3D Carbon-Network Substrates for Localized Joule Heating
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Solution Overview
Problem
Existing processes struggle with achieving precise and localized thermal energy input for chemical reactions and fluid heating operations, often leading to inefficiencies due to dead zones, hot or cold spots, and hydrodynamic distortions.
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
1Manufacturing precision
If conventional heating methods are used for chemical reactions and fluid heating, then thermal energy can be supplied to the system, but precise and localized thermal energy input cannot be achieved, resulting in dead zones, hot or cold spots, and hydrodynamic distortions
Solution Approach 1:
The patent applies local quality by creating a substrate with spatially varying electrical conductivity through non-uniform carbon network distribution. Different regions of the substrate have different carbon concentrations, enabling independent thermal control of specific zones. This allows precise localized heating where needed while minimizing energy waste in other regions, directly resolving the contradiction between heating effectiveness and energy efficiency.
Solution Approach 2:
The patent replaces conventional mechanical or thermal heating systems with an electrical heating system based on Joule heating. By applying electrical current through the conductive carbon network embedded in the substrate, thermal energy is generated directly at the source with precise spatial and temporal control. This substitution eliminates the inefficiencies of conventional heating methods and enables the desired precision in thermal energy input.
2Temperature
If conventional heating methods are used, then heating can be applied to the system, but controlled and localized thermal energy input at specific loci cannot be achieved
Solution Approach 1:
The patent implements dynamics by enabling real-time, programmable control of the electrical current distribution through the carbon network. The heating system can dynamically adjust temperature profiles across different regions of the substrate independently, allowing precise temperature control and flexible operation. This dynamic control capability resolves the contradiction by providing both precise temperature control and operational flexibility simultaneously.
Solution Approach 2:
The patent applies parameter changes by varying the electrical conductivity distribution within the substrate through controlled carbon network formation. By adjusting the local concentration and distribution of conductive carbon material, the system can modify thermal properties spatially and temporally. This enables precise temperature control at specific loci while maintaining ease of operation through electrical parameter adjustment.
3Manufacturing precision
If uniform heating is applied to prevent hot spots, then energy distribution is simplified, but localized thermal energy input cannot be achieved for specific reaction zones
Solution Approach 1:
The patent employs composite materials by integrating a conductive carbon network within a substrate matrix. This composite structure combines the structural integrity of the substrate with the electrical conductivity and thermal responsiveness of the carbon network. The composite design enables localized heating capability through spatially varying conductivity while managing the inherent structural complexity through a unified material system.
Solution Approach 2:
The patent utilizes porous materials by incorporating a porous carbon network within the substrate. The porous structure provides high surface area and enhanced conductivity pathways while maintaining structural integrity. This approach enables precise localized heating control through the three-dimensional carbon network, achieving the desired heating precision without excessive structural 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
Enables precise and efficient thermal energy input, reducing energy waste and extending catalyst life by preventing hot spots, while allowing for customizable temperature profiles and real-time adjustments.
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.