Carbon Nanotube Heating Paste for Low Power Thermal Management
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Solution Overview
Problem
Conventional heating rollers in image-forming devices, such as printers, are inefficient due to indirect heating using halogen lamps, leading to high power consumption, heat loss, and long warm-up and cool-down times, which are exacerbated by the limitations of carbon-black based sheet heating elements that cannot maintain heat resistance at 200°C or higher and require high voltage and power for operation.
Innovation Solution
A heating paste composition comprising carbon nanotube particles, graphite particles, a binder mixture, an organic solvent, and a dispersant, which is applied to form a sheet heating element, heating roller, and heating unit, enabling high heat resistance, low voltage, and low power operation, with the composition being stable at temperatures above 200°C and facilitating reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a halogen lamp is used for indirect heating, then heating function is achieved, but power consumption increases and heat loss occurs
Solution Approach 1:
The patent replaces the halogen lamp heating system with a carbon nanotube-based direct heating element. The carbon nanotube composition converts electrical energy directly into heat through resistive heating, eliminating the need for radiant heat transfer from a halogen lamp. This substitution achieves more efficient energy conversion with reduced power consumption and minimal heat loss, as the heat is generated directly at the heating surface rather than being radiated indirectly.
Solution Approach 2:
The patent changes the heating mechanism from indirect radiant heating to direct resistive heating by using carbon nanotube particles with specific electrical and thermal properties. The carbon nanotube composition exhibits high electrical conductivity and superior thermal conductivity, allowing efficient conversion of electrical energy to heat with minimal loss. This parameter change in the heating system's physical properties enables significant reduction in power consumption while maintaining effective heating function.
2Temperature
If conventional carbon-black based sheet heating elements are used, then heating function is provided, but heat resistance cannot be maintained at 200°C or higher
Solution Approach 1:
The patent employs a composite material system consisting of carbon nanotube particles combined with specific binder resins and organic solvents. The carbon nanotubes provide exceptional thermal stability and structural integrity at high temperatures, while the binder mixture (comprising polyvinyl acetal resin, phenol resin, and epoxy acrylate or hexamethylene diisocyanate) maintains adhesion and structural coherence. This composite formulation enables the heating element to reliably maintain both heating function and structural stability at temperatures of 200°C and above, overcoming the limitations of conventional carbon-black based materials.
3Speed
If conventional heating systems are used, then heating is achieved, but warm-up time and cool-down time are long
Solution Approach 1:
The patent replaces the slow thermal conduction and radiant heating system with a direct resistive heating system based on carbon nanotubes. The high electrical conductivity and superior thermal conductivity of carbon nanotubes enable rapid conversion of electrical energy to heat directly at the heating surface, dramatically reducing warm-up time. Similarly, when power is cut off, the efficient thermal properties allow rapid heat dissipation, reducing cool-down time and enabling faster cycling between heating states.
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
The solution results in a significant reduction in power consumption, enhanced printing speed due to rapid warm-up, and improved energy efficiency, while maintaining stability and flexibility, allowing for continuous operation at high temperatures.
Implementation Method 1
a heating paste composition which has high heat resistance and thus is less changed in resistance according to temperature and capable of being driven at low voltage and low power
Implementation Method 2
a heating paste composition which has high heat resistance and thus is less changed in resistance according to temperature
Data Source
AI summary
A heating paste composition, and a sheet heating element, a heating roller, a heating unit and a heating module, which use the composition, are disclosed. In one aspect, the heating paste composition includes 0.2 parts to 6 parts by weight of carbon nanotube particles, 0.5 parts to 30 parts by weight of graphite particles, 5 parts to 30 parts by weight of a binder mixture, 29 parts to 80 parts by weight of an organic solvent and 0.5 parts to 5 parts by weight of a dispersant, wherein the weights are with respect to 100 parts by weight of the heating paste composition.