Heat Transfer Medium With Epoxy-Silicone Powder Coating
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Solution Overview
Problem
Existing heat carriers made of chamotte or ceramic materials are not suitable for humid environments due to their porous structure, which leads to moisture absorption and mechanical weaknesses, such as cracking and increased porosity, and existing solutions with water-repellent layers have high production costs and low mechanical strength.
Innovation Solution
A heat carrier coated with a high-temperature-resistant powder coating based on epoxy-silicone or silicone-polyester resin, applied using a semi-automated process, providing a moisture-repellent, abrasion-resistant, and easy-to-clean surface with improved mechanical properties, suitable for electric storage heaters and damp environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If heat carriers are made from chamotte or ceramic materials with porous structure, then heat absorption and heat storage properties are improved, but moisture absorption increases making them unsuitable for humid environments
Solution Approach 1:
A powder coating based on epoxy-silicone or silicone-polyester resin is applied as an intermediary layer between the porous chamotte/ceramic heat carrier and the humid environment. This coating layer blocks moisture from penetrating into the porous structure while allowing the underlying material to maintain its heat absorption and storage capabilities.
Solution Approach 2:
The surface properties of the heat carrier are changed by applying a coating that modifies the surface energy and porosity parameters. The coating transforms the hydrophilic, porous surface into a hydrophobic, non-porous surface, preventing moisture absorption while preserving the bulk material's thermal properties.
2Object-affected harmful factors
If heat carriers are covered with a ceramic glaze layer, then moisture resistance is improved, but hairline cracks develop over time due to different coefficients of expansion
Solution Approach 1:
Instead of using traditional ceramic glaze with high thermal expansion, the patent employs a polymer-based powder coating with epoxy-silicone or silicone-polyester resin that has lower thermal expansion coefficients closer to the chamotte substrate. This parameter change in material selection prevents the development of hairline cracks during thermal cycling.
Solution Approach 2:
The solution uses a composite coating system combining epoxy-silicone or silicone-polyester resin with appropriate fillers and pigments. This composite material provides both moisture resistance and thermal compatibility, avoiding the cracking issues associated with traditional ceramic glazes while maintaining durability.
3Object-affected harmful factors
If water-repellent layers are applied to heat carriers, then moisture repulsion is improved, but production costs increase and mechanical strength decreases
Solution Approach 1:
The patent employs a cost-effective powder coating system based on epoxy-silicone or silicone-polyester resin that can be applied using standard industrial coating equipment. This coating provides durable moisture repulsion at a lower cost than traditional water-repellent treatments, making it economically viable for mass production of heating elements.
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 effectively repels moisture, enhances mechanical strength, and allows for efficient production, making it suitable for various applications including electric storage heaters and humid environments while being cost-effective and safe to use.
Implementation Method 1
The powder coating is preferably melted from the high-temperature-resistant powder based on epoxy-silicone and/or based on silicone-polyester resin
Implementation Method 2
the best possible properties are to be achieved through the selection of the fireclay or a mixture containing fireclay in relation to heat absorption, heat storage and heat emission
Implementation Method 3
heat carriers with a heat conductor embedded in the chamotte, the chamotte-containing mixture or in the ceramic material are used in particular in electric storage heaters
Data Source
AI summary
The invention relates to a heat transfer medium consisting of fireclay, a fireclay-containing mixture or a ceramic substance that is coated by a powder coating on all sides. In proposed embodiments, a thermal conductor is embedded into the heat transfer medium. The powder coating consists of a high-temperature resistant powder, preferably of a powder on the basis of epoxy-silicon and/or silicon-polyester resin, which powder is melted in a temperature range of 180oC to 230oC at a residence duration of 15 to 30 minutes in order to achieve a layer thickness of the powder coating of 20µm to 70µm. The heat transfer medium repels moisture, is abrasion-resistant and easy to clean, and is particularly suitable for electric storage heaters and convectors. The heat transfer medium can also be used as a heat and thermal storage element in hotplates for meals, in modules with hotplates, in hotplates for chick-rearing or for controlling the temperature during chick rearing, in incubating machines or in terraria.