Carbon Veil Composite Heating Element Without Adhesive Layers

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing non-metallic pipes and tanks face issues such as degradation of immersed electrical heating elements due to surface corrosion and reduced heat transfer effectiveness due to sludge build-up, which can lead to leaks and increased maintenance costs, especially in cold regions and heavy crude oil transport.

Innovation Solution

A non-metallic heating solution using a carbon veil integrated within composite material layers without a discrete adhesive layer, with a conductive carbon veil wrapped in a spiral configuration and insulated by layers to maintain heat transfer efficiency and resist corrosion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If immersed electrical heating elements are used in non-metallic pipes and tanks, then heating function is provided, but surface corrosion degrades the heating elements reducing reliability

Engineering Contradiction:

Improveheating element durabilityVSAvoidsurface corrosion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a carbon veil as an intermediary heating element that is electrically conductive and chemically inert. This carbon veil is embedded within the composite wall structure between the liner and outer layers, serving as a mediator that provides heating functionality without direct contact with corrosive environments, thus resolving the contradiction between providing heat and resisting corrosion.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces traditional immersed electrical heating elements (mechanical/electrical system) with a carbon veil integrated into the composite structure. This substitution eliminates the need for separate heating components that are susceptible to corrosion, while maintaining the heating function through the conductive properties of the carbon material embedded in the composite wall.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of energy

If traditional heating elements are used, then heating is provided, but sludge build-up reduces heat transfer effectiveness

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidsludge build-up

Core Design Contradiction:

Loss of energyVSObject-generated harmful factors

Solution Approach 1:

The patent transitions from a point-source or surface heating element to a distributed volumetric heating solution by embedding the carbon veil throughout the composite wall thickness. This dimensional change allows heat to be generated throughout the wall structure rather than from a single surface, eliminating sludge build-up issues and maintaining consistent heat transfer efficiency.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If discrete adhesive layers are used to attach heating elements, then bonding is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improveheating element integrationVSAvoiddiscrete adhesive layer

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the heating element function with the composite material structure itself by embedding the carbon veil within the composite wall during manufacturing. This integration eliminates the need for separate adhesive layers and discrete heating element attachment steps, simplifying the manufacturing process while achieving strong bonding between the heating function and the pipe/tank structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes composite material construction to integrate the carbon veil heating element within the multi-layer composite wall structure. By incorporating the heating element as part of the composite material system rather than as a separate component, the patent simplifies manufacturing and eliminates the need for additional bonding materials and processes.

Inventive Principle:

Principle #40Composite materials

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 carbon veil heating element maintains heat transfer effectiveness, reduces energy consumption, and extends the life expectancy of pipes and tanks by avoiding corrosion and sludge build-up, while allowing for controlled temperature zones.

Implementation Method 1

a conductive carbon veil wrapped in a spiral configuration and insulated by layers to maintain heat transfer efficiency

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

insulated by layers to maintain heat transfer efficiency

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250344293A1Non-metallic heating element using carbon veil

Publication Date: 2025.11.06 SAUDI ARABIAN OIL CO

AI summary

A non-metallic composite heating element assembly can be formed by winding a carbon veil onto a resin-rich structural layer before the resin-rich structural layer completely cures. The resin can wet through the carbon veil during formation, thereby bonding the carbon veil to the structural layer without the need for a separate and discrete adhesive layer. Other layers can also be formed, including a first insulating layer between the carbon veil and the first structural layer, a second insulating layer above the carbon veil, and a second structural layer formed above the second insulating layer. The carbon veil can include two busbars for supplying power to the carbon veil.