, wherein the first power density is greater than the second power density.

12. The infrared sauna of claim 10, wherein the elongated segment of each heating element comprises

an electrically resistive material adapted to emit infrared radiation in response to a current flow,

a first segment portion extending between the first power bus and the bottom end of the heating element, the first segment portion configured to generate a first segment power density in response to a current flow corresponding to the first power density, and

a second segment portion extending into the second power density zone between the first power bus and the top end of the heating element, the second segment portion configured to generate a second segment power density in response to a current flow, the first segment power density being separate from the second segment power density.

13. The infrared sauna of claim 12, wherein the first segment portion has a length different than a length of the second segment portion, the first segment power density is different than the second segment power density.

14. The infrared sauna of claim 13, wherein the first segment power density is greater than the second segment power density.

15. The infrared sauna of claim 12, wherein the first segment power density is substantially uniform along the first segment portion and the second segment power density is substantially uniform along the second segment portion.

16. The infrared sauna of claim 10, wherein the first power density is between 1 and about 1.5 times greater than the second power density.

17. The infrared sauna of claim 10, further comprising a third power bus extending perpendicularly across and electrically connecting with each of the plurality of heating elements at the top ends of the heating elements, wherein the second power bus extends perpendicularly across and electrically connects with each of the plurality of heating elements at the bottom ends of the heating elements, and wherein the first power bus comprises a first electrical connection point and further comprising a second electrical connection point for connecting the heating panel to a power source.

18. The infrared sauna of claim 17, further comprising a return segment attached to the substrate, the return segment electrically connecting the second power bus and the third power bus, wherein the second power bus or the third power bus provides the second electrical connection point.

19. The infrared sauna of claim 17, further comprising a return segment attached to the substrate, the return segment electrically connecting the second power bus and the third power bus, wherein the return segment provides the second electrical connection point proximate to the first electrical connection point.

20. A method for heating an infrared sauna, comprising:

applying power to one or more infrared heating panels, each infrared heating panel having a top edge and a bottom edge, the heating panel mounted to a wall of the sauna in a vertical orientation with the bottom edge nearest a floor of the sauna and the top edge nearest a ceiling of the sauna, each infrared heating panel comprising an electrically insulative planar substrate, a plurality of infrared heating elements, a first power bus, and a second power bus, each heating element comprising an elongated segment extending between a bottom end of the heating element proximate the bottom edge of the heating panel and a top end of the heating element proximate the top edge of the heating panel;

introducing first and second currents from the first power bus into respective first and second portions of the elongated segment of each of the heating elements;

flowing the first current through the first portion of the elongated segment between the first power bus and the bottom end of the heating element to generate infrared radiation at a first power density for heating a human in the infrared sauna;

flowing the second current through the second portion of the elongated segment between the first power bus and the top end of the heating element to generate infrared radiation at a second power density different than the first power density.