Binder-Coated Conductive Bulk Materials for Manufacturable Components
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Solution Overview
Problem
Highly engineered materials like graphene, carbon nanotubes, and boron nitride nanotubes are not readily available in bulk form suitable for manufacturing real-world components, posing challenges in transmitting high voltage and current levels and handling high heat loads.
Innovation Solution
A method involving coating particulate conductive phase materials, such as graphene, with a thin binder phase using deposition processes, followed by consolidation into bulk materials through thermal, mechanical, or additive manufacturing methods, to create components like heat exchangers and electric cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If highly engineered conductive materials are used in particulate forms, then conductivity is improved, but ease of manufacture deteriorates
Solution Approach 1:
A binder material acts as an intermediary between the particulate conductive phase and the bulk component structure. The binder coats the particles, enabling them to be consolidated into bulk forms while maintaining their conductive properties. This resolves the contradiction by providing a medium that bridges the gap between fine particulate materials and bulk component manufacturing.
Solution Approach 2:
The invention creates a composite material system consisting of conductive particles embedded in a binder matrix. This composite structure allows the conductive particles to maintain their high conductivity while the binder provides the structural integrity and manufacturability needed for bulk component formation. The composite approach enables both high conductivity and ease of manufacture.
2Reliability
If highly engineered conductive materials are used in particulate forms, then conductivity is improved, but productivity deteriorates
Solution Approach 1:
The invention changes the physical and chemical parameters of the conductive particles through binder coating and consolidation processes. By controlling parameters such as binder composition, coating thickness, and consolidation conditions, the material transitions from difficult-to-process particles to manufacturable bulk forms, thereby improving productivity while preserving conductivity.
Solution Approach 2:
The binder serves as a mediator that enables high-volume manufacturing of bulk components from conductive particles. It facilitates processes like casting, molding, and additive manufacturing, which are essential for achieving high productivity. Without the binder, direct processing of fine particles would be inefficient and low-yield.
3Reliability
If highly engineered conductive materials are used in particulate forms, then conductivity is improved, but device complexity increases
Solution Approach 1:
The invention merges the conductive particles with the binder material into a unified bulk component structure. This combination eliminates the need for separate processing steps to assemble conductive elements into components, thereby reducing device complexity. The conductive phase and binder work together as an integrated material system rather than separate components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of bulk components with enhanced conductivity and formability, facilitating the use of highly engineered materials in industrial applications.
Implementation Method 1
coating a particulate conductive phase material with a binder phase using a deposition coating process
Data Source
Figure 1~6
AI summary
A method of forming a bulk product includes the step of coating a particulate conductive phase material (20) with a binder phase, and forming the coated conductive phase material (20) into at least one of sheet stock, tape formed into a bulk material. A method of forming a bulk product includes the step of coating a particulate conductive phase material (20) with a binder phase and forming the coated conductive phase material (20) into a bulk material. The conductive phase material (20) includes at least one of two dimensional materials, single layer materials, carbon nanotubes, boron nitride nanotubes, aluminum nitride and molybdenum disulphide (MoS2). A component is also disclosed.