Graphene Carbon Nanostructure Heating Element for Automotive Defrosting
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Solution Overview
Problem
Resistance heating elements, such as those used in automobile rear windows, face challenges in achieving conductivity and durability comparable to silver-based elements while being cost-effective and environmentally friendly.
Innovation Solution
A resistance heating element composed of 10% to 45% graphene, 0.25% to 45% carbon nanostructure material, and the remainder glass frit, with a coupling agent bonding the graphene and carbon nanostructure with the glass frit, replacing metallic silver and using a low-melting glass frit to sinter and bond with the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic silver is used as the heating element material, then conductivity and durability are improved, but material cost and environmental impact worsen
Solution Approach 1:
The patent changes the material composition parameters by replacing metallic silver with a composite of graphene (10-45 wt%), carbon nanostructure material (0.25-45 wt%), and glass frit (remainder). This parameter substitution maintains electrical conductivity and durability while reducing material cost and environmental impact, as carbon-based materials are more abundant and less expensive than silver
Solution Approach 2:
The patent employs a composite material system combining graphene, carbon nanotubes (or other carbon nanostructures), and glass frit. The coupling agent bonds these components together to form a continuous electrically conductive path. This composite approach achieves silver-comparable performance through synergistic combination of materials with complementary properties
2Quantity of substance
If graphene and carbon nanostructure material are used to replace silver, then material cost is reduced, but achieving comparable conductivity and durability becomes more difficult
Solution Approach 1:
The patent introduces a coupling agent as an intermediary substance that bonds graphene and carbon nanostructure material with glass frit. This coupling agent is critical for achieving proper adhesion and forming continuous conductive paths, enabling the carbon-based composite to reach conductivity and durability levels comparable to silver-based elements
Solution Approach 2:
The glass frit component serves multiple functions: it acts as a binder holding the conductive materials together, provides adhesion to the substrate (e.g., glass window), and contributes to the overall structural integrity. This multi-functionality helps achieve silver-comparable durability while maintaining cost advantages
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 provides a durable and conductive heating element with performance similar to silver-based elements, while reducing material costs and environmental impact by using less dense carbon-based materials and a low-melting glass frit, forming a continuous electrically conductive path.
Implementation Method 1
The graphene and the CNS material include a coupling agent bonding the graphene and the carbon nanostructure material with at least the glass frit
Implementation Method 2
The paste is then heated to sinter and bond the silver and glass frit, thereby forming a continuous electrically conductive path
Implementation Method 3
The paste is then heated to sinter and bond the silver and glass frit
Implementation Method 4
The paste is then heated to sinter and bond the silver and glass frit
Data Source
AI summary
An article includes a substrate and a resistance heating element bonded to the substrate. The resistance heating element is comprised of, by weight, 10 to 45% of graphene, 0.25 to 45% of carbon nanostructure (CNS) material different than the graphene, and a remainder of glass frit. The graphene and the CNS material include a coupling agent that bonds the graphene and the CNS material with at least the glass frit.