3D Carbon-Network Substrates for Localized Joule Heating
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Solution Overview
Problem
Existing processes face challenges in achieving precise and localized thermal energy input for chemical reactions and fluid heating operations, with issues such as dead zones, hot or cold spots, and hydrodynamic distortions affecting heating efficiency.
Innovation Solution
Formation of an electrically conductive carbon network on a three-dimensional substrate through pyrolysis of a phenolic resin or polymer, enabling localized joule heating for controlled thermal management in processes like endothermic chemical reactions and fluid heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional heating methods are used for chemical reactions and fluid heating, then thermal energy can be supplied to the process, but dead zones, hot or cold spots, and hydrodynamic distortions occur that reduce heating precision and efficiency
Solution Approach 1:
The patent replaces conventional mechanical/thermal heating systems with an electrical heating system. An electrically conductive coating is applied to the substrate, and electrical current is passed through it to generate heat directly at the location where thermal energy is needed. This substitution of electrical heating for conventional thermal heating eliminates heat transfer losses and prevents the formation of dead zones and hot/cold spots, thereby improving temperature control precision and reducing energy waste.
Solution Approach 2:
The patent implements localized heating by applying an electrically conductive coating only to specific regions of the substrate where heating is required. The electrical current can be controlled to heat only the necessary areas, creating local quality in the thermal distribution. This approach prevents energy waste in areas that do not require heating and eliminates the formation of unwanted hot or cold spots, thereby improving both temperature precision and energy efficiency.
2Reliability
If conventional heating methods are used, then thermal energy can be supplied, but dead zones and hydrodynamic distortions negatively impact heating operation
Solution Approach 1:
The patent replaces conventional thermal heating with direct electrical heating through an electrically conductive coating. This substitution provides more reliable and uniform temperature distribution because the heat is generated directly within the coating layer at the substrate surface, eliminating the thermal gradients and hydrodynamic distortions that occur with external heating methods. The electrical current can be uniformly distributed across the heating zone, ensuring consistent temperature and improving both reliability and precision.
3Measurement precision
If localized heating is achieved through electrical energy input to carbon network, then precise temperature control is improved, but additional process steps (pyrolysis, coating) are required
Solution Approach 1:
The patent creates a composite structure by coating the substrate with an electrically conductive material (such as a carbon-based coating formed through pyrolysis of phenolic resin or polymer). This composite material combines the substrate's functional properties with the coating's electrical conductivity and heating capabilities. While the coating process adds a step, the resulting composite provides integrated heating functionality that simplifies the overall system by eliminating the need for separate heating devices, thereby improving localized temperature control while managing complexity through material integration.
4Adaptability or versatility
If phenolic resin or polymer is pyrolyzed to form conductive carbon network, then electrically heatable substrate is created, but additional manufacturing steps are required
Solution Approach 1:
The patent transforms the substrate's properties by pyrolyzing a phenolic resin or polymer coating at high temperatures to form an electrically conductive carbon network. This parameter change (thermal treatment) converts a non-conductive organic coating into a conductive carbon structure. While this adds a manufacturing step, it provides the substrate with electrical heating capability, greatly enhancing its adaptability and versatility for applications requiring controlled localized heating. The pyrolysis process is a well-established industrial technique, which helps mitigate the increase in manufacturing complexity.
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
Provides precise and localized heating, enhancing reaction efficiency and reducing energy waste by avoiding hot or cold spots, thus optimizing chemical processes and fluid heating operations.
Implementation Method 1
Electrical energy inputted to the electrically conductive carbon network is effective to produce localized heating throughout the three-dimensional substrate coated with the electrically conductive carbon network
Implementation Method 2
The method involves pyrolyzing a phenolic resin or a polymer that has been dispersed on or in a three-dimensional substrate to form the electrically conductive carbon network
Data Source
AI summary
An article for joule heating is described, including a three-dimensional substrate on and/or in which a pyrolyzate of a phenolic resin or polymer forms an electrically conductive carbon network. Such articles may be incorporated in structured materials applications, which may include support, sorbent, and or catalyst components. Also described are methods of fabricating such articles and structured materials, and apparatus comprising same, and methods of use of such articles and structured materials and apparatus for conducting material transformation processes requiring input of heat for their performance, such as CO2 adsorption, methane pyrolysis for hydrogen and carbon production, hydrogen-assisted conversion of CO2 to hydrocarbons, including catalytic conversion of CO2 to olefins, catalytic conversion of CO2 to propane (liquefied petroleum gas), and catalytic conversion of CO2 to renewable natural gas, reverse water gas shift reaction, steam ethane cracking, propane cracking, steam methane reforming, and dry methane reforming.