Bulk Conductive Phase Structures Using Binder-Coated Particulates
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Solution Overview
Problem
Highly engineered conductive materials like graphene and carbon nanotubes are not readily available in bulk form for manufacturing real-world components, posing challenges for applications requiring high conductivity, such as high-voltage transmission and heat management, due to their particulate shapes which are difficult to manufacture into practical components.
Innovation Solution
A method involving the deposition of a thin binder phase onto particulate conductive materials using processes like atomic layer deposition, followed by consolidation into bulk forms through thermal, mechanical, or additive manufacturing processes, enabling the formation of components like heat exchangers and electric cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If highly engineered conductive materials (graphene, carbon nanotubes, etc.) are used to provide required conductivity, then electrical and thermal conductivity is improved, but these materials are not available in bulk form appropriate for manufacture of fuel components
Solution Approach 1:
A binder material serves as an intermediary substance that coats the particulate conductive phase material, enabling the transformation from difficult-to-manufacture particulates into manufacturable bulk forms. The binder acts as a mediating agent that facilitates consolidation while preserving the conductive properties of the particulate materials.
Solution Approach 2:
The invention creates a composite material structure consisting of conductive phase particles (graphene, carbon nanotubes, etc.) embedded in a binder matrix. This composite approach combines the high conductivity of the particulate materials with the manufacturability of the binder material, achieving both improved conductivity and ease of manufacture into bulk forms.
2Reliability
If particulate conductive phase materials are used, then high conductivity is achieved, but they are not easily manufactured into real world components
Solution Approach 1:
The binder material is applied in advance to coat the particulate conductive phase material before consolidation. This preliminary coating action prepares the particles for subsequent manufacturing processes, enabling them to be formed into bulk components more easily while maintaining their conductive properties.
Solution Approach 2:
The invention changes the physical state and arrangement parameters of the conductive materials by coating them with binder and consolidating them into bulk forms. This transforms the materials from a state where they are difficult to manufacture (loose particulates) into a state suitable for real-world components (consolidated bulk forms with controlled density and structure).
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 efficient manufacture of bulk components with enhanced conductivity, facilitating the use of advanced materials in industrial applications by improving their processability and integration into practical forms.
Implementation Method 1
coating a particulate conductive phase material with a binder phase using a deposition coating process
Implementation Method 2
forming the coated conductive phase material into a bulk material through thermal, mechanical, or additive manufacturing processes
Implementation Method 3
forming the coated conductive phase material into a bulk material through thermal, mechanical, or additive manufacturing processes
Data Source
AI summary
A method of forming a bulk product includes the step of coating a particulate conductive phase material with a binder phase, and forming the coated conductive phase material 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 with a binder phase and forming the coated conductive phase material into a bulk material. The conductive phase material 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.