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US7230213A1 The negative temperature coefficient of resistance provides that minimal in rush current is drawn in response to connecting the modular heated cover to a power source or to a second modular heated cover with the first modular heated cover coupled to a power source. In one embodiment, the material of the electrical heating element comprises substantially carbon structured to form graphite. Alternatively, the material of the electrical heating element may comprise germanium, silicon, and the like. 15 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 In one further embodiment, the electrical heating element may comprise a resistive element for converting electric current to heat energy and a substantially planar heat spreading element for distributing the heat energy generated by the resistive element. In one embodiment, the electrical heating element generates substantially consistent levels of thermal energy across the surface area of the thermal cover. Additionally, the thermal cover may comprise at least one receiving power coupling and at least one conveying power coupling. In one embodiment, the conveying power coupling of a first modular heated cover can be optionally or removably coupled to the receiving power coupling of a second modular heated cover such that the first modular heated cover and second modular heated cover draw electricity from a single circuit providing up to about 120 Volts. The single circuit is preferably protected by up to about a 20 Amp breaker. In certain embodiments, the electrical heating element is configured such that the electrical heating element has a negative temperature coefficient of resistance. 14 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment. 25 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 A modular heated cover is presented with a first pliable outer layer and a second pliable outer layer, wherein the outer layers provide durable protection in an outdoor environment, and an electrical heating element between the first and the second outer layers. The electrical heating element is configured to convert electrical energy to heat energy. The electrical heating element is disposed between the first and the second outer layers such that the electrical heating element evenly distributes heat over a surface area defined substantially by the first and the second outer layers. The modular heated cover includes a thermal insulation layer positioned above the active electrical heating element and between the first and second outer layers. The thermal insulation layer is configured such that heat from the electrical heating element is conducted away from the thermal insulation layer. In a further embodiment, the thermal cover may comprise an electric power coupling connected to the electrical heating element and configured to optionally convey electrical energy from a first modular heated cover to a second modular heated cover. 12 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available ground covers. Accordingly, the present invention has been developed to provide a modular heated cover and associated system that overcomes many or all of the above-discussed shortcomings in the art. 11 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 What is needed is a modular heated cover that operates using electricity from standard job site power supplies, is cost effective, portable, reusable, and modular to provide heated coverage for variable size surfaces efficiently and cost effectively. For example, the modular heated cover may comprise a pliable material that can be rolled or folded and transported easily. Furthermore, the modular heated cover would be configured such that two or more modular heated covers can easily be joined to accommodate various surface sizes. Beneficially, such a device would provide directed radiant heat, modularity, weather isolation, temperature insulation, and solar heat absorption. The modular heated cover would maintain a suitable temperature for exposed concrete to cure properly and quickly and efficiently remove ice, snow, and frost from surfaces, as well as penetrate soil and other material to thaw the material to a suitable depth for concrete pours and other construction projects. 10 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 Currently, few conventional solutions exist that use electricity to produce and conduct heat. Traditionally, this was due to limited circuit designs. Traditional solutions were unable to produce sufficient heat over a sufficient surface area to be practical. The traditional solutions that did exist required special electrical circuits with higher voltages and protected by higher rated breakers. These special electrical circuits are often unavailable at a construction site. Thus using conventional standard circuits, conventional solutions are unable to produce sufficient heat over a sufficiently large surface area to be practical. Typically, 143 BTUs are required to melt a pound of ice. Conventional electrically powered solutions are incapable of providing 143 BTUs over a sufficiently large enough area for practical use in the construction industry. Consequently, the construction industry has turned to bulky, expensive, time consuming heated fluid solutions. 9 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 While some solutions are available for construction industries to thaw ground, keep ground thawed, and cure concrete, these solutions are large, expensive to operate and own, time consuming to setup and take down, and complicated. Conventional solutions employ heated air, oil, or fluid delivered to a thawing site by hosing. Typically, the hosing is then covered by a cover such as a tarp or enclosure. Laying and arranging the hosing and cover can be time consuming. Furthermore, heating and circulating the fluid requires significant energy in the form of heaters, pumps, and/or generators. 8 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 Although the need for a solution to these problems is particularly great in outdoor construction trades, a solution may be similarly beneficial in various residential, industrial, manufacturing, maintenance, and service fields. For example, a residence or place of business with an outdoor canopy, car port, or the like may require such a solution to keep the canopy free of snow and ice to prevent damage from the weight of accumulated precipitation or frost. Conventional solutions for keeping driveways, overhangs, and the like clear of snow, typically require permanent fixtures that are both costly to install and operate, or small portable devices that do not cover sufficient surface area. 7 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 In roofing and other outdoor construction trades, it may be similarly important to keep work surfaces free of snow, ice, and frost. Additionally, it may be important to maintain specific temperatures for setting, curing, laying, and pouring various construction products including tile, masonry, or the like. 6 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 In addition, it is important to properly cure the concrete for strength once it has been poured. Typically the concrete must cure for about seven days at a temperature within the range of 50 degrees Fahrenheit to 90 degrees Fahrenheit, with 70 degrees Fahrenheit as the optimum temperature. If concrete cures in temperatures below 50 degrees Fahrenheit, the strength and durability of the concrete is greatly reduced. In an outdoor environment where freezing temperatures exist or may exist, it is difficult to maintain adequate curing temperatures. 5 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 In construction, ice buildup is particularly problematic. For example, ice and snow may limit the ability to pour concrete, lay roofing material, and the like. In these outdoor construction situations, time and money are frequently lost to delays caused by snow and ice. If delay is unacceptable, the cost to work around the situation may be unreasonable. For example, if concrete is to be poured, the ground must be thawed to a reasonable depth to allow the concrete to adhere to the ground and cure properly. Typically, in order to pour concrete in freezing conditions, earth must be removed to a predetermined depth and replaced with gravel. This process is costly in material and labor. 4 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 Standard methods for removing and preventing ice, snow, and frost include blowing hot air or water on the surfaces to be thawed, running electric heat trace along surfaces, and/or laying tubing or hoses carrying heated glycol or other fluids along a surface. Unfortunately, such methods are often expensive, time consuming, inefficient, and otherwise problematic. 3 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. 36 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 In one embodiment, the electrical heating element comprises an electro-thermal coupling material or resistive element 208. For example, the resistive element 208 may be a copper conductor. The copper conductor may convert electrical energy to heat energy, and transfer the heat energy to the surrounding environment. Alternatively, the resistive element 208 may comprise another conductor capable of converting electrical energy to heat energy. One skilled in the art of electro-thermal energy conversion will recognize additional material suitable for forming the resistive element 208. Additionally, the resistive element 208 may include one or more layers for electrical insulation, temperature regulation, and ruggedization. In one embodiment, the resistive element 208 may include two conductors connected at one end to create a closed circuit. 47 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 In one embodiment, the flap 204 may overlap another thermal cover 200. The flap 204 may provide isolation of air trapped beneath the thermal cover 200. Isolation of the air trapped beneath the thermal cover 200 prevents heat loss due to air circulation. Additionally, the flap 204 may include one or more fasteners 206 for hanging, securing, or connecting the thermal cover 200. In one embodiment, the fasteners 206 may be attached to the corners of the cover 200. Additionally, fasteners 206 may be distributed about the perimeter of the cover 200. In one embodiment, the fastener 206 is Velcro™. For example, the flap may include a hook fabric on one side and a loop fabric on the other side. In another alternative embodiment, the fastener 206 may include snaps, zippers, adhesives, and the like. 46 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 The multilayered cover 202 may comprise a textile fabric. The textile fabric may include natural or synthetic products. For example, the multilayered cover 202 may comprise burlap, canvas, or cotton. In another example, the multilayered cover 202 may comprise nylon, vinyl, or other synthetic textile material. For example, the multilayered cover 202 may comprise a thin sheet of plastic, metal foil, polystyrene, or the like. Further embodiments of the multilayered cover 202 are discussed below with regard to FIG. 3. 45 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 FIG. 2 illustrates one embodiment of a modular heated cover 200. In one embodiment, the cover 200 includes a multilayered cover 202. The multilayered cover 202 may include a flap 204. Additionally, the cover 200 may be coupled to an electrical heating element. In one embodiment, the electrical heating element comprises a resistive element 208 and a heat spreading element 210. The cover 200 may additionally include one or more fasteners 206, one or more electric power connections 212, one or more electric power couplings 214, and an electrical connection 216 between the connections 212 and the couplings 214. In certain embodiments the thermal cover 200 may additionally include a GFI device 218 and one or more creases 220. 44 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 In one embodiment, a power extension cord 108 may be used to create an electrical connection between a modular heated cover 104, and an electrical power source 110. In one embodiment, the extended electrical coupler 108 is a standard extension cord. Alternatively, the extended electrical coupler 108 may include a heavy duty conductor such as 4 gauge copper and the required electrical connector configuration to connect to high power outlets. Power extension cords 108 may be used to connect the power source 110 to the thermal covers 104, or to connect one thermal cover 104 to another thermal cover 104. In such embodiments, the power extension cords 108 are configured to conduct sufficient electrical current to power the electrical heating element of the modular heated covers 104. One of ordinary skill in the art of power engineering will understand the conductor gauge requirements based on the electric current required to power the thermal cover 104. 43 Added by DJM 2 2021 2/22/21, 12:00 AM
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US7230213A1 In certain embodiments, the electrical power source 110 may be a power outlet connected to a 120V or 240 V AC power line. Alternatively, the power source 110 may be an electricity generator. In certain embodiments, the 120V power line may supply a range of current between about 15 A and about 50 A of electrical current to the thermal cover 104. Alternative embodiments of the power source 110 may include a 240V AC power line. The 240V power line may supply a range of current between about 30 A and about 70 A of current to the thermal cover 104. Various other embodiments may include supply of three phase power, Direct Current (DC) power, 110 V or 220 V power, or other power supply configurations based on available power, geographic location, and the like. 42 Added by DJM 2 2021 2/22/21, 12:00 AM

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